PIAGGIO 633234 Instruction manual

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.
"©Copyright2005-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
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 Piaggio-
Gilera 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 Sectionsmarked with this symbol indicatethe correct use of thevehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
INJECTION INJEC
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME

INDEX OF TOPICS
CHARACTERISTICS CHAR

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. Sul-
phuricacidis highly corrosive; in the event of contact with youreyesorskin, 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. Non-
original 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. Lubri-
cate 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.
•Forremoval, overhaul and reassemblyoperations use only toolsprovided with metric meas-
ures. 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 elec-
trical connections - especially earth and battery connections - have been implemented
properly.
X9 Evolution 500 Characteristics
CHAR - 7

Vehicle identification
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Chassis prefix ZAPM 27000 ÷ 4000001
Engine prefix M271M ÷ 1001
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification Desc./Quantity
Total dry weight 206 Kg
Width (at the mirrors) 910 mm
Wheel base 2130 mm
Length 1530 mm
Height (at the saddle) 780 mm
Height at the windscreen (high position) 1450 mm
Characteristics X9 Evolution 500
CHAR - 8

Engine
ENGINE
Specification Desc./Quantity
Engine Single-cylinder, four-stroke
Bore 92 mm
Stroke 69 mm
Cubic capacity 460 cm³
Compression ratio 10.5: 1
Timing system Single overhead camshaft with integrated tone wheel, control
from flywheel side chain, 4 valves and automatic start-up valve
lifting device.
Valve clearance: intake 0.15 mm (when cold)
Valve clearance: discharge 0.15 mm (when cold)
Valve clearance adjustment By threaded adjuster on the rockers
Engine idle speed 1500 ± 50 rpm
Air filter Dry paper filter.
CO % value (measured at the intake manifold) 1 - 1.5%
Starting system Electric starter system with freewheel.
Lubrication By trochoidal pump (inside the crankcase), pressure adjust-
ment by-pass and oil filter.
Lubrication pressure 4 bar
Minimum allowed (at 100° C) 0.8 bar
Fuel supply Electronic injection system with electric fuel pump, Ø 38 mm
throttle body and single injector.
Max. power (at crankshaft) 29.5 kW at 7500 rpm
Max. torque (at crankshaft) 43 Nm at 5500 rpm
Cooling system Fluid circulation through a motor-driven pump, 3-way thermo-
stat and electric fan.
X9 Evolution 500 Characteristics
CHAR - 9

Transmission
TRANSMISSIONS
Specification Desc./Quantity
Transmission With automatic expandable pulley variator with torque server,
V belt, automatic clutch, gear reduction unit and transmission
housing with forced air circulation cooling.
Capacities
CAPACITIES
Specification Desc./Quantity
Cooling system approx. 1.8 l
Fuel tank (including reserve ~ 2.5 l) ~ 14,5 l
Rear hub ~ 250 cc
Engine oil (empty) 1.7 lt.
Engine oil (at oil and filter change) 1.5 lt.
Electrical system
ELECTRICAL COMPONENTS
Specification Desc./Quantity
1 Ignition type Inductive, high efficiency, integrated with injection, vari-
able advance and separate HV coil.
2 Spark advance (before TDC) Variable, controlled by the injection controller
3 Spark plug CHAMPION RG6YC; NGK CR7EKB
4 Battery 12V-14Ah
5 Fuses n.1 70A_n.1 30A_n.2 15A_n.3 10A_n.4 7,5A_n.2 5A_n.
1 3A
6 Generator in three-phase alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification Desc./Quantity
Type Welded structure consisting of steel pipes with asymmetrical
trestle structure, front crosspieces and union members made
of sheet steel.
Front suspension Hydraulic telescopic fork with dual effect, Ø 40 mm stems and
back pin with couplongs for dual brake calipers.
Front fork stroke 104 mm
Rear suspension Engine based on oscillating fork pivoted to the chassis by 2-
freedomdegreeoscillatingarmandpairofdualeffecthydraulic
shock absorbers with 4-position preload adjustment
Rear suspension range 76.6 mm (minimum spring preload)
X9 Evolution 125-250-500:
Please take note that, starting from chassis serial number ZAPM2300003509521, the front small chas-
sis 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
Characteristics X9 Evolution 500
CHAR - 10

Front fork
This is to inform you that, starting from frame no. ZAPM2700004008122, the front fork has been re-
placed 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 Desc./Quantity
Front Disc brake Ø 260 (vehicle RH side), with hydraulic command
activated from handlebars with right-hand lever and 2 piston
floating caliper.
Combined With dual disc brake, Ø 260 front LH with 2 piston floating cal-
iper and Ø 240 rear, with 2 opposed piston floating caliper.
Hydraulic command activated from handlebars with left-hand
lever. The system is interlocked with a pressure distribution
valve.
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Light alloy rims (Front): 3,50x14"
Light alloy rims (rear): 4,50x14"
Tyre pressure (when cold): front 2,2 bar
Tyre pressure (when cold): rear 2,4 bar (2,6 bar with passenger or optional trunk on)
Front Tyre Michelin Gold Standard 120/70-14' M/C reinforced TL 55 S
Manufacturer / Model / Size Pirelli GTS 23 120/70_14'M/C TL 55 S
Rear Tyre Michelin Gold Standard 150/70-14' M/C TL 66 S
Manufacturer / Model / Size Pirelli GTS 24 150/70_14' M/C TL 66 S
CAUTION
IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE COR-
RECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER
TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES REC-
OMMENDED BY PIAGGIO.
X9 Evolution 500 Characteristics
CHAR - 11

Tightening Torques
STEERING UNIT
Name Torque in Nm
Steering wheel upper ring nut 36 ÷ 39
Steering wheel lower ring nut 10 ÷ 13 then loosen by 90° (see "Steering wheel ring nut lock-
ing")
Handlebar fixing screw (*) 43 ÷ 47
STEERING WHEEL LOCKING RING NUT
1) Apply to the lower ring nut a setting torque of 20±25 Nm then loosen it.
2) Tighten the ring nut again at a torque of 10±13 Nm.
3) Loosen the lower ring nut by 90°.
4) Insert the spacer.
5) Lock the upper ring nut at a torque of 36 ± 39 Nm
CHASSIS UNIT
Name Torque in Nm
Oscillating arm pin right nut - Engine 100 ÷ 120
Oscillating arm pin left nut - Engine 56 ÷ 70
Oscillating arm-chassis pin 14 ÷ 17
Oscillating arm-chassis pin lock nut 40 ÷ 50
Oscillating arm pin right nut - Chassis 66 ÷ 73
Side stand support fixing bolt 33 ÷ 41
Bolt fixing the centre stand to the frame 25 ÷ 30
Hydraulic actuator fixing screw to chassis 20 ÷ 25
Side stand screw 35 ÷ 40
Side stand switch screw 5 ÷ 7
Side stand nut 40 ÷ 45
Oscillating arm damper bar nut 33 ÷ 41
Damper pad support plate nut 33 ÷ 41
FRONT SUSPENSION
Name Torque in Nm
Fork leg tightening clamp screw 20 ÷ 25
Front wheel axle 45 ÷ 50
Wheel axle tightening clamp screw 6 ÷ 7
Front mudguard fixing screw 5 ÷ 6,5
Pumping fixing screw to fork leg 45 ÷ 50
FRONT BRAKE
Name Torque in Nm
Screw for fixing the caliper support to the fork 42 ÷ 62
Brake fluid pump-hose fitting 16 ÷ 20
Brake fluid pipe-calliper fitting 16 ÷ 20
Disc tightening screw (°) 5 ÷ 6
Oil drainage screw 12 ÷ 16
REAR SUSPENSION
Name Torque in Nm
Right and left shock absorber support fixing 20 ÷ 25
Shock absorbers fixing to chassis 33 ÷ 41
Shock absorbers fixing to lower supports 33 ÷ 41
Rear wheel axle 104 ÷ 126
Rear wheel rim screws 33 ÷ 37
Silencer support arm fixing to engine 33 ÷ 42
Characteristics X9 Evolution 500
CHAR - 12

COMBINED BRAKE
Name Torque in Nm
Oil pipe union on combined brake pump 16 ÷ 20
Combined brake pipe union on front calipers 16 ÷ 20
Combined brake pipe union on rear calipers 16 ÷ 20
Front brake caliper pipe union on combined braking device 20 ÷ 25
Rear brake caliper pipe union on combined braking device 20 ÷ 25
Brake caliper fixing screw to supports 20 ÷ 25
Rear disc tightening screw (°) 14 ÷ 17
Oil bleed screw 12 - 16
Rear brake caliper fastening screw to engine 20 ÷ 25
Rear brake piping support fixing screw to engine 5 ÷ 6,5
Rear brake piping support fixing screw to chassis 9 ÷ 11
SILENCER
Name Torque in Nm
Manifold fixing screw to silencer 16 ÷ 18
Silencer support bracket fixing screw to engine 33 ÷ 41
Silencer heat guard fixing screw 3 ÷ 4
Exhaust gas inlet screw 22 ÷ 26
ENGINE UNIT
Name Torque in Nm
Clutch locking nut 65 ÷ 75
Driven pulley shaft support fixing screw 23 ÷ 26
Belt anti-flapping roller fixing screw 17 ÷ 20
Driving pulley nut (°) 160 ÷ 175
Flywheel nut (°) 115 ÷ 125
Driven pulley nut 92 ÷ 100
Half-crankcase union screw 11 ÷ 13
Head cover screws 11 ÷ 13
Head nuts (°) (§) (*) 38 ÷ 42
Cylinder stud bolts 44 ÷ 46
Camshaft bell screw (#) 30 ÷ 35
Camshaft plate fixing screw (#) 4 ÷ 6
Valve clearance adjustment lock nut 6 ÷ 8
Water pump impeller 4 ÷ 6
Starter motor fastening screw 11 ÷ 13
Ignition spark plug 12 ÷ 14
Hub oil drainage cap 15 ÷ 17
Rear hub cap screw 24 ÷ 27
Transmission cover screw 11 ÷ 13
Oil pump head screw 8 ÷ 10
Engine oil drainage cap 24 ÷ 30
Water pump cover screw 3 ÷ 4
Screw fixing the oil pump to the crankcase 5 ÷ 6
Stator fastening screw 8 ÷ 10
Screw fixing the start-up free wheel to the flywheel (#) 13 ÷ 15
Flywheel cover screw 11 ÷ 13
Head intake manifold screw 11 ÷ 13
Screw fixing the throttle body to the manifold 11 ÷ 13
Chain tightener sliding block screw (#) 10 ÷ 14
Timing chain tensioner central screw 5 - 6
Timing chain tensioner support screw 11 ÷ 13
Counter-rotating shaft fixing nut (#) 25 ÷ 29
Screw fixing the silencer to the support arm 20 ÷ 25
Exhaust manifold - cylinder nuts 27 ÷ 33
Screw fixing the rear brake caliper support bracket to the en-
gine 20 ÷ 25
Driving shaft timing cap 3,5 ÷ 4,5
Head water outlet cover screw 3 ÷ 4
Calibrated dowel 5 ÷ 7
Oil cap with level bar 1,5 ÷ 2,5
Oil filter 12 ÷ 16
Oil filter engagement union 18 ÷ 22
X9 Evolution 500 Characteristics
CHAR - 13

Name Torque in Nm
Oil vent pipe fixing 3 ÷ 4
Minimum oil pressure sensor 12 ÷ 14
Fairlead bracket fixing 3 ÷ 4
Head/Cylinder/Crankcase fixing 10 ÷ 12
Revolution timing sensor fixing screw 3 ÷ 4
Coolant temperature sensor 10 ÷ 12
Pressure reducer counterweight retainer 7 ÷ 8.5
Counter shaft gear fixing on driving shaft (#) 10 ÷ 12
Thermostat cover 1,5 ÷ 2
Start-up rim counter shaft plate fixing 3 ÷ 4
Injector support fixing (#) 3 ÷ 4
Head lubrication control jet 5 - 7
(°)Lubricate parts before fitting.
(^) Apply LOCTITE for surfaces type 510.
(#) Apply thread-holding LOCTITE medium type 242.
(§) 1st locking: 20 N·m crossed, locking at torque 38 - 42 N·m crossed, crossed loosening.
(*) 2nd tightening: 20 N·m crossed, locking at torque 38 - 42 N·m crossed.
N.B.
LUBRICATE THE THREADS.
NOTICE OF TECHNICAL SERVICING
For correct tightening, the expansion tank cap locking torque has been standardised to 2.5 Nm
Pleasetake note that we have normalized to17 - 20 Nm the temperature sensor locking torque, inorder
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
Characteristics X9 Evolution 500
CHAR - 14

Cylinder - piston assy.
(Values in mm)
HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED
Specification Desc./Quantity
A: 10 mm
B: 43 mm
CATEGORIES OF COUPLING
Name Initials Cylinder Piston Play on fitting
Cylinder Piston A 91.990 - 91.997 91.954 - 91.961 0.029 - 0.043
Cylinder Piston B 91.997 - 92.004 91.961 - 91.968 0.029 - 0.043
Cylinder Piston C 92.004 - 92.011 91.968 - 91.975 0.029 - 0.043
Cylinder Piston D 92.011 - 92.018 91.975 - 91.982 0.029 - 0.043
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
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
X9 Evolution 500 Characteristics
CHAR - 15

SEALING RINGS
Name Initials Cylinder Piston Play on fitting
1st Compression ring A 0.15 ÷ 0.35 0.5 </>
Middle piston ring A 0.25 ÷ 0.50 0.65 </>
Oil scraper ring A 0.25 ÷ 0.50 0.65 </>
Crankcase - crankshaft - connecting rod
Characteristic
Drive shaft / crankcase axial clearance:
0.1 - 0.5 mm (when cold)
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Description Dimensions Initials Quantity
Transmission-side
shoulder 0.8 ± 0.025 A D= 0.20 - 0.40
Transmission-side half-
shaft 19.6 + 0.050 B D= 0.20 - 0.40
Connecting rod 22 0.10-0.15 C D= 0.20 - 0.40
Flywheel-side shoulder 13 ± 0.025 F D= 0.20 - 0.40
Flywheel-side half-shaft 19.6 +0.050 E D= 0.20 - 0.40
Complete drive shaft 63.5+0.1-0.05 G D= 0.20 - 0.40
Characteristics X9 Evolution 500
CHAR - 16

Diameter of crankshaft bearings.
Measure the capacity on both axes x-y.
CRANKSHAFT
Specification Desc./Quantity
Cat. 1 Standard diameter: 40.010 ÷ 40.016
Cat. 2 Standard diameter: 40.016 ÷ 40.022
Crankshaft alignment
Specific tooling
020335Y Magnetic support for dial gauge
MAX. ADMISSIBLE DISPLACEMENT
Specification Desc./Quantity
A = 0.15 mm
B = 0.010 mm
C = 0.010 mm
D = 0.10 mm
Crankcase / countershaft coupling
Besides considering it should match the crankshaft, the crankcase is chosen according to the centre
to centre distance between the seat of the crankshaft and that of the contra-rotating shaft.
Both the centre to centre distance and the pair of gears driving the contra-rotating shaft are divided into
two types (A and B) to be matched (Awith Aand Bwith 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 Desc./Quantity
Centre to centre distance of the gears without clearance 76.937 ÷ 76.867
Centre to centre distance on the crankcase 77.022 ÷ 76.992
TYPE B
Specification Desc./Quantity
Centre to centre distance of the gears without clearance 76.907 ÷ 76.837
X9 Evolution 500 Characteristics
CHAR - 17

Specification Desc./Quantity
Centre to centre distance on the crankcase 76.992 ÷ 76.962
The gears with centre to centre distance without clearance between 76.867 and 76.907 are considered
universal and can be fitted to either crankcase type.
Either the pair of gears or the crankcase is identified with the letter referring to the type (on the crank-
case, 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 CYL-
INDER 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 Measure A Thickness
«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05
«A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05
«A» MEASURE TAKEN + 0.10 ÷ + 0.185 0.8 ± 0.05
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE
CYLINDER PLANE.
Characteristics X9 Evolution 500
CHAR - 18

Products
PRODOTTI
Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP CITY HI TEC 4T Engine oil SAE5W-40,APISL,ACEAA3,JASO MA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
AUTOSOL METAL POLISH Muffler cleaning paste specialproduct for cleaningand polishing
stainless steel muffler
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based
spraygrease with NLGI2; ISO-L-XBCIB2
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
ARNICA 46 Electro-hydraulic centre-stand Highly viscous oil for hydraulic controls
X9 Evolution 500 Characteristics
CHAR - 19

INDEX OF TOPICS
TOOLING TOOL