PIAGGIO 633234, X9 Evolution 500 Workshop Manual

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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 PiaggioGilera 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 Sections marked with this symbol indicate the correct use of the vehicle 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

X9 Evolution 500 Characteristics

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. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, 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. Nonoriginal 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. Lubricate 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.

•

For removal, overhaul and reassembly operations use only tools provided with metric measures. 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 electrical connections - especially earth and battery connections - have been implemented properly.

CHAR - 7

Characteristics X9 Evolution 500

Vehicle identification

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Chassis prefix ZAPM 27000 ÷ 4000001

Engine prefix M271M ÷ 1001

Dimensions and mass

Specification

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

CHAR - 8

WEIGHT AND DIMENSIONS

Desc./Quantity

X9 Evolution 500 Characteristics

Engine

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

ENGINE

Specification

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

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.

Starting system Electric starter system with freewheel.

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

Lubrication pressure 4 bar

Minimum allowed (at 100° C) 0.8 bar

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

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-

Desc./Quantity

lifting device.

ment by-pass and oil filter.

throttle body and single injector.

stat and electric fan.

CHAR - 9

Characteristics X9 Evolution 500

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

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.

6 Generator in three-phase alternating current

Desc./Quantity

1 3A

Frame and suspensions

FRAME AND SUSPENSIONS

Specification

Type Welded structure consisting of steel pipes with asymmetrical

trestle structure, front crosspieces and union members made

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-

freedom degree oscillating arm and pair of dual effect hydraulic

shock absorbers with 4-position preload adjustment

Rear suspension range 76.6 mm (minimum spring preload)

Desc./Quantity

of sheet steel.

X9 Evolution 125-250-500:

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

CHAR - 10

X9 Evolution 500 Characteristics

Front fork

This is to inform you that, starting from frame no. ZAPM2700004008122, the front fork has been replaced 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

Brakes

Specification

Combined With dual disc brake, Ø 260 front LH with 2 piston floating cal-

Wheels and tyres

Specification

Light alloy rims (Front): 3,50x14"

Light alloy rims (rear): 4,50x14"

Tyre pressure (when cold): front 2,2 bar

Tyre pressure (when cold): rear 2,4 bar (2,6 bar with passenger or optional trunk on)

Front Tyre Michelin Gold Standard 120/70-14' M/C reinforced TL 55 S

Manufacturer / Model / Size Pirelli GTS 23 120/70_14'M/C TL 55 S

Rear Tyre Michelin Gold Standard 150/70-14' M/C TL 66 S

Manufacturer / Model / Size Pirelli GTS 24 150/70_14' M/C TL 66 S

CAUTION

BRAKES

Desc./Quantity

Front Disc brake Ø 260 (vehicle RH side), with hydraulic command

activated from handlebars with right-hand lever and 2 piston

floating caliper.

iper and Ø 240 rear, with 2 opposed piston floating caliper.

Hydraulic command activated from handlebars with left-hand

lever. The system is interlocked with a pressure distribution

valve.

WHEELS AND TYRES

Desc./Quantity

IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE CORRECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES RECOMMENDED BY PIAGGIO.

CHAR - 11

Characteristics X9 Evolution 500

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-

Handlebar fixing screw (*) 43 ÷ 47

STEERING WHEEL LOCKING RING NUT

1) Apply to the lower ring nut a setting torque of 20±25 Nm then loosen it.

2) Tighten the ring nut again at a torque of 10±13 Nm.

3) Loosen the lower ring nut by 90°.

4) Insert the spacer.

5) Lock the upper ring nut at a torque of 36 ± 39 Nm

CHASSIS UNIT

Name Torque in Nm

Oscillating arm pin right nut - Engine 100 ÷ 120

Oscillating arm pin left nut - Engine 56 ÷ 70

Oscillating arm-chassis pin 14 ÷ 17

Oscillating arm-chassis pin lock nut 40 ÷ 50

Oscillating arm pin right nut - Chassis 66 ÷ 73

Side stand support fixing bolt 33 ÷ 41

Bolt fixing the centre stand to the frame 25 ÷ 30

Hydraulic actuator fixing screw to chassis 20 ÷ 25

Side stand screw 35 ÷ 40

Side stand switch screw 5 ÷ 7

Side stand nut 40 ÷ 45

Oscillating arm damper bar nut 33 ÷ 41

Damper pad support plate nut 33 ÷ 41

ing")

FRONT SUSPENSION

Name

Fork leg tightening clamp screw 20 ÷ 25

Front wheel axle 45 ÷ 50

Wheel axle tightening clamp screw 6 ÷ 7

Front mudguard fixing screw 5 ÷ 6,5

Pumping fixing screw to fork leg 45 ÷ 50

Torque in Nm

FRONT BRAKE

Name

Screw for fixing the caliper support to the fork 42 ÷ 62

Brake fluid pump-hose fitting 16 ÷ 20

Brake fluid pipe-calliper fitting 16 ÷ 20

Disc tightening screw (°) 5 ÷ 6

Oil drainage screw 12 ÷ 16

Torque in Nm

REAR SUSPENSION

Name

Right and left shock absorber support fixing 20 ÷ 25

Shock absorbers fixing to chassis 33 ÷ 41

Shock absorbers fixing to lower supports 33 ÷ 41

Rear wheel axle 104 ÷ 126

Rear wheel rim screws 33 ÷ 37

Silencer support arm fixing to engine 33 ÷ 42

Torque in Nm

CHAR - 12

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 ÷ 25 Rear brake caliper pipe union on combined braking device 20 ÷ 25

Brake caliper fixing screw to supports 20 ÷ 25

Rear disc tightening screw (°) 14 ÷ 17

Oil bleed screw 12 - 16

Rear brake caliper fastening screw to engine 20 ÷ 25

Rear brake piping support fixing screw to engine 5 ÷ 6,5

Rear brake piping support fixing screw to chassis 9 ÷ 11

SILENCER

Name Torque in Nm

Manifold fixing screw to silencer 16 ÷ 18

Silencer support bracket fixing screw to engine 33 ÷ 41

Silencer heat guard fixing screw 3 ÷ 4

Exhaust gas inlet screw 22 ÷ 26

ENGINE UNIT

Name Torque in Nm

Clutch locking nut 65 ÷ 75

Driven pulley shaft support fixing screw 23 ÷ 26

Belt anti-flapping roller fixing screw 17 ÷ 20

Driving pulley nut (°) 160 ÷ 175

Flywheel nut (°) 115 ÷ 125

Driven pulley nut 92 ÷ 100

Half-crankcase union screw 11 ÷ 13

Head cover screws 11 ÷ 13

Head nuts (°) (§) (*) 38 ÷ 42

Cylinder stud bolts 44 ÷ 46

Camshaft bell screw (#) 30 ÷ 35

Camshaft plate fixing screw (#) 4 ÷ 6

Valve clearance adjustment lock nut 6 ÷ 8

Water pump impeller 4 ÷ 6

Starter motor fastening screw 11 ÷ 13

Ignition spark plug 12 ÷ 14

Hub oil drainage cap 15 ÷ 17

Rear hub cap screw 24 ÷ 27

Transmission cover screw 11 ÷ 13

Oil pump head screw 8 ÷ 10

Engine oil drainage cap 24 ÷ 30

Water pump cover screw 3 ÷ 4

Screw fixing the oil pump to the crankcase 5 ÷ 6

Stator fastening screw 8 ÷ 10

Screw fixing the start-up free wheel to the flywheel (#) 13 ÷ 15

Flywheel cover screw 11 ÷ 13

Head intake manifold screw 11 ÷ 13

Screw fixing the throttle body to the manifold 11 ÷ 13

Chain tightener sliding block screw (#) 10 ÷ 14

Timing chain tensioner central screw 5 - 6

Timing chain tensioner support screw 11 ÷ 13

Counter-rotating shaft fixing nut (#) 25 ÷ 29

Screw fixing the silencer to the support arm 20 ÷ 25

Exhaust manifold - cylinder nuts 27 ÷ 33

Screw fixing the rear brake caliper support bracket to the en-

gine

Driving shaft timing cap 3,5 ÷ 4,5

Head water outlet cover screw 3 ÷ 4

Calibrated dowel 5 ÷ 7

Oil cap with level bar 1,5 ÷ 2,5

Oil filter 12 ÷ 16

Oil filter engagement union 18 ÷ 22

20 ÷ 25

CHAR - 13

Characteristics X9 Evolution 500

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 ÷ 12

Pressure reducer counterweight retainer 7 ÷ 8.5

Counter shaft gear fixing on driving shaft (#) 10 ÷ 12

Thermostat cover 1,5 ÷ 2

Start-up rim counter shaft plate fixing 3 ÷ 4

Injector support fixing (#) 3 ÷ 4

Head lubrication control jet 5 - 7

(°)Lubricate parts before fitting. (^) Apply LOCTITE for surfaces type 510. (#) Apply thread-holding LOCTITE medium type 242. (§) 1st locking: 20 N·m crossed, locking at torque 38 - 42 N·m crossed, crossed loosening. (*) 2nd tightening: 20 N·m crossed, locking at torque 38 - 42 N·m crossed.

N.B.

LUBRICATE THE THREADS.

NOTICE OF TECHNICAL SERVICING

For correct tightening, the expansion tank cap locking torque has been standardised to 2.5 Nm Please take note that we have normalized to 17 - 20 Nm the temperature sensor locking torque, in order

to guarantee a correct locking

This is to inform you that the tightening torque for screws with dwg. no. 842502 has been increased from 8-10 Nm to 14-16 Nm, to prevent the exhaust pipe from coming loose.

Overhaul data

This section provides the main information for scooter servicing.

Assembly clearances

CHAR - 14

X9 Evolution 500 Characteristics

Cylinder - piston assy.

(Values in mm)

HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED

Specification Desc./Quantity

A: 10 mm B: 43 mm

CATEGORIES OF COUPLING

Name

Cylinder Piston A 91.990 - 91.997 91.954 - 91.961 0.029 - 0.043 Cylinder Piston B 91.997 - 92.004 91.961 - 91.968 0.029 - 0.043 Cylinder Piston C 92.004 - 92.011 91.968 - 91.975 0.029 - 0.043 Cylinder Piston D 92.011 - 92.018 91.975 - 91.982 0.029 - 0.043

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

Initials Cylinder Piston Play on fitting

Piston rings

* Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the openings in the rings as shown here. *** Value «A» of sealing ring inside the cylinder **** Ring opening

CHAR - 15

Characteristics X9 Evolution 500

SEALING RINGS

Name Initials Cylinder Piston Play on fitting

1st Compression ring A 0.15 ÷ 0.35 0.5 </>

Middle piston ring A 0.25 ÷ 0.50 0.65 </>

Oil scraper ring A 0.25 ÷ 0.50 0.65 </>

Crankcase - crankshaft - connecting rod

Characteristic

Drive shaft / crankcase axial clearance:

0.1 - 0.5 mm (when cold)

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name

Transmission-side

shoulder

Transmission-side half-

shaft

Connecting rod 22 0.10-0.15 C D= 0.20 - 0.40

Flywheel-side shoulder 13 ± 0.025 F D= 0.20 - 0.40

Flywheel-side half-shaft 19.6 +0.050 E D= 0.20 - 0.40

Complete drive shaft 63.5+0.1-0.05 G D= 0.20 - 0.40

CHAR - 16

Description Dimensions Initials Quantity

0.8 ± 0.025 A D= 0.20 - 0.40

19.6 + 0.050 B D= 0.20 - 0.40

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. ADMISSIBLE DISPLACEMENT

Specification

A = 0.15 mm B = 0.010 mm C = 0.010 mm D = 0.10 mm

Crankcase / countershaft coupling

Besides considering it should match the crankshaft, the crankcase is chosen according to the centre to centre distance between the seat of the crankshaft and that of the contra-rotating shaft. Both the centre to centre distance and the pair of gears driving the contra-rotating shaft are divided into two types (A and B) to be matched (A with A and B with B). This selection is useful to keep the difference between the working distance of the gears and their

Desc./Quantity

distance without clearance at a given value in order to avoid abnormal noise.

TYPE A

Specification

Centre to centre distance of the gears without clearance 76.937 ÷ 76.867

Centre to centre distance on the crankcase 77.022 ÷ 76.992

Desc./Quantity

TYPE B

Specification

Centre to centre distance of the gears without clearance 76.907 ÷ 76.837

Desc./Quantity

CHAR - 17

Characteristics X9 Evolution 500

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 crankcase, this mark is found at the cylinder mouth, flywheel side).

Slot packing system

Shimming system for limiting the compression ratio Rc = 10.5 : 1

DISTANCE "A" IS A PROJECTION OR RECESS VALUE OF THE PISTON TOP FROM THE CYLINDER PLANE. DISTANCE "A" ALLOWS THE THICKNESS OF THE GASKET TO BE DETERMINED THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE THE COMPRESSION RATIO. THE BASE GASKET MUST BE THICKER, THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND, THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER THE GASKET THICKNESS.

BASE GASKET THICKNESS

Name

«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05 «A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05 «A» MEASURE TAKEN + 0.10 ÷ + 0.185 0.8 ± 0.05

N.B.

VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE.

CHAR - 18

Measure A Thickness

X9 Evolution 500 Characteristics

Products

PRODOTTI

Product Description Specifications

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreeze

AUTOSOL METAL POLISH Muffler cleaning paste special product for cleaning and polishing

AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based

AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO

ARNICA 46 Electro-hydraulic centre-stand Highly viscous oil for hydraulic controls

quirements of API GL3 specifications

creased adhesiveness

Synthetic oil

fluid, CUNA NC 956-16

stainless steel muffler

spray grease with NLGI 2; ISO-L-XBCIB2

FC, ISO-L-EGD

CHAR - 19

INDEX OF TOPICS

TOOLING TOOL

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

Tooling X9 Evolution 500

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

020055Y Wrench for steering tube ring nut

headstock

TOOL - 22

X9 Evolution 500 Tooling

Stores code Description

020074Y Support base for checking crankshaft

020150Y Air heater support

020151Y Air heater

alignment

020193Y Oil pressure gauge

020306Y Punch for assembling valve seal rings

020329Y MityVac vacuum-operated pump

TOOL - 23

Tooling X9 Evolution 500

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

TOOL - 24

020358Y 37x40-mm adaptor

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

Tooling X9 Evolution 500

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

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

Tooling X9 Evolution 500

Stores code Description

020467Y Flywheel extractor

020468Y Piston fitting band

020469Y Reprogramming kit for scooter diagnosis

020470Y Pin retainers installation tool

020471Y Pin for countershaft timing

tester

TOOL - 28

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

Tooling X9 Evolution 500

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

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

INDEX OF TOPICS

MAINTENANCE MAIN

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 suggested, 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. All scheduled maintenance services must be carried out at the specified intervals, even if the stated mileage has not yet been reached. Punctual scooter servicing is essential to ensure your warranty remains valid. For any further information concerning Warranty procedures and "Scheduled Maintenance", please refer to the "Warranty Booklet".

EVERY 2 YEARS

60'

Action

Coolant - change Brake fluid - change

EVERY 3,000 KM

Action

Engine oil - level check/ top-up Brake pads - check condition and wear

AFTER 1,000 KM OR 4 MONTHS

90'

Action

Engine oil - replacement Hub oil - change Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Steering - adjustment Brake control levers - greasing Brake fluid level - check Safety locks - check Electrical system and battery - check Vehicle and brake test - road test

MAIN - 33

Maintenance X9 Evolution 500

AFTER 6,000 KM OR 12 MONTHS

80'

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 Brake fluid level - check Electrical system and battery - check Tyre inflation and wear - Check Vehicle and brake test - road test

AFTER 12,000 KM OR 24 MONTHS AND 60,000 KM

205'

Action

Engine oil - replacement Hub oil - level check Spark plug/electrode gap - replacement Air filter - clean Engine oil - change Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Driving belt - replacement Coolant level - check Steering - adjustment Brake control levers - greasing Transmission elements - lubrication Brake fluid level - check Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test

150'

Engine oil - replacement Hub oil - level check Spark plug / electrode gap - check Air filter - change Engine oil - change Valve clearance - check Base vent - check Variable speed rollers - replacement Driving belt - checking Coolant level - check Radiator - external cleaning/ check Brake fluid level - check Electrical system and battery - check Tyre inflation and wear - Check Vehicle and brake test - road test

MAIN - 34

AFTER 18,000 KM AND AFTER 54,000 KM

Action

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 Driven pulley bushing - check / grease Driving belt - replacement Coolant level - check Steering - adjustment Brake control levers - greasing 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 30,000 KM, 42,000 KM AND 66,000 KM

80'

Engine oil - replacement Hub oil - level check Spark plug / electrode gap - check Air filter - cleaning Engine oil - change Base vent - check Variable speed rollers - replacement Driving belt - checking Coolant level - check Brake fluid level - check Electrical system and battery - check Tyre inflation and wear - Check Vehicle and brake test - road test

365'

Engine oil - replacement Hub oil - level check Spark plug/electrode gap - replacement Air filter - change Engine oil - change Valve clearance - check Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Driving belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment

Action

AFTER 36,000 KM

Action

MAIN - 35

Maintenance X9 Evolution 500

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

255'

Action

Engine oil - replacement Hub oil - change Spark plug / electrode gap - replacement Air filter - clean Engine oil - change Fuel filter - replacement Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Driven pulley bushing - check / grease Driving belt - replacement Coolant level - check Steering - adjustment Brake control levers - greasing 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

405'

Engine oil - replacement Hub oil - change Spark plug / electrode gap - check / replacement Air filter - change Engine oil - change Fuel filter - check Valve clearance - check Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Driven pulley bushing - check / grease Driving belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake fluid hoses - replacement Brake fluid level - check Safety locks - check Suspensions - check

MAIN - 36

AFTER 72,000 KM

Action

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. THE SPARK PLUG SHOULD BE CHECKED EVERY 6,000 KM AND REPLACED EVERY 12,000 KM. THE USE OF NON-CONFORMING IGNITION CONTROL UNITS AND SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.

Characteristic

Recommended spark plugs:

CHAMPION RG6YC - NGK CR 7 EKB

- Position the scooter on centre stand.

- Open the door on the left side and remove the relevant screw lifting from the lower part in the specific groove.

- Disconnect the shielded spark plug cap

- Unscrew the spark plug.

- Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are not excessively worn or grimy, the conditions of the washer, and measure the distance between the electrodes using the appropriate feeler gauge.

Characteristic

Electrode gap

0.7-0.8 mm Adjust the gap if necessary, carefully bending the

earth electrode. In the event of irregularity, replace the spark plug with a recommended type.

- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it.

Locking torques (N*m)

Spark plug 12 ÷ 14

- Insert the cap onto the spark plug and proceed with the reassembly operations.

Hub oil

MAIN - 37

Maintenance X9 Evolution 500

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 between the MAX and MIX levels indicated on the bar (see figure); if the level is below the MIN value, restore the proper amount of oil in the hub.

- Screw the oil bar back on, checking that it is tightly in place.

N.B. THE NOTCHES ON THE HUB OIL LEVEL BAR, WITH THE

EXCEPTION OF THOSE INDICATING THE MAX AND MIN LEVEL, REFER TO SOME OF THE MANUFACTURER'S OTHER MODELS AND HAVE NO SPECIFIC FUNCTION AS FAR AS REGARDS THIS VEHICLE.

Replacement

- Prepare a suitable container.

- Remove the oil drainage cap «B» and let the oil drain out completely.

- Tighten the drainage cap again and fill the hub with oil.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid In normal weather conditions, the fluid should be

replaced every 20,000 km or in any case every 2 years. Never use braking fluid from containers that have already been opened, or partially used.

CAUTION THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT AB-

SORBS MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKE FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED.

CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

WARNING BRAKE CIRCUIT FLUID IS VERY CORROSIVE; DO NOT

LET IT COME INTO CONTACT WITH PAINTED PARTS. N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO

THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Headlight adjustment

- Place the vehicle in use conditions, with no load, with tyres inflated at the prescribed pressure on flat ground at 10 m from a white screen placed in dim light, making sure that the vehicle's axle is perpendicular to the screen.

- Trace a horizontal line on the screen at 70 - 73 cm above ground level.

MAIN - 46

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.

Checking the end compression pressure

- With the engine cold remove the sparkplug cap.

- Remove the sparkplug.

- Fit a compression testing pressure gauge in the sparkplug seat with a 10 mm sparkplug fitting tightened

to the correct torque.

- With the switch on "ON" wait a few seconds and then disconnect the rpm-timing sensor to disable

operation of the injector and sparkplug.

- Run the engine using the starter motor and with the throttle body fully open, until the reading on the

pressure gauge is stable.

- If the pressure is greater than XX - XX, remove the device and reassemble the vehicle.

- If pressure values lower than those indicated are measured, check the engine rpm used for the test;

if under 450 rpm, check the starter system. When the compression end pressure is under the norm, remove the fitting from the pressure gauge and pour a few cc of oil in the combustion chamber, rotate the engine (preferably by hand) to lubricate the cylinder. Repeat the pressure test: if the new values are still low check the valve seals. Higher pressure values of a new engine indicate poor sealing of the parts.

Locking torques (N*m)

Spark plug 12 ÷ 14

MAIN - 47

Maintenance X9 Evolution 500

MAIN - 48

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Troubleshooting X9 Evolution 500

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.

Check that the clutch casing is not scored or worn in an anom-

alous way

Insufficient braking

INSUFFICIENT BRAKING

Possible Cause Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.

Brakes overheating

Possible Cause

Rubber gaskets swollen or stuck Replace gaskets.

Compensation holes on the pump clogged Clean carefully and blast with compressed air

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

Defective piston sliding Check calliper and replace any damaged part.

Braking vibrations or noise

VIBRATIONS OR NOISE WHEN BRAKING

Possible Cause

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

Electrical system

BRAKES OVERHEATING

Operation

a wheel mounted on the vehicle to measure the axial shift of

the disc.

Operation

a wheel mounted on the vehicle to measure the axial shift of

the disc.

TROUBL - 50

X9 Evolution 500 Troubleshooting

Battery

BATTERY

Possible Cause Operation

Battery This is the device in the system that requires the most frequent

Turn signal lights malfunction

TURN INDICATOR NOT WORKING

Possible Cause Operation

Electronic ignition device failure With the key switch set to "ON" jump the contacts 1 (Blue -

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. The battery runs down completely in the course of 3 months. If the battery is fitted on a motorcycle,

be careful not to invert the connections, keeping in mind that

the black ground wire is connected to the negative terminal

while the red wire is connected to the terminal marked+.

Black) and 5 (Red/Blue) on the control unit connector. If by

operating the turn indicator control the lights are not steadily

on, replace the control unit; otherwise, check the cable harness

and the switch.

Steering and suspensions

Controls

STEERING CONTROLS AND SUSPENSIONS

Possible Cause

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front

Seal fault or breakage Replace the shock absorber Check the condition of wear of the

Operation

larities in turning the steering continue even after making the above adjustments, check the seats on which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

larities in turning the steering continue even after making the above adjustments, check the seats on which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

shock absorbers; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers and the movement

bushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disk in the

attachment to the hub and the steering tube.

steering covers and the adjustments.

Heavy steering

Torque not conforming Check the tightening of the top and bottom ring nuts.

Possible Cause

STEERING HARDENING

Operation

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.

TROUBL - 51

Troubleshooting X9 Evolution 500

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.

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

NOISY SUSPENSION If the front suspension is noisy, check: the efficiency of the front

shock absorbers; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers and the movement

bushings.

Suspension oil leakage

Possible Cause

Oil leakage from suspension Service the pumping members and check the sleeves and

OIL LEAKAGE FROM SUSPENSION

Operation

sealing rings are in good conditions. Replace the damaged

parts

TROUBL - 52

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system X9 Evolution 500

ELECTRICAL SYSTEM

Specification

1 Outside temperature sensor 2 Rear brake stop button 3 Light switch with flash 4 Indicators switch 5 Horn button 6 Emergency flashing button 7 Front fuse holder box 8 Fuse no.3 7,5A 9 Horn 10 Fuse 15A 11 Side stand switch 12 Intercom connectors 13 Voltage regulator 14 Electric side stand control unit 15 Engine stop remote control switch 30A 16 Remote electronic controller switch 30A 17 No. 2 side stand pump remote control switches 18 Fuse 70A 19 Fuse holder box with side stand pump base 20 LH taillight with sidelights bulb and flashing light bulb 21 Fuse 7,5A 22 Fuse 10A 23 Fuse 5A 24 Fuse 3A 25 No. 2 rear fuse holder boxes for control unit 26 Anti-tilting sensor 27 Saddle opening actuator 28 Intercom control unit

Desc./Quantity

ELE SYS - 54

X9 Evolution 500 Electrical system

Specification Desc./Quantity

29 Front left-hand direction indicator with bulb 30 Analogue instrument unit (5 bulbs) 31 Radio display 32 Digital instrument unit with no. 11 LED indicators 33 Front headlight 34 Front right-hand direction indicator with bulb 35 Diode unit 36 Diode 6A 37 Diode 1A 38 Main remote control switch 30A 39 Socket 12V 40 Helmet compartment glass bowl with lamp 41 Rear brake light with no. 5 bulbs 42 Number plate light with bulb 43 RH taillight with sidelights bulb and flashing light bulb 44 Start-up remote control switch 45 Battery 12V-14Ah 46 Helmet compartment light button 47 Starter motor 48 No. 3 7.5A fuses 49 Fuse holder box 50 Fuse 15A 51 HV coil 52 Connector cap 53 Saddle opening button 54 Fuel level indicator with pump 55 Immobilizer aerial 56 Key switch 57 Anti-theft alarm fitting 58 Electric fan 59 Electric fan remote control switch 30A 60 Fitting for accessories 61 Side stand button 62 Start up button 63 Reset button 64 Actuators control unit 65 Engine stop switch 66 Decoder 67 Front brake stop button 68 Wheel rpm sensor 69 Injection ECU 70 Side stand pump motor 71 End of stroke button 72 Enable button 73 No. 2 buttons with clamp 74 Fuel injector 75 Throttle potentiometer 76 Idle adjustment motor 77 Engine rpm sensor 78 Engine rpm sensor 79 Engine water temperature sensor 80 Stuck relay indicator 81 Engine oil pressure sensor 82 Magneto flywheel

WIRING COLOUR CHART: B = White - Bl = Blue - G = Yellow - Mr = Brown - N = Black - BV = White - Green - GN = Yellow - Black

- G = Grey - Rs Pink - R = Red - Vi = Purple - V = Green - VN = Green - Black - BN = White - Black - BBl = White - Blue - GV = Yellow - Green - Ar = Orange - Az = Light blue - GrBl = Grey - Blue - GrN

= Grey - Black.

CAUTION

ELE SYS - 55

Electrical system X9 Evolution 500

SHOULD ANY INTERVENTIONS TO THE ELECTRIC SYSTEM BE REQUIRED, MAKE SURE THAT THE LEADS TO THE ELECTRONIC IGNITION DEVICE ARE PROPERLY CONNECTED ACCORDING TO POLARITY AND TO THE LEAD COLOURS.

Components arrangement

COMPONENTS LOCATION

Specification

1 Side stand switch 2 Voltage regulator 3 Side stand control unit 4 Electronic control unit remote control switch 5 Engine stop remote control switch 6 Service remote control switch 7 Fuse holder box (n.3 7.5A, n.1 15A) 8 No. 2 start-up remote control switches 9 Magneto flywheel 373W 10 No. 2 buttons for side stand 11 Side stand pump motor 12 Pump unit with level indicator 13 Starter motor 14 Helmet compartment lighting button 15 Helmet compartment glass bowl 16 Socket 12V 17 No. 2 rear fuse holder boxes for control unit (n.1 3A, n.1

5A, n.1 10A, n.1 3A) 18 (Diode holder box (n. 2 6A and 2A diodes) 19 Fuse holder box (n.2 7.5A, n.1 15A and 5A) 20 Fuse holder box with base for stand pump remote control

switch (n.1 70A) 21 Digital instrument unit (11 indicators and led) 22 Analogue instrument unit (5 bulbs) 23 Headlight with n. 2 position bulbs and n.2 high/low beam

bulbs 55W 24 Front LH direction indicator with 10W bulb 25 Rear brake stop button

Desc./Quantity

ELE SYS - 56

X9 Evolution 500 Electrical system

Specification Desc./Quantity

26 Light switch with flash 27 Indicators switch 28 Horn button 29 Emergency flashing button 30 Reset button 31 Horn 32 LH taillight with sidelights bulb 5W and flashing light bulb

33 Rear tail light with 5 2.3W bulbs 34 Number plate light bulb 12V-5W 35 Rh taillight with sidelights bulb 5W and flashing light bulb

36 Battery 12V-14Ah 37 Front brake stop button 38 Engine stop switch 39 Wheel rpm sensor 40 Front RH direction indicator with 10W bulb 41 Main remote control switch 42 Light switch 43 Start up button 44 Side stand button 45 Key switch 46 Radio display 47 Electric fan remote control 48 30A fuse with start-up remote control switch 49 Radio/intercom/handsfree control unit 50 No. 2 pump remote control switches 51 Stuck relay indicator 52 No. 2 headlight remote control switches

10W

Conceptual diagrams

Ignition

ELE SYS - 57

Electrical system X9 Evolution 500

IGNITION SECTION

Specification Desc./Quantity

1 Anti-theft alarm fitting 2 Side stand switch 3 Engine stop switch 4 Voltage regulator 5 Battery 12V - 4Ah 6 Start up button 7 Diode 6A 8 Starter motor 9 Fuse no. 13 30 A 10 Remote starter switch 11 Main remote control switch 12 Diode 2 A 13 Key switch contacts 14 Two brake light buttons 15 Digital instrument unit 16 Engine stop remote control switch 17 Electronic control unit remote control switch 18 Immobilizer aerial 19 Decoder 20 HV coil 21 Start-up/injection electronic control unit 22 Fuse no. 2 10 A 23 Fuse no. 3 3A 24 Fuse no. 10 7,5A

Headlights and automatic starter section

HEADLIGHTS AND AUTOMATIC STARTER SECTION

Specification

1 Anti-theft alarm fitting 2 Bulb for upper beams 12V - 55W 3 Bulb for lowerbeams 12V - 55W

ELE SYS - 58

Desc./Quantity

X9 Evolution 500 Electrical system

Specification Desc./Quantity

4 Light switch 5 Side stand switch 6 Engine stop switch 7 Voltage regulator 8 Roof lamp for box helmet illumination with lamp 9 Helmet compartment lighting button 10 Battery 12V - 14 Ah 11 Fuse no. 13 30 A 12 Main remote control switch 13 Diode 2 A 14 Key switch contacts 15 No. 2 bulbs for front sidelight 12V-3W 16 License plate light bulb 12V - 5W 17 Two (2) taillight bulbs 12V - 5W 18 Digital instrument unit 19 4 Turn indicator bulbs 12V-10W 20 Indicators switch 21 Emergency flashing light button (4 direction indicators) 22 Engine stop remote control switch 23 Connettore per predisposizione accessori 24 Start-up/injection electronic control unit 25 Fuse no. 5 15 A 26 Fuse no. 8 7,5 A 27 Fuse no. 4 5 A 28 Fuse no. 12 7,5 A 29 Fuse no. 11 7,5 A 30 Fuse no. 9 15 A

Battery recharge and starting

BATTERY RECHARGE AND START-UP SECTION

Specification

1 Side stand switch 2 Engine stop switch 3 Magneto flywheel

Desc./Quantity

ELE SYS - 59

Electrical system X9 Evolution 500

Specification Desc./Quantity

4 Voltage regulator 5 Battery 12V - 4Ah 6 Start up button 7 Diode 6A 8 Starter motor 9 Fuse no. 13 30 A 10 Remote starter switch 11 Main remote control switch 12 Diode 2 A 13 Key switch contacts 14 Two brake light buttons 15 No. 5 bulbs for brake light 12V-2,3W 16 Digital instrument unit 17 Control unit power supply remote control switch (engine

18 Start-up/injection electronic control unit 19 Fuse no. 4 5 A 20 Fuse no. 10 7,5A

stop)

Level indicators and enable signals section

LEVEL INDICATORS AND ENABLE SIGNALS SECTION

Specification

1 Anti-theft alarm fitting 2 Side stand switch 3 Engine stop switch 4 Saddle opener actuator 5 Saddle opening button 6 Voltage regulator 7 Key switch contacts 8 Roof lamp for box helmet illumination with lamp 9 Helmet compartment lighting button 10 Battery 12V - 4Ah 11 Fuse no. 13 30 A 12 Main remote control switch

ELE SYS - 60

Desc./Quantity

X9 Evolution 500 Electrical system

Specification Desc./Quantity

13 Diode 2 A 14 Key switch contacts 15 Engine warning indicator 16 Engine not enable indicator 17 Low fuel warning light 18 High-beam warning light 19 Wheel RPM sensor 20 Outside temperature sensor 21 Digital instrument unit 22 Fuel level sender 23 Control unit power supply remote control switch (engine

24 Electronic control unit components remote control switch 25 Saddle opener receiver 26 Pump remote control switches 27 Side stand pump motor 28 Stuck relay indicator 29 Side stand out enable button 30 Side stand in enable button 31 Electro-hydraulic side stand actuation button 32 Side stand control unit 33 Tilting sensor 34 Air temperature sensor 35 Engine rpm sensor 36 Double wire screened cable 37 Fuel injector 38 Idle adjustment motor 39 Fuel pump 40 Engine temperature sensor 41 Diagnostics socket connector 42 Throttle potentiometer 43 Start-up/injection electronic control unit 44 Fuse no. 5 15A 45 Fuse no. 6 10A 46 Fuse no. 14 70A 47 Fuse no. 2 10A 48 Fuse no. 1 5A 49 Fuse no. 4 5 A 50 Fuse no. 12 7,5 A

stop)

Checks and inspections

Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. This system therefore requires no connection to the key switch. The three- phase generator provides good recharge power and at low revs, a good compromise is achieved between generated power and idle stability.

Stator check

Stator winding check-up

WARNING

THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

ELE SYS - 61

Electrical system X9 Evolution 500

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

4) Check that there is insulation between the each yellow cable and the ground.

5) If values are incorrect, replace the stator.

Recharge system voltage check

Look for any leakage

1) Check that the battery does not show signs of leaking fluid before checking the output voltage.

2) Turn the ignition key to OFF and connect the multimeter leads between the battery negative pole (-) and the Black cable.

3) With the multimeter leads connected, disconnect the Black cable from the battery negative pole (-).

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

Maximum current output check.

- With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter. With an efficient battery a value must be detected: > 20A

Check the charging current

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the tester terminals between the battery terminals..

3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm.

VOLTAGE REGULATOR/RECTIFIER

Specification

Type Non-adjustable three-phase transistor

Voltage 14 ÷ 15V at 5000 rpm with lights off

ELE SYS - 62

Desc./Quantity

X9 Evolution 500 Electrical system

Lights list

LIGHTS LIST

Specification Desc./Quantity

1 Dipped beam light N° 1, 12V-55W, halogen 2 Upper beam light N° 1, 12V-55W, halogen 3 Front position lights N° 2, 12V-3W, all glass 4 Front direction indicator lights N° 2, 12V-10W, spherical 5 Rear position lights N° 2, 12V-5W, spherical 6 Stop lights N° 5, 12V-2,3W, spherical 7 Rear turn indicator bulbs Two, 12V-10W, spherical 8 Instrument panel lights N° 5, 12V-2W, all glass 9 Helmet compartment light N° 1, 12V-5W, cylindrical 10 Number plate lights N° 1, 12V-5W, cylindrical

Fuses

The electric system is equipped with:

1. four fuses «A» into the under saddle compartment.

FUSE

Specification

1 N.1 Capacity: 15 A

Protected Circuits : Socket 12V for users- Under sad-

2 N.1 Capacity: 10 A

Protected Circuits : Saddle opening by button

3 N.1 Capacity: 10 A

Protected Circuits : PICS device

4 N.1 Capacity: 7,5 A

Protected Circuits : Dipped and high beam bulb

Desc./Quantity

dle compartment light

2. five fuses «B» next to the battery, on the left side.

FUSE

Specification

1 N.1 Capacity: 70 A

Protected Circuits : Electro-hydraulic stand

2 N.1 Capacity: 5 A

Protected Circuits : Electro-hydraulic stand

3 N.1 Capacity: 10 A

Protected Circuits : Fuel pump - Injector - H.V. coil

4 N.1 Capacity: 3 A

Protected circuits: Immobilizer (Decoder and EMS en-

Desc./Quantity

gine management control unit)

ELE SYS - 63

Electrical system X9 Evolution 500

Specification Desc./Quantity

5 N.1 Capacity: 5 A

Protected circuits: Diagnostic outlet - Decoder and

control unit enable signal

3. four fuses «C» into the trunk on the left side.

FUSE

Specification Desc./Quantity

1 N.1 Capacity: 15 A

2 N.1 Capacity: 7,5 A

3 N.1 Capacity: 7,5 A

4 N.1 Capacity: 7,5 A

Protected circuits: Horn - High beam bulb - Accesso-

ries

Protected circuits: Start-up enable signal - Brake light

lamp

Protected circuits: Front and rear position light - Num-

ber plate light

Protected circuits: PICS - Saddle opening by remote

control

4. a 30A fuse (main fuse), located next to the battery on the right side and on the start-up remote control switch; a spare fuse is provided below it.

ELE SYS - 64

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) controlled by the fifth wheel by the digital section;

- RPM counter controlled by the signal sent by the injection control unit;

- Fuel level indicator controlled by a resistive sensor (into the tank)

- Cooling fluid temperature indicator controlled by a resistive sensor (on the head) These instruments are electrical and managed by stepping motors.

The digital section has the following indications:

- Fuel reserve: amber coloured;

- Position and dipped beam lights: green coloured;

- Upper or passing beams: blue coloured;

- Left direction indicator: green coloured;

- Right direction indicator: green coloured;

- Emergency lights (four direction indicators): red coloured;

- Engine disabled: red coloured;

- ABS system failure (optional): red coloured;

- Oil pressure: red coloured;

- Injection warning: amber coloured;

- ALARM (electro-hydraulic stand): red coloured.

The fuel reserve, direction indicators and emergency flashing functions are activated by the instrument electronics. For example, the fuel reserve indicator light only turns on when the reserve indication coming from the engine lasts at least 13.5 seconds. This prevents the intermitting turning on of the reserve light indicator.

- The intermitting function is built in the instrument electronics: this allows operating the emergency lights with switch in position "OFF" and control switch off. The control switch is only active when the instrument panel is on.

ELE SYS - 65

Electrical system X9 Evolution 500

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.

- The LCD display gives a 5 digit indication for the total kilometres covered by the vehicle. It can be expressed in kilometres or in miles: of course, this indication cannot be reset. To select the indication,

press "Trip" and "M" at the same time, then tirn the key switch to "ON"; keep these 2 buttons pressed for more than 3" to display "SET" on the display, then the display switches from miles to kilometres, or vice versa.

The instrument panel digital section is completed by a liquid crystal display and 4 control buttons. The display has 3 icons:

- Oil

- Service

- Belt

- The "Oil" icon warns the user of the need of replacing the engine oil.

- The "Service" icon warns the user of the need of servicing the vehicle.

- The "Belt" icon warns the user of the need of replacing the driving belt. After servicing by the authorised workshop, the icon message must be reset by the "Reset" button located in the front side of the vehicle under the headlight upper cover. The "Reset" button allows resetting the kilometres covered and, in the case of "OIL" and "BELT" and "SERVICE", also the year count. This count remains active even if the battery is disconnected for a short time.

To reset one of the icons, press the "Reset" button for less than a second, then on the icon before that to be reset press "Reset" for at least 3" so as to display:

- The selectionj of the desired icon through the relevant solid light.

- The flashing of this light confirms the reset.

- For example, to reset the "Service" icon, go to "Oil" and press the "Reset" button for at least 3". To reset "Oil", repeat the above procedure going to "Belt". This procedure must be repeated since the selection of the icon and its reset are operations to be made at the same time (it is not possible to view the desired function and reset by two different button pressures since in this way the next icon would be reset).

Data check function

The date must be adjusted upon the vehicle delivery to the customer. This is because the clock starts counting the year for the «Service» function. If the clock has already been started, reset the functions

ELE SYS - 66

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. The digital section also has a functional check of the 4 analogue instruments and of the flashing light control. To start this check, keep buttons «Clock» and «Set» pressed and set the key switch to «ON». Within 4 seconds, the software version is displayed, the instruments indicate the scale bottom and the direction indicators turn on. At the end of the above procedure, there is the normal check of the indicator lights.

pics

PICS SECTION

Specification

1 Display pics 2 Intercom Controller 3 Intercom connectors 4 Battery 12V - 4Ah 5 Fuse no. 13 30 A 6 Key switch contacts 7 Fuse no. 7 10A 8 Fuse no. 12 7,5 A

Desc./Quantity

ELE SYS - 67

Electrical system X9 Evolution 500

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 K = Vehicle control unit connector M = MODE button P = Satellite connector S = Selection button V = Pilot connection Y = UP button C = Mobile phone G = Control unit audio connection cables

ELE SYS - 68

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 motorriders and that of hadsfree kit for mobile phones and RDS radios. The voice activation of the intercom function allows eliminating the ground noise caused by the wind It can be enabled both in automatic and manual mode selecting the two available levels high/low. Without passenger, the control unit can be used by the pilot as telephone handsfree and/or to listen to the radio or to the external audio source. The phone talk sets automatically to the pilot when the call signal is detected, but it can be switched to the passenger and/or vice versa by the button (Y) located on the satellite. The listening volume is adjusted by hand using buttons (R) and (X) for the two loudspeakers; this adjustment affects the audio, intercom and telephone. The control unit is provided with an auxiliary audio socket for a portable CD or cassette reader. During the telephone conversation, the external source is disconnected from the conversation channel and is restored at the end of the same. The control unit is adapted to specific mobile phones by the telephone cable (D) (supplied separately).

N.B.

THE MOBILE PHONE-CONTROL UNIT INTERFACE CABLE IS AVAILABLE FOR MOST MOBILE PHONES AVAILABLE ON THE MARKET. CHECK THE AVAILABILITY OF THE INTERFACE CABLE FOR YOUR SPECIFIC MOBILE PHONE AT THE CONCESSIONAIRE'S.

The microphone stem is provided with an elastic metal clip to fix it to the bottom edge of the helmet, on the right side. The loudspeaker (J) is fixed inside the helmet, at the ear height, by an attachment velcro (N). To optimise the intercom communication quality:

- For crash helmets, bend the microphone stem so that the capsule is fully seated into the helmet, with the white identification spot (see figure 2) facing the mouth.

- For open helmets, bend the microphone stem so that the capsule sensitive part is as close as possible to the mouth, using the white identification spot (see figure).

WARNING

ELE SYS - 69

Electrical system X9 Evolution 500

DON'T REMOVE THE MICROPHONE CAPSULE PROTECTION.

Insert both headsets into the connectors; the pilot's is the front one, the passenger's is the rear one. Move the ignition key to ON and the intercom will start automatically, at the low level (LOW); the intercom can be started in manual mode too. Adjust the volume using buttons (X) (R). The voice activation level can be switched to two levels (high; low). In automatic mode, the intercom starts automatically when the pilot or the passenger talk, and it remains active for 20 seconds at the end of the talk (be careful to the level set). To switch it to the high level (HIGH), press button (M) and then button (S) when the radio function is displayed.

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). The call can be temporarily interrupted by button (W) to switch to the intercom, and then resumed pressing the same button. In any case, when the call is received, the control unit emits a short sound on both loudspeakers, optionally with the phone's tone, if the phone model has one. When the vehicle is stopped, if a call is in progress the control unit remains on until the conversation is ended. The mobile phone should be set to the automatic answer function to prevent having to press a key to start the conversation. For the models not provided with this function: you can select the answer by any key option. The conversation volume can only be set by the mobile phone. The volume should be set to maximum. It is possible to connect a scatterer (2.5 W max) by the external scatterer socket (see figure 1). Besides the radio, intercom and handsfree kit functions, it is possible to connect the control unit to a portable CD reader or a walkman by a cable with stereo jack termination 3.5 mm. Adjust the external source volume so that it can be heard corrctly without having to adjust the intercom volume. During a conversation in intercom mode, the audio from the radio or from the external source remains in background at a lower volume.

N.B.

ALWAYS REFER TO THE USE MANUAL OF YOUR MOBILE PHONE TO SET UP THE FUNCTIONS DESCRIBED ABOVE.

N.B.

THE USERS OF MOTOROLA 8700, STARTAC 130™ CD920 CD930 AND BOSCH M-COM 506 MUST CONNECT THEIR MOBILE TO THE CONTROL UNIT WITH PHONE OFF: THE PHONE WILL SWITCH ON AUTOMATICALLY.

ELE SYS - 70

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-

senger crossed out

Passenger headphone inserted - Driver/passenger helmet -

driver crossed out

Driver and passenger headphones inserted - Driver and pas-

senger helmets

N.B.

EVERY TIME THE KEY SWITCH IS SET TO "ON" THE PICS SYSTEM DISPLAY CHECKS ALL AVAILABLE ICONS.

TURNING ON/OFF THE DEVICE (VEHICLE RUNNING)

Specification Desc./Quantity

Turn off - M > 4 sec. Turn on - M > 4 sec.

N.B.

WHEN THE VEHICLE IS STARTED, IF THE DEVICE HAD BEEN TURNED OFF THE ICON CHECK WILL BE DISPLAYED AND AT THE END OF THIS STEP IT WILL RETURN TO THE PREVIOUS POSITION (OFF). TO RESTART, PRESS "M" FOR MORE THAN 4 SEC.

Tuner - source - Speakerphone Tuner - source - Speakerphone

Tuner - source - Speakerphone - Intercom

MANUAL INTERCOM

Specification

Activation - M two times Short

Deactivation - M two times Short

N.B.

AFTER MANUAL DISABLING, THE INTERCOM SWITCHES TO AUTOMATIC MODE WITH LESS SENSITIVE ENABLE LEVEL (LOW).

Desc./Quantity

TUNER/SOURCE

Specification

Radio on - S Short Radio off - S Short

Source on - M go after S Short, > 2 sec.

Source off -M go after S short, > 2 sec

Manual tuning UP - M go after ^ Short, Continuous

Manual tuning DOWN -M go after ^ short, continuous

Automatic tuning UP - M go after ^ Short, Continuous

Automatic tuning DOWN -M go after ^ short, short

Memory scanning UP - ^ Short

Memory scanning DOWN - v Short

AUTOSTORE memorization - ^ > 2 sec.

RDS - M go after vol + (AF - TA - PTY) Short, Short

PTY functions (can only be selected after enabling PTY) - Vol.

Manual station memorization - Select station* go after S** go

after ^ o V (select station) and after S (to confirm)

Desc./Quantity

Short

> 4 sec., short, short

* By automatic or manual tuning described above ** Press until the display flashes

N.B.

THE BUTTONS MUST BE PRESSED IN A SEQUENCE NOT AT THE SAME TIME. RDS Radio Data System

ELE SYS - 71

Electrical system X9 Evolution 500

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. The same also applies to traffic news.

AF Alternative Frequencies

This allows the receiver to automatically tune on an alternative frequency stronger than the currently listened by relating to the same station.

TA Traffic Announcement identification

When the traffic news are on air, the function starts and interrupts any other radio stations to listen to the traffic news. You must be tuned on the station that transmits the news.

PTY Program Type

This allows identifying different types of music programs, to listen to the news, etc. There will be: News, Affairs, Info, Sport ecc.

Specification Desc./Quantity

Driver-passenger conversation passage - ^ Short

Intercom-telephone passage - v Short

Volume adjustment icon

Headphone inserted icon

Passenger headphone not inserted icon

SPEAKERPHONE TELEPHONE

Driver headphone not inserted icon

ELE SYS - 72

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

SPECIFICHE TECNICHE

Specification

1 Power 10.5V ÷ 16V

Desc./Quantity

1.4 A max

ELE SYS - 73

Electrical system X9 Evolution 500

Specification Desc./Quantity

2 Key 10.5V ÷ 16V 3 Maximum output power 500 mW per channel

4 Power consumption vehicle off ~0 mA

5 Frequency response audio 200 Hz - 20 kHz ± 3 dB

intercom 200 Hz - 5 kHz ± 3 dB 6 Microphones -69 dB ± 3 dB one-way 7 Frequency response: audio 200 Hz ÷ 20 kHz ± 3 dB 8 Loudspeakers 8 Ω - 0.5 mΩ

1.5 mA max

in stand-by ~280 mA

at maximum power ~500 mA

Sealed battery

Airtight battery start-up operations

If the vehicle is provided with an airtight battery, the only maintenance required is the check of its charge and recharging, if needed. These operations should be carried out before delivering the vehicle, and on a six-month basis for storage with open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every six months. INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

Before installing the battery on the vehicle, perform an open-circuit voltage check using a conventional tester.

- If voltage exceeds 12.60 V, the battery may be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained at 2).

2) Constant-voltage battery instructions

- Constant voltage charge equal to 14.40-14.70V

- Initial charge current equal to 0.3-0.5 x rated capacity

- Charge time:

- Recommended 10-12

- Minimum 6 h

- Maximum 24 h

Constant-current battery instructions

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: 5 h

WARNING

WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Recharging the battery

Normal bench charging must be performed using the specific battery charger (single) or (multiple), setting the battery charge selector to the type of battery that requires recharging (i.e., at a current equal

ELE SYS - 74

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.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the + positive sign.

Dry-charge battery

- BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN

- Lift the seat.

- Remove the two screws and the seat lock cover.

- Loosen the two Allen screws, pull the rear cover upwards and detach the stop light wiring.

- Remove the securing belt and the plastic cover.

- Remove the battery by detaching the negative (-) terminal first, followed by the positive one (+).

ELE SYS - 75

Electrical system X9 Evolution 500

- 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 retaining clip.

N.B. THE VENT PIPE WITH THE RETAINING CLIP ARE AL-

READY MOUNTED ON THE VEHICLE. N.B. AFTER RECHARGING AND BEFORE INSTALLING, EN-

SURE THAT THE BATTERY ELECTROLYTE DOES NOT EXCEED THE MAX LEVEL.

The figure shows two front hooks for the battery retaining belt: The top one, obtained in the chassis metal crosspiece, must be used for version 500 cc.

• Position the battery and fit the plastic cap, then lock by the plastic belt.

• Connect the wires to the battery terminals.

- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of

1.26, corresponding to 30 Bé at a minimum temperature of 15°C until the upper level is reached.

- Allow to stand for at least 2 hours, then top up the level with sulphuric acid.

- Within 24 hours, recharge using the special battery charger (single) or (multiple) at an intensity of about 1/10 of the battery nominal capacity and until

ELE SYS - 76

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".

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

1 Keep the pipe in vertical position 2 Inspect visually 3 The float must be freed

Checking the electrolyte level

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.

Charging status check

After topping-up the electrolyte level, check its density using special density gauge. When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. When refitting the battery onto the scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must be attached to the positive, + terminal.

Battery recharge

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.

Remove the battery from the vehicle removing the negative clamp first. Normal bench charging must be performed using the special battery charger (single) or (multiple), setting the battery charge selector to the type of battery that requires recharging (i.e., at a current equal

ELE SYS - 77

Electrical system X9 Evolution 500

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.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY.

Phonic wheel

- Ensure that the tone wheel is correctly installed on the scooter and connected to the electrical system.

- Turn the key switch to "ON".

- Access the tone wheel connector on the system side.

- Carry out the following measurements using the special tool.

Specific tooling

020331Y Digital multimeter

Check the supply voltage.

Keeping the connector in the position shown in the photo, check for battery voltage (12 V) with the polarity shown. If incorrect values are measured, check the electrical system and the digital instrument.

N.B. A DROP IN VOLTAGE OF 1 V IN RELATION TO THE BAT-

TERY VOLTAGE CAN BE CONSIDERED NORMAL.

ELE SYS - 78

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.

N.B. THE DIGITAL MULTIMETER IS NOT ABLE TO DISPLAY

THE VOLTAGE WHEN THE WHEEL IS ROTATED FAST.

If other voltages are measured or there is no alternation, replace the tone wheel.

Connectors

ECU

DIGITAL DASHBOARD CONNECTOR AND WIRING

Specification

1 Analogue card negative 2 Battery positive (+30) for analogue card 3 Analogue card serial clock output 4 Antitheft led output 5 Analogue card serial data output 6 Lights on output 7 (Not connected) 8 (Not connected) 9 Warning light input 10 Stuck relay alarm light input 11 Abs indicator input (not connected) 12 RH direction indicator output 13 RH direction indicator button input 14 LH direction indicator button input

Desc./Quantity

ELE SYS - 79

Electrical system X9 Evolution 500

Specification Desc./Quantity

15 Upper beam indicator input 16 Air temperature sensor input 17 Engine not actuable input 18 Oil pressure indicator input 19 (Not connected) 20 LH direction indicator output 21 Direction indicator stop button input 22 Reset service management button input 23 Water temperature sensor input 24 Fuel level sensor input 25 Battery positive (+30) 26 Tachometer sensor power supply 27 Tachometer sensor return to ground 28 Rpm sensor input 29 Battery positive (+30) 30 Antitheft led 31 Key positive (+15) 32 Tachometer sensor input 33 Negative 34 Air temperature sensor return to ground 35 Emergency light button input (hazard) 36 Lights on input

Seat opening receiver

RECEIVER CONTROL UNIT FOR SADDLE OPENER

Specification

1 Radio aerial 2 Actuator positive output 1 3 Reset / Input clearing 4 Battery positive 5 (Not connected) 6 Live positive lead 7 Ground lead 8 (Not connected) 9 (Not connected) 10 Selection input CH1 / CH3 11 Positive output actuator 1 12 Data for alarm output

Desc./Quantity

ELE SYS - 80

X9 Evolution 500 Electrical system

Immobiliser decoder

IMMOBILIZER DECODER

Specification Desc./Quantity

1 2 Immobilizer LED control (negative) 3 Base power supply (positive) 4 Negative 5 6 Electronic control unit EMS (serial) 7 8 Continuous power supply (positive) Immobilizer aerial

Engine rev. sensor

REV SENSOR

Specification Desc./Quantity

1 M: Male 2 F: Female 3 S: Shielding

Analogue odometer

ANALOGUE ODOMETER

Specification Desc./Quantity

1 STEPPER MOTOR A 2 STEPPER MOTOR B 3 STEPPER MOTOR C 4 STEPPER MOTOR D

ELE SYS - 81

Electrical system X9 Evolution 500

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.

Battery replacement

To separate the two half-shells of the remote control, insert a blade or a very thin tip of a screwdriver into a point of the outside edge, then let it slide along the entire circumpherence.

- Access the printed circuit and remove the two batteries from the contact reed.

- Place the new batteries with the positive pole facing the contact reed.

Characteristic

Batteries used:

CR1616

- Replace the card on the rear half-shell with the button and the led facing outwards.

- Install the pressure rubber on the button (the direction of installation is only one)

- Make the other half engage snap-wise.

Zeroing

- Remove the metal terminal by pliers and connect it to earth or to terminal 7 (black), for at least 10 seconds.

- This operation clears all remote controls stored in the control unit.

N.B. THE CONTROL UNIT CAN PROGRAMME UP TO 7 REMOTE

CONTROLS.

ELE SYS - 82

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 control unit.

- To program, the remote controls, set the key switch to «ON» for 1 to 3 seconds, then set it to «OFF».

- Within 10 seconds, reset the switch to «ON» and within 3 seconds, press the remote control button, then set to «OFF» again.

- If the saddle opens with this last operation, the programming was successful.

- You can program up to 7 remote controls by the above procedure.

ELE SYS - 83

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

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. MOREOVER, UPON REASSEMBLY, PREVENT THE EXHAUST PIPE FROM DAMAGING THE NEW GASKET. CHECK THE JOINT SEAL WITH ENGINE ON TO PREVENT FURTHER TROUBLES.

Removal of the engine from the vehicle

Removal of engine

WARNING

CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD.

- Disconnect the battery

- Remove the underseat compartment.

- Drain the coolant.

- Remove the complete muffler assembly.

- Remove the rear wheel.

- Remove the swinging arm.

- Remove the throttle control transmission.

- Remove the air filter coupling and the collector.

- Disconnect the ground cable from the engine.

- Disconnect the carburettor electrical devices and the starter motor power supply cable.

- Disconnect the fuel delivery and return pipes from the carburettor and the cooling system piping (outlet from the head and inlet to the thermostat).

ENG VE - 85

Engine from vehicle X9 Evolution 500

- 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 NEGATIVE LEAD.

Removing the support arm

- Release the lower fixing bolt of the right shock absorber from the support arm.

- Loosen the 2 screws fixing the arm to the engine.

- Remove the shim adjustment and release the wheel axle nut; to prevent rotation, use the integral brake keeping the LH lever pulled.

- Remove the support arm.

Removal of the lower bolt from LHS shock-absorber

- Remove the bolt shown in the figure.

N.B. TO REMOVE THE SHOCK ABSORBER SUPPORT, RE-

MOVE THE TWO NUTS FROM THE BRAKE CALIPER SIDE AND EXTRACT THE SCREWS.

Engine - swing-arm bolt removal

- Suitably support the engine.

- Remove the nut shown in the figure.

- Extract the pin.

- The engine can now be removed.

- Perform the operations for removal in the reverse order according to the proper tightening torques.

CAUTION

BE VERY CAREFUL NOT TO REVERSE THE TWO ACCELERATOR CONTROL TRANSMISSIONS. CHECK THAT WITH VALVE IN ABUTMENT AGAINST THE REGISTER THERE IS A SMALL CLEARANCE.

N.B.

ENG VE - 86

X9 Evolution 500 Engine from vehicle

CAREFULLY CLEAN THE INJECTOR «T» BRANCH BEFORE REPLACING THE QUICK COUPLINGS.

- 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.

- Check that accelerator and electric devices are in good working order.

ENG VE - 87

INDEX OF TOPICS

ENGINE ENG

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.

- Remove the nut and the two washers.

N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-

ENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

- Remove the six M6 screws.

ENG - 89

Engine X9 Evolution 500

- 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.

- Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor.

- Remove the transmission cover.

- Unscrew the two screws shown in the figure to remove the air conveyor.

Locking torques (N*m)

Air conveyor screws 11 ÷ 12

ENG - 90

X9 Evolution 500 Engine

Air duct filter

- Remove the external air conveyor.

- Unscrew the 2 fastening screws shown in the figure to remove the conveyor filter.

Removing the driven pulley shaft bearing

- Remove the transmission cover.

- Remove the Seeger ring.

- Place transmission cover on a wood surface and use the special tool so that it is adequately supported.

- Pull out the bearing using the special tool.

N.B. BELL MUST BE PLACED INTO THE TRANSMISSION COV-

ER, CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND. NOT ONLY IN THE AREA OF MAXIMUM STURDINESS.

Specific tooling

001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020439Y 17 mm guide

ENG - 91

Engine X9 Evolution 500

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.

- Install the new bearing using the special tool.

N.B. PROPERLY SUPPORT THE OUTSIDE COVER TO PRE-

VENT DAMAGING THE PAINTED SURFACE.

Specific tooling

020376Y Adaptor handle 020358Y 37x40-mm adaptor 020439Y 17 mm guide

Baffle roller

Plastic roller

- Check that the roller does not show signs of wear and that it turns freely.

- Loosen the retaining bolt using a 13 mm spanner.

- Remove the complete roller with bearing.

N.B. IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE

THE COMPLETE ROLLER.

ENG - 92

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 torque.

N.B. TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A

CORRECT TENSIONING OF THE BELT IS OBTAINED.

Locking torques (N*m)

Anti-vibration roller screw 16.7 ÷ 19.6

Removing the driven pulley

- Remove the driven pulley assembly with the belt.

Inspecting the clutch drum

- Remove the clutch bell.

ENG - 93

Engine X9 Evolution 500

- 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;

- Arrange the tool with the mean pins screwed in position "E" on the inside;

- Install the driven pulley unit onto the tool inserting the pins into the ventilation holes;

- Move the rear stop screw in abutment against the fixed driven pulley as shown in the figure.

CAUTION

THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIAL TOOL. DO NOT TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD CAUSE AN IRREVERSIBLE TOOL DEFORMATION. USING THE SPECIAL 55-MM WRENCH, REMOVE THE FASTENING RING NUT. LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT, CLUTCH, SPRING WITH SHEATH.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

Pin retaining collar

- Extract the collar using 2 screwdrivers.

ENG - 94

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 halfpulley.

- Remove the lock ring using pliers.

- Using the special tool inserted through the roller bearing, pull out the ball bearing.

N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAM-

AGING THE THREADING.

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide

N.B.

IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS NECESSARY TO SUPPORT THE UNIT BY THE BELL

Specific tooling

001467Y002 Driver for OD 73 mm bearing

ENG - 95

Engine X9 Evolution 500

- 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.

- Measure the outer diameter of the pulley bushing.

Characteristic

Minimum admissible diameter

49.91 mm

Standard diameter:

50.00 -0.015 -0.035 mm

Inspecting the driven sliding half-pulley

- Check that the belt contact surface is free from wear.

- Remove the 2 inside sealing rings and the 2 outside O-rings.

- Measure the movable half-pulley bushing inside diameter.

Characteristic

Maximum admissible diameter:

50.05 mm

Standard diameter:

50.00 +0.035 0.00 mm

Refitting the driven half-pulley bearing

- Install a new roller bearing using the special tool.

N.B.

PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUTWARDS.

- Properly support the half-pulley to prevent damaging the threading.

ENG - 96

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 020363Y 20 mm guide

- Insert the Seeger lock ring.

Refitting the driven pulley

- Insert the new oil guards

- Insert the new O-rings

N.B.

O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RADIUS, AT THE BASE OF THE HALF-PULLEY.

- Install the half-pulley on the bushing being careful not to damage the top sealing ring during the introduction.

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of grease, this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.

PIAGGIO 633234, X9 Evolution 500 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual