PIAGGIO X8 125 Service Manual X8 200 Workshop

WORKSHOP MANUAL 618126 X8 125-200 Downloaded from www.Manualslib.com manuals search engine

WORKSHOP MANUAL X8 125-200 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions shown in this publication are available in all countries. The availability of single models should be checked at the official Piaggio sales network. "© 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) Downloaded from www.Manualslib.com manuals search engine

WORKSHOP MANUAL X8 125-200 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- 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. Downloaded from www.Manualslib.com manuals search engine

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INDEX OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE-DELIVERY PRE DE TIME TIME Downloaded from www.Manualslib.com manuals search engine

INDEX OF TOPICS CHARACTERISTICS CHAR Downloaded from www.Manualslib.com manuals search engine

This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are 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 Downloaded from www.Manualslib.com manuals search engine

Engine prefix: M363M 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 Downloaded from www.Manualslib.com manuals search engine

DATA 200 Specification Desc./Quantity Version 200 cc Engine single-cylinder, four-stroke Raffreddamento A liquido Bore x stroke 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 T RANSMISSIONS 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 - 125 CC 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 advance, 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 Downloaded from www.Manualslib.com manuals search engine

E LECTRICAL COMPONENTS 200 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 advance, 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 B RAKES Specification Desc./Quantity Front brake Ø 260 disc brake (left-hand side of vehicle), with hydraulic control operated from the right-hand brake lever on the handlebar. Rear brake Ø 240-mm disc brake with hydraulic control activated by handlebar left-side lever. Wheels and tyres W HEELS 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 Downloaded from www.Manualslib.com manuals search engine

PIAGGIO X8 125 Service Manual X8 200 Workshop

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