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PIAGGIO X9 Evolution 125 2008 User Manual

PIAGGIO X9 Evolution 125 2008
262 pages
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SERVICE STATION MANUAL
664627 IT-664628 EN-664629 FR-664630 DE-664631
ES-664632 PT-664633 OL-664634 EL
X9 Evolution 125

Table of Contents

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PIAGGIO X9 Evolution 125 2008 Specifications

General IconGeneral
BrandPIAGGIO
ModelX9 Evolution 125 2008
CategoryScooter
LanguageEnglish

Summary

CHARACTERISTICS

General Safety and Maintenance Rules

Outlines essential safety precautions and maintenance guidelines for vehicle servicing.

Vehicle Identification and Specifications

Details chassis/engine prefixes, dimensions, mass, and engine/transmission data.

System Components Overview

Covers capacities, electrical system, frame, suspensions, brakes, and wheels.

Carburettor and Tightening Torques

Details carburettor versions and specifications, plus tightening torque values.

TOOLING

Appropriate Tools for Servicing

Lists specialized tools required for vehicle maintenance and repair, with store codes.

Guides, Adaptors, and Extractors

Details various guides, adaptors, and tools for bearing extraction and other operations.

Specialized Engine Tools

Lists tools for engine support, flywheel extraction, and steering components.

Valve, Pulley, and Electrical Tools

Describes tools for valve removal, pulley fitting, and electrical system checks.

Timing, Measurement, and Wrenches

Lists tools for timing checks, measurements, and specialized wrenches.

Specialized Tools for Various Systems

Details tools for piston assembly, engine components, and electrical testers.

Piston, Crankshaft, and Bearing Tools

Lists tools for piston position checks, crankshaft alignment, and bearing work.

Valve, Pump, and Electrical Tools

Describes tools for valve removal, vacuum pumps, and pulley lock wrenches.

Multimeters, Rev Counters, and Crankshaft Tools

Lists tools for electrical testing and crankshaft alignment checks.

Circlip, Seat, and Bearing Tools

Details tools for circlips, steering seats, and bearing extractors.

Adaptors and Bearing Tools

Lists specific adaptors and tools for bearing extraction.

MAINTENANCE

Maintenance Schedule

Provides a schedule of maintenance tasks based on time and mileage intervals.

Carburettor and Ignition System Checks

Details carburettor servicing and spark advance checking procedures.

Spark Plug and Hub Oil Service

Describes procedures for spark plug service and rear hub oil maintenance.

Air Filter and Engine Oil Maintenance

Details air filter cleaning and engine oil replacement procedures.

SAS Filters and Stator Assembly Torque

Explains SAS filter inspection and torque for stator assembly screws.

TROUBLESHOOTING

Engine Performance Issues

Addresses poor performance, difficult starting, and excessive oil consumption.

Engine Operation Problems

Covers engine stoppages, lubrication pressure, and exhaust noise.

Fuel Consumption and System Malfunctions

Addresses high fuel consumption, SAS malfunctions, and clutch issues.

Braking, Battery, and Lighting Issues

Covers insufficient braking, overheating, battery, and turn signal problems.

Steering and Suspension Issues

Addresses steering control, torque, and suspension malfunctions.

ELECTRICAL SYSTEM

Component Identification Key

Lists and identifies key electrical system components with corresponding numbers.

Electrical System Components List

Provides an extensive list of electrical components numbered for reference.

Instrument Panel and Wiring Diagrams

Details instrument panel displays, keys, and wiring color codes.

Ignition and Starter System Schematics

Presents schematic diagrams for ignition, starter, and battery recharge systems.

Lighting and Indicator System Schematics

Shows schematic diagrams for headlights, stop lights, and turn indicators.

Battery Recharge and Starting Schematics

Illustrates the electrical schematic for battery recharge and starting systems.

Level Indicators and Control Signals Diagrams

Displays schematics for level indicators, enable signals, and sensors.

Device and Accessory Wiring

Shows wiring diagrams for devices, accessories, and immobiliser system.

Immobiliser System Operation and Checks

Explains the immobiliser system components and diagnostic procedures.

Immobiliser Diagnostic Codes and Checks

Details diagnostic LED functions and checks for control unit supply.

Ignition Circuit and Spark Plug Troubleshooting

Covers ignition circuit operation and troubleshooting no spark plug issues.

Pick-Up and HV Coil Electrical Checks

Details resistance and voltage checks for Pick-Up and HV coil circuits.

Battery Recharge and Stator Checks

Describes battery recharge circuit and stator check procedures.

Voltage Regulator and System Checks

Details checks for the voltage regulator and recharge system.

Choke and Fuse Information

Explains choke inspection and provides fuse table details.

Dashboard, Fuses, and Battery

Covers fuse table, dashboard layout, and battery maintenance.

Instrument Panel and Data Check

Details instrument panel displays, icons, and the data check function.

Battery Charging Procedures

Provides instructions for checking and recharging sealed and dry-charge batteries.

Pump Electrics Check

Describes how to check the fuel pump's electrical supply and operation.

ENGINE FROM VEHICLE

Engine Removal Procedure

Outlines the step-by-step procedure for safely removing the engine from the vehicle.

ENGINE

Automatic Transmission and Air Duct

Details removal of transmission cover, air duct, and filter.

Pulley Shaft Bearing and Rollers

Explains removal and refitting of pulley shaft bearings and rollers.

Driven Pulley and Clutch Inspection

Details removing and inspecting the driven pulley and clutch drum.

Clutch and Pin Retaining Collar Operations

Describes clutch removal and inspection, plus pin retaining collar removal.

Half-Pulley and Drive-Belt Inspection

Explains inspection of half-pulleys and the drive belt.

Pulley and Clutch Refitting

Details refitting driven half-pulley bearings, driven pulley, and clutch.

Engine Component Refitting and Torque

Explains refitting the driven pulley, clutch nut torque, and transmission cover.

Engine Assembly and Inspection

Details inspection of rollers case, and assembly of driving pulley.

Crankcase and Crankshaft Operations

Outlines refitting transmission cover, crankcase halves, and flywheel cover.

Flywheel Magneto and Starter Motor Operations

Details removing, inspecting, and refitting flywheel magneto and starter motor.

Engine Component Removal Procedures

Explains removal of intake manifold and timing system drive components.

Cam Shaft and Cylinder Head Removal

Details removing the camshaft and cylinder head.

Valve and Piston/Cylinder Removal

Explains removing valves, cylinder head, and cylinder-piston assembly.

Piston and Cylinder Inspections

Details inspecting small end, wrist pin, piston, and piston rings.

Piston and Cylinder Refitting

Describes refitting piston rings and the cylinder.

Cylinder Head and Timing System Inspections

Explains inspecting cylinder head, camshaft, and timing system components.

Valve Inspections and Refitting

Details inspecting valve sealings, housings, and the valves themselves.

Cam Shaft Inspections

Explains how to inspect the camshaft for wear and clearances.

Crankcase and Crankshaft Operations

Outlines procedures for splitting crankcase halves and checking crankshaft clearance.

Crankshaft Alignment and Bearing Checks

Details checking crankshaft alignment, dimensions, and bearing diameters.

Crankcase Halves Inspections and Refitting

Explains inspecting crankcase halves and refitting them.

Lubrication System Checks

Details oil pressure checks and procedures for crankshaft oil seals.

Oil Pump and By-pass Valve Operations

Explains oil pump removal, inspection, refitting, and by-pass valve inspection.

SAS Valve and Cut-off Valve Inspections

Describes inspecting the one-way SAS valve and the cut-off valve.

Fuel Supply and Carburettor Removal

Details fuel filter cleaning and carburettor removal procedures.

Carburettor Component Operations

Explains removing carburettor parts like diaphragm chamber and nozzles.

Carburettor Refitting and Adjustments

Details refitting the carburettor and making air adjustments.

Automatic Choke Device Inspection

Explains inspection of the automatic starter piston and its protrusion.

SUSPENSIONS

Front Wheel and Handlebar Removal

Outlines procedures for removing the front wheel and handlebar.

Steering Tube Overhaul and Refitting

Details steering tube overhaul, oil replacement, and refitting steps.

Steering Tube Bearing Adjustment

Explains lubricating bearings and tightening steering tube nuts.

Steering Bearing Removal and Refitting

Outlines procedures for removing and refitting steering bearings.

Rear Wheel and Swinging Arm Removal

Details removing the rear wheel, muffler bracket, and swinging arm.

Shock Absorber Removal and Refitting

Explains the procedure for removing and refitting the shock absorbers.

Centre-stand Removal and Reassembly

Outlines steps for removing and reassembling the centre-stand.

BRAKING SYSTEM

Interventions Rules and Caliper Removal

General rules for hydraulic braking system maintenance and front calliper removal.

Front Brake Calliper Overhaul

Explains the overhaul process for the floating type brake calliper.

Disc and Pad Replacement

Describes checking and replacing brake discs and pads.

Brake Bleeding Procedures

Details the procedure for bleeding the front brake circuit.

Front Brake Pump Overhaul

Details the overhaul process for the front brake pump.

COOLING SYSTEM

Cooling System Circuit Diagram

Provides a schematic diagram of the vehicle's cooling system.

Water Pump Overhaul

Details the overhaul procedure for the water pump, including bearing and seal replacement.

Water Pump Component Checks and Assembly

Explains checking water pump components and assembly steps.

Thermostat Removal, Check, and Refitting

Outlines procedures for removing, testing, and refitting the thermostat.

CHASSIS

Helmet Bay and Fuel Tank Access

Explains access to helmet bay, battery, and fuel tank removal.

Radiator Fan and Expansion Tank Removal

Details removing the radiator fan and expansion tank.

Top-case Removal

Outlines the procedure for removing the top-case and saddle latch.

PRE-DELIVERY

Aesthetic and Torque Inspections

Covers visual checks and tightening torque verification before delivery.

Electrical System and Battery Checks

Lists checks for electrical system components and battery handling precautions.

Levels Check and Road Test

Outlines fluid level checks and the procedure for a road test.

Static and Functional Inspections

Covers static controls after test ride and functional checks of systems.

TIME

Crankcase and Crankshaft Repair Times

Lists repair codes and durations for crankcase and crankshaft operations.

Cylinder and Head Assembly Repair Times

Specifies repair codes and durations for cylinder, head, valves, and camshafts.

Engine Component Repair Times

Lists repair codes and durations for oil filter, oil pump, and driven pulley.

Chassis and Suspension Repair Times

Specifies repair codes and durations for frame, centre-stand, and mudguards.

Electrical System Repair Times

Lists repair codes and durations for battery, headlight, and wiring harness.

Wheel and Brake System Repair Times

Specifies repair codes and durations for front/rear wheels and brake calipers.

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