1 2 3 Removal of the rider's saddle Removal of the passenger's saddle Procedure 1. - Open the saddle cover storage compartment. - Remove: . The screw. . The saddle cover. . The rider's saddle. Open the passenger's saddle. - Remove: . The 2 upper pivot clips. . The 2 pivot pins. 4 - Flip up the seat to the front of the vehicle. - Remove: . The 2 lower pivot clips. . The 2 pivot pins. - Remove the passenger seat. Removal of a RH or LH grab handle Procedure 2. - Remove the grab handle trim. - Remove the 2 nuts and the screw that secure the handle. - Remove the grab handle. 5 Removal of a RH or LH taillight taillight bulb - Remove the grab handle. See: Procedure 2. - Remove the taillight. (1 screw). Removal of a - Remove the 4 screws from the taillight unit. - Separate the 2 parts in order to reach the bulbs. 6 Removal of a RH or LH side cover Procedure 3 - Remove: - The rider's saddle. See: Procedure I. Page: 30. - The grab handles. See: Procedure 2. Page: 31. S Remove the rear cover and its trim. (4 screw). - Remove the 2 screws that secure the side cover linkage and the footboard. 7 - Push aside the footboard in order to clear side cover holder eyelet. Remove the side cover. - Disconnect the taillight. Removal of the storage compartment Procedure 4. - Remove the side fairings. See: Procedure 3. Page: 32. - Disconnect the plate light and the saddle opening contact switch. Remove the storage compartment. (4 screws and 2 nuts). 8 When dismantling the splash guard, fit the screws with standard thread lock. Removal of the tank covers Procedure 5. - The rider's saddle. See: Procedure I. - Page: 30. Open the tank filler cap door. Remove the 4 screws that secure the rear panel. Remove the upper fairing. 9 - Remove the utility hanger. (2 screw). - Remove 1 nut and 2 screws that secure the lower fairing. - Remove the screw that secures the rear cover I footboard on each side of the vehicle. (1) - Push slightly aside the cover I footboard assembly and remover the fuel tank cover panel by sliding it backwards. - Removal of a RH or LH footboard Procedure 6. - Remove the tank cover panel. See: Procedure 5. - Remove the footboard mat. - On each side remove: . 8 plastic screws. (1) . 3 washer head screws. 06 mm. (2) . I washer head screw. 05 mm. (3) 10 - Press on the underbody panel in order to separate it from the footboard. (A) - Separate the footboard from the rear fairing and bracket that anchors it to the body. (B) - Separate the front of the footboard which is linked to the rear part of the leg shield panel. (C) 11 - Removal of the front top cover panel - Procedure 7. - Remove the front top cover panel. (4 screw). Removal of the headlight and sidelight assemblies Removal of the headlight bulbs - Remove the front top cover panel. See: Procedure 7. To reach the bulbs, remove the headlight. (3 screw) 12 - Removal of the front shield panel - Procedure 8. - Remove the front top cover panel. See: - Procedure 7. - On each side remove: . 2 plastic screws that secure the front leg shield to the underbody cover. (1) . 2 plastic screws that secure the footboard the underbody cover. (2) - Push aside the underbody cover to reach the screw that secures the front shield panel. (3) - On each side remove: . 5 plastic screws. (4) . I washer head screw. 06 mm. (5) . I washer head screw. 05 mm. (6) - Disconnect the headlights. - Remove the front shield panel. 13 - Removal of the rear shield panel - Remove the ignition key. - Remove the tank cover panel. See: - Procedure 5. - Remove the front top cover panel. See: - Procedure 7. - Remove: · The ignition switch trim. · The handlebar upper fairing (8 screw) (1). - On each side remove: · 2 plastic screws that secure the front leg shield to the underbody cover. · 2 plastic screws that secure the footboard to the underbody cover. - Push aside the underbody cover to reach the screw that secures the front shield panel. (2) 14 - On each side remove: · 6 plastic screws. (3) · 2 washer head screws. 06 mm. (4) - Separate the front shield panel from the rear shield panel in order to reach the bracket that connects the rear shield panel to the footboard. (A) - Pull upwards the lower part of the shield panel in order to separate it from the footboard. 15 - Relove the eyelet (B) from the shield panel and the eyelet (C) from the instrument cluster fairing in order free the rear shield panel. - Topple the rear shield panel while separating it from the footboards in order to reach the header tank and the accessory plug. - Remove the header tank. (Right side). - Disconnect the accessory plug. (Left side). - Remove the rear shield panel. 16 - Removal of the dirt shield - Remove the front shield panel. See: Procedure 8. - Remove the center screw which secures the dirt shield to the underbody cover. - Disconnect the speed sensor. - Pull the speed sensor control out of the dirt cover. - Lift the front of the vehicle while making sure the wheel is in line with the vehicle. - Remove the dirt cover by sliding it behind the wheel as shown. - Removal of the battery holder Procedure 9. - Remove the tank cover panel. See: Procedure 5. - Disconnect and remove the battery. - Unclip from the battery holder: · The fuses. (1) · The relays. (2) · The diagnosis plug.(3) - Remove the battery bracket. (2 screws and I nuts). 17 - Removal of the instrument cluster - Remove: - The front top cover panel. See: Procedure 7. · The wind deflector. · The handlebar upper fairing. - On each side remove: · 1 plastic screw. (1) · 1 washer head screw. 05 mm. (2) · 1 washer head screw. 06 mm. (3) - Press the locking system (1) to actuate the positioning lever (2) of the instrument cluster's connector. - Push the lever all the up (A) in order to remove the connector from the instrument cluster. - Remove the instrument cluster fairing. Note: When connecting, the lever must be pushed all the way to (A) in order not to damage the connector. 18 PIAGGIO MOTOR SERVICE STATION MANUAL Engine Master 500 cc 19 SERVICE STATION MANUAL PEUGEOT SATELIS 500 cc This manual has been prepared by Piaggio & C. S.p.A. for use in the workshops of authorised Piaggio subagents. It is assumed that the person utilising this manual for servicing or repairing Piaggio vehicles has a knowledge principles of mechanics and standard procedures for vehicle repair. Any important changes in vehicle or specific repair operations will be divulged by means of updates to this manual. Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer of this manual concerning specific tools and equipment and the special tools catalogue. Critical information in the manual is indicated as follows. N.B.: Important information for facilitating and explaining a procedure. Warning - Procedures that must be followed to avoid damage to the vehicle. Caution - Procedures that must be followed to eliminate the risk of injury to repair / service personnel. 20 Specifications (500 cc 4-stroke, 4-valves H2 0 engine) ENGINE Type .............................................................................................................single-cylinder, 4 stroke Bore.........................................................................................................................................92 mm Stroke.......................................................................................................................................69 mm Displacement........................................................................................................................460 cm3 Compressionratio....................................................................................................................10.5 : 1 Timing ..............................................................................................chain-operated overhead single-shaft flywheel side, integrated phonic wheel, 4- valves and automatic starting valve lifter Valves play: intake............................................................................................................... 0.20 mm exhaust............................................................................................................ 0.20 mm Valves play adjustment........................................................................................ threaded register on equalizers Idle speed......................................................................................................................1450±50 rpm CO% value ................................................................................................................................. 1±1. Starting system ............................................................................................................electric starter Lubrication........................................... trochoid pump (inside the crankcase), oil filter and pressure adjustment by-pass Lubrication pressure.................................................................................................................. 4 bar Minimum allowed pressure (at 100° ................................................................................... 0.8 bar C) Fuel system ........................................................electronic injection with electric fuel pump, throttle body Ø 38mm and single injector Max power (at crankshaft) ......................................................................................29 kW (39 CV) bei 7250 rpm Max torque (at crankshaft) .................................................................................... 40 N·m (4 Kgm) bei 5500 rpm Cooling system.................... liquid, by means of motorized pump, 3-way thermostat and electric fan. Transmission .............................automatic speed variator by means of expanding pulleys, V-belt, automatic clutch, reduction gear, and transmission compartment cooling by air forced-circulation. Ignition type .................... high efficiency inductive type integrated with injection, variable spark advance and separated high voltage coil Spark advance (before T.D.C.) ............... variable controlled by injection power unit Spark plug .............................................................................CHAMPION RG 6 YC NGK CR7 EKB Engine-wheel ratio ............................................................................. short: 1/11.988 long: 1/ 4.86 Engine oil ................................................................................................SAE 5W/40 exceeding API SJ specifications Quantity ............................................................................................................................. ~ 1.7 l Hub oil........................................................................................................................TUTELA ZC 90 Quantity ....................................................................................................................................250cc Cooling system capacity ........................................................................................................... ~ 1.8 21 Spark plug Check and replacement Warning - Remove the spark plug when the engine cold. Replace the spark plug every 12,000 Km. The use of unsuitable control units or spark plugs other than those specified can seriously damage the engine. Recommended spark plug: CHAMPION RG 6 YC NGK CR 7 EKB - Put the vehicle on its central stand. - Open the door on the left side of the vehicle by levering in the recess in the lower part of the door after removing the screw. - Disconnect the spark plug high voltage cable cap; - Unscrew the spark plug with the spanner provided; check the spark plug to see if the insulator is cracked, the electrodes are worn out or excessively sooty. Also check the condition of the sealing washer and measure : 0.7 - 0.8 mm - If necessary adjust the gap by carefully bending the side electrode. If the spark plug has any of the defects mentioned above replace it with a plug of the recommended type; - Insert the plug into the hole with the proper inclination, screw it in fully by hand and then tighten it with the specially designed spanner. Tightening torque: 10 N·m (1 Kg·m) - Push the spark plug cap all the way down onto the spark plug and then proceed to the reassembly. Air filter - Remove the left-hand lower side panel - Remove the cleaner cap after unscrewing the eight fixing screws, including one screw of the knob type. - Pull out the filter element. - Replace the air filter with a new one. N.B.: Check and if necessary blow the air filter every 6,000 km. Direct the air jet from the inside to the outside of the filter (i.e. in the opposite direction to the air flow during normal engine operation). Warning - If the vehicle is mostly used on dusty roads, the air filter needs to be cleaned and replaced at shorter intervals than indicated in the Maintenance ...