All rights reserved. Reproduction, in whole or in part, forbidden.”
Data subject to change without notice.
No responsibility is assumed for the use of non-genuine components and accessories other than those tested
and approved by the Manufacturer.
C.L.D. - Pontedera (PI)
Page 2
SERVICE STATION
MANUAL
X9 500 cc
This manual has been designed by Piaggio for use in authorized dealers' and subdealers' workshops.
It is assumed that those who use this publication for maintaining and repairing Piaggio vehicles are familiar with the
principles of mechanics and with vehicle repairing procedures and techniques. Any significant changes to the
characteristics of the vehicles or to specific repairing procedures will be covered in updates of this manual.
Since satisfactory results cannot be obtained without the necessary equipment and tooling, we recommend referring
to the pages of this manual concerning the specific equipment required and to the catalogue of specific tools.
Pieces of particularly important information are identified as follows:
Note: Provides important information intended to simplify and clarify a procedure.
Warning
Caution
NOTE - For any intervention to the engine, refer to the “Service Station Manual” for 500 cc Engines.
- Denotes specific procedures to be used to avoid damaging the vehicle.
- Identifies specific procedures to be followed to avoid injury to repairing personnel.
Page 3
TABLE OF CONTENTS
VEHICLE SPECIFICATIONS
AND OVERHAUL DATA
SPECIFIC TOOLING
MAINTENANCE AND TROUBLESHOOTING
ELECTRICAL EQUIPMENT
1
2
3
4
ENGINE
FRONT AND REAR SUSPENSIONS
BRAKING SYSTEM
BODYWORK
5
6
7
8
PREDELIVERY OPERATIONS
TABLE OF WORKING TIMES
9
10
Page 4
Assembly plays
Vehicle overhaul data
1
(Values in mm)
DIAMETER
MEASURING
HEIGHT
A43.2
B 43
01_004
Mating between piston and cylinder
(Values in mm)
PARTDIMENSIONSMATING CLASSESASSEMBLY
CODECYLINDERPISTONCLEARANCE
Cylinder92
Ø CB91.997 - 92.00491.954 - 91.961
Piston91.961
- 0.010
+ 0.018
+ 0.014
- 0.014
A91.990 - 91.99791.947 - 91.954
C92.004 - 92.01191.961 - 91.968
0.036
-
0.050
Ø PD92.011 - 92.01891.968 - 91.975
The piston must be fitted so that the arrow faces the exhaust side. The piston rings must be fitted so that the marks
face upwards.
Piston rings
Ring opening
Arrange for the
piston rings
opening as shown
Assemble the rings
2 and 3 with the
“Top” writing facing
upwards.
in the figure
“A” value of the ring
inside the cylinder
(Values in mm)
PARTDIMENSIONSCLEARANCESEATCLEARANCE
CODECLEARANCEAFTER USE
1st Compression ring92 x 1.5A0.15 - 0.350.5
2nd Compression ring92 x 1.25A0.25 - 0.500.65
Scraper ring92 x 2.5A0.25 - 0.500.65
01_005
1 - 7
Page 5
Vehicle overhaul data
SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO: CR = 10.5 : 1
+
“A” MEASUREMENT
(WITH PISTON AT TDC)
-
N.B.: The “A” measurement is referred to the piston
projection or recess value; it indicates the type of
gasket to be fitted on the cylinder to restore the
compression ratio. Therefore the more the surface
formed by the piston crown sticks out of the surface
formed by the cylinder top, the thicker the gasket will
be. Vice versa, the more the piston crown is hollow to
the cylinder top, the less thick the gasket will be.
FIT THE GASKETS SHOWN IN THE TABLE
ACCORDING TO THE “A” MEASUREMENT
NOTE: THE “A” MEASUREMENT MUST BE TAKEN WITH NO
GASKET FITTED BETWEEN CRANKCASE AND CYLINDER
“A” MEASUREMENTTHICKNESS OF BASE GASKET
- 0.185 - - 0.100.4 ± 0.05
- 0.10 - + 0.100.6 ± 0.05
+ 0.10 - + 0.1850.8 ± 0.05
Crankshaft/crankcase axial clearance 0.1 - 0.5 mm (cold engine)
01_006
1 - 8
01_010
Page 6
Crankshaft/connecting rod axial clearance
PARTDIMENSIONSCLEARANCE
Web, transmission sideA =0.8
Shaft section, transmission sideB =19.6
Connecting rodC =22
Shaft section, flywheel sideE =19.6
Web, flywheel sideF =13
Crankshaft assemblyG =63.5
± 0.025
+ 0.05
0
- 0.10
- 0.15
+ 0.05
0
± 0.025
+ 0.1
- 0.05
Vehicle overhaul data
1
01_007
D = 0.20 - 0.40
Crankshaft alignment and diameters
- Measure the housings on both axes x and y.
Standard diameter
Class 1 40.010 - 40.016
Class 2 40.016 - 40.022
Max. allowable runout:A = 0.15 mm
B = 0.01 mm
C = 0.010 mm
D = 0.10 mm
01_008
01_009
1 - 9
Page 7
TABLE OF CONTENTS
SPECIFIC TOOLING
2
Page 8
Specific Tooling
Specific tools for Piaggio X9 500 cc 4-stroke 4-valve
RECOMMENDED TOOLS
TOOL NAMEPART NO.
Circlip pliers002465Y
Steering thrust ring removing drift020004Y
Crankshaft aligning tool020074Y
Support for “METABO HG 1500/2” air heater020150Y
“METABO HG 1500/2” air heater020151Y
Mityvac-type vacuum pump020329Y
Stroboscopic gun for two- and four-stroke engines020330Y
Digital multimeter020331Y
Single battery charger020333Y
Multiple battery charger020334Y
Magnetic stand and dial gauge020335Y
Engine support connection020482Y
Engine mount base020527Y
Engine mount revolving base020604Y11
= New tools
2 - 2
Page 9
Specific Tooling
NECESSARY TOOLS
TOOL NAMEPART NO.
STEERING SEAT FITTING TOOL, to be fitted with parts 9 - Lower001330Y
bearing adaptor, 10 - Upper bearing adaptor
Bell Ø 80 mm001467Y002
20 mm pliers001467Y006
Bell Ø 63 mm001467Y007
18 mm pliers001467Y008
Bell Ø 45 mm001467Y017
Bell Ø 60 mm001467Y031
15 mm pliers001467Y034
Hub bearing extraction bell001467Y035
Steering tube ring spanner020055Y
Oil pressure gauge020193Y
Valve seal rings assembly tool020306Y
37x40 mm adaptor020358Y
42x47 mm adaptor020359Y
52x55 mm adaptor020360Y
20 mm guide (Driven pulley bearings)020363Y
25 mm guide (Driven pulley bearings)020364Y
Ø 28x30 mm adaptor020375Y
Adapter sleeve020376Y
Bushing (valve removing tool)020382Y012
15 mm guide020412Y
Valve oil seal extractor020431Y
Oil pressure gauge unio020434Y
17 mm guide (countershaft bearings)020439Y
Driven half pulley spring compressor020444Y
46-55 mm spanner020444Y009
Ø 24 mm adaptor020456Y
Steering tube lower bearing extractor020458Y
Drift for fitting bearing on steering tube020459Y
Injection tester kit020460Y
Flywheel extractor020467Y
Piston fitting band020468Y
Injection tester reprogramming kit020469Y
Piston pin retainer fitting tool020470Y
Countershaft timing peg020471Y
Flywheel retaining tool020472Y
Clutch bell housing retaining tool020473Y
Drive pulley stop spanner020474Y
Piston position comparator support020475Y
Pillar kit020476Y
Ø 37 mm adaptor020477Y
Driven pulley needle roller drift020478Y
Countershaft stop spanner020479Y
Fuel pressure measuring kit020480Y
Control unit interface wiring harness020481Y
30 mm guide020483Y
Piston stop fork020512Y
Compass wrench (valve lifter bell stop)020565Y
Exhaust gas analyser494929
2
2 - 3
Page 10
Spark plug
Check and replacement
Maintenance
Warning
is cold. Replace the spark plug every 12,000 km. The
use of unsuitable ignition control units and spark plugs
other than those specified can seriously damage the
engine.
Recommended spark plug: CHAMPION RG 6 YC
- Put the vehicle on the central stand.
- Open the door on the left side of the vehicle by
levering in the recess in the lower part of the door after
removing the screw.
- Disconnect the spark plug HV cable cap.
- Unscrew the spark plug with the spanner provided.
- Check the spark plug to see if the insulator is cracked,
the electrodes are worn out or excessively sooty. Also
check the condition of the seal washer and measure
the spark gap with a suitable thickness gauge.
Spark gap: 0,7 - 0,8 mm
- If necessary adjust the spark gap by carefully bending the side electrode.
If the spark plug has any of the defects mentioned
above, replace it with a plug of the recommended
type.
- Insert the plug into the hole with the proper inclination, screw it in fully by hand and then tighten it with
the specially designed spanner.
Tightening torque: 10 N·m (1 Kg·m)
- Push the spark plug cap all the way down onto the
spark plug and then proceed to the reassembly.
- Remove the spark plug when the engine
NGK CR 7 EKB
03_001
3
03_002
Air filter
- Remove the left-hand lower side panel as described
in Chapter 8-Bodywork.
- Remove the cleaner cap after loosening the eight
fixing screws, including one screw of the knob type.
- Pull out the filter element.
- Replace the air filter with a new one.
Note: Check and if necessary blow the air filter every
6,000 km. Direct the air jet from the inside to the outside
of the filter (i.e. in the opposite direction to the air flow
during normal engine operation).
Warning
roads, the air filter needs to be cleaned and replaced at
shorter intervals than indicated in the Maintenance
Schedule.
Warning
in place as this would result in excessive wear of the
cylinder and piston as well as in damage to the throttle
body.
- If the vehicle is mostly used on dusty
- Do not run the engine if the air filter is not
03_003
03_004
3 - 3
Page 11
Maintenance
Engine oil level
In four-stroke engines oil is used to lubricate the valve
gear components, the crankshaft bearings and the
power plant. A lack of engine oil can cause seriousdamage to the engine.
In all four-stroke engines, oil deterioration and consumption are, to some extent, normal, especially during
running-in. Consumption partly depends on the riding
style (for example, constantly riding at full throttle
increases oil consumption).
Checking the oil level
Perform this operation when the engine cold, as described below:
1) Put the vehicle on its central stand on a flat surface.
2) Unscrew dipstick «A», dry it with a clean cloth andrefit by screwing it completely.
3) Remove the dipstick again and check that the oil
level is between the MAX and MIN marks on the
dipstick; top up if necessary.
The MAX level mark indicates an amount of about 1700
cc of engine oil.
The level will be lower if checked after using the vehicle
(i.e. when the engine is hot). To obtain a correct
indication of the oil level, wait for at least 10 minutes
after switching off the engine.
Since a certain amount of oil remains in the circuit, the
replenishment must be made by adding approximately
1,500 cc of fresh oil through cap «A». Subsequently
start the engine, let it idle for a few minutes and then
switch it off. After about 5 minutes, check the level and
if necessary top up without exceeding the MAX level.
The filter cartridge must be replaced every time the oil
is changed. For top-ups and renewals use fresh oil of
the Selenia HI Scooter 4 Tech type.
Note: Renew the oil when the engine is hot.
MAX MIN
03_005
Topping up
If the oil level is too low, top up by adding fresh oil
without exceeding the MAX level.
Approximately 400 cc of oil are needed to restore thelevel between the MIN and MAX marks.
Oil pressure warning light
A warning light on the instrument panel comes on when
the ignition key is turned to the “ON” position. The light
must go out after the engine has started.
Should the warning light come on while braking,
idling or cornering, check the oil level and the
lubrication system as soon as possible.
Renewing the oil and the filter
The oil and the filter must be renewed every 6,000 km.
Drain all the oil from the engine by removing gauze
strainer drain plug «B» on the transmission side. To
facilitate the outflow, also remove cap/dipstick «A».
Once the oil has drained completely through the drain
hole, unscrew oil filter cartridge «C» and remove it as
described below.
A
C
03_006
B
03_007
3 - 4
Page 12
Replacing the filter
Maintenance
Warning
ment. Carry out the disposal of the oil, the gasket and
the filter in accordance with the law.
Caution
hot engine parts.
- Remove the silencer.
- Remove filler plug «A».
- Remove and clean the drain plug gauze strainer with
compressed air.
- Using a strap wrench for filters, remove cartridge
filter «C».
- Ensure that the O-rings on the prefilter and the drain
plug are in good condition.
- Lubricate the O-rings and then refit the gauze strainer
and the oil drain plug. Tighten the drain plug with the
prescribed torque.
- Fit a new cartridge filter after lubricating the O-ring.
Turn in until the gasket makes contact and then
tighten it with the prescribed torque.
- Put the vehicle on the central stand on level ground.
- Unscrew oil dipstick «A», wipe it with a clean cloth,
reinsert it and then screw it in fully.
- Pull out the dipstick again and check that the oil level
is between the MIN and MAX marks (see figure); if the
level is below the MIN mark, top up with oil.
- Reinsert the dipstick and screw it tight.
Renewing the hub oil
- Remove oil filler plug «A».
- Unscrew oil drain plug «B» and drain all the oil.
- Retighten the oil drain plug and then fill the hub with
fresh oil.
Engine cooling
Adding coolant and bleeding air from the system
The level of the fluid must be checked every 6,000 km
when the engine is cold.
Follow these steps:
- Put the vehicle on the central stand on level ground.
- Remove the expansion tank cap and top up if the
coolant is below or near the MIN level in the expansion
tank. The level of the fluid should always be between
the MIN and MAX marks.
- To have an indication of the coolant level, refer to the
groove in the plastic strip that can be seen through the
coolant filler hole. The upper and lower parts of the
groove correspond to the MAX and MIN levels respectively.
- The coolant consists of a 50 percent mixture of
demineralized water and antifreeze solution with a
base of ethylene glycol and corrosion inhibitors.
Total coolant capacity: ~ 1,8 lt
- To check the presence of air in the circuit follow the
procedure described in Chapter 11-Cooling, in the
manual of Engine 500 cc.
- Switch off the engine and allow it to cool down. After
a few minutes, remove the expansion tank cap and
check the level of the fluid.
- If necessary, top up by pouring fresh coolant into the
expansion tank up to the correct level.
03_010
Warning
- To prevent the coolant from leaking out
of the expansion tank during use, be sure to never
exceed the MAX level when refilling.
Water pump
If the water pump becomes noisy or liquid leaks through
the pump drain hole, check the water pump as described in Chapter 5-Flywheel cover of the manuale
Engine 500 cc. Perform the following preliminary operations:
- Put the vehicle on the central stand on level ground.
- Remove the lower right-hand side panel and the
right-hand footboard as described in Chapter 8Bodywork.
- Remove the silencer to gain access to the flywheel
cover as described in Chapter 5-Engine;
- Remove the sleeves from the water pump cover and
the filler cap from the expansion tank and empty the
cooling circuit.
Warning
- Perform the operation when the engine
is cold.
03_011
- As described in the manual Engine 500cc, partially
drain the system and overhaul the pump.
- After solving the problem and refitting all components,
fill and bleed the cooling circuit again.
N.B.: Change the coolant as described in Chapter 11Cooling of the Manual Engine 500 cc
- Remove the water pump cover shown in the figure
after loosening the six fixing screws.
- Cooling circuit capacity: ~ 1,8 lt.
3 - 6
03_013
Page 14
Adjusting the play of the valves - Checking the valve
gear timing
To adjust the play of the valves and to check the valve
gear timing as described in Chapter 7-Thermal Unit and
Timing system of the Engine manual, follow these
preliminary steps:
- Put the vehicle on the central stand;
- Remove the relevant body sections to gain access to
the pivot fixing the engine to the swingarm (refer to
Chapter 8-Bodywork);
- Support the bottom of the engine, e.g. with a jack;
- Remove the engine from the frame as described in
Chapter 5-Engine;
- Shift the engine backwards to make room for the
removal of the cylinder head cover (until the swingarm
cross member touches the starter motor).
- After adjusting the play of the valves, refit the components by following the reverse procedure to the removal.
Maintenance
03_012
3
Warning
prevent it from touching the stop push button of the
electrohydraulic stand.
Note: The checking areas are shown in the two figures
at the right.
Play of valves:
Intake0,20 mm cold engine
0.15
Exhaust0,20 mm cold engine
0.15
Checking the level
To gain access to the front and rear brake fluid reservoirs, remove the covers on the handlebar cover.
Follow these steps:
- Put the vehicle on the central stand and turn the
handlebar to the central position.
- Remove cap «A» after loosening fixing screw «B».
- Check the level of the fluid through the sight.
A certain decrease in the level of the fluid occurs as a
result of pad wear.
Restoring the brake fluid level
- Do not lower the engine too much to
03_012_4
B
A
03_012_1
Warning
Brake fluid type: TUTELA TOP 4
Use the following procedure:
Remove the «A», covers and the tank cap by unscrewing the two screws, remove the gasket and restore the
brake fluid level with liquid of the recommended type,
without exceeding the max. level.
- Only use brake fluid classified as DOT 4.
03_012_2
3 - 7
Page 15
Maintenance
Warning
- Keep the brake fluid away from the skin,
the eyes and clothing. In case of contact, rinse generously with water.
Warning
- The brake fluid is highly corrosive. Take
care not to spill it on the paintwork.
Warning
- The brake fluid is hygroscopic, i.e. it
absorbs humidity from the air. If the humidity contained
in the fluid exceeds a given concentration, the braking
action becomes insufficient.
Never draw the fluid from open or partly empty containers.
Under normal climatic conditions the fluid should be
renewed every 20,000 km, or in any case every two
years.
N.B.: Change the brake fluid and bleed the system as
described in Chapter 7-Braking system.
03_012_3
Steering lock
Disassembly with lock turned to “OFF”
- Remove the rear shield as described in Chapter 8-
Bodywork.
- Remove the immobilizer aerial shown in the figure.
- Disconnect the wiring.
- Pull out the retaining spring shown in the figure and
remove the ignition switch.
03_014
3 - 8
03_015
Page 16
- Push the bolt lightly and extract the retainer from the
70÷73 cm
10 m
milled part shown in the figure.
- Extract the bolt assembly from the lock body.
- To refit, follow the reverse procedure.
Maintenance
03_016
Removal with lock in LOCK position
The bolt retaining spring is not accessible in the LOCK
position. It is then necessary to drill the bolt as show in
the figure to eject it.
Note: To refit the bolt from this position, first disengage
the steering lock by putting the lock body (inner and
outer part) in the OFF position.
Proceed as described in the previous paragraph.
Adjusting the headlight
- Place the unloaded vehicle on a level surface, 10
metres from a half-lit white screen, with the tyres
inflated to the prescribed pressure. Ensure that the
axis of the vehicle is perpendicular to the screen.
- Draw a horizontal line on the screen 70-73 cm above
the ground.
- Switch on the headlight, turn on the low beam and
check that the horizontal line that divides the dark
area from the lighted area is not above the line
previously drawn on the screen. To shift the headlight, use the specially designed screw in the front
shield (see figure).
3
03_017
03_018
3 - 9
Page 17
TABLE OF CONTENTS
ELECTRICAL EQUIPMENT
4
Page 18
ELECTRICAL EQUIPMENT
3
43
38
8
16
20
33
35
15
48
36
34
17
9
32
13
10
42
19
41
51
37
44
2
3
11
50
21
49
4
5
7
45
14
12
1
31
28
29
27
46
26
25
22
6
47
18
2
30
52
24
40
39
SIDESTAND SWITCH
1
VOLTAGE REGULATOR
2
STAND CONTROL UNIT
3
ELECTRONIC CONTROL UNIT RELAY SWITCH
4
ENGINE STOP RELAY SWITCH
5
SERVICES ELECTROMAGNETIC SWITCH
6
FUSE BOX (3 X 7.5A, 1 X 15A)
7
NO. 2 SOLENOID STARTERS
8
375W FLYWHEEL MAGNETO
9
2 X STAND BUTTON
10
STAND PUMP MOTOR
11
PUMP ASSEMBLY WITH LEVEL INDICATOR
12
STARTER MOTOR
13
HELMET COMPARTMENT LAMP BUTTON
14
HELMET COMPARTMENT LAMP
15
12V SOCKET
16
2 X REAR FUSE BOX FOR CONTROL UNIT (1 X 3A, 1 X 5A,
17
1 X 10A, 1 X 3A)
DIODE BOX (2 X 6 A AND 2 A DIODE)
18
FUSE BOX (2 X 7.5A, 1 X 15A AND 5A)
19
FUSE BOX WITH STRIP FOR STAND PUMP
20
ELECTROMAGNETIC SWITCH (NO. 1 OF 70A)
DIGITAL INSTRUMENT SET (11 WARNING LIGHTS AND LEDS)
21
ANALOG INSTRUMENT SET (5 LAMPS)
22
HEADLIGHT, 2 X PARKING LIGHT BULB, HIGH/LOW BEAM
23
55/55W BULB
LH FRONT TURN INDICATOR WITH 10W BULB
24
REAR BRAKE LIGHT BUTTON
25
LIGHTS SWITCH WITH HEADLIGHT FLASH
26
27
TURN INDICATOR SWITCH
28
HORN BUTTON
29
HAZARD WARNING LIGHT BUTTON
30
RESET BUTTON
31
TRUMPET HORN
32
LH REAR LIGHT WITH 5W PARKING LIGHT BULB AND 10W
TURN INDICATOR BULB
33
REAR BRAKE LIGHT, 5 X 2.3W BULB
34
NUMBER-PLATE LIGHT 12V-5W
35
RH REAR LIGHT WITH 5W PARKING LIGHT BULB AND 10W
TURN INDICATOR BULB
ment, take special care to ensure that the leads that link
up to the electronic control device are properly connected by observing the polarity and colour coding of
the connectors.
- When working on the electrical equip-
4 - 5
Page 20
Schematic wiring diagrams
Ignition section
8
4
5
6
12
87
85
2
13
87
30
86
30
85
86
20
9
7
11
10
3
15
+
14
-
DOWN
OFF RUN
16
UP
17
1
87
85
86
18
30
19
1
IMMOBILIZER DECODER
2
IGNITION SWITCH CONTACTS
3
VOLTAGE REGULATOR
4
FLYWHEEL MAGNETO
5
INJECTION ELECTRONIC POWER UNIT
6
HV COIL
7
SPARK PLUG
8
DIGITAL INSTRUMENT SET
9
5A FUSE
10
3A FUSE
4 - 6
11
IMMOBILIZER AERIAL
12
ENGINE STOP RELAY SWITCH
13
MAIN RELAY SWITCH
14
12V-14Ah BATTERY
15
30A FUSE
16
ENGINE STOP SWITCH
17
10A FUSE
18
ELECTRONIC POWER UNIT ELECTROMAGNETIC SWITCH
19
SIDE STAND SWITCH
20
2A DIODE
04_002
Page 21
Lights section
Schematic wiring diagrams
22
19
3
1
2
I
0
P
30
86
30
86
85
85
87
87
6
0
1
4
2
5
7
8
4
86
23
15
20
-
+
21
-
18
14
13
+
17
12
16
30
85
87
9
10
11
1
12V-55W LOW BEAM BULB
2
12V-55W HIGH BEAM BULB
3
LOW BEAM RELAY SWITCH
4
HIGH BEAM RELAY SWITCH
5
DIGITAL INSTRUMENT SET
6
LIGHTS SWITCH
7
2 x 12V-5W FRONT PARKING LIGHT BULB, 2 x 12V-5W REAR
PARKING LIGHT BULB, 1 x 12V-5W NUMBER-PLATE LIGHT BULB
8
IGNITION SWITCH CONTACTS
9
MAIN RELAY SWITCH
10
FLYWHEEL MAGNETO
11
VOLTAGE REGULATOR
7.5 A FUSE
12
15 A FUSE
13
7.5 A FUSE
14
7.5 A FUSE
15
30 A FUSE
16
12V-14Ah BATTERY
17
HELMET COMPARTMENT LAMP BUTTON
18
12V-5W HELMET COMPARTMENT LAMP BULB
19
12V-180W SOCKET
20
15A FUSE
21
LIGHTS SELECTOR SWITCH
22
23
2A DIODE
04_003
4 - 7
Page 22
Schematic wiring diagrams
Battery recharge and starter section
7
-
18
DOWN
10
6
14
M
4
+
11
8
3
15
19
17
UP
OFF RUN
87
86
16
13
9
12
1
30
85
5
20
87
30
85
21
86
2
1
IGNITION SWITCH CONTACTS
2
FLYWHEEL MAGNETO
3
7.5A FUSE
4
STARTER RELAY SWITCH
5
VOLTAGE REGULATOR
6
STARTER MOTOR
7
12V-14Ah BATTERY
8
FRONT BRAKE LIGHT BUTTON AND START INHIBITOR SWITCH
9
REAR BRAKE LIGHT BUTTON AND START INHIBITOR SWITCH
10
DIGITAL INSTRUMENT PANEL
11
START BUTTON
4 - 8
30A FUSE
12
6A DIODE
13
5 X 12V-2.3W BRAKE LIGHT BULB
14
INJECTION POWER UNIT
15
ENGINE STOP RELAY
16
ENGINE STOP SWITCH
17
STAND SWITCH
18
5A FUSE
19
MAIN RELAY SWITCH
20
2A DIODE
21
04_004
Page 23
Consent, electrohydraulic central stand device and level indicators section
Schematic wiring diagrams
13
2
1
4
5
6
7
8
10
3
9
24
12
14
M
85
8730
25
15
11
16
23
22
+
30
18
21
19
87
30
30
86
85
-
86
87
85
26
M
20
4
86
17
30
28
86
85
87
27
29
1
DIGITAL INSTRUMENT
2
ANALOG INSTRUMENT SET
3
INJECTION ELECTRONIC CONTROL UNIT
4
OUTSIDE TEMPERATURE SENSOR
5
WHEEL REVOLUTION SENSOR
6
FUEL LEVEL THERMISTOR
7
OIL PRESSURE SENSOR
8
RESET BUTTON
9
EMERGENCY BUTTON
10
7.5A FUSE
11
IGNITION SWITCH CONTACTS
12
RADIATOR ELECTRIC FAN MOTOR
13
ENGINE TEMPERATURE SENSOR
14
FLYWHEEL MAGNETO
15
VOLTAGE REGULATOR
16
30A FUSE
17
12V-14Ah BATTERY
18
70A FUSE
19
STAND HYDRAULIC PUMP RELAY SWITCHES
20
STAND HYDRAULIC PUMP MOTOR
21
STAND ELECTRONIC CONTROL UNIT
22
STAND INHIBITOR SWITCH
23
STAND LIMIT SWITCH
24
BUTTON
25
ELECTRIC FAN RELAY SWITCH
26
5A FUSE
27
MAIN ELECTROMAGNETIC SWITCH
28
2A DIODE
29
RELAY SIGNALER GLUED
30
1A DIODE
04_005
4 - 9
Page 24
Schematic wiring diagrams
Turn indicators, horn and accessories prewiring section
6
1
14
13
12
5
10
2
4
9
3
7
15
86
85
8
11
30
87
(+)
8
1
DIGITAL INSTRUMENT PANEL
2
TURN INDICATORS, 2 + 2 X 12V-10W BULB
3
TURN INDICATOR SWITCH
4
ACCESSORIES PREWIRING
5
HORN BUTTON
6
HORN
7
15A FUSE
8
GNITION SWITCH CONTACT
4 - 10
9
7.5A FUSE
10
7.5A FUSE
11
MAIN RELAY SWITCH
12
PRESETTING FOR INTERCOM POWER UNIT INPUT
13
PRESETTING FOR RADIO POWER UNIT SIDE
14
PRESETTING FOR RADIO DISPLAY SIDE
15
2A DIODE
04_006
Page 25
Control panel, warning lights, instruments
Schematic wiring diagrams
18
5
7
6
8
17
20
19
21
22
23
24
31
32
33
34
36
35
4
1
3
2
4
10
9
12
11
13
14
15
16
25
26
27
28
30
29
1
ANALOG CARD GND
2
BATTERY POSITIVE TERMINAL (+30) FOR ANALOG CARD
3
ANALOG CARD SERIAL CLOCK OUTPUT
4
ANTITHEFT DEVICE LED OUTPUT
5
ANALOG CARD SERIAL DATE OUTPUT
6
LIGHTS-ON OUTPUT
7
(NOT CONNECTED)
8
(NOT CONNECTED)
9
INJECTION WARNING LIGHT INPUT
10
RELAY ALARM WARNING LIGHT INPUT GLUED
11
MALFUNCTIONING BRAKE LIGHT OUTPUT
12
RH TURN INDICATOR OUTPUT
13
RH TURN INDICATOR BUTTON INPUT
14
LH TURN INDICATOR BUTTON INPUT
15
HIGH BEAM WARNING LIGHT INPUT
16
AIR TEMPERATURE SENSOR INPUT
17
ENGINE START DISABLED WARNING LIGHT INPUT
18
OIL PRESSURE WARNING LIGHT INPUT
19
MALFUNCTIONING BRAKE LIGHT WARNING LIGHT INPUT
20
LH TURN INDICATOR OUTPUT
21
TURN INDICATOR STOP BUTTON INPUT
22
RESET SERVICE BUTTON INPUT
23
COOLANT TEMPERATURE SENSOR INPUT
24
FUEL LEVEL SENSOR INPUT
25
BATTERY POSITIVE TERMINAL (+30)
26
SENSOR POWER SUPPLY
27
SPEEDOMETER SENSOR EARTH RETURN
28
RPM SENSOR INPUT
29
BATTERY POSITIVE TERMINAL (+30)
30
ANTITHEFT DEVICE LED
31
KEY POSITIVE TERMINAL (+15)
32
SPEEDOMETER SENSOR INPUT
33
GND
34
AIR TEMPERATURE SENSOR EARTH RETURN
35
HAZARD WARNING LIGHT BUTTON INPUT
36
LIGHTS-ON INPUT
04_007
4 - 11
Page 26
Electrical equipment
Battery recharge system
The battery recharge system includes a three-phase
generator with a permanent-magnet flywheel.
The generator is directly connected to the voltage
regulator.
The latter is in turn directly connected to earth and to the
battery positive terminal via the 30A fuse.
Therefore, the system is not connected to the ignition
switch.
The three-phase generator allows considerable recharging power and a fair compromise between supplied power and slow running stability at low rpm.
Recharging system
Searching for leaks
1) Before measuring the output voltage, ensure that no
electrolyte is leaking from the battery.
2) Turn the ignition key to the OFF position and connect
the tester terminals between the battery negative
pole (-) and the black cable.
3) Detach the black cable from the battery negative
pole (-) while keeping the tester terminals connected.
4) With the ignition key still in the OFF position, the
ammeter should read ≤ 0,5 mA.
Checking the charging voltage
Warning
that the battery is in good condition.
1) Put the vehicle on the central stand.
2) With the battery properly connected to the circuit,
position the multimeter prods between the battery
terminals.
3) Start the engine with all lights out and rev up while
measuring the voltage.
- Before performing the check, ensure
VOLTAGE: 14.0-15.0V at 5,000 rpm.
4 - 12
Page 27
Checking the stator winding
Electrical equipment
Warning
stator in place.
1) Remove the undersaddle compartment door
2) Detach the connector between stator and regulator
with the three yellow cables.
3) Measure the resistance between each of the yellow
terminals and the other two.
Resistance:0.2 - 1 Ω
4) Check that each yellow wire is insulated from earth.
5) If the resistance is not as specified, replace the stator.
Checking the peak current
- With the engine off and swithboard “ON”, turn the
vehicle lights on and let the battery tension set to 12V.
- Connect the amperometric pliers to the 2 outlet re-
charge positive poles of the regulator.
- With lights on, start the engine and read the value on
the pliers with the engine running at high speed.
- The check can be performed with the
4
With efficient battery, the measured value is: > 20A
Voltage regulator/rectifier
Specifications
ITEMSTANDARD VALUE
TypeTransistorized, non-adjustable, three-phase
Voltage regulator/rectifier
Voltage 14 - 15V at 5000 rpm with lights off
4 - 13
Page 28
Electrical equipment
Instrument panel
The X9 is equipped with a dual instrument panel consisting of an analog section installed in the front fairing
and a digital section mounted on the handlebars.
The analog section includes:
- A dual-scale (km/h-mph) speedometer controlled by
the speed sensor by means of the digital section;
- A tachometer controlled by a signal coming from the
power unit-injection;
- A fuel gauge controlled by a resistive sensor (in the
fuel tank);
- A coolant temperature indicator controlled by a resistive sensor (on the cylinder head).
These instruments are of the electrical type, and are
operated by step-by-step motors.
The digital section includes the following indicators:
- Reserve fuel warning light: amber.
- Lights-on and low beam warning light: green.
- High beam warning light: blue.
- Left-hand turn indicator warning light: green.
- Right-hand turn indicator warning light: green.
- Hazard warning lights (four turn indicators): red
The reserve fuel, turn indicator and hazard warning lights are activated by the electronics of the instrument. For
example, the fuel reserve warning light comes on only when the reserve fuel indication from the fuel tank lasts a
minimum of 13.5 seconds. This prevents the warning light from blinking when the engine begins to run on reserve
fuel.
- The flashing function is built in the electronics of the instrument, which allows the hazard warning lights to work
when the ignition switch is in the “OFF” position and the control switch is disabled. The control switch is active only
when the instrument panel is on.
For greater riding safety, the “turn indicator control” function is connected to the mileometer. If the turn indicators are
inadvertently left on, they are automatically switched off after 1 kilometre.
- The “engine start disabled” warning light is activated by the sidestand switch and the emergency switch on the right
side of the handlebar.
- The indication “brake light bulb burnt-out” is activated when at least two of the five bulbs fail to operate.
- The warning light is controlled by a circuit that measures the absorption of the brake light bulb.
- The liquid crystal display shows a 5-digit total mileage count in either kilometres or miles. Naturally, this counter
can never be reset. To select the unit, with key turned to “OFF”, press the “Trip” and “M” buttons at the same
time and turn the ignition switch to the “ON” position. If the two buttons are depressed for longer than three
seconds, the word “SET” is displayed and then the unit toggles between kilometres and miles.
4 - 14
Page 29
3 Four fuses «C» in the glove compartment, on the left
side.
FuseProtected circuits
1 x 15 AFlash, horn, accessories
1 x 7.5 ABrake light buttons, start button, starter
relay switch
1 x 7.5 ALights switch, parking lights,
number-plate light
1 x 7.5 ADigital instrument panel, PICS control
unit power supply
4 One fuse «D» of 30A (main fuse) located next to the
battery on the solenoid starter. A spare fuse is also
provided underneath.
Electrical equipment
C
04_016
D
List of bulbs
FunctionTypePower
Low beam bulbhalogen12V-55W
High beam bulbhalogen12V-55W
Front parking light bulball-glass12V-5W x 2
Front turn indicator bulbspherical12V-10W x 2
Rear parking light bulbspherical12V-5W x 2
Brake light bulbsspherical12V-2.3W x 5
Rear turn indicator bulbspherical12V-10W x 2
Instrument panel lighting bulball-glass12V-2W x 5
Glove compartment lamp bulbcylindrical12V-5W
Number-plate light bulbcylindrical12V-5W
4
04_017
4 - 23
Page 30
Electrical equipment
Battery (12V - 14Ah)
Caution
- The battery electrolyte causes severe
burns as it contains sulphuric acid. Avoid contact with
the eyes, the skin and clothing.
In case of contact with the eyes or the skin, rinse
generously with water for about 15 minutes and immediately seek medical attention.
In case of ingestion, immediately drink large quantities
of water or milk. Subsequently administer milk of magnesia, beaten eggs or vegetable oil. Immediately seek
medical attention.
Batteries produce explosive gases. Keep them away
from open flames, sparks and cigarettes. If the battery
is charged in a closed place, ensure adequate ventilation.
Always protect the eyes when working close to batteries.
Keep out of reach of children.
Installing charged-dry batteries:
1) - Remove the short closed tube and the plugs. Fill
the cells to the upper level with accumulator sulphuric acid, specific weight 1.26, corresponding to
30° Bé at a temperature of at least 15°C.
2) - Leave at rest for at least two hours and then restore
the level by adding sulphuric acid.
3) - Recharge within 24 hours by means of the specific
charger 020333Y (single station) or 020334Y (multiple station) with intensity equal to about 1/10 of
the battery rated power, until the acid density
reaches the value of about 1,27, corresponding to
31 Bé, and until such values have stabilized.
4) - When the charging is over, level off the acid (by
adding distilled water), put the plugs back into
place and clean thoroughly.
5) - Proceed to install the battery on the vehicle, taking
care to observe the connections described at item
3) of the paragraph Recharging the battery.
Removing and installing the battery
1
Hold tube upright
2
Check visually
3
Float must be disengaged
04_026
- Lift the saddle;
- Remove the rear optical unit and the covering ele-
ment;
- Disconnect the battery by detaching the negative (-)
cable first and then the positive (+) cable.
- Remove the battery strap and then the battery itself.
- To install the battery, follow these steps:
- Fit the lower support shown in the figure on the
battery compartment bottom.
4 - 24
04_018
Page 31
- Fit the front element.
- At last, fit the left side element.
Electrical equipment
04_019
- Cut the breather pipe supplied as shown in the figure.
- Fit the pipe until it contacts the battery and in the
direction shown in the figure.
4
04_020
NOTCHING
NOTCHING
04_021
In contact
The notching
must be in the
lower half of
the pipe
04_022
4 - 25
Page 32
Electrical equipment
- Lock the pipe with a tear-clamp and cut the end that
sticks out of the clamp.
- Insert the battery in the compartment taking care to fit
the breather pipe in the bottom hole.
04_023
- Insert the battery in the compartment taking care to fit
the breather pipe in the bottom hole.
04_024
04_025
4 - 26
Page 33
Electrical equipment
Checking the electrolyte level
Frequently check that the electrolyte reaches the upper
level. To top up, only use distilled water.
If you need to top up the battery too frequently, check
the vehicle electrical equipment as the battery is certainly working in overload conditions, which will lead to
rapid deterioration.
Checking the battery charge
After restoring the electrolyte level, check its density
with the special hydrometer (see figure).
When the battery is charged, electrolyte density must
be between 30 and 32 Bé, corresponding to specific
gravity of 1.26-1.28 at a temperature not lower than
15°C. If density has fallen below 20° Bé, the battery is
completely discharged and needs recharging.
If the vehicle is not used for some time (1 month or more)
the battery must be periodically recharged. In three
months the battery runs down completely.
When refitting the battery take care not to invert the
connections: the ground lead (black) is to be connected
to the negative (-) terminal and the other lead (red)
must be connected to the positive (+) terminal.
Battery recharge
Caution
cell plugs. Keep free flames or sparks away from the
battery during recharge. When the battery has to be
removed from the vehicle, disconnect the negative
terminal first.
Charge the battery using the specific charger 020333Y
(single station) or 020334 (multiple station), by putting
the charger selector on the type of battery to be recharged (use current at 1/10 of the battery rated power).
Connection to the power supply must be made by means
of the corresponding poles (+ with + and – with -).
4) Cleaning the battery
Keep the battery clean, especially the top; coat the
terminals with Vaseline.
Warning
pacity than the one recommended. The use of a fuse of
unsuitable capacity may result in serious damage to the
whole vehicle or even cause a fire.
- Before charging the battery remove all
- Never use fuses having a greater ca-
Warning
that are harmful for batteries. Use only distilled water.
Warning
battery must be charged before using the vehicle.
Failure to properly charge the battery before starting the
vehicle will cause the battery premature breakdown.
Sealed battery
Putting a sealed battery into service
If the vehicle is equipped with a sealed battery, servicing
is limited to checking the charge level and, if necessary,
recharging the battery.
These operations must be performed during predelivery,
and every six months of open-circuit storage.
Therefore, in addition to checking and, if necessary,
charging the battery before delivery, it is necessary to
carry out these operations before storing the vehicle,
and subsequently every six months.
RECHARGING THE BATTERY FOLLOWING OPENCIRCUIT STORAGE
1) Checking the voltage
Before installing the battery on the vehicle, measure the
open-circuit voltage with an ordinary multimeter.
- If the voltage exceeds 12.60 V, the battery can be
installed without recharging.
- If the voltage is less than 12.60 V, recharge the battery
as described at item 2).
2) Constant-voltage charging method
- Constant voltage: 14.40-14.70 V
- Initial charging current: 0.3-0.5 x rating
- Charging time:Recommended 10-12 hrs
3) Constant-current charging method
- Initial charging current: 1/10 of rating
- Charging time:Maximum5 hrs
Caution
(far below 12.6V), 5 hours’ recharging may not be
enough to obtain optimum performance.
In these conditions, however, to avoid damaging the
battery beyond repair, it is essential not to recharge it for
more than 8 consecutive hours.
- Normal drinking water contains salts
- To ensure maximum performance the
Minimum6 hrs
Maximum24 hrs
- When the battery is deeply discharged
4
4 - 27
Page 34
TABLE OF CONTENTS
ENGINE
5
Page 35
Engine
Engine disassembly from frame
Caution
- Perform these operation with the en-
gine cold.
- Disconnect the battery.
- Remove the saddle, and the upper and lower body
sides (Chapter 8 - Bodywork)
- Drain the coolant (Chapter 3 - Maintenance)
- Disassemble the muffler assembly and relevant support, as described below.
- Remove the rear wheel (Chapter 6 - Front/Rear
Suspension)
- Remove the accelerator control transmissions and
mark their position on the throttle body control.
- Disconnect the air filter sleeve and the engine oil
values collecting pipe.
- Disconnect the earth cable from the engine.
- Disconnect the electrical devices from the throttle
body, head, and starter feed cable.
- Detach the fuel delivery and return pipes to the
injector and the coolant system pipes (head outlet
and thermostat input)
- Close the injector Tee Joint with rubber plugs to
prevent dirt from entering.
- Detach the H.V. cable from the spark plug.
- Detach the generator harness from the vehicle electrical system.
Caution
Warning
- Take care when handling the petrol.
- When installing the battery, first fix the
positive cable and then the negative cable.
Muffler assembly disassembly
- Unloose the two fixings of the exhaust manifold on
the head.
- Unloose the 3 screws fixing the muffler to the supporting arm.
- Remove the muffler assembly.
05_001
5 - 2
05_002
Page 36
Supporting arm disassembly
- Unscrew and remove the r.h. shock absorber to
supporting arm lower fixing bolt
- Unloose the arm to engine 2 fixing screws.
- Remove the split pin and unscrew the wheel axle nut;
avoid the wheel turning by means of the integral
brake.
- Remove the supporting arm.
Disassembly of l.h. shock absorber lower pin
- Remove the bolt shown in the figure.
N.B.: To be able to remove the shock absorber support,
remove the two nuts on the brake caliper side and the
screws.
Engine
05_003
Engine pin/swing arm disassembly
- Adequately support the engine.
- Remove the nut shown in the figure.
- Remove the pin.
- Now the engine is free.
Engine assembly to vehicle
- Perform the assembly in the reverse order observing the tightening torques indicated in Chapter 1.
Warning
a slight play with the valve in contact with the register.
- Take care not to invert the position of the two accelerator control transmissions. Check that both show
05_004
5
05_005
N.B.: Carefully clean the injector Tee Joint before reassembling the quick-connections. Direct the injector in such
a way as to avoid any interferences of the electrical cables with the coolant and fuel pipes.
- Check the engine oil level, top up if necessary with oil of the recommended type.
- Fill the cooling system (Chapter 11-Cooling).
- Check the accelerator and electrical devices function.
5 - 3
Page 37
Handlebar
Removal
- Begin by removing the radio-interphone and then
disconnect the feeder cable.
- Remove the digital panel support and the front and
rear sections of the handlebar cover as described in
Chapter 8-Bodywork.
- Disengage the handlebar from the components installed on it.
- Remove the two counterpoises after loosening the
side screws.
- Remove the pumps after loosening the screws on the
clevises shown in the figure.
- Slide the throttle control off the handlebar after loosening the fixing screws.
- Remove the left handgrip.
- Loosen the bolt fastening the handlebar to the steering tube shown in the figure and then remove it.
Remove the handlebar and the plastic support.
Note: If the handlebar is removed to proceed to the
removal of the front fork, simply overturn the handlebar
onto the front of the vehicle without removing the parts
fitted on it. Take care not to damage the flexible transmissions, the pipes or the bodywork.
Fitting
Perform the removing procedure in reverse order. To
align the handlebar with the steering tube, align the
notch on the handlebar with the notch on the sterring
tube. Tighten the fasteners with the torques specified in
Chapter 1.
- Remove the two brake calipers as described in
Chapter 7-Braking system.
- Unscrew the axle locknut.
- Disengage the axle by loosening the two screws on
the right-hand fork sheath (see figure).
- While supporting the wheel, remove the axle on the
right side of the vehicle.
Caution
not to damage the speed sensor.
Overhauling the front wheel
Check the bearings for any excessive play or stickiness
causing noise and uneven rotation of the wheel.
Should the wheel bearings need to be replaced, follow
these steps:
- Using a suitable extractor on the inner race, remove
the two bearings on the left side of the wheel (speed
sensor side).
- When removing the wheel, take care
6
06_003
06_004
6 - 3
Page 38
Front and rear suspensions
- Support the wheel to allow the removal of the internal
parts.
- Using a mallet and a drift of suitable diameter, simultaneously drive out the inner spacer, the right-hand
bearing and the outer spacer complete with the dust
ring on the same side.
- Refit the two bearings on the left side of the wheel rim.
- Using a tube of suitable diameter on the outer race of
the bearings, push them home into their seats.
- Fit the spacer in the right side of the wheel as shown
in the figure.
- Fit the right-hand bearing by following the same
procedure as the other bearings.
06_005
- Refit the two front brake discs as described in Chapter 7-Braking system.
- Fit the outer spacer and the related ring taking care
not to compress it excessively against the wheel
bearing.
- Check the condition of the speed sensor seal ring and
of the related groove in the wheel rim.
- Insert the pin from the r.h. side by aligning the spacers.
- Take care not to damage the phonic wheel.
- Offset the drives beforehand by about 90°.
- Tighten the wheel axle nut.
- Tighten the two screws of the clamp on the pin
housing, on the r.h. sheath.
- Remove the mudguard as described in Chapter 8Bodywork.
- Remove the handlebar and the front wheel as previously described.
- Loosen the two screws fastening the brake line supports (see figure).
Note: It is also possible to remove one of the two fork
rods after loosening the two related screws on the fork
upper plate.
- Remove the two rings, the middle washer shown in
the figure and the spacer below.
Front and rear suspensions
06_009
Caution
allow the steering tube to come out of the head tube.
Warning
the fork assembly so as to prevent it from falling.
- Pull out the fork assembly.
Specific tool:
Steering tube ring spanner: 020055Y
Replacing the steering bearings
- Using the specially designed tool shown in the figure
and a mallet, remove the upper ball bearing.
N.B.:Act at different times between the two points at
180°. Failure to observe this instruction may damage
the housing.
Specific tool:
Steering thrust ring removing drift: 020004Y
- Adequately support the vehicle so as to
- Before unscrewing both rings, support
06_010
6
06_011
- Use the same method to extract the seat of the lower
roller bearing.
N.B.: Act at different times between the two points at
180°. Failure to observe this instruction may damage
the housing.
Specific tool:
Steering thrust ring removing drift: 020004Y
06_012
6 - 5
Page 40
Front and rear suspensions
- Remove the lower roller bearing and the dust cover
ring from the fork by means of the specific tool.
- Use the larger half ring pair and the shorter steering
tube protection.
Specific tool:
Steering tube lower bearing extractor: 020458Y
Fitting the steering bearing
- Check the condition of the bearing races and rollers.
- Fit the upper bearing and the lower bearing housing
by inserting the specific tool in the steering sleeve,
provided with 2 adapters.
- Fit the dust cover ring and the roller bearing on the
steering tube by means of a piece of tube having a
suitable diameter, and by resting against the inner
race of the roller bearing.
- Loosen the two screws shown in the figure and
disengage the calipers from their supports.
- Remove the retaining ring and the pin. During the
operation pay special attention to the pin retaining
spring as it may spring off abruptly.
- Remove the two pads by pulling them downwards.
- Check the thickness of the pads.
Wear limit: 1.5 mm
- Repeat the operations on the brake caliper on the
opposite side.
To fit the pads, follow these steps:
- Insert the two pads into the caliper.
- Fit the pin retaining spring.
- Press down the spring to allow the insertion of the pin
(see figure).
- Insert the pin.
- Fit the retainer.
- Fit the caliper on its support and then tighten the two
screws with the prescribed torque.
Tightening torques:
Screws fixing caliper to support: 20 - 25 N·m
N.B.: If during the assembly it is not possible to fit the
caliper on the disc, refit the pistons in the caliper
carefully.
Braking system
07_001
07_002
Removing and replacing the rear brake pads
Follow these steps:
- Remove the left-hand rear shock absorber support
with the shock absorber itself and the rear wheel as
described in Chapter 6-Front and rear suspensions.
- Unloose the two screws fixing the brake caliper support to the engine.
- Remove the caliper from its support.
- Remove the retaining ring and the pin.
- Remove the two pads by pulling them downwards.
- Check the thickness of the pads.
Wear limit: 1.5 mm
- If the thickness of the pads is less than the prescribed
limit, replace them.
- Refit the parts by following the same procedure used
for the front brake pads.
- Tighten the two screws fixing the caliper support to the
engine with the prescribed torque.
7
07_003
Tightening torques:
Screws fixing caliper to support: 20 - 25 N·m
Screws fixing caliper support to engine: 20 - 25 N·m
7 - 3
Page 46
Braking system
Brake discs
Checking disc thickness
It is important to check the brake discs. The discs
should always be perfectly clean and free from rust,
grease and dirt and shown no deep scoring.
Thickness of front discs when new .............. 4.0 mm
Thickness of rear disc when new .................5.0 mm
Wear limit (front discs) ................................. 3.5 mm
Wear limit (rear) ........................................... 4.5 mm
Checking disc distortion
Take down the wheel and, using suitable equipment,
check that the axial runout of the braking surface does
not exceed the specified limit.
Max. axial runout: 0.1 mm
If the runout exceeds the specified limit, replace the disc
as described below and repeat the measurement.
If the problem persists, check and if necessary replace
the wheel hub.
07_004
Note: When refitting, thoroughly clean the disc and its
seat on the hub.
Replacing the front brake discs
Follow these steps:
- Remove the front wheel as described in Chapter 6Front and rear suspensions.
- For each disc, loosen the five screws shown.
- Carefully clean the seats on the front wheel hub and
the discs.
- When fitting the disc, take care to position it properly
by referring to the arrow stamped on it.
- Tighten the screws with the prescribed torque and
smear them with LOCTITE Threadlocker medium 242.
Note: The disc side bearing the arrow indicating the
direction of rotation must face the outside of the vehicle.
General guidelines for servicing the hydraulic braking system
Caution
wear protective gloves when working on the hydraulic
system. In case of contact with the eyes, rinse generously with water.
The used brake fluid is harmful to the environment.
Collect and dispose of used oil according to the regulations in force.
Under normal climatic and riding conditions the brake
fluid should be renewed every two years. However, if
the brakes are subjected to heavy stress the fluid
should be renewed at shorter intervals.
When reassembling, reused parts should be perfectly
clean and free from oil, diesel fuel and grease. It is
therefore necessary to thoroughly clean them with
denatured alcohol. Braking system.
- The brake fluid is corrosive. Always
Note: When topping up or renewing the brake fluid, only
use DOT4 - NHTSA 116 fluid.
Always ensure that all parts are perfectly clean.
The brake fluid is highly corrosive. Take care not to spill
it on painted surfaces.
The brake fluid is hygroscopic, i.e. it absorbs humidity
from the air. If the humidity contained in the fluid
exceeds a given concentration, the braking action becomes insufficient owing to a reduction in the boiling
point of the liquid.
Note: Always take the brake fluid from sealed containers.
Note: Rubber parts must not be left immersed in alcohol
for longer than 20 seconds. After the washing, dry the
parts with a compressed air jet and wipe them with a
clean cloth.
Seal rings must be immersed in the liquid of use. The
use of the PRF1 protective agent is permitted.
Caution
fluid is present on the brake discs or pads. Should the
discs and the pads become contaminated with brake
fluid, replace the pads and clean the disc with a goodquality solvent.
- The braking action is decreased if brake
Renewing the brake fluid and bleeding air from
the brake circuit
Front brake
Follow these steps:
1) Put the vehicle on the stand on level ground.
2) Remove the brake fluid pump reservoir cap as
described in Chapter 8-Bodywork.
3) Remove the two screws shown in the figure and
open the front brake fluid reservoir.
4) Using the bleeder screw on the brake caliper,
empty the brake circuit through a pipe of suitable
diameter.
5) Collect the used fluid in a suitable container.
6) Operate the brake pump until all the fluid has come
out.
7) Close the bleeder valve.
8) Fill the circuit reservoir to the maximum level with
fluid of the prescribed type.
9) Attach the pipe of the specific tool (Mityvac-type
manual pump) to the bleeding connection.
10) While acting on the bleeder with the specific tool,
constantly pour fresh fluid into the reservoir so as to
avoid sucking in air. Stop pumping as soon as the
fluid flows out of the bleeder with no air bubbles.
11) Tighten the bleeder screw with the prescribed
torque.
7
07_008
Tightening torque:
Drain screw: 12 - 16 N·m
7 - 5
Page 48
Braking system
Note: If air keeps coming out during the bleeding,
check all connections. If these are tight, check the
different pump seals and the caliper pistons.
During the operation oil may trickle from the bleeder
screw onto the caliper and the disc. In that case,
carefully dry the caliper and degrease the disc.
Specific tool:
Vacuum pump MITIVAC type: 020329Y
Combined brake
A control system allows the left brake lever to
simultaneously operate the left-hand front caliper and
the rear caliper.
To empty the circuit, follow the procedure given for the
right-hand front brake, using the bleeder of both brake
calipers, front and rear.
07_009
To bleed the system, follow these steps:
1) Attach the specific Mityvac tool to the bleeder fitted
on the pressure divider valve shown in the figure.
2) Fill the left brake fluid reservoir to the maximum
level.
3) Slowly operate the left brake lever while pouring
fresh fluid into the reservoir until all the air has come
out, thus obtaining the bleeding of the first section
of the combined brake line. Tighten the bleeder
valve with the prescribed torque.
4) Proceed to bleed each caliper - the front caliper first
and then the rear caliper - following the same
procedure used for the front brake.
Specific tool:
Vacuum pump MITIVAC type: 020329Y
Tightening torque:
Oil drain screw: 12 - 16 N·m
07_010
7 - 6
Page 49
Removing the brake calipers
Check the condition of the brake lines, the gaskets and
the related connections. Should any fluid leak onto the
calipers, replace them by following these steps:
- Empty the circuit as previously described for the
brake fluid renewal.
- Remove the caliper pipe connection shown in the
figure.
- Collect any fluid residues left in the pipe.
- Remove the two screws fixing the caliper to the
support.
- Remove the caliper.
- Remove the brake pads from the caliper as previously described.
- Replace the caliper with a new one and then follow
the reverse procedure to the removal.
Note: Fit new copper gaskets on the connection.
- Tighten the two fixing screws with the prescribed
torque.
- Complete the operation by filling and bleeding the
circuit.
- Use the same procedure for the three calipers, the
only difference being that the rear brake caliper must
be removed from the vehicle together with its support.
This is obtained by loosening the two screws shown
in the figure after removing the rear wheel as described in Chapter 6-Front and rear suspensions.
To remove and replace the brake pumps, follow these
steps:
- Empty the related braking circuit as described in the
previous paragraphs.
- Remove the connection shown in the figure taking
care to prevent any fluid residues from coming out.
- Remove the two screws fastening the clevis to the
handlebar.
- Replace the broken pump.
- Reassemble taking care to replace the copper gaskets. Fasten the connection and tighten the two
screws fixing the pump to the handlebar.
7
07_013
07_014
7 - 7
Page 50
Braking system
Note: Take care to properly insert the specially designed
projection on the pump clevis in the related hole in the
handlebar (see figure).
- Complete the overhaul by filling and bleeding the
circuit.
- The removing procedure is the same for both brake
pumps (see figure).
Replacing the pressure divider valve
Removal
Should the braking action between the front left and
rear calipers by unevenly distributed (e.g. with the
same surface and adhesive force on both wheels the
rear brake jams while the front brake is not applied or
vice versa, or the brakes work in a completely different
manner, or the divider valve does not work properly),
follow these steps:
07_015
2
1
- Empty the combined brake circuit as previously described.
- Remove the front countershield as described in Chapter 8-Bodywork.
- Unscrew rear caliper connection 1 (see figure).
Note: Place a rag under the divider valve to prevent
brake fluid from soiling the brake pads or other components.
- Remove front brake caliper connection 2.
- Remove connection 3, conveying the fluid from the
pump to the valve.
- Remove the two cheese-headed socket screws fixing
the valve to the frame in the two holes shown in the
figure.
- Remove the valve and replace it with a new one.
Fitting
Follow the reverse procedure to the removal.
3
07_016
07_017
Note: Fit new copper gaskets on the connections.
- Tighten the screws fixing the valve to the frame and,
above all, the connections on the brake lines with the
prescribed torque.
- Fill and bleed the brake circuit as previously de-
scribed.
7 - 8
Tightening torques:
Oil pump - Integral braking device tube
connection: 16 - 20 N·m
Front brake caliper - Integral braking device connection: 20 - 25 N·m
Rear brake caliper - Integral braking device connection: 20 - 25 N·m
Page 51
TABLE OF CONTENTS
BODYWORK
8
Page 52
BODYWORK
8 - 2
: Perform all operations with great care. Plastics are easily damaged.
: Avoid cleaning painted plastics with solvents containing petrol and its derivatives.
LUBRICATE WITH OIL
LUBRICATE WITH GREASE
APPLY PRODUCT
CLEAN CAREFULLY
WARNING - HANDLE WITH CARE
ALWAYS REPLACE
Page 53
Front central cover
Bodywork
- Lift the rearview mirror covers.
- Unscrew the five fixing screws shown in the figure.
- Remove the front central cover with the weather strip.
Lower guard - Windscreen
- Remove the rearview mirrors;
- Unloose the 3 fixing screws shown in the figure and
relevant spacers;
- Remove the upper windscreen;
- Unloose the 4 fixing screws with washers, located
under the rearview mirrors and under the front central
cover;
- Remove the lower guard and relevant weather strip.
➡
➡
➡
➡
➡
08_001
➡
➡
➡
Note: When refitting, take care to properly reinsert the
weather strips into their seats.
Front lamp cluster
- Remove the three fixing screws.
- Detach the electrical connectors.
- Remove the front lamp cluster by pulling it forward.
Front shield
- Remove the two front screws.
- Remove the two screws behind the wheel.
- Unscrew the remaining six fixing screws.
- Detach the electrical connectors.
- Remove the front shield with the turn indicators.
08_002A
➡
➡
➡
08_003
8
➡
➡
08_004
8 - 3
Page 54
Bodywork
Digital instrument panel support
- Remove the three fixing screws.
- Detach the electrical connectors.
- Remove the support with the digital instrument panel.
- Pay special attention to the electrical connectors.
Front handlebar cover
- Loosen the two screws fixing the radio-interphone
unit.
- Detach the electrical connectors.
- Remove the radio-interphone.
- Remove the two handlebar cover lower screws (one
on each side).
➡
➡
➡
08_005
- Remove the brake fluid pump cover on the right side.