PIAGGIO X8 125 Workshop Manual

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. "© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO & C. S.p.A. - After-Sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific 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.

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

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 well- ventilated, 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. Vehicle identification Version 125 Chassis prefix: ZAPM36300 ÷ 1001 X8 125-200 Characteristics CHAR - 7

Version 200 Chassis prefix: ZAPM36200 ÷ 1001 Engine prefix: M362M Dimensions and mass DIMENSIONS AND WEIGHT Specification Desc./Quantity Dry weight 157 kg Wheelbase 1490 mm Height 1370 mm Overall length 2050 mm Width (handlebar) 760 mm Engine DATA 125 Specification Desc./Quantity Version 125 Engine Single-cylinder, four-stroke Bore x stroke 57 x 48.6 mm Cubic capacity 124 cm³ Compression ratio 12 : 1 ignition advance (before TDC) 10° at 2000 rpm - 34° at 6000 rpm Walbro carburettor WVF 7G* Ø 29 Carburettor Keihin CVEK-30 Spark plug CHAMPION RG 4 HC Maximum speed 105 km/h Timing system: 125 Single overhead camshaft driven by chain on left side, three- arm rockers with threaded adjuster. Valve clearance: intake 125 0,10 mm Valve clearance: exhaust 125 0,15 mm Air filter 125 sponge soaked in 50 percent petrol-oil mixture. Starting system 125 electric starter with Bendix gear Lubrication 125 lubrication with chain driven lobe pump in crankcase, mesh strainer and cartridge filter. Fuel supply Petrol (unleaded, with minimum octane rating of 95) through carburettor Engine - wheel ratio 125 Long: 1/9,1 Engine - wheel ratio 125 Short: 1/30,36 * The identification letter can vary every time the carburettor is up-dated. Characteristics X8 125-200 CHAR - 8

72 x 48.6 mm Cubic capacity 198 cm³ Compression ratio 11.5 :1 ignition advance (before TDC) 10° ± 1° at 2000 rpm - 32° ± 1° at 6500 rpm Walbro carburettor WVF 7H* Ø 29 Carburettor Keihin CVEK-30 Spark plug CHAMPION RG 6 YC Valve clearance: intake 200 0,10 mm Valve clearance: exhaust 200 0,15 mm Timing system 200 Single overhead camshaft driven by chain on left side, three- arm rockers with threaded adjuster. Air filter 200 sponge soaked in 50 percent petrol-oil mixture. Starter System 200cc Electric starter motor with bendix-type drive-gear and torque- limiter Lubrication 200 lubrication with chain driven lobe pump in crankcase, mesh strainer and cartridge filter. Power supply 200 Fuel (minimum octane number 95, leadless), with vacuum pump and by carburettor * The identification letter can vary every time the carburettor is up-dated. 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. Capacities CAPACITY Specification Desc./Quantity Engine oil ~ 1000 cc (recommended oil: Selenia HI Scooter 4 Tech) Fuel tank (including a ~ 2 l reserve) ~ 9.5 l Rear hub 150 cc (recommended oil: TUTELA ZC 90) Cooling system fluid approx. 2.100 ÷ 2.150 l PARAFLU 11FE (Diluted) Electrical system ELECTRICAL COMPONENTS - 125CC VERSION Specification Desc./Quantity Generator 125 Three-phase alternating current Battery 125 12V-12Ah Spark plug NGKCR8EB Ignition type 125 Electronic capacitive discharge ignition (CDI) and variable ad- vance, with separate HV coil. variable ignition advance (before T.D.C.) 125 10°±1° at 2000 rpm - 34°±1° at 6000 rpm X8 125-200 Characteristics CHAR - 9

Specification Desc./Quantity Generator Three-phase alternating current Battery 12V-12Ah Spark plug 200 Champion RG6YC Ignition type Electronic capacitive discharge ignition (CDI) and variable ad- vance, with separate HV coil. variable ignition advance (before T.D.C.) 200 10°±1 at 2000 rpm - 32°±1 at 6500 rpm Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Chassis Tubular and steel sheets. Front suspension Hydraulic telescopic fork with Ø 35 mm stem Rear suspension Single arm with two double-acting hydraulic shock absorbers and preloading adjustment in 4 positions. Brakes BRAKES Specification Desc./Quantity Front brake Ø 260 disc brake (left-hand side of vehicle), with hydraulic con- trol operated from the right-hand brake lever on the handlebar. Rear brake Ø 240-mm disc brake with hydraulic control activated by han- dlebar left-side lever. Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front wheel alloy rim: 14'' x 3.50 Front tyre Without inner tube: 120/70-14" 55P Rear wheel alloy rim: 12"x3.50 Rear tyre Without inner tube: 130/70-12" 62P TYRE PRESSURE Specification Desc./Quantity Front wheel pressure (basic model) Front wheel inflation pressure (basic model): 2.0 bar Front wheel pressure (model with accessories) Front tyre inflation pressure (model with accessories): 2.3 bar Rear tyre pressure - rider Rear tyre pressure (rider only): 2.2 bar Rear tyre pressure (rider and passenger): 2.6 bar Carburettor 125cc Version Characteristics X8 125-200 CHAR - 10

Specification Desc./Quantity Depression carburettor CVEK-30 Body stamping CVEK Stamping 303A Max. jet 105 Minimum jet 38 Max. air jet 70 Minimum air jet 130 Throttle valve spring 100 ÷ 160 g Minimum mixture set screw initial opening 2 ± ¼ Tapered pin stamping NDVA Tapered pin notches position from top Fixed position Diffuser nozzle Ø 2.8 Starter air jet Ø 1.5 (body) Starter diffuser nozzle Ø 1.5 (body) Starter jet 42 Starter device resistance ~ 20 Ω (at 24°) Diffuser Ø 29 N.B. * THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE. Walbro CARBURETTOR WALBRO WVF-7R Specification Desc./Quantity Depression type WVF-7R* Printing on the body 7R1 Max jet printing 100 Max jet 103 Minimum jet 38 Max air jet 60 Minimum air jet 110 Throttle valve spring 100 g Idle mixture adjustment screw initial opening 2 7/8 ± 1/2 Conical pin printing 653 Conical pin notches position from top 2 Diffuser nozzle Ø 2.7 Starter air jet 200 Starter diffuser jet 130 Starter jet 48 Starter device resistance ~ 40 Ω Venturi diffuser Ø 29 (30.3x27) N.B. * THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE. 200cc Version Kehin CARBURETTOR KEIHIN CVEK-30 Specification Desc./Quantity Depression carburettor CVEK-30 Body stamping CVEK Stamping 303A X8 125-200 Characteristics CHAR - 11

70 Minimum air jet 115 Throttle valve spring 150 ÷ 250 g Minimum mixture adjustment screw initial opening 2 ½ ± ¼ Tapered pin stamping NDWA Tapered pin notches position from top Fixed position Diffuser nozzle Ø 2.8 Starter air jet Ø 1.5 (body) Starter diffuser jet Ø 1.2 Starter jet 42 Starter device resistance ~ 20 Ω (at 24°) Diffuser Ø 29 N.B. THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE Walbro CARBURETTOR WALBRO WVF-7S Specification Desc./Quantity Depression type WVF-7S* Printing on the body 7S Max jet printing 118 Max. jet 105 Minimum jet 34 Max. air jet 150 Minimum air jet 31 Throttle valve spring 120 g Minimum mixture set screw initial opening 3 ± 1/4 Tapered pin stamping 465 Tapered pin notches position from top 3 Diffuser nozzle Ø 2.7 Starter air jet 200 Starter diffuser jet 130 Starter jet 50 Diffuser Ø 29 (30.3x27.0) N.B. THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE Tightening Torques REAR BRAKE Name Torque in Nm Rear brake disc screws(°) 5 ÷ 6.5 Rear brake calliper-pipe fitting 20 ÷ 25 Rigid / flexible pipe fitting 13 ÷ 18 Rear brake pump-pipe fitting 16 ÷ 20 Rear brake calliper fixing screws 20 ÷ 25 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 Characteristics X8 125-200 CHAR - 12

Disc tightening screw (°) 5 ÷ 6.5 Brake fluid tube-calliper fitting 20 ÷ 25 Brake fluid pump-hose fitting 16 ÷ 20 Tightening screw for calliper support to the fork 20 ÷ 25 Screw tightening calliper to the support 42 ÷ 52 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 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 Side stand bolt (°) 35 ÷ 40 Engine arm bolt - frame arm 33 ÷ 41 Swinging arm buffer nut 64 ÷ 72 Frame-swinging arm bolt 64 - 72 Engine-swinging arm bolt 64 - 72 CHASSIS Product Description Specifications (°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength threadlock STEERING Name Torque in Nm Upper steering ring nut 30 ÷ 33 Steering lower ring nut 10 ÷ 13 then loosen by 90° Handlebar fixing screw 50 ÷ 55 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 X8 125-200 Characteristics CHAR - 13

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 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 Overhaul data Assembly clearances Characteristics X8 125-200 CHAR - 14

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 X8 125-200 Characteristics CHAR - 15

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 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 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 Characteristics X8 125-200 CHAR - 16

Characteristic Compression ratio, 125 models Cr: 11.50 ÷ 13:1 Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa. N.B. NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL- INDER 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 125 WITH METAL HEAD GASKET (0.3) Name Measure A Thickness Shimming 125 - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.4 1.40 ÷ 1.65 0.4 ± 0.05 Shimming 125 - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.6 1.65 ÷ 1.90 0.6 ± 0.05 Characteristic Compression ratio, 125 models Cr: 11.50 ÷ 13:1 X8 125-200 Characteristics CHAR - 17

by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa. N.B. NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL- INDER 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 125 WITH FIBRE HEAD GASKET (1.1) Name Measure A Thickness Shimming 125 - Cylinder 67 - Head gas- ket 1.1 - Base gasket 0.4 2.20 ÷ 2.45 0.4 ± 0.05 Shimming 125 - Cylinder 67 - Head gas- ket 1.1 - Base gasket 0.6 2.45 ÷ 2.70 0.6 ± 0.05 Characteristic Compression ratio, 200 models Cr: 11÷12 :1 Characteristics X8 125-200 CHAR - 18

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 CYL- INDER 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 METALLIC HEAD GASKET (0.3) Name Measure A Thickness Shimming 200 - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.4 2.50 ÷ 2.40 0.4 ± 0.05 Shimming 200 - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.6 2.40 ÷ 2.20 0.6 ± 0.05 Shimming 200 - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.8 2.20 ÷ 2.10 0.8 ± 0.05 Characteristic Compression ratio, 200 models Cr: 11÷12 :1 X8 125-200 Characteristics CHAR - 19

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 CYL- INDER 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 Characteristics X8 125-200 CHAR - 20

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 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 X8 125-200 Characteristics CHAR - 21

Grease for steering bearings and spindle seats Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L- XBCIB2 of the swinging arm MONTBLANC MOLYBDENUM GREASE Grease for driven pulley shaft adjusting ring and movable driven pulley housing Grease with Molybdenum disulphide AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in- creased adhesiveness AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-L-XBCHA3, DIN K3K-20 AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications AGIP GP 330 Calcium complex soap-based grease with NLGI 2; ISO-L-XBCIB2 Grease (brake control levers, throttle grip) AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 Characteristics X8 125-200 CHAR - 22

020334Y Multiple battery charger 001467Y014 Pliers to extract ø 15-mm bearings Tooling X8 125-200 TOOL - 24

020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47-mm Adaptor X8 125-200 Tooling TOOL - 25

020459Y Punch for fitting bearing on steering tube 020458Y Puller for lower bearing on steering tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Oil pressure control fitting Tooling X8 125-200 TOOL - 26

020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch for assembling valve sealing rings 020360Y 52x55-mm Adaptor X8 125-200 Tooling TOOL - 27

020376Y Adaptor handle 020444Y Tool for fitting/ removing the driven pulley clutch 020330Y Stroboscopic light to check timing 001467Y035 Belle for OD 47-mm bearings Tooling X8 125-200 TOOL - 28

020319Y Immobilizer check tester 020287Y Clamp to assemble piston on cylinder 020263Y Driven pulley assembly sheath 020262Y Crankcase splitting strip 020430Y Pin lock fitting tool X8 125-200 Tooling TOOL - 29

020426Y Piston fitting fork 020425Y Punch for flywheel-side oil seal 020423Y Driven pulley lock wrench 020414Y 28-mm guide 020393Y Piston assembly band Tooling X8 125-200 TOOL - 30

moval tool 020455Y 10-mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum-operated pump 020357Y 32x35-mm Adaptor X8 125-200 Tooling TOOL - 31

tion 020456Y Ø 24 mm adaptor 020332Y Digital rev counter 020074Y Support base for checking crankshaft alignment 020055Y Wrench for steering tube ring nut Tooling X8 125-200 TOOL - 32

001330Y Tool for fitting steering seats 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020444Y011 adapter ring 020444Y009 wrench 46 x 55 001467Y Extractor for bearings for holes X8 125-200 Tooling TOOL - 33

020444Y010 adapter ring Tooling X8 125-200 TOOL - 34

Action Coolant - change Brake fluid - change Secondary air filter (external/internal) - cleaning (125) EVERY 3,000 KM 10' Action Engine oil - level check/ top-up AFTER 1,000 KM 65' Action Engine oil - replacement Hub oil - change Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test (*) See instructions in the «Idle speed adjustment» section AFTER 6000 KM 120' Action Engine oil - replacement Hub oil level - check Spark plug/ electrode gap - check Air filter - clean Engine oil - change Valve clearance 200 - check valve clearance 125 - check Variable speed rollers - check or replacement Driving belt - checking Coolant level - check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test AFTER 12,000 KM; 60,000 KM 130' Action Engine oil - replacement Hub oil level - check Air filter - clean Engine oil - change Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Maintenance X8 125-200 MAIN - 36

Driving belt - replacement Sliding blocks / variable speed rollers - check Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test (*) See instructions in the «Idle speed adjustment» section AT 18000 KM AND AT 54000 KM (VERSION 125 CC) Action Engine oil - replacement Hub oil level - check Spark plug/ electrode gap - check Air filter - clean Engine oil - change Variable speed rollers - check or replacement Driving belt - checking Coolant level - check Radiator - external cleaning/ check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test AT 18000 KM AND AT 54000 KM (VERSION 200CC) Action Engine oil - replacement Hub oil level - check Spark plug/ electrode gap - check Air filter - clean Engine oil - change Valve clearance 200 - check Variable speed rollers - check or replacement Driving belt - checking Coolant level - check Radiator - external cleaning/ check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test AFTER 24,000 KM AND AFTER 48,000 KM (125 CM3 VERSION) 175' Action Engine oil - replacement Hub oil - change Air filter - clean Engine oil - change Spark plug - replacement valve clearance 125 - check Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement X8 125-200 Maintenance MAIN - 37

Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Driven pulley roller casing - Greasing Tyre pressure and wear - check Vehicle and brake test - road test (*) See instructions in "Idle speed adjustment" section AT 24000 KM AND AT 48000 KM (VERSION 200 CC) Action Engine oil - replacement Hub oil - change Air filter - clean Engine oil - change Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement Driving belt - replacement Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test (*) See regulations in section «Idling speed adjustment» AT 30000 KM, AT 42000 KM AND AT 66000 KM 80' Action Engine oil - replacement Hub oil level - check Spark plug/ electrode gap - check Air filter - clean Engine oil - change Variable speed rollers - check or replacement Driving belt - checking Coolant level - check Driven pulley roller casing - Greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test AT 36000 KM (VERSION 125 CC) Action Engine oil - replacement Hub oil level - check Air filter - clean Maintenance X8 125-200 MAIN - 38

Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement Driving belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid hoses - replacement Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test (*) See regulations in section «Idling speed adjustment» AT 36000 KM (VERSION 200 CC) Action Engine oil - replacement Hub oil level - check Air filter - clean Engine oil - change Spark plug - replacement Valve clearance 200 - check Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement Driving belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid hoses - replacement Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test (*) See regulations in section «Idling speed adjustment» AFTER 72000 KM 240' Action Engine oil - replacement Hub oil - change Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change valve clearance 125 - check Valve clearance 200 - check Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement Driving belt - replacement X8 125-200 Maintenance MAIN - 39

Driven pulley roller casing - Greasing Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid hoses - replacement Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test (*) See instructions in «Idle speed adjustment» section Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condition. - The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due to wear. - If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it is new), replace the carburettor. - It is advisable to replace the gaskets at every refit WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS Checking the spark advance - To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire. - Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug). - Place the light selector in central position (1 spark = 1 crankshaft revolution as in 2 T engines). - Start the engine and check that the light works properly and the rpm indicator can read also the high rpm (e.g. 8000 rpm). - If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive Maintenance X8 125-200 MAIN - 40

series to AT cable). - Remove the plastic cover from the slot on the fly- wheel cover. - Operating on the flash corrector displacement of the bulb, make the reference on the flywheel cover coincide with level on the water pump drive. Read the advance degrees indicated by the stroboscop- ic light. - Check that the advance degrees corresponds with the rotation rpm as indicated in the table. - If there are anomalies, check the Pick-Up and the control unit power supply (positive-negative), re- place the control unit if necessary. - The brand new control unit prevents that the en- gine rotation exceeds 2000 rpm. - The programmed control unit allows the engine to rotate within the prescribed limits. Characteristic Check ignition advance 125 10° ± 1° at 2000 rpm - 34° ± 1° at 6000 rpm variable ignition advance (before T.D.C.) 200 10°±1 at 2000 rpm - 32°±1 at 6500 rpm Spark advance variation VERSION 125 Specification Desc./Quantity Operation threshold First threshold : 10700 ±50 Second threshold : 11000 ±50 Reactivation threshold First threshold : 10600±50 Second threshold : 10900±50 Spark elimination First threshold : 1 spark on 7 Second threshold : 2 sparks on 3 X8 125-200 Maintenance MAIN - 41

Version 200 : Operation threshold First threshold : 9900 ±50 Second threshold : 10100 ±50 Version 200 : Reactivation threshold First threshold : 9800 ±50 Second threshold: 10000 ±50 Maintenance X8 125-200 MAIN - 42

of oil contained ~ 150 cm³). To check the rear hub oil level, proceed as follows: 1) Park the scooter on level ground and place it on the centre stand. 2) Unscrew the dipstick "A", dry it with a clean rag and then reinsert it, screwing it tightly into place; 3) Remove the dipstick and check that the oil level is above the first notch from the bottom. 4) Screw the dipstick back in, checking that it is locked in place. N.B. THE REFERENCE MARKS ON THE HUB OIL LEVEL DIP- STICK, EXCEPT FOR THE ONE INDICATING THE "MAX" LEVEL, REFER TO OTHER MODELS BY THE MANUFAC- TURER AND HAVE NO SPECIFIC FUNCTION FOR THIS MODEL. CAUTION RIDING THE VEHICLE WITH INSUFFICIENT HUB LUBRI- CATION OR WITH CONTAMINATED OR IMPROPER LU- BRICANTS ACCELERATES THE WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE SERIOUS DAMAGE. CAUTION USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR OIL CHANGE, CONTACT AN AU- THORISED SERVICE CENTRE, WHICH IS EQUIPPED TO Maintenance X8 125-200 MAIN - 44

FRIENDLY AND LEGAL WAY. CAUTION UPON REPLACING HUB OIL, AVOID THE OIL COMING IN- TO CONTACT WITH THE REAR BRAKE DISC. Recommended products AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Check - Rest the vehicle on its centre stand on an even surface. - Unscrew the oil dipstick, dry it with a clean cloth and reinsert it, screwing it in thoroughly.- Take out the dipstick and check that the oil level reaches the 2nd notch from the bottom.- Screw the dipstick back into place completely. Recommended products AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Locking torques (N*m) Hub oil drainage plug 15 ÷ 17 Replacement -Remove the oil cap «A». - Unscrew the oil drainage cap "B" and drain out all the oil. - Screw on the drainage plug and fill up the hub with oil (about 150 cc) X8 125-200 Maintenance MAIN - 45

tainer screws, then extract the filter. - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of com- pressed air. - Soak with a mixture of 50% petrol and 50% SE- LENIA AIR FILTER OIL. -Drip dry the filter and then squeeze it between the hands without wringing. CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER. CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART. Engine oil Replacement The oil and cartridge filter «C» should be replaced every 6,000 km (125 cc) or 12,000 Km (250 cc) at an Authorized Piaggio Service Centre. The en- gine should be emptied by draining the oil from the filter drainage tap «B» on the flywheel side. In or- der to facilitate the oil drainage, loosen the cap/ bar. Since a certain quantity of oil remains in the circuit still, the fill-up should be carried out with around 600 ÷ 650 cc of oil from cap «A». Then start up the vehicle, leave it running for a few minutes and switch it off: after around 5 minutes, check the level and top up if necessary without ever ex- ceeding the MAX level. The cartridge filter should be replaced every time the oil is changed. For top ups and replacements use new oil of the recom- mended type. WARNING Maintenance X8 125-200 MAIN - 46

TION OR WITH INADEQUATE LUBRICANTS ACCELER- ATES THE WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE. WARNING EXCESSIVE OIL LEVEL AT TOP-UPS CAN LEAD TO SCALE FORMATION AND VEHICLE MALFUNCTIONING. CAUTION USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR OIL REPLACEMENT, CONTACT AN AUTHORISED SERVICE CENTRE, WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY. CAUTION USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE OF THE ENGINE. Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Syn- thetic oil Check Every time the vehicle is used, visually inspect the level of the engine oil when the engine is cold (after completely unscrewing the oil cap/dipstick). The oil level should be somewhere between the MAX and MIN index marks on the level rod; «A»; during the oil check, the vehicle must be resting on its centre stand on an even, horizontal surface. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level. Characteristic Engine oil (oil and oil filters change) Capacity: 1.0 l X8 125-200 Maintenance MAIN - 47

gine cold and following the procedure below: 1) Rest the scooter on the central stand and on a flat ground. 2) Set the strut that regulates the position to its minimum height. 3 ) Screw off cap/dipstick «A», dry it off with a clean cloth and reinsert it, screwing down complete- ly. 4) Remove the cap/dipstick «A» again and check that the level is between the MAX and MIN marks; top up, if required. The MAX level as shown in the figure indicates that there is about 1700 cc of oil in the engine. 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. Checking the ignition timing -Remove the 4 fixing screws and move away from the engine the flywheel cover fitted with a water pump and cooling manifolds. -Rotate the flywheel until the reference matches the crankcase operation end as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the ref- erence point on the head as shown in the second figure. If the reference mark is opposite the indi- cator on the head, make the crankshaft turn once more. -The TDC reference mark is repeated also be- tween the flywheel cooling fan and the flywheel cover. Maintenance X8 125-200 MAIN - 48

and turn the engine in the opposite direction to the normal direction using a calliper spanner applied to the camshaft command pulley casing. N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE. Checking the valve clearance -To check valve clearance, centre the reference marks of the timing system - Use a thickness gauge to check that the clear- ance between the valve and the register corre- sponds with the indicated values. When the valve clearance values, intake and drainage respective- ly, are different from the ones indicated below, adjust them by loosening the lock nut and operate on the register with a screwdriver as shown in the figure. Intake: 0.10 mm (when cold) Discharge: 0.15 mm (when cold) Headlight adjustment X8 125-200 Maintenance MAIN - 49

1. Position the unloaded scooter, in running order and with the tyres inflated to the prescribed pres- sure, on a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the scooter is perpendicular to the screen; 2. Turn on the headlight and check that the bor- derline of the projected light beam should be lower than 9/10 of the distance from the ground to the centre of the vehicle's headlight, and higher than 7/10; 3. If not, adjust the projection by turning the central screw «A» set inside the glove box. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO- PEAN STANDARDS REGARDING MAXIMUM AND MINI- MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU- TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED. CO check Preparing the vehicle - Remove the 2 bottom sides as explained in the Body chapter. - Remove the 3 fastening screws of the filter box. - Remove the filter box to access the 6 screws M6 closing the crankcase and the heat guard plate at- tachments. - Remove the plate to access the flow adjustment screw on the carburettor. - Remove the gas cap on the exhaust pipe. - Using the original washer, install the exhaust gas collection Kit union. - Suitably orientate the components (Figure 2). - Close the gas outlet terminal of the tool. - Start the engine and let it warn until the electric fan starts. - Stop the engine. - Disconnect the vacuum feeding pipe from the SAS control valve. Maintenance X8 125-200 MAIN - 50

pump. - Connect the MITIVAC vacuum pump to the SAS control valve using a suitable pipe having the same size as the original fitted on the vehicle. - Start the vacuum up to -0.6 -0.8 Bar so as to close the valve and cut off the SAS system. - Remove the exhaust gas collection Kit closing cap and connect the analyser properly pre-heated. N.B. IN CASE OF 1000 PPM UNBURNED HYDROCARBONS (HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYS- TEM, THE VALVE CLEARANCE AND THE EXHAUST VALVE TIGHTNESS. N.B. IN CASE OF UNSTABLE CO, CHECK THAT THE CARBU- RETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYS- TEM AND THE DEPRESSION SEALS WORK ADEQUATE- LY N.B. OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN THE TANK AND THE FUEL CIRCUIT. N.B. ALSO CHECK THE CARBURETION ADJUSTMENT IS OB- TAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS. N.B. CHECK THAT THE RESULT IS OBTAINED WITH THE VALVE GAS IN CLOSED POSITION. N.B. CHECK THE CONDITIONS DISPLAYED BY THE ANALY- SER AND THE ENGINE RPM AND ADJUST THE CO VALUE AT 3.8 ± 0.7 AT 1,650 ± 50 RPM. Specific tooling 020332Y Digital rev counter 494929Y Exhaust fumes analyser 020329Y MityVac vacuum-operated pump X8 125-200 Maintenance MAIN - 51

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 ref- erences 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 con- trol 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. Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4 Maintenance X8 125-200 MAIN - 52

dary 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 com- pressed 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 com- pressed 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 WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART. Maintenance X8 125-200 MAIN - 54

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. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. 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 Air filter dirty Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. 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. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components X8 125-200 Troubleshooting TROUBL - 57

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 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 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 using the recommended oil type (Selenia HI Scooter 4 Tech) 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 Troubleshooting X8 125-200 TROUBL - 58

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 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. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. 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 X8 125-200 Troubleshooting TROUBL - 59

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. Electrical system 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 Troubleshooting X8 125-200 TROUBL - 60

Possible Cause Operation Idling rpms too high Adjust the engine idle speed and the CO%, if necessary. Clutch fault Check the springs / clutch masses 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. X8 125-200 Troubleshooting TROUBL - 61

5 Instrument panel 6 Open saddle button 7 Horn 8 Headlight remote control switch 9 Radio display preset 10 Front left turn signal lamp N°2 lamps 12V - 5W 11 Complete headlamp N°2 lamps (H7), n°2 front position lamps 12V - 5W 12 Front right turn signal lamp N° 2 lamps 12V - 5W 13 Stop switch on front brake 14 Engine stop switch 15 Rear trunk push button 16 Start up button 17 Clock reset push button 18 Output 12V - 180W 19 Key switch 20 Immobilizer aerial X8 125-200 Electrical system ELE SYS - 63

22 Thermistor 23 Thermal switch 24 Electric fan motor 25 Fuel level sender 26 HV coil 27 Voltage regulator 28 Engine oil pressure sensor 29 Automatic starter 30 Output for immobilizer diagnostic instrument 31 Magneto flywheel 32 Pick - up 33 Starter motor 34 Roof lamp for box helmet illumination with lamp 35 Rear right turn signal lamp N° 2 lamps 12V - 5W 36 Complete tail lamp N° 2 lamps for rear position light 12V - 5W, N° 2 lamps for stop light 12V - 10W 37 Rear left turn signal lamp N° 2 lamps 12V - 5W 38 Licence plate lamp lamp 12V-5W 39 Actuator for open rear trunk 40 Rear trunk illumination push button 41 Actuators control device 42 Box helmet illumination push button 43 Saddle opening actuator 44 Fuses holder N° 2 fuses (15A), n° 2 fuses (10A) and n° 1 fuse (5A) 45 Remote control switch 12V - 80A 46 Battery 12V-12Ah 47 Anti-theft alarm fitting 48 Radio unit power preset 49 Unit radio display preset 50 Fuses holder N° 1 fuse (5A), n° 2 fuses (7,5A) and n° 1 fuse (10A) Conceptual diagrams Electrical system X8 125-200 ELE SYS - 64

2 Magneto flywheel 3 Fuse 15A 4 Electronic controller 5 Spark plug 6 HV coil 7 Voltage regulator 8 Battery 12V-12Ah X8 125-200 Electrical system ELE SYS - 65

HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity 1 Number-plate light bulb 12V 5W 2 Four (4) light dashboard lighting bolbs 12V - 1.2W 3 Headlight warning light 12V - 1.2W 4 Two front parking light bulbs 12V - 5W 5 Two (2) taillight bulbs 12V - 5W 6 Light remote control switch 7 Light switch 8 Bulb for dipped beams 12V-55W 9 Key switch contacts 10 Fuse (Rear position light protection, number plate light, front position light) 7.5A 11 High-beam warning light 12V - 1.2W 12 Bulb for upper beams 12V-55W 13 Fuse (headlight remote control protection) 10 A 14 Automatic starter 15 Battery 12V 12Ah 16 Fuse 15A 17 Electronic control unit Electrical system X8 125-200 ELE SYS - 66

BATTERY RECHARGE AND START-UP SECTION Specification Desc./Quantity 1 Engine stop switch 2 Key switch contacts 3 Fuse 5A 4 Front and rear brake light button 5 Start up button 6 Starter motor 7 Remote starter switch 8 Two (2) stop light bulbs 12V - 10W 9 Fuse 15 A 10 Electronic ignition 11 Battery 12V-12Ah 12 Voltage regulator 13 Magneto flywheel 14 Pick - up X8 125-200 Electrical system ELE SYS - 67

ENABLE SIGNALS Specification Desc./Quantity 1 Coolant temperature gauge 2 Fuel gauge 3 Fuel level sender 4 Thermistor 5 Low fuel warning light 12V - 2W 6 Low oil pressure warning light 12V - 2W 7 Oil pressure sensor 8 Fuse (Rear position light protection, number plate light, front position light) 7.5A 9 Key switch contacts 10 Battery 12V - 12Ah 11 Fuse 15A 12 Electronic ignition 13 Radiatore electric fan motor 14 Thermal switch for electric fan Thermal switch Electrical system X8 125-200 ELE SYS - 68

ZAPM2300003507739 (X9) ZAPM3620000003383 (X8) ZAPM2850000001025 (Beverly), in order to prevent possible malfunctioning of the thermal switch. Turn signal lights FLASHING LIGHTS Specification Desc./Quantity 1 Antitheft 2 Boot opening actuator 3 Saddle opening actuator 4 Horn 5 Eight (8) turn signal light bulbs 12V - 5W 6 Two (2) turn signal warning light bulbs 12V - 2W 7 Horn button 8 Indicators switch 9 Saddle opening button 10 Fuse (Rear position light protection, number plate light, front position light) 7.5A X8 125-200 Electrical system ELE SYS - 69

14 Key switch contacts 15 Key switch contacts 16 Anti-theft alarm fitting 17 Fuses 10A 18 Clock reset push button 19 Immobilizer LED 20 Analogue clock 21 Antenna 22 Fuse 5A 23 Output for immobilizer diagnostic instrument 24 Boot button 25 Seat button 26 Socket for users 12V - 180W max 27 Helmet compartment lamp bulb 12V-5W 28 Open boot warning light 12V - 2W 29 Battery 12V - 12Ah 30 Fuse 15A 31 Immobilizer aerial 32 Electronic ignition 33 Fuse 15A 34 Actuators control device prewiring Checks and inspections This section is devoted to the checks on the electrical system components. Immobiliser The electric ignition system is fed with direct cur- rent 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 -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". Electrical system X8 125-200 ELE SYS - 70

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; oth- erwise check the wiring and the following compo- nents: - Engine stop remote control; - Emergency cut-off switch; - Side stand contacts; - Key switch contacts. X8 125-200 Electrical system ELE SYS - 71

the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evi- dent 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 pro- grammed 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 MAS- TER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stor- ed 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. 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: Electrical system X8 125-200 ELE SYS - 72

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 X8 125-200 Electrical system ELE SYS - 73

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, proceed to encode the service keys (Black). - 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, trans- ponder, programmed key and aerial working prop- erly. 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 im- mediately 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. Electrical system X8 125-200 ELE SYS - 74

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 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 detected, replace the Pick-Up, otherwise check the cable har- ness and the connections. In case conforming values are measured and the wiring and connections check is OK, 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. If no sparks are produced with the new control unit, proceed as follows. - HV primary coil check Disconnect the two connectors on the HV coil and check continuity (see figure). If non-conforming values are measured, replace the HV coil. If con- forming values are measured, check the cable harness taking into account that the HV coil posi- tive wire has a branch that comes into the digital instrument panel (violet cable). Therefore, make sure this line is in perfect conditions. If failures are detected, check the HV coil secondary. Electric characteristic High voltage coil primary resistance value High voltage coil primary 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. Electric characteristic X8 125-200 Electrical system ELE SYS - 75

High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm - Pick-Up. - Disconnect the control unit connector and con- nect the positive terminal to connector No. 2 and the negative terminal to connector No. 8 (see fig- ure). 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. Electric characteristic Pick-Up voltage value Pick-Up voltage value: > 2 Volt - HV coil With the control unit and HV coil connected, meas- ure the voltage of the coil primary during the start- up test with the voltage peak adaptor and con- necting 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 TER- MINAL ONE IS GREEN. Electric characteristic High voltage coil voltage value High voltage coil voltage value: > 100 Volt Stator check Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables. Electrical system X8 125-200 ELE SYS - 76

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 rep- etitions of incorrect values replace the stator or repair the wiring. - With a tester, check the circuit between connec- tions 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 connec- tions 4 and ground (with engine off) is not inter- rupted. 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 TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. X8 125-200 Electrical system ELE SYS - 77

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. Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive terminal, measure the bat- tery 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 gen- erated 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 re- gards voltage supply, keep the connector connec- ted to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If voltage is detected, replace the automatic starter as it is surely failing. Electrical system X8 125-200 ELE SYS - 78

negative terminal to the earth terminal and the positive terminal to the automatic starter orange cable; with the key switch set to «ON» check whether there is battery voltage; if there is no volt- age, check the wiring connections to the key switch and that the 15A fuse works properly. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start the engine and keep it at idle speed. Check if there is voltage when the multimeter positive probe is connected to the terminal No. 5 (Sky blue) and the negative one to the terminal No. 7 (Black/ White) (see figure). Replace the control unit if there is no voltage; oth- erwise, check the wiring connections between the starter and the control unit. Lights list Function Power Low-beam light bulb 12V - 55W High-beam light bulb 12V - 55W Front position light bulb 12V-5W x 2 Front turn indicator bulbs 12V-10W x 2 Rear tail light bulbs 12V-5W x 2 Stop light bulb 12V-2.3W x 5 Rear turn indicator bulbs 12V-10W x 2 Instrument panel lighting bulb 12V-2W x 5 Glove-box light bulb 12V - 5W License plate lighting bulb 12V - 5W X8 125-200 Electrical system ELE SYS - 79

- four protective fuses «A» into the helmet com- partment, - four fuses «B» for the system circuitry safety, lo- cated inside the port in the rear left side of the shield. The tables shows the features of the fuses on the vehicle. CAUTION BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE USING ANY OTHER MATERIAL (A PIECE OF ELECTRICAL WIRE, FOR EXAMPLE) OR A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED. Electric characteristic Light indicator on digital instrument panel, front and rear side/taillights 7.5 A Digital instrument panel, diagnostic led indi- cator on analogue instrument. 10 A Brake lights, vehicle start-up enabling signal 7.5 A Horn, upper beam and indicator on "Passing" function 10 A FUSES Specification Desc./Quantity 1 Helmet compartment, 12-V socket 15 A 2 General (battery recharge, lights, radiator electric fan, electronic control unit). 15 A 3 Headlight (upper and dipped beams). 10 A 4 Digital instrument panel 7.5 A Electrical system X8 125-200 ELE SYS - 80

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 X8 125-200 Electrical system ELE SYS - 81

tery, may be set by pressing the «T» button loca- ted 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 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 Electrical system X8 125-200 ELE SYS - 82

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 CON- TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF. Dry-charge battery COMMISSIONING A NEW DRY-CHARGED BATTERY - Remove the battery air pipe stop cap and each single cell cap. - Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an am- bient temperature not below 15°C, until it reaches the upper level indicated on the block. - Tilt the battery slightly to remove any air bubbles formed during filling. - Place the caps on each single cell filling hole without screwing them and leave the battery to rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases. - Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes). - Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water; - Before 24 hours elapse, recharge the battery following these steps: - Connect the battery charger terminals observing the correct polarity; - Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity; - Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge. Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge. - Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester. - If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging. - Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle. - If the voltage indicated is low, charge the battery another 4-6 hours in the way described above. X8 125-200 Electrical system ELE SYS - 83

Check function. The value indicated on the display must be higher than the value indicated on the chart; otherwise, recharge the battery again in the same way indicated above. Connectors CONNECTOR A Specification Desc./Quantity 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 bulb 6 6 Earth 7 7 + Clock battery 8 8 Right direction warning light CONNECTOR B Specification Desc./Quantity 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 Desc./Quantity 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 Dashboard 12-WAY INSTRUMENT CONNECTOR Specification Desc./Quantity 1 BATTERY POSITIVE LEAD (+30) BATTERY POSITIVE LEAD (+30) 2 SPEEDOMETER SENSOR POWER SUPPLY SPEEDOMETER SENSOR POWER SUPPLY 3 SPEEDOMETER SENSOR BACK TO GROUND SPEEDOMETER SENSOR BACK TO GROUND 4 REVOLUTION SENSOR INPUT REVOLUTION SENSOR INPUT 5 BATTERY POSITIVE LEAD (+30) BATTERY POSITIVE LEAD (+30) 6 ANTITHEFT DEVICE LED ANTITHEFT DEVICE LED 7 KEY POSITIVE TERMINAL (+15) KEY POSITIVE TERMINAL (+15) 8 SPEEDOMETER SENSOR INPUT SPEEDOMETER SENSOR INPUT 9 GROUND GROUND 10 AIR TEMPERATURE SENSOR BACK TO GROUND AIR TEMPERATURE SENSOR BACK TO GROUND 11 EMERGENCY LIGHT BUTTON (HAZARD) INPUT EMERGENCY LIGHT BUTTON (HAZARD) INPUT 12 LIGHTS ON INPUT LIGHTS ON INPUT 8-WAY INSTRUMENT CONNECTOR Specification Desc./Quantity 1 GROUND ANALOGUE CHART GROUND ANALOGUE CHART 2 BATTERY POSITIVE LEAD (+30) FOR ANALOGUE CARD BATTERY POSITIVE LEAD (+30) FOR ANALOGUE CHART 3 ANALOGUE CARD SERIAL CLOCK OUTPUT ANALOGUE CARD SERIAL CLOCK OUTPUT Electrical system X8 125-200 ELE SYS - 84

ANTITHEFT DEVICE LED OUTPUT 5 ANALOGUE CARD SERIAL DATE OUTPUT ANALOGUE CARD SERIAL DATE OUTPUT 6 LIGHTS ON OUTPUT LIGHTS ON OUTPUT 7 (Not connected) 8 (Not connected) 16-WAY INSTRUMENT CONNECTOR Specification Desc./Quantity 1 GENERAL USE WARNING LIGHT INPUT GENERAL USE WARNING LIGHT INPUT 2 ABS WARNING LIGHT INPUT (NOT CONNECTED) ABS WARNING LIGHT INPUT (NOT CONNECTED) 3 STOP LIGHT NOT WORKING OUTPUT STOP LIGHT NOT WORKING OUTPUT 4 RIGHT TURN INDICATOR OUTPUT RIGHT TURN INDICATOR OUTPUT 5 RIGHT TURN INDICATOR BUTTON INPUT RIGHT TURN INDICATOR BUTTON INPUT 6 LEFT TURN INDICATOR BUTTON INPUT LEFT TURN INDICATOR BUTTON INPUT 7 HIGH-BEAM WARNING LIGHT INPUT HIGH-BEAM WARNING LIGHT INPUT 8 AIR TEMPERATURE SENSOR INPUT AIR TEMPERATURE SENSOR INPUT 9 ENGINE UNABLE TO START WARNING LIGHT INPUT ENGINE UNABLE TO START WARNING LIGHT INPUT 10 OIL PRESSURE WARNING LIGHT INPUT OIL PRESSURE WARNING LIGHT INPUT 11 STOP LIGHT NOT WORKING WARNING LIGHT IN- PUT STOP LIGHT NOT WORKING WARNING LIGHT IN- PUT 12 LEFT TURN INDICATOR OUTPUT LEFT TURN INDICATOR OUTPUT 13 TURN INDICATOR OFF SWITCH INPUT TURN INDICATOR OFF SWITCH INPUT 14 RESET SERVICE MANAGEMENT BUTTON INPUT RESET SERVICE MANAGEMENT BUTTON INPUT 15 WATER TEMPERATURE SENSOR INPUT WATER TEMPERATURE SENSOR INPUT 16 FUEL LEVEL SENSOR INPUT FUEL LEVEL SENSOR INPUT X8 125-200 Electrical system ELE SYS - 85

Exhaust assy. Removal • Unscrew the 3 screws fixing the muffler to the engine crankcase and the sup- porting arm; • Loosen the bolt holding the muffler to the exhaust manifold; after that, re- move the muffler backwards. • Unscrew the 2 nuts that fix the exhaust manifold to the head and remove it. Removal of the engine from the vehicle • Remove the side panels • Undo the 2 screws fixing the rear brake calliper to the supporting arm and re- move it. • Keep the pipes connected to the cal- liper and move it aside towards the vehicle front part so as not to hinder the next removal operations. X8 125-200 Engine from vehicle ENG VE - 87

• Remove the clamps and disconnect the coolant feeding (engine compart- ment) and return (water pump) pipes. • Remove the holding springs and re- move the coolant out pipes; • Remove the holding springs and re- move the petrol pump low-pressure tube from the inlet manifold; • Move the accelerator wire from the throttle control rocking lever; unscrew the adjuster and disconnect the trans- mission from the carburettor. • Disconnect the HV wire from the spark plug; • Disconnect the thermistor electrical connection after removing the rubber cap. Engine from vehicle X8 125-200 ENG VE - 88

the petrol feed pipe to carburettor; • Cut the plastic clamp and disconnect the starter supply connection. • Loosen the two screws fixing the rear shock-absorbers to the crankcase and the mounting arm; • Cut the zip-tie on the transmission air duct, and then detach the manifold from the air intake on the frame. • Disconnect the electric connector link- ing the magneto flywheel to the vehicle cable harness. • Remove the starter motor electrical connections operating on the two screws. • Remove the footrest and the left side fairing; move the lower central cover slightly to the outside; after that, re- move the three supporting plate fixing screws from the swinging arm buffer. Remove the buffer seal seeger ring X8 125-200 Engine from vehicle ENG VE - 89

the swinging arm buffer. • Support the vehicle adequately with the jack. Remove the engine - swinging arm fixing pin operating on the nut and the pin head. • The engine is now free. Locking torques (N*m) Engine swinging arm pin nut 33 ÷ 41 Lower shock absorber clamp 33 ÷ 41 Rear brake callip- er tightening screws 20 ÷ 25 Engine from vehicle X8 125-200 ENG VE - 90

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 vehi- cle, remove the cooling air supply coupling of the transmission housing. Air duct Version 125 - Remove the 4 screws and the housing. Engine X8 125-200 ENG - 92

els, as well as the small casing. - To remove the intake throat on the transmission cover, just 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 X8 125-200 Engine ENG - 93

- 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 Engine X8 125-200 ENG - 94

- 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 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 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. X8 125-200 Engine ENG - 95

measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic support for dial gauge Characteristic clutch bell inspection: Limit eccentricity. Admissible limit eccentricity: 0.15 mm Removing the clutch Clutch removal (125 cm³ H2O) 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 intro- ducing the rivets heads in the adapter ring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to loosen/tight- en 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 CON- TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE. Specific tooling 020444Y009 wrench 46 x 55 020444Y010 adapter ring Engine X8 125-200 ENG - 96

tool with the medium-length pins in position "C" screwed up from the inner side of the tool. - Introduce the adapter ring 11 with the chamfering facing the inside of the tool. - Fit the driven pulley unit on the tool with the in- sertion of the 3 pins in the ventilation holes in the mass holder support. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to loosen/tight- en the clutch nut. - Use the special 46x55 wrench component 9 to remove the nut fixing the clutch in place. - Separate the driven pulley into its components (Clutch and spring with its plastic holder) CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CON- TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE. Specific tooling 020444Y009 wrench 46 x 55 020444Y011 adapter ring 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 X8 125-200 Engine ENG - 97

- 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. - Remove the 4 torque server pins and pull the pulley halves apart. Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - 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 Engine X8 125-200 ENG - 98

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. - Check the riveted joints are functional. - Check the evenness of the belt contact surface. Characteristic Half-pulley minimum diameter Minimum admissible diameter: Ø 40.96 mm Half-pulley standard diameter Standard diameter: Ø 40.985 mm Wear limit 0.3 mm X8 125-200 Engine ENG - 99

puleggia. - Verificare la superficie di contatto con la cinghia non presenti usure anomale. Characteristic Half-pulley standard diameter Standard diameter: Ø 40.985 mm Half-pulley minimum diameter Minimum admissible diameter: Ø 40.96 mm Inspecting the driven sliding half-pulley - Rimuovere i 2 anelli di tenuta interni e i 2 O-R; - Misurare il diametro interno del boccolo della semipuleggia mobile. 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 - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check that the faying surface with the belt is not abnormally worn. - Check the riveted joints are functional. - Check the evenness of the belt faying surface. Engine X8 125-200 ENG - 100