PIAGGIO X7 250ie Service Station Manual

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SERVICE STATION MANUAL

xxxxxx

X7 250ie

SERVICE STATION

MANUAL

X7 250ie

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.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL

X7 250ie

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.

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 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

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; 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 it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust 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 appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools 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.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

Characteristics X7 250ie

CHAR - 2

Vehicle identification

To read the chassis prefix, lift the saddle and remove the lid «A».

The engine prefix «B» is stamped near the lower support of the rear left shock absorber.

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Chassis prefix M62200

Engine prefix M622M

X7 250ie Characteristics

CHAR - 3

Dimensions and mass

VEHICLE EARTHING

Specification Desc./Quantity

Kerb weight 162 kg

Maximum weight allowed 360 kg

Engine

ENGINE

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Cubic capacity 244 cm³

Bore x Stroke 72 x 60 mm

Compression ratio 11 ± 0.5 : 1

Engine idle speed 1,700 ± 100 rpm

Timing system 4 valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm

Max. Power 16.3 kW at 8,750 rpm

MAX. torque 11.2 Nm at 8,500 rpm

Lubrication Engine lubrication with lobe pump (inside crank-

case) controlled by a chain with double filter: mesh

and paper.

Lubrication pressure 4 bar

Characteristics X7 250ie

CHAR - 4

Specification Desc./Quantity

Minimum lubrication pressure (100° C) 0.8 bar

Fuel supply Electronic injection with Ø 32-mm throttle body

and electric fuel pump.

Cooling Forced coolant circulation system.

Fuel Unleaded petrol (95 RON)

Exhaust muffler Absorption-type exhaust muffler with 3-way cata-

lytic converter and lambda probe.

Emission regulations EURO 3

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque

server, V belt, dry self-ventilating automatic cen-

trifugal clutch and transmission housing with

forced air circulation.

Final reduction Gear reduction unit in oil bath.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1.3 l

Transmission oil 250 cm³

Cooling system fluid ~ 2 l

Fuel tank (reserve) ~ 12 l (~2 l)

Fork oil (quantity per stem) 133 cm³

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Start-up Electric

Ignition Electronic inductive discharge ignition, high effi-

ciency, with separate HV coil.

Ignition advance α/N three-dimensional map managed by control

unit

Spark plug CHAMPION RG 4 PHP

Alternative spark plug -

Battery 12V-12Ah

Generator In alternating current

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Chassis Tubular and sheet steel.

X7 250ie Characteristics

CHAR - 5

Specification Desc./Quantity

Front suspension Hydraulic telescopic fork with Ø 35 mm stem

Front suspension travel 94 mm

Rear suspension Two double-acting shock absorbers, adjustable to

four positions at preloading.

Rear suspension travel 89 mm

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 260 disc brake with hydraulic control activated

by handlebar right lever.

Rear brake Ø 240 mm disc brake with hydraulic control acti-

vated by the handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rim type Light alloy rims.

Front rim 14'' x 3.50 Rear rim 13'' x 3.50

Front tyre Tubeless, 120/70-14'' 55P

Rear tyre Tubeless, 140/60 - 13'' 63P

Front tyre pressure (with passenger) 2 bar (2 bar)

Rear tyre pressure (with passenger) 2.2 bar (2.5 bar)

Tightening Torques

STEERING

Name Torque in Nm

Fixing screws for handlebar control assembly U-

bolts

7 ÷ 10

Steering tube upper ring nut 40 ÷ 45

Steering tube lower ring nut 14 ÷ 17

Handlebar fixing screw 43 ÷ 47

CHASSIS

Name Torque in Nm

Stand fixing bolt 40 ÷ 45

Engine and vehicle side swinging arm junction bolt 33 ÷ 41

Engine-swinging arm bolt 64 - 72

Body shell - Swinging arm pin 76 ÷ 83

Screw fixing the silent-block support plate to the

body

42 ÷ 52

FRONT SUSPENSION

Name Torque in Nm

Fork leg screw 6 ÷ 7

Characteristics X7 250ie

CHAR - 6

Name Torque in Nm

Front wheel shaft 45 ÷ 50

Fork plate screw 25 ÷ 34

Hydraulic rod fixing screw 25 ÷ 35*

Stem support clamp tightening screws 20 ÷ 25

Fork locking screws cap 15 ÷ 30

FRONT SUSPENSION

Product Description Specifications

(*) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-

strength threadlock

REAR SUSPENSION

Name Torque in Nm

Upper shock absorber clamp 33 ÷ 41

Shock absorber lower clamp 33 ÷ 41

Shock absorber-crankcase attachment bracket 20 ÷ 25

Rear wheel axle 104 ÷ 126

Muffler arm clamping screws 27 ÷ 30

Silencer - muffler supporting arm fixing screws 24 ÷ 27

Lambda probe clamp on exhaust manifold 40 ÷ 50

Manifold - muffler diaphragm tightening clamp 16 ÷ 18

FRONT BRAKE

Name Torque in Nm

Oil bleed screw 12 - 16

Brake disc screws 8 ÷ 10

Brake fluid pipe-calliper fitting 20 ÷ 25

Brake fluid pump - hose fitting 16 ÷ 20

Screw tightening calliper to the support 20 ÷ 25

Tightening screw for calliper support to the fork 41 ÷ 51

REAR BRAKE

Name Torque in Nm

Oil bleed screw 12 - 16

Brake disc screws 8 ÷ 10

Rear brake calliper-pipe fitting 20 ÷ 25

Rear brake pump-pipe fitting 16 ÷ 20

Screw tightening calliper to the support 42 ÷ 52

REAR BRAKE

Product Description Specifications

(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-

strength threadlock

FLYWHEEL

Name Torque in Nm

Flywheel cover screw 11 ÷ 13

Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength

threadlock)

Flywheel nut (250) 94 ÷ 102

Pick-Up clamping screws 3 ÷ 4

Screw fixing freewheel to flywheel 13 ÷ 15

X7 250ie Characteristics

CHAR - 7

LUBRICATION

Name Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 4 ÷ 6

Oil pump cover screws 7 ÷ 9

Screws fixing oil pump to the crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

CYLINDER HEAD

Name Torque in Nm

Spark plug 12 ÷ 14

Head cover screws 6 ÷ 7

Nuts fixing head to cylinder 7±1 + 10±1 + 270°

Head fixing side screws 11 ÷ 12 Nm

Starter ground screw 7 ÷ 8.5

Tappet set screw lock nut 6 ÷ 8

Inlet manifold screws 11 ÷ 13

Timing chain tensioner slider screw 10 ÷ 14

Starter ground support screw 11 ÷ 15

Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 4 ÷ 6

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11 ÷ 13

Clutch unit nut on driven pulley 45 ÷ 50

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screws 24 ÷ 27

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws

4 ÷ 6

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength

threadlock)

COOLING

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Bleed screw: 3

Characteristics X7 250ie

CHAR - 8

Overhaul data

Assembly clearances

Cylinder - piston assy.

ENGINE COUPLING CATEGORY

Name Initials Cylinder Piston Play on fitting

Cylinder M 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder N 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064

Piston O 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 - 0.064 Piston P 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 - 0.064

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo Durata/Valore Testo Breve (< 4000

car.)

Indirizzo Immagine

Crankshaft Crankshaft to crankcase

axial clearance

Crankshaft to crankcase axial clearance

X7 250ie Characteristics

CHAR - 9

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

16.6 +0-0.05 A D = 0.20 - 0.50

Flywheel-side half-

shaft

16.6 +0-0.05 B D = 0.20 - 0.50

Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50

Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

Slot packing system

Characteristic

Compression ratio

10.5 ÷ 11.5 : 1

Characteristics X7 250ie

CHAR - 10

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.

N.B.

MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON A GROUND PLANE

ENGINE 250 SHIMMING

Name Measure A Thickness

shimming 3.70 - 3.60 0.4 ± 0.05 shimming 3.60 - 3.40 0.6 ± 0.05 shimming 3.40 - 3.30 0.8 ± 0.05

X7 250ie Characteristics

CHAR - 11

Products

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Transmission oil

250 cm³

Locking torques (N*m)

Hub oil drainage plug 15 ÷ 17

Air filter

To reach the air filter:

- Undo the nine screws «A».

- Remove the air-box cover «B»

Cleaning:

- Wash the sponge with water and mild soap.

- Dry it with a clean cloth and short blasts of compressed air.

- Soak it in a mixture of 50% petrol and 50% specified oil.

- Gently squeeze the filtering element with your hands but do not wring it; allow it to drip dry and then refit.

CAUTION

X7 250ie Maintenance

MAIN - 7

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CONTROLS OF THE AIR FILTER TO AVOID DAMAGING THE ENGINE.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil

Replacement

Change oil and replace filter as indicated in the scheduled maintenance table.

- In order to facilitate oil drainage, unscrew the cap/ dipstick «A».

- Unscrew the mesh pre-filter drainage plug «B» on the flywheel side and let the oil drain off.

- Once all the oil has drained through the drainage hole, unscrew and remove the oil cartridge filter «C ».

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Add the recommended engine oil through plug «A». Then start up the vehicle, let it run for a few

Maintenance X7 250ie

MAIN - 8

minutes and shut it off. After five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed.

N.B.

THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Characteristic

Engine oil

1.3 l

Check

This operation must be carried out with the engine cold and following the procedure below:

- Place the vehicle on its centre stand and on flat ground.

- Make sure the adjustment of the rear suspension is set to the minimum preloading position.

- Unscrew the cap/dipstick «A», dry it with a clean cloth and reinsert it, by screwing it in complete- ly.

-Remove the cap/dipstick «A» again and check that the level is between the MAX and MIN marks. top-up, if required. 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, wait at least 10 minutes after the engine has been stopped so as to get the correct level.

Oil top up

X7 250ie Maintenance

MAIN - 9

The oil should be topped up after having checked the level and in any case by adding oil without exceeding the MAX level indicated on the cap/ dipstick.Restoring the level from MIN to MAX requires approximately 400 cm³ of oil.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before the fitting. Change the engine oil.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

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

-Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the flywheel cover as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference is opposite the indicator on the head, turn the crankshaft once more.

Maintenance X7 250ie

MAIN - 10

For the use of this reference mark, remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a calliper spanner applied to the camshaft command pulley casing.

Cooling system

Level check

Check coolant when the engine is cold and as indicated in the scheduled maintenance tables, following the steps below.

- Set the vehicle upright on the stand and remove the cover by undoing screw «A».

- Remove the expansion tank cover «B» by turning it anticlockwise.

- Look inside the expansion tank and check that the level is between MIN and MAX. Top up if the coolant is below the MIN level. If the level is not correct, proceed to top-up when the engine is cold. If it is necessary to top up the coolant frequently, or if the expansion tank is completely dry, you should look for the cause in the cooling system.

WARNING

X7 250ie Maintenance

MAIN - 11

IN ORDER TO AVOID BURNS, DO NOT UNSCREW THE EXPANSION TANK CAP WHILE THE ENGINE IS STILL HOT.

WARNING

IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RIDING, IT IS IMPORTANT TO MAKE SURE THAT THE LEVEL DOES NOT EXCEED THE REFERENCE TONGUE TOO MUCH. IN ORDER TO GUARANTEE THE PROPER FUNCTION OF THE ENGINE, IT IS NECESSARY TO KEEP THE RADIATOR GRILLE CLEAN.

Recommended products

SPECIAL AGIP PERMANENT fluid coolant

Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16

Braking system

Level check

The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows:

- Rest the vehicle onto the centre stand, with the handlebar centred.

- Check the fluid level through the sight glass «A». A certain lowering of the level is caused by wear on the pads.

Top-up

Proceed as follows:

- Remove the rear-view mirrors.

- Working from both sides of the vehicle, undo the

three screws «A» and remove the front frame.

Maintenance X7 250ie

MAIN - 12

- Remove the windshield.

- Undo the screw «B» and remove the front han-

dlebar cover «C» partially.

- Remove the cap «E» by loosening the two screws «D» and restore the fluid level by adding prescribed fluid type only, without exceeding the maximum level. This operation applies to top up the rear brake pump. Follow the same procedure for the front one.

WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. COOLING SYSTEM FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION

AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN, AND CLOTHING. IN CASE OF CONTACT, RINSE WITH WATER. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING. NEVER USE BRAKING FLUID KEPT IN CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT4 Synthetic fluid

X7 250ie Maintenance

MAIN - 13

Headlight adjustment

Proceed as follows:

- Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pressure, onto a flat surface, 10 m away from a half-lit white screen; make sure the vehicle axis is perpendicular to the screen.

- Turn on the headlight and check that the borderline of the projected light beam should be lower than 9/10 of the distance from the ground to the centre of the vehicle's headlight, and higher than 7/10.

- Otherwise, adjust the headlight.

N.B.

THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.

In order to adjust the light beams:

- Remove the PIAGGIO clip-on badge and undo the screw «A».

- Working on both sides of the vehicle, undo the screw «B» and remove the front headlight cover.

Maintenance X7 250ie

MAIN - 14

- Act on the screws «C» in order to aim the light properly.

X7 250ie Maintenance

MAIN - 15

Maintenance X7 250ie

MAIN - 16

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

Fuel pump Check the injection load relay

Excess of encrustations in the combustion cham-

ber

Descale the cylinder, the piston, the head and the

valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Air filter blocked or dirty. Remove the sponge, wash with water and car

shampoo, then soak it in a mixture of 50% petrol

and 50% specific oil. Press with your hand without

squeezing, allow it to drip dry and refit.

Oil level exceeds maximum Check for causes and fill to reach the correct level

Lack of compression parts, cylinder and valves

wear

Replace the worn parts

Transmission belt worn Replace

Inefficient automatic transmission Check the rollers, the pulley movement and make

sure the drive belt is in good conditions; replace

the damaged parts and lubricate the moveable

driven pulley with specific grease.

Clutch slipping Check the clutch system and/or the bell and re-

place if necessary

Overheated valves Remove the head and the valves, grind or replace

the valves

Wrong valve adjustment Adjust the valve clearance properly

Valve seat distorted Replace the head assembly

Starting difficulties

DIFFICULT STARTING

Possible Cause Operation

Rpm too low at start-up or engine and start-up

system damaged

Check the starter motor, the system and the torque

limiter

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clear-

ance

- Engine flooded. Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to

expel the fuel excess taking care to connect the

cap to the spark plug, and this in turn to the ground.

If the fuel tank is empty, refuel and start up.

Air filter blocked or dirty. Remove the sponge, wash with water and car

shampoo, then soak it in a mixture of 50% petrol

and 50% specific oil. Press with your hand without

squeezing, allow it to drip dry and refit.

Troubleshooting X7 250ie

TROUBL - 2

Possible Cause Operation

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit

components

Battery flat Check the charge of the battery, if there are any

sulphur marks, replace and use the new battery

following the instructions shown in the chapter

Intake coupling cracked or clamps incorrectly

tightened

Replace the intake coupling and check the clamps

are tightened

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace

the valves

Misshapen/worn valve seats Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston

rings

Worn or broken piston rings or piston rings that

have not been fitted properly

Replace the piston cylinder unit or just the piston

rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou-

pling seal

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Care-

fully clean the By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump

components

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level adding the recommended oil

type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Faulty clutch 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 anom-

alous way

X7 250ie Troubleshooting

TROUBL - 3

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation

Inefficient braking system 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 replace

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.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump

seals, replace

Brake disc slack or distorted Check the brake disc screws are locked; measure

the axial shift of the disc with a dial gauge and with

wheel mounted on the scooter.

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective sliding of pistons Replace the calliper.

Brake disc slack or distorted 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.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Re-inflated or glued rubber gaskets Replace the calliper.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the rotation seats and the steering fifth

wheels.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the rotation seats and the steering fifth

wheels.

Troubleshooting X7 250ie

TROUBL - 4

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

Malfunctions in the suspension system If the front suspension is noisy, check: locking tor-

ques, headstock components, inspect forks.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Seal fault or breakage Replace the shock absorber

X7 250ie Troubleshooting

TROUBL - 5

Troubleshooting X7 250ie

TROUBL - 6

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Components arrangement

1. Injection ECU: Remove the inspection flap

placed in the helmet compartment to reach it.

2. Stator: Remove the left side fairing to reach the connector.

Electrical system X7 250ie

ELE SYS - 2

3. Remote control switches: Remove the shield back plate to reach them.

KEY A. Injection load remote control switch B. Stop light remote control switch C. Remote control switch for electric fan D. Headlight remote control switch

4. Turn indicators control device: Remove the front

shield to reach it.

5. Horn: Remove the left footrest to reach it.

6. Fuel level transmitter: Remove the central cover

to reach it.

X7 250ie Electrical system

ELE SYS - 3

7. Spark plug: Remove the lid placed on the right side fairing to reach it.

Characteristic

Spark plug

CHAMPION RG 4 PHP

8. HV coil: Remove the right side fairing to reach it.

Characteristic

HV coil resistance primary value:

~ 0.9 Ω

HV coil secondary resistance value

~ 3.4 kΩ

9. Oil pressure sensor: Placed at the bottom at the back of the right side fairing.

10. Start-up remote control switch: Remove the right side fairing to reach it.

Electrical system X7 250ie

ELE SYS - 4

11. Voltage regulator: Remove the side fairings to reach it.

12. Battery: Remove the battery cover placed in the helmet compartment to reach it.

Electric characteristic

Battery

12V 12Ah

13. Diagnostics socket: Remove the battery cover placed in the helmet compartment to reach it.

14. Fuses: Remove the battery cover placed in the helmet compartment to reach it.

Punti di massa

There are three ground points in the electrical system:

X7 250ie Electrical system

ELE SYS - 5

A. Ground point on the chassis. Remove the left footrest to reach it.

B. Ground point on the chassis. Remove the left footrest to reach it.

C. Ground point on the engine. Placed at the bottom at the back of the left side fairing.

Checks and inspections

This section is devoted to the checks on the electrical system components.

Ignition circuit

No spark plug

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

Electrical system X7 250ie

ELE SYS - 6

HV coil primary resistance value:

Disconnect the connector of the HV coil and measure the resistance between the two terminals.

Characteristic

HV coil resistance primary value:

~ 0.9 Ω

HV coil secondary resistance value:

1) Disconnect the HV cable from the spark plug

and measure the resistance between the spark plug cap and the HV coil negative terminal.

2)Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable end and the HV coil negative terminal (see figure).

3) Measure the resistance between the 2 ends of the spark plug cap.

Characteristic

HV coil secondary resistance value with spark plug cap

~ 8.4 kΩ

HV coil secondary resistance value:

~ 3.4 kΩ

Spark plug cap resistance value

~ 5 kΩ

Battery recharge circuit

The recharge system is provided with a three-phase alternator with permanent magneto 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. 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

WARNING

THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

X7 250ie Electrical system

ELE SYS - 7

1) Disconnect the connector between stator and regulator with the three yellow cables as shown in the photograph.

2) Measure the resistance between each of the yellow terminals and the other two.

Characteristic

Stator phase resistance value

~ 0.6 Ω

3) Check that there is insulation between the each yellow cable and the ground.

Voltage regulator check

With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. Voltage should not exceed 15 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.

Electric characteristic

Control voltage

14÷15 V to 1500÷12000 rpm

Recharge system voltage check

Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and, turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine. In case the generated current value is lower than 10A, repeat the test using a new regulator and/ stator alternatively.

Electrical system X7 250ie

ELE SYS - 8

Starter motor

KEY

1. Battery

2. Fuse No. 2

3. Key switch contacts

4. Fuse No. 10

5. Stop button on rear brake

6. Stop button on front brake

7. Injection ECU

8. Starter button

9. Start-up remote control switch

10. Starter motor

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

If the starter motor does not operate correctly, proceed as follows:

1) Check the continuity of the Red cable between the battery and the start-up remote control switch. Also check continuity between the latter and the starter motor.

2) Check the starter motor ground connection.

3) Check fuses No. 2 and No. 10.

4) Check key switch contacts.

5) Check stop buttons and the starter button.

X7 250ie Electrical system

ELE SYS - 9

6) Check the start-up remote control switch.

7) Check wiring continuity.

Horn control

KEY

1. Battery

2. Fuse No. 2

3. Key switch contacts

4. Fuse No. 10

5. Horn button

6. Horn

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

In case the horn does not operate correctly, proceed as follows:

1) Check fuses No. 2 and No. 10.

2) Check key switch contacts and horn button.

3) Check wiring continuity.

4) Check the horn ground connection.

Electrical system X7 250ie

ELE SYS - 10

Turn signals system check

KEY

1. Battery

2. Fuse No. 2

3. Key switch contacts

4. Fuse No. 10

5. Turn indicators control device

6. Turn indicator switch

7. Left turn indicator bulbs

8. Right turn indicator bulbs

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

If the circuit does not work properly, proceed as follows:

1) Check that bulbs operate properly.

2) Check fuses No. 2 and No. 10.

3) Check key switch contacts.

4) With the key switch set to «ON», check if there is intermittent voltage between the output Blue-Black

cable from the turn indicator control device and the ground lead.

5) If no voltage is detected, check cable harness continuity and, if necessary, restore it. If it is not damaged, replace the turn indicator control device.

6) Check the turn indicator switch.

X7 250ie Electrical system

ELE SYS - 11

7) Check turn indicator switch cable harness continuity.

8) Check the bulbs ground connection.

level indicators

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

If faults are detected:

1) With a multimeter, check resistance values between the White-Green cable and the Black cable of the fuel level transmitter by moving the arm with the float.

2) If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted.

Electric characteristic

Resistance value when the tank is full

<= 7 Ω

Resistance value when the tank is empty

90 +13/-3 Ω

Lights list

LIGHT BULB TABLE

Specification Desc./Quantity

1 High-beam light bulb Type: HALOGEN (H7)

Power: 12V - 55W

Quantity: 1

2 Low-beam bulb Type: HALOGEN (H1)

Power: 12V - 55W

Quantity: 1

3 Front tail light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 2

4 Instrument panel bulb Type: ALL GLASS

Power: 12V - 1.2W

Quantity: 3

5 Front turn indicator bulb Type: ALL GLASS

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

6 Rear turn indicator light bulb Type: SPHERICAL

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

7 Tail light and stop light bulb Type: SPHERICAL, TWIN-FILAMENT

Electrical system X7 250ie

ELE SYS - 12

Specification Desc./Quantity

Power: 12V - 5/21W

Quantity: 2

8 License plate light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 1

Fuses

The electrical system is fitted with twelve fuses divided between two fuse boxes, located in the battery compartment, for the protection of the various circuits in the system. The chart shows the position and specifications of the fuses in the vehicle.

CAUTION

BEFORE REPLACING THE BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

FUSES

Specification Desc./Quantity

1 Fuse No. 1 Capacity: 30 A

Protected circuits: Battery recharge circuit.

2 Fuse No. 2 Capacity: 15A

Protected circuits (live):Headlight remote

control switch, high-beam light in flashing

mode, fuses No. 7-8-9-10.

3 Fuse No. 3 Capacity:15A

X7 250ie Electrical system

ELE SYS - 13

Specification Desc./Quantity

Protected circuits: Light switch (via remote

control)

4 Fuse No. 4 Capacity: 15A

Protected circuits:Electric fan (via remote

control)

5 Fuse No. 5 Capacity: 15A

Protected circuits:Injection load (via remote

control), injection ECU.

6 Fuse No. 6 Capacity:3A

Protected circuits: Clock, pre-installation

for antitheft device.

7 Fuse No. 7 Capacity:3A

Protected circuits (live): Pre-installation for

antitheft device, instrument panel.

8 Fuse No. 8 Capacity: 7.5 A

Protected circuits (live): ECU remote con-

trol, injection ECU, electric fan remote con-

trol.

9 Fuse No. 9 Capacity: 7.5 A

Protected circuits (live): Position lights, li-

cense plate light, instrument panel lighting.

10 Fuse No. 10 Capacity: 7.5 A

Protected circuits (live): Stop lights, start-

up circuit, horn, turn indicators.

11 Fuse No. 11 Capacity: 7.5 A

Protected circuits (live): High-beam light.

12 Fuse No. 12 Capacity:7.5 A

Protected circuits (live):Low-beam light.

Dashboard

Electrical system X7 250ie

ELE SYS - 14

A = Coolant temperature gauge B = Engine control telltale light and injection system failure warning light F = Low oil pressure warning light D = Left turn indicator warning light E = Speedometer with twin scale (km/h and mph) F = Odometer G = Right turn indicator warning light H = High-beam warning light I = Low fuel warning light L = Fuel gauge M = Digital clock

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in 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 up

Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 ÷ 14.70V

-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity

- Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: Maximum 5 h

Dry-charge battery

COMMISSIONING A NEW DRY-CHARGED BATTERY

- Remove the battery air pipe stop cap and each single element caps.

X7 250ie Electrical system

ELE SYS - 15

- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an ambient temperature not below 15°C, until it reaches the upper level indicated on the block.

- Tilt the battery slightly to remove any air bubbles formed during filling.

- Place the caps on each single element filling holes without screwing them and leave the battery to rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases.

- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).

- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water;

- Before 24 hours elapse, recharge the battery following these steps:

- Connect the battery charger terminals observing the correct polarity;

- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity;

- Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge. Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge.

- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester.

- If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging.

- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle.

- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.

Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the Check function. The value indicated on the display must be higher than the value indicated on the chart;

otherwise, recharge the battery again in the same way indicated above.

Electrical system X7 250ie

ELE SYS - 16

Controllo teleruttori

To check the operation of a remote control:

1) Check that, given regular conditions, there is no continuity between terminals 87 and 30.

2) Apply a 12V voltage to power terminals 86 and 85 of the remote control.

3) With the remote control fed, check that there is continuity between terminals 87 and 30.

4) If these conditions are not met, the remote control is surely damaged and, therefore, it should be replaced.

Controllo interruttori

To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts.

KEY Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

ENGINE STOP SWITCH

STARTER BUTTON

X7 250ie Electrical system

ELE SYS - 17

LIGHT SWITCH

TURN INDICATOR SWITCH

HORN BUTTON

Connectors

INSTRUMENT PANEL CONNECTOR «A»

1. Low fuel warning light (Yellow-Green)

2. Live supply (White-Red)

3. High-beam warning light (Purple)

4. Right turn indicator warning light (White-Blue)

5. Fuel level indicator (White-Green)

6. Instrument panel lighting (Yellow-Black)

Electrical system X7 250ie

ELE SYS - 18

INSTRUMENT PANEL CONNECTOR «B»

1. Ground (Black)

2. Left turn indicator warning light (Pink)

3. Coolant temperature signal (Blue-Black)

4. Live supply (White-Red)

5. Injection telltale light (Brown-Black)

FUEL PUMP CONNECTOR

1. Not connected

2. Ground (Black)

3. Not connected

4. Not connected

5. power via remote control (Black-Green)

ELECTRIC FAN CONNECTOR

1. Power via remote control (Red)

2. Ground (Black)

MAGNETO FLYWHEEL CONNECTOR

1. Engine revolution sensor ECU positive (Red)

2. Engine revolution sensor ECU negative (Brown)

3. Oil pressure sensor (White-Pink)

X7 250ie Electrical system

ELE SYS - 19

ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR

1. LHS Turn indicator bulbs (Pink)

2. RHS Turn indicator bulbs (White-Blue)

3. Ground (Black)

4. Battery-powered (Blue-Red)

5. Live supply (White-Red)

6. Not connected

7. Not connected

8. Not connected LAMBDA PROBE CONNECTOR

1. Lambda probe ECU positive (Sky blue-Yellow)

2. Lambda probe ECU negative (Sky blue-Black)

3. Heater ECU negative (Sky blue-Red)

4. Heater power via remote control (Black-Green)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red)

2. Ground (Black)

3. Battery positive (Red)

4. Ground (Black)

INJECTION ELECTRONIC CONTROL UNIT

1. Injection telltale light (Brown-Black)

2. Not connected

3. Not connected

4. Lambda probe negative (Sky blue-Black)

3. Live supply (Red-Green)

6. Battery-powered (Orange-Blue)

7. Not connected

8. Electric fan remote control (Green-White)

9. Coolant temperature sensor (Yellow-Pink)

10. Not connected

Electrical system X7 250ie

ELE SYS - 20

11. Lambda probe positive (Sky blue-Yellow)

12. Engine stop switch (Orange)

13. Engine revolution sensor positive (Red)

14. Injector negative (Yellow-Red)

15. Engine revolution sensor negative (Brown)

16. Diagnostics socket (Orange-Black)

17. Not connected

18. Ground (Black)

19. Lights remote control (Black)

20. Injection load remote control (Black-Purple)

21. Lambda heater negative (Sky blue-Red)

22. HV coil negative (Pink-Black)

23. Not connected

24. Start-up remote control switch (Blue-Green)

25. Not connected

26. Ground (Black) INJECTOR CONNECTOR

1. Power via remote control (Black-Green)

2. Control unit negative (Yellow-Red)

HV COIL CONNECTOR

1. Control unit negative (Pink-Black)

2. Power via remote control (Black-Green)

X7 250ie Electrical system

ELE SYS - 21

FUEL LEVEL TRANSMITTER CONNECTOR

1. Low fuel warning light (Yellow-Green)

2. Ground (Black)

3. Fuel level indicator (White-Green)

COOLANT TEMPERATURE SENSOR CONNECTOR

1. Ground (Grey-Green)

2. Ground (Black)

3. Injection ECU (Yellow-Pink)

4. Instrument panel (Sky blue-Black)

Electrical system X7 250ie

ELE SYS - 22

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

This section describes the operations to carry out when removing the engine from the vehicle.

Exhaust assy. Removal

- Remove the Lambda probe from its support and disconnect it.

- Undo the two exhaust manifold fixings on the head. To undo the nuts fixing the muffler flange to the head properly, you must use a jointed wrench that enables you to get at the right nut as well, according to the direction of travel, that is difficult to get at with a traditional straight wrench.

- Undo the three screws fixing the muffler to the support arm. Remove the full muffler unit.

Remove the lambda probe from the manifold.

Engine from vehicle X7 250ie

ENG VE - 2

CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

Removal of the engine from the vehicle

- Disconnect the battery

- Remove the engine cover inside the helmet compartment

- Remove the side panels Remove the full muffler assembly.

CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Remove the pipe feeding coolant into the pump as shown in the photograph and then empty the system.

- Remove the engine-chassis ground lead.

- Disconnect the fuel delivery and return pipes from the injector by removing the screw locking the retaining clamp.

- Disconnect the injector wiring and the throttle body control unit wiring.

X7 250ie Engine from vehicle

ENG VE - 3

- Remove the coolant outlet pipe from the motor as indicated.

- Remove the spark plug cap.

- Remove the coolant temperature sensor connector indicated in the photo.

- Remove the throttle cables from the throttle body by undoing the nuts indicated in the photograph.

- Remove the positive and negative wiring from the starter motor as shown in the photo.

Engine from vehicle X7 250ie

ENG VE - 4

- Disconnect the connectors from the flywheel wiring as shown in the photo.

- Remove the cable from the retaining clip on the flywheel cover.

- Undo the fixing screw of the locking clamps of the brake pipe from the muffler supporting arm.

Muffler supporting arm removal

- Unscrew and remove the screw fixing the righthand shock absorber to the supporting plate.

- Remove the cotter pin, the cap and unscrew the wheel axle nut. Operate the rear brake by pulling the left lever on the handlebar so that the axle does not turn.

X7 250ie Engine from vehicle

ENG VE - 5

- Undo the 2 screws fixing the rear brake calliper.

- Remove the calliper and its pipes from the muffler supporting arm.

- Undo the 2 screws fixing the swinging arm to the engine.

- Remove the muffler support arm

- Slide off the entire wheel with its disc from the wheel axle. Move the right shock absorber backwards to facilitate removing the wheel.

- Use a jack to support the vehicle properly. Remove the engine-swinging arm fixing pin by undoing the nut and the head of the pin as shown in the photograph.

- The engine is now free.

When refitting the engine onto the scooter, carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter.

-Check the engine oil level and if necessary top it up with the recommended type.

Engine from vehicle X7 250ie

ENG VE - 6

- Fill and bleed the cooling circuit.

- Check the functioning of the accelerator and the electrical devices.

CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY.

X7 250ie Engine from vehicle

ENG VE - 7

Engine from vehicle X7 250ie

ENG VE - 8

INDEX OF TOPICS

ENGINE ENG

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.

Specific tooling

020423Y driven pulley lock wrench

- Remove the cap/dipstick from the engine oil filling hole.

- Remove the ten screws.

Engine X7 250ie

ENG - 2

- Remove the transmission cover.

N.B.

WHEN YOU ARE REMOVING THE TRANSMISSION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH BELL.

Air duct

- Remove the transmission compartment air intake cover shown in the photograph.

- Remove the five screws on two different levels as well as the small casing.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by means of:

Specific tooling

020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020412Y 15 mm guide

X7 250ie Engine

ENG - 3

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase from the inside so as not to damage the painted surface.

- Insert the bearing in its seat.

- Refit the seeger ring.

CAUTION

USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.

N.B.

ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING.

Specific tooling

020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide

Baffle roller

Plastic roller

- Check that the roller does not show signs of wear and that it turns freely.

- Remove the special clamping screws as indicated in the photograph

- Check the outer diameter of the roller does not have defects that could jeopardise belt functioning

- For refitting, place the roller with the belt containment edge on the engine crankcase side

- Tighten the wrench to the prescribed torque.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Engine X7 250ie

ENG - 4

Removing the driven pulley

- Remove the clutch bell housing and the driven pulley assembly.

N.B.

THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

Characteristic

Max. value clutch bell

Max. value: Ø 134.5 mm

Clutch bell standard value

Standard value: Ø 134 - 134.2 mm

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2 bearings (inner diameter 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft assembly on the support to check the crankshaft alignment.

X7 250ie Engine

ENG - 5

- Using a feeler pin gauge and the magnetic base, measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central, internal, external).

- If faults are found, replace the bell.

Specific tooling

020074Y Support base for checking crankshaft alignment

020335Y Magnetic support for dial gauge

Characteristic

clutch bell inspection: Limit eccentricity.

Admissible limit eccentricity: 0.15 mm

Removing the clutch

Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side.

- Introduce the adapter ring No. 11 with the chamfering facing the inside of the tool.

- Fit the driven pulley unit on the tool with the insertion of the 3 pins in the ventilation holes in the mass holder support.

- Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to loosen/tighten the clutch nut.

- Use the special 46x55 wrench component No. 9 to remove the nut fixing the clutch in place.

- Dismantle the driven pulley components (Clutch and spring with its plastic holder)

CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE.

Specific tooling

020444Y011 adapter ring 020444Y009 46x55 Wrench

Engine X7 250ie

ENG - 6

020444Y Tool for fitting/ removing the driven pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction material.

- The masses must not show traces of lubricants; otherwise, 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.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

Pin retaining collar

- Simultaneously turn and pull the collar manually to remove it.

N.B.

USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY.

N.B.

BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O-RING SEAL.

X7 250ie Engine

ENG - 7

- Remove the four torque server pins and pull the pulley halves apart.

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisiness; - Replace with a new one if there are.

- Remove the retaining ring using two flat blade screwdrivers.

- Support the pulley bushing adequately from the threaded side using a wooden surface.

- Using a hammer and pin, knock the ball bearing out as shown in the figure.

- Support the pulley properly using the bell as shown in the figure.

Specific tooling

001467Y035 Belle for OD 47-mm bearings

- Remove the roller bearing using the modular punch.

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide

Engine X7 250ie

ENG - 8

Inspecting the driven fixed half-pulley

- Measure the outer diameter of the pulley bushing.

- Check the contact surface with the belt to make sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

Characteristic

Half-pulley minimum diameter

Minimum admissible diameter Ø 40.96 mm

Half-pulley standard diameter

Standard diameter: Ø 40.985 mm

Wear limit

0.3 mm

Inspecting the driven sliding half-pulley

- Remove the two internal grommets and the two O-rings.

- Measure the movable half-pulley bushing inside diameter.

- Check the contact surface with the belt to make sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt faying surface.

X7 250ie Engine

ENG - 9

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Specification Desc./Quantity

Wear limit 0.3 mm

standard diameter Diameter 41.000 - 41.035 mm

maximum allowable diameter Ø 41.08 mm

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the threaded side using a wooden surface.

- Fit a new roller sleeve as in the figure.

- For the fitting of the new ball bearing, follow the example in the figure using a modular punch. Fit the retention ring

WARNING N.B.

FIT THE BALL BEARING WITH THE VISIBLE SHIELD

Specific tooling

020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020424Y Driven pulley roller casing fitting

punch

Refitting the driven pulley

- Insert the new oil guards and O-rings on the movable half-pulley.

- Lightly grease the O-rings «A» shown in the figure.

- Fit the half-pulley over the bushing using the specific tool.

- Check that the pins are not worn and proceed to refitting them in their slots.

- Refit the torque server closure collar.

- Using a curved-spout grease gun, lubricate the driven pulley unit with approximately 6 gr. of

Engine X7 250ie

ENG - 10

grease. Apply the grease through one of the holes in the bushing until it comes out through the hole on the opposite side. This operation is necessary to avoid the presence of grease beyond the Orings.

N.B.

THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED; UNDERTAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling

020263Y Sheath for driven pulley fitting

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel revolving ring

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

123 mm

acceptable limit after use:

118 mm

X7 250ie Engine

ENG - 11

Refitting the clutch

- Support the driven pulley spring compressor appropriate tool with the control screw in vertical axis.

- Arrange the tool with the medium length pins screwed in position "C" on the inside.

- Introduce the adapter ring No. 11 with the chamfering facing upwards.

- Insert the clutch on the adapter ring.

- Lubricate the end of the spring that abuts against the servo-system closing collar.

- Insert the spring with its plastic holder in contact with the clutch.

- Insert the driving belt into the pulley unit according to their direction of rotation.

- Insert the pulley unit with the belt into the tool.

- Slightly preload the spring.

- Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut.

- Place the tool in the clamp with the control screw on the horizontal axis.

- Fully preload the spring.

- Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench.

- Loosen the tool clamp and insert the belt according to its direction of rotation.

- Lock the driven pulley again using the specific tool.

- Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position.

- Remove the driven pulley /belt unit from the tool.

N.B.

DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING.

N.B.

FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE

Engine X7 250ie

ENG - 12

SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

020444Y011 adapter ring 020444Y009 46x55 Wrench

Locking torques (N*m)

Clutch unit nut on driven pulley 45 ÷ 50

Refitting the driven pulley

- Refit the clutch bell.

Drive-belt

- Check that the driving belt is not damaged.

- Check the width of the belt.

Characteristic

Driving belt Standard width:21.3 ± 0.2 mm Driving belt Minimum width: 19.5 mm

During the wear checks foreseen in the scheduled maintenance, check that the rim bottom of the toothing does not show signs of incisions or cracking (see figure); otherwise, replace the belt.

X7 250ie Engine

ENG - 13

Removing the driving pulley

- Turn the crankshaft until the ropes of the pulley are on a horizontal axis

- Insert the adaptor sleeve of the appropriate tool in the hole shown in the photograph

- Insert the tool in the hollows and apply the retention ring

- Bring in the ring's clamping screws while keeping the tool to support the pulley

Specific tooling

020626Y Driving pulley lock wrench

- Remove the fixing nut and the washer

- Remove the stationary drive pulley half.

Engine X7 250ie

ENG - 14

Inspecting the rollers case

- Check that the internal bushing shown in the figure is not abnormally worn and measure inner diameter A.

- Measure outer diameter B of the pulley sliding bushing shown in the figure.

- Check that the rollers are not damaged or worn.

- 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.

- Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt.

- Check that the O-ring is not pushed out of shape.

CAUTION

DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic

Movable driving half-pulley bushing: Standard Diameter

26.000 - 26.021 mm

Movable driving half-pulley bushing: Maximum allowable diameter

Ø 26.12 mm

Sliding bushing: Standard Diameter

Ø 25.959 ÷ 25.98 mm

Sliding bushing: Minimum admissible diameter

Ø 25.95 mm

Roller: Standard Diameter

Diameter 20.5 - 20.7 mm

Roller: Minimum diameter permitted

Ø 20 mm

X7 250ie Engine

ENG - 15

Refitting the driving pulley

- Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation.

- Check that the roller contact plate does not have flaws and is not damaged on the grooved edge.

- Mount the complete bushing unit on the driving shaft.

- Fit the driven pulley/Clutch/belt unit on the engine.

- Fit the steel shim in contact with the bushing and the stationary drive pulley.

- Install the appropriate tool as described in the removal phase.

-Tighten the nut with washer to the prescribed torque.

Specific tooling

020626Y Driving pulley lock wrench

Locking torques (N*m)

Drive pulley nut 75 ÷ 83

Engine X7 250ie

ENG - 16

Refitting the transmission cover

- Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover.

- Replace the cover tightening the 10 screws at the specified torque.

- Refit the oil loading cap/bar.

- refit the steel washer and the driven pulley nut.

- Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools.

- Replace the plastic cover.

Specific tooling

020423Y driven pulley lock wrench

Locking torques (N*m)

Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60

End gear

X7 250ie Engine

ENG - 17

Removing the hub cover

- Empty the rear hub through the oil drainage plug.

- Remove the 7 flanged screws indicated in the figure.

- Remove the hub cover and its gasket.

Removing the wheel axle

- Remove the wheel axis complete with gear.

- Remove the intermediate gear.

Engine X7 250ie

ENG - 18

PIAGGIO X7 250ie Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual