PIAGGIO X8 User Manual

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SERVICE STATION MANUAL

633779 ÷ 633786

X8 400 Euro 3

SERVICE STATION

MANUAL

X8 400 Euro 3

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. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

www.piaggio.com

SERVICE STATION MANUAL

X8 400 Euro 3

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, completely satisfactory work cannot be carried out without the necessary equipment and tools. It is therefore advisable to read the sections of this manual relating to appropriate tools, along with the appropriate 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

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

X8 400 Euro 3 Characteristics

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

•

Should it be necessary to keep the engine running while servicing, make sure that the area or room is well ventilated, and use special exhaust fans, if required. never let the engine run in an enclosed area. Exhaust fumes are toxic.

•

The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. 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 in some conditions it can be explosive. Do not smoke in the working area, and avoid open flames or sparks.

•

Clean the brake pads in a well ventilated environment, directing the compressed air jet so as to not inhale the dust produced by the wear of the friction material. Even though the latter contains no asbestos, dust inhalation is harmful.

Maintenance rules

•

Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Nonoriginal or non-conforming spares may damage the vehicle.

•

Use only the special tools designed for this scooter.

•

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

•

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

•

After reassembly, check that all components have been installed properly and that they are in good working order.

•

For removal, overhaul and reassembly operations use only tools provided 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.

•

Should any interventions to the scooter electrical system be required, check that the electrical connections - especially earth and battery connections - have been implemented properly.

CHAR - 7

Characteristics X8 400 Euro 3

Vehicle identification

Chassis prefix

ZAPM52100÷1001

Engine prefix

M521M÷1001

Dimensions and mass

Specification

Kerb weight 206 kg

Overall width 750 mm

Overall length 2190 mm

Wheelbase 1540 mm Saddle height 790 mm Overall height 1360 mm

WEIGHT

Desc./Quantity

CHAR - 8

X8 400 Euro 3 Characteristics

Engine

ENGINE

Specification Desc./Quantity

Engine single-cylinder, four-stroke

Bore x stroke 85.8 X 69 mm

Cubic capacity 399 cm³

Compression ratio 10.6 ± 0.5 : 1

Timing system Single overhead camshaft with integrated tone wheel, control

Valve clearance: intake 0.15 mm (when cold)

Valve clearance: discharge 0.15 mm (when cold)

Valve clearance adjustment By threaded adjuster on the rockers

Engine idle speed 1500 ± 50 rpm

Air filter sponge, impregnated with mixture (50% petrol and 50% oil)

CO % value (measured at the intake manifold) 1 - 1.5%

Starting system Electric starter system with freewheel.

Lubrication By trochoidal pump (inside the crankcase), pressure adjust-

Lubrication pressure 4 bar

Minimum allowed (at 100° C) 0.8 bar

Fuel supply Electronic injection system with electric fuel pump, Ø 38 mm

Maximum power (to the crankshaft) 24.5 kW at 7250 rpm

Maximum torque (to the crankshaft) 36 Nm at 5500 rpm

Cooling system Fluid circulation through a motor-driven pump, 3-way thermo-

from flywheel side chain, 4 valves and automatic start-up valve

lifting device.

ment by-pass and oil filter.

throttle body and single injector.

stat and electric fan.

Transmission

Specification

Transmission With automatic expandable pulley variator with torque server,

Capacities

Specification

Engine oil (empty) 1.7 lt.

Engine oil (at oil and filter change) 1.5 lt.

Fuel tank capacity Tank capacity: ~12 l (approximate value)

Cooling system approx. 1.8 litres

Electrical system

Specification

Electronic ignition inductive, high efficiency integrated with the injection system,

Spark plug NGK CR7EKB Spark plug CHAMPION RG6YC

Generator Three-phase alternating current

TRANSMISSIONS

Desc./Quantity

V belt, automatic clutch, gear reduction unit and transmission

housing with forced air circulation cooling.

CAPACITY

Desc./Quantity

Rear hub approx. 250 cc.

ELECTRICAL SYSTEM

Desc./Quantity

with variable timing and separate HV coil.

Battery Dry-cell lead-acid battery, 12V-14Ah

CHAR - 9

Characteristics X8 400 Euro 3

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Chassis Welded steel pipes with pressed sheet metal stiffening

Front suspension Double effect hydraulic telescopic fork with Ø 35 mm stems and

Front fork max. stroke 104 mm

Rear suspension Engine with swinging fork attached to the frame by means of

pin backwards with connections for double brake calliper

an arm with one degree of freedom and a pair of double effect hydraulic shock absorbers with 4 adjustable preload positions.

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 240mm double disk brake with hydraulic control activated by

Rear brake Ø 240 mm disc brake with hydraulic control activated by han-

the handlebar right-hand lever.

dlebar left lever.

Wheels and tyres

WHEELS AND TYRES

Specification

Tyre pressure (cold) front 2.1 bar

Tyre pressure (cold) rear 2.3 bar (2.5 bar with passenger)

Front wheel rim Die-cast aluminium alloy, 3.50"x14'' Rear wheel rim Die-cast aluminium alloy 4.50"x14"

Front tyre Tubeless 120/70 - 14'' - Michelin Gold Standard M/C 55S Rear tyre Tubeless 140/70 - 14'' - Michelin Gold Standard M/C 68S

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

CAUTION

IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE CORRECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES RECOMMENDED BY PIAGGIO.

Desc./Quantity

Tightening Torques

CHAR - 10

FRAME

Name

Electric pump locking ring nut 20

Torque in Nm

BRAKE SYSTEM

Name

Brake calliper coupling 20 - 24

Front brake disc mounting 5 ÷ 6 •

Torque in Nm

X8 400 Euro 3 Characteristics

Name Torque in Nm

Rear brake disc mounting 11 ÷ 13

Front brake calliper mounting on fork 20 ÷ 25

Rear calliper support on crankcase retainer 20 ÷ 25

Pipe / brake calliper coupling 20 ÷ 25

Pipe / brake pump coupling 20 ÷ 25

Front brake pipe splitter coupling 20 ÷ 25

• Lock with Loctite 243 medium strength threadlock

FRONT SUSPENSION

Name Torque in Nm

Front wheel axle 45 ÷ 50 Holding torque of lower ring nut 20 ÷ 25 Fork stem mounting to the plate 20 ÷ 25

Steering lower ring nut 10 - 13 **

Upper steering ring nut 36 - 39

Stem upper cap 35 - 55

Fixing screw handlebar to steering tube 45 ÷ 50

Pumping element fixing screw 25 - 35

Safety screw on fork leg 6 ÷ 7 Wheel fastening screws 33 - 37

* tighten and loosen completely. ** tighten and loosen by 90°.

REAR SUSPENSION

Name Torque in Nm

Upper shock absorber clamp 33 ÷ 41 Lower shock absorber clamp 33 ÷ 41

Shock absorber-crankcase attachment bracket 20 ÷ 25

Rear wheel axle 104 ÷ 126

Muffler arm clamping screws 27 ÷ 30

ENGINE ASSEMBLY

Name

Starter motor screws 11 ÷ 13

Torque in Nm

THERMAL GROUP AND TIMING SYSTEM

Name

Spark plug 12 ÷ 14

Head fixing stud bolts ***

Head fixing nuts 10 - 12

Exhaust / intake head fixing nuts 10 - 12

Head lubrication control jet 5 - 7

Coolant temperature sensor: 10 - 12

Lambda probe on exhaust manifold 10 - 12

injector fixing screw 3 ÷ 4

Counterweight screw 7 ÷ 8.5

Tensioner sliding block fixing screw 10 - 14

Rpm timing sensor fixing screw 3 - 4

Valve lifter mass stop bell fixing screws 30 - 35

Inlet manifold screws 11 ÷ 13 Tappet cover fixing screws 7 - 9 Throttle body fixing screws 11 ÷ 13

Head fixing screws 10 - 12

Camshaft retaining bracket screws: 4 ÷ 6

Tightener screw: 5 - 6

Tightener fastening screws: 11 ÷ 13

*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90° in a crossed sequence. - tighten again by 90° in a criss-crossed sequence.

Torque in Nm

CRANKCASE AND CRANKSHAFT

Name

Countershaft fixing nut 25 ÷ 29

Engine oil filter 12 - 16

Torque in Nm

CHAR - 11

Characteristics X8 400 Euro 3

Name Torque in Nm

Engine oil drainage plug 24 ÷ 30

Engine-crankcase coupling screws 11 ÷ 13

Oil pump screws 5 - 6

Gear mounting on crankshaft screws 10 -12

Bulkhead screws for oil pump housing cover 8 - 10

FINAL REDUCTION

Name Torque in Nm

Rear hub cover screws 24 ÷ 27

TRANSMISSION COVER

Name Torque in Nm

Driven pulley nut 92 - 100

driving pulley nut 160 - 175

Anti-vibration roller screw 16.7 ÷ 19.6

M8 retainers for transmission cover 23 ÷ 26

M6 retainer 11 ÷ 13

Anti-vibration roller retainer 17 - 19

Clutch ring nut 65 - 75

Air conveyor screws 11 ÷ 12

Water pump cover screws 3 ÷ 4

External transmission cover screws 7 ÷ 9

Flywheel cover screws 11 - 13

FLYWHEEL COVER

Name

Chain guide sliding block retain plate fastening screws 3 ÷ 4

Flywheel fixing nut 115 - 125

Stator retainers 8 - 10

Blow-by recovery duct fixing screws 3 - 4

Screw fixing freewheel to flywheel 13 ÷ 15

Stator cable harness guide bracket screws 3 - 4

Supporting screws with bulkhead 0.3 - 0.4

Minimum oil pressure sensor 12 ÷ 14

Water pump impeller 4 ÷ 5

LUBRICATION

Name

Oil pump cover screws 0.7 ÷ 0.9

Screws fixing oil pump to crankcase 5 - 6

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil

In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

MAIN - 35

Maintenance X8 400 Euro 3

Check

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

1) Rest the vehicle on the central stand and on a flat ground.

2) Unscrew the cap/dipstick "A", dry it with a clean cloth and reinsert it, screwing it thoroughly.

3) Remove the cap/dipstick again and check that the level is between the max. and min levels; topup, if required. Topping up from the MIN to MAX. level requires around 1700 cc. 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 it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level.

Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc.

Engine oil filter

CAUTION

DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. OIL, GASKET AND FILTER SHOULD BE DISPOSED OF ACCORDING TO THE REGULATIONS IN FORCE.

WARNING

AVOID TOUCHING PARTS OF THE ENGINE WHEN HOT, AS THIS MAY CAUSE BURNS.

- Remove the muffler.

- Remove the filler plug.

MAIN - 36

X8 400 Euro 3 Maintenance

- Remove and clean the mesh pre-filter of the drain cap with compressed air.

- Use a belt spanner for filters to remove cartridge filter "C".

- Make sure the pre-filter and drain cap O-rings are in good condition.

- Lubricate them and refit the mesh filter and oil drain cap by tightening to the prescribed torque.

- Refit a new cartridge filter making sure to lubricate the O-ring before fitting, then screw until it comes into contact with the seal and further tighten to the prescribed torque.

- Refit the muffler.

- Add recommended engine oil.

- Start the engine and let it run for a few minutes and then turn it off. After 5 minutes check the level and top up, if necessary, never exceed the MAX. level.

N.B.

IF THE OIL IS CHANGED WITHOUT CHANGING THE CARTRIDGE FILTER (1ST COUPON) ADD AROUND 1500 CC OF OIL INSTEAD OF 1700 CC SINCE PART OF THE LUBRICATION CIRCUIT IS FILLED.

Characteristic

Engine oil:

1700 cm³

Locking torques (N*m)

Engine oil drainage plug 24 ÷ 30 Engine oil filter 12 - 16

MAIN - 37

Maintenance X8 400 Euro 3

Oil pressure warning light

Warning light (low oil pressure)

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 comes on during braking, at idling speed or while turning, it is necessary to first switch off the engine and then to check the oil level and the lubrication system

Checking the valve clearance

- To check the clearance in the valves collimate the references between the cam shaft control pulley and head.

- Use a feeler to make sure the clearance between the valve and register screw correspond to the indicated values. If the clearance does not correspond, adjust it by loosening the lock nut using a screwdriver on the set screw as shown in the figure.

Characteristic

Valve clearance: intake

0.15 mm (when cold)

Valve clearance: discharge

0.15 mm (when cold)

Cooling system

If noise or loss of liquid at the drain bore of the water pump is discovered, it will be necessary to overhaul the pump as described in chapter "Flywheel cover". Proceed to carry out a few preliminary operations as described below:

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

- Remove the right footrest as described in the «Bodywork» Chapter.

- Remove the muffler to access the flywheel cover, as described in the «Engine» Chapter.

- Empty the cooling system by removing the couplings on the pump cover and the filler plug on the expansion tank.

MAIN - 38

X8 400 Euro 3 Maintenance

CAUTION

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

- Remove the water pump cover as indicated in the figure by loosening the 6 retaining screws.

- Proceeding as described in chapter "Engine", partially drain the system and overhaul the pump.

- Refill and drain the system again once after having repaired the damaged and reinstalled all the components.

N.B. FOR CHANGING THE COOLANT AND BLEEDING THE

SYSTEM, SEE CHAPTER "COOLING SYSTEM".

Characteristic

Cooling system

approx. 1.8 litres

Level check

Adding engine coolant.

The fluid level must checked every 10,000 kilometres with a cold engine, in the way shown below: Place the scooter on its centre stand and on flat ground.

- Undo the screw shown in the figure and remove the expansion tank cap on RHS.

- Top up if the fluid level is near or below the MIN level edge. The liquid level must always be between the MIN and MAX level.

-The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised waterantifreeze solution mix.

CAUTION DO NOT EXCEED THE MAX LEVEL WHEN FILLING SO

THAT COOLANT DOES NOT SPILL OVER THE EXPANSION TANK WHEN THE VEHICLE IS BEING USED.

Braking system

MAIN - 39

Maintenance X8 400 Euro 3

Level check

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

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

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

Top-up

Proceed as follows: Loosen the screw "B" and lift the plastic cover "A" in order to access the brake fluid reservoir. Loosen the two fixing screws and remove the reservoir cover; top-up with the recommended fluid without exceeding the 'MAX.' mark. This procedure applies to the rear brake pump topup operation; follow the same procedure for the front brake pump. Under normal climatic conditions, the fluid must be changed every 20,000 km or anyway every two years.

WARNING

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. BRAKE CIRCUIT FLUID IS VERY CORROSIVE; MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

MAIN - 40

X8 400 Euro 3 Maintenance

Headlight adjustment

Proceed as follows:

1. Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the vehicle is perpendicular to the screen;

2. Turn on the headlight and check that the borderline of the projected light beam is lower than 9/10 and higher than 7/10 of the distance from the ground to the centre of the vehicle headlight;

3. If not, adjust the headlight by turning the central screw «A» placed behind the Piaggio badge.

N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

Checking the end compression pressure

- Remove the spark plug hood with cold engine.

- Remove the ignition spark plug.

- Fit a compression test gauge into the spark plug seat using a 10 mm spark plug coupling, at the proper locking torque.

- Set ignition switch to «ON», wait a few seconds and then disconnect the revolution timing sensor connector in order to deactivate the injector and the spark plug.

- Let the engine run using the starter motor and with the throttle body in fully open position until the gauge value is steady.

- If the pressure is higher than the indicated, remove the tool and proceed to refit to the vehicle.

- If the pressure is lower than indicated, check the rpm at which the test is carried out; if lower than 450 g/1', check the start-up system.

MAIN - 41

Maintenance X8 400 Euro 3

If the end of compression pressure is lower than the standard, remove the test gauge connector and add some cc of oil to the combustion chamber, make the engine turn (preferably manually) to lubricate the cylinder. Repeat the pressure test: if the new values are low again, check the condition of the valve gaskets. Pressure values too high in a new engine signal poor sealing of the rings.

Characteristic

Compression ratio

10.6 ± 0.5 : 1

Locking torques (N*m)

Spark plug 12 ÷ 14

MAIN - 42

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system X8 400 Euro 3

KEY:

1. Magneto flywheel

2. Voltage regulator

3. Revolution sensor

4. Throttle valve position sensor

5. Ambient temperature sensor

6. Stepper motor for idle jet

7. Electric fan

8. Engine temperature sensor

9. Remote control for electric fan

10. Key switch

11. Injection load remote control

12. Fuse holder B

13. Fuse holder A

14. 12V - 180W socket

15. Engine stop remote control

16. Engine stop switch

17. Diode

18. Battery

19. Starter motor

ELE SYS - 44

X8 400 Euro 3 Electrical system

20. Start up remote control switch

21. Starter button

22. Wiring for radio display

23. Wiring for radio

24. Stop button on rear brake

25. Stop button on front brake

26. Boot switch

27. Boot actuator

28. Saddle opening switch

29. Saddle opening actuator

30. Horn button

31. Horn

32. Wiring for saddle opening control unit

33. Helmet compartment light switches

34. Helmet compartment light bulb

35. Wiring for antitheft device

36. Left rear turn indicator bulbs

37. Rear headlight assembly A. Tail light Bulb B. Stop light Bulb

38. License plate bulb

39. Right rear turn indicator bulbs

40. Left front turn indicator bulbs

41. Front headlight assembly A. Low-beam bulb B.A. Parking light C. High-beam headlight bulb

42. Right front turn indicator bulbs

43. Light switch

44. Turn indicator switch

45. Turn indicator remote control

46. Remote control headlight

47. Fuel level transmitter

48. Clock reset button

49. Instrument panel

50. Oil pressure sensor

51. Immobilizer aerial

52. Immobilizer decoder

ELE SYS - 45

Electrical system X8 400 Euro 3

53. Fuel pump

54. Fuel injector

55. Spark plug

56. High voltage coil

57. Lambda probe

58. Diagnostics socket

59. Injection ECU

60. Stand switch 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

Electrical system layout - Version without switch on stand

WARNING

WE INFORM THAT THE FIRST 1000 VEHICLES ARE NOT EQUIPPED WITH THE SWITCH ON THE SIDE STAND AND THE RELEVANT WIRING. THE LAYOUT INDICATED HERE IS THE REFERENCE FOR THESE VEHICLES.

KEY:

1. Magneto flywheel

2. Voltage regulator

3. Revolution sensor

4. Throttle valve position sensor

ELE SYS - 46

X8 400 Euro 3 Electrical system

5. Ambient temperature sensor

6. Stepper motor for idle jet

7. Electric fan

8. Engine temperature sensor

9. Remote control for electric fan

10. Key switch

11. Injection load remote control

12. Fuse holder B

13. Fuse holder A

14. 12V - 180W socket

15. Engine stop remote control

16. Engine stop switch

17. Diode

18. Battery

19. Starter motor

20. Start up remote control switch

21. Starter button

22. Wiring for radio display

23. Wiring for radio

24. Stop button on rear brake

25. Stop button on front brake

26. Boot switch

27. Boot actuator

28. Saddle opening switch

29. Saddle opening actuator

30. Horn button

31. Horn

32. Wiring for saddle opening control unit

33. Helmet compartment light switches

34. Helmet compartment light bulb

35. Wiring for antitheft device

36. Left rear turn indicator bulbs

37. Rear headlight assembly A. Tail light Bulb B. Stop light Bulb

38. License plate bulb

39. Right rear turn indicator bulbs

40. Left front turn indicator bulbs

ELE SYS - 47

Electrical system X8 400 Euro 3

41. Front headlight assembly A. Low-beam bulb B.A. Parking light C. High-beam headlight bulb

42. Right front turn indicator bulbs

43. Light switch

44. Turn indicator switch

45. Turn indicator remote control

46. Remote control headlight

47. Fuel level transmitter

48. Clock reset button

49. Instrument panel

50. Oil pressure sensor

51. Immobilizer aerial

52. Immobilizer decoder

53. Fuel pump

54. Fuel injector

55. Spark plug

56. High voltage coil

57. Lambda probe

58. Diagnostics socket

59. Injection ECU

Components arrangement

Diagnostic socket

In order to access the diagnostic socket remove the battery cover.

ELE SYS - 48

X8 400 Euro 3 Electrical system

H.V. coil

In order to access the HV coil remove the chassis central cover; to remove it, loosen the screws inside the battery compartment.

Saddle opening remote control unit.

In order to access the saddle opening control unit, remove the left side fairing.

Electronic control unit ECU

In order to access the control unit remove the front top fairing and the shield back plate.

ELE SYS - 49

Electrical system X8 400 Euro 3

Immobilizer decoder

In order to access the immobilizer decoder remove the front top fairing and the shield back plate.

Relays and diode group

In order to access the relays and the diode unit remove the front top fairing and the shield back plate.

Voltage regulator

In order to access the voltage regulator, remove the right side fairing cover.

Lambda probe

The lambda probe is mounted on the exhaust manifold

Conceptual diagrams

ELE SYS - 50

X8 400 Euro 3 Electrical system

Ignition

KEY:

3. Revolution sensor

10. Key switch

11. Injection load remote control

12. Fuse holder B

13. Fuse holder A

15. Engine stop remote control

16. Engine stop switch

17. Diode

18. Battery

49. Instrument panel

51. Immobilizer aerial

52. Immobilizer decoder

55. Spark plug

56. High voltage coil

59. Injection ECU

60. Stand switch

ELE SYS - 51

Electrical system X8 400 Euro 3

Headlights and automatic starter section

KEY:

10. Key switch

12. Fuse holder B

13. Fuse holder A

15. Engine stop remote control

16. Engine stop switch

17. Diode

18. Battery

35. Wiring for antitheft device

36. Left rear turn indicator bulbs

37. Rear headlight assembly A. Tail light Bulb B. Stop light Bulb

38. License plate bulb

39. Right rear turn indicator bulbs

40. Left front turn indicator bulbs

41. Front headlight assembly A. Low-beam bulb

ELE SYS - 52

X8 400 Euro 3 Electrical system

B. Parking light C. High-beam headlight bulb

42. Right front turn indicator bulbs

43. Light switch

44. Turn indicator switch

45. Turn indicator remote control

46. Remote control headlight

49. Instrument panel

60. Stand switch

Battery recharge and starting

KEY:

1. Magneto flywheel

2. Voltage regulator

10. Key switch

12. Fuse holder B

13. Fuse holder A

16. Engine stop switch

17. Diode

18. Battery

ELE SYS - 53

Electrical system X8 400 Euro 3

19. Starter motor

20. Start up remote control switch

21. Starter button

24. Stop button on rear brake

25. Stop button on front brake

37. Rear headlight assembly A. Tail light Bulb B. Stop light Bulb

60. Stand switch

Level indicators and enable signals section

KEY:

3. Revolution sensor

4. Throttle valve position sensor

5. Ambient temperature sensor

6. Stepper motor for idle jet

8. Engine temperature sensor

10. Key switch

11. Injection load remote control

12. Fuse holder B

ELE SYS - 54

X8 400 Euro 3 Electrical system

13. Fuse holder A 15 Engine stop remote control

16. Engine stop switch

17. Diode

18. Battery

47. Fuel level transmitter

49. Instrument panel

50. Oil pressure sensor

53. Fuel pump

54. Fuel injector

57. Lambda probe

59. Injection ECU

60. Stand switch

Devices and accessories

KEY:

7. Electric fan

8. Engine temperature sensor

9. Remote control for electric fan

10. Key switch

ELE SYS - 55

Electrical system X8 400 Euro 3

12. Fuse holder B

13. Fuse holder A

14. 12V - 180W socket

15. Engine stop remote control

16. Engine stop switch

17. Diode

18. Battery

26. Boot switch

27. Boot actuator

28. Saddle opening switch

29. Saddle opening actuator

30. Horn button

31. Horn

32. Wiring for saddle opening control unit

33. Helmet compartment light switches

34. Helmet compartment light bulb

35. Wiring for antitheft device

59. Injection ECU

60. Stand switch

Checks and inspections

Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobiliser system consists of the following components:

- electronic control unit

- decoder

- immobilizer aerial

- master key with integrated transponder (brown key)

- service key with incorporated transponder (black key)

- HV coil

- diagnosis LED The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition

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X8 400 Euro 3 Electrical system

switch is turned to the "ON" position, the theft-deterrent blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or the instrument panel is not initiated, check if:

•

there is battery voltage

•

efficiency of fuse No. 7

•

there is power to the control unit as specified below:

Disconnect the connector from the control unit. Check the following conditions:

With the key switch set to OFF:

•

Battery voltage between terminals 17-23 and terminals 17-chassis ground (continuous power supply). If there is no voltage, check that fuse No. 6 is in good conditions.

With the key switch in position ON and the engine stop switch in RUN:

•

Battery voltage between terminals 26-23 and terminals 26-chassis ground (continuous power supply). If there is no voltage, check:

1. that fuses No. 11 and No. 2 and their wirings are in good conditions.

2. that the engine stop remote control switch is in good conditions.

•

Check for voltage on the white-black cable at the exit from the engine stop remote control switch. If there is no voltage, check:

1. key switch contacts

2. the condition of the engine stop switch, then the ground connection of the green/black cable of the

engine stop remote control switch with the stand lifted and the engine stop switch in the RUN position.

3. that the engine stop remote control switch diode is in good conditions. If no fault is found, replace the control unit.

N.B.

AN ACCIDENTAL LOSS OF THE SERVICE KEY PROGRAMMING CAN ARISE FROM GENERAL FAULTS OF THE IGNITION SYSTEM. IN THIS CASE, CHECK THE HV LINE SHIELDING.

In any case it is advisable to use resistive spark plugs.

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Electrical system X8 400 Euro 3

Virgin circuit

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised when the decoder has been correctly programmed. The procedure for programming a new decoder requires the recognition of the "master" key as the first key to be programmed: this is particularly important as it is the only key that allows the decoder to be reset and reprogrammed for programming the service keys. The master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits 1 to 3 seconds).

- Insert the service key and turn it to «ON» for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- Insert the MASTER key again and turn it to «ON» for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to keep using. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thor-

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X8 400 Euro 3 Electrical system

oughly inspected: In any case it is advisable to use resistive spark plugs.

Characteristic

MASTER key:

BROWN KEY

SERVICE key.

BLACK KEY

Diagnostic codes

The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the led remains on permanently, it means the ignition is inhibited:

1. New decoder - key inserted: a single 2 second flash is displayed, after which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs.

2. New decoder - transponder missing or illegible: The LED is permanently ON; in this condition,

no operations are possible, including starting of the vehicle.

3. Decoder programmed - service key inserted (normal operating condition): a single 0.7-sec-

ond flash is displayed, after which the LED remains off steadily. The engine can be started.

4. Decoder programmed - master key inserted: a 0.7-sec flash is displayed followed by the

LED remaining off for 2 sec. and then by short

0.46-sec flashes the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been com-

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Electrical system X8 400 Euro 3

pleted, the LED remains permanently OFF. The engine can be started.

5. Decoder programmed - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are:

•

1-flash code

•

2-flash code

•

3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessary.

Diagnostic code - 2 flashes

A 2-flash code indicates a system where the decoder does not recognise the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. Otherwise replace the faulty key and/or reprogram the decoder. If the problem persists, replace the decoder.

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X8 400 Euro 3 Electrical system

Diagnostic code - 3 flashes

The 3-flash code indicates a system where the decoder does not recognise the key. Turn the switch to ON using several keys: If the error code is repeated even with the Master key, replace the decoder. If this is not the case, reprogram the decoder.

Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent 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. This system therefore requires no connection to the key switch. 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

Checking the stator windings

WARNING

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

1) Remove the right side panel.

2) Disconnect the connectors between stator and regulator with the three yellow cables.

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

Electric characteristic

Resistance:

0.2 - 1 Ω

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Electrical system X8 400 Euro 3

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

5) If values are incorrect, replace the stator.

Recharge system voltage check

Maximum current output check.

- With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter. With an efficient battery a value must be detected: > 20A

VOLTAGE REGULATOR/RECTIFIER

Specification

Type Non-adjustable three-phase transistor

Voltage 14 ÷ 15V at 5000 rpm with lights off

Look for any leakage

1) Check that the battery does not show signs of leaking fluid before checking the output voltage.

2) Turn the ignition key to OFF and connect the multimeter leads between the battery negative pole (-) and the Black cable.

3) With the multimeter leads connected, disconnect the Black cable from the battery negative pole (-).

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

Charging current check

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

Desc./Quantity

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the tester terminals between the battery terminals..

3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm.

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X8 400 Euro 3 Electrical system

Turn signals system check

The turn indicator circuit is controlled by the electronic control unit. In the case it does not work, it is necessary to:

1. Check that fuse 8 is in working order

2. Check the function of the bulbs

3. Check the function of the turn signal indicator switch

4. Check that the turn indicator remote control is in working order

5. With the key switch set to ON, switch the stop engine to RUN without removing the turn indicator

remote control; check that there is voltage to the battery on the turn indicator switch connector. Next, check for voltage on the blue-black cable of the remote control, on the control unit side. If there is no voltage, check the wiring and the correct function of the electrical control units. Replace the control unit if the failure continues.

Lights list

LIGHT BULBS TABLE

Specification

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

2 Low-beam bulb Type: HALOGEN (H1)

3 Front tail light bulb Type: ALL GLASS

4 Instrument panel bulb Type: ALL GLASS

5 Clock light bulb Type: ALL GLASS

6 Front turn indicator bulb Type: ALL GLASS

7 Helmet compartment light bulb Type: CYLINDRIC

8 Rear turn indicator light bulb Type: ALL GLASS

9 Rear tail light bulb Type: ALL GLASS

10 Stop light bulb Type: SPHERICAL

11 License plate light bulb Type: ALL GLASS

12 12V - 1.2W warning light bulb Type: ALL GLASS

Application: Lighting system warning light - Full beam

headlamp warning light - Open boot warning light - In-

Desc./Quantity

Power: 12V - 55W

Quantity: 1

Power: 12V - 55W

Quantity: 1

Power: 12V - 5W

Quantity: 2

Power: 12V - 1.2W

Quantity: 4

Power: 12V - 2W

Quantity: 1

Power: 12V - 5W

Quantity: 2 RHS + 2 LHS

Power: 12V - 5W

Quantity: 1

Power: 12V - 5W

Quantity: 2 RHS + 2 LHS

Power: 12V - 5W

Quantity: 2

Power: 12V - 10W

Quantity: 2

Power: 12V - 5W

Quantity: 1

jection warning light

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Electrical system X8 400 Euro 3

Specification Desc./Quantity

Quantity: 4

13 12V - 2W warning light bulbs Type: ALL GLASS

14 12V - 3W warning light bulbs Type: ALL GLASS

Application:Fuel reserve

Quantity: 1

Application: Turn indicators

Quantity: 2

Application:Engine oil pressure

Quantity: 1

Fuses

The electrical system is equipped with 12 protective fuses for the various circuits on the scooter, subdivided into two fuse boxes located alongside the battery. The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE). BESIDES, IF AFTER REPLACING A FUSE, THE NEW FUSE ALSO BLOWS, THE SCOOTER NEEDS TO BE TAKEN TO AN AUTHORISED PIAGGIO/GILERA SERVICE CENTRE TO IDENTIFY THE CAUSE OF THE FAULT AND AVOID FURTHER DAMAGE TO THE ELECTRIC SYSTEM COMPONENTS OR THE VEHICLE ITSELF.

CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE.

FUSE TABLE

Specification

1 Fuse No. 1 Threshold of operation: 30 A

Location: Battery compartment on the left side

Protected circuits: Battery charge

2 Fuse No. 2 Threshold of operation: 15A

Location: Battery compartment on the left side

Protected circuits: Lines protected by fuses 8, 9, 10,12

3 Fuse No. 3 Threshold of operation: 15A

Location: Battery compartment on the left side

Protected circuits: 12V 180W socket - Wiring for anti-

theft device - Electrical fan remote control - Saddle opening control unit - Actuator for opening saddle and glove-

4 Fuse No. 4 Threshold of operation: 10 A

Desc./Quantity

- Engine stop remote control

box

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X8 400 Euro 3 Electrical system

Specification Desc./Quantity

Location: Battery compartment on the left side

Protected circuits: Remote control for injection com-

ponents (fuel pump, injector, h.v. coil.)

5 Fuse No. 5 Threshold of operation: 10 A

6 Fuse No. 6 Threshold of operation: 3 A

7 Fuse No. 7 Threshold of operation: 7.5A

8 Fuse No. 8 Threshold of operation: 7.5A

9 Fuse No. 9 Threshold of operation: 10 A

10 Fuse No. 10 Threshold of operation: 7.5A

11 Fuse No. 11 Threshold of operation: 7.5A

12 Fuse No. 12 Threshold of operation: 7.5A

Location: Battery compartment on the left side

Protected circuits: Headlight remote control - Bulb for

helmet compartment light - Warning light for saddle/rear

compartment cover open

Location: Battery compartment on the left side

Protected circuits: Ignition ECU - Immobilizer decoder

Location: Battery compartment on the right side

Protected circuits: Instrument panel - Wiring for radio

Location: Battery compartment on the right side

Protected circuits: Saddle opening control unit - Turn

indicator remote control

Location: Battery compartment on the right side

Protected circuits: Headlight remote control - Start-up

remote control - Stop light bulbs

Location: Battery compartment on the right side

Protected circuits: Horn - Taillight and license plate

light bulbs - Instrument panel

Location: Battery compartment on the right side

Protected circuits: Remote control for injection com-

ponents (fuel pump, injectors, h.v. coil.) - Electrical fan

remote control - Ignition ECU - Immobilizer decoder

Location: Battery compartment on the right side

Protected circuits: Wiring for radio - Wiring for anti-theft

device - Instrument panel

Remote controls - Diode unit

The electrical system is fitted with 5 remote control switches plus the diode unit located under the front shield, and a start-up switch located under the right side fairing. In order to access the remote control switches under the shield it is necessary to:

•

- Remove the front shield.

•

Remove the knee-guard panel.

To access the starter remote control it is necessary to remove the right side fairing. The following table shows the functions of each remote control switch:

A: Diode unit (yellow) B: Electric fan starter C. Light remote control D: Injection load remote control

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Electrical system X8 400 Euro 3

E: Engine stop remote control switch F: Turn indicator remote control G: Starter remote control

Dashboard

A = Twin scale speedometer (km/h and mph) B = Fuel gauge C = Antitheft device LED D = Coolant temperature gauge E = Right turn indicator warning light E = Left turn indicator warning light H = Low fuel warning light I = Lights ON warning light L = High-beam warning light M = Low oil pressure warning light N = Helmet compartment light ON warning light O = Preset warning light P = Analogue clock Q = Total odometer R = Trip odometer S = Trip odometer reset button

The clock, powered directly by the vehicle's battery, may be set by pressing the «T» button located inside the LHS glove-box on the knee-guard panel. Pressing the button for less than one second will add one minute to the displayed time; Keep the «T» button pressed to rapidly increase the time.

Sealed battery

Commissioning sealed batteries

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.

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X8 400 Euro 3 Electrical system

INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

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 nominal capacity of the battery

- Charge time: 5 h

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Cleaning the battery The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY.

If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the + positive sign.

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Electrical system X8 400 Euro 3

Dry-charge battery

- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of

1.26, corresponding to 30 Bé at a minimum temperature of 15°C until the upper level is reached.

- Allow to stand for at least 2 hours, then top up the level with sulphuric acid.

- Within 24 hours, recharge using the special battery charger (single) or (multiple) at an intensity of about 1/10 of the battery nominal capacity and until the acid gravity is about 1.27, corresponding to 31 Bé and such values become steady.

- After charging, top up the acid (adding distilled water). Close and clean carefully.

- After carrying out the operations above, install the battery on the scooter, observing the connections described in point 3) of paragraph "Battery re-

charge".

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

1 Keep the pipe in vertical position 2 Inspect visually 3 The float must be freed

Checking the electrolyte level

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.

Charging status check

After topping-up the electrolyte level, check its density using special density gauge. When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery.

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X8 400 Euro 3 Electrical system

The battery runs down completely in the course of three months. When refitting the battery onto the scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must be attached to the positive, + terminal.

Battery recharge

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.

Remove the battery from the vehicle removing the negative clamp first. Normal bench charging must be performed using the special battery charger (single) or (multiple), setting the battery charge selector to the type of battery that requires recharging (i.e., at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ).

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY.

Battery installation

To access the battery, proceed as follows:

1. Place the scooter on its centre stand;

2. Open the saddle.

3. Remove the two screws A and the cover B.

4. Remove the electrical connections, disconnect

the breather pipe C and take out the battery. To refit, follow the steps but in reverse order.

CAUTION

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Electrical system X8 400 Euro 3

IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCONNECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE SCOOTER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BATTERY ELECTROLYTE.

Connectors

ECU

Layout of the system-side connectors and the connectors on the electronic control unit.

ECU

Specification

1 Throttle potentiometer power supply +5 V 2 Oxygen sensor (-) 3 4 Engine temperature (+) 5 86 electric fan remote control switch 6 Stepper motor Stepper motor 7 Engine rpm sensor 8 Oxygen sensor (+) 9 EMS diagnostic connector 10 EMS diagnostic connector 11 Throttle potentiometer signal 12 Engine rpm sensor

Desc./Quantity

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Specification Desc./Quantity

13 Injector control (negative) 14 Stepper motor Stepper motor 15 Injection telltale light (-) 16 Decoder (serial) Overturn sensor 17 Battery powered (+) 18 Air temperature sensor (+) 19 Fuel pump (-) 20 H.V. coil (negative control) 21 Stepper motor Stepper motor 22 Sensor power supply (-) 23 Control unit negative 24 Stepper motor Stepper motor 25 Turn indicator control device 26 Continuous power supply (positive)

Seat opening receiver

SADDLE OPENING RECEIVER CONTROL UNIT

Specification

1 Radio aerial 2 Actuator positive output 1 3 Reset / Input clearing 4 Battery positive 5 (Not connected) 6 Live positive lead 7 Ground lead 8 (Not connected) 9 Actuator positive output 2 10 Data for alarm output 11 (Not connected)

Immobiliser decoder

Desc./Quantity

Specification

1 -

IMMOBILIZER DECODER

Desc./Quantity

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Electrical system X8 400 Euro 3

Specification Desc./Quantity

2 Immobilizer LED control (negative) 3 Base power supply (positive) 4 Negative 5 6 Electronic control unit EMS (serial) 7 8 Continuous power supply (positive) Immobilizer aerial

Engine rev. sensor

REV SENSOR

Specification Desc./Quantity

1 M: Male 2 F: Female 3 S: Shielding

Dashboard

CONNECTOR A

Specification

1 1 Engine oil pressure warning light 2 2 electronic control unit 3 3 + Battery 4 4 To the clock reset button 5 5 Instrument panel lighting and headlight warning light

6 6 Earth 7 7 + Clock battery 8 8 Right direction warning light

CONNECTOR B

Specification

1 1 Left turn indicator warning light 2 2 Water thermometer 3 3 Live battery 4 4 Engine control warning light 5 5 Low-fuel warning light

CONNECTOR C

Specification

1 1 Fuel level gauge 2 2 Earth 3 3 ABS warning light preinstallation 4 4 High-beam lamp warning light 5 5 Open boot warning light

Desc./Quantity

bulb

Desc./Quantity

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Remote seat opening

The vehicle is equipped with a remote control to open the saddle. This remote control is supplied together with the keys and at the manufacturing stage, it has been programmed to work together with the ECU that control the opening device. If the remote control is lost, a new one can be requested and reprogram it by resetting the ECU memory and following the same steps as per programming the immobilizer system in the keys.

Battery replacement

The remote control for the black key is powered by inner batteries that get discharged after extended used. You may need to replace the batteries if the remote control fails or if its range of operation is reduced. To replace the batteries remove the three screws and uncouple the two half-shells.

Electric characteristic

Batteries used:

CR1616

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Electrical system X8 400 Euro 3

Zeroing

- To access the saddle opening control/reception unit, remove the left side fairing.

- A white cable, that comes from pin 3 of the control unit, goes out from the wiring.

- Earth the cable at least 10 seconds in order to delete all the remote controls stored in the control unit.

Programming

- Follow these steps to program the remote controls:

1. Insert the remote control key to be programmed in the steering lock key block.

2. Turn the key to ON, press the button on the remote control, release the button, turn the key back to OFF from the ON position, all within four seconds.

3. Wait 1 to 8 seconds

4. Repeat steps 2 and 3 for 4 times without removing the key. The control unit confirms the programming has been successful by opening the saddle.

N.B.

THE CONTROL UNIT CAN PROGRAMME UP TO 7 REMOTE CONTROLS.

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle X8 400 Euro 3

Exhaust assy. Removal

- Remove the right-hand side fairing

- Undo the two exhaust manifold fixings on the head.

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

Remove the screw indicated in the photograph.

- Loosen the screw shown in the figure so as to loosen the muffler strap and remove the whole muffler.

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X8 400 Euro 3 Engine from vehicle

N.B. DUE TO MUFFLER DIMENSIONS IT IS NOT POSSIBLE TO

ACTUATE ON THE SCREW PERPENDICULARLY TO REMOVE IT; USE A COMMERCIALLY AVAILABLE «BONDUS» MALE HEXAGONAL WRENCH.

Remove the lambda probe from the manifold.

Removal of the engine from the vehicle

CAUTION

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

- Disconnect the battery.

- Remove the side fairings.

- Remove the helmet compartment. Remove the full muffler unit.

- Remove the rear wheel.

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

- Remove the engine coolant outlet pipe as indicated.

- Disconnect the delivery and reverse fuel pipes "B".

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

- Remove the spark plug cap.

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Engine from vehicle X8 400 Euro 3

- Remove the electrical connections to the sensors and devices.

- Remove the throttle control cable from the throttle body by undoing the nut "C".

- Remove the positive and negative wiring from the starter motor.

- Disconnect the connectors from the flywheel wiring harness.

- Remove the lower screw of the left shock absorber "D".

- Use a jack to support the vehicle properly.

- Remove the engine-swinging arm fixing pin by undoing the nut "E" and operating on the head of the pin "F" indicated in the photograph.

- Remove the rear brake calliper and the relevant pipes from the engine crankcase.

- The engine is now free.

Installing the engine on the scooter

- Carry out the removal operations but in reverse order and respect the locking torques indicated in the «Specifications» Chapter.

CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.

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X8 400 Euro 3 Engine from vehicle

Check that there is a small clearance when the valve is in abutment against the set screw.

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

- Top-up the cooling circuit.

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

ENG VE - 79

INDEX OF TOPICS

ENGINE ENG

X8 400 Euro 3 Engine

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

Automatic transmission

Transmission cover

- Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap.

- Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush.

- Remove the nut and the two washers.

N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-

ENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

- Remove the six M6 screws.

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Engine X8 400 Euro 3

- Remove the four M8 screws.

- Remove the transmission cover.

- Check that the bearing rotates freely, otherwise replace it.

- Loosen the 4 fastening screws

- Extract the outside plastic transmission cover.

Air duct

- Remove the transmission cover.

- Unscrew the two screws shown in the figure to remove the air conveyor.

Locking torques (N*m)

Air conveyor screws 11 ÷ 12

- Remove the external transmission cover.

- Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor.

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X8 400 Euro 3 Engine

Air duct filter

- Remove the external air conveyor.

- Unscrew the 2 fastening screws shown in the figure to remove the conveyor filter.

Removing the driven pulley shaft bearing

- Remove the transmission cover.

- Remove the Seeger ring.

- Place transmission cover on a wood surface and use the special tool so that it is adequately supported.

- Pull out the bearing using the special tool.

N.B. BELL MUST BE PLACED INTO THE TRANSMISSION COV-

ER, CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND. NOT ONLY IN THE AREA OF MAXIMUM STURDINESS.

Specific tooling

001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020439Y 17 mm guide

ENG - 83

Engine X8 400 Euro 3

Refitting the driven pulley shaft bearing

- Heat the transmission cover interior using the heat gun.

N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS

WOULD DAMAGE THE OUTSIDE PAINTED SURFACE.

Specific tooling

020151Y Air heater

- Place the bearing onto the special tool with a little grease to prevent it from coming out.

- Install the new bearing using the special tool.

N.B. PROPERLY SUPPORT THE OUTSIDE COVER TO PRE-

VENT DAMAGING THE PAINTED SURFACE.

Specific tooling

020376Y Adaptor handle 020358Y 37x40-mm Adaptor 020439Y 17 mm guide

Baffle roller

Plastic roller

Installation of belt anti-vibration roller

- Install the anti-flapping roller with the lip facing the engine crankcase.

- Tighten the central screw to the prescribed torque.

N.B. TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A

CORRECT TENSIONING OF THE BELT IS OBTAINED.

Locking torques (N*m)

Anti-vibration roller screw 16.7 ÷ 19.6

ENG - 84

X8 400 Euro 3 Engine

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

- Loosen the retaining bolt using a 13 mm spanner.

- Remove the complete roller with bearing.

N.B. IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE

THE COMPLETE ROLLER.

Removing the driven pulley

- Remove the driven pulley assembly with the belt.

Inspecting the clutch drum

- Remove the clutch bell.

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

- Measure the clutch bell inside diameter.

N.B. CHECK THE ECCENTRICITY MEASURED, 0.2 MM MAX.

Characteristic

Max. value:

160.5 mm

Standard value:

160.2 mm

ENG - 85

Engine X8 400 Euro 3

Removing the clutch

- To remove the clutch with the driven pulley it is necessary to use the special tool;

- Arrange the tool with the mean pins screwed in position "E" on the inside;

- Install the driven pulley unit onto the tool inserting the pins into the ventilation holes;

- Move the rear stop screw in abutment against the fixed driven pulley as shown in the figure.

CAUTION

THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIAL TOOL. DO NOT TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD IRRETRIEVABLY DEFORM THE TOOL. USING THE SPECIAL 55-MM WRENCH, REMOVE THE FASTENING RING NUT. LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT, CLUTCH, SPRING WITH SHEATH.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

Pin retaining collar

- Extract the collar using 2 screwdrivers.

- Remove the 4 guide pins.

- Extract the moving driven half-pulley.

ENG - 86

X8 400 Euro 3 Engine

Removing the driven half-pulley bearing

- Check that the bushing is free from wear and damage; otherwise replace the fixed driven halfpulley.

- Remove the lock ring using pliers.

- Using the special tool inserted through the roller bearing, pull out the ball bearing.

N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAM-

AGING THE THREADING.

Specific tooling

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

N.B.

IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS NECESSARY TO SUPPORT THE UNIT BY THE BELL

Specific tooling

001467Y002 Driver for OD 73 mm bearing

- Remove the roller bearing using the special tool, supporting the fixed half-pulley with the bell.

Specific tooling

020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020364Y 25-mm guide 001467Y002 Driver for OD 73 mm bearing

ENG - 87

Engine X8 400 Euro 3

Inspecting the driven fixed half-pulley

- Check that the belt contact surface is free from wear.

- Measure the outer diameter of the pulley bushing.

Characteristic

Minimum admissible diameter

49.91 mm

Standard diameter:

50.00 -0.015 -0.035 mm

Inspecting the driven sliding half-pulley

- Check that the belt contact surface is free from wear.

- Remove the 2 inside sealing rings and the 2 outside O-rings.

- Measure the movable half-pulley bushing inside diameter.

Characteristic

Maximum admissible diameter:

50.05 mm

Standard diameter:

50.00 +0.035 0.00 mm

Refitting the driven half-pulley bearing

- Install a new roller bearing using the special tool.

N.B.

PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUTWARDS.

- Properly support the half-pulley to prevent damaging the threading. If you are working on the driven pulley unit fully assembled, use the special tool.

ENG - 88

X8 400 Euro 3 Engine

Specific tooling

020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing

- Install a new ball bearing using the special tool.

Specific tooling

020376Y Adaptor handle 020477Y Adaptor 37 mm 020363Y 20 mm guide

- Insert the Seeger lock ring.

Refitting the driven pulley

- Insert the new oil guards

- Insert the new O-rings

N.B.

O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RADIUS, AT THE BASE OF THE HALF-PULLEY.

- Install the half-pulley on the bushing being careful not to damage the top sealing ring during the introduction.

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of grease, this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.

PIAGGIO X8 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual