PIAGGIO 500 cc - Flywheel and Starting System

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TABLE OF CONTENTS

FLYWHEEL AND STARTING SYSTEM

6

Table of Contents

Table of Contents3
Safety Prescriptions5
Maintenance Regulations5
Spark Plug7
Check and Replacement7
Air Filter7
Engine Oil Level8
Checking the Oil Level8
Topping up8
Oil Pressure Warning Light8
Replacing the Filter9
Checking the Hub Oil Level9
Renewing the Hub Oil9
Water Pump10
Adding Coolant and Bleeding Air from the System10
Engine Cooling10
Checking the Valve Gear Timing11
Valves Play Check/Adjustment11
Checking Pressure at the End of the Compression11
Specific Tooling12
Specific Tools for Piaggio X9 500 CC 4-Stroke 4-Valve13
Recommended Tools13
Necessary Tools14
Automatic Transmission15
External Transmission Cover17
Transmission Cover17
Belt Antiflapping Roller17
Driving Pulley17
Driven Pulley Axle Support18
Clutch Housing19
Driven Pulley Assembly19
Clutch Disassembly20
Pins Stop Collar20
Specific Tools20
Automatic Transmission20
- Fixed Driven Half Pulley Bearings21
- Fixed Driven Half Pulley21
- Mobile Driven Half Pulley22
- Fixed Driven Half Pulley Bearings Assembly22
- Spring23
- Driving Belt23
- Mobile Driving Half Pulley24
- Clutch Reassembly24
- Rollers Housing Assembly25
- Driven Pulley Unit Assembly26
- Housing Assembly26
- Driven Pulley Axle Support Assembly26
- Driven Pulley Axle Support Bearings Disassembly26
- Driven Pulley Axle Support Bearing Assembly27
- Fixed Driving Half Pulley Assembly29
- Belt Antiflapping Roller Assembly30
- Final Reduction32
Final Reduction33
Flywheel Cover34
Flywheel Cover35
- Thermostat Cover Disassembly36
- Flywheel Cover Disassembly37
- Water Pump Cover Disassembly37
- Flywheel Cover Components Disassembly38
- Checking the Cover Case Components41
- Cover Case41
- Bypass Piston and Spring42
- Water Pump Shaft43
- Water Pump Rotor43
- Checking the Water Pump Cover43
- Reed Valve44
- Assembling the Flywheel Cover Components44
- Stator Assembly46
- Flywheel Cover Assembly on the Engine47
- Water Pump Cover Assembly48
- Thermostat Cover Assembly49
- Flywheel and Starting System51
Flywheel and Starting System52
- Starting Motor Disassembly53
- Magneto Flywheel Disassembly53
- Checking the Magneto Flywheel Components56
- Starting Ring Gear and Freewheel57
- Idler Gear with Torque Limiter57
- Freewheel Assembly on Magneto Flywheel58
- Starting Ring Gear Assembly on Magneto Flywheel59
- Idler Gear with Torque Limiter Assembly59
- Magneto Flywheel Assembly on Engine60
- Starting Motor Assembly61
- Flywheel Cover Assembly62
- Thermal Unit and Timing System63
Thermal Unit and Timing System64
- Intake Manifold Disassembly65
- Tappet Cover Disassembly65
- Valve Gear Disassembly66
- Camshaft and Equalizers Disassembly68
- Head Disassembly69
- Valves Disassembly70
- Cylinder and Piston Disassembly71
- Checking Connecting Rod Small End72
- Gudgeon Pin Diameter72
- Piston73
- Gas Rings73
- Piston Assembly74
- Cylinder Gasket Selection75
- Cylinder Assembly76
- Compression Rings Assembly76
- Head Check77
- Checking the Valve Sealing Surfaces77
- Checking Valve Seat Wear78
- Valves Check78
- Standard Diameter78
- Minimum Allowed Diameter78
- Valve-Guide Play Check79
- Valve Standard Length79
- Valves Tightness Test80
- Springs, Caps, Cotters Check80
- Valves Assembly81
- Camshaft Check82
- Limits Allowed82
- Head and Timing System Parts Assembly83
- Checking Timing System Parts83
- Checking the Revs-Timing Sensor Air Gap89
- Tappets Cover Assembly90
- Intake Manifold Parts Disassembly91
- Injector Disassembly91
- Injector Assembly92
- Disassembly of Throttle Body from Manifold92
- Throttle Body Assembly to Manifold93
- Intake Manifold Assembly to Engine93
- Crankcase and Driving Shaft94
Crankcase and Driving Shaft95
- Engine Crankcase Opening97
- Removing the Countershaft Control Gear and the Oil Pump98
- Driving Shaft Disassembly98
- Countershaft Disassembly99
- Oil Pump Disassembly99
- Replacing the Countershaft Bearings100
- Half Crankcase Flywheel Side100
- Checking Driving Shaft Components102
- Driving Shaft Alignment Check104
- Engine Half Crankcase Check105
- Main Bearing Brass Check106
- Half Shafts Coupling with Half Crankcase and Brass107
- Oil Pump108
- Countershaft108
- Oil Pump Assembly108
- Driving Shaft Assembly109
- Crankcase Coupling110
- Fuel Injection113
- Index114
- EMS Fuel Injection System115
- Precautions117
- Troubleshooting118
- Suggestions for Troubleshooting118
- Components Layout119
- Layout of the Ems Control Unit Terminals and Immobilizer120
- Control Unit Side120
- System Side120
- Ems Control Unit120
- Ems System Diagram121
- The Engine Does Not Start Even with Normal Motoring over122
- Difficult Cold Start or Warm Start of the Engine123
- The Engine Does Not Maintain Idling Speed124
- Idling Speed Is Unstable124
- Idling Speed Is too Low124
- The Engine Does Not Turn over on Idling Speed125
- Idling Speed too High125
- Backfiring in Deceleration125
- Irregular Running of the Engine with Throttle Valve Slightly Open126
- Poor Engine Running on Full Power127
- Irregular Running of the Engine During Acceleration Stage127
- Presence of Detonation (Combustion Shock)127
- Immobilizer System128
- System Components128
- Unprogrammed System129
- With Master Key130
- LED Indications130
- System Programming130
- Blinking Deterrent Light131
- System Reprogramming in Case of Component Replacement132
- Diagnostic Codes132
- Diagnostic Code N1132
- Feed Circuit of the Decoder and the Fuel Injection Control Unit139
- Check that Circuit Feed Is Constant139
- Control of the Feed Circuit Deriving from the Key Switch142
- Diagnosis Tester Link Circuit146
- Circuit Diagram146
- Fuel Injection Indicator Circuit148
- Self-Diagnosis System150
- General Details151
- Fuel Supply System151
- Pump Feed Circuit152
- Circuit Control153
- Hydraulics Control and System Maintenance158
- Pressure Regulator Control159
- Pump and Fuel Filter Control161
- Check the Free Flow Capacity164
- Pump Electrical Controls165
- Resistive Check165
- Pump Absorption Control165
- Fuel Filter Control166
- Pump Support Overhaul166
- Installation of the Pump Support on to the Tank169
- Injector Circuit Control170
- Injector Hydraulics Control174
- Revolutions Sensor176
- Hv Coil180
- Shielded Cap Control184
- Ignition Timing184
- Coolant Temperature Sensor186
Injection187
- Air Intake Temperature Sensor190
- Pressure Sensor194
- T.p.s.=Throttle Position Sensor195
- Tps Reset199
- Stepper Motor201
- Minimum Carburation Regulation207
- Electrical Fan Control Circuit211
- To Control the Circuit212
- Revolutions Counter Control Circuit216
- Lubrication220
- Specifications221
- General Characteristics of the Lubrication System222
- Diagnostics Guide223
Cooling System228
- Cooling229
- System Description231
- System Filling Rule231
- Thermostat Control232
- Electroventilation Control234
- System Seal Control235
- Starting236
- Starting System Description237
Starter237
Controls and Diagnostics Guide238

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