PIAGGIO X9 Evolution 125 2008 Service Station Manual

Download

Page 1

SERVICE STATION MANUAL

664627 IT-664628 EN-664629 FR-664630 DE-664631

ES-664632 PT-664633 OL-664634 EL

X9 Evolution 125

Page 2

SERVICE STATION

MANUAL

X9 Evolution 125

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet 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 models

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)

Page 3

SERVICE STATION MANUAL

X9 Evolution 125

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.

Page 4

Page 5

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

Page 6

INDEX OF TOPICS

CHARACTERISTICS CHAR

Page 7

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 solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- 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 vehicle.

- 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.

X9 Evolution 125 Characteristics

CHAR - 7

Page 8

Vehicle identification

Chassis prefix: ZAPM481000000 ÷ 1001 Engine prefix: M482M

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification

Desc./Quantity

Kerb weight 172±5 kg

Saddle height 790 mm

Wheelbase 1500 mm Overall length 2130 mm Overall height 1450 mm

Overall width 910 mm

Characteristics X9 Evolution 125

CHAR - 8

Page 9

Engine

TECHNICAL DATA

Specification

Desc./Quantity

Type Single-cylinder, 4-stroke Timing system 4 valves, single overhead camshaft, chain-driven. Cubic capacity 124 cm³

Bore x stroke 57 x 48.6 mm

Compression ratio 12 ± 0.5: 1

Carburettor KEIHIN CVK 29

ignition advance (before TDC) 10° at 2000 rpm

Valve clearance intake: 0.10 mm discharge: 0.15 mm

Spark plug CHAMPION RG4HC

Alternative spark plug NGK CR8EB

Idle speed 1650 ± 100 rpm

Max. power 11 kW at 10,000 rpm

Max. torque 12 Nm at 8000 rpm

Maximum speed 105 km/h

Transmission

TRANSMISSIONS

Specification

Desc./Quantity

Transmission With automatic expandable pulley variator, V belt, automatic

clutch, gear reduction unit and transmission housing with

forced-circulation air cooling.

X9 Evolution 125 Characteristics

CHAR - 9

Page 10

Capacities

CAPACITY

Specification Desc./Quantity

Rear hub 150 cm³

Cooling system ~ 1.2 l

Engine oil ~ 1000 cm³

Fuel tank (including a ~ 2.5 l reserve) ~ 14.5 l

Electrical system

ELECTRICAL COMPONENTS

Specification Desc./Quantity

Generator Three-phase alternating current

Battery 12V -10 Ah

Ignition type Electronic capacitive discharge ignition (CDI) and variable ad-

vance, with separate HV coil.

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification

Desc./Quantity

Rear wheel max. travel 90 mm.

Rear suspension Engine with oscillating fork articulated to the chassis by means

of a double swinging arm. Double-acting hydraulic shock ab-

sorbers, coaxial helicoidal spring with variable step, adjustable

at preloading on 4 positions.

Front fork stroke 90 mm

Front suspension Hydraulic telescopic fork with Ø 35-mm stem

Type of chassis Welded tubular steel chassis with stamped sheet reinforce-

ments.

Brakes

BRAKES

Specification

Desc./Quantity

Rear Ø 240 mm stainless steel disc with Brembo "Serie Oro" floating

calliper with Ø 34 mm twin plungers

Integral braking system Left lever acts on the left front and rear discs, through a valve

that distributes the pressure; the right lever acts on the right

front disc only

Front Ø 240 mm stainless steel double disc with Ø 34 mm Brembo

"Serie Oro" floating calliper (front Right) / Ø 32 (front Left)

Wheels and tyres

WHEELS AND TYRES

Specification

Desc./Quantity

Tyre pressure (when cold) Front: 2.1 bar Rear: 2.3 bar (2.5 bar with driver and luggage)

Front tyre Without inner tube: 120/70-14" 55P

Rear tyre Without inner tube: 140/60-14" 64P

Front wheel alloy rim: 14'' x 3.50

Rear wheel alloy rim: 14'' x 3.50

Characteristics X9 Evolution 125

CHAR - 10

Page 11

Secondary air

The SAS for 125cc leader engines operates in a similar manner to the SAS for 2T engines. The differences are the following: instead of entering through the muffler as for 2T engine, the secondary air enters directly in the discharge pipe on the head.

The 2T reed valve has a diaphragm. The unit, indicated by an arrow in the figure, has a cut-off connected to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions in the muffler.

Air is drawn through the opening «A», goes through the first filter and is channelled through the opening «B».

Air gets to the second filter «B» through the opening shown in the figure. Now, the filtered air enters the diaphragm device, and then is channelled to the head.

X9 Evolution 125 Characteristics

CHAR - 11

Page 12

The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reaction of the catalytic converter.

125cc Version

ble border="1" cellpadding="5" cellspacing="1" class="piag_tabella2">

Carburettor Keihin Walbro

Vacuum type CVK 30 WVF-7G* Body stamping CVK 7G Stamping 303A Max. jet 105 108 Minimum jet 35 36

Characteristics X9 Evolution 125

CHAR - 12

Page 13

Carburettor Keihin Walbro

Max. air jet 70 115 Minimum air jet 130 100 Throttle valve spring 100 ± 160 g 100 g Minimum mixture set screw initial opening

2 ± 1/4 2 5/8 ± 1/2

Tapered pin stamping NDYA 51C Tapered pin notches position from top Fixed position 2 Diffuser nozzle Ø 2.8 Ø 2.7 Starter air jet Ø 1.5 (body) 200 Starter diffuser jet 130 Starter jet 42 50 Starter device resistance ~ 20 Ω ~ 40 Ω Diffuser Ø 29 Ø 29 (30.3x27.0)

* The identification letter can vary with each carburettor update.

Kehin

KEHIN CARBURETTOR

Specification

Desc./Quantity

Depression carburettor CVEK-30

Body stamping CVEK

Stamping 303A

Max. jet 105

Minimum jet 35

Max. air jet 70

Throttle valve spring 100 ÷ 160 g

Minimum mixture set screw initial opening 2 ± ¼

Tapered pin stamping NDYA

Tapered pin notches position from top Fixed position

Diffuser nozzle Ø 2.8

Starter diffuser jet

Starter jet 42

Starter device resistance ~ 20 Ω

Diffuser Ø 29

125 keihn - Minimum air jet 130

125 keihn - Maximum air jet 70

N.B.

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

Walbro

WALBRO CARBURETTOR

Specification

Desc./Quantity

Venturi diffuser Ø 29 (30.3x27)

Starter device resistance ~ 40 Ω

Starter jet 50

Starter diffuser jet 130

Starter air jet 200

X9 Evolution 125 Characteristics

CHAR - 13

Page 14

Specification Desc./Quantity

Diffuser nozzle Ø 2.7

Tapered pin notches from above 2

Tapered pin stamping 51C

Minimum mixture set screw initial opening 2 5/8 ± 1/2

Throttle valve spring 100 g

Minimum air jet 100

Max. air jet 115

Minimum jet 36

Max. jet 108

Stamping

Body stamping 7GO

125 Walbro: Minimum jet 100

125 Walbro: Max. jet 115

N.B.

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

200cc Version

Carburettor Keihin Walbro Vacuum type CVK30 WVF-7H* Body stamping CVK 7H Stamping 303A Max. jet 100 118 Minimum jet 38 34 Max. air jet 70 150 Minimum air jet 115 50 Throttle valve spring 150 ÷ 250 g 120 g Minimum mixture set screw initial opening

± 1/4 3 ± 1/4

Tapered pin stamping NDWA 465 Tapered pin notches position from top Fixed position 3 Diffuser nozzle Ø 2.8 Ø 2.7 Starter air jet 200 Starter diffuser jet Ø 1.5 (body) 130 Starter jet 42 50 Starter device resistance ~ 20 Ω ~ 40 Ω Diffuser Ø 29 Ø 29 (30.3x27.0)

ò The identification letter can vary with each carburettor update.

Kehin

KEHIN CARBURETTOR

Specification

Desc./Quantity

Depression carburettor CVEK-30

Body stamping CVEK

Characteristics X9 Evolution 125

CHAR - 14

Page 15

Specification Desc./Quantity

Stamping 303A

Tapered pin notches position from top Fixed position

Max. air jet 70

Diffuser nozzle Ø 2.8

Starter jet 42

Starter device resistance ~ 20 Ω

Diffuser Ø 29

Tapered pin stamping NDWA

Minimum mixture set screw initial opening ± ¼

Throttle valve spring 150 ÷ 250 g

Minimum air jet 115

Minimum jet 38

Max. jet 100

Starter air jet Ø 1.5 (body)

Starter diffuser nozzle Ø 1.5 (body)

N.B.

THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE

Walbro

WALBRO CARBURETTOR

Specification Desc./Quantity

Tapered pin notches position from top 3

Tapered pin stamping 465

Minimum mixture set screw initial opening 3 ± 1/4

Throttle valve spring 120 g

Minimum air jet 50

Max. air jet 150

Minimum jet 34

Max. jet 118

Body stamping 7HO

Vacuum type WVF-7H*

Diffuser Ø 29 (30.3x27.0)

Starter jet 50

Starter diffuser jet 130

Starter air jet 200

Diffuser nozzle Ø 2.7

Stamping

N.B.

THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE

Tightening Torques

TECHNICAL SERVICE NOTES

For correct tightening, the expansion tank cap locking torque has been standardised to 2.5 Nm

REAR BRAKE

Product

Description Specifications

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

threadlock

FRONT BRAKE

Name

Torque in Nm

Oil bleed screw 8 ÷ 12

Disc tightening screw (°) 5 ÷ 6

Brake fluid pipe-calliper fitting 16 ÷ 20

X9 Evolution 125 Characteristics

CHAR - 15

Page 16

Name Torque in Nm

Brake fluid pump-hose fitting 16 ÷ 20

Tightening screw for calliper support to the fork 45 ÷ 55

REAR SUSPENSION

Name Torque in Nm

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

Rear wheel axle 104 ÷ 126

FRONT SUSPENSION

Name Torque in Nm

Fork leg screw 6 ÷ 7 Front wheel axle 45 ÷ 50 Fork plate screw 25 ÷ 34

CHASSIS

Name Torque in Nm

Centre stand bolt 25 ÷ 30

Frame arm-engine arm bolt 60 ÷ 64

Swinging arm buffer nut 20 ÷ 25 Frame-swinging arm bolt 66 ÷ 80 Engine-swinging arm bolt 33 ÷ 41

STEERING

Name

Torque in Nm

Upper steering ring nut 30 ÷ 36

Steering lower ring nut 10 ÷ 13 then loosen by 90°

Handlebar fixing screw (*) 45 ÷ 50

Fixing screws for the handlebar control unit U-bolts 7 ÷ 10

ENGINE - COOLING

Product

Description Specifications

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

threadlock

CRANKCASE AND CRANKSHAFT

Name

Torque in Nm

Internal engine crankcase bulkhead (transmission-side half

shaft) screws

4 ÷ 6

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing system cover screws (°) 3.5 ÷ 4.5

ENGINE - FLYWHEEL

Name

Torque in Nm

Pick-Up clamping screws 3 ÷ 4

Stator assembly screws (°) 3 ÷ 4

Flywheel cover fixing screws 5 - 6

Flywheel nut (250) 94 ÷ 102

Screw fixing freewheel to flywheel 13 ÷ 15

ENGINE - TRANSMISSION

Name

Torque in Nm

Rear hub cover screws 24 ÷ 27

Driven pulley shaft nut 54 ÷ 60

Transmission cover screws 11 ÷ 13

Drive pulley nut 75 ÷ 83

Clutch unit nut on driven pulley 55 ÷ 60

Belt support roller screw 11 ÷ 13

Characteristics X9 Evolution 125

CHAR - 16

Page 17

ENGINE - CYLINDER HEAD

Name Torque in Nm

Manifold-silencer retaining bolt 15 ÷ 20

Nut fixing muffler to cylinder head 16 ÷ 18

Camshaft retention plate screw 4 ÷ 6

Timing chain tensioner central screw 5 ÷ 6 Timing chain tensioner support screw 11 ÷ 13 Start up counterweight support screw 11 ÷ 15

Timing chain tensioner slider screw 10 ÷ 14

Inlet manifold screws 11 ÷ 13

Tappet set screw lock nut 6 ÷ 8

Starter ground screw 7 ÷ 8.5

Head fixing side screws 11 ÷ 12

Nuts fixing head to cylinder (*) 27 ÷ 29

Tappet cover screws 6 ÷ 7

Spark plug 12 ÷ 14

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 0.7 ÷ 0.9

Screws fixing oil pump to crankcase 5 - 6

Oil pump command crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

N.B.

Before fitting the nuts, lubricate them with engine oil

N.B.

Use new nuts

Cylinder - piston assy.

ENGINE 125 COUPLING CATEGORIES

Name

Initials Cylinder Piston Play on fitting

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059

Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059 Cylinder 1st Oversize A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059 Cylinder 1st Oversize B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059

Piston 1st Oversize C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059

Piston 1st Oversize D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059 Cylinder 2nd Oversize A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059 Cylinder 2nd Oversize B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059

Piston 2nd Oversize C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059

Piston 2nd Oversize D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059 Cylinder 3rd Oversize A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059 Cylinder 3rd Oversize B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059

Piston 3rd Oversize C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059

Piston 3rd Oversize D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

X9 Evolution 125 Characteristics

CHAR - 17

Page 18

ENGINE 200 COUPLING CATEGORIES

Name

Initials Cylinder Piston Play on fitting

Cylinder / piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 Cylinder / piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044 Cylinder / piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044

Characteristics X9 Evolution 125

CHAR - 18

Page 19

ENGINE 125 COUPLING CATEGORIES

Name

Initials Cylinder Piston Play on fitting

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059

Piston 1st Oversize C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059

Piston 2nd Oversize C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059

Piston 3rd Oversize C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059

Piston 3rd Oversize D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo

Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine

Crankshaft Crankshaft to connecting rod

axial clearance

Crankshaft to connecting rod axial clearance

X9 Evolution 125 Characteristics

CHAR - 19

Page 20

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name

Description Dimensions Initials Quantity

Half-shaft, transmission

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, 200 models

Cr: 11÷12 :1

Characteristics X9 Evolution 125

CHAR - 20

Page 21

Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part 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.

NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND ON A RECTIFIED PLANE.

VERSION 200 WITH FIBRE HEAD GASKET (1.1)

Name

Measure A Thickness

Shimming 200 - Cylinder 67 - Head gas-

ket 1.1 - Base gasket 0.4

1.70 ÷ 1.60 0.4 ± 0.05

Shimming 200 - Cylinder 67 - Head gas-

ket 1.1 - Base gasket 0.6

1.60 ÷ 1.40 0.6 ± 0.05

Shimming 200 - Cylinder 67 - Head gas-

ket 1.1 - Base gasket 0.8

1.40 ÷ 1.30 0.8 ± 0.05

X9 Evolution 125 Characteristics

CHAR - 21

Page 22

ENGINE 200 SHIMMING

Name

Measure A Thickness

200 1.40 ÷ 1.30 0.8 ± 0.05 200 1.60 ÷ 1.40 0.6 ± 0.05 200 1.70 ÷ 1.60 0.4 ± 0.05

ENGINE 125 SHIMMING

Name

Measure A Thickness

125 2.2 ÷ 2.4 0.4 ± 0.05

Characteristics X9 Evolution 125

CHAR - 22

Page 23

Name Measure A Thickness

125 2.4 ÷ 2.6 0.6 ± 0.05

N.B.

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 IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.

Oversizes

ENGINE 125 OVERSIZE

Name

Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 ÷ 0.30

Oil scraper ring 57 x 1 A 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35

Compression ring 1st

oversize

57.2 x 1 A 0.15 ÷ 0.30

Oil scraper ring 1st

Oversize

57.2 x 1 A 0.10 ÷ 0.30

Oil scraper ring 1st

Oversize

57.2 x 2.5 A 0.15 ÷ 0.35

Compression ring 2nd

Oversize

57.4 x 1 A 0.15 ÷ 0.30

Oil scraper ring 2nd

Oversize

57.4 x 1 A 0.10 ÷ 0.30

Oil scraper ring 2nd

Oversize

57.4 x 2.5 A 0.15 ÷ 0.35

Compression ring 3rd

Oversize

57.6 x 1 A 0.15 ÷ 0.30

Oil scraper ring 3rd

Oversize

57.6 x 1 A

Oil scraper ring 3rd

Oversize

57.6 x 2.5 A 0.15 ÷ 0.35

X9 Evolution 125 Characteristics

CHAR - 23

Page 24

ENGINE 200 OVERSIZE

Name Description Dimensions Initials Quantity

Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40 Oil scraper ring 72 x 1 A 0.20 ÷ 0.40

Compression ring 72 x 1.5 A 0.15 ÷ 0.30

Products

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

Level check

SAS filters inspection and cleaning

Undo the 3 fixing screws "A", remove the secondary air filter cover and then take out the filtering element "B".

- Wash with water and neutral soap.

-Dry with a clean cloth and short blasts of compressed air. Remove the flywheel cover by operating on its clamps and remove the primary filtering element.

- Wash with water and neutral soap.

-Dry with a clean cloth and short blasts of compressed air. Check that the filter casing is clean paying special attention to "A" and "B" passages

CAUTION NEVER RUN THE ENGINE WITHOUT THE SECONDARY

AIR FILTER CAUTION

Maintenance X9 Evolution 125

MAIN - 46

Page 47

WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

Insert the filter into its housing. Fit the valve support with the 3 screws Insert the rubber spacer on the valve and proceed with the assembly on the support. Fix the support with the 2 screws. Fit the pre-filter and position it matching the 2 references shown in the figure. Fit the sealing gasket. Align the drive with the reference on the crankcase cover. Place the flywheel in the TDC position and align the references as shown in the figure. Check the correct fitting of the 2 reference dowels and fit the engine cover. Be careful to properly fit the flywheel connector to the relative supplements. Secure the rotor cover by using a new gasket with the 4 screws. Connect the flywheel connector and the valve control vacuum-operated pipe. Fit the coupling to the valve and position it as shown in the figure. Lock the upper clamp. Fix the metal tube to the head using the gasket and the 2 screws. Lock the lower clamp connecting manifold / pipe.

X9 Evolution 125 Maintenance

MAIN - 47

Page 48

Locking torques (N*m)

Stator assembly screws (°) 3 ÷ 4

Maintenance X9 Evolution 125

MAIN - 48

Page 49

X9 Evolution 125 Maintenance

MAIN - 49

Page 50

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 51

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

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-

place

Excess of encrustations in the combustion chamber 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.

Automatic starter failure Check: mechanical movement, electric connection and fuel

supply, replace if required.

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

Lack of compression: parts, cylinder and valves worn Replace the worn parts

Transmission belt worn Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-

aged parts and lubricate the driven pulley moveable guide with

Montblanc Molybdenum Grease

Clutch slipping Check the clutch system and/or the bell and replace if neces-

sary

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

Defective floating valve Check the proper sliding of the float and the functioning of the

valve

Starting difficulties

DIFFICULT STARTING

Possible Cause

Operation

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill

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

aged

Check the starter motor, the system and the torque limiter

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

- 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.

Automatic starter failure Check: mechanical movement, electric connection and fuel

supply, replace if required.

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.

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

The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-

place

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

X9 Evolution 125 Troubleshooting

TROUBL - 51

Page 52

Possible Cause Operation

Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-

ened

Defective floating valve Check the proper sliding of the float and the functioning of the

valve

Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air

Fuel pump fault Check the pump control device

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Worn valve guides Check and replace the head unit if required

Worn valve oil guard Replace the valve oil guard

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn or broken piston rings or piston rings that have not been

fitted properly

Replace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

Operation

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

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLE

Possible Cause

Operation

Faulty fuel supply Check or replace the pump and the vacuum valve, check the

vacuum intake and the pipe sealing

Incorrect float level Restore the level in the tank by bending on the float the thrust-

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

Water in the carburettor Empty the tank through the appropriate bleed nipple.

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air

Engine tends to cut-off at idle

ENGINE STOP IDLING

Possible Cause

Operation

Incorrect timing Time the system and check the timing system components

Cut off device failure Check that the following parts work properly: valve; diaphragm;

spring; and that the air calibration elements are clean; check if

the sponge filter is clean too

Incorrect idle adjustment Adjust using the rpm indicator

Pressure too low at the end of compression Check the thermal group seals and replace worn components

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

The starter remains on Check: electric wiring, circuit not interrupted, mechanical

movement and power supply; replace if necessary

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air

Troubleshooting X9 Evolution 125

TROUBL - 52

Page 53

Excessive exhaust noise

EXCESSIVE EXHAUST NOISE

Possible Cause Operation

Secondary air device cut-off valve not working Replace the secondary air device

Depression intake pipe of the secondary air device disconnec-

ted or dented

Replace the pipe

Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the

head pipe

Replace the device and the coupling

High fuel consumption

HIGH FUEL CONSUMPTION

Possible Cause Operation

Float level Restore the level in the tank by bending on the float the thrust-

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

Loose nozzles Check the maximum and minimum nozzles are adequately

fixed in their fittings

Fuel pump failure Check that there is no fuel in the low-pressure duct

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

power supply

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.

SAS malfunctions

ANOMALIES IN THE SECONDARY AIR DEVICE

Possible Cause

Operation

Secondary air device cut-off valve not working Replace the secondary air device

Depression intake pipe of the secondary air device disconnec-

ted or dented

Replace the pipe

Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the

head pipe

Replace the device and the coupling

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

X9 Evolution 125 Troubleshooting

TROUBL - 53

Page 54

Insufficient braking

INSUFFICIENT BRAKING

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 change 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

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Rubber gaskets swollen or stuck Replace gaskets.

Compensation holes on the pump clogged Clean carefully and blast with compressed air

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.

Defective piston sliding Check calliper and replace any damaged part.

Battery

BATTERY

Possible Cause

Operation

Battery This is the device in the system that requires the most frequent

attention and the most thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 3 months. If the battery is fitted on a motorcycle,

be careful not to invert the connections, keeping in mind that

the black ground wire is connected to the negative terminal

while the red wire is connected to the terminal marked+.

Turn signal lights malfunction

TURN INDICATOR NOT WORKING

Possible Cause

Operation

Electronic ignition device failure With the key switch set to "ON" jump the contacts 1 (Blue -

Black) and 5 (Red/Blue) on the control unit connector. If by

operating the turn indicator control the lights are not steadily

on, replace the control unit; otherwise, check the cable harness

and the switch.

Steering and suspensions

Rear wheel

REAR WHEEL ROTATES WITH ENGINE AT IDLE

Possible Cause

Operation

Idling rpm too high Adjust the engine idle speed.

Clutch fault Check the springs / clutch masses

Troubleshooting X9 Evolution 125

TROUBL - 54

Page 55

Controls

STEERING CONTROLS AND SUSPENSIONS

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the

above adjustments, check the seats in which the ball bearings rotate: if they are recessed or if the balls are squashed, replace

them.

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the

above adjustments, check the seats in which the ball bearings rotate: if they are recessed or if the balls are squashed, replace

them.

Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front

shock absorber; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers; and the movement

bushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disc in the

attachment to the hub and the steering tube.

Seal fault or breakage Replace the shock absorber Check the condition of wear of the

steering covers and the adjustments.

X9 Evolution 125 Troubleshooting

TROUBL - 55

Page 56

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 57

This section is devoted to the description of the electrical system components.

KEY

1. Electronic ignition device

2. Immobilizer aerial

3. Magneto flywheel Pick-up

4. Relay for disabling start-up

5.Relay engine stop

6. Voltage regulator

7. Engine stop switch

8. Main fuses

9. 12V-180W socket

10. Battery

X9 Evolution 125 Electrical system

ELE SYS - 57

Page 58

11. Starter motor

12. Relay for start-up

13. Secondary fuses

14. Stop button on rear brake

15. Stop button on front brake

16. Start-up button

17. Reset

18. Saddle opening control unit wiring

19. Helmet compartment light switch

20. Wiring for antitheft device

21. Light switch

22. Relay for headlight

23. Diode

24. Helmet compartment internal light

25. License plate light

26. Rear left light A. Tail light B. Rear left turn indicator

27. Rear stop light

28. Rear right light A. Rear right turn indicator B. Tail light

29. Front left turn indicator

30. Left headlight A. Tail light B. High-beam light

31. Right headlight A. Low-beam light B. Tail light

32. Front right turn indicator

33. Horn button

34. Horn

35. Oil pressure sensor

36. Accessories wiring

37. Reset button

38.Wheel turning sensor

39. Fuel level transmitter

40. Thermistor

Electrical system X9 Evolution 125

ELE SYS - 58

Page 59

41. Digital instrument panel A. Preset warning light B. ABS wiring warning light C. Stop light bulb burned warning light D. Disabled engine warning light E. Oil warning light F. Low fuel warning light G. Headlight warning light H. High-beam warning light I. Left turn indicator warning light L. Emergency flashing warning light M. Right turn indicator warning light

42. Analogue instrument panel A. Immobilizer warning light B. Instrument panel bulb

43. Emergency flashing button

44. Turn indicator switch

45. Wiring for control unit power

46. External temperature sensor

47. Thermoswitch

48. Electric fan

49. Key switch

50. Side stand button

51. Automatic starter

52. Saddle opening actuator

53. Saddle opening switch

54. Fuel pump

55. Wiring for radio display

56. Control unit display wiring

57. Electric pump control device

58. Spark plug

59. HV coil 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

X9 Evolution 125 Electrical system

ELE SYS - 59

Page 60

Conceptual diagrams

Ignition

KEY

1. Electronic ignition device

2. Immobilizer aerial

5.Relay engine stop

7. Engine stop switch

8. Main fuses

10. Battery

49. Key switch

50. Side stand button

58. Spark plug

59. HV coil

Electrical system X9 Evolution 125

ELE SYS - 60

Page 61

Headlights and automatic starter section

KEY

1. Electronic ignition device

5.Relay engine stop

7. Engine stop switch

8. Main fuses

10. Battery

13. Secondary fuses

21. Light switch

22. Relay for headlight

23. Diode

25. License plate light

26. Rear left light A. Tail light

28. Rear right light B. Tail light

30. Left headlight A. Tail light B. High-beam light

X9 Evolution 125 Electrical system

ELE SYS - 61

Page 62

31. Right headlight A. Low-beam light B. Tail light

41. Digital instrument panel G. Headlight warning light H. High-beam warning light

42. Analogue instrument panel B. Instrument panel bulb

49. Key switch

50. Side stand button

51. Automatic starter

Battery recharge and starting

KEY

1. Electronic ignition device

3. Magneto flywheel Pick-up

4. Relay for disabling start-up

5.Relay engine stop

6. Voltage regulator

7. Engine stop switch

Electrical system X9 Evolution 125

ELE SYS - 62

Page 63

8. Main fuses

10. Battery

11. Starter motor

12. Relay for start-up

13. Secondary fuses

14. Stop button on rear brake

15. Stop button on front brake

16. Start-up button

27. Rear stop light

49. Key switch

50. Side stand button

Level indicators and enable signals section

KEY

1. Electronic ignition device

2. Immobilizer aerial

4. Relay for disabling start-up

5.Relay engine stop

7. Engine stop switch

8. Main fuses

X9 Evolution 125 Electrical system

ELE SYS - 63

Page 64

10. Battery

13. Secondary fuses

35. Oil pressure sensor

38.Wheel turning sensor

39. Fuel level transmitter

40. Thermistor

42. Analogue instrument panel A. Immobilizer warning light

46. External temperature sensor

49. Key switch

50. Side stand button

Electrical system X9 Evolution 125

ELE SYS - 64

Page 65

Devices and accessories

KEY

1. Electronic ignition device

5.Relay engine stop

7. Engine stop switch

8. Main fuses

9. 12V-180W socket

10. Battery

13. Secondary fuses

17. Reset

18. Saddle opening control unit wiring

19. Helmet compartment light switch

20. Wiring for antitheft device

24. Helmet compartment internal light

26. Rear left light B. Rear left turn indicator

28. Rear right light A. Rear right turn indicator

29. Front left turn indicator

X9 Evolution 125 Electrical system

ELE SYS - 65

Page 66

32. Front right turn indicator

33. Horn button

34. Horn

36. Accessories wiring

37. Reset button

41. Digital instrument panel I. Left turn indicator warning light L. Emergency flashing warning light M. Right turn indicator warning light

43. Emergency flashing button

44. Turn indicator switch

45. Wiring for control unit power

47. Thermoswitch

48. Electric fan

49. Key switch

50. Side stand button

52. Saddle opening actuator

53. Saddle opening switch

54. Fuel pump

55. Wiring for radio display

56. Control unit display wiring

57. Electric pump control device

58. Spark plug

59. HV coil

Checks and inspections

Immobiliser

The electric ignition system is fed with direct current and is protected by an antitheft immobilizer integrated to the control unit. The ignition system consists of:

- electronic control unit

- immobilizer aerial

- master and service keys with built-in transponder

- HV coil

- diagnosis LED

Electrical system X9 Evolution 125

ELE SYS - 66

Page 67

-The diagnostic LED also works as a deterring blinker. This function is activated every time the key switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process. When the key switch is turned to "ON", this blinking function is deactivated. A flash then confirms the system has switched to "ON". The duration of the flash depends on the electronic control unit program (see figure). If the led turns off and remains so when switching to "ON", it is necessary to check if there is battery voltage in the electric control unit. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located below the spark plug inspection port. If the serial LED remains off, proceed to check the control unit supply as follows:

- Disconnect the control unit connector and check if:

- There is battery voltage between terminal No. 4 (Red/Black) and the ground lead.

- There is battery voltage between the terminal No. 4 (Red/Black) and terminal No. 8 (Negative) as shown in the figure. If no voltage is detected, check the wiring to the battery positive lead and see if the 15A fuse is in good conditions (see the start-up diagram)

- There is battery voltage between terminals No. 5 and No. 8 with the key switch set to "ON", the side stand retracted and the emergency switch set to "RUN". If no faults are found, replace the control unit; otherwise check the wiring and the following components:

- Engine stop remote control;

- Emergency cut-off switch;

- Side stand contacts;

X9 Evolution 125 Electrical system

ELE SYS - 67

Page 68

- Key switch contacts.

Virgin circuit

If the ignition system has not been programmed, the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evident loss of power may be felt. Program the system with the MASTER (Brown) and SERVICE (Black) keys as follows:

- Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 ÷ 3 seconds).

- Alternately insert all the available black keys and turn each one of them to "ON" for 2 seconds.

- 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 (Black) service keys can be programmed at one time. Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start. Once the control unit has been programmed, the control unit is inseparably matched with the MASTER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stored one is deleted. If a service key setting is lost, it is essential to carefully check the efficiency of the high voltage system: Shielded cap resistance ~ 5000 Ω. In any case it is advisable to use resistive spark plugs.

Diagnostic codes

The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings.

Electrical system X9 Evolution 125

ELE SYS - 68

Page 69

That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:

2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial. Ignition disabled-Vehicle immobilised

3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans- ponder code. Ignition disabled-Vehicle immobilised

Diagnostic code - 2 flashes

Diagnosis code: 2-flashes When the 2-flash code is detected, carry out the following checks:

- Check if the failure continues after changing key (MASTER key included). If the failure persists with any key, disconnect the aerial connector from the control unit and check the aerial continuity with the 020331Y multimeter. If non-conforming values are measured, replace the aerial. If no failures are found in the aerial, replace the control unit.

CAUTION

BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT

Electric characteristic

immobilizer aerial

~ 7 ÷ 9 Ohm

X9 Evolution 125 Electrical system

ELE SYS - 69

Page 70

Diagnostic code - 3 flashes

If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the key switch.

- If the failure disappears when the MASTER key is used, encode the service keys (Blue) again.

- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case, replace the control unit and then encode the keys. The immobilizer system is efficient when, after switching over to "ON", only a 0.7-second flash is detected (see diagram). In this case, the engine can be started. Example with programmed control unit, transponder, programmed key and aerial working properly.

Ignition is enabled (regular conditions of use)

Ignition circuit

Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control unit is connected to the Pick-Up by the chassis and the engine ground lead. To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.

No spark plug

Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure:

- Pick-Up check. Disconnect the control unit connector and check that the cable between terminal No. 2 (Green) and terminal No. 8 (Black) is not interrupted. Check the Pick-Up and its power line:

Electric characteristic

Pick-up resistance value

Electrical system X9 Evolution 125

ELE SYS - 70

Page 71

Pick-up resistance value: 105 ÷ 124 Ohm

If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine manual). If non-conforming values are measured, replace the Pick-Up; otherwise, repair the cable harness. In case conforming values are measured, try replacing the control unit (without programming) and make sure the failure has been solved by checking sparks are produced in the spark plug; only then program the control unit.

- HV coil primary check Disconnect the control unit connector and check that the cable between terminal No. 3 and terminal No. 8 is not interrupted (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals. If non-conforming values are measured, repair the cables or replace the HV coil.

N.B. THE MULTIMETER MUST BE SELECTED TO DETECT

CONTINUOUS VOLTAGE.

Electric characteristic

Resistance value:

0.4 ÷ 0.5 Ohm

- HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.

Specific tooling

020409Y Multimeter adaptor - Peak voltage detection

X9 Evolution 125 Electrical system

ELE SYS - 71

Page 72

Electric characteristic

Resistance value:

~ 3000 ± 300 Ohm

- Pick-Up Disconnect the control unit connector and connect the positive wire to connector No. 2 and the negative wire to connector No. 8 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up. Replace Pick-Up if non-conforming values are measured.

N.B. THE MULTIMETER MUST BE SELECTED TO DETECT

CONTINUOUS VOLTAGE.

Electric characteristic

Resistance value:

> 2 Volt

- HV coil With the control unit and HV coil connected, measure the voltage of the coil primary during the startup test with the voltage peak adaptor and connecting the positive terminal to the ground one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit.

N.B. THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE

HV COIL PRIMARY IS BLACK AND THE NEGATIVE TERMINAL ONE IS GREEN.

Electric characteristic

Resistance value:

> 100 Volt

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. In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse. This system therefore requires no connection to the key switch.

Electrical system X9 Evolution 125

ELE SYS - 72

Page 73

The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Stator check

- With a tester, check the circuit between connections 5-3 and 5-1 is not interrupted.

- Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Ω Minimum oil pressure switch check

- With a tester, check the circuit between connections 4 and ground (with engine off) is not interrupted. Pick-Up check

- Check that there is a resistance of about 105 ÷ 124 Ω at 20° C between connection 2 and ground.

- In case of values different from the ones stated, replace the defective parts.

N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A

CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.

Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.

Electric characteristic

Ohm value:

0.7 ÷ 0.9 Ohm

X9 Evolution 125 Electrical system

ELE SYS - 73

Page 74

Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.

Voltage regulator check

With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 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.

Electrical system X9 Evolution 125

ELE SYS - 74

Page 75

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.

Choke Inspection

Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If no voltage is detected, connect the multimeter negative probe to the ground lead and the positive probe to the automatic starter Orange cable; with the key switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the key switch and that the 15A fuse (No. 7) works properly. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed; then check whether there is voltage connecting the multimeter with the positive probe to terminal No. 5 (Blue), and the nega-

X9 Evolution 125 Electrical system

ELE SYS - 75

Page 76

tive one to terminal No. 7 (White/Black) (see figure). If there is no voltage, replace the control unit after making sure that the fuses are not blown; otherwise, check the cable harness between the starter and the control unit and, as a last resource, replace the starter.

Lights list

LIGHT BULBS 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 - 2W

Quantity: 5

5 Front turn indicator bulb Type: Spherical

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

6 Helmet compartment light bulb Type: CYLINDRIC

Power: 12V - 5W

Quantity: 1

7 Rear turn indicator light bulb Type: Spherical

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

8 Stop light bulb Type: ALL GLASS

Power: 12V - 2.3W

Quantity: 5

9 Rear tail light bulb Type: SPHERICAL

Power: 12V - 5W

Quantity: 2

10 License plate light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 1

Fuses

The electrical system is equipped with:

1. Four protection fuses «A» inside the helmet compartment.

2. Four protection fuses «B» for the various circuits of the electrical system, located inside the front glove-box to the left.

Electrical system X9 Evolution 125

ELE SYS - 76

Page 77

The tables show the position and characteristics of the fuses on the scooter.

CAUTION

BEFORE REPLACING A 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).

FUSE TABLE

Specification Desc./Quantity

1 Fuse No. 1 Position on fuse holder:1

Capacity: 15A

Protected circuits: 12V-180W Socket for electrical

equipment - Helmet compartment light - Electrical saddle

opening - Antitheft device pre-installation

Location:helmet compartment

2 Fuse No. 2 Position on fuse holder: 2

Capacity: 15A

Protected circuits: Radiator electrical fan - Battery re-

charge - Vehicle lights - Power for antitheft device wiring

- Electric fuel pump - Lines protected by fuses 4; 5; 6; 7 and 8

Location:helmet compartment

3 Fuse No. 3 Position on fuse holder: 3

Capacity: 10 A

Protected circuits: High- and low-beam lights - Front

and rear tail lights - License plate bulb

Location:helmet compartment

4 Fuse No. 4 Position on fuse holder: 4

Capacity: 7.5 A

Protected circuits: Power for radio/intercom control

unit pre-installation - Analogue indicator

Location:helmet compartment

5 Fuse No. 5 Position on fuse holder: 5

Capacity: 7.5 A

Protected circuits: Headlight warning light - Front and

rear tail lights - License plate light

Location: front case

6 Fuse No. 6 Position on fuse holder: 6

Capacity: 10 A

Protected circuits: Digital instrument panel - Immobil-

izer LED

Location: front case

7 Fuse No. 7 Position on fuse holder: 7

Capacity: 10 A

Protected circuits: High-beam bulb and warning light in

"passing" - Horn - Power for accessories pre-installation

Location: front case

8 Fuse No. 8 Position on fuse holder: 8

Capacity: 7.5 A

Protected circuits: Stop lights - Vehicle start-up ena-

bling button - Power for radio/intercom control unit pre-

installation and antitheft device installation

Location: front case

Dashboard

instrument panel

X9 Evolution 125 Electrical system

ELE SYS - 77

Page 78

The X9 model has an instrument panel subdivided into 2 sections: the analogue section fastened to the windshield, and the digital section integral to the handlebar. The analogue section comprises:

- A speedometer with double scale (MPH/KMH) controlled by the tone wheel;

- An rpm indicator controlled by the signal coming from the HV coil.

- A fuel gauge controlled by a resistive sensor (inside the tank)

- A coolant temperature gauge controlled by a resistive sensor (on the head) These instruments are electrically controlled by stepper motors.

The digital section provides the displays of:

A: Preset warning light * B: Preset warning light * C: Preset warning light * D: Engine disabled E: Oil pressure F: Fuel reserve G: Tail lights and low-beam lights: green H: High-beam lights on I: Left turn indicator L: Emergency lights (four arrows) M: Right turn indicator

* The DGT instrument does not have the preset warning light LED

Low fuel indicators, turn indicators and emergency flashing light are activated by the instrument electronic components. For instance, the fuel reserve warning light bulb lights up only when the reserve signal coming from the tank persists for over 13.5 seconds. This prevents the reserve warning light from flickering.

- This flashing function has been incorporated to the instrument electronic components: that is, the emergency lights can work with the switch set to "OFF" and the control switch deactivated. The control switch is active only when the instrument panel is on. To guarantee safety while riding, the "turn indicator control" function is connected to the odometer. In case you forget the signal ON, it will turn off automatically after riding 1 kilometre.

- The "engine disabled" warning light is activated through the side stand switch and the emergency switch located on the handlebar right side.

- The LCD display provides a 5-digit indication for the total distance covered by the vehicle. This can be expressed in kilometres or miles: naturally such indication cannot be reset. To select the indication it is necessary to push simultaneously the

"Trip" and "M" buttons and then turn the key switch to "ON"; by holding these 2 buttons for another 3 seconds, the word "SET" is displayed, and then the distance covered shifts from miles to kilometres or vice versa.

The instrument panel digital section has a liquid crystal display and 4 control buttons.

Electrical system X9 Evolution 125

ELE SYS - 78

Page 79

The display provides 3 icons with the words:

- Oil

- Service

- Belt

- The "Oil" icon flashes when a distance of 1000 km has been covered, and then every 3000 km.

- The "Service" icon flashes for the first time at 1000 km or after 1 year. After that, every 6000 km or after 1 year.

- The "Belt" icon warns the rider about the need to replace the driving belt. It lights up every 12000 km

After the maintenance operations at the authorised workshop, it is necessary to cancel the indication by the icon/s with the "Reset" button located on the front of the vehicle under the fairing. The "Reset" button resets the distance covered, and, in the case of the "Service" icon, also the year count. This count remains active even if the battery is disconnected for short periods of time. To reset an icon, press the "Reset" key for less than a second to select the icon preceding the one to be reset and then hold the "Reset" key for at least 3 seconds so that the following is displayed:

- The desired icon selected lights up.

- The flashing of that icon confirms the reset. For instance, to reset "Service" icon, select "Oil" and keep the "Reset" key pressed for at least 3 seconds. To reset "Oil", repeat the procedure described selecting "Belt". Care must be taken with this procedure since icon selection and reset are simultaneous operations (for this operation it is not possible to view the desired function and reset in two different key strokes because, if you do so, the following icon could be reset).

Data check function

Date and check function Date should be adjusted out when delivering the vehicle to the customer. This is because the clock activation starts the year count for the "Service" function. If the clock has been previously activated, reset the "Oil", "Service" and "Belt" functions. The calendar is programmed from 2000 to 2050. For date and time adjustment act on the "Clock" and "Set" buttons. To guarantee vehicle safety, each time the key switch is set to "ON", there is an automatic checking of all the indicators on the digital section. The digital section provides also a functional checking of the 4 analogue instruments and of the turn indicator control. To activate this checking, press and holed the "Clock" and "Set" buttons simultaneously and then set the key switch to "ON". Within 4 seconds max, the software version is displayed, the gauges go to the end of scale and the turn indicators light up.

X9 Evolution 125 Electrical system

ELE SYS - 79

Page 80

At the end of the operation above, the normal warning light bulbs check is carried out.

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 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

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. CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS TO BE RECHARGED PERIODICALLY. 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 TAKING INTO ACCOUNT THAT THE GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL MARKED WITH THE +POSITIVE SIGN

WARNING

WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Electrical system X9 Evolution 125

ELE SYS - 80

Page 81

Dry-charge battery

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

- 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.

- Incline 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

N.B.

THIS IS THE LAST TIME THAT ELECTROLYTE CAN BE ADDED. FUTURE TOP-UPS SHOULD BE DONE ONLY WITH DISTILLED WATER.

Within 24 hours 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.

N.B.

BATTERIES THAT HAVE BEEN STORED FOR A LONG TIME CAN TAKE A LONGER CHARGING TIME. 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, THE ACTIVATION OF THE SAFETY SYSTEM AND NOT A GREEN LED ON INDICATES 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 created 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.

N.B.

WITH BATTERY CHARGER DRW. 020334Y, THE BATTERY CHARGE LEVEL CAN BE CHECKED WITH THE "CHECK" FUNCTION. THE VALUE INDICATED ON THE DISPLAY MUST BE HIGHER THAN THE VALUE INDICATED IN THE TABLE; OTHERWISE RECHARGE THE BATTERY AGAIN IN THE SAME WAY INDICATED ABOVE.

X9 Evolution 125 Electrical system

ELE SYS - 81

Page 82

Pump electrics check

Connect the tester positive probe to pin 4 of the connector of the fuel pump control device, and the negative probe to pin 3, making sure there is battery voltage as indicated in the table.

PUMP SUPPLY

Specification Desc./Quantity

Key set to «KEY ON» Supply to the pump for 13 seconds

Engine revs from 0 to 200 rpm Always «OFF»

Engine revs from 200 to 1200 rpm Always «ON»

Engine revs from 1200 to 2000 rpm 0.2 seconds «ON»

9 seconds «OFF»

Engine rpm ] 2000 r.p.m. Always «ON»

Electrical system X9 Evolution 125

ELE SYS - 82

Page 83

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 84

Removal of the engine from the vehicle

- Carry out the removal operations but in reverse order, observing the prescribed tightening torques.

Locking torques (N*m)

Lower shock absorber clamp 33 ÷ 41 Engine-swinging arm bolt 33 ÷ 41

- Remove the nut shown in the figure, then take out the pin. The engine is now free.

- Remove the saddle and the side covers,

- Drain engine oil and coolant,

- Disconnect the battery,

- Remove the muffler assembly,

- Remove the rear wheel,

- Remove the throttle grip transmission,

- Disconnect the electrical devices,

- Disconnect the hoses (petrol-oil-vacuum-operated cock control).

WARNING

Wear safety goggles when using hitting tools.

WARNING

BE VERY CAREFUL WHEN HANDLING FUEL.

CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.

Engine from vehicle X9 Evolution 125

ENG VE - 84

Page 85

- Remove the nut shown in the figure, then take out the pin.

X9 Evolution 125 Engine from vehicle

ENG VE - 85

Page 86

INDEX OF TOPICS

ENGINE ENG

Page 87

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.

- Remove the transmission cover. If this operation is carried out directly on the vehicle, remove the cooling air supply coupling of the transmission housing.

Air duct

- Remove the 4 screws and the housing.

X9 Evolution 125 Engine

ENG - 87

Page 88

Air duct filter

To remove the intake throat on the transmission cover, remove the 2 fixing screws indicated in the figure.

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

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 DAM-

AGING THE COVER PAINT. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE

UPON REFITTING.

Specific tooling

020376Y Adaptor handle 020357Y 32x35-mm Adaptor 020412Y 15 mm guide

Engine X9 Evolution 125

ENG - 88

Page 89

- 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 DAM-

AGING THE COVER PAINT. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE

UPON REFITTING.

Specific tooling

020376Y Adaptor handle 020357Y 32x35-mm Adaptor 020412Y 15 mm guide

Baffle roller

Metallic roller

Removal

Belt support roller (200 cm³ models only)

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

- Remove the special fixing screw and the roller together with the bearing.

Refitting

- Heat the roller and insert the bearing using the specific punch:

Specific tools:

Specific tooling

020455Y 10-mm guide

X9 Evolution 125 Engine

ENG - 89

Page 90

- Refit the roller with the special screw.

- Tighten to the specified torque.

- Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing.

Locking torques (N*m)

Anti-flapping roller 12 - 16

- Heat the roller and insert the bearing using the specific punch:

Specific tools:

Specific tooling

020455Y 10-mm guide

- Refit the roller with the special screw.

- Tighten to the specified torque.

- Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Engine X9 Evolution 125

ENG - 90

Page 91

Removing the driven pulley

- Remove the spacer, the clutch bell and the whole driven pulley unit.

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

- 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

X9 Evolution 125 Engine

ENG - 91

Page 92

Checking the bell working surface eccentricity

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

- Lock with the original spacer and nut.

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

Removing the clutch

Fit the driven pulley spring compressor specific tool with medium length pins screwed in position F from the tool internal side.

- Insert the adapter ring 8 in the pins.

- Assemble the driven pulley unit on the tool introducing the rivets heads in the adapter ring.

- 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 n°9 to remove the nut fixing the clutch in place.

- Separate the driven pulley components (Clutch, fan and spring with plastic fitting).

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

020444Y009 wrench 46 x 55 020444Y010 adapter ring

Engine X9 Evolution 125

ENG - 92

Page 93

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 CEN-

TRAL FAYING 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 ANY DIFFICUL-

TY. N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO

FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.

X9 Evolution 125 Engine

ENG - 93

Page 94

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

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.

Characteristic

Half-pulley standard diameter

Standard diameter: Ø 40.985 mm

Half-pulley minimum diameter

Minimum admissible diameter: Ø 40.96 mm

Engine X9 Evolution 125

ENG - 94

Page 95

Inspecting the driven sliding half-pulley

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

- Measure the movable half-pulley bushing inside diameter.

Characteristic

Movable driven half-pulley max. diameter

Max. diameter admitted: Ø 41.08 mm

Movable driven half-pulley standard diameter

Standard diameter: Ø 41.000 ÷ 41.035 mm

Refitting the driven half-pulley bearing

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

- Fit a new roller casing as shown in the figure.

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

X9 Evolution 125 Engine

ENG - 95

Page 96

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 appropriate 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 assembly with approximately 6 g of 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 Driven pulley assembly sheath

PIAGGIO X9 Evolution 125 2008 Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual