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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.
"© Copyright 2005 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
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
PRE-DELIVERY
TIME
CHAS
PRE DE
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
X9 Evolution 500
Characteristics
Vehicle identification
VEHICLE IDENTIFICATION
Specification
Chassis prefix
Engine prefix
Desc./Quantity
ZAPM 27000 ÷ 4000001
M271M ÷ 1001
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification
Total dry weight
Width (at the mirrors)
Wheel base
Length
Height (at the saddle)
Height at the windscreen (high position)
CHAR - 8
Desc./Quantity
206 Kg
910 mm
2130 mm
1530 mm
780 mm
1450 mm
X9 Evolution 500
Characteristics
Engine
ENGINE
Specification
Engine
Bore
Stroke
Cubic capacity
Compression ratio
Timing system
Valve clearance: intake
Valve clearance: discharge
Valve clearance adjustment
Engine idle speed
Air filter
CO % value (measured at the intake manifold)
Starting system
Lubrication
Lubrication pressure
Minimum allowed (at 100° C)
Fuel supply
Max. power (at crankshaft)
Max. torque (at crankshaft)
Cooling system
Desc./Quantity
Single-cylinder, four-stroke
92 mm
69 mm
460 cm³
10.5: 1
Single overhead camshaft with integrated tone wheel, control
from flywheel side chain, 4 valves and automatic start-up valve
lifting device.
0.15 mm (when cold)
0.15 mm (when cold)
By threaded adjuster on the rockers
1500 ± 50 rpm
Dry paper filter.
1 - 1.5%
Electric starter system with freewheel.
By trochoidal pump (inside the crankcase), pressure adjustment by-pass and oil filter.
4 bar
0.8 bar
Electronic injection system with electric fuel pump, Ø 38 mm
throttle body and single injector.
29.5 kW at 7500 rpm
43 Nm at 5500 rpm
Fluid circulation through a motor-driven pump, 3-way thermostat and electric fan.
CHAR - 9
X9 Evolution 500
Characteristics
Transmission
TRANSMISSIONS
Specification
Transmission
Desc./Quantity
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
Cooling system
Fuel tank (including reserve ~ 2.5 l)
Rear hub
Engine oil (empty)
Engine oil (at oil and filter change)
Desc./Quantity
approx. 1.8 l
~ 14,5 l
~ 250 cc
1.7 lt.
1.5 lt.
Electrical system
ELECTRICAL COMPONENTS
1
Specification
Ignition type
2
3
4
5
Spark advance (before TDC)
Spark plug
Battery
Fuses
6
Generator
Desc./Quantity
Inductive, high efficiency, integrated with injection, variable advance and separate HV coil.
Variable, controlled by the injection controller
CHAMPION RG6YC; NGK CR7EKB
12V-14Ah
n.1 70A_n.1 30A_n.2 15A_n.3 10A_n.4 7,5A_n.2 5A_n.
1 3A
in three-phase alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Type
Front suspension
Front fork stroke
Rear suspension
Rear suspension range
Desc./Quantity
Welded structure consisting of steel pipes with asymmetrical
trestle structure, front crosspieces and union members made
of sheet steel.
Hydraulic telescopic fork with dual effect, Ø 40 mm stems and
back pin with couplongs for dual brake calipers.
104 mm
Engine based on oscillating fork pivoted to the chassis by 2freedom degree oscillating arm and pair of dual effect hydraulic
shock absorbers with 4-position preload adjustment
76.6 mm (minimum spring preload)
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
BRAKES
Specification
Front
Desc./Quantity
Disc brake Ø 260 (vehicle RH side), with hydraulic command
activated from handlebars with right-hand lever and 2 piston
floating caliper.
With dual disc brake, Ø 260 front LH with 2 piston floating caliper 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.
Combined
Wheels and tyres
WHEELS AND TYRES
Specification
Light alloy rims (Front):
Light alloy rims (rear):
Tyre pressure (when cold): front
Tyre pressure (when cold): rear
Front Tyre
Manufacturer / Model / Size
Rear Tyre
Manufacturer / Model / Size
Desc./Quantity
3,50x14"
4,50x14"
2,2 bar
2,4 bar (2,6 bar with passenger or optional trunk on)
Michelin Gold Standard 120/70-14' M/C reinforced TL 55 S
Pirelli GTS 23 120/70_14'M/C TL 55 S
Michelin Gold Standard 150/70-14' M/C TL 66 S
Pirelli GTS 24 150/70_14' M/C TL 66 S
CAUTION
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
X9 Evolution 500
Characteristics
Tightening Torques
STEERING UNIT
Name
Steering wheel upper ring nut
Steering wheel lower ring nut
Torque in Nm
36 ÷ 39
10 ÷ 13 then loosen by 90° (see "Steering wheel ring nut locking")
43 ÷ 47
Handlebar fixing screw (*)
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
Oscillating arm pin right nut - Engine
Oscillating arm pin left nut - Engine
Oscillating arm-chassis pin
Oscillating arm-chassis pin lock nut
Oscillating arm pin right nut - Chassis
Side stand support fixing bolt
Bolt fixing the centre stand to the frame
Hydraulic actuator fixing screw to chassis
Side stand screw
Side stand switch screw
Side stand nut
Oscillating arm damper bar nut
Damper pad support plate nut
Torque in Nm
100 ÷ 120
56 ÷ 70
14 ÷ 17
40 ÷ 50
66 ÷ 73
33 ÷ 41
25 ÷ 30
20 ÷ 25
35 ÷ 40
5÷7
40 ÷ 45
33 ÷ 41
33 ÷ 41
FRONT SUSPENSION
Name
Fork leg tightening clamp screw
Front wheel axle
Wheel axle tightening clamp screw
Front mudguard fixing screw
Pumping fixing screw to fork leg
Torque in Nm
20 ÷ 25
45 ÷ 50
6÷7
5 ÷ 6,5
45 ÷ 50
FRONT BRAKE
Name
Screw for fixing the caliper support to the fork
Brake fluid pump-hose fitting
Brake fluid pipe-calliper fitting
Disc tightening screw (°)
Oil drainage screw
Torque in Nm
42 ÷ 62
16 ÷ 20
16 ÷ 20
5÷6
12 ÷ 16
REAR SUSPENSION
Name
Right and left shock absorber support fixing
Shock absorbers fixing to chassis
Shock absorbers fixing to lower supports
Rear wheel axle
Rear wheel rim screws
Silencer support arm fixing to engine
CHAR - 12
Torque in Nm
20 ÷ 25
33 ÷ 41
33 ÷ 41
104 ÷ 126
33 ÷ 37
33 ÷ 42
X9 Evolution 500
Characteristics
COMBINED BRAKE
Name
Oil pipe union on combined brake pump
Combined brake pipe union on front calipers
Combined brake pipe union on rear calipers
Front brake caliper pipe union on combined braking device
Rear brake caliper pipe union on combined braking device
Brake caliper fixing screw to supports
Rear disc tightening screw (°)
Oil bleed screw
Rear brake caliper fastening screw to engine
Rear brake piping support fixing screw to engine
Rear brake piping support fixing screw to chassis
Torque in Nm
16 ÷ 20
16 ÷ 20
16 ÷ 20
20 ÷ 25
20 ÷ 25
20 ÷ 25
14 ÷ 17
12 - 16
20 ÷ 25
5 ÷ 6,5
9 ÷ 11
SILENCER
Name
Manifold fixing screw to silencer
Silencer support bracket fixing screw to engine
Silencer heat guard fixing screw
Exhaust gas inlet screw
Torque in Nm
16 ÷ 18
33 ÷ 41
3÷4
22 ÷ 26
ENGINE UNIT
Name
Clutch locking nut
Driven pulley shaft support fixing screw
Belt anti-flapping roller fixing screw
Driving pulley nut (°)
Flywheel nut (°)
Driven pulley nut
Half-crankcase union screw
Head cover screws
Head nuts (°) (§) (*)
Cylinder stud bolts
Camshaft bell screw (#)
Camshaft plate fixing screw (#)
Valve clearance adjustment lock nut
Water pump impeller
Starter motor fastening screw
Ignition spark plug
Hub oil drainage cap
Rear hub cap screw
Transmission cover screw
Oil pump head screw
Engine oil drainage cap
Water pump cover screw
Screw fixing the oil pump to the crankcase
Stator fastening screw
Screw fixing the start-up free wheel to the flywheel (#)
Flywheel cover screw
Head intake manifold screw
Screw fixing the throttle body to the manifold
Chain tightener sliding block screw (#)
Timing chain tensioner central screw
Timing chain tensioner support screw
Counter-rotating shaft fixing nut (#)
Screw fixing the silencer to the support arm
Exhaust manifold - cylinder nuts
Screw fixing the rear brake caliper support bracket to the engine
Driving shaft timing cap
Head water outlet cover screw
Calibrated dowel
Oil cap with level bar
Oil filter
Oil filter engagement union
Torque in Nm
65 ÷ 75
23 ÷ 26
17 ÷ 20
160 ÷ 175
115 ÷ 125
92 ÷ 100
11 ÷ 13
11 ÷ 13
38 ÷ 42
44 ÷ 46
30 ÷ 35
4÷6
6÷8
4÷6
11 ÷ 13
12 ÷ 14
15 ÷ 17
24 ÷ 27
11 ÷ 13
8 ÷ 10
24 ÷ 30
3÷4
5÷6
8 ÷ 10
13 ÷ 15
11 ÷ 13
11 ÷ 13
11 ÷ 13
10 ÷ 14
5-6
11 ÷ 13
25 ÷ 29
20 ÷ 25
27 ÷ 33
20 ÷ 25
3,5 ÷ 4,5
3÷4
5÷7
1,5 ÷ 2,5
12 ÷ 16
18 ÷ 22
CHAR - 13
X9 Evolution 500
Characteristics
Name
Oil vent pipe fixing
Minimum oil pressure sensor
Fairlead bracket fixing
Head/Cylinder/Crankcase fixing
Revolution timing sensor fixing screw
Coolant temperature sensor
Pressure reducer counterweight retainer
Counter shaft gear fixing on driving shaft (#)
Thermostat cover
Start-up rim counter shaft plate fixing
Injector support fixing (#)
Head lubrication control jet
Torque in Nm
3÷4
12 ÷ 14
3÷4
10 ÷ 12
3÷4
10 ÷ 12
7 ÷ 8.5
10 ÷ 12
1,5 ÷ 2
3÷4
3÷4
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
A:
B:
Desc./Quantity
10 mm
43 mm
CATEGORIES OF COUPLING
Name
Cylinder Piston
Cylinder Piston
Cylinder Piston
Cylinder Piston
Initials
A
B
C
D
Cylinder
91.990 - 91.997
91.997 - 92.004
92.004 - 92.011
92.011 - 92.018
Piston
91.954 - 91.961
91.961 - 91.968
91.968 - 91.975
91.975 - 91.982
Play on fitting
0.029 - 0.043
0.029 - 0.043
0.029 - 0.043
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.
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
X9 Evolution 500
Characteristics
SEALING RINGS
Name
1st Compression ring
Middle piston ring
Oil scraper ring
Initials
A
A
A
Cylinder
0.15 ÷ 0.35
0.25 ÷ 0.50
0.25 ÷ 0.50
Piston
0.5
0.65
0.65
Play on fitting
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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 halfshaft
Connecting rod
Flywheel-side shoulder
Flywheel-side half-shaft
Complete drive shaft
CHAR - 16
Description
Dimensions
0.8 ± 0.025
Initials
A
Quantity
D= 0.20 - 0.40
19.6 + 0.050
B
D= 0.20 - 0.40
22 0.10-0.15
13 ± 0.025
19.6 +0.050
63.5+0.1-0.05
C
F
E
G
D= 0.20 - 0.40
D= 0.20 - 0.40
D= 0.20 - 0.40
D= 0.20 - 0.40
X9 Evolution 500
Characteristics
Diameter of crankshaft bearings.
Measure the capacity on both axes x-y.
CRANKSHAFT
Specification
Cat. 1
Cat. 2
Desc./Quantity
Standard diameter: 40.010 ÷ 40.016
Standard diameter: 40.016 ÷ 40.022
Crankshaft alignment
Specific tooling
020335Y Magnetic support for dial gauge
MAX. ADMISSIBLE DISPLACEMENT
Specification
A=
B=
C=
D=
Desc./Quantity
0.15 mm
0.010 mm
0.010 mm
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
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
Centre to centre distance on the crankcase
Desc./Quantity
76.937 ÷ 76.867
77.022 ÷ 76.992
TYPE B
Specification
Centre to centre distance of the gears without clearance
Desc./Quantity
76.907 ÷ 76.837
CHAR - 17
X9 Evolution 500
Characteristics
Specification
Centre to centre distance on the crankcase
Desc./Quantity
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
«A» MEASURE TAKEN
«A» MEASURE TAKEN
Measure A
- 0.185 - - 0.10
- 0.10 - + 0.10
+ 0.10 ÷ + 0.185
Thickness
0.4 ± 0.05
0.6 ± 0.05
0.8 ± 0.05
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE
CYLINDER PLANE.
CHAR - 18
X9 Evolution 500
Characteristics
Products
PRODOTTI
Product
AGIP ROTRA 80W-90
Description
Rear hub oil
AGIP FILTER OIL
Oil for air filter sponge
AGIP CITY HI TEC 4T
Engine oil
AGIP BRAKE 4
SPECIAL AGIP PERMANENT fluid
Brake fluid
coolant
AUTOSOL METAL POLISH
Muffler cleaning paste
AGIP GP 330
Grease for brake levers, throttle
AGIP CITY TEC 2T
Mixer oil
ARNICA 46
Electro-hydraulic centre-stand
Specifications
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Mineral oil with specific additives for increased adhesiveness
SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
FMVSS DOT 4 Synthetic fluid
Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
special product for cleaning and polishing
stainless steel muffler
White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
Highly viscous oil for hydraulic controls
CHAR - 19
INDEX OF TOPICS
TOOLING
TOOL
X9 Evolution 500
Tooling
SPECIFIC TOOLING
Stores code
001330Y
Description
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
X9 Evolution 500
Tooling
TOOL - 22
Stores code
001467Y031
Description
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
headstock
020055Y
Wrench for steering tube ring nut
X9 Evolution 500
Tooling
Stores code
020074Y
Description
Support base for checking crankshaft
alignment
020150Y
Air heater support
020151Y
Air heater
020193Y
Oil pressure gauge
020306Y
Punch for assembling valve seal rings
020329Y
MityVac vacuum-operated pump
TOOL - 23
X9 Evolution 500
Tooling
TOOL - 24
Stores code
020330Y
Description
Stroboscopic light to check timing
020331Y
Digital multimeter
020333Y
Single battery charger
020334Y
Multiple battery charger
020335Y
Magnetic support for dial gauge
020358Y
37x40-mm adaptor
X9 Evolution 500
Tooling
Stores code
020359Y
Description
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
X9 Evolution 500
Tooling
TOOL - 26
Stores code
020412Y
Description
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
X9 Evolution 500
Tooling
Stores code
020444Y009
Description
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
X9 Evolution 500
Tooling
TOOL - 28
Stores code
020467Y
Description
Flywheel extractor
020468Y
Piston fitting band
020469Y
Reprogramming kit for scooter diagnosis
tester
020470Y
Pin retainers installation tool
020471Y
Pin for countershaft timing
X9 Evolution 500
Tooling
Stores code
020472Y
Description
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
X9 Evolution 500
Tooling
TOOL - 30
Stores code
020479Y
Description
Countershaft lock wrench
020480Y
Petrol pressure check set
020481Y
Control unit interface wiring
020482Y
Engine support
020483Y
30 mm guide
020512Y
Piston fitting fork
X9 Evolution 500
Tooling
Stores code
020527Y
Description
Engine support base
020565Y
Flywheel lock calliper spanner
020604Y011
494929Y
Fitting adapter
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
X9 Evolution 500
Maintenance
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
AFTER 18,000 KM AND AFTER 54,000 KM
150'
Action
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
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'
Action
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
AFTER 36,000 KM
365'
Action
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
MAIN - 35
X9 Evolution 500
Maintenance
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
AFTER 72,000 KM
405'
Action
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
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 ENGINE. 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
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 ROTRA 80W-90 rear oil hub
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Rear hub oil
250 cc
MAIN - 38
X9 Evolution 500
X9 Evolution 500
Maintenance
Air filter
- Raise the saddle.
- Remove the piston ring and the battery cover.
- Loosen the 4 mounting screws shown in the figure.
- Loosen the mounting screw located under the intake manifold.
- Replace the air filter and reassemble the various
components, reversing the removal procedure.
MAIN - 39
Maintenance
X9 Evolution 500
- An inspection and possible cleaning (with compressed air) of the air filter is scheduled every 6000
km in any case.
- The air jet must be directed from the inside to the
outside of the filter (i.e. opposite the direction of
the air flow during normal operation of the engine).
- Any deposits of condensate out of the engine oil
caused by blow-by can be removed via the pipe
shown in the figure.
N.B.
FAILURE TO OBSERVE THE RULES REGARDING CLEANING OF THE FILTER ELEMENT CAN
LEAD TO IMPROPER LUBRICATION OF THE ELEMENT. POOR LUBRICATION AFFECTS THE
FILTERING CAPACITY. EXCESSIVE LUBRICATION AS WITH A SOILED FILTER CAUSES AN
EXCESSIVELY RICH FUEL/AIR MIXTURE.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN
THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.
WARNING
DO NOT RUN THE ENGINE IF THE AIR FILTER IS NOT IN PLACE THIS WILL RESULT IN EXCESSIVE WEAR TO ALL THE PARTS OF THE COOLING SYSTEM.
Engine oil
In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the
thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced
by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Check
This operation must be carried out with the engine
cold and following the procedure below:
1) Rest the vehicle on the central stand and on a flat ground.
2) Unscrew the cap/dipstick "A", dry it with a clean cloth and reinsert it, screwing it thoroughly.
3) Remove the cap/dipstick again and check that the level is between the max. and min levels; top-up,
if required.
Topping up from the MIN to MAX. level requires around 1700 cc.
If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level
line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after
the engine has been stopped, so as to get the correct level.
MAIN - 40
X9 Evolution 500
Maintenance
Oil top up
The oil should be topped up after having checked the level and in any case by adding oil without ever
exceeding the MAX. level.
The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc.
Engine oil filter
CAUTION
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. OIL, GASKET AND FILTER SHOULD BE DISPOSED OF ACCORDING TO THE REGULATIONS IN FORCE.
WARNING
AVOID TOUCHING PARTS OF THE ENGINE WHEN HOT, AS THIS MAY CAUSE BURNS.
- Remove the muffler.
- Remove the filler plug.
- Remove and clean the mesh pre-filter of the drain
cap with compressed air.
- Use a belt spanner for filters to remove cartridge
filter "C".
- Make sure the pre-filter and drain cap O-rings are
in good condition.
- Lubricate them and refit the mesh filter and oil
drain cap by tightening to the prescribed torque.
- Refit a new cartridge filter making sure to lubricate the O-ring before fitting, then screw until it
comes into contact with the seal and further tighten
to the prescribed torque.
- Refit the muffler.
- Add recommended engine oil.
MAIN - 41
Maintenance
X9 Evolution 500
- Start the engine and let it run for a few minutes and then turn it off.
After 5 minutes check the level and top up, if necessary, never exceed the MAX. level.
N.B.
IF THE OIL IS CHANGED WITHOUT CHANGING THE CARTRIDGE FILTER (1ST COUPON) ADD
AROUND 1500 CC OF OIL INSTEAD OF 1700 CC SINCE PART OF THE LUBRICATION CIRCUIT
IS FILLED.
Characteristic
Engine oil:
1700 cm³
Locking torques (N*m)
Engine oil drainage plug 24 ÷ 30 Engine oil filter 12 - 16
Oil pressure warning light
The vehicle is equipped with a warning light on the
instrument panel that lights up when the key is
turned to the «ON» position. However, this light
should switch off once the engine has been started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication system.
Checking the ignition timing
- Using a TORX wrench, remove the timing check
cap located on the flywheel cover.
- Remove the transmission cover to access the
driving pulley fastening nut that allows the driving
shaft rotation.
- Remove the head cover as described in the Thermal unit and timing system chapter.
- Turn the driving shaft to make the reference located on the magnet support collimate with that on
the flywheel cover (TDC).
- Make sure that the reference on the wheel speed
sensor is aligned with that obtained on the head.
If the reference is located opposed to the index
MAIN - 42
X9 Evolution 500
Maintenance
obtained on the head, make the driving shaft perform a further revolution.
- Check that the two references match perfectly; if
not, remove the timing belt and install it again.
See also
Cylinder assy. and timing system
Checking the valve clearance
- To check the clearance in the valves collimate
the references between the cam shaft control pulley and head.
- Use a feeler to make sure the clearance between
the valve and register screw correspond to the indicated values. If the clearance does not correspond, adjust it by loosening the lock nut using a
screwdriver on the set screw as shown in the figure.
Characteristic
Valve clearance: intake
0.15 mm (when cold)
Valve clearance: discharge
0.15 mm (when cold)
Cooling system
Engine cooling fluid level check
The fluid level inspection should be carried out every 6,000 km when the motor is cold, following the
methods indicated below:
- Rest the vehicle on the central stand and on a flat
ground.
- Remove the expansion tank cap and top up, if the
fluid level is near to or below the MIN level into the
MAIN - 43
Maintenance
expansion tank. The fluid level should always be
between the «MIN» and «MAX» level.
- To have an indication of the fluid level, refer to a
notch made in a cylindrical insert, coaxial to the
filler and visible inside it once you remove the
loading cap.
The top side of the notch indicates the MAX level
while the lower one indicates the MIN level.
The cooling fluid consists of a mixture of 50%
demineralised water and ethylene glycol and corrosion inhibitors based anti-freeze solution.
WARNING
TO CHECK THE PRESENCE OF AIR IN THE CIRCUIT, PROCEED AS DESCRIBED IN THE «COOLING» CHAPTER
CAUTION
DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS
TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE vehicle IS IN USE.
Characteristic
Cooling system
approx. 1.8 l
See also
Cooling system
Level check
The front and rear brake fluid tanks can be accessed removing the cover located on the right
side of the handlebar cover and the display PICS
on the left side.
To check the level proceed as follows:
- rest the vehicle on the central stand with the handlebars in a central position;
- remove cover «A» loosening the fixing screw
«B» and check the front brake fluid level;
- remove screws «C» fixing the display PICS and
check the combined brake fluid level;
The level will go down to a certain extent due to
lining wear.
MAIN - 44
X9 Evolution 500
X9 Evolution 500
Maintenance
Braking system
Level check
- Rest the scooter on a flat ground and on the central stand.
- Remove the brake pump cover as shown in the
figure.
- Check the brake fluid level by the special indicator located on the pump, as shown in the figure.
N.B.
THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD
NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF REMAIN - 45
Maintenance
X9 Evolution 500
QUIRED. TOP UP THE PUMP TANK, IF REQUIRED, CONSIDERING THAT THE "MAX." LEVEL
MUST ONLY BE OBTAINED WITH NEW PADS.
Top-up
To top up the fluid proceed as follows:
Remove the right cover and/or the PICS display,
then remove the tank cap loosening the relevant
two screws, remove the intermediate rubber membrane and restore the level using the prescribed
fluid without exceeding the max level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
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 ABSORBS 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
MAIN - 48
X9 Evolution 500
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
X9 Evolution 500
Troubleshooting
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Faulty clutch
Operation
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 anomalous way
Insufficient braking
INSUFFICIENT BRAKING
Possible Cause
Inefficient braking system
Fluid leakage in hydraulic braking system
Operation
Check the pad wear (1.5 min). Check that the brake discs are
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.
Failing elastic fittings, plunger or brake pump seals, replace
Brakes overheating
BRAKES OVERHEATING
Possible Cause
Rubber gaskets swollen or stuck
Compensation holes on the pump clogged
Brake disc slack or distorted
Defective piston sliding
Operation
Replace gaskets.
Clean carefully and blast with compressed air
Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Check calliper and replace any damaged part.
Braking vibrations or noise
VIBRATIONS OR NOISE WHEN BRAKING
Possible Cause
Brake disc slack or distorted
Electrical system
TROUBL - 50
Operation
Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
X9 Evolution 500
Troubleshooting
Battery
BATTERY
Possible Cause
Battery
Operation
This is the device in the system that requires the most frequent
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+.
Turn signal lights malfunction
TURN INDICATOR NOT WORKING
Possible Cause
Electronic ignition device failure
Operation
With the key switch set to "ON" jump the contacts 1 (Blue 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
Steering hardening
Malfunctions in the suspension system
Seal fault or breakage
Operation
Check the tightening of the top and bottom ring nuts. If irregularities 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 flattened.
Check the tightening of the top and bottom ring nuts. If irregularities 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 flattened.
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. 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.
Replace the shock absorber Check the condition of wear of the
steering covers and the adjustments.
Heavy steering
STEERING HARDENING
Possible Cause
Torque not conforming
Operation
Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
TROUBL - 51
X9 Evolution 500
Troubleshooting
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause
EXCESSIVE STEERING CLEARANCE
Operation
Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
Noisy suspension
NOISY SUSPENSION
Possible Cause
NOISY SUSPENSION
Operation
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
OIL LEAKAGE FROM SUSPENSION
Possible Cause
Oil leakage from suspension
TROUBL - 52
Operation
Service the pumping members and check the sleeves and
sealing rings are in good conditions. Replace the damaged
parts
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
X9 Evolution 500
Electrical system
ELECTRICAL SYSTEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Specification
Outside temperature sensor
Rear brake stop button
Light switch with flash
Indicators switch
Horn button
Emergency flashing button
Front fuse holder box
Fuse no.3 7,5A
Horn
Fuse 15A
Side stand switch
Intercom connectors
Voltage regulator
Electric side stand control unit
Engine stop remote control switch 30A
Remote electronic controller switch 30A
No. 2 side stand pump remote control switches
Fuse 70A
Fuse holder box with side stand pump base
LH taillight with sidelights bulb and flashing light bulb
Fuse 7,5A
Fuse
Fuse 5A
Fuse 3A
No. 2 rear fuse holder boxes for control unit
Anti-tilting sensor
Saddle opening actuator
Intercom control unit
ELE SYS - 54
Desc./Quantity
10A
X9 Evolution 500
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
Specification
Front left-hand direction indicator with bulb
Analogue instrument unit (5 bulbs)
Radio display
Digital instrument unit with no. 11 LED indicators
Front headlight
Front right-hand direction indicator with bulb
Diode unit
Diode 6A
Diode 1A
Main remote control switch 30A
Socket 12V
Helmet compartment glass bowl with lamp
Rear brake light with no. 5 bulbs
Number plate light with bulb
RH taillight with sidelights bulb and flashing light bulb
Start-up remote control switch
Battery 12V-14Ah
Helmet compartment light button
Starter motor
No. 3 7.5A fuses
Fuse holder box
Fuse
HV coil
Connector cap
Saddle opening button
Fuel level indicator with pump
Immobilizer aerial
Key switch
Anti-theft alarm fitting
Electric fan
Electric fan remote control switch 30A
Fitting for accessories
Side stand button
Start up button
Reset button
Actuators control unit
Engine stop switch
Decoder
Front brake stop button
Wheel rpm sensor
Injection ECU
Side stand pump motor
End of stroke button
Enable button
No. 2 buttons with clamp
Fuel injector
Throttle potentiometer
Idle adjustment motor
Engine rpm sensor
Engine rpm sensor
Engine water temperature sensor
Stuck relay indicator
Engine oil pressure sensor
Magneto flywheel
Electrical system
Desc./Quantity
15A
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
X9 Evolution 500
Electrical system
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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Specification
Side stand switch
Voltage regulator
Side stand control unit
Electronic control unit remote control switch
Engine stop remote control switch
Service remote control switch
Fuse holder box (n.3 7.5A, n.1 15A)
No. 2 start-up remote control switches
Magneto flywheel 373W
No. 2 buttons for side stand
Side stand pump motor
Pump unit with level indicator
Starter motor
Helmet compartment lighting button
Helmet compartment glass bowl
Socket 12V
No. 2 rear fuse holder boxes for control unit (n.1 3A, n.1
5A, n.1 10A, n.1 3A)
(Diode holder box (n. 2 6A and 2A diodes)
Fuse holder box (n.2 7.5A, n.1 15A and 5A)
Fuse holder box with base for stand pump remote control
switch (n.1 70A)
Digital instrument unit (11 indicators and led)
Analogue instrument unit (5 bulbs)
Headlight with n. 2 position bulbs and n.2 high/low beam
bulbs 55W
Front LH direction indicator with 10W bulb
Rear brake stop button
ELE SYS - 56
Desc./Quantity
X9 Evolution 500
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Specification
Light switch with flash
Indicators switch
Horn button
Emergency flashing button
Reset button
Horn
LH taillight with sidelights bulb 5W and flashing light bulb
10W
Rear tail light with 5 2.3W bulbs
Number plate light bulb 12V-5W
Rh taillight with sidelights bulb 5W and flashing light bulb
10W
Battery 12V-14Ah
Front brake stop button
Engine stop switch
Wheel rpm sensor
Front RH direction indicator with 10W bulb
Main remote control switch
Light switch
Start up button
Side stand button
Key switch
Radio display
Electric fan remote control
30A fuse with start-up remote control switch
Radio/intercom/handsfree control unit
No. 2 pump remote control switches
Stuck relay indicator
No. 2 headlight remote control switches
Electrical system
Desc./Quantity
Conceptual diagrams
Ignition
ELE SYS - 57
X9 Evolution 500
Electrical system
IGNITION SECTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Specification
Anti-theft alarm fitting
Side stand switch
Engine stop switch
Voltage regulator
Battery
Start up button
Diode
Starter motor
Fuse no. 13
Remote starter switch
Main remote control switch
Diode
Key switch contacts
Two brake light buttons
Digital instrument unit
Engine stop remote control switch
Electronic control unit remote control switch
Immobilizer aerial
Decoder
HV coil
Start-up/injection electronic control unit
Fuse
Fuse
Fuse
Desc./Quantity
12V - 4Ah
6A
30 A
2A
no. 2 10 A
no. 3 3A
no. 10 7,5A
Headlights and automatic starter section
HEADLIGHTS AND AUTOMATIC STARTER SECTION
1
2
3
ELE SYS - 58
Specification
Anti-theft alarm fitting
Bulb for upper beams
Bulb for lowerbeams
Desc./Quantity
12V - 55W
12V - 55W
X9 Evolution 500
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Electrical system
Specification
Light switch
Side stand switch
Engine stop switch
Voltage regulator
Roof lamp for box helmet illumination with lamp
Helmet compartment lighting button
Battery
Fuse no. 13
Main remote control switch
Diode
Key switch contacts
No. 2 bulbs for front sidelight
License plate light bulb
Two (2) taillight bulbs
Digital instrument unit
4 Turn indicator bulbs
Indicators switch
Emergency flashing light button (4 direction indicators)
Engine stop remote control switch
Connettore per predisposizione accessori
Start-up/injection electronic control unit
Fuse
Fuse
Fuse
Fuse
Fuse
Fuse
Desc./Quantity
12V - 14 Ah
30 A
2A
12V-3W
12V - 5W
12V - 5W
12V-10W
no. 5 15 A
no. 8 7,5 A
no. 4 5 A
no. 12 7,5 A
no. 11 7,5 A
no. 9 15 A
Battery recharge and starting
BATTERY RECHARGE AND START-UP SECTION
1
2
3
Specification
Side stand switch
Engine stop switch
Magneto flywheel
Desc./Quantity
ELE SYS - 59
X9 Evolution 500
Electrical system
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Specification
Voltage regulator
Battery
Start up button
Diode
Starter motor
Fuse no. 13
Remote starter switch
Main remote control switch
Diode
Key switch contacts
Two brake light buttons
No. 5 bulbs for brake light
Digital instrument unit
Control unit power supply remote control switch (engine
stop)
Start-up/injection electronic control unit
Fuse
Fuse
Desc./Quantity
12V - 4Ah
6A
30 A
2A
12V-2,3W
no. 4 5 A
no. 10 7,5A
Level indicators and enable signals section
LEVEL INDICATORS AND ENABLE SIGNALS SECTION
1
2
3
4
5
6
7
8
9
10
11
12
ELE SYS - 60
Specification
Anti-theft alarm fitting
Side stand switch
Engine stop switch
Saddle opener actuator
Saddle opening button
Voltage regulator
Key switch contacts
Roof lamp for box helmet illumination with lamp
Helmet compartment lighting button
Battery
Fuse no. 13
Main remote control switch
Desc./Quantity
12V - 4Ah
30 A
X9 Evolution 500
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Specification
Diode
Key switch contacts
Engine warning indicator
Engine not enable indicator
Low fuel warning light
High-beam warning light
Wheel RPM sensor
Outside temperature sensor
Digital instrument unit
Fuel level sender
Control unit power supply remote control switch (engine
stop)
Electronic control unit components remote control switch
Saddle opener receiver
Pump remote control switches
Side stand pump motor
Stuck relay indicator
Side stand out enable button
Side stand in enable button
Electro-hydraulic side stand actuation button
Side stand control unit
Tilting sensor
Air temperature sensor
Engine rpm sensor
Double wire screened cable
Fuel injector
Idle adjustment motor
Fuel pump
Engine temperature sensor
Diagnostics socket connector
Throttle potentiometer
Start-up/injection electronic control unit
Fuse
Fuse
Fuse
Fuse
Fuse
Fuse
Fuse
Electrical system
Desc./Quantity
2A
no. 5 15A
no. 6 10A
no. 14 70A
no. 2 10A
no. 1 5A
no. 4 5 A
no. 12 7,5 A
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
X9 Evolution 500
Electrical system
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
Voltage
ELE SYS - 62
Desc./Quantity
Non-adjustable three-phase transistor
14 ÷ 15V at 5000 rpm with lights off
X9 Evolution 500
Electrical system
Lights list
LIGHTS LIST
1
2
3
4
5
6
7
8
9
10
Specification
Dipped beam light
Upper beam light
Front position lights
Front direction indicator lights
Rear position lights
Stop lights
Rear turn indicator bulbs
Instrument panel lights
Helmet compartment light
Number plate lights
Desc./Quantity
N° 1, 12V-55W, halogen
N° 1, 12V-55W, halogen
N° 2, 12V-3W, all glass
N° 2, 12V-10W, spherical
N° 2, 12V-5W, spherical
N° 5, 12V-2,3W, spherical
Two, 12V-10W, spherical
N° 5, 12V-2W, all glass
N° 1, 12V-5W, cylindrical
N° 1, 12V-5W, cylindrical
Fuses
The electric system is equipped with:
1. four fuses «A» into the under saddle compartment.
FUSE
1
Specification
N.1
2
N.1
3
N.1
4
N.1
Desc./Quantity
Capacity: 15 A
Protected Circuits : Socket 12V for users- Under saddle compartment light
Capacity: 10 A
Protected Circuits : Saddle opening by button
Capacity: 10 A
Protected Circuits : PICS device
Capacity: 7,5 A
Protected Circuits : Dipped and high beam bulb
2. five fuses «B» next to the battery, on the left side.
FUSE
1
Specification
N.1
2
N.1
3
N.1
4
N.1
Desc./Quantity
Capacity: 70 A
Protected Circuits : Electro-hydraulic stand
Capacity: 5 A
Protected Circuits : Electro-hydraulic stand
Capacity: 10 A
Protected Circuits : Fuel pump - Injector - H.V. coil
Capacity: 3 A
Protected circuits: Immobilizer (Decoder and EMS engine management control unit)
ELE SYS - 63
X9 Evolution 500
Electrical system
5
Specification
N.1
Desc./Quantity
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
1
Specification
N.1
2
N.1
3
N.1
4
N.1
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
Desc./Quantity
Capacity: 15 A
Protected circuits: Horn - High beam bulb - Accessories
Capacity: 7,5 A
Protected circuits: Start-up enable signal - Brake light
lamp
Capacity: 7,5 A
Protected circuits: Front and rear position light - Number plate light
Capacity: 7,5 A
Protected circuits: PICS - Saddle opening by remote
control
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
1
2
3
4
5
6
7
8
Specification
Display pics
Intercom Controller
Intercom connectors
Battery
Fuse no. 13
Key switch contacts
Fuse
Fuse
Desc./Quantity
12V - 4Ah
30 A
no. 7 10A
no. 12 7,5 A
ELE SYS - 67
Electrical system
Captions
A = Satellite
D = Mobile phone cable
F = Telephone connector
H = Spark plug inspection port
J = Loudspeaker
L = Microphone
O = Headset clip
R = Volume buttonU = 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
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
No helmet inserted - Logo X9
Driver headphone inserted - Driver/passenger helmet - passenger crossed out
Passenger headphone inserted - Driver/passenger helmet driver crossed out
Driver and passenger headphones inserted - Driver and passenger helmets
Desc./Quantity
Tuner - source - Speakerphone with external speakers
Tuner - source - Speakerphone
Tuner - source - Speakerphone
Tuner - source - Speakerphone - Intercom
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
Turn off - M
Turn on - M
Desc./Quantity
> 4 sec.
> 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.
MANUAL INTERCOM
Specification
Activation - M two times
Deactivation - M two times
Desc./Quantity
Short
Short
N.B.
AFTER MANUAL DISABLING, THE INTERCOM SWITCHES TO AUTOMATIC MODE WITH LESS
SENSITIVE ENABLE LEVEL (LOW).
TUNER/SOURCE
Specification
Radio on - S
Radio off - S
Source on - M go after S
Source off -M go after S
Manual tuning UP - M go after ^
Manual tuning DOWN -M go after ^
Automatic tuning UP - M go after ^
Automatic tuning DOWN -M go after ^
Memory scanning UP - ^
Memory scanning DOWN - v
AUTOSTORE memorization - ^
RDS - M go after vol + (AF - TA - PTY)
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
Short
Short, > 2 sec.
short, > 2 sec
Short, Continuous
short, continuous
Short, Continuous
short, short
Short
Short
> 2 sec.
Short, Short
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
X9 Evolution 500
Electrical system
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.
SPEAKERPHONE TELEPHONE
Specification
Driver-passenger conversation passage - ^
Intercom-telephone passage - v
Volume adjustment
icon
Headphone inserted
icon
Passenger headphone
not inserted icon
Driver headphone not
inserted icon
ELE SYS - 72
Desc./Quantity
Short
Short
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 headphone inserted.
Telephone call with
driver icon
Telephone call with
passenger icon
Telephone conversation intercom icon
SPECIFICHE TECNICHE
1
Specification
Power
Desc./Quantity
10.5V ÷ 16V
1.4 A max
ELE SYS - 73
X9 Evolution 500
Electrical system
2
Specification
Key
3
4
Maximum output power
Power consumption
5
Frequency response
6
7
8
Microphones
Frequency response:
Loudspeakers
Desc./Quantity
10.5V ÷ 16V
1.5 mA max
500 mW per channel
vehicle off ~0 mA
in stand-by ~280 mA
at maximum power ~500 mA
audio 200 Hz - 20 kHz ± 3 dB
intercom 200 Hz - 5 kHz ± 3 dB
-69 dB ± 3 dB one-way
audio 200 Hz ÷ 20 kHz ± 3 dB
8 Ω - 0.5 mΩ
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
- 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 ALREADY MOUNTED ON THE VEHICLE.
N.B.
AFTER RECHARGING AND BEFORE INSTALLING, ENSURE 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
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 recharge".
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 BATTERY 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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Specification
Analogue card negative
Battery positive (+30) for analogue card
Analogue card serial clock output
Antitheft led output
Analogue card serial data output
Lights on output
(Not connected)
(Not connected)
Warning light input
Stuck relay alarm light input
Abs indicator input (not connected)
RH direction indicator output
RH direction indicator button input
LH direction indicator button input
Desc./Quantity
ELE SYS - 79
X9 Evolution 500
Electrical system
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Specification
Upper beam indicator input
Air temperature sensor input
Engine not actuable input
Oil pressure indicator input
(Not connected)
LH direction indicator output
Direction indicator stop button input
Reset service management button input
Water temperature sensor input
Fuel level sensor input
Battery positive (+30)
Tachometer sensor power supply
Tachometer sensor return to ground
Rpm sensor input
Battery positive (+30)
Antitheft led
Key positive (+15)
Tachometer sensor input
Negative
Air temperature sensor return to ground
Emergency light button input (hazard)
Lights on input
Desc./Quantity
Seat opening receiver
RECEIVER CONTROL UNIT FOR SADDLE OPENER
1
2
3
4
5
6
7
8
9
10
11
12
ELE SYS - 80
Specification
Radio aerial
Actuator positive output 1
Reset / Input clearing
Battery positive
(Not connected)
Live positive lead
Ground lead
(Not connected)
(Not connected)
Selection input CH1 / CH3
Positive output actuator 1
Data for alarm output
Desc./Quantity
X9 Evolution 500
Electrical system
Immobiliser decoder
IMMOBILIZER DECODER
Specification
Immobilizer LED control
Base power supply
Negative
Electronic control unit EMS
Continuous power supply (positive)
1
2
3
4
5
6
7
8
Desc./Quantity
(negative)
(positive)
(serial)
Immobilizer aerial
Engine rev. sensor
REV SENSOR
1
2
3
Specification
M:
F:
S:
Desc./Quantity
Male
Female
Shielding
Analogue odometer
ANALOGUE ODOMETER
Specification
1
2
3
4
Desc./Quantity
STEPPER MOTOR A
STEPPER MOTOR B
STEPPER MOTOR C
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, REMOVE 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 DIFFERENT 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
- 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
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 COVER, 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
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 PREVENT 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
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 DAMAGING 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.
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel revolving ring
ENG - 97
Engine
X9 Evolution 500
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
Inspecting the clutch spring
- Measure the length of the spring, while it is relaxed.
Characteristic
Standard length:
125.5 mm
Admissible limit after use:
120 mm
- Check the thickness of the clutch mass friction material.
Characteristic
Minimum thickness permitted:
1 mm
- The masses must exhibit no traces of lubricants;
in that case, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH
TO TEAR.
- Do not open the masses using tools to prevent a variation in the return spring load.
ENG - 98
X9 Evolution 500
Engine
Refitting the clutch
- Prepare the special tool as for removal;
- Preassemble the driven pulley unit with the drive
belt according to its direction of rotation;
- Insert the driven pulley unit, the spring with
sheath and clutch into the tool.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
- Compress the spring and insert the clutch on the driven pulley bushing.
N.B.
BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END.
- Tighten the ring nut by hand and complete the
tightening using the special wrench to the prescribed torque.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
Locking torques (N*m)
Clutch ring nut 65 - 75
- To facilitate reassembly on the engine, turn the moving driven pulley and insert the belt onto the smaller
diameter.
Bell assembly
- Install the bell and the spacer.
ENG - 99
Engine
Refitting the driven pulley
- Install the driven pulley assembly with belt.
Drive-belt
- Check that the driving belt is not damaged.
- Check the width of the belt.
Characteristic
Minimum width:
25 mm
Standard width:
26.2 mm
Removing the driving pulley
- Using a 27 mm wrench, turn the central pulley nut
to horizontally align the central inside holes and
install the special tool.
Specific tooling
020474Y Driving pulley lock wrench
ENG - 100
X9 Evolution 500
X9 Evolution 500
Engine
- First install the lock ring of the special tool onto
the pulley so that the splines are completely engaged.
- Then, insert the tool so as to insert the stud bolts
on the ring into the holes obtained onto the tool
itself.
- Tighten the two tool fastening nuts, also by hand.
- Loosen the central nut.
- Remove the spring washer and the flat washer.
- Remove the fixed driving half-pulley.
- Remove the bushing connection washer.
- Move the belt downwards.
- Suitable support the roller contrast and extract
the mobile driving half-pulley with the relevant
bushing and the rear washer, being careful not to
make the rollers come out.
Inspecting the rollers case
- Check that the inside bushings shown in the figure exhibit no signs of abnormal wear and measure
the inside diameter.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHINGS
Characteristic
Maximum admissible diameter:
30.12 mm
Standard diameter:
30.021 mm
ENG - 101
Engine
- Measure the pulley sliding bushing outside diameter shown in the figure.
Characteristic
Minimum admissible diameter
Ø 29.95 mm
Standard diameter:
Ø 29.959 mm
- Check that the rollers are not damaged or worn.
Characteristic
Minimum admissible diameter
Ø 24.5 mm
Standard diameter:
Ø 24.9 mm
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt contact surfaces on both pulley halves.
ENG - 102
X9 Evolution 500
X9 Evolution 500
Engine
Refitting the driving pulley
Installing the fixed driving half-pulley
- Insert the spacer.
- Install the fixed driving half-pulley and check that
it is in contact with the spacer and with the guide
bushing of the moving driving pulley.
- Remove the flat washer and the spring washer
as shown in the figure.
- Insert the nut in the original position (nut side in
contact with the belleville washer).
ENG - 103
Engine
- Turn the central pulley nut to horizontally align
the holes and install the special tool.
N.B.
CHECK THAT THE STOP WRENCH TOOL IS EASILY INSERTED INTO THE PULLEY AND IN THE ENGINE CRANKCASE.
Specific tooling
020474Y Driving pulley lock wrench
- Install the lock ring from the rear so that the
splines are completely engaged.
- Finally install the tool by siding the nuts by hand
and ensuring the tool is resting flatly.
- Tighten the driving pulley fastening nut to the
prescribed torque
- Remove the special tool.
Locking torques (N*m)
Driving pulley nut 160 - 175
Installing the roller container
- Install the spacer with the internal chamfer facing
towards the inside.
- Position the rollers on the half-pulley as shown in
the figure.
- The closed side must rest on the inside thrust
face of the roller container.
ENG - 104
X9 Evolution 500
X9 Evolution 500
Engine
- Assembly the half-pulley with the roller contrast
plate and sliding blocks.
- Insert the half-pulley on the crankshaft.
- Insert the spacer bushing.
Refitting the transmission cover
- Install the driving pulley shaft cover, positioning
the tooth gap on the lower part with the reference
mark on the transmission crankcase.
N.B.
ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE.
- Install the outside plastic transmission cover.
- Tighten the 4 fastening screws to the prescribed
torque.
Locking torques (N*m)
External transmission cover screws 7 ÷ 9
ENG - 105
Engine
- Ensure the correct installation on the crankcase
of the 2 centring dowels.
- Insert the transmission cover with the bearing
and install the relevant retainers.
- Lock the four M8 retainers.
Locking torques (N*m)
M8 retainers for transmission cover 23 ÷ 26
- Lock the 7 M6 retainers.
Locking torques (N*m)
M6 retainer 11 ÷ 13
- Insert the washers on the driven pulley shaft.
N.B.
INSERT THE SMALLER WASHER FIRST, THEN THE LARGER ONE.
- Insert the flanged nut.
- Prepare the torque wrench for LHS locking using
a machine hexagon wrench.
- Tighten the driven pulley shaft fastening nut using
an offset wrench.
N.B.
DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFERENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED
ON THE SHAFT OR BREAK THE BUSH ITSELF.
Locking torques (N*m)
Driven pulley nut 92 - 100
ENG - 106
X9 Evolution 500
X9 Evolution 500
Engine
End gear
Removing the hub cover
- Drain the rear hub oil through the oil drainage cap
located under the engine.
- Drain the rear hub oil through the oil drainage cap
located under the engine.
-Remove the 7 fastening screws. Remove the hub
cover and the relevant gasket.
Removing the wheel axle
- Remove the countershaft.
- Remove the wheel axis complete with gear.
Removing the hub bearings
- Check all bearings (wear, clearance and noise).
In case of anomalies, proceed as follows.
To remove the gear shaft bearing on the engine
crankcase, use the following parts.
Specific tooling
001467Y014 Pliers to extract ø 15-mm bearings
001467Y034 Pliers to extract ø 15-mm bearings
001467Y031 Bell
ENG - 107
Engine
- Use the special extractor to disassemble the
bearing on the engine chassis of the countershaft.
Specific tooling
001467Y006 Pliers to extract 20 mm bearings
001467Y035 Belle for OD 47-mm bearings
- Support the hub cover using the column kit.
- Pull out the bearing using the special tool.
Specific tooling
020476Y Stud bolt set
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54-mm bearings
Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox
cover.
- Support the hub cover using the column kit.
- Pull out the bearing using the special tool.
Specific tooling
020476Y Stud bolt set
020376Y Adaptor handle
020477Y Adaptor 37 mm
020483Y 30 mm guide
ENG - 108
X9 Evolution 500
X9 Evolution 500
Engine
- Remove the oil guard using a screwdriver.
Removing the driven pulley shaft bearing
- If you have to remove the driven pulley shaft, the
relevant bearing and the oil guard, remove the
transmission cover and the clutch unit as described in the Automatic transmission chapter.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver into the
hub gear box.
- Remove the Seeger ring shown in the figure.
- Pull out the driven pulley shaft bearing from the
engine crankcase using the special tool.
Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm adaptor
020364Y 25-mm guide
Inspecting the hub shaft
- Check that the 3 shafts exhibit no wear or deformation on the grooved surfaces, at the bearings
and at the oil guards.
- In case of faults, replace the damaged parts.
Characteristic
ENG - 109
Engine
Connection diameter for countershaft:
A = diameter 20 - 0.01 -0.02 mm
Connection diameter for wheel shaft:
B = diameter 30 - 0.010 -0.023 mm
C = diameter 15 - 0.01 -0.02 mm
Bearing diameter for driven pulley shaft:
D = diameter 17 - 0.01 -0.02 mm
E = diameter 20 - 0.01 -0.02 mm
F = diameter 25 - 0.01 -0.02 mm
Inspecting the hub cover
- Check that the mounting surface is not damaged or deformed.
- Check the bearing bearings.
In case of faults, replace the hub cover.
Refitting the driven pulley shaft bearing
- Heat the crankcase using the heat gun.
Specific tooling
020151Y Air heater
- Insert the driven pulley shaft bearing until it abuts
against the bottom of the seat using the special
tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE).
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
020364Y 25-mm guide
ENG - 110
X9 Evolution 500
X9 Evolution 500
Engine
- Heat the intermediate gear bearing seat.
- Insert the intermediate shaft bearing using the
special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE).
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020363Y 20 mm guide
- Heat the gear shaft bearing seat on the crankcase.
- Insert the gear shaft bearing in the upper crankcase seat using the special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE).
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
- Place the safety lock Seeger ring of the driven
pulley shaft bearing.
N.B.
PLACE IT IN THE POSITION SHOWN IN THE FIGURE.
- Insert the pulley shaft oil guard on the transmission side.
ENG - 111
Engine
Refitting the hub cover bearings
- Heat the bearing seats on the cover using the
heat gun.
- Support the hub cover using the column kit.
Specific tooling
020151Y Air heater
020476Y Stud bolt set
- Insert the intermediate shaft bearing on the cover
using the special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE).
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
020363Y 20 mm guide
- Heat the gear shaft bearing seat from the cover
outside.
- Insert the gear shaft bearing on the cover using
the special punch until abutment.
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
020483Y 30 mm guide
- Replace the snap ring
ENG - 112
X9 Evolution 500
X9 Evolution 500
Engine
- Support the hub cover using the column kit.
- Insert the wheel shaft oil guard with the sealing
lip facing the inside of the cover.
- Place the oil guard flush with the crankcase.
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
020476Y Stud bolt set
Refitting the hub bearings
- Place the 3 shafts as shown in the figure.
Refitting the ub cover
- Check the proper position of the centring dowels.
- Install a new gasket.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Position the 7 set screws, tighten them to the prescribed torque, being careful of the position of the
bands holding the vent tube, and the position of the 3 shortest screws as indicated in the figure.
- Refill with the prescribed oil to the Max. level.
Recommended products
AGIP ROTRA 80W-90 rear oil hub
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Characteristic
Quantity:
approx. 250 cc
ENG - 113
Engine
Locking torques (N*m)
Rear hub cover screws 24 ÷ 27
Flywheel cover
- Remove the three bands shown in the figure for
an easier removal of the flywheel cover, remove
the feed hoses and disconnect the return hose
from the pump cover.
N.B.
THE BANDS MUST BE REPLACED. TO REMOVE THEM,
OPEN WITH A SCREWDRIVER OR CUT THEM.
BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.
Removing the hub cover
- Drain the engine oil by removing the drainage
cap.
- Prepare a suitable container to collect the oil.
- Remove the pre-filter.
ENG - 114
X9 Evolution 500
X9 Evolution 500
Engine
- Remove the oil filter using a filter tape or shaped
cup wrench.
- Loosen the 14 fastening screws.
- Remove the flywheel cover with the relevant gasket and the cooling system sleeve support.
N.B.
THE SCREWS ARE OF 4 DIFFERENT LENGTHS. NOTE
THE RELEVANT POSITIONS.
CAUTION
REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND
ROTOR.
CAUTION
BE CAREFUL TO PREVENT SLIPPAGE OF THE BY-PASS VALVE AND OF THE RELEVANT
SPRING.
Removing the flywheel cover components
- Loosen the six mounting screws and remove the
water pump cover.
ENG - 115
Engine
- Remove the by-pass and the relevant spring.
- Remove the oil pump seal.
Removing the stator
- Remove the two retaining screws and the cable
guide bracket.
- Unscrew the 3 fastening screws and remove stator and its wiring.
- Loosen the two retaining screws and remove the
reed valve support with bulkhead.
ENG - 116
X9 Evolution 500
X9 Evolution 500
Engine
- Remove the blow-by reed valve with the relevant
sealing gasket.
- Unscrew the fastening screw and remove the gas
outlet union with the relevant O-ring.
- Remove the water pump impeller by unscrewing
it from the relevant shaft.
N.B.
THE THREADING IS CLOCKWISE. IT IS ADVISABLE TO
PREVENT THE SHAFT ROTATION BY INSERTING A 12-MM
WRENCH INTO THE DRIVE.
- Extract the shaft with the relevant abutment
washer.
ENG - 117
Engine
- Remove the sealing ring.
- Remove the ceramic ring and the relevant gasket.
- Remove the sealing ring for the pump shaft lubrication using a suitably shaped tool.
- Remove the engine oil filling cap/dipstick and the
check hole cover for the distribution timing.
- Remove the minimum oil pressure sensor.
ENG - 118
X9 Evolution 500
X9 Evolution 500
Engine
Inspecting the cover components
- Check that the mounting surface of the crankcase
is not worn or deformed.
- Check that the by-pass valve seat, the torque
limiter and the water pump shaft are free from
wear.
Characteristic
By-pass housing hole diameter:
13.9 mm
Connection diameter for start-up gear shaft:
12 mm
Connection diameter for pump shaft:
8 mm
- Check that the oil filter union and matching surface exhibit no deformations or wear.
- Check the condition of the stator and of the respective cable harness.
ENG - 119
Engine
- Check the continuity between the 3 phases.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE
STATED.
Electric characteristic
Resistance:
0.2 - 1 Ω
- Check the ground insulation of each phase.
- If a fault is found, carry out a thorough check of
the cable harness that contains two types of cable:
Rigid cables close to the stator and flexible cables
close to the connector.
- Check that the winding is positioned so as not to
interfere with the heads of the retaining screws.
- Install a new oil filter, lubricate the gasket, screw
on and finally tighten to the prescribed torque.
Locking torques (N*m)
Engine oil filter 12 - 16
ENG - 120
X9 Evolution 500
X9 Evolution 500
Engine
- Install the supply hose to the cylinder and connect the return hose to the pump cover using 3 new
clamps.
N.B.
TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS,
PAYING ATTENTION NOT TO CONSTRICT THE HOSES
BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUFFICIENTLY.
- Install the pre-filter again and insert the engine oil
drain plug, tightening to the prescribed torque.
- Refill the engine with the prescribed type of oil.
Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil
Locking torques (N*m)
Engine oil drainage plug 24 ÷ 30
Refitting the stator
- Install the stator assembly together with the wiring harness, tightening the 3 screws to the prescribed torque.
N.B.
INSERT THE RUBBER WIRING SEALING GASKET INTO
THE SPECIAL SEAT ON THE CRANKCASE.
Locking torques (N*m)
Stator retainers 8 - 10
- Install the wiring guide bracket tightening the 2
screws to the prescribed torque.
Locking torques (N*m)
Stator cable harness guide bracket screws 3 - 4
ENG - 121
Engine
X9 Evolution 500
- Temporarily install the distribution timing check
hole cover and the engine oil filling cap/bar.
- Insert the blow-by recovery duct using a new Oring.
- Tighten the screws to the prescribed torque.
Locking torques (N*m)
Blow-by recovery duct fixing screws 3 - 4
- Insert the spring and the by-pass piston on the
flywheel cover.
N.B.
LUBRICATE THE BY-PASS VALVE.
Refitting the flywheel cover components
- Correctly fit a new O-ring, do not allow it to come into contact with grease or oil.
FAILURE TO OBSERVE THIS ADVICE CAN IRRETRIEVABLY DEFORM THE O-RING.
- Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque.
Locking torques (N*m)
Pump cover fixing screws: 3 ÷ 4
- Before reassembling, check that all components
are perfectly clean.
- For the cover, carefully check all lubrication channels, in particular:
- The 3 by-pass channels.
ENG - 122
X9 Evolution 500
Engine
- Oil feeding duct at the water pump shaft connection.
- Pump drainage duct.
- Oil pressure sensor feeding duct.
- Oil vapour decantation chamber
ENG - 123
Engine
X9 Evolution 500
- Reinstall the blow-by reed valve using a new
sealing gasket.
- Reinstall the support with head and tighten the
screws to the prescribed torque.
Locking torques (N*m)
Supporting screws with bulkhead 0.3 - 0.4
- Install a new sealing ring for the pump shaft using
the special tool
- Install the oil minimum pressure sensor and tighten to the prescribed torque.
Specific tooling
020376Y Adaptor handle
020412Y 15 mm guide
Locking torques (N*m)
Minimum oil pressure sensor 12 ÷ 14
- Pre-assemble the ceramic seal and the relevant
gasket.
N.B.
PLACE THE CHAMFERING TOWARDS THE GASKET BEING CAREFUL NOT TO FOUL THE CERAMIC RING WITH
OIL OR GREASE, WHICH WOULD IMPAIR THE SEAL.
- Insert the ceramic seal on the flywheel cover.
N.B.
ASSEMBLE BY HAND TO PREVENT DAMAGES TO THE CERAMIC SEAL.
- Insert the water pump shaft after lubricating the
flywheel cover seat.
- Insert the mechanical seal on the shaft up to the
impeller abutment surface.
N.B.
THE FINAL INTRODUCTION DEPTH WILL BE DETERMINED BY THE IMPELLER.
ENG - 124
X9 Evolution 500
Engine
- Screw the impeller and tighten to the prescribed
torque.
Locking torques (N*m)
Water pump impeller 4 ÷ 5
Refitting the flywheel cover
- Install a new gasket on the engine crankcase.
- Check the presence of the three centring dowels.
- Turn the crankshaft in order to align the countershaft movement sensor with a reference point on
the crankcase (see figure).
- Repeat the alignment for the water pump crankshaft using the same reference point on the engine.
N.B.
THIS PREPARATION IS USEFUL PARTICULARLY IN THE
EVENT OF REPAIRS WITH THE WATER PUMP COVER INSTALLED.
- Install the flywheel cover on the engine, paying attention to avoid interference between the stator and
rotor.
WARNING
ENG - 125
Engine
X9 Evolution 500
FAILURE TO OBSERVE THIS INSTRUCTION MAY RESULT IN DESTRUCTION OF THE CERAMIC
MAGNETS.
- Tighten the 14 retaining bolts of the cover to the
prescribed torque.
N.B.
THE BOLTS HAVE FOUR LENGTHS:
- THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE
FIGURE.
- THE LONGEST IS INSERTED UNDER THE ENGINE OIL
FILLER PLUG.
N.B.
- THE INTERMEDIATE BOLTS FOR THE REMAINING
MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT
FOR THE MANIFOLD SUPPORT (SHOWN IN THE FIGURE)
ARE SLIGHTLY LONGER.
Locking torques (N*m)
Flywheel cover screws 11 - 13
- Lubricate the intermediate gear seat with torque
limiter on the flywheel cover.
- Align the water pump movement sensor with a
reference and install the flywheel cover as described in the Flywheel cover chapter.
Flywheel and starting
The starter is sold as a complete part.
Before deciding to replace it, carry out the following tests:
1 - Battery
Check the voltage after not running (a few hours):
Voltage >12.5V
Check the density of the electrolyte of each cell:
Bé = 30 ÷ 32
ENG - 126
X9 Evolution 500
Engine
Specific weight: 1.25 - 1.26
YES go to 2 NO go to 3
2 - Make sure the negative terminals (battery negative and starter negative) are correctly connected
to each other and to the frame.
YES go to 4 NO go to 5
3 - Recharge and if necessary replace the battery.
4 - Connect the diagnostic tester (see chapter "Injection system").
Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor.
Remove the 10A fuse no. 12 (see "fuses" chapter).
Switch in position "ON" with interrupt switch in position "RUN" and side stand raised.
Select the "PARAMETERS" function.
Start the engine (so that it cannot move) long enough to measure the rpm and starter absorption.
N.B.
THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER, THE RPM READING IS NOT
THE REAL ONE, BUT IS VALID FOR DIAGNOSTIC PURPOSES.
Specific tooling
020460Y Scooter diagnosis and tester
Electric characteristic
Absorption at trailing speed:
80 - 120 A
Revolution speed =
approx. 300-400 rpm
YES go to 6 NO go to 7 NO go to 8 NO go to 9
5 - Restore the connections
6- The values are correct.
Finally carry out a check of the power consumption at idle speed.
Remove the starter motor (see the flywheel and starter system).
Reconnect the earth and positive and perform the test.
Electric characteristic
Current consumption at idle speed:
ENG - 127
X9 Evolution 500
Engine
<40 A
YES go to 10 NO go to 11
7- Low trailing speed
High electrical absorption
Carry out a test of the engine rotation (example: possible melting of the bushes) and if no anomalies
are found, replace the starter motor.
8- Low trailing speed
Low electrical absorption
Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing
them.
Check the new values.
YES go to 12 NO go to 13
9 - High trailing speed
Low electrical absorption
The engine turns too freely, check the compression end pressure.
If the values are not correct proceed as follows.
10 - The starter motor works properly.
11 - Check the rotation of the armature.
12 - Replace the starter remote control switch.
13 - Test the battery again and if necessary replace the starter motor.
N.B.
IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE
NOISE, CHECK THE FREEWHEEL OF THE TORQUE LIMITER (SEE THE "FLYWHEEL AND
STARTER SYSTEM" CHAPTER).
STARTER MOTOR
Specification
Type
Power
Desc./Quantity
Mitsuba sm13d
0.9 kW
BATTERY
Specification
Capacity
Starting current
Desc./Quantity
14 Ah
125 A
START-UP REMOTE CONTROL SWITCH
Specification
Type
Maximum load
Desc./Quantity
SEALED
150 A continuous
STARTER TRANSMISSION
Specification
Ring gear and freewheel coaxial to the flywheel.
Desc./Quantity
Intermediate gear with built-in torque limiter.
The starter system has a transmission between the motor armature and engine shaft equipped with
freewheel coaxial to the flywheel and torque limiter on the intermediate shaft.
ENG - 128
X9 Evolution 500
Engine
The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and
the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations.
The freewheel is used for a sufficiently silent starting.
The starter control (energised remote control) is slaved to enabling signals by the side stand and the
emergency OFF/RUN switch, which does not allow starting given dangerous conditions.
The starter control circuit is not controlled by the immobilizer system, therefore before insisting on the
starter system, check the consensus of the immobilizer.
In order to check the enabling switches circuit, see the «Electrical system» chapter, whereas to check
the engine shaft control transmission, follow what is described in the «Flywheel and starter system»
chapter.
- Remove the three bands shown in the figure for
an easier removal of the flywheel cover, remove
the feed hoses and disconnect the return hose
from the pump cover.
N.B.
THE BANDS MUST BE REPLACED. TO REMOVE THEM,
OPEN WITH A SCREWDRIVER OR CUT THEM.
BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.
Removing the starter motor
N.B.
THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED.
- Loosen the two fastening screws.
- Extract the complete starter motor.
Removing the flywheel magneto
N.B.
IF YOU MUST REMOVE THE FLYWHEEL, IT IS NECESSARY TO REMOVE THE CHAIN GUIDE
SLIDING BLOCK RETAIN PLATE FIRST.
ENG - 129
Engine
- Unscrew the 3 fastening screws and remove the
chain guide sliding block retain plate and the startup rim.
- Align the holes obtained on the flywheel with the
crankcase housing to allow the introduction of the
special tool.
- Tighten the bushing of the flywheel lock tool on
the removing tool threading.
- Insert the special tool as shown in the figure,
making sure that the pins are perfectly inserted into the previously aligned holes and that it is perfectly abutted and almost flush with the flywheel.
Specific tooling
020472Y Flywheel lock wrench
ENG - 130
X9 Evolution 500
X9 Evolution 500
Engine
- Loosen the magneto flywheel fastening nut.
- Remove the special tool and the fastening nut.
- Remove the washer.
- Insert the nut again so as to slightly uncover the
shaft and free the space that was occupied by the
washer.
CAUTION
THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS
STRONGLY LOCKED; THE CONE DETACHMENT MAY
THEREFORE CAUSE THE ROTOR SLIPPAGE, WITH THE
CONSEQUENT BREAKAGE OF THE MAGNETS.
- Insert the special removing tool.
- Using a 27-mm wrench and a 19-mm bushing,
release the flywheel.
Specific tooling
020467Y Flywheel extractor
ENG - 131
Engine
- Remove the extractor.
- Remove the nut and extract the flywheel with the
start-up rim.
- Remove the crankshaft key.
- To remove the start-up rim from the freewheel it
is necessary to turn it clockwise and pull it out.
- Remove the freewheel from the flywheel by loosening the 6 fastening screws.
SINCE THE FREEWHEEL MUST BE REMOVED, IT IS ADVISABLE TO LOOSEN THE 6 FASTENING SCREWS IN
ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON
THE CRANKSHAFT.
- The freewheel is coupled to the flywheel with high
precision; if removal is difficult, use 2 screws as
gripping points and as removing tools, if required.
ENG - 132
X9 Evolution 500
X9 Evolution 500
Engine
- Extract the intermediate gear provided with torque limiter.
Inspecting the flywheel components
- Check the integrity of the magnets.
- Check that the magnet support cage is free from
deformation or cracks.
- Check that the flywheel splines exhibit no loosening.
Starter gear rim
- Check that there is no wear or abnormal impressions on the "rollers" of the freewheel and on the
surface of the starter ring gear hub.
- Check the hub outside diameter.
Characteristic
Hub outside diameter:
Diameter 45.665 + 0.008 +0.005 mm
- Check the inside diameter of the bushing of the
starter gearing.
- Check that the toothing is not worn.
Characteristic
Inside diameter of the bushing:
Diameter 27 + 0.020 +0.041 mm
N.B.
ENG - 133
Engine
X9 Evolution 500
IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND
FREEWHEEL.
IF ONLY THE BUSHING IS WORN, IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE STARTUP RIM. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE CONNECTION ON THE CRANKSHAFT. IN CASE OR IRREGULARITIES, REPLACE THE CRANKSHAFT.
Intermediate gear
- Check that the toothing is not worn.
- Check the diameter of the two bearings.
Characteristic
Gear bearing diameter:
12 - 0 0.011 mm
Also check the shaft diameter on the flywheel cover and on the engine crankcase.
Characteristic
Bearing diameter on the flywheel cover
12 + 0.034 -0.016 mm
Bearing diameter on the engine crankcase:
12 + 0.034 -0.016 mm
N.B.
THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH
DRIVE PLATES.
Driven plates consist of 4 Belleville springs provided with grooved profiles; this assembly allows
transmitting torque lower than 10 kgm.
In case of incorrect start-up manoeuvres, the limiter prevents any kicks, with consequent reversal
of direction of the crankshaft which would impair
the engine structure.
The limiter assembly cannot be overhauled. In case of irregularities on the toothed discs, replace the
assembly.
Refitting the free wheel
- Make sure the freewheel faying surfaces are in good condition.
- Thoroughly clean the free wheel to remove LOCTITE residue.
ENG - 134
X9 Evolution 500
Engine
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
- Fit the freewheel on the magneto flywheel making
sure that the ground side is in contact with the flywheel itself, i.e. with wheel seeger ring visible.
- Lock the six clamping screws in criss-cross fashion to the prescribed torque.
Locking torques (N*m)
Screw fixing freewheel to flywheel 13 ÷ 15
- Oil the free wheel "rollers".
Refitting the intermediate gear
- Lubricate the gear housing on the engine crankcase.
ENG - 135
Engine
- Insert the intermediate gear with torque limiter
- Lubricate the inside bushing and the starter ring
gear hub surface.
- Install the start-up rim on the flywheel turning it
clockwise and inserting at the same time.
Refitting the flywheel magneto
- Insert the key on the crankshaft.
- Install the flywheel checking the proper insertion
of the key and engaging the torque limiter gear
with the start-up rim.
ENG - 136
X9 Evolution 500
X9 Evolution 500
Engine
- Insert washer and nut on the crankshaft.
- Tighten thoroughly the guide bushing of the flywheel lock tool and loosen by 1/4 turn.
N.B.
FAILURE TO OBSERVE THIS RULE CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL.
Specific tooling
020472Y Flywheel lock wrench
- Align the 2 holes of the flywheel with the case
housing to allow the introduction of the special tool.
- Insert the special tool checking that the pins are
perfectly introduced into the seat.
Specific tooling
020472Y Flywheel lock wrench
ENG - 137
Engine
- Tighten the flywheel lock nut to the prescribed
torque.
Locking torques (N*m)
Flywheel fixing nut 115 - 125
- Install the chain guide retain plate tightening the
3 screws to the prescribed torque.
N.B.
BEFORE TIGHTENING THE SCREWS, MOVE THE STARTUP RIM IN CONTACT WITH THE CRANKCASE AND CHECK
THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIRECTION.
Locking torques (N*m)
Chain guide sliding block retain plate fastening screws 3 ÷ 4
Refitting the starter motor
- Check that the O-ring is in good working order
and lubricate it.
- Insert the starter motor.
- Tighten the 2 fastening screws to the prescribed
torque.
Locking torques (N*m)
Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
- Remove the external and internal transmission
cover.
ENG - 138
X9 Evolution 500
X9 Evolution 500
Engine
- Remove the flywheel cover, the flywheel and the
torque limiter.
Removing the intake manifold
- Remove the 3 mounting screws.
- Remove the intake manifold unit.
Removing the rocker-arms cover
- Loosen the 6 special screws with stop and the
relevant rubber gaskets.
- Remove the tappet cover with relevant gasket.
ENG - 139
Engine
Removing the timing system drive
- Turn the engine to close the intake valves, i.e.,
moving the reference on the tone wheel to the top,
as shown in the figure.
- Remove the central screw and the valve lifting
device mass stop bell using the special tool.
Specific tooling
020565Y Flywheel lock calliper spanner
- Remove the return spring and the valve lifting
mass with relevant travel end washer.
N.B.
BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING
TO FALL INTO THE ENGINE THROUGH THE CHAIN COMPARTMENT.
- Align the references located on the tone wheel
and on the head.
ENG - 140
X9 Evolution 500
X9 Evolution 500
Engine
- Loosen the central screw on the tensioner first.
- Unscrew the 2 fastening screws and remove the
tensioner with relevant gasket.
Remove the inside hexagon screw and the counterweight as shown in the figure.
- Remove the timing belt rim from the camshaft.
- Remove the timing belt rim.
- Remove the tone wheel.
ENG - 141
Engine
- Remove the engine revolution timing sensor and
relevant O-ring by loosening the fastening screw
and removing the mounting band from the special
hole obtained on the head gasket.
N.B.
TO CHECK THIS COMPONENT, SEE THE INJECTION
CHAPTER.
Removing the cam shaft
- Unscrew the 3 fastening screws and remove
camshaft retaining bracket.
N.B.
REMOVING THE FASTENING SCREWS MAY BE DIFFICULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEXAGON. IF NECESSARY, SEPARATE THE THREADS IN
ADVANCE.
- Remove the cam shaft.
- Remove pins and rocking levers by the transmission side holes.
ENG - 142
X9 Evolution 500
X9 Evolution 500
Engine
Removing the cylinder head
- Remove the spark plug.
- Remove the cooling system outlet sleeve with
thermostat.
- Remove the coolant temperature sensor.
N.B.
THE SENSOR CONTROLS BOTH INJECTION AND THE ANALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS
COMPONENT, SEE THE INJECTION CHAPTER.
- Remove the 2 fastening nuts on the head, on the
exhaust and on the intake side.
- Remove the two M6 screws into the distribution
channel and the M6 screw on the spark plug side
with the thermostat support.
N.B.
THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKING LEVER PINS AND FITTING
BRACKET IF NECESSARY.
ENG - 143
Engine
X9 Evolution 500
- Loosen the 4 head-cylinder fastening nuts in 2 or
3 times and in a crossed sequence.
- Remove the head, the 2 centring dowels, the
gasket and the lower chain guide sliding block.
N.B.
DO NOT REMOVE THE DOWELS IF THEY ARE FORCED
INTO THEIR SEAT.
CAUTION
WHEN YOU HAVE TO REMOVE THE HEAD, PREPARE A SUITABLE CONTAINER SINCE THE
THERMAL GROUP CONTAINS COOLANT.
Removing the valves
- Using the appropriate tool fitted with an adaptor,
remove the cotters, caps, springs and valves.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)
CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD (FLYWHEEL SIDE AND TRANSMISSION SIDE).
- Remove the oil guards using the special tool.
Specific tooling
020431Y Valve oil seal extractor
ENG - 144
X9 Evolution 500
Engine
- Remove the spring supports.
N.B.
BLOW THE SEATS WITH COMPRESSED AIR TO FACILITATE THE SPRING SUPPORT REMOVAL.
Removing the cylinder - piston assy.
- Remove the timing chain.
- Loosen the fastening screw and remove the
spacer and the tightening sliding block.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
- Extract the cylinder with the relevant gasket and
the centring dowel.
N.B.
THE SECOND CENTRING IS ENSURED BY A PIN SET INTO
THE CYLINDER.
CAUTION
TO PREVENT DAMAGES TO THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.
- Remove the 2 piston pin locking rings by the specific housings.
- Extract the pin and remove the piston.
N.B.
USE PAPER OR A CLOTH TO CLOSE THE CYLINDER
HOUSING MOUTH ON THE CRANKCASE TO PREVENT
SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO
THE CASE.
ENG - 145
Engine
- Remove the piston sealing rings and the oil scraper.
CAUTION
NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO
PREVENT INVERTING THE POSITION IN CASE OF REUSE.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.
Inspecting the small end
- Using a bore gauge, measure the connecting rod
small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.
Characteristic
Standard diameter:
22 + 0.025 +0.015 mm
Inspecting the wrist pin
- Check the pin outside diameter using a micrometer.
Characteristic
Standard diameter:
22 0 -0.004 mm
- Calculate the coupling clearance between pin
and connecting rod end.
Characteristic
Standard clearance:
0.015 ÷ 0.029 mm
- Measure the diameter of the bearings on the piston.
Characteristic
Standard diameter:
22 + 0.006 + 0.001 mm
ENG - 146
X9 Evolution 500
X9 Evolution 500
Engine
- Calculate the piston pin coupling clearance.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 ÷ 0.010 mm
Inspecting the piston
- Carefully clean the seal housings.
- Measure the coupling clearance between the
seal rings and the grooves using suitable sensors,
as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.
Fitting clearance (Cylindrin/Pison)
Standard coupling clearance A 0.9 - 0.005 -0.030mm B 1.5 - 0.005 -0.03mm Maximum permissible
clearance after use C 0.9 + 0.03 +0.01mm D 2 + 0.05 +0.02mm Standard coupling clearance </>
1.2 - 0.005 mm </> </> Maximum permissible clearance after use </> 1.25 + 0.03 mm </> </>
Standard coupling clearance </> 2.5 - 0.005 mm </> </> Maximum permissible clearance after
use </> 2.5 + 0.03 mm </> </>
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
- Take the measurement in the position shown in
the figure.
Characteristic
A=
43.2 mm
Piston diameter:
92 mm
ENG - 147
Engine
X9 Evolution 500
- Using a bore meter, measure the inner cylinder
diameter at three different points according to the
directions shown in the figure.
Characteristic
Standard diameter:
92 + 0.018 +0.010 mm
- Check that coating is free from flakes.
- Check that the head matching surface exhibits no deformations or wear.
Characteristic
Maximum allowable run-out:
0.05 mm
- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried
out in pairs (A-A, B-B, C-C, D-D).
Inspecting the piston rings
- Alternately insert the three sealing rings into the
cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis.
- Measure the opening (see figure) of the sealing
rings using a feeler gauge.
- If higher values than those prescribed are measured, replace the linings.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN
THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE
CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH
A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
Fitting clearance (Cylindrin/Pison)
Compression ring 0.15 ÷ 0.35 mm Max. value. 0.5 mm </> Oil scraper ring 0.25 ÷ 0.50 mm Max.
value. 0.65 mm </> Oil scraper ring 0.25 ÷ 0.50 mm Max. value. 0.65 mm </>
ENG - 148
X9 Evolution 500
Engine
Removing the piston
- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing towards the exhaust.
- Insert the locking ring into the special tool, with
the opening in the position indicated on the tool.
S = left
D= right
- Place the wrist pin stop ring into position using a
punch
- Install the pin lock using the key shown in the
figure.
Specific tooling
020470Y Pin retainers installation tool
N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.
ENG - 149
Engine
X9 Evolution 500
Choosing the gasket
- Provisionally fit the piston into the cylinder, without any base gasket.
- Install a comparator on the special tool using the short union, as shown in the figure.
Specific tooling
020475Y Piston position checking tool
- Using an abutment plane, reset the comparator
with a preload of a few millimetres.
- Finally fix the comparator.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the comparator position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)
- Measure the deviation from the reset value.
- Identify the thickness of the cylinder base gasket to be used for reassembly by the table below. Correctly identify the cylinder base gasket thickness to keep the correct compression ratio.
- Remove the special tool and the cylinder.
N.B.
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY
ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.
Characteristic
Recess / Projection measured 1
- 0.185 - - 0.10
Gasket thickness 1
0.4 ± 0.05
Recess / Projection measured 2
- 0.10 - + 0.10
Gasket thickness 2
0.6 ± 0.05
Recess / Projection measured 3
ENG - 150
X9 Evolution 500
Engine
+ 0.10 ÷ + 0.185
Gasket thickness 3
0.8 ± 0.05
Refitting the piston rings
- Place the scraper ring spring on the piston.
- Install the scraper ring keeping the opening opposed to the spring junction and with the writing
"top" facing the piston top. The chamfered side of
the oil scraper ring should always be facing the
piston crown.
- Fit the second lining with the identification letter
or the writing "top" facing the piston crown. In any
case, the step must be facing opposite the piston
top.
- Install the first compression lining in the direction
imposed by the housing.
- It is advisable to use a fitter to facilitate the installation of the linings.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.
- Misalign the lining openings at 120° as shown in the figure.
- Lubricate the components with engine oil.
- The engine uses the first compression lining with an L section.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness
determined above.
- Using the fork and the ring clamp, fit the cylinder
as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER. CHECK THE PRESENCE OF THE TWO REFERENCE DOWELS.
Specific tooling
020468Y Piston fitting band
020512Y Piston fitting fork
ENG - 151
X9 Evolution 500
Engine
Inspecting the cylinder head
- Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or
distorted.
Characteristic
Maximum allowable run-out:
0.1 mm
- In case of irregularities, replace the head.
- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the bearings of the camshaft and the
rocker pins exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant sealing pad exhibits no
oxidation.
STANDARD DIAMETER
Specification
A
B
C
Desc./Quantity
13 + 0.018 0
20 + 0.021 0
42 + 0.025 0
- If wear is discovered, replace the head and check also the corresponding component.
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Check that the crankshaft pinion and the camshaft timing gear and crankshaft pinion exhibit no
wear.
In case of wear of the sliding blocks, replace them.
In case of wear of the chain or rim, replace the entire unit.
N.B.
IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED IN
CHAPTER CRANKCASE AND CRANKSHAFT.
ENG - 152
X9 Evolution 500
Engine
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
Inspecting the valve sealings
- Insert the valves into the cylinder head.
- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
- Visually inspect the valve sealing surface.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
- If the sealing surface of the valve is found to be
interrupted at one or more points or is not flat, replace the valve.
ENG - 153
X9 Evolution 500
Engine
Inspecting the valve housings
- Clean the valve seats of any carbon residues.
- Using the Prussian blue, check the width of the
impression on the valve seat "V".
- Measure the inside diameter of each valve guide.
- Measure according to the rocking lever thrust direction at three different heights.
Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm
- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damages, replace the head.
Inspecting the valves
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Specification
Inlet:
Outlet:
Desc./Quantity
4.987 - 4.972 mm
4.975 - 4.960 mm
MINIMUM ADMISSIBLE DIAMETER
Specification
Inlet:
Outlet:
- Calculate the clearance between valve and valve guide.
ENG - 154
Desc./Quantity
4.96 mm
4.945 mm
X9 Evolution 500
Engine
- Check the deviation of the valve stem by resting
it on a "V" shaped abutment and measuring the
extent of the deformation with a comparator.
Characteristic
Limit values admitted:
0.1 mm
- Check the concentricity of the valve head by arranging a comparator at right angle relative to the
valve head and rotate it on a "V" shaped abutment.
Characteristic
Admissible limit:
0.03 mm
Inspecting the valve stem guide clearance
- After measuring the valve guide diameter and the valve stem diameter, check the clearance between
guide and stem.
INLET
Specification
Standard clearance:
Admissible limit:
Desc./Quantity
0.013 - 0.04 mm
0.08 mm
OUTLET
Specification
Standard clearance:
Admissible limit:
Desc./Quantity
0.025 ÷ 0.052 mm
0.09 mm
ENG - 155
X9 Evolution 500
Engine
STANDARD VALVE LENGTH
Specification
Inlet:
Outlet:
Desc./Quantity
95.0 ± 0.3 mm
94.2 ± 0.3 mm
- Check that there are no signs of wear on the surface of contact with the articulated register terminal.
- If the checks above give no failures, you can use
the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently
with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the
lapping compound residues from penetrating between the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO
LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES
WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter
halves show no signs of abnormal wear.
ENG - 156
X9 Evolution 500
Engine
- Measure the unloaded spring length.
Characteristic
Standard length:
44.4 mm
Admissible limit after use:
42.4 mm
Refitting the valves
- Place the valve spring support washers on the
head.
- Alternately insert the 4 oil guards using the special tool.
- Lubricate the oil guards and the valve guides.
Specific tooling
020306Y Punch for assembling valve seal
rings
- Fit the valves, the springs and the caps. Using
the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).
Inspecting the cam shaft
- Check that the camshaft bearings exhibit no scores or abnormal wear.
- Using a micrometer, measure the camshaft bearings.
STANDARD DIAMETER
Specification
Bearing A Ø:
Bearing B diameter:
Desc./Quantity
42 - 0.060 -0.085 mm
20 - 0.020 -0.041 mm
ENG - 157
X9 Evolution 500
Engine
MINIMUM ADMISSIBLE DIAMETER
Specification
Bearing A Ø:
Bearing B diameter:
Desc./Quantity
41.910 mm
19.940 mm
-Using a gauge, measure the cam height.
STANDARD HEIGHT
Specification
Intake
Exhaust:
Desc./Quantity
33.988 mm
33.417 mm
ADMISSIBLE LIMITS
Specification
Intake
Exhaust:
Standard axial clearance:
Maximum admissible axial clearance:
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- Check that the retaining plate seat shown in the
figure exhibits no wear.
- Check that the automatic valve lifting device cam,
the travel end roller and the rubber abutment on
the containment bell are free from wear.
ENG - 158
Desc./Quantity
33.740 mm
33.170 mm
0 - 0.22 mm
0.3 mm
X9 Evolution 500
Engine
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check that the rocking lever pins exhibit no scores or wear.
Characteristic
Standard diameter:
13 - 0.010 -0.018 mm
- Measure the inside diameter of each rocking lever.
Characteristic
Standard diameter:
13 + 0.026 +0.015 mm
- Check that the cam contact sliding block and the
articulated register plate is free from wear.
- In case of wear, replace the component.
Refitting the head and timing system components
- Insert the chain guide sliding block.
- Insert the two centring dowels between head and
cylinder.
- Install the head gasket.
N.B.
THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN
HEAD AND CYLINDER. THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY
THE DOWELS.
ENG - 159
Engine
- The head gasket is made of steel and has a
standard thickness.
- Check that the head lubrication channel is perfectly clean. Clean with compressed air jets, if
required.
- Insert the head.
- Lubricate the stud bolts and the 4 fixing stud
bolts.
- Tighten the 4 fastening columns crosswise to the
prescribed torque as shown in the figure.
- Tighten the 4 screws by 90° in the sequence
shown in the figure.
- Further tighten by 90° in the sequence shown in
the figure.
Locking torques (N*m)
Head fixing stud bolts ***
- Tighten the fastening nuts on the exhaust and on
the intake side to the prescribed torque.
Locking torques (N*m)
Exhaust / intake head fixing nuts 10 - 12
ENG - 160
X9 Evolution 500
X9 Evolution 500
Engine
- Tighten the 3 side screws to the prescribed torque.
Locking torques (N*m)
Head fixing screws 10 - 12
- Install the coolant temperature sensor with the
washer and tighten to the prescribed torque.
CAUTION
FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN
DAMAGE THE SENSOR.
Locking torques (N*m)
coolant temperature sensor: 10 - 12
- Install the spark plug and tighten to the prescribed torque.
Locking torques (N*m)
Spark plug 12 ÷ 14
- Insert the timing control belt on the crankshaft
according to the initial direction of rotation.
- Install the tensioner shoe with its spacer, tightening the bolt to the prescribed torque, using the
recommended product.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Tensioner sliding block fixing screw 10 - 14
- Insert pins and rocking levers on the flywheel
side.
- Lubricate the two rocking levers through the
holes at the top.
ENG - 161
Engine
X9 Evolution 500
- Clean the camshaft by blowing with little compressed air jets, especially the retaining plate
housing.
- Lubricate the 2 shafts.
- Insert the camshaft into the head with the cams
opposite the rocking levers.
- Remove any LOCTITE residues from the screws fixing the camshaft retaining bracket using a brush.
- Apply the recommended product to the fixing screws and tighten the screws after wiping off any
threadlock deposits.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
- Insert the camshaft retain bracket with visible
countersinks and tighten the 3 fastening screws to
the prescribed torque, being careful not to damage
the inside hexagon.
Locking torques (N*m)
Camshaft retaining bracket screws: 4 ÷ 6
- Check that the toothing and the housing of the
tone wheel timing peg are free from deformations
or dents.
ENG - 162
X9 Evolution 500
Engine
- Insert the wheel speed sensor on the camshaft
keeping the stroke reference visible.
- Install the engine revolution timing sensor using
a new O-Ring, orientating it as shown in the figure.
Tighten the 2 fastening screws to the prescribed
torque.
N.B.
TO CHECK THIS COMPONENT, SEE CHAPTER "INJECTION".
Locking torques (N*m)
Rpm timing sensor fixing screw 3 - 4
- Install the intermediate gear with torque limiter,
the flywheel and its cover, as described in Chapter
"Flywheel and start-up system", and in Chapter
"Flywheel cover".
N.B.
FOR MORE CONVENIENCE, INSTALL THE FLYWHEEL
COVER WITHOUT THE COOLING SYSTEM SLEEVES.
- Using the TORX wrench, remove the timing
check cap.
ENG - 163
Engine
- Align the wheel speed sensor references with the
head as shown in the figure.
- Keeping the belt slightly pulled, turn the crankshaft using the driving pulley to make the reference
on the magnet support collimate with that on the
flywheel cover.
- Insert the belt on the camshaft control timing rim.
- Insert the timing rim on the camshaft checking
that the references are aligned.
N.B.
DURING THE STROKE CHECK, KEEP THE BELT TENSIONED BY PRESSING ON THE TIGHTENER COMPARTMENT SIDE.
- Install the counterweight mass.
- Centre using the bell fastening screw.
- Lock the mass fixing screws to the prescribed
torque, using the recommended product.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Counterweight screw 7 ÷ 8.5
ENG - 164
X9 Evolution 500
X9 Evolution 500
Engine
- Remove the central screw.
- Install the valve lifting mass being careful to the
proper positioning of the travel end ring.
- Lubricate the mass and de-compressor control
pin.
- Install the return spring and load it by about 3/4
turn.
- Turn the engine to move the references to the top
as shown in the figure (intake end).
- Insert the valve lifting device mass stop bell.
- Tighten the retaining screw to the prescribed torque, using the recommended product.
N.B.
THE BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
ENG - 165
X9 Evolution 500
Engine
- Check that the decompression mass is free and
that it is pulled by the spring.
Locking torques (N*m)
Valve lifter mass stop bell fixing screws 30 - 35
- Place the engine with the valve clearance adjustment timing references aligned with the head.
- Check the clearance between valve and rocking lever using a thickness gauge.
PRESCRIBED CLEARANCE
Specification
Inlet
drainage
Desc./Quantity
0.15 mm (engine cold)
0.15 mm (engine cold)
- In case different values are found, adjust by loosening the lock nut and use a screwdriver for the set
screw as shown in the figure.
Refitting the timing chain
This section described the operations to be carried out on the manifold components.
Ignition advance is determined electronically on the basis of parameters known by the control unit. For
this reason it is not possible to interpret the reference values based on the engine rpm.
The ignition advance value is detectable at any time using the diagnostic tester.
It is possible to check whether the ignition advance determined by the injection system matches the
value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light to check timing
ENG - 166
X9 Evolution 500
Engine
Proceed as follows:
- Remove the outside transmission cover as described in the automatic transmission chapter.
- Remove the TDC reference inspection cap between flywheel and crankcase cover. See the flywheel cover chapter.
- By the driving pulley, turn the engine to find the
alignment of the references to identify the TDC.
- Repeat for the reference between driving pulley
and transmission housing.
ENG - 167
Engine
- Replace the inspection cap on the flywheel side.
- Connect the diagnostic tester.
- Start the engine.
- Select the «parameter» function in this menu.
- Select the stroboscopic light command in the traditional four-stroke engine position (1 spark 2
revs).
- Check that the real values of rpm and ignition
advance match those measured using the diagnostic tester.
Specific tooling
020460Y Scooter diagnosis and tester
If the values do not match, check:
- distribution timing
- rpm-timing sensor
- injection control unit
Inspecting the radial air gap
- Align a tooth of the tone wheel with the revolution timing sensor.
- Check the air gap using a probe.
Characteristic
Standard air gap:
from 0.20 to 0.70 mm
- Repeat the check at 3 - 4 points.
ENG - 168
X9 Evolution 500
X9 Evolution 500
Engine
- Place the tightener cursor in the rest position,
keeping the retain tab pressed.
- Install a new tightener on the cylinder using a new
gasket.
- Tighten the two fastening screws to the prescribed torque.
Locking torques (N*m)
Tightener fastening screws: 11 ÷ 13
- Insert the spring with the central screw and the
washer.
- Tighten the central screw to the prescribed torque.
Locking torques (N*m)
Tightener screw: 5 - 6
Refitting the rocker-arms cover
- Check that the gasket is in good working order.
ENG - 169
Engine
- Tighten the two screws indicated in the figure with
«1» and «2» to limit the reciprocal sliding of the
cover surface with the head surface.
- Tighten the remaining 4 screws in a crossed sequence (3, 4, 5, 6).
N.B.
CHECK THE PROPER POSITION OF THE GASKET.
Locking torques (N*m)
Tappet cover fixing screws 7 - 9
- Install the transmission cover and the relevant net
filter and the outside transmission cover as described in the "Automatic transmission" chapter.
- Install the cooling system sleeves using new
bands, as described in the "Flywheel cover" chapter.
Refitting the intake manifold
- Install the intake manifold on the engine.
- Insert the 3 fastening screws, one of which with
a support band for the cooling system sleeve, and
tighten to the prescribed torque.
Locking torques (N*m)
Inlet manifold screws 11 ÷ 13
ENG - 170
X9 Evolution 500
X9 Evolution 500
Engine
Crankcase - crankshaft
- Remove the outside and inside transmission cover and the complete driving pulley as described in
"Automatic transmission".
- Remove the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover"
chapter.
- Remove the flywheel with the starting system following the instruction given in "Flywheel and Starting system".
- Remove the thermal group (cylinder, head, piston) as described in the «Thermal group and timing
system chapter».
ENG - 171
Engine
X9 Evolution 500
- Before opening the crankcase, check the crankshaft axial clearance.
For this purpose, use a plate (e.g. the special tool)
and a support with special tool comparator.
Specific tooling
020262Y Crankcase splitting strip
020335Y Magnetic support for dial gauge
Characteristic
Standard clearance:
0.10 - 0.50 mm
Admissible increase limit after use:
0.60 mm
- Upper clearances are an indication of wear on the surfaces of the crankshaft casing support.
- To carry out an accurate measurement, measure the clearance in both directions between crankcase
and crankshaft.
Splitting the crankcase halves
- Remove the engine support retain screw on the
flywheel side half-crankcase.
ENG - 172
X9 Evolution 500
Engine
- Remove the 14 crankcase coupling screws.
N.B.
THE FASTENING SCREWS ARE OF 3 DIFFERENT
LENGTHS. NOTE THEIR CORRECT POSITION.
- Split the crankcases while keeping the crankshaft
inserted on the flywheel side half-crankcase.
- Remove the coupling gasket.
N.B.
THE BUSHING SUPPORT CAN BE LEFT IN THE FLYWHEEL SIDE HALF-CRANKCASE.
Removing the crankshaft
- Before removing the crankshaft, check the timing
with the countershaft. To carry out this check, turn
the crankshaft to align the two holes obtained on
the crankshaft with the hole on the countershaft
control gear.
This is an optimal position also to remove the
crankshaft.
- Remove the crankshaft with the shim adjustment
washer on the flywheel side.
CAUTION
WHILE OPENING THE CRANKCASE AND REMOVING THE
CRANKSHAFT, CHECK THAT THE SHAFT THREADED
ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS.
FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE
THE MAIN BEARING.
ENG - 173
Engine
Removing the oil pump and countershaft control gear.
- To remove the control gear, loosen the 4 fastening screws.
Remove the gear only if actually required.
CAUTION
THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR
THREADING IS LOCKED BY LOCTITE. BE CAREFUL NOT
TO DAMAGE THE CONTROL HEXAGON. TO OBTAIN BETTER RESULTS IT IS PREFERABLE TO USE AN INSIDE
HEXAGON SOCKET WRENCH.
Removing the countershaft
- Place the special tool as shown in the figure.
Specific tooling
020479Y Countershaft lock wrench
- Remove the fastening nut with relevant washer.
- Remove the special tool and extract the countershaft with the control gear.
ENG - 174
X9 Evolution 500
X9 Evolution 500
Engine
Replacing the countershaft bearings
- Check that the bearings are free from irregular
noise or clearance. If it does, replace it.
Flywheel-side half-crankcase
- Remove the inside Seeger ring.
- Upturn the half-crankcase.
- Remove the bearing from the flywheel side halfcrankcase using the special tool and a mallet.
Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm adaptor
020439Y 17 mm guide
- Remove the bearing from the transmission side
half-crankcase using the special tool.
Specific tooling
001467Y008 Pliers to extract 17 mm ø bearings
001467Y007 Driver for OD 54-mm bearings
- Before installing a new bearing, heat the flywheel
side half-crankcase using the special tool.
- Place the half-crankcase on a wooden base.
Specific tooling
020151Y Air heater
ENG - 175
Engine
- Insert a new bearing on the special tool after
greasing the guide seat.
- Install the new bearing on the half-crankcase using the special tool.
N.B.
IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE
BALLS VISIBLE FROM THE CRANKCASE INTERNAL
SIDE.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020439Y 17 mm guide
- Fit the Seeger ring.
- Before installing the new bearing on the transmission side crankcase, heat the seat using the
special tool.
Specific tooling
020151Y Air heater
- Insert a new bearing on the special tool after
greasing the guide seat.
- Install the new bearing on the engine crankcase
using the special tool.
N.B.
IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE
BALLS VISIBLE FROM THE CRANKCASE INTERNAL
SIDE.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
ENG - 176
X9 Evolution 500
X9 Evolution 500
Engine
020439Y 17 mm guide
Inspecting the crankshaft components
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance:
0.20 ÷ 0.40 mm
- Check the connecting rod diametrical clearance.
Characteristic
Standard clearance:
0.046 ÷ 0.076 mm
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
N.B.
BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard dimensions:
63.6 - 63.45 mm
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
FALLS WITHIN THE STANDARD VALUES AND THE SURFACES ARE FREE FROM SCRATCHES.
Shimming
- Check the overall height of the crankshaft - shoulders - gear assembly.
Characteristic
Standard thickness:
71.804 - 72.000 mm
ENG - 177
X9 Evolution 500
Engine
- Check that shim adjustment is free from scratches.
N.B.
IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FITTING POSITION.
Specific tooling
020074Y Support base for checking crankshaft alignment
- If the crankshaft - crankcase axial clearance is higher than the standard value and the crankshaft
exhibits no irregularity, the problem is caused by wear or by a wrong machining on the engine crankcase.
- Check the diameters of both the bearings of the
crankshaft in accordance with the axes and surfaces shown in the figure. Half-shafts are classified
into two categories, Cat. 1 and Cat. 2.
STANDARD DIAMETER
Specification
Cat. 1
Cat. 2
Desc./Quantity
40.010 ÷ 40.016
40.016 ÷ 40.022
Inspecting the crankshaft alignment
- Install the crankshaft on the support and measure the displacement at the 4 points shown in the figure.
Specific tooling
020074Y Support base for checking crankshaft alignment
MAX ADMISSIBLE DISPLACEMENT:
Specification
A
B
C
D
Desc./Quantity
= 0.15 mm
= 0.01 mm
= 0.01 mm
= 0.10 mm
- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded
tangs are in good working order.
ENG - 178
X9 Evolution 500
Engine
- In case of failures, replace the crankshaft.
N.B.
MAIN BEARINGS CANNOT BE MODIFIED.
The connecting rod cannot be replaced. To check the connecting rod small end diameter, see chapter
"Thermal group and timing system".
- When cleaning the crankshaft, be careful to prevent any impurity from entering into the shaft lubrication
hole.
N.B.
IN CASE OF REPLACEMENT OF A CRANKSHAFT CONSISTING OF TWO HALF-SHAFTS OF DIFFERENT CATEGORY, REPLACE THE TWO HALF-CRANKCASES AS WELL, COUPLING THE TWO
COMPONENTS (SHAFT AND CRANKCASE) WITH THE SAME CATEGORY.
- To check the gearing of the crankshaft, see section "Thermal group and timing system".
See also
Cylinder assy. and timing system
Inspecting the crankcase halves
- Before proceeding to check the crankcase
halves, thoroughly clean all surfaces and oil ducts.
- For the transmission-side half-crankcase, special
attention should be given to the bushings, to the
cooling jet on the transmission side (see figure)
and to the lubrication duct.
ENG - 179
Engine
X9 Evolution 500
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE
PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
- For the flywheel side half-crankcase, special attention should be given to the lubrication channels
for the main bearings and to the compartment and
the channels for the oil pump, as well as to the duct
for the by-pass located on the flywheel cover.
N.B.
AS ALREADY DESCRIBED IN THE "LUBRICATION" CHAPTER, IT IS ESPECIALLY IMPORTANT THAT THE BY-PASS
HOUSING ON THE FLYWHEEL COVER IS FREE FROM
WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE
LUBRICATION PRESSURE ADJUSTMENT PISTON. THE
HEAD LUBRICATION CHANNEL IS EQUIPPED WITH A
SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION. THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP.
The jet clogging impairs the head lubrication and the timing mechanisms.
A jet failure causes a decrease in the main bearing and connecting rod lubrication pressure.
- Check that the surfaces exhibit no dents or deformations, with special attention to the crankcase
coupling and the crankcase-cylinder surfaces.
- Any defects in the crankcase gasket or matching surfaces (see Flywheel cover coupling) can cause
pressurised oil leaks, thereby affecting the connecting rod and main bearing lubrication pressure.
- Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. For
the dimensional check, refer to the instructions about checking the axial clearance and the dimensions
on the crankshaft
ENG - 180
X9 Evolution 500
Engine
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one with holes and channels for lubrication whereas the other is solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposite the cylinder.
- To prevent obstructions in the oil feeding channels, the matching surface of the two half-bearings must
be perfectly perpendicular to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION, DRIVING IS FORCED ON
CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.
- Check the inside diameter of the main bushings
in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing
half. see diagram.
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALFSHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
- The standard bushing diameter after driving is variable on the basis of a coupling selection.
- The bushing seats into the crankcases are classified into 2 categories as for the drive shaft Cat. 1 and
Cat. 2.
- Bushings are divided into 3 categories according to their thickness. See the table below:
CHECK THE BENCH BUSH
Name
Type A - Red
Type B - Blue
Type C - Yellow
Description
Dimensions
1.982 - 1.987
1.987 - 1.992
1.992 - 1.997
Initials
Quantity
ENG - 181
X9 Evolution 500
Engine
Coupling chart
COUPLING THE SEMI-SHAFTS WITH THE SEMI-CHASSIS AND BUSHES
Name
Half-shaft category 1 Bushing category B
Description
Dimensions
Half-shaft category 2 Bushing category C
Half-shaft category 1 Bushing category A
Half-shaft category 2 Bushing category B
Initials
Spare crankcase set-up
FC1 - Dis.
CM1033015001
Spare crankcase set-up
FC1 - Dis.
CM1033015001
Spare crankcase set-up
FC2 - Dis.
CM1033015002
Spare crankcase set-up
FC2 - Dis.
CM1033015002
Quantity
N.B.
FOR SERVICING WITH SPARE PARTS, MATCH THE SHAFT WITH TWO SHOULDERS OF CATEGORY 1 TO CRANKCASE FC1 (OR CATEGORY 2 TO CRANKCASE FC2).
A spare crankcase cannot be combined with a driving shaft with mixed categories. Spare shafts have
half-shafts of the same category.
N.B.
TO REPLACE THE HALF-SHAFTS, REMOVE THE COUNTERSHAFT BEARINGS AS DESCRIBED
ABOVE. REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI-FLAPPING ROLLER FROM
THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN CHAPTER "AUTOMATIC
TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS
DESCRIBED IN CHAPTER "FINAL REDUCTION".
Countershaft
- Using a micrometer, measure the 2 bearings of
the countershaft as shown in the figure.
Characteristic
Standard diameter:
17 - 0.01 - 0.02 mm
- Check that the water pump drive is not worn.
Refitting the crankshaft
- Check that the oil pump and countershaft control gear are free from deformations or dents. Replace,
if required.
N.B.
IF YOU HAVE TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NECESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL.
ENG - 182
X9 Evolution 500
Engine
- Before installing the gear on the crankshaft, carefully clean the two matching surfaces removing
any residues of LOCTITE from the holes using a
brush.
Blow with compressed air and degrease the mounting holes on both surfaces to make the new LOCTITE
grip.
Apply the recommended product to the holes again.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
- Repeat the same procedure for the 4 fastening screws.
- Insert the control gear on the crankshaft with the hole countersink visible.
- Tighten the 4 fastening screws to the prescribed torque.
N.B.
TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH.
Locking torques (N*m)
Gear mounting on crankshaft screws 10 -12
- Lubricate the main bearing on the flywheel side
half-crankcase.
- Lubricate the shim adjustment washer.
- Insert the shim adjustment washer on the crankshaft in its original position.
- Insert the special timing tool in the hole on the
countershaft.
Specific tooling
020471Y Pin for countershaft timing
ENG - 183
Engine
X9 Evolution 500
- Insert the crankshaft on the pin and into the bushing.
- Before inserting thoroughly, make the oil pump
gear align with the control gear.
- Insert thoroughly and remove the special tool.
N.B.
WHEN INSERTING THE SHAFT ON THE HALF-CRANKCASE, BE CAREFUL NOT TO DAMAGE
THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIMING CONTROL TOOTHED PINION.
- Install the oil pump closing plate.
- Tighten the 2 flanged fastening screws to the
prescribed torque.
Locking torques (N*m)
Bulkhead screws for oil pump housing cover 8
- 10
Refitting the crankcase halves
- Remove the oil guard from the transmission side
half-crankcase using a screwdriver.
- Install a new oil guard after lubricating it, using
the special tool, arranging it at a 0.5 mm recess
from the crankcase plane.
CAUTION
A WRONG POSITIONING OF THE OIL GUARD AFFECTS
THE LUBRICATION OIL CIRCULATION.
Specific tooling
020360Y Adaptor 52 x 55 mm
020376Y Adaptor handle
ENG - 184
X9 Evolution 500
Engine
- Insert the gasket on the flywheel side half-crankcase.
- Lubricate the main bearing on the transmission
side half-crankcase.
- Couple the 2 half-crankcases being careful
not to damage the bushing on the transmission side half-crankcase with the threaded
tang of the crankshaft.
- Insert the engine support retain screw on the flywheel side half-crankcase without tightening.
- Insert the 14 fastening screws by arranging the
single shorter screw «A» and the single longer
screw «B» as shown in the figure.
- Tighten the screws thoroughly and tighten to the prescribed torque.
- Check that the crankshaft rotates freely.
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER
PLANE, TO ENSURE BETTER SEALING PERFORMANCE.
Locking torques (N*m)
Engine-crankcase coupling screws 11 ÷ 13
- Install the thermal group (cylinder, head, piston)
as described in section «Thermal group and timing
system».
ENG - 185
X9 Evolution 500
Engine
- Install the flywheel with start-up control as described in the "Flywheel and start-up" chapter.
- Install the flywheel cover with the cooling system
sleeves, as described in the "Flywheel cover chapter".
- Install the complete driving pulley, the transmission cover and the relevant mesh filter and the
outside transmission cover as described in the
section "Automatic transmission".
See also
Cylinder assy. and timing system
Flywheel cover
Lubrication
TECHNICAL SPECIFICATIONS
SUMP CAPACITY
Specification
Overhaul
Oil and filter replacement
Desc./Quantity
1.7 l
1.5 l
RECOMMENDED ENGINE OIL
Product
AGIP CITY HI TEC 4T
ENG - 186
Description
Engine oil
Specifications
SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
X9 Evolution 500
Engine
OIL PUMP
Specification
Type
Rotor washers
Assembly clearances
External rotor radial clearance
Rotor axial clearance
Desc./Quantity
Trochoidal
8 mm
Lobe ends 0.05-0.008 mm
0.05- 0.12 mm
0.025 - 0.065 mm
BY-PASS
Specification
Type
Plunger diameter
Spring free length
Calibration pressure
Desc./Quantity
with piston
13.9 - 0.039 -0.057 mm
62.5 mm
4 bar
PRE-FILTER
Specification
Type
Desc./Quantity
mesh, plastic
OIL FILTER
Specification
Type
Desc./Quantity
Paper with pressure relief and anti-drain back by-pass valves
OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH
Specification
Calibration
Desc./Quantity
0.3 - 0.6 bar
HEAD LUBRICATION CONTROL JET
Specification
Diameter
Desc./Quantity
1 ± 0.05 mm *
* Tightening torque 5÷7 N·m
PISTON COOLING NOZZLE
Specification
Diameter
Desc./Quantity
0.8 ± 0.05 mm
CRANKCASE VENTILATION CHECK
Specification
Device
Desc./Quantity
metal reed valve and decantation chamber
ENG - 187
X9 Evolution 500
Engine
Conceptual diagrams
PRINCIPLE DIAGRAM
Specification
A
B
C
D
E
F
G
H
L
M
N
O
Desc./Quantity
Camshaft
Cylinder-head plane
Cylinder-crankcase plane
Water pump impeller
Minimum oil pressure sensor
Oil filter cartridge
To the oil sump
By-pass valve
Oil pump
Mesh pre-filter
Crankshaft
Connecting rod
General characteristics
The lubrication system is divided into two sections:
- High pressure
- Low pressure
The high pressure section includes all components located on the engine crankcase whereas the low
pressure section only refers to the thermal group.
The trochoidal pump is installed in the sump and is controlled by a pair of gears.
To guarantee the integrity of the pump, a pre-filter is fitted.
This is a screw-in type pre-filter and the relevant plug serves at the same time as an engine oil drain
plug.
ENG - 188
X9 Evolution 500
Engine
The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the
cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the
pressure of the circuit.
The by-pass located before the cartridge filter improves the operating conditions for the filter, particularly
with cold oil.
The filter is equipped with an anti-drain back valve and a pressure relief valve; the latter intervenes
when the filtering mass causes a pressure drop above 1 ± 0.2 bar.
These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged.
The filtered oil is used to lubricate the water pump shaft and once at the engine crankcase, to lubricate
the main bearings, the connecting rod head and the piston cooling nozzle, on the transmission-side
bearing.
The main bearing on the transmission side is fitted with an oil seal and the respective drain line.
The supply line for the timing system comes from the flywheel-side bearing; the supply to the head is
controlled by the respective spray jets in the engine crankcase.
The components of the timing system function with low-pressure oil lubrication.
The camshaft bearings are installed directly on the aluminium of the head; the camshaft axial clearance
is partially compensated by the oil supplied to the smaller diameter bearing.
The camshaft supplies the lubricant to the rocking levers via the holes provided; these are installed in
a position to ensure that the lubrication is maintained even after the scooter has stopped. This is achieved when the camshaft reaches its most usual and likely position when the engine is shut off.
The oil used to lubricate the head returns to the sump via the chain casing channel and therefore it also
provides lubrication for the chain.
A one-way valve and a decantation chamber are used so that gases from the crankcase do not carry
any oil. The one-way valve is a metal reed valve; the decantation chamber has a drainage hole. A failure
in these components implies oil getting into the line supplying air to the engine.
Excessive oil vapours may result in clogged ducts on the throttle body.
In order to signal low oil pressure in the system, a pressure switch is used, located immediately after
the oil filter outlet.
The lubrication circuit does not include the countershaft. The countershaft is lubricated by the oil transported by the gears or by the centrifugal effect of the crankshaft
The same applies to the piston or the pin, but in this case the cooling nozzle is particularly important.
Diagnosis guide
1 - Minimum oil pressure warning light on with hot engine.
AHEAD - go to 2
2 - Remove the minimum pressure switch electric connector.
Check that the warning light turns off.
YES - go to 3 NO go to 11
ENG - 189
X9 Evolution 500
Engine
3 Check the actual oil pressure.
AHEAD - go to 4
4 - Remove the switch and fit the special tool with the relevant gasket.
Specific tooling
020193Y Oil pressure gauge
020434Y Oil pressure control fitting
- Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied
with the special tool. Insert the probe to feel contact with the crankcase bottom and pull back a few
millimetres.
Specific tooling
020331Y Digital multimeter
AHEAD - go to 5
5 - Measure the pressure with cold and idling engine.
STANDARD VALUES
Specification
20°C Temperature
1400 rpm
Desc./Quantity
approx. 4.5 bar
N.B.
RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE DIAGNOSTIC
TESTER
Specific tooling
020460Y Scooter diagnosis and tester
YES go to 6 NO go to 12
6 - Let the engine warm up and repeat the check with hot oil.
STANDARD VALUES
Specification
80°C Temperature
1400 rpm
approx. 1.5 bar
YES go to 7 NO go to 8
7 - Replace the oil minimum pressure switch.
ENG - 190
Desc./Quantity
X9 Evolution 500
Engine
8 - If pressure lower than 1.3 ÷ 1.5 bar is measured.
AHEAD go to 9
9 - Replace the oil filter and repeat the pressure check with oil at 80°C.
YES go to 10 NO go to 13
10 - The failure was fixed.
It is recommended to respect the suggested number of kilometres covered.
11 - Check and restore the electrical system.
12 - If pressure lower than 4 bar is measured.
AHEAD go to 9
13 - Remove the flywheel cover and check the by-pass and the cover sealing gasket efficiency towards
the case internal side, as described in the "Flywheel cover" chapter.
YES go to 14 NO go to 15
14 - Check whether there is an irregular clearance on the crankshaft:
- axial clearance (see the "Crankcase and crankshaft" chapter)
- radial clearance, especially in the direction of the cylinder axis
- clearance according to the direction of rotation with the connecting rod in quadrature
YES go to 16 NO go to 17
15 - Replace the faulty components ("Flywheel cover" chapter).
16 - Overhaul the engine ("Crankcase and crankshaft" chapter).
17 - Open the engine crankcase and remove the oil pump as described in the "Crankcase and crankshaft" chapter.
- Check the oil pump as described in the following pages.
- Check that the cooling nozzle and the timing system feeding jet are properly installed.
- Visually inspect the crankshaft couplings and their size ("Crankcase and crankshaft" chapter).
N.B.
POTENTIAL IRREGULARITIES IN COUPLINGS AND THE TIMING SYSTEM COMPONENTS CANNOT BE DETECTED WHEN INSPECTING THE LUBRICATION PRESSURE. THEY MAY BECOME
EVIDENT BY AN INCREASE IN NOISE.
N.B.
IN CASE OF IRREGULAR PRESSURE ON THE CRANKCASE, CARRY OUT A VISUAL AND DIMENSIONAL INSPECTION OF THE TIMING SYSTEM COMPONENTS (SEE "THERMAL GROUP
AND TIMING SYSTEM" CHAPTER).
Oil pressure check
1 - In case of oil leaks from the oil filter or from the flywheel cover coupling gasket, check the lubrication
pressure.
AHEAD go to 2
2 - Install the special tool.
Specific tooling
020193Y Oil pressure gauge
ENG - 191
Engine
X9 Evolution 500
020434Y Oil pressure control fitting
AHEAD go to 3
3 - Check the system pressure with cold engine and medium - high speed.
Standard pressure < 6 bar
YES go to 4 NO go to 5
4 - Replace the damaged components.
5 - Check the working order of the adjustment by-pass (see "flywheel cover" chapter) and restore proper
sliding.
N.B.
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY. A
HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE.
1 - If oil consumption is above 250 g/1000 km on a run-in engine, proceed as follows.
AHEAD go to 2
2 - Check the presence of oil at the scavenge duct on the filter box.
YES go to 3 NO go to 4
3 - Check the one-way reed valve and the decantation chamber drainage hole.
YES go to 5 NO go to 4
4 - Check the thermal group seals (piston rings, valve guides and oil guards), see "Thermal group and
Timing system" chapter.
5 - Restore the valve or the drainage hole efficiency.
Oil pump
Removal
- Remove the two screws and the oil pump cover.
ENG - 192
X9 Evolution 500
Engine
- Remove the inside rotor retaining snap ring turning it to move the opening at the shaft face.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Extract the shaft with its gear and check that it is
in good working order and free from wear.
- Reassemble the rotors in the pump body, keeping the two reference marks visible
- Insert the shaft with the gear and install the lock
ring; then, turn it with the opening opposed to the
shaft face.
- Check any irregular clearance between shaft and
pump body.
- Using a thickness gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Admissible limit clearance:
0.012 mm
ENG - 193
Engine
- Check the distance between external rotor and
pump body; see figure.
Characteristic
Admissible limit clearance:
0.25 mm
- Check the rotor axial clearance using a rectified
bar as reference plane, as shown in the figure.
Characteristic
Limit values admitted:
0.1 mm
- Remove the closing plate of the oil pump housing
by loosening the 2 retaining screws with their
washers.
- Remove the oil pump complete with the gearing
by loosening the 2 retaining screws through the
eyes machined in the gearing proper.
ENG - 194
X9 Evolution 500
X9 Evolution 500
Engine
- Remove the gasket.
Inspection
- For tests on the oil pump, see the "Lubrication"
chapter.
Refitting
- Lubricate the internal rotors.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If non-conforming values or signs of wear are
found, replace the pump.
- Fit the pump cover in the position that permits the
crankcase fixing screws to be aligned.
- Tighten the two fastening screws to the prescribed torque.
Locking torques (N*m)
Oil pump cover screws 0.7 ÷ 0.9
ENG - 195
Engine
X9 Evolution 500
- Make sure the gasket is in the correct position.
N.B.
THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
- Insert the oil pump with gear
- Insert the 2 retaining screws through the slots on the gear and tighten to the prescribed torque.
N.B.
THE ASSEMBLY POSITION OF THE PUMP IS FIXED BY INSTALLATION OF THE SCREWS.
Failure to observe the tightening torque may alter
the coupling clearance of the rotors with the pump
body.
Locking torques (N*m)
Screws fixing oil pump to crankcase 5 - 6
- Insert the countershaft with gearing into the flywheel-side half-crankcase.
- Install the special tool in the position shown in the
figure.
Specific tooling
020479Y Countershaft lock wrench
- Keep the countershaft in position and insert the
washer with the nut.
- Tighten the nut to the prescribed torque, using
the recommended product.
- Remove the special tool.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
ENG - 196
X9 Evolution 500
Engine
Countershaft fixing nut 25 ÷ 29
Inspecting the by-pass valve
- Ensure there are no scratches or any other signs of damage on the outer by-pass surface.
Characteristic
External diameter:
10,5 mm
- Check the unloaded spring length.
Characteristic
Standard length:
65,2 mm
Maximum allowable length after use:
64,0 mm
ENG - 197
INDEX OF TOPICS
INJECTION
INJEC
X9 Evolution 500
Injection
EMS injection system
This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
Injection and ignition are timed on the 4-stroke cycle using a tonne wheel pivoted on the camshaft control
and a reluctance variation sensor.
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature.
- Intake air temperature
- Ambient pressure
The system implements an idle feeding correction with cold engine through a Stepper motor on a bypass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening
time, thereby ensuring the idle steadiness and the proper combustion.
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel supply pressure is kept constant based on the ambient pressure.
The fuel supply circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by two pipes provided with quick couplings. This allows obtaining a continuous
circulation, thereby avoiding the risk of fuel boiling. The pressure regulator is situated at the end of the
circuit.
The fuel pump is controlled by the EMS control unit; this ensures the scooter safety
The ignition circuit consists of:
- HV coil
- HV cable
- Shielded cap
- EMS control unit
- Spark plug
The EMS control unit manages the ignition with optimum timing, ensuring the timing on the 4-stroke
cycle (ignition only during compression).
The EMS injection/ignition system manages the engine function according to a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
INJEC - 199
Injection
- Fuel pump
- HV coil
- Injector
The control unit is provided with a self-diagnosis
system connected to an indicator light in the instrument panel.
Failures are detected and restored by the diagnostic tester.
In any case, when the fault is no longer present,
the data storage is automatically cleared after 16
cycles of use (cold start, running at regular engine
temperature, stop).
The diagnostic tester is also required to adjust the
idle mixture.
Specific tooling
020460Y Scooter diagnosis and tester
The EMS injection-ignition system has a control
function over the rpm indicator and the radiator
cooling electric fan.
The EMS is connected to the anti-theft immobilizer
system decoder.
In turn, the decoder is connected to a flashing diagnostic LED that also serves as deterrent.
The EMS control unit power supply is further controlled by the emergency switch and by the side
stand switch, that is to provide further safety for the
scooter.
INJEC - 200
X9 Evolution 500
X9 Evolution 500
Injection
The ignition system control unit is programmed to ensure optimal carburetion while riding along streets.
The idle carburetion needs to be adjusted to compensate for the production tolerances and engine
settlement.
This adjustment is done by modifying the injector opening time with the engine running at idle.
To adjust, proceed as follows:
1 - Idle carburetion adjustment must be performed on an engine ready for precision adjustment.
Check in advance:
- spark plug
- that air filter is clean
- that throttle body is clean
- intake system for sealing
- exhaust system for sealing
- valve clearance
- fuel filter
- Fuel pressure
N.B.
IDLE SPEED IS OBTAINED BY PRE-CALIBRATING THE THROTTLE BODY AND THE ACTIVITY
OF THE STEPPER.
Characteristic
Engine idle speed
1500 ± 50 rpm
Check that the throttle body is not tampered.
YES go to 2
2 - Preheat and check the zero setting of the exhaust fumes analyser.
Remove the exhaust manifold cover and connect
the extension to the coupling clamp for the analyser pipe.
YES go to 3
3 - Connect the diagnostic tester.
Set the switch to "ON" with switch to "RUN" and
side stand raised.
YES go to 4
4 - Select the menu on the "ERRORS" function.
Check whether there are any failures.
YES go to 6 NO go to 5
INJEC - 201
X9 Evolution 500
Injection
5 - Select the menu on the "PARAMETERS" function.
YES go to 7
6 - Repair according to indications supplied.
YES go to 4
7 - Start the engine and let it warm up until the
following conditions are present:
- coolant temperature = over 80°C
- intake air temperature = 25 ÷ 30°C
YES go to 8
8 - Activate the exhaust fumes analyser and check
the following conditions are present:
- CO = 1.25±0.25%
- CO2 = 14.50±1%
YES go to 9 NO go to 10
9 - The adjustment is correct.
10 - If a different CO value is read, adjust the idle
injection timing.
YES go to 11
11 - Select the diagnostic tester menu on the «CO
CALIBRATION» option.
Activate the adjustment function.
YES point 12
12 - «TRIMMER VALUE» is displayed.
The numbers displayed can be positive or negative.
YES go to 13
13 â To increase the CO the injection time needs to be increased.
To decrease the CO the injection time needs to be decreased.
Adjust the trimmer value according to the indications in the table:
YES go to 14
TRIMMER VALUE
INJECTION TIME
CO
+100
HIGH
INCREASE
+ 50
Ã
Ã
+ 10
LOW
Ã
0
Ã
DECREASE
- 10
MEDIUM
INJEC - 202
X9 Evolution 500
Injection
- 50
-100
N.B.
THE TRIMMER VALUE 0 CORRESPONDS TO THE AVERAGE INJECTION TIMING.
AFTER ADJUSTMENT ENGINES CAN HAVE CARBURETION WITH BOTH POSITIVE AND NEGATIVE TRIMMER VALUES.
THIS IS DUE TO NORMAL PRODUCTION TOLERANCES.
14 - After having modifying a trimmer value, wait
until the CO value becomes steady.
In case of incorrect adjustment, press OK to store
the value in the control unit memory.
YES go to 15
15 - Select «PARAMETERS» and «ECU DATA»
to confirm the new trimmer change has been stored.
N.B.
WHEN THE CO PERCENTAGE IS RIGHT AND THE CO2 PERCENTAGE DOES NOT FALL INTO
THE SPECIFIED VALUES, THE LAMBDA VALUE IS ALSO DISTORTED. IF THIS OCCURS, CAREFULLY CHECK THE EXHAUST SYSTEM FOR ADEQUATE SEALING.
When the CO percentage is correct and the HC (PPM) value exceeds the maximum limit allowed, check:
- spark plug
- valve clearance
- timing system phase
- outlet valves for sealing
When the control unit is replaced, reset TPS and pre-program the trimmer value of the original control
unit (if available) preventively.
In any case, check the CO value again.
N.B.
WHEN THE CO PERCENTAGE IS RIGHT AND THE CO2 PERCENTAGE DOES NOT FALL INTO
THE SPECIFIED VALUES, THE LAMBDA VALUE IS ALSO DISTORTED.
If this occurs, carefully check the exhaust system for adequate sealing.
When the CO percentage is correct and the HC (PPM) value exceeds the maximum limit allowed, check:
- spark plug
INJEC - 203
X9 Evolution 500
Injection
- valve clearance
- timing system phase
- outlet valves for sealing
When the control unit is replaced, reset TPS and pre-program the trimmer value of the original control
unit (if available) preventively.
In any case, check the CO value again.
Make sure the entire exhaust system is sealed.
Remove the intake cap on the exhaust pipe, connect the dissipater and the extension pipe.
Warm-up the engine and use an exhaust analyser to check the carburation of the idle speed, if necessary, restore the correct setting using a scooter Tester, see «Adjusting idle carburation».
Specific tooling
020625Y Kit for sampling gas from the exhaust manifold
494929Y Exhaust fumes analyser
Connect the gas collection kit at the muffler outlet being careful to ensure that it is sealed and stable
by making sure the band is correctly fitted.
Transfer the connection of the exhaust gas analyser from the manifold collection extension pipe to the
extension pipe for the muffler outlet.
Use the exhaust collection kit for this connection.
Close the extension outlet for collection from the manifold to make sure air does not infiltrate.
Specific tooling
020623Y Pre-service gas extraction set
Check the exhaust emissions from the muffler (after the catalytic converter) with the engine warm and
idling.
STANDARD VALUES WITH THE ENGINE IDLING
Specification
CO
CO2
HC
O2
Lambda factor:
Desc./Quantity
= < di XXX %
= > di XXX %
= < di XXX ppm
= XXX %
XX
If the values measured are the same as those obtained with what was collected from the exhaust pipe,
increase the catalytic converter temperature keeping then engine at average rpm and repeat the idle
test.
If the anomaly persists and the carburation setting was correct, replace the muffler with catalytic converter.
TERMINALS
INJEC - 204
CONDITIONS
STANDARD
X9 Evolution 500
5 - 23
Injection
Switch in position "ON"
Battery voltage
Switch on "RUN"
Side stand raised
Electric fan off
CIRCUIT LAYOUT
1
2
3
4
5
Specification
electronic control unit
Electric fan
Fuse
Key switch
Electric fan remote control switch
Desc./Quantity
30A
The electric fan system is powered by a remote
control switch connected to the continuous power
supply controlled by the electronic control unit of
the injection system.
The electronic control unit of the injection system
controls the electric fan in relation to the measured
engine temperature.
If prolonged running of the electric fan is noticed,
check the following carefully before starting to
check the electrical system:
- Coolant level in the expansion tank - bleeding of
the inlet hose to the engine
INJEC - 205
Injection
- Bleeding of the outlet from the head
- Function of the thermostat
- Function of the pump
For these checks, see chapter "Cooling system".
To check the circuit, proceed as follows:
1 - Connect the diagnostic tester. Set the switch to
"ON" with switch to "RUN" and side stand raised.
Select the "ERRORS" function. Check whether the
control unit has detected any failures relating to the
electric fan control circuit.
YES go to 8 NO go to 2
2 - Select the menu on the "ACTIVE DIAGNOSIS"
function. Activate the electric fan diagnostic function. Check acoustically for rotation of the electric
fan. Wait for the exit from the diagnostic tester.
YES go to 3 NO go to 4
3 - Test successful. The fan is rotating.
YES go to 5
4- Test failed. The fan is not rotating.
YES go to 8 NO go to 6
5- The electric fan system is OK
6 - Test successful. The fan is not functioning
YES go to 7
7 - The remote control switch circuit is OK. Check
the connections to the electric fan, the function of
the contacts of the remote control switch, the positive lines, the negative line and the motor of the
electric fan.
8 - Disconnect the remote control unit of the electric fan. Check the continuity of the excitation coil.
85 - 86 = 100 ± 50Ω
YES go to 10 NO go to 9
INJEC - 206
X9 Evolution 500
X9 Evolution 500
Injection
9 - Replace the remote control switch
YES go to 8
10 - Connect the special tool between the control
unit and the system. Do not connect the electronic
control unit
YES go to 11
11 - Check for positive battery voltage at pin 85 of
the remote control switch connector.
85 (blue/grey) - 23 = Battery voltage with switch in
position "ON"
YES go to 13 NO go to12
12 - Repair or replace the wiring.
13 - Leaving the remote control switch disconnected, check for continuity between pin 86 of the
remote control switch connector and pin 5 of the
electronic control unit.
86 (green/white) - 5 = 0Ω (continuity)
YES go to 14 NO go to15
14 - Check the earth insulation.
5 - 23 >1 MΩ (infinite)
YES go to 16 NO go to 15
15 - Repair or replace the cable harness.
16 - Connect the remote control switch and check
for battery voltage between terminals 5 and 23 with
the key switch in position "ON".
5 - 23 = Battery voltage with panel in position "ON"
YES go to 17
17 - Repeat the check with the electronic control unit connected and the engine cold.
5 - 23 = Battery voltage with panel in position "ON"
INJEC - 207
Injection
X9 Evolution 500
If the fault continues, replace the electronic control unit.
Precautions
1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel supply system is pressurised at 300 kPa (3 BAR). Before disconnecting the quick coupler
of a pipe in the fuel supply system, check that there are no naked flames. Do not smoke. Act with caution
to prevent spraying in the eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to
respect this norm will damage the fuel pump.
6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and wiring.
8. When an ignition fault is detected, start the checks from the battery and the injection system connections.
9. Before disconnecting the EMS control unit connector, perform the following operations in the following
order:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the polarity when fitting the battery.
11. In order to prevent damages, disconnect and reconnect the EMS connectors only if actually required.
Before reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, protect the system connector with
its cap. Failure to respect this norm may damage the EMS control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
Terminals setup
Layout of the system-side connectors and the connectors on the electronic control unit.
INJEC - 208
X9 Evolution 500
Injection
ELECTRONIC CONTROL UNIT SIDE
SYSTEM SIDE
EMS CONTROLLER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Specification
Throttle potentiometer power supply
Digital instrument (rpm counter control)
Engine temperature
86 electric fan remote control switch
Stepper motor
Engine rpm sensor
EMS diagnostic connector
EMS diagnostic connector
Throttle potentiometer signal
R.P.M. sensor (+)
Injector control
Stepper motor
Instrument unit
Decoder (serial)
Base power supply
Air temperature sensor
85 remote control switch
H.V. coil
Stepper motor
Sensor power supply
Control unit negative
Stepper motor
Continuous power supply
Desc./Quantity
+5 V
(+)
Stepper motor
(negative)
Stepper motor
(injection indicator - negative)
Overturn sensor
(positive)
(+)
(pump - injector - h.v. coil) (-)
(negative control)
Stepper motor
(-)
Stepper motor
(positive)
INJEC - 209
X9 Evolution 500
Injection
IMMOBILIZER DECODER
1
2
3
4
5
6
7
8
Specification
Immobilizer LED control
Base power supply
Negative
Electronic control unit EMS
Continuous power supply (positive)
Desc./Quantity
(negative)
(positive)
(serial)
Immobilizer aerial
EMS circuit diagram
[P]
1
2
3
4
5
INJEC - 210
Specification
Electric fan remote control switch
Electric fan
Control unit remote control switch
HV coil
Fuel pump
Desc./Quantity
X9 Evolution 500
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Injection
Specification
Instrument panel
Injector
Fluid temperature sensor
Air temperature sensor
Throttle potentiometer
Stepper motor
Electronic control unit EMS
Immobilizer aerial
Decoder
EMS diagnostic socket
Stroke revolution sensor
Stand switch
Emergency stop switch
Diode
Fuse
Engine stop remote control switch
Main remote control switch
Key switch
Rectifier regulator
Fuse
Fuse
Fuse
Utilities
Desc./Quantity
Stepper motor
(serial)
2A
3A
10 A
30A
5A
Troubleshooting procedure
This section makes it possible to find what solutions to apply when troubleshooting.
Engine does not start
ENGINE DOES NOT START IF ONLY PULLED
Possible Cause
Immobiliser enabling signal
Presence of faults detected by the self diagnosis
Fuel supply
Power to the spark plug
Parameter reliability
End of compression pressure
Operation
System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Pump relay
HV coil
Injector
revolution timing sensor
Fuel in the tank
Fuel pump activation
Fuel pressure (low)
Injector capacity (low)
Shielded spark-plug cap HV coil (secondary insulation)
Coolant temperature
Distribution timing - injection ignition
Intake air temperature
End of compression pressure
Starting difficulties
ENGINE START-UP PROBLEMS
Possible Cause
Presence of faults detected by the self diagnosis
Operation
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
INJEC - 211
X9 Evolution 500
Injection
Possible Cause
Start up engine speed
End of compression pressure
Power to the spark plug
Fuel supply
Correctness of the parameters
Operation
Atmospheric pressure
Starter motor and remote control
Battery
Ground connections
End of compression pressure
Spark plug
Shielded cap
HV coil
Rpm-timing sensor
Ignition advance
Fuel pressure (low)
Injector capacity (low)
Injector seal (poor)
Coolant temperature
Stepper throttle valve position intake air temperature (steps
and actual opening)
Cleaning of the auxiliary air pipe and throttle valve; air filter efficiency
Engine stops at idle
ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Correctness of the parameters
Intake system cleaning
Intake system sealing (infiltrations)
Fuel feed (low pressure)
Analysis of exhaust fumes before the catalytic converter
Operation
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Atmospheric pressure
Spark plug
Ignition timing
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Trimmer value adjustment (CO % adjustment)
Engine does not rev down
ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Correctness of the parameters
INJEC - 212
Operation
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Atmospheric pressure
Ignition timing
Throttle valve position sensor
Stepper
X9 Evolution 500
Possible Cause
Intake system sealing (infiltrations)
Fuel feed (low pressure)
Analysis of exhaust fumes before the catalytic converter
Injection
Operation
Coolant temperature sensor
Intake air temperature sensor
Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Trimmer value adjustment (CO % adjustment)
Exhaust backfires in deceleration
EXHAUST BACKFIRES WHEN DECELERATING
Possible Cause
Presence of faults detected by the self diagnosis
Correctness of the parameters
Intake system sealing (infiltrations)
Fuel feed (low pressure)
Exhaust system sealing (infiltrations)
Analysis of exhaust fumes before the catalytic converter
Operation
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Atmospheric pressure
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Manifold - head
Manifold - muffler
Analyser socket
Muffler welding
Trimmer value adjustment (CO % adjustment)
Engine revs irregularly
IRREGULAR PROGRESS OF THE ENGINE WITH VALVE SLIGHTLY OPEN
Possible Cause
Presence of faults detected by the self diagnosis
Intake system cleaning
Intake system seal
Ignition system
Parameter reliability
TPS reset successful
Operation
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Atmospheric pressure
Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake sleeve
Filter box
Spark plug wear check
Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
TPS reset successful
INJEC - 213
X9 Evolution 500
Injection
Possible Cause
Analysis of exhaust fumes before the catalytic converter
Operation
Trimmer value adjustment (CO % adjustment)
Poor performance at full throttle
POOR ENGINE PERFORMANCE AT FULL POWER/ IRREGULAR ENGINE PROGRESS
ON PICKUP
Possible Cause
Presence of faults detected by the self diagnosis
Spark plug power supply
Intake system
Parameter reliability
Fuel supply
Operation
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Atmospheric pressure
Spark plug
Shielded cap
HV cable
HV coil
Air filter
Filter box (sealing)
Intake sleeve (sealing)
Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity
Engine knocking
PRESENCE OF KNOCKING (OVERHEAD KNOCKING)
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Parameter reliability
Intake system seal
TPS reset successful
Fuel supply
Selection of the cylinder base gasket thickness
Operation
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Atmospheric pressure
Spark plug
Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Intake sleeve
Filter box
TPS reset successful
Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Selection of the cylinder base gasket thickness
Decoder master-box circuit
This section describes the operations to be carried out to check the power supply circuit.
INJEC - 214
X9 Evolution 500
Injection
Constant supply circuit check
The decoder basic power supply is necessary for the deterrent flashing management. The injection
control unit power supply is necessary for the Stepper motor management.
A power supply failure disables both ignition and injection.
In case of power supply faults, the diagnostic tester gives the information "NO REPLY FROM THE
CONTROL UNIT".
To carry out the check, proceed as follows:
Specific tooling
020460Y Scooter diagnosis and tester
1 - Check whether the immobiliser system LED indicates that the switch is in position "ON" and that
the deterrent flashing is on.
YES go to 2 NO go to 7
2 - The decoder is properly programmed.
YES go to 3
3 - Switch set to "ON" with side stand raised and
emergency switch set to "OFF". The injection telltale light turns on for about 3 seconds.
YES go to 5 NO go to 4
4 - Check the instrument unit and its power supply.
YES go to 3
5 - Set the emergency switch to "RUN". The injection telltale light comes on for about 5 seconds.
YES go to 6 NO go to 7
6 - The injection controller is certainly powered.
7 - Check the efficiency of the 3 A fuse no. 3 located in the fuse-holder under the right side.
YES go to 10 NO go to 8
INJEC - 215
Injection
X9 Evolution 500
8 - Fix any wiring short circuits and replace the
fuse.
YES go to 1 NO go to 9
9 - Check any short circuit on decoder or control
unit and replace, if necessary.
YES go to 1
10 - Place the special tool between control unit and
power supply system. Disconnect the main decoder connector and check the following conditions:
Terminal no. 3= battery positive
Terminal no. 4= battery negative
YES go to 11 NO go to 13
Specific tooling
020481Y Control unit interface wiring
11 - Decoder with proper base power supply.
Use the special tool to check the control unit power
supply:
Pin 17 = battery positive
Pin 23 = battery negative
YES go to 12 NO go to 13
12 - Control unit with proper base power supply.
13 - If the battery negative is not present, check
continuity between Pin 23 of the special tool and
earth.
Detect the presence of the battery positive on Pin
17 of the special tool and on pin 3 of the decoder
connector.
YES go to 12 NO go to 14
YES go to 11
14 - Fix the cable harness.
Key-switch power supply circuit check
A failure of the constant power supply disables both ignition and injection functions. In case of power
supply faults, the diagnostic tester gives the information "NO REPLY FROM THE CONTROL UNIT".
INJEC - 216
X9 Evolution 500
Injection
Specific tooling
020460Y Scooter diagnosis and tester
1 - Check whether the immobilizer system LED indicates switching to "ON"
YES go to 2 NO go to 4
2 - Raise the side stand. Set the emergency switch
to "OFF". Turn the key switch to "ON". Set the
emergency switch to "RUN". Check whether the
injection telltale light turns on for 5 seconds
YES go to 3 NO go to 4
3 - Continuous power supplies are regular
4 - Check the working order of the fuse no. 4 and
5 located in the fuse holder on the right side.
YES go to 5 NO go to 6
5 - Place the special tool between control unit and injection system.
YES go to 7
Specific tooling
020481Y Control unit interface wiring
6 - Fix any short circuits and replace the fuse.
Check decoder and control unit, if necessary
YES go to 1
7 - Disconnect the main decoder connector and
check the following conditions: switch set to "ON",
switch to "RUN" and side stand raised
Terminal no. 8 = battery positive
Terminal no. 4= battery negative
YES go to 8 NO go to 10
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8 - Decoder with proper continuous power supply.
Use the special tool to check the control unit continuous power supply. Switch set to "ON", switch
to "RUN" and side stand raised.
Pin 26 = battery positive
Pin 23 = battery negative
YES go to 9 NO go to 10
Specific tooling
020481Y Control unit interface wiring
9 - Control unit with proper continuous power supply.
10 - If only one component is not powered check
the relevant connector. If the problem involves
both the decoder and CPU check the continuity of
the decoder CPU power supply line.
Pin 26 electronic control unit - Pin 87 engine stop
remote control switch = continuity
Pin 8 decoder - Pin 87 engine stop remote control
switch = continuity
YES go to 12 NO go to 11
11 - Fix the cable harness or the connection
YES go to 10
12 - Proper continuous power supply
YES go to 13
13 - Check the connector and the continuity of the
key switch set to "ON"
Pin 1 - 2 = continuity
YES go to 14
14 - Check the engine stop remote control switch
connector and the switch efficiency.
The connector can be recognised by its larger section white lead.
85 - 86 = approx. 70W
YES go to 15
N.B.
CHECK THE COIL RESISTANCE
15 - Check the signal circuit:
INJEC - 218
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Injection
- emergency switch and connector
- side stand switch and connector
YES go to 16
16 - Check the cable harness continuity. Check the utility control main remote control switch.
Disconnect the master remote control switch.
Check the diode installed on the earth connection of the main remote control switch pickup.
86 - earth = continuity with high resistance (connect the tester: positive with 86; negative with earth).
When the polarity is inverted there should be no continuity.
Diagnostic circuit
* CONNECTOR FOR DIAGNOSTIC TESTER
A = INJECTION CONTROL UNIT
Connect the diagnostic tester.
Specific tooling
020460Y Scooter diagnosis and tester
If the diagnostic tester displays «No reply from the
control unit», disconnect the continuous power
supply for 10 seconds and switch to «ON» again;
if the message is still displayed, proceed as follows:
1 - Check the diagnostic tester connections.
YES go to 2 NO go to 3
INJEC - 219
Injection
2 - Check the control unit base and continuous
power supplies.
YES go to 4
3 - Restore
4 - Place the special tool between control unit and
system. Keep the control unit disconnected.
YES go to 5
Specific tooling
020481Y Control unit interface wiring
5 - Check the following conditions:
PIN 1 diagnostic socket - PIN 10 control unit =
continuity
PIN 2 diagnostic socket - PIN 23 control unit =
continuity with earth
PIN 3 diagnostic socket - PIN 9 control unit = continuity
10 - 23 = insulation (>1 MΩ)
9 - 23 = insulation (>1 MΩ)
YES go to 6 NO go to 7
6 - The circuit is in good working order. Check the control unit.
7 - Fix the interruption or short-circuit.
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Injection warning light circuit
CIRCUIT LAYOUT
1
2
3
Specification
Instrument panel
Fuse
Electronic control unit
Desc./Quantity
7.5 A
[P]
1
Specification
TERMINAL: 15 - 23
2
TERMINAL: 15 - 23
Desc./Quantity
CONDITIONS: DURING THE CHECK
- Switch set to "ON"
- Side stand raised
- Switch to "RUN"
STANDARD VALUES : O V
CONDITIONS: AFTER THE CHECK
- Switch set to "ON"
- Side stand raised
- Switch to "RUN"
STANDARD VALUES : Battery voltage
The injection telltale light is controlled upon every switching to "ON" by the 3-second timing generated
by the digital instrument. This step is normally interrupted by the injection control unit control. The timing
lasts 5 seconds.
The diagnostic tester is not programmed to check this circuit.
Proceed as follows:
Specific tooling
020460Y Scooter diagnosis and tester
1 - Turn the switch to the "ON" position Turn the emergency switch to position "RUN". Keep the side
stand raised. Make sure the light goes on for 5 seconds.
INJEC - 221
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X9 Evolution 500
YES go to 2 NO go to 3
2 - The system is working.
3 - Put the special tool between the control unit and system.
YES go to 4
Specific tooling
020481Y Control unit interface wiring
4 - Switch in «ON» position Emergency switch on
«RUN».
Side stand up Wait more than 5 seconds.
15 - 23 = battery voltage
YES go to 5 NO go to 6
5 - Check the control unit connector. Check the
control unit.
6 - Check the continuity between pin 15 of the CPU
and the brown-black wire of the 6 input connector
of the instrument unit.
The injection ECU manages the negative of the light. The light must go off after the initial check. The
light goes on again when the ECU self-diagnosis detects a fault. When the fault disappears the light
goes back off, however, the related operating tests need to be carried out. The light can go on whether
the engine is able to run or not.
Self-diagnosis system
The injection control unit is provided with an auto-diagnosis function.
When a failure is detected, the control unit:
- turns on the injection telltale light (only when it is current).
- enables the engine management check according to the data entered in the control unit (where possible).
- stores the failure (always).
In the event of intermittent failures, the indicator follows the failure trend and storage remains active.
Stored data are automatically deleted when the failure does not occur for over 16 usage cycles of the
scooter (heating - use - cooling). The battery disconnection does not delete stored data.
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Checking stored failures
Connect the diagnostic tester to the scooter system.
Select the function "ERROR" in the menu.
Specific tooling
020460Y Scooter diagnosis and tester
The tester pages display the list of errors detectable by the auto-diagnosis.
Errors detected by the auto-diagnosis are marked
by one or two reference dots.
They are arranged on two lines:
Line A = current failures (present)
Line M = stored failures
Errors detectable by the auto-diagnosis may refer to the following system circuits or sectors of the
control unit:
- Throttle valve position signal
- ambient pressure signal
- coolant temperature signal
- intake air temperature signal
- wrong battery voltage
- Injector and relevant circuit
- HV coil and relevant circuit
- Stepper and relevant circuit
- Pump relay circuit
- Electric fan relay circuit
- RAM memory
- ROM memory
- EEPROM
- Microprocessor
- Signals panel (stroke - revolution signal - unsteady cycle)
Underlined failures cause the engine to stop.
In the other cases, the engine works managed by the basic data.
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X9 Evolution 500
Deleting stored failures
After mounting any failures, connect the diagnostic
tester.
Select the menu on the "errors deleting" function.
Press "OK" and follow the instructions. Perform a
trial cycle and check whether the failure occurs
again.
Specific tooling
020460Y Scooter diagnosis and tester
For troubleshooting for any faults see the related chapter sections.
Fuel supply system
Fuel is fed to the injector by a pump, a filter and a
pressure regulator integrated with the fuel level indicator inside the tank.
The pump unit is connected to the injector by:
2 semi-flexible pipes
4 quick unions
1 T union with O-ring and retain bracket for the injector
The pipes are crossed and fixed to the intake manifold to prevent wear of the quick unions connected
to the T union for the injector.
N.B.
BEFORE WORKING ON THE FUEL SUPPLY SYSTEM, CAREFULLY CLEAN THE PARTS TO
PREVENT DAMAGING THE FAST-RELEASE COUPLING SEAL OR TO PREVENT DIRT GETTING
INTO THE DUCTS.
CAUTION
THE SYSTEM IS UNDER PRESSURE.
DO NOT SMOKE DURING ANY OPERATION.
PREVENT ANY FUEL SPRAYING.
WARNING
- BEFORE STARTING THE ENGINE, CHECK WHETHER THERE IS FUEL IN THE TANK.
- DO NOT USE THE SCOOTER IN RESERVE FOR A LONG TIME, UP TO THE POSSIBILITY OF
RUNNING OUT OF FUEL.
- IF THE SCOOTER IS EXPECTED TO REMAIN UNUSED FOR A LONG TIME, REFILL THE TANK
AT LEAST TO HALF THE LEVEL.
FAILURE TO OBSERVE THESE RULES CAN DAMAGE THE PUMP.
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Circuit diagram
CIRCUIT LAYOUT
1
2
3
4
5
6
7
8
9
10
11
12
13
Specification
Fuse
Fuse
Switch
Engine stop remote control switch
Fuse
Control unit remote control switch
HV coil
Fuel pump
Injector
Electronic injection control unit
Main remote control switch
Engine stop switch
Stand switch
Desc./Quantity
30A
10 A
5A
Removing the injector
N.B.
ONLY REMOVE THE INJECTOR FROM THE MANIFOLD IN THE EVENT OF A PROVEN DEFECT.
OPERATING TEST OF THE INJECTOR MUST BE PERFORMED WITH THE INJECTOR INSTALLED
ON THE MANIFOLD (SEE "INJECTION").
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- To remove the injector, remove the central set
screw of the "T" shunt acting as a support for the
injector.
- Remove the injector from the manifold.
- Once the engine is repaired check the CO% value again while idling to make sure it is within the
prescribed limits. If the CO% is not in conformity, proceed with calibration as described in the "Carburetion adjustment" chapter.
Refitting the injector
Carefully check to make sure the components are
clean.
- Fit new O-rings and grease them.
- Apply the recommended product to the set
screws and tighten to the prescribed torque.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
injector fixing screw 3 ÷ 4
N.B.
ONCE THE ENGINE IS REPAIRED CHECK THE CO% VALUE WHILE IDLING TO MAKE SURE IT
IS WITHIN THE PRESCRIBED LIMITS. IF THE CO% IS NOT IN CONFORMITY, PROCEED WITH
CALIBRATION AS DESCRIBED IN THE ADJUSTING IDLE CARBURETION PARAGRAPH.
Removing the butterfly valve
N.B.
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THE THROTTLE BODY IS A PART WHICH INCLUDES VARIOUS COMPONENTS AND IS USUALLY SUPPLIED COMPLETE. TO TEST THESE COMPONENTS SEE THE "INJECTION" CHAPTER.
- Remove the 3 retaining screws indicated in the
figure.
CAUTION
THE THROTTLE BODY COMES PRE-CALIBRATED. TAMPERING WITH THE THROTTLE STOP
REGISTER IS TO BE ABSOLUTELY AVOIDED. THIS REGISTER HAS BEEN SEALED FOR THIS
PURPOSE. FOR PROBLEMS WITH IDLING SEE THE "INJECTION" CHAPTER.
N.B.
REMOVAL OF THE THROTTLE BODY CAN BE EFFECTED WITH THE MANIFOLD ON OR OFF
THE ENGINE.
- Make sure the seal rims on the coupling surfaces
between the manifold-throttle body and manifoldhead are in good condition.
CAUTION
IF AIR GETS IN IT CAN JEOPARDISE THE OPERATION OF
THE INJECTION SYSTEM, ESPECIALLY WHEN THE ENGINE IS IDLING.
- Make sure the throttle valve and related conduit
are clean.
- Make sure the supplementary air channel managed by the Stepper motor is clean.
N.B.
IF THE THROTTLE BODY IS REPLACED RESET THE T.P.S. AND ADJUST THE CO%.
ONCE THE ENGINE IS REPAIRED CHECK THE CO% VALUE WHILE IDLING TO MAKE SURE IT
IS WITHIN THE PRESCRIBED VALUES.
IF THE CO% IS NOT IN CONFORMITY, PROCEED WITH CALIBRATION AS DESCRIBED IN THE
ADJUSTING IDLE CARBURETION CHAPTER.
throttle body
Upon analysing the material sent and covered by the warranty, it seems several throttle bodies have
been mistakenly replaced due to valve fouling. Dirt deposited on that valve, mainly on the inlet manifold
INJEC - 227
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Injection
side, can be easily removed. Once clean, the throttle body guarantees an air flow exactly the same as
the original. Throttle valve fouling is phenomenon that happens at different times depending on how
the scooter is used, weather conditions and idle speed adjustment. This phenomenon can be easily
detected as a gradual poor idle signals it. Carry out a thorough check with a scooter diagnostic tester,
drw. 020460y. With engine temperature of at least 90°, the parameters may be as follows:
Standard
Dirty throttle body
1500±5
< 1400
Ignition advance
5°÷7°
10°
Throttle valve opening
5.24°
5.24°
Engine revs
The error menu displays the signals stored in the "RPM sensor". This takes place only when the engine
stops with the key switch set to "on." An exhaust fumes analysis will show a very rich and non adjustable
idle carburetion (CO > 4% - CO2 < 12%). Measure with the tool in drw. 020625y. It is evident that,
except for cases of early fouling, cleaning should not be carried out when still covered by the warranty.
After cleaning the throttle body, check and, if necessary, adjust C0. If these indications occur when the
injection warning light turns on or further errors or wrong parameters are present, it is necessary to carry
out the relevant controls indicated in the manual. In such a case, there is a real fault evidently.
Refitting the butterfly valve
- Carry out the removal operations but in reverse
order, tighten the 3 fixing screws to the prescribed
torque.
Locking torques (N*m)
Throttle body fixing screws 11 ÷ 13
Pump supply circuit
The control unit starts the pump in the following conditions:
- by setting the switch to «ON» with the emergency switch to «RUN» and side stand raised. The pump
does not supply.
- If the rpm-timing signal is received. Continuous supply.
The initial timing is useful to bleed the system especially after a stop with engine in temperature. In
these conditions, the fuel altered by boiling will be mixed with that in the tank.
During use, the pump operation will be subject to the engine speed.
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Circuit check
Proceed as follows:
1 - Set the switch to "ON" with emergency switch to "RUN" and side stand raised. The pump rotates for
2 seconds.
YES go to 2 NO go to 3
2 - Try to start up. Check that the engine speed matches the pump rotation.
YES go to 4 NO go to 5
3 - The pump does not rotate, or it rotates uninterruptedly.
YES go to 5
4 - The pump power supply is conforming.
5 - Connect the diagnostic tester to the scooter system.
YES go to 6
Specific tooling
020460Y Scooter diagnosis and tester
6 - Try to start up. Select the function "ERRORS"
in the menu. Check whether there are any failures.
YES go to 7 YES go to 8 NO go to 28
7 - Pump control relay circuit failure.
YES go to 9
8 - Failure of:
- injector
- H.V. coil
- Signals panel
YES go to 18
9 - The control unit has detected a failure on the line of pin 19
YES go to 10 YES go to 11
10 - Line to earth. In this case, the pump always starts to rotate if there is a continuous power supply.
YES point 12
11 - Interrupted line. The relay cannot control the pump feeding
YES go to 13
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X9 Evolution 500
12 - Check and restore the earth insulation of the control unit line 19 and of the pump remote control
switch line 85.
YES go to 14
13 - Install the special tool between control unit and the injection system.
YES go to 15
Specific tooling
020481Y Control unit interface wiring
14 - Delete the code and check from the beginning.
15 - Set the switch to "ON" with switch to "RUN"
and side stand raised. Wait more than two seconds and check the following conditions:
19 - 23 = battery voltage
YES go to 16 NO go to 17
16 - Replace the control unit.
17 - Check the presence of voltage (+ batt.) between pin 86 of the pump remote control switch
and pin 23 of the control unit. Fix the wiring, if required. Check the relay coil continuity.
85 - 86 = 100 ± 50Ω
18 - Check the efficiency of the 10 A fuse no. 2
YES go to 20 NO go to 19
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19 - Disconnect the following connectors: fuel
pump, H.V. coil, injector
YES go to 22
20 - Check the efficiency of the pump remote control switch. Check the wiring continuity between
remote control switch and pump.
87 (remote control switch) - green/black (pump) =
continuity
NO go to 21
21 - Fix the wiring and repeat the check from the
beginning.
22 - Check the earth insulation of wiring
87 (pump remote control switch) - 23 = insulation
(>1 MΩ)
YES go to 24 NO go to 23
23 - Restore the wiring insulation and replace the
fuse.
24 - Check the ground insulation of the primary
winding of the HV coil and of the injector coil.
YES, go to 25
25 - Check the pump winding resistance: approx.
1.5Ω
YES go to 26 NO go to 27
26 - Replace the fuse and check the pump.
27 - Check the absorbed current.
28 - Select the diagnostic tester menu on the "ACTIVE DIAGNOSIS" function. Select the fuel pump
simulation function. Enable the function with continuous power supply on and engine off.
YES go to 29
Specific tooling
020460Y Scooter diagnosis and tester
29 - The tester prompts the control unit to start the pump for 30 seconds
YES go to 30
30 - Acoustically check the following conditions:
INJEC - 231
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X9 Evolution 500
- Relay closure
- Pump rotation
- Relay opening
YES go to 31 NO go to 32
31 - The pump is fed. Perform a functional check of the pump.
32 - Check the efficiency of the pump connector.
YES go to 33 NO go to 34
33 - Replace the fuel pump.
34 - Restore
The injection CPU manages the negative of the light. The light must go off after the initial check. The
light goes on again when the CPU autodiagnosis detects a fault. When the fault disappears the light
goes back off, however, the related operating tests need to be carried out. The light can go on whether
the engine is able to run or not.
Circuit leak test
Before performing the checks concerning the system pressure, it is necessary to carefully clean all
feeding system components.
To perform the inspections it is necessary to use
the special tooling kit for fuel pressure check.
Specific tooling
020480Y Petrol pressure check set
Before disconnecting any fastener, reduce the system pressure.
Detach the electrical connector from the pump support with the engine running, and wait for the shutdown.
The engine stops at approximately 1.5 bar.
CAUTION
CAREFULLY DETACH THE HOSE TERMINAL PREVENT ANY POSSIBLE SPRAYING INTO THE
EYES.
The special tool is equipped with fast-release fittings, similar to those provided for the circuit.
In order to disconnect the female terminals (injector side), it is necessary to press the two extensions and draw them.
CAUTION
DO NOT FORCE THE TERMINAL IF THIS DOES NOT COME
LOOSE; EVENTUALLY, TRY TWISTING IT. THE TERMINAL
IS DESIGNED SO THAT AN INCREASE IN TENSION INCREASES THE LOCKING FORCE.
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To detach male type terminals (pump side) it is
necessary to press the coaxial rings towards the
pump, and extract the terminals.
CAUTION
DO NOT FORCE THE TERMINAL IF THIS DOES NOT COME
LOOSE; EVENTUALLY, TRY TWISTING IT. THE TERMINAL
IS DESIGNED SO THAT AN INCREASE IN TENSION INCREASES THE LOCKING FORCE.
The system pressure check must be carried out,
for practical reasons, by connecting on the pump
side.
Connect the manometer to the outlet duct (RHS)
and the extension tube to the inlet duct (LHS).
CAUTION
BEFORE REASSEMBLING CHECK THE TOOL DUCTS ARE
CLEAN.
Pressure regulator check
1 - Connect the diagnostic tester.
Specific tooling
020460Y Scooter diagnosis and tester
Select the menu on the "ACTIVE DIAGNOSIS"
function.
Select the "PUMP DIAGNOSIS" function.
YES go to 2
2 - Enable the function with continuous power supply on and engine off.
The control unit starts the pump for 30 seconds
YES go to 3
3 - Let the system bleed for a few seconds.
Make sure that there are no external leaks.
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Check the regulation pressure with pump power
supply voltage higher than 12 V.
Regulation pressure = 300 - 320 kPa (3 - 3.2 BAR)
YES go to 4 NO go to 5
4 - The pressure regulator is efficient.
5 - Pressure too high
Check that the return duct is not clogged or
squashed
YES go to 6 NO go to 7
6 - Replace the pressure regulator.
7 - Pressure regulation too low
Start the pump rotation again. Using pliers with flat
and long tips, temporarily clamp the return duct by
the extension of the specific tool (the serial pipe
does not allow this operation).
fuel pressure = over 300 kPa (3 BAR)
YES go to 8 NO go to 9
8 - Replace the pressure regulator.
9 - Replace the fuel pump.
Fuel pump and filter check
This procedure is useful during maintenance to check the filter efficiency in delivery.
Connect the diagnostic tester.
Connect the fuel pressure check kit.
Specific tooling
020460Y Scooter diagnosis and tester
020480Y Petrol pressure check set
1 - Select the diagnostic tester menu on the «ACTIVE DIAGNOSIS» function.
Select the «PUMP DIAGNOSIS» function.
The pump starts for 30 seconds.
YES go to 2
INJEC - 234
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2 - Let bleed for a few seconds.
Make sure that there are no leaks.
Using pliers with flat and long tips, temporarily
clamp the return duct by the extension of the special tool with pump power supply voltage higher
than 12 V, check the system maximum pressure.
Maximum pressure = > 600 kPa (6 BAR)
YES go to 3 NO go to 4
Specific tooling
020480Y Petrol pressure check set
3 - Check the system seal.
Start the pump for 30 seconds using the diagnostic tester.
When the pump stops, wait 3 minutes.
Check the system pressure.
Fuel pressure = over 200 kPa (2 BAR)
YES go to 5 NO go to 6
Specific tooling
020460Y Scooter diagnosis and tester
4 - If pressure is lower, carefully check the voltage
with pump under stress.
If voltage is higher than 12 V, replace the pump.
5 - The system seal is efficient.
Check the free flow rate.
AHEAD go to 16
6 - Repeat the test. When the pump stops, use pliers with flat and long tips to temporarily clamp the
return duct by the extension of the special tool.
This causes an increase of the fuel pressure.
AHEAD go to 7
7 - Check whether the pressure decreases with the
same trend as the system when free from bottlenecks
AHEAD go to 8
8 - Pressure decreases much more slowly
YES go to 9 NO go to 10
9 - Replace the pressure regulator. Check the system seal again.
INJEC - 235
Injection
X9 Evolution 500
10 - There occur trend variations
YES go to 11 NO go to 13
11 - Repeat the test clamping the pipe of the special tool in the portion between the branch and the
injector.
Check whether the pressure decreases with the
same trend as the system when free. Pressure
decreases much more slowly
YES go to 12 NO go to 13
Specific tooling
020480Y Petrol pressure check set
12 - Check and replace the injector, if required,
due to an insufficient seal.
(see "THERMAL GROUP AND TIMING SYSTEM
")
13 - There are no trend variations
Repeat the test clamping the pipe of the special
tool in the portion between the branch and the
pump. Check whether pressure decreases much
more slowly.
YES go to 14 NO go to 15
Specific tooling
020480Y Petrol pressure check set
14 - The pump unidirectional valve is faulty. Replace the pump. (see Pump bracket overhaul)
15 - Check the pipe and the injector union seals more carefully.
Check the component seals again, if necessary.
A POOR SYSTEM SEAL ONLY AFFECTS THE START-UP VELOCITY.
16 - Disconnect the pump connector, start the engine, wait until it stops and connect the connector
again.
Disconnect the fuel return pipe from the pump support (left pipe).
AHEAD go to 17
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17 - Introduce the return pipe into a graduated
container.
Using the diagnostic tester, start the fuel pump for
10 seconds.
Make sure that the power supply voltage is more
than 12V.
Measure the amount of fuel delivered.
Pump free flow rate = 300 - 320 cc.
YES go to 18 NO go to 19
Specific tooling
020460Y Scooter diagnosis and tester
18 - The fuel filter is not clogged.
The scooter can be used respecting the limit of 48000 km.
19 - The flow rate is less than 250 cc.
The fuel filter is dirty. Replace the pump support.
Pump electrics check
This section describes the operations to be carried out to perform electric checks on the pump.
Resistor check
Disconnect the connector from the pump support.
Using a tester, measure the pump winding resistance.
Connect the tester probes to the pump support
pins as shown in the figure.
Electric characteristic
Resistance:
approx. 1.5 Ω
In case of infinite resistance, replace the pump.
With infinite resistance, the pump does not rotate.
With resistance close to 0 Ω, the pump power consumption is too high, with the possibility of blowing
the 10 A fuse No. 2. Perform the following check.
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X9 Evolution 500
Pump consumption check
The pump power consumption may vary according
to:
- Power supply voltage
- Pump running-in
- Regulation pressure
- Delivery filter cleaning
To check the current consumption, proceed as follows
- Disconnect the pump remote control switch connector.
- With key switch set to "OFF", connect the jumpers 30-87 on the connector using the tester probes
in ammeter function (see figure).
- Check the pump rotation and power consumption
N.B.
THIS CONSUMPTION REFERS TO:
- POWER SUPPLY VOLTAGE = approx. 12 V
- PUMP RUN IN
- SYSTEM PRESSURE = 300 kPa (3 BAR)
- FUEL FILTER CLEAN
Electric characteristic
Current consumption:
approx. 3.5 - 4.2 A
A dirty filter causes an increase of input. If the pressure-relief valve opens, the pump absorbs approx.
6-7A.
In case of excessive input (5A), replace the filter. See pump support overhaul.
If the fault continues, replace the pump.
Fuel filter check
To check the fuel filter inspect the following:
- Free flow
- Current consumed by the pump. A clogged filter causes:
- Poor performance especially at full power
- Pump input increase
N.B.
DO NOT BLOW THE FILTER WITH COMPRESSED AIR. A DAMAGED FILTER MAY CAUSE THE
INJECTOR CLOGGING.
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Injection
Pump bracket overhaul
To remove the pump support from the tank, proceed as follows:
- Disconnect the electric connector.
- Start the engine and wait for the spontaneous
stop.
- Clean the tank and the pump support (wash and
blow with compressed air, if necessary).
- Disconnect the delivery and return pipes by the
fast-release fittings.
CAUTION
PREVENT ANY FUEL SPRAYING.
- Loosen the pump support mounting ring nut (RH
threading).
- Remove the pump support and the sealing gasket.
N.B.
UPON EXTRACTING IT, BE CAREFUL NOT TO DEFORM
THE FLOATING ARM.
To replace the components, proceed as follows:
(1) Level indicator:
- Note the assembly position and the path of the
two connecting wires.
pos 2 = wire connected to the circuit
pos 3 = wire connected to the movable arm
INJEC - 239
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Injection
Pass the wires through the hole found between filter and pressure regulator.
- Disconnect and extract the wires
- Using a screwdriver on the retain tab as shown
in the figure, extract the level indicator from the
support
- Level indicator check
The check may also be carried out before removing it from the support.
Measure the resistance between the two level indicator wires.
Moving the float arm, check that the resistance is subject to gradual variations according to the arm
motion.
LIMIT VALUES
1
2
Specification
Empty tank position:
Full tank position:
Desc./Quantity
95 - 105 Ω
0-9Ω
- To refit, repeat the removal operations but in reverse order.
(2) Pressure regulator:
- Remove the locking spring
- Extract the pressure regulator with sealing rings.
N.B.
TO OVERCOME THE RESISTANCE OF THE O-RINGS, LEVER WITH A SCREWDRIVER THROUGH
THE OPENINGS OBTAINED ON THE STOP INSERTION SIDE.
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Injection
- Lubricate the O-rings and repeat the operations
in the reverse order for reassembly.
(3) Fuel pump
- Note the position of the power supply wires on the support
pos 1 = positive (red)
pos 4 = negative (black)
- Disconnect the power supply cables
- Cut the delivery pipe fastening clamp on the support.
- Remove the pump mounting washer
INJEC - 241
Injection
- Remove the filter coupling pipe
- Remove the pump with annular support and prefilter.
- If the pump requires replacement, remove the
pre-filter and the annular support.
- For reassembly, perform the removal operations
but in the reverse order using a new clamp for the
delivery pipe and a new pump mounting washer.
N.B.
TO CLEAN THE PRE-FILTER, USE PETROL AND COMPRESSED AIR.
Orientate the pump properly.
(4) Fuel filter
The fuel filter is supplied already assembled to the
pump support.
To replace the support, move the level indicator,
the pressure regulator and the pump from the old
to the new support.
For these operations, follows the instructions given above.
INJEC - 242
X9 Evolution 500
X9 Evolution 500
Injection
Pump bracket installation
- Before reassembling, carefully check that the
tank is clean.
In case of dirt or water, remove the tank.
- Install the sealing gasket on the pump support.
- Introduce the pump into the tank being careful not
to deform the level indicator arm.
- Place the sealing gasket on the tank.
- Install the pump support onto the seat aligning
the connector with the scooter longitudinal axle.
N.B.
AN INCORRECT ORIENTATION MAY IMPAIR THE LEVEL
INDICATOR PERFORMANCE.
- Screw the mounting ring nut and tighten thoroughly.
Locking torques (N*m)
Electric pump locking ring nut 20
- Connect the feeding circuit pipes again and check the proper introduction by pulling and turning upwards.
- Reconnect the electric connector.
- Recharge the system with at least 4÷5 timings (key switch «OFF-ON»)
N.B.
DO NOT START THE PUMP BEFORE REFILLING THE TANK. FAILURE TO OBSERVE THIS RULE
CAN DAMAGE THE PUMP.
- Check that the fuel feeding system fast-release fitting seal is efficient.
Inspecting the injector circuit
Electric characteristic
TERMINAL: 13 - 23
CONDITIONS: During the pump timing with engine off
STANDARD: Battery voltage
INJEC - 243
X9 Evolution 500
Injection
CIRCUIT LAYOUT
1
2
3
4
5
6
Specification
Electronic control unit
Injector
HV coil
Pump
Control unit remote control switch
Fuse
1 - Connect the diagnostic tester. Select the menu
on the "ACTIVE DIAGNOSIS" function.
Select the "INJECTOR" function.
YES go to 2
Specific tooling
020460Y Scooter diagnosis and tester
2 - Enable the function with continuous power supply on and engine off. The control unit controls the
fuel pump continuously and at the same time starts
the injector opening. The injector openings are repeated for a few seconds.
YES go to 3
3 - Acoustically check the injector openings and
wait for the tester results
YES go to 4 NO go to 5
4 - 5 injector openings detected. The injection tester displays «test successful».
YES go to 7
INJEC - 244
Desc./Quantity
10 A
X9 Evolution 500
Injection
5 - No injector openings detected. The injection
tester displays «test failed».
YES go to 9 NO go to 6
6 - No injector openings detected. The injection
tester displays «test successful».
YES go to 8
7 - The injector control circuit is efficient. Perform
the injector hydraulic check.
8 - The injector control circuit is efficient. Repeat
the acoustic check and perform the injector hydraulic check for safety reasons.
9 - Select the menu on the "ERRORS" function.
Check whether the injector failure message only is
displayed.
YES go to 14 NO go to 10
10 - There are also fault messages for: pump relay
YES go to 13 NO go to 11
11 - There is also a fault message for the HV coil.
YES point 12
12 - Check the power supply circuit with the 10A fuse and the remote control switch. Common feeding
to the fuel pump.
13 - Check the pump relay control circuit
14 - Install the special tool between the injection system and the control unit.
YES go to 15
Specific tooling
020481Y Control unit interface wiring
INJEC - 245
Injection
X9 Evolution 500
15 - Arrange a multimeter with positive prod on pin
13 and negative prod on pin 23. Set the switch to
"ON" with switch to "RUN" and side stand raised.
Check the presence of battery voltage during the
fuel pump timing.
13 - 23 = battery voltage for 2 seconds.
YES go to 16 NO go to 17
16 - The injector electric circuit is steady Repeat
the checks. If the fault continues, check the control
unit connector. If necessary, replace the electronic
control unit.
17 - Repeat the test using the resistance multimeter. Check the resistance between pin 13 and pin
87 (black/green cable) of the pump remote control
switch.
13 - black/green = 14.5Ω ± 5% (resistance of the
injector)
YES go to 19 NO go to 18
18 - No continuity. Disconnect the connector and
repeat the resistive check directly at the injector
terminals.
Resistance = 14.5 Ω ± 2%
YES go to 21 NO go to 22
19 - Check the earth insulation of the injector negative line. Disconnected control unit and injector
connectors.
13 - 23 = Ω infinity
NO go to 20
20 - Repair or replace the cable harness.
21 - Check the continuity between the injector power supply connector (red - yellow) and pin 13. Restore
the continuity, if required, or replace the wiring
22 - Replace the injector.
INJEC - 246
X9 Evolution 500
Injection
Inspecting the injector hydraulics
To check the injector it is advisable to remove the
intake manifold along with throttle body and injector.
The injector should be removed from the manifold
only if necessary.
For these operations, see the "thermal group and
timing system" chapter
1 - Connect the diagnostic tester. Use the socket
in the under-saddle compartment.
Install the fuel pressure check kit special tool.
In this case, the injector can be connected directly
to the tool quick couplings.
AHEAD go to 2
Specific tooling
020460Y Scooter diagnosis and tester
020480Y Petrol pressure check set
2 - Prepare a graduated container with minimum
capacity of 100 cm3 and a resolution of 10-20 cm3
Connect the injector to the wire supplied with the
injection tester. The wire is provided with alligator
clips for direct connection to the battery.
Prepare an auxiliary battery.
Set the switch to "ON" with switch to "RUN" and
stand raised.
Select the "active diagnosis" function.
Start the pump diagnosis.
During the first 30 seconds of pump diagnosis,
power the injector by the wire and the auxiliary
battery for 15 seconds.
Collect the fuel delivered by the injector into the
graduated container.
Power supply pressure = 300 kPa (3 BAR)
Quantity delivered = approx. 40 cm3
YES go to 3 NO go to 4
INJEC - 247
X9 Evolution 500
Injection
3 - Perform the injector sealing test.
Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute
YES go to 5 NO go to 6
4 - Higher quantities are not expected.
For lower quantities, replace the injector (THERMAL GROUP AND TIMING SYSTEM).
5 - The injector is conforming.
6 - Repeat the test. If the fault continues, replace
the injector (THERMAL GROUP AND TIMING
SYSTEM)
The injector atomisation cannot be checked by
simple methods. The injector is provided with 5
holes whose angulation forms a jet with a taper of
about 80°. The jet thus formed impinges both intake valves.
N.B.
- AN INJECTOR WITH LOW FLOW RATE AFFECTS THE
MAXIMUM PERFORMANCE.
- AN INJECTOR WITH POOR SEAL AFFECTS IDLING AND
THE START-UP FEATURES AFTER A SHORT STOP WITH
HOT ENGINE.
- IN CASE OF CLOGGING OF THE INJECTOR, IT IS NECESSARY TO REPLACE IT, ALONG WITH THE FUEL FILTER
CONTAINED IN THE TANK. CAREFULLY CLEAN THE SYSTEM AND THE TANK.
Troubleshooting
1 - A failure of the EMS system is more likely to be due to the connections than to the components.
Before searching the EMS system for failures, perform the following checks:
SUGGESTION FOR TROUBLESHOOTING
1
Specification
1. Power supply
2
3
2. Chassis earth
3. Fuel supply
4
4. Ignition system
INJEC - 248
Desc./Quantity
- Battery voltage
- Burnt fuse
- Remote control switches
- Connectors
- Faulty fuel pump
- Dirty fuel filter
- Faulty spark plug
- Faulty coil
- Faulty screened cap
X9 Evolution 500
Injection
5
Specification
5. Intake circuit
6
6. Other
Desc./Quantity
- Dirty air filter
- Dirty by-pass circuit
- Faulty stepper motor
- Wrong distribution timing
- Wrong idle speed carburetion
- Wrong reset of the throttle valve position sensor
2 - Failures to the EMS system may depend on loosened connectors. Make sure that all connections
are properly implemented.
Check the connectors being careful of the following: 1. check that terminals are not bent. check that
connectors are properly engaged.
Check whether the failure changes if the connector is slightly vibrating.
3 - Before replacing the EMS control unit, check the whole system carefully.
If the fault is fixed by replacing the EMS control unit, install the original control unit again and check
whether the fault occurs again.
4 - For troubleshooting, use a multimeter with an internal resistance of more than 10KΩ/V.
Improper instruments may damage the EMS control unit.
The instruments to be preferred have a definition of more than 0.1V and 0.5Ω and an accuracy of more
than ± 2%.
Immobiliser circuit
The EMS system is integrated with the immobiliser
anti-theft device.
Its functions are:
- Start-up enabled by key recognition.
- Deterrent flashing.
System components
The system consists of:
-EMS system control unit
- Decoder
- Aerial
- Master key (red)
- Service key (black)
- Deterrent and diagnosis LED
INJEC - 249
X9 Evolution 500
Injection
[P]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Specification
Main fuse
Fuse
Fuse
Fuse
Stand switch
Emergency switch
Key switch
Engine stop remote control switch
Main remote control switch
Diode
Instrument panel
Immobilizer LED
Decoder
Immobilizer aerial
Electronic control unit ECU
Virgin circuit
When control unit (ECU) and decoder are not programmed, the following conditions occur:
- Key switch set to "OFF". Deterrent flashing inactive.
- Key switch set to "ON". Ignition and injection disabled and LED on with solid light.
When the key switch is set to "ON", the LED
switches on as shown in the figure.
INJEC - 250
Desc./Quantity
30 A
7.5 A
3A
5A
2A
X9 Evolution 500
Injection
The LED is turned on by the decoder.
The control unit data can be checked by the diagnostic tester.
Specific tooling
020460Y Scooter diagnosis and tester
To connect the diagnostic tester, open the spark
plug inspection port and pull out the EMS Diagnosis socket. Remove the protection cap and connect the tester terminal.
Power the diagnostic tester by connecting the terminals to the battery poles, or the specific connector to the socket inside the gloves compartment.
Set the switch to "ON" and select the diagnostic
tester menu to the immobiliser function.
Scroll the pages to display the control unit data.
N.B.
AN UNPROGRAMMED SYSTEM CANNOT BE DETECTED UPON FIRST FITTING, OR IN CASE
THE DECODER AND THE CONTROL UNIT ARE REPLACED CONCURRENTLY.
The information will be as follows:
Unprogrammed control unit «ON»
Start-up disabled «ON»
Key number Zero › 250
INJEC - 251
Injection
X9 Evolution 500
Setting the circuit
The scooter is supplied with two keys:
- Master key (red) with removable transponder
- Service key (black) with fixed transponder
The master and service keys must be used to code the system as follows:
- Insert the master key, set to «ON» and keep this position for 2 seconds (limit values 1÷3 seconds).
- Insert the black key and set to "ON" for 2 seconds.
- If you have copies of the key, repeat the operation with each key.
- Insert the master key again and set to "ON" for 2 seconds.
The maximum time to change keys is 10 seconds.
Seven service keys (black coloured) can be programmed within the same storage operation.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, master key transponder, decoder and control unit are strictly
matched.
With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc.
Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat
the procedure using all the keys you intend to keep using.
N.B.
AN ACCIDENTAL LOSS OF THE SERVICE KEY PROGRAMMING CAN ARISE FROM GENERAL
FAULTS OF THE IGNITION SYSTEM. IN THIS CASE, CHECK THE HV LINE SHIELDING.
In any case it is advisable to use resistive spark plugs.
LED signals
When the key switch is set to "ON" and programming is performed normally, the LED switches on
as shown in the figure.
WITH MASTER KEY
After the confirmation flash when switching to
"ON", a number of flashes are emitted, equal to the
number of keys used for programming.
INJEC - 252
X9 Evolution 500
Injection
WITH SERVICE KEYS
Deterring blink
Switching from «ON» to «OFF» with programmed
system causes the intermittent switching on of the
LED, with an antitheft effect.
This occurs with any key used for programming.
If the scooter is not used, the deterrent light stops automatically after 48 hours to prevent discharging
the battery. A new 48-h cycle starts by switching from "OFF" to "ON" and "OFF" again.
Checking master-box data
Connect the diagnostic tester.
Set to «ON» and select the immobilizer function.
Scroll the pages the find the data.
Specific tooling
020460Y Scooter diagnosis and tester
The information will be as follows:
- Unprogrammed control unit «OFF»
- Start-up disabled «OFF»
- Number of keys 2*
*The number denotes how many keys have been used for programming, master key included.
Resetting the circuit
1 Replacing the small cylinder
INJEC - 253
Injection
X9 Evolution 500
- Remove the original master key transponder and install it on the master key of the new cylinder.
- Program the system again as described above.
2 Decoder replacement
When the decoder is replaced it is necessary to program the system again.
Programming is indispensable for the engine start-up. (see System programming).
3 Control unit replacement
Programming is indispensable when the control unit is replaced to enable the engine start-up.
In this case it is sufficient to switch to "ON" using the master key.
N.B.
- THE SERVICE KEY (BLACK-COLOURED) IS NOT USED FOR PROGRAMMING.
- WHEN NOT PROGRAMMED, THE CONTROL UNIT ALLOWS NO FUNCTIONAL DIAGNOSIS ON
THE ENGINE.
4 Replacing or duplicating service keys
Keys can be duplicated using the blank keys and the original master key.
A copy may also be requested using the scooter CODE CARD.
Program the system again using the master key and all service keys (see System programming).
N.B.
THE CODE CARD CAN ONLY BE USED WHEN THE ORIGINAL MASTER KEY IS AVAILABLE.
Diagnostic codes
The LED indication is divided into 3 steps:
1st step: A flash: "ON" switching recognition
2nd step: Series of flashes: diagnosis code indication
3rd step: Steady light on or off:
on = start-up disabled off = start-up enabled
Code 1
Code 1 indicates a non-programmed system.
If the code is still displayed after having carried out
the programming procedure, repeat the procedure
carefully observing the "ON" times of each key.
If the code is still displayed, proceed as follows:
- Disconnect the battery negative.
- Remove the control unit connector.
- Connect the special tool between the injection system and the control unit.
- Remove the main decoder connector.
INJEC - 254
X9 Evolution 500
Injection
N.B.
TO ACCESS THE COMPONENTS, SEE THE COMPONENTS LAYOUT CHAPTER.
Specific tooling
020481Y Control unit interface wiring
1 - Using a multimeter, check the continuity between pin 16 of the control unit and pin 6 of the
decoder connector.
YES go to 3 NO go to 2
2 - Repair or replace the wiring.
3 - Check the connections carefully
YES go to 5 NO go to 4
4 - Restore
5 - Replace the decoder. Connect the battery. Repeat the programming. YES go to 7 NO go to 6
6 - Disconnect the battery, replace the control unit, connect the battery. Repeat the programming.
7 - The system is OK
Code 2
Code no. 2 denotes a system where the decoder
does not perceive the transponder signal.
- Start-up disabled
- Injection telltale light on, steady
In this case, proceed as follows:
1 - Check whether the code is repeated using the
second key.
YES go to 3 NO go to 2
2 - Failure detected with the service key Replace
and program again. Failure detected with the master key.
Replace the transponder using one from the new
cylinder kit.
Replace decoder and control unit.
INJEC - 255
Injection
X9 Evolution 500
Program again.
3 - Check the proper connection of the aerial connector.
YES go to 5 NO go to 4
4 - Restore the connection and check the presence
of the code
5 - Disconnect the aerial connector and check continuity (8 ± 2 W).
YES go to 7 NO go to 6
6 - Replace the aerial.
7 - Check the proper position of the aerial.
YES go to 9 NO go to 8
8 - Place it in proper position
9 - Replace the decoder and check the presence of the code
Code 3
Code no. 3 denotes a system where the decoder
perceives a transponder not provided for by programming.
- Start-up disabled
- Injection telltale light on, steady
1- Check whether the code is still displayed using the master key
YES go to 3 NO go to 2
2 - Program again using all service keys
3 - Check that all components (keys - decoder - control unit) are properly matched.
YES go to 5 NO go to 4
4 - Restore
5 - Replace decoders and control unit. Program the components again.
INJEC - 256
X9 Evolution 500
Injection
Code 4
Code no. 4 denotes a system where the decoder
is blank and the control unit is programmed.
The key is recognised by the control unit.
- Start-up disabled
- Indicator light
N.B.
REPEAT THE KEY PROGRAMMING PROCEDURE USING THE ORIGINAL MASTER KEY.
Diagnosis guide
Immobiliser LED does not come on
1 - Check whether the injection indicator turns on
for 5 sec. after switching to "ON"
YES go to 2 NO go to 11
2 - Check 7.5A fuse No.10 located on the front
glove-box.
YES go to 4 NO go to 3
3 - Check for any short circuits on the instrument
unit power supply line, check that the instrument
unit has not short-circuited
YES go to 5
4 - Check whether the LED comes on when pin No.
2 of the decoder connector is connected to ground
(yellow/grey cable).
YES go to 6 NO go to 7
5 - Restore
YES go to 2
6 - Replace the decoder and reprogram.
7 - Check for continuity on the yellow/grey cable,
measuring between the decoder connector and
the 8 pin connector of the instrument panel
YES go to 8 NO go to 10
INJEC - 257
X9 Evolution 500
Injection
8 - Check for positive battery voltage on the red/
black cable of the 8-way connector of the instrument panel.
YES go to 9 NO go to 10
9 - Faulty led, replace the instrument panel.
10 - Repair or replace the wiring.
11 - If the injection light does not come on, continue with the check of the supply circuit to the decoder
and of the central control unit.
Tachometer
Electric characteristic
TERMINAL: 7 - 12
CONDITIONS : Start-up speed
STANDARD: approx. 0.8 - 4.5 V
CIRCUIT LAYOUT
1
2
Specification
Electronic control unit
Engine rpm sensor
Desc./Quantity
The sensor allows the rotations and the angular position of the crankshaft to be recognised by reference
to the TDC. Since the wheel speed sensor is pivoted on the camshaft it is also possible to recognise
INJEC - 258
X9 Evolution 500
Injection
the 4-stroke cycle. Such solution allows controlling the injector and the spark plug every two revolutions
of the crankshaft.
The sensor is of the reluctance variation type and is therefore comparable to an alternate current generator that powers the control unit.
The signal frequency is interrupted by the vacuum generated by the two missing teeth on the wheel
speed sensor.
The sensor signal is fundamental for obtaining starting of the engine.
The ECU self-diagnosis is enabled on this circuit in 2 different ways based on use conditions.
Right after turning to «ON» (Power under the panel present in the CPU), the continuity and isolation of
the sensor and related circuit are checked.
Any faults discovered in this phase are signalled via the injection telltale light.
The fault continues to be signalled, but the circuit is only checked when turning to "ON". Therefore faults
which occur or disappear after turning to "ON" are not acknowledged.
During and after the start phase, the self-diagnosis checks the alternating current produced by the
sensor (synchronisation of the signal panel).
INJEC - 259
Injection
X9 Evolution 500
If a signal panel is detected which is not perfectly synchronised, corrective interventions are applied
used to reconstruct the cycle. In this case the self-diagnosis records the number of lost synchronisations
and signals the fault via the injection telltale light.
The light remains on during the period the cycle is reconstructed.
If the rpm-timing signal is completely missing due to mechanical faults or lack of magnetic activity, it
will be impossible to start the engine (or it will stop while driving) and the self-diagnosis will not be able
to record any faults.
To check the sensor and related circuit, proceed as follows:
1 - Connect the scooter tester.
Select the function "ERRORS" in the menu.
Check for any faults on the «Signal panel».
YES go to 2 NO go to 3
Specific tooling
020460Y Scooter diagnosis and tester
2 THE FAULT HAS BEEN RECORDED IN MEMORISED STATUS:
The signal panel may be synchronised with possibility of starting. The fault is probably occasional.
N.B.
A NON-CONFORMING SIGNAL PANEL FAULT MAY ALSO BE DETECTED IF THE ENGINE STOPS
AFTER A FAULT INVOLVING IDLING.
THE FAULT HAS BEEN RECORDED IN CURRENT STATUS:
The control circuit gave a negative result when
switching to "ON".
AHEAD go to 8
3 Select the "PARAMETERS" function on the
menu.
Check the number of «lost synchronisations»:
1 TOOTH and > 1 TOOTH
YES go to 4 NO go to 5
4 THE INDICATION INCREASES PROGRESSIVELY OVER TIME WITH THE ROTATION OF
THE ENGINE.
AHEAD go to 8
5 INDICATION = 1-3
THE RPM-TIMING CIRCUIT IS IN COMPLIANCE.
Make an attempt to start and use the parameters
function to check for the «engine revs» indication.
INJEC - 260
X9 Evolution 500
Injection
YES go to 6 NO go to 7
6 The signal panel is in conformance.
7 CHECK THE AIR GAP AND MAGNETIC ACTIVITY OF THE SENSOR.
See engine mechanics.
8 Check the sensor and related connection circuit
with the control unit.
AHEAD go to 9
9 Install the connection wiring between the control
unit and injection system. Do not make the connection with the control unit.
CONTINUE at 10
Specific tooling
020481Y Control unit interface wiring
10 Install the connection connector between the rpm timing sensor and injection system.
Measure the sensor resistance by connecting a multimeter between the terminals marked + and - (see
the "Electrical system" chapter).
RESISTANCE OF THE RPM TIMING SENSOR: (AT 25°C)
1
2
Specification
Model with 1 clamp:
Model with 2 clamps:
Desc./Quantity
860 Ω ± 130 Ω
680 Ω ± 100 Ω
YES go to 11 NO go to 12
11 - Check the earth isolation between a pole and the shielding.
(see the «Electrical system» chapter).
Electric characteristic
S-+=
infinite (>MΩ)
INJEC - 261
Injection
X9 Evolution 500
YES go to 13 NO go to 12
12 - Replace the revolution sensor.
13 - Reconnect the rpm-timing sensor connector.
Repeat the resistance check through the injection
wiring pin 7, pin 12.
Electric characteristic
7-12 =
680 Ω ± 100 Ω (Model with 2 clamps)
7-12 =
890 Ω ± 130 Ω (Model with 1 clamp)
The value should be very close to that detected directly by the sensor.
YES go to 17 NO go to 14
14 - Higher or infinite resistance.
YES go to 15 NO go to 16
15 - Check the connectors carefully. Disconnect and check the continuity between connector and pin
7-12
Electric characteristic
Connector - 7 =
Continuity
Connector - 12 =
Continuity
Fix the connectors or replace the cable harness.
16
Electric characteristic
Resistance
0
Repair or replace the injection wiring (short circuit)
17 - Check the earth insulation again.
Electric characteristic
7-23 =
INJEC - 262
X9 Evolution 500
Injection
infinite (>1MΩ)
YES go to 19 NO go to 18
18 - Check the sensor and control unit connectors.
Repair or replace the injection wiring
19 - Measure the alternated voltage between pins
7 and 12 with engine at start-up speed.
Electric characteristic
7-12 =
approx. 0.8 - 4.5 V eff
Revolution speed =
approx. 300-400 rpm
YES go to 20 NO go to 21
20 The sensor circuit is in conformance.
Use the parameter function to check if the engine rpm indication is present when trying to start.
If not, carefully check the ECU connection connector and replace it if necessary.
21 Check the air gap and magnetic activity of the sensor.
See the "Combustion unit and distribution" chapter.
If there is no magnetic activity replace the sensor.
N.B.
-THE SENSOR CABLE MUST BE PROPERLY INSTALLED FOR SERVICING.
-DO NOT FORCE THE CABLE.
-A POOR CABLE SHIELDING CAN IMPAIR THE ENGINE PERFORMANCE AT HIGH SPEED.
HT coil
This section describes the ignition system operation.
Circuit diagram
Electric characteristic
TERMINALS: 20 - 23
CONDITIONS : During the pump timing with engine off.
STANDARD: Battery voltage
INJEC - 263
X9 Evolution 500
Injection
CIRCUIT LAYOUT
1
2
3
4
5
6
Specification
Electronic control unit
Injector
HV coil
Pump
Control unit remote control switch
Fuse
Desc./Quantity
10 A
The ignition system is integrated with the injection
and it is a high-efficiency inductive type ignition.
The control unit manages two important parameters:
- Ignition advance
This is optimised according to the engine rpm, to
the engine load, temperature and ambient pressure
With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'. - Magnetisation time
The coil magnetisation time is controlled by the
control unit. The ignition power is increased during
the engine start-up.
The injection system recognises the 4-stroke cycle
and therefore, ignition is only controlled during
compression.
To check the ignition circuit, proceed as follows:
1 - Connect the diagnostic tester. Select the menu
on the "ACTIVE DIAGNOSIS" function. Start the
HV coil check with switch set to «ON», switch to
«RUN» and side stand raised. Wait for the tester
to display: "TEST SUCCESSFUL"
YES go to 3 NO go to 2
Specific tooling
020460Y Scooter diagnosis and tester
2 - The tester displays: "TEST FAILED". Repeat the test and wait for the tester to display: "TEST SUCCESSFUL"
YES go to 3 NO go to 4
3 - Select the menu on the "ERRORS" function. Check the presence of current or stored errors relating
to the H.V. coil.
YES go to 6 NO go to 5
INJEC - 264
X9 Evolution 500
Injection
4 - Test failed
YES go to 6
5 - The coil control circuit is efficient.
Check the H.V. coil secondary, the cable and the screened cap
6 - Install the special tool between the injection system and the control unit.
Measure voltage between pins 20 and 23 of the specific
Specific during the timing phase of the fuel pump.
To start the timing, set the switch to "ON" with switch to "RUN" and side stand raised.
Electric characteristic
20-23 =
Battery voltage (coupled to the pump rotation -2 seconds).
If you want to increase the test time, enable the
"pump relay diagnosis" function
(30 seconds)
YES go to 7 NO go to 8
7 - The coil primary control circuit is efficient.
Carefully check the connectors to the control unit and to the coil.
Replace the control unit, if necessary.
8 - Disconnect the connector to the HV coil primary.
Repeat the voltage check between the black-green wire and earth.
Electric characteristic
Black-green-23 =
battery voltage
(coupled to the pump rotation-2 seconds).
YES go to 10 NO go to 9
9 - Check the black-green wire continuity.
Repair or replace the cable harness.
INJEC - 265
Injection
X9 Evolution 500
N.B.
A FAILURE OF THE REMOTE CONTROL SWITCH WOULD CAUSE THE PUMP ROTATION FAILURE
10 - The positive power supply is conforming. Check the continuity between the pink-black wire of the
connector and pin 20.
Electric characteristic
Pink-black-20 =
Continuity
YES go to 12 NO go to 11
11 - Check the continuity of the pink-black wire in the two systems.
Electric characteristic
Pink-black (coil connector)-20 =
Continuity
YES go to 12 NO go to 13
12 - Check the earth insulation of the negative line.
Electric characteristic
20-23 =
Ω infinite (>1MΩ)
INJEC - 266
X9 Evolution 500
Injection
YES go to 15 NO go to 14
13 - Repair or replace the faulty system. Repeat the check with the menu on "ACTIVE DIAGNOSIS".
14 - Repeat the earth insulation check in the two sections. Repair or replace the wiring. Repeat the
check with the menu on "ACTIVE DIAGNOSIS" H.V. coil control simulation. Delete the errors stored in
memory.
15 - Check the continuity of the H.V. coil primary. See figure.
Electric characteristic
Primary resistance =
0.5 ± 8%
YES go to 16 NO go to 19
16 - Check the earth insulation of the primary circuit
Measure between one of the primary terminals and earth.
Electric characteristic
Primary-earth =
Ω infinite (>1MΩ)
INJEC - 267
Injection
X9 Evolution 500
YES go to 17 NO go to 1 9
17 - Check the secondary resistance.
Measure the resistance between one of the primary terminals and the spark plug cable output
Electric characteristic
Primary HV cable output =
3.1 K ± 9%
YES go to 18 NO go to 19
18 - The coil is conforming.
19 - Replace the coil
Inspecting the spark plug shielded cap
Measure the shielded cap resistance.
Electric characteristic
Resistance:
5 KΩ
INJEC - 268
X9 Evolution 500
Injection
If different values are measured (<1; >20KΩ), replace the shielded cap.
N.B.
A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM.
FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTENANCE» CHAPTERS.
Spark advance
The ignition advance is determined electronically on the basis of parameters known by the control unit.
For this reason it is not possible to declare the reference values based on the engine rpm.
The ignition timing value is detectable any time using the diagnostic tester.
It is possible to check whether the ignition advance determined by the system does in fact correspond
with the value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light to check timing
Proceed as follows:
- Remove the transmission compartment cover as
described in the "automatic transmission" chapter.
- Remove the TDC reference inspection cap between flywheel and crankcase cover. See the "flywheel cover" chapter
INJEC - 269
Injection
- By the driving pulley, turn the engine to find the
alignment of the references to identify the TDC.
- Repeat for the reference between driving pulley
and engine crankcase.
- Replace the inspection cap on the flywheel side.
- Connect the diagnostic tester.
- Start the engine.
- Select the «parameter» function in this menu.
- Select the stroboscopic light command in the traditional four-stroke engine position (1 spark 2
revs).
- Check that the real values of rpm and ignition
advance match those measured using the diagnostic tester.
If the values do not match, check:
- distribution timing
- rpm-timing sensor
- Injection control unit
Coolant temperature sensor
Electric characteristic
TERMINALS: 4 - 22
CONDITIONS : coolant temperature
STANDARD:
With connected sensor:
20° = 2500 ± 100 Ω
INJEC - 270
X9 Evolution 500
X9 Evolution 500
Injection
80° = 308 ± 6 Ω
CIRCUIT LAYOUT
1
2
3
4
Specification
Electronic control unit
Valve position sensor
Air temperature sensor
Fluid temperature sensor
Desc./Quantity
The coolant temperature sensor is installed on the engine head and provides the indications for the
digital instrument and for the injection.
It is realised with two electrically different sections.
The injection section is realised with an NTC sensor connected to a 5V powered circuit. The resistance
variation causes a variation of the circuit voltage. Such voltage is combined with a temperature value.
By this value, the control unit can manage the engine operation, optimising it for all temperatures.
A failure of this circuit causes the switching on of the injection telltale light and the tripping of the safeties
(among which the electric fan continuous start). In these conditions, the engine works, even though not
in an optimum way, always safeguarding the catalytic converter integrity.
A false temperature value that falls within the range of possible temperatures is a failure very difficult
to manage. This can cause a failure of the safeties and an improper management of the ignition. Such
failure is more easily detected upon the engine start-up.
To check the sensor and related circuit, proceed as follows:
1 - Connect the injection diagnostic tester and select the menu on the "errors" function.
Check whether faults have been recorded regarding the coolant temperature sensor.
YES go to 3 NO go to 2
INJEC - 271
Injection
X9 Evolution 500
Specific tooling
020460Y Scooter diagnosis and tester
2 - The EMS system has received no indications of temperatures out of the range of possible temperatures.
If you suspect a wrong temperature indication, proceed to perform the following check.
N.B.
A WRONG TEMPERATURE SIGNAL CAN BE DETECTED BY COUPLING THE ANALOGUE INSTRUMENT INDICATION WITH THE ELECTRIC FAN START.
IN ANY CASE, BEFORE CHECKING THE SENSOR, CHECK THE FILLING AND BLEEDING OF
THE COOLING SYSTEM
3 - Before checking the sensor and the relevant circuit, wait until the engine has cooled down and the
scooter has set to the working area temperature.
YES go to 4
4 - Set the switch to "ON" with switch to "RUN" and side stand raised. Select the menu on the "parameters" function. Do not start the engine.
YES go to 5
5 - Check the following values: coolant temperature intake air temperature ambient temperature The
three indications are equal or they are slightly different (e.g. 1° C).
YES go to 6 NO go to 7
6 - The temperature sensor is providing probably correct information.
Check at approx. 80° C.
7 - Install the special tool.
WARNING
DO NOT CONNECT THE CONTROL UNIT CONNECTOR.
Specific tooling
020481Y Control unit interface wiring
YES go to 8
8 - Disconnect the coolant temperature sensor
connector. Measure the sensor resistance between the terminals shown in the figure.
Check that the resistance matches the values declared according to the temperature.
Electric characteristic
TEMPERATURE RESISTANCE
9.6KW -10° C
5.975KW. 0
3.81KW +10° C .
2.5KW +20° C
1.68KW +30° C
0.3KW +80° C
YES go to 10 NO go to 9
9 - Replace the sensor.
INJEC - 272
X9 Evolution 500
Injection
10 - Connect the sensor connector and repeat the resistive check at terminals 4 and 22;
Electric characteristic
4-22 =
Resistance equal to the value directly detected at the sensor.
YES go to 13 NO go to 11
11 - If slightly higher values are detected, check the connectors.
If infinite resistance is detected (>1MW), check the continuity between the two lines with disconnected
connectors.
Electric characteristic
Blue-white-4 =
0W (continuity)
Light blue/green-22 =
0 ohm. (Continuity)
YES point 12
12 - Repair or replace the cable harness.
YES go to 10
13 - Check that the sensor circuit is earth insulated.
Electric characteristic
4-23 =
Ω infinite (>1MΩ)
22-23 =
Ω infinite (>1MΩ)
INJEC - 273
X9 Evolution 500
Injection
YES go to 15 NO go to 14
14 - Repair or replace the wiring.
Check the air temperature lines and the throttle
valve position.
YES go to 13
15 - Connect the special tool to the control unit.
Set the switch to "ON" with switch to "RUN" and
side stand raised.
YES go to 16
Specific tooling
020481Y Control unit interface wiring
16 - Measure voltage at terminals 4 and 22;
TEMPERATURE VOLTAGE
1
2
3
4
5
6
Specification
XV
XV
XV
XV
XV
XV
YES go to 21 NO go to 17
17
Electric characteristic
Measured value =
5±0.2 V
Repeat the wiring and sensor continuity checks.
INJEC - 274
Desc./Quantity
-10° C
0
+10° C
+20° C
+30° C
+80° C
X9 Evolution 500
Injection
YES go to 18
18
Electric characteristic
Measured value =
0V
Repeat the sensor and circuit earth insulation
check.
YES go to 19 NO go to 20
19 - Check the control unit connector.
Check the control unit power supply.
Replace the control unit, if necessary.
20 - Repair or replace the cable harness.
21 - Start the engine and check that voltage decreases gradually according to the temperature
increase as per table.
YES go to 22 NO go to 23
22 - The temperature signal is conforming.
23 - Replace the temperature sensor.
N.B.
FOR A MORE ACCURATE CHECK OF THE SENSOR, REMOVE IT FROM THE ENGINE AND CHECK ITS RESISTANCE AT CONTROLLED TEMPERATURE.
USING A SUITABLE CONTAINER, IMMERSE THE METAL
PORTION OF THE SENSOR IN WATER, HEAT GRADUALLY AND READ THE TEMPERATURE AND RESISTANCE
VALUES.
CHECK THE MATCHING AS PER TABLE
Intake air temperature sensor
Electric characteristic
TERMINALS: 18 - 22
CONDITIONS: Intake air temperature 20°
STANDARD: With connected sensor: 3750 ± 200 Ω
INJEC - 275
X9 Evolution 500
Injection
CIRCUIT LAYOUT
1
2
3
4
Specification
Electronic control unit
Valve position sensor
Air temperature sensor
Fluid temperature sensor
The sucked air temperature sensor is installed in
the bottom side of the throttle body on the filter box
side.
The sensor is an NTC and has the same functional
layout as the coolant temperature sensor.
This signal is used to optimise the engine performance. Anyway, this data is less important than the
coolant temperature signal.
A failure of this circuit causes the control unit to
turn on the injection warning light and activate the
safety control, thereby ensuring the engine operation.
To check the sensor and related circuit, proceed
as follows:
1 - Connect the diagnostic tester.
Select the function "ERRORS" in the menu.
INJEC - 276
Desc./Quantity
X9 Evolution 500
Injection
Check whether there are any indications regarding
the sucked air temperature sensor.
YES go to 3 NO go to 2
Specific tooling
020460Y Scooter diagnosis and tester
2 - The EMS system has received no indications of temperatures out of the range of possible values.
If you suspect a wrong temperature indication, proceed to perform the following check.
3 - Before checking the sensor and the relevant circuit, wait until the engine has cooled down and the
scooter has set to the working area temperature.
YES go to 4
4 - Set the switch to "ON" with switch to "RUN" and side stand raised. On the diagnostic tester, select
the «PARAMETERS» menu.
YES go to 5
5 - Check the following values:
coolant temperature
intake air temperature
ambient temperature indicated by the digital instrument.
The three indications are equal or they are slightly different (e.g. 1° C).
YES go to 6 NO go to 7
6 - The intake air temperature sensor is providing an incorrect information.
7 - Install the special tool. Do not connect the control unit connector.
YES go to 8
Specific tooling
020481Y Control unit interface wiring
8 - Disconnect the intake air temperature sensor connector.
Measure the resistance between the sensor terminals. Check that the resistance matches the values
declared according to the temperature.
TEMPERATURE RESISTANCE
1
2
3
4
5
Specification
9,6 KΩ
5,975 KΩ
3,81 KΩ
2,5 KΩ
1,68 KΩ
Desc./Quantity
-10° C
0
+10° C
+20° C
+30° C
INJEC - 277
Injection
X9 Evolution 500
YES go to 10 NO go to 9
9 - Replace the sensor.
10 - Connect the sensor connector and repeat the resistive check at terminals 18 and 22.
Electric characteristic
18-22 =
Resistance equal to the value directly detected at the sensor.
YES go to 13 NO go to 11
11 - If slightly higher values are detected, check the connectors.
If infinite resistance is detected (>1MΩ), check the continuity of the two lines with disconnected connectors.
Electric characteristic
Grey-white-18 =
0 Ω (continuity)
Light blue/green-22 =
0 Ω (continuity)
YES point 12
INJEC - 278
X9 Evolution 500
Injection
12 - Repair or replace the cable harness.
YES go to 10
13 - Check that the sensor circuit is earth insulated.
Electric characteristic
18-23 =
infinite (>1MΩ)
22-23 =
infinite (>1MΩ)
YES go to 15 NO go to 14
14 - Repair or replace the wiring. Check the valve position and the fluid temp. lines.
YES go to 13
15 - Connect the special tool to the control unit.
Set the switch to "ON" with switch in "RUN" and side stand raised.
YES go to 16
Specific tooling
020481Y Control unit interface wiring
16 - Measure voltage at terminals 18 and 22.
Electric characteristic
18-22 =
V as in the table.
TEMPERATURE VOLTAGE
1
2
3
4
5
6
Specification
XV
XV
XV
XV
XV
XV
Desc./Quantity
-10° C
0
+10° C
+20° C
+30° C
+80° C
INJEC - 279
Injection
X9 Evolution 500
YES go to 21 NO go to 17
17
Electric characteristic
Measured value =
5±0.2 V
Repeat the wiring and sensor continuity checks.
YES go to 18
18
Electric characteristic
Measured value =
0V
Repeat the sensor circuit earth insulation check.
YES go to 19 NO go to 20
19 - Check the control unit connector. Check the control unit power supply. Replace the control unit, if
necessary.
20 - Repair or replace the cable harness.
21 - Start the engine and check that voltage decreases gradually according to the air filter box temperature increase.
N.B.
WITH MILD WEATHER, 30° C CAN BE EASILY REACHED AFTER A FEW MINUTES OF STOP
WITH IDLE ENGINE.
INJEC - 280
X9 Evolution 500
Injection
Pressure sensor
This sensor does not have a system since it is directly installed into the control unit.
The sensor allows the control unit to optimise the
engine performance based on altimetric variations.
To check the sensor, proceed as follows:
1 - Connect the diagnostic tester.
Select the function "ERRORS" in the menu.
Check whether there are any indications regarding
the pressure sensor.
YES go to 2 NO go to 3
Specific tooling
020460Y Scooter diagnosis and tester
2 - Replace the injection control unit.
3 - Select the menu on the "PARAMETERS" function.
Check that the pressure value in mm/Hg matches that of another scooter or of an external barometer.
Electric characteristic
Max error:
± 20 mmHg
YES go to 4 NO go to 5
4 - The ambient pressure signal is correct.
5 - Replace the injection control unit.
Throttle valve opening sensor
Throttle position sensor (t.p.s.)
Electric characteristic
TERMINALS: 1 - 22
CONDITIONS: Switch set to "ON"
INJEC - 281
X9 Evolution 500
Injection
STANDARD: 5 V
TERMINALS: 11 - 22
CONDITIONS: Opening the throttle gradually
STANDARD: Volt= Progressive increase
CIRCUIT LAYOUT
1
2
3
4
Specification
Electronic control unit
Valve position sensor
Air temperature sensor
Fluid temperature sensor
The throttle valve position sensor is not removable
and is installed on the throttle body.
This sensor receives a 5-V power supply from the
control unit and transmit a gradually increasing
voltage to the same, with an increase of the throttle
valve opening. The control unit converts this voltage at an angular position of the valve.
The engine rpm and the throttle valve position are
the two basic signals for the engine management.
A failure of this circuit causes the switching on of
the injection telltale light and the tripping of the
safeties. In these conditions, the engine works,
INJEC - 282
Desc./Quantity
X9 Evolution 500
Injection
even though not in an optimum way, always safeguarding the catalytic converter integrity.
The throttle valve position signal is especially important at the small valve openings. These areas
are also where the sensor works more frequently,
and therefore they require more frequent checks
after a high number of kilometres run.
To check the sensor and related circuit, proceed
as follows:
1 - Connect the diagnostic tester.
Set the switch to "ON" with switch to "RUN" and
side stand raised.
Select the tester menu on the «ERRORS» function.
Check whether the control unit has detected any
failures relating to the throttle valve position signal.
YES go to 6 NO go to 2
Specific tooling
020460Y Scooter diagnosis and tester
2 - Select the diagnostic tester menu on the "PARAMETERS" function.
Check whether the control unit recognises the extreme positions:
Throttle valve to minimum
Throttle valve to maximum
YES go to 4 NO go to 3
3 - Check the adjustment of the throttle valve control flexible transmissions. Fix or replace, if required.
YES go to 2
4 - Gradually open the throttle valve, check that the mV value increases progressively and proportionally
with the opening variation.
YES go to 5 NO go to 6
5 - The throttle valve position signal is conforming.
6 - Connect the special tool to the injection system.
Do not connect the tool to the control unit.
Disconnect the throttle valve position sensor connector.
Check the continuity between the connector's terminals and the relevant pins on the control unit.
Specific tooling
INJEC - 283
Injection
020481Y Control unit interface wiring
Electric characteristic
Light blue/green-22 =
0 Ω (continuity)
Brown-yellow-1 =
0 Ω (continuity)
Orange-light blue-11 =
0 Ω (continuity)
YES go to 8 NO go to 7
7 - Repair or replace the injection wiring.
YES go to 6
8 - Check the earth insulation of the three circuit lines.
Electric characteristic
22-23 =
Ω infinite (>1M)
1-23 =
Ω infinite (>1M)
11-23 =
Ω infinite (>1M)
YES go to 10 NO go to 9
9 - Repair or replace the injection wiring
YES go to 8
10 - Connect the special tool to the control unit.
Set the switch to "ON" with switch to "RUN" and side stand raised.
INJEC - 284
X9 Evolution 500
X9 Evolution 500
Injection
Measure voltage between terminals 1 and 22 of the special tool.
Specific tooling
020481Y Control unit interface wiring
Electric characteristic
1-22 =
5±0.2 V
YES go to 12 NO go to 11
11 - Check the control unit connector.
Replace the control unit, if necessary.
YES go to 10
12 - Connect the throttle valve position sensor connector.
Repeat the voltage measurement between terminals 1 and 22 of the special tool.
Electric characteristic
1-22 =
5±0.2 V
YES go to 13 NO go to 14
13 - Measure voltage between terminals 11 and 22. Gradually open the throttle valve and check that
the voltage value increases progressively.
N.B.
BY WAY OF AN INDICATION, VOLTAGE MAY VARY FROM APPROX. 700MV AT MINIMUM, AND
ABOVE 4V AT MAXIMUM.
Electric characteristic
11-22 =
V (progressive variation)
INJEC - 285
Injection
X9 Evolution 500
The possible variations of the limit values are
caused by the sensor installation tolerances.
YES go to 15 NO go to 14
14 - Replace the throttle body along with sensors
and Stepper.
YES point 12
15 - Check that the voltage measured at pins 11
and 22 matches that indicated by the diagnostic
tester set to "PARAMETERS".
YES go to 16 NO go to 17
16 - The throttle valve position sensor and relevant circuit are conforming.
17 - Replace the control unit.
Zeroing the throttle
Resetting the throttle valve position signal (TPS reset)
The throttle body is supplied with throttle valve position sensor and is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position. The control unit will recognise such value as angle 5.24°.
To reset, proceed as follows:
INJEC - 286
X9 Evolution 500
Injection
Connect the diagnostic tester.
Set the switch to "ON" with switch in "RUN" and
side stand raised.
Select the functions of the diagnostic tester on
«TPS RESET».
Specific tooling
020460Y Scooter diagnosis and tester
Make sure that the throttle valve with the control is
supporting the stop screw.
Guaranteeing that this position will be kept, send
a confirmation for the TPS reset procedure.
Select the "PARAMETERS" function and check
that the TPS reset "YES" is displayed.
Reset should be performed in the following cases:
- on first fitting.
- in case of replacement of the throttle body
- if the injection control unit is replaced.
N.B.
INJEC - 287
X9 Evolution 500
Injection
THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE
BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING
MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Step motor
CIRCUIT LAYOUT
1
2
Specification
Electronic control unit
Stepper motor
The throttle body is provided with an auxiliary air
circuit. This is enabled by a piston valve controlled
by a Stepper motor.
The Stepper is powered by the control unit only
when the opening must be changed.
The revolution is divided into portions called
"steps".
By changing the opening "steps" it is possible to
properly feed the engine to facilitate the start-up
procedure and adjust the air feeding with cold engine. When the engine reaches the working temperature, the Stepper partly closes again.
INJEC - 288
Desc./Quantity
Stepper motor
X9 Evolution 500
Injection
To prevent wear of the adjustment piston, operation at full speed is obtained with a minimum opening of 43 - 45 "steps".
To recover possible adjustments, every switching
to "OFF" causes the piston to close up to end of
travel and to open up again by a fixed number of
steps (self-reset).
When the control unit changes the Stepper opening "steps" it also changes the injection time to
ensure proper ignition.
The engine idle speed is practically stabilised at
1550-50 rpm. After a hot start-up step you can
perceive the first increase in the revolutions and
the subsequent closing of the Stepper to stabilise
the speed.
In case of irregular speed, before carrying out
electric checks inspect the throttle valve and the
auxiliary air circuit cleaning.
To check the Stepper and the relevant circuit, proceed as follows:
1 - Connect the diagnostic tester.
Set the switch to "ON" with switch to "RUN" and
side stand raised.
Lift the scooter on the central stand. Select the
function "ERRORS" in the menu.
Check whether the control unit has detected any
failures relating to the Stepper circuit.
YES go to 8 NO go to 2
Specific tooling
020460Y Scooter diagnosis and tester
2 - Select the menu on the "PARAMETERS" function. Check the number of "steps" programmed by
the control unit to obtain start-up. This setting is a function of the engine temperature.
Electric characteristic
20° C =
approx. 135 - 140 steps
INJEC - 289
Injection
X9 Evolution 500
YES go to 3 NO go to 4
3 - Start the engine and let it warm up.
With a coolant temperature of more than 70°C, the
control unit must control the Stepper with about 45
«steps».
YES go to 5 NO go to 4
4 - Check the coolant temperature sensor signal. Check the control unit, if necessary.
5 - Select the menu on the «ACTIVE DIAGNOSIS» function. Select «STEPPER» diagnosis. Start the
diagnosis with idle engine at the working temperature. Check whether the Stepper controls some revolution variations and wait for the diagnostic tester response.
N.B.
THE ECU ENABLES THE DIAGNOSIS ONLY WHEN THE IDLE SPEED IS WITHIN THE SPECIFICATIONS.
YES go to 6 NO go to 8
6 - Test successful. Variations of revolutions perceived.
YES go to 7 NO go to 9
7 - Stepper and relevant circuit efficient.
8- Test failed. No variations of revolutions. Check the Stepper circuit. Disconnect the Stepper connector.
Check the resistance of the Stepper circuits by connecting the tester as indicated in the figure. The two
measurements must have the same value.
Electric characteristic
INJEC - 290
X9 Evolution 500
Injection
Resistance =
approx. 51 Ω
YES go to 11 NO go to 10
9 - Test successful.
No variations of revolutions.
Remove the throttle body.
Check the auxiliary air circuit cleaning. Switch from
"ON" to "OFF" and again to "ON" and check whether the piston valve moves. If the valve does not
move, replace the throttle body.
10 - Replace the throttle body
11 - Connect the special tool.
For these checks, do not connect the special tool to the control unit. Check the continuity of the 4 power
supply lines of the Stepper.
Specific tooling
020481Y Control unit interface wiring
Electric characteristic
A Light blue-red-14 =
0 Ω (continuity)
B Orange-blue-6 =
0 Ω (continuity)
C Light blue-yellow-21 =
0 Ω (continuity)
D Light blue-black-24 =
0 Ω (continuity)
INJEC - 291
Injection
YES go to 12 NO go to 13
12 - Check the earth insulation of the 4 Stepper lines.
Electric characteristic
14-23 =
>1 MΩ (infinite)
6-23 =
>1 MΩ (infinite)
21-23 =
>1 MΩ (infinite)
24-23 =
>1 MΩ (infinite)
YES go to 14 NO go to 13
13 - Repair or replace the wiring.
YES go to 11
14 - Connect the Stepper connector.
Repeat the continuity check with the tool pins.
Electric characteristic
14-24 =
approx. 51 Ω
6-21 =
approx. 51 Ω
INJEC - 292
X9 Evolution 500
X9 Evolution 500
Injection
YES go to 16 NO go to 15
15 - Check cable harness and connectors more carefully.
16 - Connect the control unit connector.
Set the switch to «ON» with switch to «RUN» and side stand raised. Repeat the «ON» «OFF» «ON»
switching.
Check the presence of voltage pulses on the Stepper command lines.
Set-up for direct voltage measurements.
N.B.
PULSES ARE USED TO CHANGE THE STEPPER POSITION.
Electric characteristic
14-24 =
V (pulses for a few seconds)
6-21 =
V (pulses for a few seconds)
After reaching the optimum position, the power
supply voltage becomes null.
YES go to 17 NO go to 18
17 - The Stepper circuit is efficient.
18 - Check the control unit connector. Replace the control unit, if necessary.
INJEC - 293
INDEX OF TOPICS
SUSPENSIONS
SUSP
X9 Evolution 500
Suspensions
This section is devoted to operations that can be carried out on the suspension.
Front
Removing the front wheel
Loosen the two wheel axle fastening screws
shown in the figure
- Remove the wheel axle locking nut keeping the
axle still by a socket head wrench on the right side
- Extract the wheel axle and remove the wheel
- Be careful not to damage the wheel speed sensor
during removal
- Check that the wheel axle is free from wear or
deformations. Replace it, if necessary
Front wheel hub overhaul
Check that the wheel bearings are free from wear.
If you have to replace the wheel bearings, proceed as follows:
- Remove the 2 bearings on the odometer motion drive side using pliers 14 or 34 and bell 9.
- Remove the inside spacer.
Specific tooling
001467Y014 Pliers to extract ø 15-mm bearings
001467Y034 Pliers to extract ø 15-mm bearings
SUSP - 295
Suspensions
Either 001467Y014 or 001467Y034 can be used.
- Support the front wheel with two wooden shims
to prevent scratches in case of contact with the
rim.
- Insert the punch consisting of the adapter handle,
adapter and 15-mm guide on the odometer motion
drive side to allow removing the LH bearing and
the spacer bushing.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020412Y 15 mm guide
- Heat the LH bearing seat using the thermal gun.
- Insert the bearing by the punch consisting of
adapter handle, adapter 42x47 mm and 15-mm
guide to abutment.
SUSP - 296
X9 Evolution 500
X9 Evolution 500
Suspensions
- Reinsert the spacer bushing on the brake disc
side by the specific tool and move it to abutment.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
020201Y Spacer bushing driving tube
- Upturn the wheel and insert the inside spacer
with the portion provided with snap ring facing the
LH bearing installed before.
- Heat the wheel speed sensor side bearing seat
using the thermal gun.
- Insert the 2 bearings by the punch consisting of
adapter handle, adapter 32x35 mm and 15-mm
guide to abutment.
Specific tooling
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
Refitting the front wheel
- For re-assembly, perform the operations for removal in the reverse order according to the prescribed torques.
- Place the wheel speed sensor in advance to insert the reference into its seat.
Locking torques (N*m)
Wheel axle fixing screws: 6 ÷ 7 Nm Front wheel
axle 45 ÷ 50
Handlebar
SUSP - 297
Suspensions
X9 Evolution 500
Removal
- Remove the radio-intercom display releasing the
two screws "C" located at the back and disconnect
the wiring.
- Remove the digital panel support, the front and
rear side of the handlebar cover.
- Release the handlebar of the components mounted above.
- Remove the 2 balance weights by the side
screws.
- remove the pumps releasing the screws on the
locking U bolts.
- Remove the gas control releasing the fixing
screws and extracting it from the handlebar.
- Remove the left knob.
- Loosen the bolt fixing the handlebar to the steering tube and extract it, removing the plastic support
also.
IF THE HANDLEBAR IS REMOVED TO REMOVE THE FORK, SIMPLY TILT THE HANDLEBAR TO
THE COUNTER SHIELD WITHOUT REMOVING THE PARTS MOUNTED ABOVE AND PREVENTING DAMAGES TO THE TRANSMISSIONS, PIPES OR BODY.
Refitting
Perform the above operations in the reverse order
for reassembly. To align the handlebar with the
steering wheel, match the notch on the handlebar
clamp with that on the steering tube.
Tighten at the prescribed torque.
Locking torques (N*m)
Handlebar fastening bolt: 43 ÷ 47 N•m
Front fork
SUSP - 298
X9 Evolution 500
Suspensions
Removal
- Remove the front wheel
- Remove the front mudguard and the brake caliper screws
- Remive the handlebar fixing bolt and tilt it towards
the counter shield
N.B.
BE VERY CAREFUL NOT TO DAMAGE THE COUTER
SHIELD WITH THE HANDLEBAR METAL TABS
- Loosen the two screws of the brake piping supports shown in the figure
N.B.
IT IS ALSO POSSIBLE TO REMOVE ONLY ONE OF THE
TWO FORK STEMS LOOSENING THE TWO SCREWS LOCATED ON THE FORK PLATE CLAMPS.
- Remove the two ring nuts, the intermediate washer shown in the figure and the spacer below.
- Extract the complete fork.
WARNING
SUITABLY SUPPORT THE VEHICLE TO MAKE THE
STEERING TUBE COME OUT OF THE HEAD.
CAUTION
BEFORE REMOVING BOTH RING NUTS, SUPPORT THE
FORK UNIT TO PREVENT IT FROM FALLING.
Specific tooling
020055Y Wrench for steering tube ring nut
SUSP - 299
Suspensions
Overhaul
Sealing ring replacement and stanchion removal - Loosen the cap (2);
- Extract the spring and stem;
- Drain the oil from the suspension;
- Remove the inside pumping fixing (1) bottom
screw;
-Replace the sealing rings (3-4-5) with new ones;
- Insert new rings after lubricating their seat;
- Insert the spring and stem;
- Insert from top a socket head screw 12 mm to
lock the pump and replace the lower screw (1);
- Pour 268±2 cc of hydraulic oil 7.5W;
- Repeat the operations in reverse order for re-assembly.
Recommended products
AGIP FORK 7,5W Front fork oil
Hydraulic oil SAE 7,5W
Refitting
- Grease the tapered bearing using the specified
product.
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
- Insert the fork into the headstock.
- Insert the tapered bearing after applying the
specified product.
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
SUSP - 300
X9 Evolution 500
X9 Evolution 500
Suspensions
- Using the special tool, tighten the first ring-nut on the steering tube to a holding torque, then tighten
completely.
Locking torques (N*m)
Holding torque of lower ring nut 20 ÷ 25
- Tighten with a prescribed torque and turn the spanner 90° anticlockwise.
Locking torques (N*m)
Steering lower ring nut 10 - 13 **
- Install the space washer.
- Using the special tool, tighten the second locking ring nut on the steering tube to the prescribed torque.
Locking torques (N*m)
Upper steering ring nut 36 - 39
- Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on
the handlebar with that on the steering tube as
shown in the figure.
- Tighten the fastening screw on the steering tube at the prescribed torque.
- Reinstall the front and rear handlebar covers as described in the «Body» chapter.
- Reinstall the front mudguard.
- Reinstall the front wheel.
- Reinstall the front brake caliper
- Tighten the screws fixing the brake caliper to the support.
Specific tooling
020055Y Wrench for steering tube ring nut
Locking torques (N*m)
Screw fixing the handlebar to the steering tube: 43 ÷ 47 N•m Steering wheel lower ring nut: 10
÷ 13 N•m, then loosen by 90° Upper steering ring nut 36 - 39
Steering column
Overhaul
Servicing tapered bearing seats
- Check that the seats and the tapered bearings exhibit no scratches or wear.
N.B.
THE TAPERED BEARING SEATS SHOULD BE REMOVED ONLY IF STRICTLY NECESSARY.
SUSP - 301
Suspensions
X9 Evolution 500
In case of replacement, proceed as follows:
- Using a bearing removal punch, inserted from the
bottom, remove the top seat on the steering head.
Then, remove the bottom seat of the tapered bearing inserting the punch from the top of the headstock.
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
Servicing tapered bearing on fork
- Check that the conical bearing on the fork exhibits no deformations or wear.
THE BEARING SHOULD BE REMOVED ONLY IF STRICTLY NECESSARY.
In case of replacement, proceed as follows:
- Support the fork in a vice.
- Insert the contrast plate in the upper end of the
steering tube
- Insert the specific tool as shown in the figure.
- Insert the two half-ring retain band and push it
downwards to engage it with the half-ring teeth in
the bearing lower base.
SUSP - 302
X9 Evolution 500
Suspensions
- Using a 19-mm hexagonal wrench, extract the
roller bearing.
Specific tooling
020458Y Puller for lower bearing on steering
tube
Steering bearing
Refitting
Reassembling the steering conical bearing housings
Using the specific tool, reassemble the conical bearing housings on the head as described below:
- Place a new top housing on the head and a new bearing seat on the bottom side.
- Insert the screw setup with the adapters for inserting bearing and seat, into the steering head, as
shown in the figure.
- Using two 24-mm wrenches, tighten the screw to
move the two seats in abutment.
- Lubricate the steering wheel bearing seats with
lithium soap and zinc oxide grease.
N.B.
ALWAYS USE NEW SEATS AND BEARINGS.
Specific tooling
001330Y013 Top plate adapter
001330Y009 Bottom plate adapter
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
SUSP - 303
Suspensions
X9 Evolution 500
Reassemble conical bearing on the steering
tube
- Insert the a new plate and a new dust guard in
the steering tube
- Insert the a new conical bearing in the steering
tube
- Using the specific tool and a mallet to move the
dust guard and the bearing in abutment.
Specific tooling
006029Y Punch for fitting fifth wheel seat on
steering tube
Rear
Removing the rear wheel
- Remove the RH rear shock absorber
- Remove the silencer and the support arm.
- Remove the 5 screws fixing the rear wheel to the
hub.
- Remove the wheel.
Locking torques (N*m)
Rear wheel rim screws 33 ÷ 37 Rear wheel axle
104 ÷ 126
Refitting the rear wheel
Reassemble in the reverse order, tightening the rear wheel screws and the wheel axle nut at the prescribed torque.
Locking torques (N*m)
Rear wheel rim screws 33 ÷ 37 Rear wheel axle 104 ÷ 126
Swing-arm
SUSP - 304
X9 Evolution 500
Suspensions
Removal
- Remove the nut and the washer fixing the oscillating arm/engine pin and tie rod.
- Remove the locking nut, the washer and the tie
rod pad.
N.B.
BE CAREFUL TO THE PIPES AND UNIONS OF THE SYSTEM FEEDING FUEL TO THE INJECTOR.
- Suitably support the engine by a jack under the
oil sump.
- Remove the nut of the pin fixing the oscillating
arm to the chassis.
- Remove the counter-nut then, with the aid of a 15
mm spanner, loosen the bolt securing the wingarm to the the frame.
SUSP - 305
Suspensions
X9 Evolution 500
- Detach the swing-arm from the frame and remove the shaped washer.
- Remove the 2 fixing screws and the support of
the tie rod to the chassis.
- Remove the tie rod with washer and pad.
- Restrain the rotation of the bolt connecting the
swing-arm to the engine, using a 19 mm spanner.
- Remove nut and washer from the LHS of the vehicle.
- Pull out the pin from the right side and remove
the oscillating arm with the washer on the right.
N.B.
CHECK THAT THE SWINGING ARM DOES NOT INTERFERE WITH THE THROTTLE BODY COMPONENTS IF PULLED USING THE SPACER BUSHING.
N.B.
IF NECESSARY, REMOVE THE CABLE HARNESS SUPPORT BRACKET MOUNTING SCREW.
SUSP - 306
X9 Evolution 500
Suspensions
- Remove the bushing from the bearing on the engine left support.
- Ensure there no signs of wear or seizures on the following components:
• Engine crankcase supports;
• Ball bearing with bushing, on swing-arm;
• Swing-arm roller bearing;
Ensure the bolt to the frame does not show any sign of wear or handling on the surface housing the
roller bearing:
Characteristic
Diameter of shaft:
Ø 18 -0.034 mm
If anomalies are found replace the bearing and the bolt.
- Ensure the bolt connecting the swing-arm to the engine is not worn at the location of the RHS bearing:
Characteristic
Diameter of pin:
Ø 20 -0.041 mm
Overhaul
- Properly support the oscillating arm in the vice.
- Remove the snap ring.
SUSP - 307
Suspensions
- Disassemble the bushing from the ball bearing.
Specific tooling
020376Y Adaptor handle
020412Y 15 mm guide
- Extract the ball bearing by the specific tool.
Specific tooling
001467Y034 Pliers to extract ø 15-mm bearings
001467Y017 Bell for bearings, OD 39 mm
- Remove the roller bearing with the specific tool
N.B.
POSITION THE PLIERS FOR EXTRACTING UNDER THE
UPPER EDGE OF THE ROLLER BEARING.
Specific tooling
001467Y019 Extraction pliers for ø 18 mm bearings
001467Y010 Driver for OD 25 mm bearings
Reassembling the bearings on the oscillating
arm
- Insert the spacer on the ball bearing by the specific tool.
Specific tooling
020376Y Adaptor handle
020362Y 12 mm guide
020357Y 32 x 35 mm adaptor
SUSP - 308
X9 Evolution 500
X9 Evolution 500
Suspensions
- Heat the seat of the bearing on the swing arm.
- Insert the bearing all the way with the specific tool
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020362Y 12 mm guide
020357Y 32 x 35 mm adaptor
N.B.
THE BEARING SPACER MUST BE INSERTED FROM THE INSIDE OF THE SWINGING ARM.
N.B.
DO NOT DETERIORATE THE PAINTED SURFACE WHILE WARMING THE SWINGING ARM.
- Install the snap ring.
- Fit the roller bearing with the specific tool
Specific tooling
020083Y Punch
Replacing the bearings on the engine crankcase
- Extract the left bearing by the specific tool.
Specific tooling
001467Y006 Pliers to extract 20 mm bearings
001467Y031 Bell
SUSP - 309
Suspensions
X9 Evolution 500
- Extract the right bearing with the blanking punch
through the seat of the left bearing (previously removed).
Specific tooling
020363Y 20 mm guide
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
Assembling the bearings on the crankcase
- Heat the connections on the engine crankcase
and insert the bearings to abutment by the modular
punch.
- To install the right bearing, lower the engine.
Specific tooling
020376Y Adaptor handle
020363Y 20 mm guide
020359Y 42x47-mm adaptor
020151Y Air heater
N.B.
WHEN HEATING THE LEFT SEAT MOVE THE HOSE FOR OIL TO THE BRAKE CLAMP AWAY
FROM THE ENGINE CRANKCASE. FOR THE RIGHT PART REMOVE AND MOVE AWAY THE
BRACKET SUPPORTING THE WIRING.
Refitting
- Lubricate the inside tracks of the bearings on the
crankcase.
- Lubricate the roller bearing into the oscillating
arm.
- Lubricate the bearing connection on the oscillating arm/engine pin.
Lubricate the roller bearing connection on the oscillating arm/chassis pin.
SUSP - 310
X9 Evolution 500
Suspensions
- Insert the spacer bushing in the left bearing «A».
- Assemble the engine connecting pin with the
washer «B» and the oscillating arm.
- Install the washer and the flanged nut and move
them close without tightening.
- Check that the tie rod silent block is free from
wear; if not, replace the complete tie rod.
- Check that the 2 tie rod spring pads are in good
working order.
- Assemble the tie rod with the washer and a pad.
- Assemble the tie rod inserting oscillating arm /
engine the connecting pin.
- Fasten the bracket to the chassis by the 2 screws
(with flat and spring washers) and tighten at the
prescribed torque.
Locking torques (N*m)
Tie rod support fixing screws: 33 ÷ 41 Nm
- Apply the rubber buffer and the washer on the tie
and secure it.
N.B.
PAY ATTENTION TO THE TUBES AND FITTINGS OF THE
FUEL SUPPLY SYSTEM ONTO THE INECTOR.
Locking torques (N*m)
Upper tie mounting: 33-41 Nm
- Grease the shaped washer and position it onto
the bearing.
- Insert the securing bolt through the frame.
- Zero the axial play between swing-arm and frame
by tightening the bolt to the prescribed torque.
- Tighten the counter-nut at the prescribed torque.
Locking torques (N*m)
bolt securing swinging arm to chassis 14 ÷ 17
Lock nut 40 ÷ 50
SUSP - 311
Suspensions
X9 Evolution 500
- Tighten the right end of the chassis connecting
pin at the prescribed torque, using a new nut
- Use a 19-mm fork wrench to prevent the rotation
of the pin connecting the oscillating arm to the engine and tighten the right nut (with washer) and the
left nut at the prescribed torque.
Locking torques (N*m)
RHS chassis pin nut 66 ÷ 73 Transmission-side
nut 100 - 120 Muffler-side nut 56 ÷ 70
Shock absorbers
Removal
Proceed as follows:
- Rest the vehicle on the central stand;
- Slightly raise the engine by a jack to free both
shock absorbers;
- Remove the silencer;
- Remove the sides.
- Loosen the shock absorber spring unit fastening
bolt from the support fixed to the engine on the left
side and from that fixed to the silencer support arm
on the right side;
- Loosen the two top screws (one by side) fixing
the shock absorber spring unit to the chassis and
remove the shock absorbers.
Refitting
Perform the operations for removal in the reverse order according to the proper tightening torques.
Locking torques (N*m)
Shock absorber bottom fastening screw: 33 ÷ 41 N•m Shock absorber top fastening screw: 33
÷ 41 N•m
SUSP - 312
X9 Evolution 500
Suspensions
Centre-stand
Centre-stand (Base version)
- Release the springs from the fixing pins.
- Use a socket head wrench on the fixing bolts
keeping the right and left nuts locked.
- Remove the entire stand. For reassembly, perform the operations for removal in the reverse
order according to the tightening torques.
CAUTION
LUBRICATE THE FOLLOWING PARTS WITH GREASE TUTELA Z2: SPRING PINS, BUSHES ON STAND FIXING
BRACKETS.
Locking torques (N*m)
Stand fastening bolt to chassis: 25 ÷ 30 Nm
Side stand
- Release the springs.
- Loosen the nut.
- Extract the screw.
- Remove the switch.
Assembly
Perform the removal operations in the reverse order.
Locking torques (N*m)
Side stand screw: 35 ÷ 40 N•m Side stand switch
screw: 5 ÷ 7 N•m
SUSP - 313
X9 Evolution 500
Suspensions
Electro-hydraulic stand
ELECTRO-HYDRAULIC STAND .
1
2
3
4
5
6
7
8
9
10
Specification
Two stand switches (safety switch RHS and end-run
switch LHS).
Motor for electro-hydraulic pump.
Relay for electro-hydraulic actuator.
Stuck relay signaller.
Centre-stand button
Two fuse holders (one 5A fuse)
Relay and 70A fuse
Centre-stand master-box
Phonic wheel
Digital dashboard assembly.
Desc./Quantity
CONCEPTUAL DIAGRAMS
1
2
3
SUSP - 314
Specification
Pump motor
Diode 1A
Battery
Desc./Quantity
X9 Evolution 500
4
5
6
7
8
9
10
11
12
13
14
15
16
Specification
Fuse 70A
No. 2 relays
Pump wire unit
Stuck relay indicator
Side stand control unit
Fuse 5A
To the main relay
To the instrument panel
Stand control button
the wheel speed sensor
End of stroke button
End of stroke button
To the start up relay
Suspensions
Desc./Quantity
Stand electric system diagram.
G=yellow - V=green - GR=grey - GrN=grey-black - Vi=purple - Ar=orange - ArBl=orange-blue
Stand control unit
1 - Under key power supply
4 - Wheel speed sensor earth
8- Earth
11 - Stand remote control switch control signal
12 - Wheel speed sensor signal
14 - Enable button signal
15 - End of stroke button signal
16 - Stand control button signal
Stuck relay indicator
1 - Under key power supply
3 - To the remote control switches
4 - Remote control switch control signal
5- Earth
6 - To the instrument panel (alarm light)
Removal
- Fix the vehicle steadily and raise it from the back
by a jack
- Release the central stand.
- Release the return springs by a hook.
SUSP - 315
Suspensions
- Extract the 2, left and right hand-side, safety
switches from their housing.
- Remove the two hexagon screws and the stand.
- Remove the fixing bolt.
- Remove the negative power supply cable using
a hexagon wrench.
- Remove the positive power supply cable releasing the screw under the rubber cap.
SUSP - 316
X9 Evolution 500
X9 Evolution 500
Suspensions
- Remove the 4 centre-stand plate fixing bolts.
Overhaul
- Check that the stand exhibits no wear or deformation.
- Check that the engine crankcase resting roller
rotates freely and is free from wear. If required, replace it removing the split pin and the two shim
adjustment washers.
- Ensure the housings of the 4 articulating bushes
are not worn.
- Check the safety switch and end-run sensor pins
are not deformed.
- Check the driving motion of the stand's electrohydraulic actuator is free and that this rotates freely on the two roller bearings.
- Check the conditions of the O-ring reducing the
play with the drive shaft.
SUSP - 317
Suspensions
- Check that the spring coupling pin groove is free
from wear.
- In case of anomalies, replace the stand.
- Check the diameter of the working surfaces of the
4 bushings.
Characteristic
Working diameter
Ø 14,9 +0 - 0,018
- Check that there are no breakages or deformations on the switch couplings and on the return
spring support pin.
In case of anomalies, replace the complete support.
- Ensure the return springs are not yielded or broken.
Characteristic
Unloaded spring length:
137mm
SUSP - 318
X9 Evolution 500
X9 Evolution 500
Suspensions
Refitting
- remove the caps closing the two control joint roller bearing seats.
- Lubricate the bearings.
Recommended products
AGIP GREASE MU3 Grease for odometer
transmission gear case
Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
- Grease the 4 bushings and install the stand on
the bracket using the 2 bolts with the nut from the
inside.
Locking torques (N*m)
Centre-stand bolt: 25 ÷ 30 Nm
- Check that the switches exhibit no wear or deformation.
- Check the control pin sliding.
- Use a multimeter to measure the continuity with
pin at rest.
- Check that the circuit opens as soon as the control pin is pressed.
Specific tooling
020331Y Digital multimeter
- Check the virtual earth for both switches' pins.
Specific tooling
020331Y Digital multimeter
SUSP - 319
Suspensions
X9 Evolution 500
End of stroke switch installation
- Place the stand to end of stroke (as in the raised
vehicle).
- Keep the nut resting against the support, tighten
the end of stroke switch to preceive the contact
with the abutment.
- From this position, tighten the switch by 0.5 - 1
turns more.
- Keeping the switch in the fixed position, tighten
the lock nut at the prescribed torque.
N.B.
FAILURE TO OBSERVE THIS PROCEDURE CAN CAUSE
TWO FAULTS:
1. SWITCH TOO TIGHTENED: THE ELECTRO-HYDRAULIC
ACTUATOR THRUST ENDS BEFORE THE TRIPPING
POINT AND THE STAND RETURNS TO REST, RECALLED
BY THE SPRINGS.
2. SWITCH LITTLE TIGHTENED: THE ACTUATOR THRUST
CONTINUES WITH STAND AT THE END OF STROKE;
SUCH FAULT CAUSES AN OVERLOAD ON MECHANICAL
AND ELECTRIC COMPONENTS.
Locking torques (N*m)
End of stroke switch: 15 ÷ 20 Nm
N.B.
TO IMPROVE THE SAFETY IT IS SUGGESTED TO PROCEED WITH THE FOLLOWING CHECK:
CONNECT THE MULTIMETER TO THE END-RUN SWITCH AND THROUGH THE "BEEP" CONTINUITY CHECK, ENSURE THE OPEN-CIRCUIT IS OBTAINED BEFORE REACHING THE ENDRUN.
Electro-hydraulic actuator
- Ensure the silent-block does not show signs of
wear or deformations.
- Ensure there are no leakages between the stanchion seal ring and the mating planes.
Finding any anomalies, proceed by replacing the
actuator.
- Position the actuator vertically.
- Remove the draining screw.
- Remove the bleed screw and check the oil outlet.
If any oil exits tighten the bleeding screw and proceed with the level check, otherwise pour oil
through the filler hole until this starts escaping the
bleed hole thus completing the top-up procedure.
SUSP - 320
X9 Evolution 500
Suspensions
For a practical level check, proceed as shown in
the figure. The level is correct when it is at ~27 mm
from the loading screw resting surface.
Recommended products
ARNICA 46 Electro-hydraulic centre-stand
Highly viscous oil for hydraulic controls
Characteristic
Prescribed oil quantity:
145 ± 2 cm3
Enable switch installation
- Select the stand position that gives rise to the
smalles distance between cam and support of the
enable switch.
- Set the switch and keeping the rear nut in contact
with the support, tighten the switch to perceive the
contact with the cam.
From this position, tighten the switch by 1.5 turns
more.
- Maintaining the safety switch in the pre-determined position lock the counter-nut at the prescribed torque.
- Attach the electrical contacts and position the
protective cap.
Locking torques (N*m)
Safety switch: 15 ÷ 20 Nm
Electrical controls
Using a multimeter measure the resistance between the positive pole and the starter motor earth.
Electric characteristic
Standard resistance 0,3 ÷ 1 OHM
SUSP - 321
Suspensions
X9 Evolution 500
This is a nominal value and the starter motor is to
be considered as faulty for values close to 0 OHM
(short-circuit) or infinite (open circuit).
To perform a more thorough inspection it is necessary to proceed with the measurement of the
absorbed currents whilst running.
- Secure the actuator in a vertical position.
- Using a 12V 14Ah battery, fully charged, power
the starter motor and, with an ammeter record the
absorbed current readings. Perform two measurements:
1. Unloaded.
2. Absorption when at end-run.
N.B.
DO NOT INVERT THE POLARITY AND USE CABLES OF SUITABLE SECTION.
N.B.
THE LOADLESS ABSORPTION MEASURE IS AVAILABLE FOR FEW SECONDS; AN ANALOGUE
MULTIMETER SHOULD BE USED FOR THIS REASON.
THE MAX CURRENT MEASUREMENT WITH ACTUATOR AT END OF STROKE MUST BE PERFORMED QUICKLY TO MINIMISE THE COMPONENT HYDRAULIC AND ELECTRIC STRESSES.
Electric characteristic
Loadless absorbed current:
30A
Maximum current absorbed at end of stroke:
70A
The maximum normal current is ~ 60A. Lower currents can be caused by a system unable to reach the
calibration pressures, so the drainage and level check operations should be repeated. Perform also a
vehicle functional check. If the actuator cannot raise the vehicle, replace it. If loadless absorption currents are too high, replace the motor, if the fault continues, replace the actuator. To replace the motor,
remove the 2 fixing screws and lubricate the pinion.
Recommended products
AGIP GREASE MU3 Grease for odometer transmission gear case
Soap-based lithium grease with NLGI 3; ISO-L-XBCHA3, DIN K3K-20
SUSP - 322
X9 Evolution 500
Suspensions
- Connect the negative supply cable to the lower
starter motor fixing screw, and the positive to the
battery with its cap.
- Insert the electro-hydraulic actuator inside the
centre-stand mechanism.
N.B.
ENSURE THE BOLT END RING TOUCHES THE FLAT SURFACE OF THE MECHANISM.
- Position the electric supply system on the outer
side of the motor and apply a zip tie
N.B.
INGNORING THIS ASSEMBLY RULE MAY RESULT IN THE
DAMAGE OD THE SYSTEM DUE TO THE HEAT GENERATED BY THE EXHAUST PIPE.
- Fasten the actuator to the chassis by the screw
and the flat and glover washers at the prescribed
torque.
- Manually actuate the stand and check that the
fixing of the wiring to the chassis causes no tensioning following the vertical movement of the actuator.
Locking torques (N*m)
Electro-hydraulic actuator screw: 20÷25 Nm
N.B.
TIGHTEN THE ACTUATOR LOCK-NUT TO THE FRAME WITH THE CENTRE-STAND DOWN. DOING SO WILL RESULT IN SLIGHTLY PRE-LOADING THE SILENT-BLOCK THUS ELIMINATING
ANY NOISE WHEN RIDING.
- Using an adequate hook reattach the centre-stand return springs. - Grease the moving points.
Recommended products
AGIP GREASE PV2 Grease for steering bearings, bolt seatings for swinging arms and faying
surface of driven pulley spring (only pulley side)
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2
SUSP - 323
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
X9 Evolution 500
Braking system
Interventions rules
General rules for interventions on the brake hydraulic system
WARNING
THE BRAKING SYSTEM FLUID IS CORROSIVE: USE ALWAYS SAFETY GLOVES.
IN CASE OF ACCIDENTAL CONTACT WITH YOUR EYES, WASH WITH WATER.
EXHAUST BRAKING SYSTEM FLUID IS NOXIOUS FOR THE ENVIRONMENT.
COLLECT AND DISPOSE ACCORDING TO THE REGULATIONS IN FORCE.
IN NORMAL DRIVING CONDITIONS, REPLACE THE FLUID EVERY TWO YEARS.
IF THE BRAKES ARE SUBJECT TO HEAVY OPERATION, REPLACE THE FLUID MORE FREQUENTLY.
UPON REASSEMBLY, THE PARTS REUSED MUST BE PERFECTLY CLEAN AND FREE FROM
OIL, GREASEAND FUEL: CAREFULLY WASH USING DENATURATED ALCOHOL.
N.B.
TO TOP UP, USE ONLY FLUID DOT4 - NHTSA 116.
HYDRAULIC FLUID IS HIGHLY CORROSIVE FOR PAINTED SURFACES.
THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, I.E., IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR.
IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, IT WILL LEAD TO
INEFFICIENT BRAKING, DUE TO THE LOWER BOILING POINT OF THE FLUID.
N.B.
ALWAYS TAKE FLUID FROM SEALED CONTAINERS.
N.B.
RUBBER PARTS MUST NOT BE IMMERSED IN ALCOHOL FOR OVER 20 SECONDS.
AFTER WASHING, THE PARTS MUST BE DRIED WITH A JET OF COMPRESSED AIR AND A
CLEAN CLOTH.
SEALING RINGS MUST BE IMMERSED IN THEIR LIQUID; THE PROTECTIVE PRF1 MAY BE
USED.
WARNING
THE PRESENCE OF THE BRAKE FLUID ON THE DISC OR ON THE PADS DECREASES THE
BRAKING EFFICIENCY.
IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A GOOD SOLVENT.
Rear brake calliper
Removal
Check that the brake pipes, gaskets and unions are in good condition. In case of fluid leaks on the brake
calipers, replace them.
BRAK SYS - 325
Braking system
X9 Evolution 500
- Remove the rear wheel.
- Remove the snap ring of the pad retaining pin.
- Using a key, partially slide off the pad retaining
pin until the circlip is released.
- Remove the screws fixing the brake calliper to
the bracket, then remove the brake calliper complete with pipe.
- Fully extract the pads retain pin, spring and pads.
N.B.
SHOULD THE BRAKE CALLIPER BE REPLACED OR SERVICED, BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET, LOOSEN THE OIL HOSE FITTING
AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAMINED.
BRAK SYS - 326
X9 Evolution 500
Braking system
Overhaul
- Remove the rear brake calliper
- Suitably support the brake calliper in a vice
- Remove the two calliper coupling screws as
shown in the photograph.
- Remove the two plungers from the calliper body
with the aid of short blasts of compressed air
through the brake fluid feed holes.
- Remove the dust ring and the O-ring of each half
calliper.
- Remove the two O-rings in the right half-calliper.
N.B.
WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO
SCRATCH THE HALF CALLIPER SEATS
- Check that the pistons and their seats show no
scratches.
- Wash and blow all the components carefully.
- Fit new sealing rings and dust guards.
- Refit the plungers in their seats being careful to
lubricate with brake fluid
- Couple the half-caliper and tighten the two screws at the prescribed torque.
Locking torques (N*m)
Calliper coupling screws: 20-25 N•m
BRAK SYS - 327
Braking system
X9 Evolution 500
Refitting
- The rear break calliper can be recognised by its
Ø 34 mm plungers and the bleed screw as shown
in the figure.
- Insert the brake pads into the caliper according
to the arrow that indicates the direction of rotation
of the brake disc
- Insert the pad fixing pin and the retain spring arranging its ends facing the bleed screw.
- Insert the circlips on the pad fixing pin.
N.B.
FAILURE TO RESPECT THE PAD POSITIONING REQUIREMENTS WITH RESPECT TO THE DIRECTION OF ROTATION COULD COMPROMISE PROPER BRAKE FUNCTIONING AND NOISELESSNESS.
BRAK SYS - 328
X9 Evolution 500
Braking system
- Keep the pads in contact with the pistons and
insert the caliper into the brake disc.
- Fasten the caliper to the support by the two
screws with spring washer
- Fasten the brake pipe union to the caliper and tighten at the prescribed torque
- Bleed the system and replace the rear wheel.
N.B.
IF YOU REMOVE THE REAR BRAKE CALIPER SUPPORT PLATE, UPON REASSEMBLY YOU
MUST BEND THE WASHER EDGES ON THE CRANKCASE FIXING SCREW HEAD TO PREVENT
LOOSENING.
Locking torques (N*m)
Rear calliper support on crankcase retainer 20 ÷ 25 Caliper to the support: 20÷25 N•m Brake pipe
connection 20 to 25 N•m
Front brake calliper
Removal
- Check the good condition of the brake hoses, of
the seals and of the respective fittings. If any loss
of brake fluid is discovered at the brake callipers,
the callipers must be replaced.
- Remove the two retaining screws of the front
brake calliper at the fork as indicated in the photo.
N.B.
BEFORE STARTING TO SERVICE OR REPLACE THE CALLIPER, LOOSEN THE CONNECTION OF THE PRESSURE
HOSE AT THE BRAKE CALLIPER AFTER HAVING DEPRESSURISED THE CIRCUIT AS A WHOLE.
BRAK SYS - 329
Braking system
Overhaul
- Remove the front brake calliper and the corresponding pads.
- Remove the two pistons from the calliper body
with the aid of small blasts of compressed air
through the brake fluid feeding hole. A piece of
rubber pipe may be needed to seal with the compressor gun.
N.B.
PAY ATTENTION WHEN THE PISTONS COME OUT AS THE
STRONG BLASTS OF COMPRESSED AIR CAN MAKE THE
PISTONS COME OUT OF THE PUMP BODY VIOLENTLY
- Remove the dust-cover ring «A» and the sealing
ring «B» of each piston.
N.B.
DO NOT SCRATCH THE SEATS WHILE REMOVING THE
RINGS.
- Check that the pistons and relevant seats exhibit
no scratches.
- Wash only with alcohol and blow all the components carefully.
- Fit new sealing rings and dust guards.
- Assembly the pistons into the appropriate seats
being careful to lubricate the sealing ring «B» with
brake fluid. The dust guard ring «A» has an internal groove with specific grease.
BRAK SYS - 330
X9 Evolution 500
X9 Evolution 500
Braking system
- Decouple the floating support of the calliper body
separating the 2 rubber dust-covers off their seats.
N.B.
TO EXTRACT THE LONG DUST-COVER PULL IT BY ITS
HEAD AND INTRODUCE THE BELLOWS ( LOCATED ON
THE OTHER SIDE) INTO THE CALLIPER HOLE. LUBRICATE THE SLIDING PINS WITH SPECIFIC GREASE (APPROPRIATE FOR RUBBER GASKETS).
- After cleaning and replacing, replace all parts in the reverse order.
Refitting
- Attach the front brake sliding plate to the fork by
the two screws with spring washer at the prescribed torque
- Fasten the brake pipe union to the caliper and
tighten at the prescribed torque, orientating the
union towards the front and parallel to the vehicle
axis, as shown in the figure
Locking torques (N*m)
Brake calliper fastening screws: 20-25 N•m Pipe /
brake calliper coupling 20 ÷ 25
Rear brake disc
Removal
- Remove the rear brake caliper
- Remove the wheel axle and the brake disc with
hub.
- To remove the brake disc from the hub, support
the unit in a vice and tighten the 5 fastening bolts
with self-locking nuts.
Refitting
- To re-assemble the brake disc on the hub, carry out the removal operations in the reverse order
arranging the brake disc on the hub on the side opposed the wheel keying
BRAK SYS - 331
Braking system
X9 Evolution 500
N.B.
THE DISC FACE WITH THE DIRECTION ARROW MUST FACE THE VEHICLE OUTSIDE.
- Lubricate the seat on the wheel axle of the bearing supporting the muffler with recommended grease.
N.B.
APPLYING AN EXCESSIVE QUANTITY OF GREASE MAY IMPAIR THE BRAKE PERFORMANCE.
Recommended products
AGIP GREASE PV2 Grease for steering bearings, bolt seatings for swinging arms and faying
surface of driven pulley spring (only pulley side)
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2
- Insert the hub - disc assembly in the wheel axle
Locking torques (N*m)
Bolt fixing the disc to the hub: 14÷17
Disc Inspection
Checking the disc is very important; it must be perfectly clean, without rust, oil, grease or other dirt
and free from scratches.
- Using a micrometer, check the disc thickness as
shown in the figure.
Characteristic
Standard thickness:
5 +0.2-0.1 mm
Minimum admissible thickness after use:
4,5 mm
- Repeat the measurement at no fewer than six
points on the disc.
- Check the regular nature of the rotation of the
brake disc assembly using the appropriate tool
fixed onto the brake calliper as shown in the photo.
- Suitably fasten the flange on the wheel axle by a nut and the original spacer, and a bearing Ø 17mm
BRAK SYS - 332
X9 Evolution 500
Braking system
N.B.
SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN
IN ORDER TO ROTATE THE DISC.
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Max. deviation allowed:
0.1 mm
- If you detect incorrect values, replace the disc. If the anomaly persists, replace the hub.
Front brake disc
Removal
- Remove the front wheel.
- Adequately support the front wheel and remove
the break disc operating on the five screws shown
in the photograph.
Refitting
- Perform the removal operations in the reverse
order according to the direction of rotation of the
disc, as shown by the arrow on the disc.
- Tighten the 5 screws of each disc at the prescribed torque
Locking torques (N*m)
Brake disc tightening torque: 5÷6
BRAK SYS - 333
Braking system
Disc Inspection
Checking the disc is very important; it must be perfectly clean, without rust, oil, grease or other dirt
and free from scratches.
- Using a micrometer, check the disc thickness as
shown in the figure.
Characteristic
Standard thickness:
5+0,1-0,2mm
- Repeat the measurement in at least 6 points of
the disc.
Remove the front brake caliper
- Place the magnetic base with comparator on the
brake caliper support bracket as shown in the figure
- Place the comparator on the disc outside edge
- Lift the front wheel, make it rotate and check the disc deviation.
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Max admissible deviation:
0,1 mm
Front brake pads
Removal
- Remove the front brake calliper unscrewing the
2 retainers but leaving the hoses connected.
- Disengage the upper part of the pad from the seat
located into the calliper body.
BRAK SYS - 334
X9 Evolution 500
X9 Evolution 500
Braking system
- Using a calliper, remove the 2 retaining pins of
the pad sliding pin.
- Unscrew the retaining pin and the pads too.
- Check that the thickness of the friction material
is more than 1.5 mm.
- Otherwise, replace it.
Refitting
- Assemble the brake pads into the calliper inserting the upper tip into the groove and pressing it
towards the thrust spring to facilitate inserting the
pin.
- Insert the pad fixing pin from the reaction plate
side, so that the pin head clicks in the seat in the
groove on that plate.
BRAK SYS - 335
Braking system
- Insert the 2 locking split pins of the pin orientating
the heads towards the calliper body as shown in
the figure.
Rear brake pads
Removal
- Remove the rear brake calliper
- Remove the brake pad and check there are no
faults or warping. If it does, replace it.
- Check that the thickness of the friction material
is over 1.5 mm. Otherwise, replace it.
Refitting
- Insert the brake pads according to the direction
of rotation of the brake disc, as indicated by the
arrow on the anti-vibration pad.
BRAK SYS - 336
X9 Evolution 500
X9 Evolution 500
Braking system
- Insert the pad mounting pin and the retaining
spring with its ends facing the bleed screw as
shown in the figure.
- Insert the retaining ring on the pin
- Fasten the rear brake caliper to the bracket and tighten the 2 screws at the prescribed torque.
Locking torques (N*m)
Rear brake caliper fastening screw torque: 20÷25
Fill
Rear - combined
- Rest the vehicle on the central stand and on a flat
ground.
- Remove the oil tank cover (LH) releasing the 2
screws so as to top up the fluid
The left brake lever allows controlling the front left
brake caliper and the rear brake caliper at the
same time.
To bleed the integral system, start by bleeding the
rear brake caliper.
- Fill the left brake fluid tank to max level.
- Remove the rubber cap from the bleeding screw
and insert a rubber pipe to recover the brake fluid.
BRAK SYS - 337
Braking system
X9 Evolution 500
- With the left-had brake lever, load the system and
bring it up to the required pressure.
- Keeping the left-hand brake lever pulled, loosen
the bleed screw to purge the air. Then tighten the
bleed screw.
- Repeat the operation until only brake fluid comes
out of the rubber pipe.
- The above operations must be repeated for the
pressure adjustment valve and for the LH front
caliper
- To access the regulating valve, it is necessary to remove the front shield.
- Top up the brake fluid to the right level in the tank.
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
N.B.
IF DURING DRAINAGE AIR STILL COMES OUT, CHECK ALL UNIONS: IF THEY EXHIBIT NO
FAILURES, CHECK THE AIR INLET IN THE VARIOUS SEALING GASKETS OF THE PUMP AND
IN THE PISTONS.
DURING THE OPERATION, OIL MAY LEAK FROM THE DRAINAGE SCREW ON THE CALIPER
AND ON THE DISC: IN THIS CASE, DRY THE CALIPER AND DEGREASE THE DISC.
If necessary, bleeding can be done using a special vacuum pump
Specific tooling
020329Y MityVac vacuum-operated pump
Locking torques (N*m)
Circuit bleed calliper fitting 12 - 16
BRAK SYS - 338
X9 Evolution 500
Braking system
Front
- Rest the vehicle on the central stand and on a flat
ground.
- Remove the oil tank cover (LH) releasing the 2
screws so as to top up the fluid
- Fill the right brake fluid tank to max level.
- Remove the rubber cap from the bleeding screw.
- Insert a rubber pipe in the bleeding screw to allow
recovering the brake fluid.
- Move the RH brake lever to load the system and
put it under pressure.
- Keep the RH lever actuated and loosen the
bleeding screw to allow the exit of the system inside air. Tighten the bleeding screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and fit the rubber cap on the bleeding screw.
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
It is possible to bleed by a specific vacuum pump, if required.
N.B.
IF DURING DRAINAGE AIR STILL COMES OUT, CHECK ALL UNIONS: IF THEY EXHIBIT NO
FAILURES, CHECK THE AIR INLET IN THE VARIOUS SEALING GASKETS OF THE PUMP AND
IN THE PISTONS.
DURING THE OPERATION, OIL MAY LEAK FROM THE DRAINAGE SCREW ON THE CALIPER
AND ON THE DISC: IN THIS CASE, DRY THE CALIPER AND DEGREASE THE DISC.
Specific tooling
020329Y MityVac vacuum-operated pump
Locking torques (N*m)
Circuit bleed calliper fitting 12 - 16
BRAK SYS - 339
Braking system
X9 Evolution 500
Brake fluid level check
- Rest the vehicle on a flat ground and on the central stand.
- Remove the front brake pump cover «C» releasing screw D».
- On the RH side, remove the PICS display to access the combined brake pump tank.
- Check the brake fluid level by the special indicator located on the pump, as shown in the figure
- If the level is below minimum, fill by the screws
shown in the figures
- Remove the gasket and fill with fluid DOT 4 to
fully cover the indicator
- If required, restore the original position of the bellows membrane (a fluid drop causes the membrane deformation due to the decrease of the
inside volume)
For re-assembly, perform the operations for removal in the reverse order according to the tightening
torques of the tank cover screws.
Locking torques (N*m)
BRAK SYS - 340
X9 Evolution 500
Braking system
Brake pump tank screws: 1÷1,5
Front brake pump
Removal
- Remove the front handlebar cover.
- Drain off the braking system corresponding to the
circuit being tested.
- Remove the two fixing screws from the brake
pump to the handlebar indicated in the photograph.
- Remove the oil pipe fitting from the pump undoing
the screw indicated in the figure.
- Remove the stop light switch connector
BRAKE PUMP TECHNICAL DATA
Specification
Pump right piston diameter:
Pump left piston diameter:
Desc./Quantity
Ø 12
Ø 15
Refitting
- For re-assembly, perform the operations for removal in the reverse order according to the tightening torques.
N.B.
BE VERY CAREFUL TO THE PROPER INSTALLATION OF
THE TAB ON THE PUMP U BOLT INTO THE HOLE ON THE
HANDLEBAR (SEE FIGURE).
Locking torques (N*m)
Oil pipe joint to the pump: 20 - 25
BRAK SYS - 341
Braking system
Rear brake pump - combined
Removal
Replace the pressure distribution valve
If problems are discovered in the brake force distribution between the front left brake calliper and
the rear brake calliper (e.g. equal surface contact
and braking of both the wheels, the rear brake engages but the front brake does not operate or vice
versa, or the brakes function in completely different modes, or the distribution valve does not function correctly), proceed as described below:
- Bleed the brakes of the combined system.
- Remove the front knee guard.
- Loosen fitting 1 shown in the figure for the rear
brake calliper.
N.B.
INSERT A CLOTH UNDER THE DISTRIBUTION VALVE TO
AVOID BRAKE FLUID DRIPPING ONTO THE PLASTIC OR
OTHER COMPONENTS OF THE SCOOTER.
- Remove fitting 2 of the front brake calliper.
- Remove fluid inlet fitting 3 from the pump to the
valve.
- Remove the 2 TCEI socket head retaining screws
of the holding the valve to the frame in the 2 bores
shown in the figure.
- Remove the valve and replace with a new valve.
BRAK SYS - 342
X9 Evolution 500
X9 Evolution 500
Braking system
Refitting
To refit carry out the disassembly steps but in reverse order.
N.B.
USE NEW COPPER GASKETS ON THE JOINTS.
- Tighten the screws fixing the valve to the chassis,
but above all tighten the brake piping to the prescribed locking torques.
- Fill and purge the braking system as described in
the relevant section.
Locking torques (N*m)
Coupling for oil on the integral braking system
pump 16 ÷ 20 Coupling on the integral braking
system device (from the pump) 20 ÷ 25 Front
brake calliper - integral braking system device
coupling 20 ÷ 25 Rear brake calliper - integral
braking system device coupling 20 ÷ 25
BRAK SYS - 343
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
X9 Evolution 500
Cooling system
Circuit diagram
The cooling system is a forced circulation type system, with continuous venting and air pressurisation.
Circulation takes places by a centrifugal pump driven by the countershaft.
The pump delivers the coolant to the thermal group.
The two-way thermostat support is connected in output to the head. One way is connected to the pump
and the other to the radiator (of the horizontal circulation type).
The radiator output is directly connected to the pump.
The expansion tank is connected in parallel to the radiator.
The radiator hot box is connected to the upper side of the expansion tank (in air).
The radiator cold box is connected to the lower side of the expansion tank (in the fluid).
When the engine is cold, the thermostat output to the radiator is closed, even though there is still a little
flow for de-aeration obtained by a hole into the closing plate.
In this case, the circulation into the thermal group is active to ensure an even heating.
Once the working temperature has been reached, the main circulation on radiator and expansion tank
starts.
With the small openings in the thermostat there is a flow overlapping (recirculation and main one).
When the temperature is higher, the thermostat allows excluding the recirculation to favour the main
circulation.
In this case, the flow is consistent in the expansion tank as well, and this ensures a continuous automatic
venting.
COOL SYS - 345
X9 Evolution 500
Cooling system
For the system venting during the circuit filling step, there is a special union at the top of the head (see
filling rules).
To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection
system.
TECHNICAL SPECIFICATIONS
Specification
Cooling system capacity
Prescribed fluid
Desc./Quantity
1.7 l
Mixture of 50% water and fluid for sealed circuits (PARAFLU
MOTO RIDER)
Cap calibrated at 0.9 bar
Sealing pressure
THERMOSTAT
Specification
Type
Starts opening
Desc./Quantity
Wax-type, with deviator
82 ± 2°C
ELECTRIC VENTILATION
Specification
Type
Electric ventilation starts at
Electric ventilation stops at
Desc./Quantity
With piston
107°C
103°C
WATER PUMP
Specification
Type
Control
Desc./Quantity
Centrifugal
Coaxial at the countershaft
RADIATOR
Specification
Type
Desc./Quantity
Aluminium, with horizontal circulation
EXPANSION TANK
Specification
Calibration
Electric fan check
- Connect the injection diagnostic tester and select
the «ERRORS» function in this menu.
- Check any failures in the electric fan control circuit (see «Injection»chapter)
Specific tooling
020460Y Scooter diagnosis and tester
COOL SYS - 346
Desc./Quantity
Automatic bleeding, in parallel with the radiator
X9 Evolution 500
Cooling system
- Select the menu on the "ACTIVE DIAGNOSIS"
function and start the electric fan operation simulation (see "Injection" chapter).
- If the electric fan is certainly efficient, check the
ventilation start and stop temperatures.
- Select the «PARAMETERS» function in this
menu to display the coolant temperature.
Electric fan starts: 107°C
Electric fan stops: 103°C
- If non-conforming values are detected, replace
the injection control unit (see «Injection» Chapter).
- If the analogue instrument temperature is close
to the red zone, but the degrees indicated by the
diagnostic tester are below the electric fan start
temperature, check the temperature sensor on the
head and the relevant injection circuit (see «Injection» chapter);
N.B.
THE ELECTRIC FAN TEMPERATURE AT 107° C CAN ONLY BE MANAGED BY A SYSTEM SUPPLIED WITH A 50% MIXTURE AND PRESSURISED AT 0.9 BAR.
AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOILING TEMPERATURE BEFORE THE ELECTRIC FAN STARTS WORKING.
IN CASE OF AN INCREASE OF THE ELECTRIC FAN START TIME, CHECK THE THERMOSTAT
OPENING TEMPERATURE AND CHECK THAT THE COOLANT DENSITY IS CORRECT. THE OPTIMUM DENSITY IS OBTAINED WITH A 50% WATER / 50% COOLING CIRCUIT FLUID MIXTURE.
System sealing check
- Check the proper circuit sealing when it is under
pressure and at the temperature.
- For a more accurate check, wait until the system
has cooled down since small leaks may not be
visible due to evaporation
- The water pump is provided with a drainage hole
in case of leaks from the cooling system mechanical seal, or from the shaft sealing oil guard.
- If coolant or oil leaks are detected, inspect the pump (see Flywheel cover chapter).
N.B.
COOL SYS - 347
Cooling system
X9 Evolution 500
DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OBSERVE THIS REGULATION CAN CAUSE IRREVERSIBLE DEFORMATION TO THE SEALING
GASKETS.
Coolant replacement
System top-up instructions
- Prepare the mixture of 50% water and 50% coolant.
- Fill the system to reach a level ranging between
the MIX and MAX levels indicated in the expansion
tank filler.
- Do not close the expansion tank with the cap.
- Use a transparent hose to connect the venting
union with the expansion tank filler.
- Loosen the vent and start the engine.
- Keep it open until the air has been fully vented.
- Close the bleed screw.
- Stop the engine.
- Restore the level into the expansion tank and tighten the cap.
- Start the engine and let it warm up to reach the electric ventilation temperature.
- Stop the engine.
- Restore the level with cold engine.
CAUTION
ELECTRIC VENTILATION IS CONTROLLED BY THE TEMPERATURE MEASURED AT THE HEAD.
THE ELECTRIC VENTILATION START DOES NOT MEAN THAT THE VENTING HAS BEEN COMPLETED.
VENTING IS COMPLETE WHEN THE EXPANSION TANK TEMPERATURE RISES.
COOL SYS - 348
X9 Evolution 500
Cooling system
Water pump - overhaul
In case of noise or fluid leaks from the water pump
drainage hole, inspect the pump as described in
the "Flywheel cover" chapter.
Proceed to carry out a few preliminary operations
as described below:
- Rest the vehicle on the central stand and on a flat
ground.
- Remove the bottom RH side and the RH footboard as described in the "Body" chapter;
- Remove the silencer to access the flywheel cover;
- Empty the cooling system, removing the hoses
located on the water pump cover and the loading
cap located on the expansion tank.
- Open the water pump cover shown in the figure
by loosening the 6 fixing screws and proceed to
the pump overhaul.
- Once the fault has been fixed and all components
have been replaced, fill and drain the system.
N.B.
TO REPLACE THE COOLING FLUID AND THE AIR BLEED
AS LISTED IN THE PROGRAMMED MAINTENANCE OPERATION, SEE THE «COOLING» CHAPTER.
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE
ENGINE IS COLD.
Characteristic
Cooling system
approx. 1.8 l
See also
Flywheel cover
Chassis
COOL SYS - 349
Cooling system
X9 Evolution 500
- Make sure that the water pump shaft is not worn
on the delivery in contact with the chassis, in the
area where the oil seal works and on the intake.
- Make sure that the work surfaces of the ceramic
seal are not lined or worn.
- Make sure the impeller is not deformed or
cracked.
- Make sure that the plastic impeller is perfectly
attached to the metal part.
- Make sure the pump cover is not deformed or
cracked.
- Make sure the o-ring seal is in good condition.
- Make sure that the tab on the blow-by closes
correctly.
Water pump ceramic seal
Our Leader, Quasar, and Master liquid cooled engines are equipped with water pumps fitted with the
ceramic seal in the subject. This component is intended to guarantee the leak tightness of the coolant
COOL SYS - 350
X9 Evolution 500
Cooling system
in relation to the pump shaft. The seal achieved via two special ceramics, a static one and a spinning
one, kept in contact by the thrust of a spring, coaxially mounted onto the pump shaft. The efficiency of
this system is guaranteed by the accurate machining and cleaning of the components as they are fitted;
in any case, ceramic seals are subjected to a running in period. During this period (1,000 ± 1,500 km),
there may be small leaks through draining holes, which remain visible on the aluminium crankcase.
This phenomenon is particularly visible there where the hole is more exposed (Quasar and Master). In
such cases we recommend cleaning the casing in order to be able to check again for leaks after a
distance of more than 1500 km. If leaks continue or in the event of real losses, the ceramic seal should
be replaced. For these operations, observe the tools and instructions given in the relevant service
station manuals.
Note: The ceramic seal may be overhauled according to the following couplings:
•
Coupling "A": seal ring no. 485084 with ceramic seal no. 486216
•
Coupling "B": seal ring no. 841329 with ceramic seal no. 841330
The couplings above may be selected according to their availability, as they are interchangeable.
Thermostat
Check
Before proceeding to disassemble, carry out a few
checks:
- Connect the diagnostic tester and select the «PARAMETERS» function (see Injection chapter).
- Start the cold engine and let it warm up.
- Manually check the moment when there is a sudden increase in temperature at the output of the
radiator cold box.
N.B.
THERE SHOULD BE A SLIGHT AND GRADUAL HEATING
CAUSED BY A SMALL PASSAGE ON THE THERMOSTAT
TO THE OFF POSITION.
Specific tooling
020460Y Scooter diagnosis and tester
COOL SYS - 351
Cooling system
X9 Evolution 500
- Check the temperature read by the diagnostic
tester.
Thermostat opening starts: approx. 80°C
- If opening occurs at different temperatures,
check the thermostat.
- Remove the thermostat as described in the flywheel cover paragraph.
- Visually check that the thermostat exhibits no
mechanical faults.
- Prepare a metal container with approx. 1 litre of
water.
- Immerse the thermostat, keeping it in the centre
of the container.
- Immerse the multimeter temperature probe close
to the thermostat.
- Warm up the container using the heat gun.
- Heat the water and periodically pull the thermostat out until its opening becomes visible.
- Insert a thin copper wire between the seat and the thermostat closing plate.
- Keep the wire into position until locking up is perceived.
- Let water and thermostat cool down.
- Progressively heat the water keeping the thermostat immersed by the wire.
- Check the opening temperature when the thermostat is released from the wire.
Opening starts temperature approx. 82° C
Specific tooling
020331Y Digital multimeter
020151Y Air heater
- Heat up until the thermostat is completely open:
N.B.
HEATING SHOULD BE GRADUAL.
N.B.
AVOID CONTACT BETWEEN THERMOSTAT AND CONTAINER FOR A CORRECT TEST PERFORMANCE.
COOL SYS - 352
X9 Evolution 500
Cooling system
- If incorrect values are detected, replace the thermostat.
- Repeat the filling and bleeding procedure.
diagnosis
Excessive system pressure
1 - Check the expansion tank cap efficiency.
N.B.
THE CAP IS EQUIPPED WITH A PRESSURE RELIEF VALVE CALIBRATED AT 0.9 BAR.
There is also a valve that must allow air inlet during the cooling step.
YES go to 2 NO go to 3
2 - Check the head gasket seal (see «Thermal group and timing system» chapter)
3 - Replace the cap.
Cooling fluid consumption
1 - Check the system outside seals as described above.
YES go to 2 NO go to 3
2 - Check the head gasket seal (see «Thermal group and timing system» chapter)
- If water leaks are detected in the engine oil, inspect the pad on the head cooling circuit.
3 - Fix any damaged seals.
Oil in the fluid
1 - Presence of oil in the coolant.
YES go to 2
2 - Check the head gasket seal (see «Thermal group and timing system» chapter)
COOL SYS - 353
INDEX OF TOPICS
CHASSIS
CHAS
X9 Evolution 500
Chassis
Seat
- Raise the saddle
- Remove the gas shock absorber coupling pin;
- Remove the 3 screws fixing the saddle plate to
the central cover and remove the saddle.
Rear handlebar cover
- Loosen the 3 fastening screws;
- Disconnect the electric connectors,
- Remove the rear handlebar cover.
Instrument panel
- Remove the upper shield back plate.
- Loosen the 5 nuts of 10 mm holding the instrument panel.
CHAS - 355
Chassis
Front handlebar cover
- Remove the 2 fixing screws «C» of the intercom
radio display;
- Disconnect the electric connectors,
- remove the radio-intercom display;
- Remove the right oil pump cover;
- Loosen the 2 lower handlebar cover screws (one
for side).
- Remove the front handlebar cover.
Headlight assy.
- Unscrew the 3 fixing screws;
- Disconnect the electric connectors;
- Extract the optical unit from the front.
CHAS - 356
X9 Evolution 500
X9 Evolution 500
Chassis
Frame central cover
- Open the tank port;
- Remove the fuel tank cap and the safety rubber
- Loosen the 2 fixing screws inside the same;
- Extract the central cover;
- Remove the tank port opening transmission.
Legshield
- Loosen the 2 front screws;
- Loosen the 2 screws located in the high side of
the wheel compartment.
- Loosen the remaining 6 fixing screws in the counter-shield.
- Remove the complete front shield.
N.B.
THE 2 TOP SCREWS AND THE 2 SCREWS LOCATED UNDER THE RADIATOR AIR OUTLETS ARE NOT USED TO
FIX THE FRONT SHIELD AND CAN BE LEFT FITTED.
CHAS - 357
Chassis
X9 Evolution 500
Knee-guard
- Loosen the 2 screws fixing the fuse holder to the
front trunk compartment and extract it;
- Remove the fixing screw into the gloves compartment;
- Remove the rear side of the front shield with the
saddle closing transmission.
N.B.
TO EXTRACT THE SADDLE TRANSMISSION YOU MUST ACT FROM THE REAR SIDE OF THE
LEVER TO RELEASE THE CABLE COUPLING PIN.
Removing the ignition key-switch when on *off*
- Remove the rear shield as described in the Body
chapter.
- Remove the immobilizer antenna shown in the
figure.
- Detach the electrical wiring.
- Remove the ignition key-switch, by removing the
spring retainer shown in the figure.
CHAS - 358
X9 Evolution 500
Chassis
- Lightly push the master-cylinder and extract the
lock from the notch shown in the figure.
- Hence extract the master-cylinder complete with
the key-switch.
- For the reassembly proceed in the reverse order.
Removing the ignition key-switch when on *lock*
In position "Lock", it is not possible to access the
cylinder retaining spring. The spring must then be
removed as shown in the figure, allowing the lock
spring to be pressed out.
N.B.
FOR REASSEMBLY FROM THIS POSITION, RELEASE THE
STEERING WHEEL AND SET THE LOCK BODY (INSIDE
AND OUTSIDE PART) TO "OFF". THEN, PROCEED AS DESCRIBED IN PARAGRAPH REMOVAL, LOCK IN OFF POSITION.
Front wheel housing
- Remove the spoiler.
- Remove the front fork.
- Remove the plate supporting bracket for the horn
and voltage regulator by loosening the two retaining screws shown in the figure in order to release
the two lower retainer of the wheel housing.
- Remove the upper fixing screw of the wheel
housing to permit movement.
CHAS - 359
Chassis
X9 Evolution 500
- In order to remove the wheel housing it is necessary to remove the front brake hose to the tank and
combination with the splitter.
Taillight assy.
- Loosen the 2 fixing screws of the saddle coupling
covering element;
- Release it from the rear cover and remove it.
- Unscrew the 2 fixing screws shown in the figure
and remove them;
- Disconnect the brake light wiring;
- Remove the brake light support (battery cover) extracting it from top to release the side coupling teeth.
Footrest
- With the help of a small slotted screwdriver, remove the fixing caps and then the safety covers;
- Unscrew the fixing screws on the frame at the
rear shield and at the tunnel cover;
- Remove the footrest board complete with the
passenger boards.
CHAS - 360
X9 Evolution 500
Chassis
Side fairings
- Remove the side union member, then release the
rear screw of the lower side;
- release the lower spoiler connecting screw;
- Extract the lower side pulling it towards the back;
- Remove the rubber caps covering the fixing
screws;
- Remove the hexagon screws;
- Remove the passenger handles.
- Remove the screw below the rear headlight.
CHAS - 361
Chassis
X9 Evolution 500
- Remove the side top screw;
- Disconnect the light group wiring;
- Remove the top side pulling it towards the vehicle
back.
License plate holder
<DIV class=cnt_summary title="Testo Breve (<4000 car.)">
In order to inspect the spark plug, follow the operation described when the engine is cold:
1. Remove the spark plug inspection door «A» after unscrewing the corresponding screws;
2. Detach the spark plug cap;
3. slide door «B» up on the engine cover;
4. Remove the spark plug with the spanner supplied (with fixing rubber).
To refit, repeat the procedure in reverse order using the spanner to insert the spark plug or to tighten
it in its seat. Care should be taken to installing and fixing it with correct inclination
To refit the inspection door for the spark plug, follow the operations in reverse order, making sure to
insert the tooth in the central part of the cover.
WARNING
THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE USE OF A SPARK PLUG WITH THERMAL
GRADE OR THREAD OTHER THAN THE INDICATED TYPE (SEE «DATA» SECTION) CAN SERIOUSLY DAMAGE THE
ENGINE. REPLACE SPARK PLUGS AT THE INTERVALS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.
N.B.
THE USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR OF SHIELDLESS SPARK PLUG CAPS CAN
CAUSE ELECTRICAL SYSTEM FAILURES.
Characteristic
Spark plug (125)
Champion RG6YC- NGK CR7EB
Spark plug
Champion RG6YC
CHAS - 362
X9 Evolution 500
Chassis
TO FIX THE NUMBER PLATE HOLDER TO THE SUPPORT, INTRODUCE THE RIVETS WITH THE
HEAD FACING THE WHEEL TO PREVENT THE PROJECTING PART OF THE RIVET FROM INTERFERING WITH THE TYRE DURING USE.
Air filter
- Remove the helmet compartment.
- Remove the straps of the oil vapour recovery
hose and the air bellows shown in the figure.
- Loosen the two screws shown in the figure.
- Loosen the two retainers shown in the figure and
remove the complete air filter.
CHAS - 363
Chassis
- Remove the general fuse.
- Disconnect the battery housing from its metallic
support and remove the complete filter housing.
Electric characteristic
Fuse
30A
Rear mudguard
- Remove the two clamps shown in the figure.
- Remove the retainer of the mudguard/strut reinforcement plate to remove the complete mudguard.
Helmet bay
- Remove all electric devices;
- Remove the 4 fuse carrier enclosures;
- Free the cables fixed to the frame with the relative
support clamps;
- Remove the battery;
- Unscrew the fixing screws on the rear frame;
- Remove the rear frame by lifting it from the front
and extracting it from behind.
CHAS - 364
X9 Evolution 500
X9 Evolution 500
Chassis
- Remove the saddle closing coupling;
- Unscrew the remaining fixing screws on the
frame;
- Extract the helmet compartment.
spoiler
- Loosen the remaining chassis fastening screws;
- Remove the spoiler.
Fuel tank
N.B.
THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.
- Remove the footboard;
- Remove the central cover
- Remove the spoiler;
- Disconnect the fuel pump electric connection;
- Press the coupling rings on the motor pump and
pull the fuel delivery and return pipes from top.
N.B.
BE VERY CAREFUL WHEN PULLING OUT THE CARBURETTOR PIPING SINCE AN EXCESSIVE
FORCE MAY DAMAGE THE PLASTIC INSERTS ON THE PUMP BODY. UPON REASSEMBLY, IT
IS THEREFORE NECESSARY TO SLIGHTLY PRESS THE PIPING AND THE RETAIN RIM TOWARDS THE PUMP, THEN KEEP THE RIM PRESSED AND PULL THE COUPLING UPWARDS.
CHAS - 365
Chassis
- Remove the horn loosening the fixing screw and
disconnecting the electric connection;
- Loosen the 4 screws fixing the lower support
bracket and remove it;
- Loosen the 2 chassis fastening screws;
- Slightly tilt the tank;
- Extract it from the bottom.
Electric fuel pump
- Remove the supply wiring and the fuel delivery
and return pipes;
- Loosen the ring nut;
- Remove the motor pump.
N.B.
PROPERLY ORIENTATE THE PUMP UPON REASSEMBLY,
LUBRICATE THE GASKET AND BE CAREFUL TO ITS POSITION.
CAUTION
A WRONG ORIENTATION OF THE PUMP COULD MAKE
THE LEVEL INDICATOR HIT THE TANK.
Rear central cover
- Unscrew the 4 fixing screws;
- Remove the rear centre cover.
CHAS - 366
X9 Evolution 500
X9 Evolution 500
Chassis
Front mudguard
- Remove the screws and the LH wheel speed
sensor cable and brake piping support straps;
- Loosen the 2 front fork fixing screws (one for
side).
- Remove the mudguard.
Radiator fan
- Prepare a container to collect the cooling fluid;
- Remove the expansion tank delivery and return
pipes;
- Remove the main radiator
cooling fluid delivery and return pipes;
- Loosen the fastening screws;
- Release the radiator and the electric fan.
Expansion tank
- Unscrew the 2 fixing screws and remove the expansion tank;
- Remove the cap to release it from the countershield extracting it from the bottom;
- Prepare a container to collect the cooling fluid;
- Remove the radiator cooling fluid (high) delivery
and return (low) pipes.
CHAS - 367
Chassis
Digital panel support
- Unscrew the 3 fixing screws;
- Disconnect the electric connectors while paying
special attention to the coupling teeth;
- Remove the support with digital panel;
Front central cover
- To disassemble the front centre cover, it is necessary to first unscrew the screws «A» shown in
the figure (2 per side) and remove them together
with the right and left mirrors. You have to remove
the rubber cover plugs in order to get to the
screws.
- Remove the 2 centre screws «B»
- Remove the lower screw «C» found under the
optical unit
CHAS - 368
X9 Evolution 500
X9 Evolution 500
Chassis
Flyscreen
- Loosen the 3 top windscreen screws with the
spacers; - Remove the top windscreen;
- Remove the 6 plastic cap and the windscreen
support protection rubber parts with the central
adjustment flange to access the 2 lower windscreen top screws.
- Remove the 2 screws shown in the figure.
- loosen the 4 fixing screws with washers located
under the rearview mirrors and the front central
cover;
- Remove the bottom cap.
N.B.
INSTALL THE GASKET INTO THEIR SEAT UPON REASSEMBLY.
CHAS - 369
Chassis
Analogue instrument panel support
- Loosen the 6 fastening screws;
- Remove the instrument panel support with the
electric connections.
Radiator cover
Remove the front shield;
Remove the counter-shieldwith the trunk;
- Remove the footboards;
- Remove the spoiler;
- Remove the steering tube (Front suspension);
- Loosen the remaining fastening screws;
- Disconnect the electric connectors,
- Remove the pipes;
- Remove the radiator cover.
Adjustable windscreen attachment
- Remove the front shield central cover as described above;
- Install the windscreen support brackets.
CHAS - 370
X9 Evolution 500
X9 Evolution 500
Chassis
- Insert the spacers into the cap pads as shown in
the figure.
- Insert a washer for each of the 4 M6 screws, 29
mm long, as shown in the figure.
- Put the cap close to the chassis and the fixings,
then lock it by the 4 screws described above and
inserted into the guiding spacers.
- Fix the cap to the windscreen support brackets
by the 2 M6 screws, 22 mm long.
CHAS - 371
Chassis
- Place the 3 gaskets with 3 holes as shown in the
figure and lock them by the special pressure buttons leaving the thread to be used to position the
windscreen free (the intermediate position is
shown in the figure).
- Apply the 3 rubber pads to the windscreen as
shown in the figure.
- Apply the 3 rubber shims to the windscreen as
shown in the figure.
- Using the 2 shorter countersunk screws, install
the windscreen on the side support brackets. The
longest screw must be used for the central fixing.
- Place the metal plate provided with 3 threaded
holes into the cap, as shown in the figure. This
plate acts as central fixing between cap and windscreen.
- Manually tighten the three screws in a crossed
sequence.
CHAS - 372
X9 Evolution 500
X9 Evolution 500
Chassis
- Apply the specific gasket on the central cover of
the front shield.
- Replace the front shield central cover.
Pilot lights kit
- Remove the handlebar cover.
- Remove the three screws shown in the figure,
then pull the complete group from the front handlebar cover.
Battery
- Remove the elastic strap and the battery cover.
CHAS - 373
Chassis
Lower cover
- Remove the two rear screws shown in the figure.
- Remove the 4 bottom screws shown in the figure
and the complete bottom cover.
CHAS - 374
X9 Evolution 500
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
X9 Evolution 500
Pre-delivery
Carry out the listed tests before delivering the vehicle.
WARNING
BE VERY CAREFUL WHEN HANDLING FUEL.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Lock check
- Safety locks
SAFETY LOCKS:
Name
Rear shock absorber retainer to the chassis
Front wheel axle
Rear wheel axle
Rear brake disc mounting
Engine - chassis fixing pin
Fixing screw handlebar to steering tube
Upper steering ring nut
Steering lower ring nut
Torque in Nm
38 - 46
45 ÷ 50
104 ÷ 126
11 ÷ 13
100 - 120
45 ÷ 50
36 - 39
10 - 13 **
** tighten and loosen by 90°
- Cover retaining screws
Electrical system
- Master switch
- Headlights: upper beams, dipped beams, side/taillights , stop lights and relevant light indicators
- Headlight setting according to the regulations in force
- Rear light, parking light, stop light
- Front and rear stop switches
- Direction indicators and relevant lights
- Instrument panel lights
- Instruments: fuel and temperature indicator
- Instrument unit indicator lights
- Horn
- Electro-hydraulic side stand (Version SL)
- Radio/Intercom/Handsfree
- Emergency flashing lights
PRE DE - 376
X9 Evolution 500
Pre-delivery
- Engine stop by emergency stop switch and side stand
START THE VEHICLE BATTERY AS EXPLAINED IN THE ELECTRIC SYSTEMCHAPTER. REMOVE THE BATTERY FROM THE VEHICLE DISCONNECTING THE NEGATIVE TERMINAL FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
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. IN THE EVENT OF CONTACT WITH EYES AND SKIN, RINSE THOROUGHLY WITH WATER FOR ABOUT 15 MINUTES AND CONSULT A DOCTOR IMMEDIATELY.
IN THE EVENT OF FLUID INGESTION, DRINK ABUNDANT WATER OR VEGETAL OIL IMMEDIATELY. CONSULT A DOCTOR IMMEDIATELY.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP AWAY FROM FREE FLAMES, SPARKS OR
CIGARETTES. IF RECHARGING THE BATTERY IN A CLOSED ENVIRONMENT, ENSURE PROPER VENTILATION.
ALWAYS SHIELD YOUR EYES WHEN WORKING CLOSE TO BATTERIES.
KEEP AWAY FROM THE REACH OF CHILDREN
Levels check
Level check:
- Hydraulic brake system liquid level.
- Rear hub oil level
- Engine coolant level
- Engine oil level
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
Static test
Static test after test ride:
- Restarting when warmed up
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
PRE DE - 377
Pre-delivery
X9 Evolution 500
- Possible leaks
- Operation of the radiator electric fan
Functional inspection
Operating test:
- Hydraulic brake system
- Lever travel
- Clutch - Check for correct operation
- Engine - Check for correct general operation and make sure there is no unusual noise
- Other
- Check documents:
- Check the frame and engine numbers
- Check tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 378
INDEX OF TOPICS
TIME
TIME
X9 Evolution 500
Time
This section is devoted to the time necessary to carry out repairs.
For each operation, the description, code and time envisages are specified.
Engine
ENGINE
1
TIME - 380
Code
001001
Action
Engine to chassis - Replacement
Duration
X9 Evolution 500
Time
Crankcase
CRANKCASE
1
2
3
Code
001100
001133
001153
Action
Oil seal, clutch side - Replacement
Engine crankcase- Replacement
Crankcase half gasket - Replacement
Duration
TIME - 381
X9 Evolution 500
Time
Crankshaft
CRANKSHAFT
1
2
TIME - 382
Code
001117
001098
Action
Crankshaft - Replacement
Countershaft - Replacement
Duration
X9 Evolution 500
Time
Cylinder assy.
CYLINDER GROUP
1
2
3
Code
001002
001154
001129
Action
Cylinder piston - Replacement
Pin-ring-piston assembly - Service
Chain tensioner - Service and Replacement
Duration
TIME - 383
X9 Evolution 500
Time
Cylinder head assy.
HEAD UNIT
1
2
3
4
5
6
7
TIME - 384
Code
001045
001049
001056
001126
001083
005116
007012
Action
Valves - Replacement
Valves - Adjustments
Head gasket - Replacement
Head - Replacement
Thermistor - Replacement
Rpm timing sensor - Replacement
Coolant bleed valve - Replacement
Duration
X9 Evolution 500
Time
Rocker arms support assy.
ROCKING LEVER SUPPORT UNIT
1
2
Code
001044
001148
Action
Camshaft - Replacement
Rocking lever valve - Replacement
Duration
TIME - 385
X9 Evolution 500
Time
Cylinder head cover
HEAD COVER
1
2
3
TIME - 386
Code
001089
001093
001088
Action
Head cover - Replacement
Spark plug - Replacement
Head cover gasket - Replacement
Duration
X9 Evolution 500
Time
Flywheel cover
FLYWHEEL COVER
1
2
3
4
5
6
Code
001087
001113
001123
001124
001057
001062
7
001150
8
001160
9
007011
Action
Flywheel cover - Replacement
Water pump - Replacement
Oil filter -Replacement
By-pass valve - Replacement
Thermostat - Replacement
Water pump command shaft - Replacement
Flywheel cover gasket - Replacement
Minimum oil pressure sensor - Replacement
By-pass manifold - thermostat - drain
valve - Replacement
Duration
TIME - 387
X9 Evolution 500
Time
Driven pulley
DRIVEN PULLEY
1
2
3
4
TIME - 388
Code
001022
001012
001110
001155
Action
Clutch - Replacement
Driven pulley - Overhaul
Driven pulley - Replacement
Clutch bell housing - Replacement
Duration
X9 Evolution 500
Time
Oil pump
OIL PUMP AND STARTER MOTOR
1
2
3
4
Code
001112
001042
001051
001125
5
6
7
8
001102
003064
001017
001020
Action
Oil pump - Replacement
Oil pump - Overhaul
Timing belt/chain - Replacement
Chain guide sliding blocks - Replacement
Net oil filter - Replacement / Cleaning
Engine oil - Change
Starter pinion - Replacement
Starter motor - Replacement
Duration
TIME - 389
X9 Evolution 500
Time
Final gear assy.
FINAL REDUCTION GEAR ASSEMBLY
1
2
Code
001010
001156
3
4
003065
004125
TIME - 390
Action
Geared reduction unit - Service
Gear reduction unit cover - Replacement
Gear box oil - Replacement
Rear gear shaft - Replacement
Duration
X9 Evolution 500
Time
Driving pulley
DRIVING PULLEY
1
2
3
4
Code
001086
001011
001006
001141
5
001066
Action
Driving half-pulley - Replacement
rear-view belt - Replacement
rear-view pulley - Service
Belt anti-flapping roller - Replacement
rear-view pulley - Replacement
Duration
TIME - 391
X9 Evolution 500
Time
Transmission cover
TRANSMISSION COVER
1
Code
001065
2
001096
3
001131
4
001135
5
001170
TIME - 392
Action
Internal transmission cover - Replacement
External transmission cover - Replacement
Transmission air intake - Replacement
Transmission cover bearing - Replacement
Air manifold - replacement
Duration
X9 Evolution 500
Time
Flywheel magneto
MAGNETO FLYWHEEL
1
2
3
4
5
Code
001173
001067
001058
001104
001151
Action
Rotor - Replacement
Stator - Replacement
Flywheel - Replacement
Start-up freewheel - Replacement
Start-up driven gearing - Replacement
Duration
TIME - 393
X9 Evolution 500
Time
Butterfly valve
BUTTERFLY VALVE
1
2
3
4
TIME - 394
Code
001013
001047
001166
001171
Action
Intake manifold - Replacement
Injector - Replacement
Throttle body - Replacement
Throttle body - Overhaul
Duration
X9 Evolution 500
Time
Exhaust pipe
EXHAUST
1
2
3
4
Code
001009
001092
001095
001136
Action
Muffler - Replacement
Exhaust manifold - Replacement
Muffler guard - Replacement
Exhaust emissions - Adjustment
Duration
TIME - 395
X9 Evolution 500
Time
Air cleaner
AIR CLEANER
1
2
3
TIME - 396
Code
001015
001014
001074
Action
Air filter box - change
Air filter - Replacement/Cleaning
Oil vapour recovery pipe - Replacement
Duration
X9 Evolution 500
Time
Frame
CHASSIS
1
2
3
Code
004001
004146
004116
Action
Chassis - Replacement
Front frame - Replacement
Rear frame - Replacement
Duration
TIME - 397
X9 Evolution 500
Time
Centre-stand
ELECTRO-HYDRAULIC CENTRE STAND/SIDE STAND
1
2
3
4
Code
004004
004102
005079
005122
5
005123
6
008004
TIME - 398
Action
Stand - Replacement
Side stand - Replacement
Stand switch - Replacement
Side stand electro-actuator - Replacement
End of stroke/enabling switches - Adjustment/replacement
Electric engine - Replacement
Duration
X9 Evolution 500
Time
Legshield spoiler
LEGSHIELD SPOILER AND REARVIEW MIRRORS
1
Code
004064
2
3
4
5
6
006012
004149
006006
004066
005067
7
8
9
005091
004159
005081
Action
Front shield, front side - Replacement
Front shield - Paintwork
shield central cover - Replacement
Headstock cover - Paintwork
Rear view mirrors - Replacement
Front direction indicator bulb - Replacement
Turn indicator glass - Replacement
Plates / Stickers - Replacement
Temperature sensor - Replacement
Duration
TIME - 399
X9 Evolution 500
Time
Rear cover
REAR COVER
1
Code
004065
2
3
004081
002082
4
004156
5
004082
TIME - 400
Action
Front shield, rear part - Removal and
refitting
Glove box door - Replacement
Fuel tank door opening drive - Replacement
Glove box flap and/or support - Replacement
Trunk gasket - Replacement
Duration
X9 Evolution 500
Time
Central cover
CENTRAL FRAME COVER
1
2
3
4
5
Code
004011
004104
004105
004079
004143
Action
Central chassis cover - Replacement
Left side cover - Replacement
Right side cover - Replacement
Rear footrest - Replacement
Footrest support - replace
Duration
TIME - 401
X9 Evolution 500
Time
Underseat compartment
UNDERSEAT COMPARTMENT
1
2
Code
005033
005026
3
005027
4
5
6
004142
004016
004150
TIME - 402
Action
Trunk light switch - Replacement
Helmet compartment light - Replacement
Helmet compartment bulb - Replacement
Plug socket - Replacement
Helmet compartment - Replacement
Saddle shock absorber - Replacement
Duration
X9 Evolution 500
Time
Mudguard
MUDGUARDS
1
2
3
4
Code
004167
004009
004002
003087
Action
Grill / radiator cover - replace
Rear mudguard - Replacement
Front mudguard - change
Wheel housing - Replacement
Duration
TIME - 403
X9 Evolution 500
Time
Fuel tank
FUEL TANK
1
2
TIME - 404
Code
004005
004109
Action
Fuel tank - Replacement
Fuel tank bleed - Replacement
Duration
X9 Evolution 500
Time
Radiator
RADIATOR FAN
1
2
Code
007002
007016
3
007003
4
5
6
007024
007001
007013
7
001052
Action
Radiator - Replacement
Fan complete with support - Replacement
Coolant delivery and return pipe Repl.
Expansion tank cap - Replacement
Expansion tank - Replacement
Expansion tank / radiator connecting
hose - Replacement
Coolant and air bleed - replacement
Duration
TIME - 405
X9 Evolution 500
Time
Rear shock-absorber
REAR SHOCK-ABSORBER
1
TIME - 406
Code
003007
Action
Rear shock absorbers - Replacement
Duration
X9 Evolution 500
Time
Steering column bearings
STEERING COLUMN BEARINGS AND FRONT FORK
1
2
3
4
5
Code
003051
003079
003048
003076
004119
6
7
003002
003073
Action
Fork assembly - Replacement
Fork stem - Replacement
Fork oil seal - Replacement
Fork oil sheath - Replacement
Bearing / Steering support fifth wheel
- Replacement
Steering fifth wheel - Replacement
Steering clearance - Adjust
Duration
TIME - 407
X9 Evolution 500
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
004151
2
004018
3
004019
4
004152
TIME - 408
Action
Instrument panel support - Replacement
Handlebar front section - Replacement
Handlebar rear section - Replacement
Board computer cover - Replacement
Duration
X9 Evolution 500
Time
Handlebar components
HANDLEBAR COMPONENTS
1
Code
002060
2
3
4
002037
003001
002063
5
6
002059
003061
7
8
9
10
11
002088
005017
003059
002071
002024
Action
Complete gas command - Replacement
Brake or clutch lever - Replacement
Handlebar - Removal and refitting
Throttle control transmission - Replacement
Right hand grip - Replacement
Accelerator transmission - Adjustment
Integral brake pump - Replacement
Stop switch - Replacement
Counterweight - Replacement
Left hand grip - Replacement
Front brake pump - replace
Duration
TIME - 409
X9 Evolution 500
Time
Swing-arm
SWING-ARM
1
Code
001072
2
003082
TIME - 410
Action
Engine/chassis fixing oscillating arm
- Replacement
Damper arm - Replacement
Duration
X9 Evolution 500
Time
Seat
SEAT
1
2
3
Code
004003
004144
004067
Action
Saddle - Replacement
Bag - Replacement
Back - Replacement
Duration
TIME - 411
X9 Evolution 500
Time
Instrument panel
INSTRUMENT PANEL
1
2
Code
005014
005078
3
005082
4
005083
TIME - 412
Action
Odometer - Replacement
Odometer plastic cover - Replacement
Instrument panel cable harness - Replacement
Onboard computer - Replacement
Duration
X9 Evolution 500
Time
Locks
SEAT LOCK AND LOCKS
1
Code
002083
2
002092
3
005099
4
5
6
7
8
005016
004010
005072
004001
004054
Action
Saddle opening transmission - Replacement
Transmission splitter/ hook transmission - Replacement
Electric saddle opening device - Replacement
Key switch - Replacement
Anti-theft lock - Replacement
Immobilizer antenna - Replacement
Chassis - Replacement
Saddle lock catch - Replacement
Duration
TIME - 413
X9 Evolution 500
Time
Turn signal lights
FRONT HEADLIGHTS
1
2
3
TIME - 414
Code
005002
005008
005044
Action
Front headlamp - Replacement
Front headlamp bulbs - Replacement
Front lights cable unit - replace
Duration
X9 Evolution 500
Time
REAR HEADLIGHTS
1
2
3
4
Code
005090
005028
005066
005068
5
6
005005
005031
7
005032
8
005030
Action
Stop light bulb - Replacement
Rear optical unit plastic cover - Repl.
Rear light bulbs - replace
Rear turn indicator bulb - Replacement
Taillight - change
Licence plate light bulb - Replacement
Number plate light plastic cover - Replacement
Rear indicator and headlight wire unit
- Replacement
Duration
TIME - 415
X9 Evolution 500
Time
Front wheel
FRONT WHEEL
1
2
3
4
5
6
7
8
Code
003037
003047
004123
003063
003040
002041
005089
003038
Action
Front wheel rim- Replacement
Front tyre - Replacement
Front wheel - Replacement
Tyre pressure - Check
Front wheel bearings - Replacement
Front brake disc - Replacement
Tone wheel - Replacement
Front wheel axle - Replacement
Grease tone wheel or drive
Please take note that the code has been introduced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated
components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide).
In the following points we indicate with an arrow
the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 416
Duration
X9 Evolution 500
Time
Rear wheel
REAR WHEEL
1
2
3
4
5
6
Code
001071
004126
001016
003063
003014
003077
7
8
002070
002028
Action
Rear wheel rim - Replacement
Rear wheel tyre - Replacement
Rear wheel - Replacement
Tyre pressure - Check
Rear suspension arm - Replacement
muffler/rear shock absorber support
arm - Service
Rear brake disc - Replacement
Rear wheel hub - Replacement
Duration
TIME - 417
X9 Evolution 500
Time
Fuel pump
FUEL PUMP
1
2
TIME - 418
Code
004073
004137
Action
Fuel pump - Replacement
Injector pump pipe - Replacement
Duration
X9 Evolution 500
Time
Electric devices
VEHICLE WIRING
1
Code
005001
2
005045
3
4
005025
005114
Action
Electric system - Removal and reassembly
Starter motor wire group - Replacement
Battery fuse box - Replacement
Electrical system - Service
Duration
TIME - 419
X9 Evolution 500
Time
BATTERY AND H.T. COIL
1
2
3
Code
001069
005007
005011
4
005097
5
6
7
001094
005024
005126
8
005073
TIME - 420
Action
HV coil - Replacement
Battery - Replacement
Start-up remote control switch change
Electric central stand remote control
switch - Replacement
Spark plug cap - Replacement
Battery fuse - Replacement
Saddle opening receiver - Replacement
Immobilizer decoder - Replacement
Duration
X9 Evolution 500
Time
ELECTRICAL DEVICES ON HANDLEBARS
1
2
3
Code
005040
005041
005084
4
5
005095
005077
6
7
005039
005006
8
9
005003
005085
Action
Horn button - Replacement
Starter button - Replacement
Emergency light switch - Replacement
Electric stand button - Replacement
Emergency stop switch - Replacement
Light switch - Replacement
Light switch or turn indicators - Replacement
Horn - Replacement
Reset button - Replacement
Duration
TIME - 421
X9 Evolution 500
Time
INJECTION MASTER-BOX - VOLTAGE REGULATOR
1
2
3
Code
001023
005009
005098
4
005088
5
005096
6
7
005125
005126
8
005127
TIME - 422
Action
Injection ECU - Replacement
Voltage regulator - Replacement
Side stand control unit - Replacement
Emergency stop remote control - Replacement
Remote control for injection components - Replacement
Stuck relay indicator - Replacement
Saddle opening receiver - Replacement
Roll-over sensor - Replacement
Duration
X9 Evolution 500
Time
pics
PICS
1
Code
005092
2
3
005093
005094
Action
Radio/intercom control unit - Replacement
Radio/intercom wires - Replacement
Radio/intercom display - Replacement
Duration
TIME - 423
X9 Evolution 500
Time
Fuel tank filler flap
CENTRAL TUNNEL COVER AND FUEL TANK FILLER FLAP
1
2
3
TIME - 424
Code
004135
004011
004157
Action
Fuel tank lid - Replacement
Central chassis cover - Replacement
Fuel port coupling - Replacement
Duration
X9 Evolution 500
Time
Footrests
SPOILER AND FOOTREST
1
2
3
4
5
6
7
8
9
Code
004075
004079
004015
004068
004129
004012
004085
004056
004059
10
004053
Action
Front mat - Replacement
Footboard (1) - Replacement
Footboard (2) - Replacement
Passenger handgrip - Replacement
Rear fairing - Replacement
Rear side panels (2) - Replacement
Fairing (1) - Replacement
Upper rear light cover - Replacement
Spark plug inspection flap - Replacement
Spoiler - Replacement
Duration
TIME - 425
X9 Evolution 500
Time
Front mudguard
FRONT MUDGUARD AND RADIATOR COVER
1
2
TIME - 426
Code
004002
004167
Action
Front mudguard - change
Radiator grille/cover - Replacement
Duration
X9 Evolution 500
Time
Helmet bay
HELMET COMPARTMENT
1
2
Code
004016
005033
3
005026
4
5
004142
005027
Action
Helmet compartment - replace
Glove-box light switch - Replacement
Helmet compartment light - Replacement
Plug socket - Replacement
Helmet compartment bulb support Replacement
Duration
TIME - 427
X9 Evolution 500
Time
Rear side fairings
REAR SIDE FAIRINGS
1
2
Code
004057
004136
3
4
005048
005046
TIME - 428
Action
Taillight lower cover - Replacement
License plate holder support - Replacement
Licence plate holder - Replacement
Battery cover - Replacement
Duration
X9 Evolution 500
Time
Front suspension
FRONT SUSPENSION
1
2
3
4
5
6
7
8
Code
003051
003010
003076
003079
003048
003073
003002
004119
Action
Complete fork - Replacement
Front suspension - service
Fork housing - replacement
Fork stem - Replacement
Fork oil seal - Replacement
Steering clearance - Adjustment
Steering fifth wheels - change
Upper steering bearing - replacement
Duration
TIME - 429
X9 Evolution 500
Time
Rear suspension
REAR SUSPENSION
1
2
3
Code
003085
003007
004120
4
003086
TIME - 430
Action
Suspension strut - Replacement
Rear shock absorber - Replacement
Rear suspension linkage - Replacement
Suspension strut support - replacement
Duration
X9 Evolution 500
Time
Cooling system
COOLING SYSTEM
1
Code
007002
2
3
4
5
6
007016
007001
007024
007019
007013
7
8
001052
007022
Action
Water cooling radiator - Replacement
Fan with support - Replacement
Expansion tank - Replacement
Expansion tank cap - Replacement
Coolant return pipe - replacement
Expansion tank / radiator connecting
hose - Replacement
Coolant and air bleed - replacement
Coolant delivery pipe - Replacement
Duration
TIME - 431
X9 Evolution 500
Time
Braking system
BRAKING SYSTEM
1
2
Code
002021
002084
3
002085
4
002087
5
002090
6
002047
7
002089
8
9
10
11
12
13
002039
002048
002007
003070
002002
003071
TIME - 432
Action
Front brake piping - Replacement
Integral break pump pipe, device Replacement
Integral brake device pipe- front calliper - Replacement
Rear caliper integral braking device
pipe - Replacement
Integral brake fluid and bleeding system - Replacement
Front brake fluid and air bleeding
system - Replacement
Integral breaking device - Replacement
Front brake calliper - Replacement
Rear calliper - Replacement
Front brake pads - Replacement
Front brake pads - Wear check
Rear brake pads - Replacement
Rear brake pads - Wear check
Duration
X9 Evolution 500
Time
Windscreen
WINDSCREEN
1
2
Code
004028
004101
Action
Windshield glass - Replacement
Windshield - Replacement
Duration
TIME - 433
A
Air filter: 39, 363
B
Battery: 51, 59, 61, 74, 75, 82, 373
Brake: 325, 329, 331, 333, 334, 336, 340–342
Brake fluid: 340
C
Coolant: 270, 348
E
Engine oil: 40
F
Fuel: 224, 234, 238, 365, 404, 418, 424
Fuses: 63
H
Headlight: 46, 356
Hub oil: 37
I
Identification: 8
Immobilizer:
Instrument panel: 355, 370, 412
L
Light switch:
M
Maintenance: 7, 33
Mirrors:
O
Odometer: 81
Oil filter: 41
S
Saddle:
Shock absorbers: 312
Spark plug: 37, 268
Stand: 313, 314
Start-up:
T
Tank: 365, 367, 404, 424
Technical Data:
Transmission: 10, 50, 89, 105, 392
Tyres: 11
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