1Piaggio X9 500 Service Station Manual (2002-ENGLISH-70 Pages).pdf

SERVICE STATION

MANUAL

• X9 500 cc

Piaggio & C. S.p.A.

Pontedera

After Sales Service

Dis. 594523 - 04/01

Grafica e Stampa: C.L.D. - Pontedera (PI)

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.

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

- Denotes specific procedures to be used to avoid damaging the vehicle.

Caution

- Identifies specific procedures to be followed to avoid injury to repairing personnel.

NOTE - For any intervention to the engine, refer to the “Service Station Manual” for 500 cc Engines.

TABLE OF CONTENTS

VEHICLE SPECIFICATIONS

AND OVERHAUL DATA

SPECIFIC TOOLING

MAINTENANCE AND TROUBLESHOOTING

ELECTRICAL EQUIPMENT

ENGINE

FRONT AND REAR SUSPENSIONS

BRAKING SYSTEM

BODYWORK

PREDELIVERY OPERATIONS

TABLE OF WORKING TIMES

Vehicle overhaul data

Assembly plays

(Values in mm)

DIAMETER

MEASURING

HEIGHT

A 43.2

B 3

01_004

Mating between piston and cylinder

(Values in mm)

PART

DIMENSIONS

MATING CLASSES

ASSEMBLY

CODE

CYLINDER

PISTON

CLEARANCE

Cylinder

92 - 0.010

91.990 - 91.997

91.947 - 91.954

0.036

0.050

Ø C

91.997 - 92.004

91.954 - 91.961

Piston

91.961 + 0.014

92.004 - 92.011

91.961 - 91.968

Ø P

92.011 - 92.018

91.968 - 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

Assemble the rings

2 and 3 with the

“Top” writing facing

upwards.

Arrange for the

piston rings

opening as shown

in the figure

“A” value of the ring

inside the cylinder

01_005

(Values in mm)

PART

DIMENSIONS

CLEARANCE

SEAT

CLEARANCE

CODE

CLEARANCE

AFTER USE

1st Compression ring

92 x 1.5

0.15 - 0.35

0.5

2nd Compression ring

92 x 1.25

0.25 - 0.50

0.65

Scraper ring

92 x 2.5

0.25 - 0.50

0.65

1 - 7

+ 0.018

- 0.014

Vehicle overhaul data

SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO: CR = 10.5 : 1

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

01_006

“A” MEASUREMENT

THICKNESS OF BASE GASKET

- 0.185 - - 0.10

0.4 ± 0.05

- 0.10 - + 0.10

0.6 ± 0.05

+ 0.10 - + 0.185

0.8 ± 0.05

Crankshaft/crankcase axial clearance 0.1 - 0.5 mm (cold engine)

01_010

1 - 8

Plik z chomika:

Inne pliki z tego folderu:

Inne foldery tego chomika: