PIAGGIO 500 cc Manuals

PIAGGIO 500 cc Manuals

Manuals and User Guides for PIAGGIO 500 cc. We have 1 PIAGGIO 500 cc manual available for free PDF download: Service Manual

PIAGGIO 500 cc Service Manual

PIAGGIO 500 cc Service Manual (240 pages)

Engine 500 cc 4-stroke 4-valve

Brand: PIAGGIO | Category: Engine | Size: 44.7 MB

Table of Contents

Table of Contents
3
Safety Prescriptions
5
Maintenance Regulations
5
Spark Plug
7
Check and Replacement
7
Air Filter
7
Engine Oil Level
8
Checking the Oil Level
8
Topping up
8
Oil Pressure Warning Light
8
Replacing the Filter
9
Checking the Hub Oil Level
9
Renewing the Hub Oil
9
Water Pump
10
Adding Coolant and Bleeding Air from the System
10
Engine Cooling
10
Checking the Valve Gear Timing
11
Valves Play Check/Adjustment
11
Checking Pressure at the End of the Compression
11
Specific Tooling
12
Specific Tools for Piaggio X9 500 CC 4-Stroke 4-Valve
13
Recommended Tools
13
Necessary Tools
14
Automatic Transmission
15
External Transmission Cover
17
Transmission Cover
17
Belt Antiflapping Roller
17
Driving Pulley
17
Driven Pulley Axle Support
18
Clutch Housing
19
Driven Pulley Assembly
19
Clutch Disassembly
20
Pins Stop Collar
20
Specific Tools
20
Automatic Transmission
20
- Fixed Driven Half Pulley Bearings
  21
- Fixed Driven Half Pulley
  21
- Mobile Driven Half Pulley
  22
- Fixed Driven Half Pulley Bearings Assembly
  22
- Spring
  23
- Driving Belt
  23
- Mobile Driving Half Pulley
  24
- Clutch Reassembly
  24
- Rollers Housing Assembly
  25
- Driven Pulley Unit Assembly
  26
- Housing Assembly
  26
- Driven Pulley Axle Support Assembly
  26
- Driven Pulley Axle Support Bearings Disassembly
  26
- Driven Pulley Axle Support Bearing Assembly
  27
- Fixed Driving Half Pulley Assembly
  29
- Belt Antiflapping Roller Assembly
  30
- Final Reduction
  32
Final Reduction
33
Flywheel Cover
34
Flywheel Cover
35
- Thermostat Cover Disassembly
  36
- Flywheel Cover Disassembly
  37
- Water Pump Cover Disassembly
  37
- Flywheel Cover Components Disassembly
  38
- Checking the Cover Case Components
  41
- Cover Case
  41
- Bypass Piston and Spring
  42
- Water Pump Shaft
  43
- Water Pump Rotor
  43
- Checking the Water Pump Cover
  43
- Reed Valve
  44
- Assembling the Flywheel Cover Components
  44
- Stator Assembly
  46
- Flywheel Cover Assembly on the Engine
  47
- Water Pump Cover Assembly
  48
- Thermostat Cover Assembly
  49
- Flywheel and Starting System
  51
Flywheel and Starting System
52
Thermal Unit and Timing System
64
- Intake Manifold Disassembly
  65
- Tappet Cover Disassembly
  65
- Valve Gear Disassembly
  66
- Camshaft and Equalizers Disassembly
  68
- Head Disassembly
  69
- Valves Disassembly
  70
- Cylinder and Piston Disassembly
  71
- Checking Connecting Rod Small End
  72
- Gudgeon Pin Diameter
  72
- Piston
  73
- Gas Rings
  73
- Piston Assembly
  74
- Cylinder Gasket Selection
  75
- Cylinder Assembly
  76
- Compression Rings Assembly
  76
- Head Check
  77
- Checking the Valve Sealing Surfaces
  77
- Checking Valve Seat Wear
  78
- Valves Check
  78
- Standard Diameter
  78
- Minimum Allowed Diameter
  78
- Valve-Guide Play Check
  79
- Valve Standard Length
  79
- Valves Tightness Test
  80
- Springs, Caps, Cotters Check
  80
- Valves Assembly
  81
- Camshaft Check
  82
- Limits Allowed
  82
- Head and Timing System Parts Assembly
  83
- Checking Timing System Parts
  83
- Checking the Revs-Timing Sensor Air Gap
  89
- Tappets Cover Assembly
  90
- Intake Manifold Parts Disassembly
  91
- Injector Disassembly
  91
- Injector Assembly
  92
- Disassembly of Throttle Body from Manifold
  92
- Throttle Body Assembly to Manifold
  93
- Intake Manifold Assembly to Engine
  93
- Crankcase and Driving Shaft
  94
Crankcase and Driving Shaft
95
- Engine Crankcase Opening
  97
- Removing the Countershaft Control Gear and the Oil Pump
  98
- Driving Shaft Disassembly
  98
- Countershaft Disassembly
  99
- Oil Pump Disassembly
  99
- Replacing the Countershaft Bearings
  100
- Half Crankcase Flywheel Side
  100
- Checking Driving Shaft Components
  102
- Driving Shaft Alignment Check
  104
- Engine Half Crankcase Check
  105
- Main Bearing Brass Check
  106
- Half Shafts Coupling with Half Crankcase and Brass
  107
- Oil Pump
  108
- Countershaft
  108
- Oil Pump Assembly
  108
- Driving Shaft Assembly
  109
- Crankcase Coupling
  110
- Fuel Injection
  113
- Index
  114
- EMS Fuel Injection System
  115
- Precautions
  117
- Troubleshooting
  118
- Suggestions for Troubleshooting
  118
- Components Layout
  119
- Layout of the Ems Control Unit Terminals and Immobilizer
  120
- Control Unit Side
  120
- System Side
  120
- Ems Control Unit
  120
- Ems System Diagram
  121
- The Engine Does Not Start Even with Normal Motoring over
  122
- Difficult Cold Start or Warm Start of the Engine
  123
- The Engine Does Not Maintain Idling Speed
  124
- Idling Speed Is Unstable
  124
- Idling Speed Is too Low
  124
- The Engine Does Not Turn over on Idling Speed
  125
- Idling Speed too High
  125
- Backfiring in Deceleration
  125
- Irregular Running of the Engine with Throttle Valve Slightly Open
  126
- Poor Engine Running on Full Power
  127
- Irregular Running of the Engine During Acceleration Stage
  127
- Presence of Detonation (Combustion Shock)
  127
- Immobilizer System
  128
- System Components
  128
- Unprogrammed System
  129
- With Master Key
  130
- LED Indications
  130
- System Programming
  130
- Blinking Deterrent Light
  131
- System Reprogramming in Case of Component Replacement
  132
- Diagnostic Codes
  132
- Diagnostic Code N1
  132
- Feed Circuit of the Decoder and the Fuel Injection Control Unit
  139
- Check that Circuit Feed Is Constant
  139
- Control of the Feed Circuit Deriving from the Key Switch
  142
- Diagnosis Tester Link Circuit
  146
- Circuit Diagram
  146
- Fuel Injection Indicator Circuit
  148
- Self-Diagnosis System
  150
- General Details
  151
- Fuel Supply System
  151
- Pump Feed Circuit
  152
- Circuit Control
  153
- Hydraulics Control and System Maintenance
  158
- Pressure Regulator Control
  159
- Pump and Fuel Filter Control
  161
- Check the Free Flow Capacity
  164
- Pump Electrical Controls
  165
- Resistive Check
  165
- Pump Absorption Control
  165
- Fuel Filter Control
  166
- Pump Support Overhaul
  166
- Installation of the Pump Support on to the Tank
  169
- Injector Circuit Control
  170
- Injector Hydraulics Control
  174
- Revolutions Sensor
  176
- Hv Coil
  180
- Shielded Cap Control
  184
- Ignition Timing
  184
- Coolant Temperature Sensor
  186
Injection
187
- Air Intake Temperature Sensor
  190
- Pressure Sensor
  194
- T.p.s.=Throttle Position Sensor
  195
- Tps Reset
  199
- Stepper Motor
  201
- Minimum Carburation Regulation
  207
- Electrical Fan Control Circuit
  211
- To Control the Circuit
  212
- Revolutions Counter Control Circuit
  216
- Lubrication
  220
- Specifications
  221
- General Characteristics of the Lubrication System
  222
- Diagnostics Guide
  223
Cooling System
228
- Cooling
  229
- System Description
  231
- System Filling Rule
  231
- Thermostat Control
  232
- Electroventilation Control
  234
- System Seal Control
  235
- Starting
  236
- Starting System Description
  237
Starter
237
Controls and Diagnostics Guide
238

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