Piaggio X9 500 Rear Brake Caliper And Rotor Repair Guide

Difficulty

Moderate

Steps

Time Required

Suggest a time??

Sections

Disassembling Piaggio X9 500 Exhaust Removal
3 steps
Disassembling Piaggio X9 500 Swingarm
4 steps
Piaggio X9 500 Rear Wheel Removal
1 step
Piaggio X9 500 Rear Brake Caliper and Rotor
2 steps

Flags

BackPiaggio X9 500
Full Screen
Options
History
Save to Favorites
Download PDF
Edit
Translate
Get Shareable Link
Embed This Guide
Notify Me of Changes
Stop Notifications

Introduction

What you need

Step 1

              Disassembling Piaggio X9 500 Exhaust Removal

Loosen the exhaust strap:
Use an 12mm wrench to loosen the exhaust band lock nut.
A 6mm Allen key is required to unscrew the bolt at the bottom of the band.
The Allen bolt is screwed into a loose nut in a cavity cast into the swing arm. It may fall out or become twisted. A magnet is helpful in retrieving it to re-align it for reassembly.
Once the bottom of the strap is loose, you can push it upward and slide the retaining pin that secures the top of the strap out to release it.

Loosen the exhaust strap:

Use an 12mm wrench to loosen the exhaust band lock nut.

A 6mm Allen key is required to unscrew the bolt at the bottom of the band.

The Allen bolt is screwed into a loose nut in a cavity cast into the swing arm. It may fall out or become twisted. A magnet is helpful in retrieving it to re-align it for reassembly.

Once the bottom of the strap is loose, you can push it upward and slide the retaining pin that secures the top of the strap out to release it.

1024

Step 2

Use a 13mm socket to loosen the clamp between the muffler and header pipe.
You do not need to remove the bolt, but you want to loosen the clamp enough to allow the exhaust to be removed without damaging the gasket between the muffler and header pipe.

Use a 13mm socket to loosen the clamp between the muffler and header pipe.

You do not need to remove the bolt, but you want to loosen the clamp enough to allow the exhaust to be removed without damaging the gasket between the muffler and header pipe.

Step 3

A Torx T40 driver is required to remove the final bolt securing the exhaust.
The Exhaust assembly is now free. Pull and wiggle the muffler back (taking care not to damage your exhaust joint gasket) until the muffler comes free from the header pipe.

A Torx T40 driver is required to remove the final bolt securing the exhaust.

The Exhaust assembly is now free. Pull and wiggle the muffler back (taking care not to damage your exhaust joint gasket) until the muffler comes free from the header pipe.

Step 4

              Disassembling Piaggio X9 500 Swingarm

Remove the 15mm nut securing the upper front corner of the swingarm.
Remove the 15mm nut securing the lower front corner of the swing arm.
Access to this nut is limited by the header pipe. A swivel extension maybe required to reach it.

Remove the 15mm nut securing the upper front corner of the swingarm.

Remove the 15mm nut securing the lower front corner of the swing arm.

Access to this nut is limited by the header pipe. A swivel extension maybe required to reach it.

Step 5

Straighten and remove the cotter pin securing the rear hub nut cover.
Don’t worry about damaging the cotter pin. It is intended to be replaced each time it is removed.
Remove the cover from the rear hub nut.

Straighten and remove the cotter pin securing the rear hub nut cover.

Don’t worry about damaging the cotter pin. It is intended to be replaced each time it is removed.

Remove the cover from the rear hub nut.

Step 6

Remove the 24mm rear hub nut. Having a friend hold the rear brake handle will help break it loose. You can also use an impact wrench to remove it if you cannot get enough torque with a hand ratchet.
There is a spacer behind the rear hub nut. It will slide off with little or no force.
There is a spacer behind the rear hub nut. It will slide off with little or no force.

Remove the 24mm rear hub nut. Having a friend hold the rear brake handle will help break it loose. You can also use an impact wrench to remove it if you cannot get enough torque with a hand ratchet.

There is a spacer behind the rear hub nut. It will slide off with little or no force.

Step 7

Grip the swingarm and pull it free of the 2 15mm studs and rear axle. You will now have access to the rear wheel.
and dont forget to remove 2 allen screws from shocks absorber and tilt it to remove swingers and tyre

Grip the swingarm and pull it free of the 2 15mm studs and rear axle. You will now have access to the rear wheel.

and dont forget to remove 2 allen screws from shocks absorber and tilt it to remove swingers and tyre

Step 8

              Piaggio X9 500 Rear Wheel Removal

Remove the five 10mm bolts securing the rear wheel.
Pull the wheel towards you, sliding it free of the rear axle.

Remove the five 10mm bolts securing the rear wheel.

Pull the wheel towards you, sliding it free of the rear axle.

Step 9

              Piaggio X9 500 Rear Brake Caliper and Rotor

Loosen the two 6mm Allen bolts securing the rear caliper.
Apply blue Locktite or a similar product to these bolts upon reassembly to prevent them from rattling loose.
Lift the caliper up and free of the brake rotor.
Take care not to damage the brake line when moving the caliper. Do not let the caliper just hang from the brake line.

Loosen the two 6mm Allen bolts securing the rear caliper.

Apply blue Locktite or a similar product to these bolts upon reassembly to prevent them from rattling loose.

Lift the caliper up and free of the brake rotor.

Take care not to damage the brake line when moving the caliper. Do not let the caliper just hang from the brake line.

Step 10

There is a spacer between the rear wheel and hub. It is not pressed on and should slide off easily.
The rear hub with rotor attached should now slide freely off of the rear axle.
Remove the five 10mm nuts, then the five 4mm Allen bolts they were locking into place to remove the rear brake rotor for replacement.
Apply Loctite or a similar product to the rotor hardware before reinstalling.

There is a spacer between the rear wheel and hub. It is not pressed on and should slide off easily.

The rear hub with rotor attached should now slide freely off of the rear axle.

Remove the five 10mm nuts, then the five 4mm Allen bolts they were locking into place to remove the rear brake rotor for replacement.

Apply Loctite or a similar product to the rotor hardware before reinstalling.

To reassemble your device, follow these instructions in reverse order.

Cancel: I did not complete this guide.

                                                                                      4 other people completed this guide.

Author

                                      with 4 other contributors

                    Eric Essen

Member since: 06/04/2010

17,473 Reputation

                                      8 Guides authored                  



                       Badges:
                       35







                                                        +32 more badges

Team

                       iFixit                        

                                                  Member of iFixit 



                    Community                     


                                            141 Members                     


                                            15,767 Guides authored

Introduction#

What you need#

Team#

Introduction

What you need

Team