Page 1 WORKSHOP MANUAL 618126 X8 125-200...
Page 2 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."...
Page 3 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.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
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.
Page 8: Dimensions And Weight
X8 125-200 Characteristics 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)
Page 9 X8 125-200 Characteristics 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...
Page 10: Wheels And Tyres
X8 125-200 Characteristics LECTRICAL COMPONENTS 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...
Page 11 X8 125-200 Characteristics Kehin KEHIN CVEK-30 CARBURETTOR Specification Desc./Quantity Depression carburettor CVEK-30 Body stamping CVEK Stamping 303A Max. jet Minimum jet Max. air jet Minimum air jet Throttle valve spring 100 ÷ 160 g Minimum mixture set screw initial opening 2 ±...
Page 12: Tightening Torques
X8 125-200 Characteristics Specification Desc./Quantity Max. jet Minimum jet Max. air jet Minimum air jet 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...
Page 13: Rear Suspension
X8 125-200 Characteristics Name Torque in Nm 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 ÷...
Page 14: Assembly Clearances
X8 125-200 Characteristics Name Torque in Nm 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 ÷...
Page 15 X8 125-200 Characteristics Cylinder - piston assy. ENGINE 200 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder / piston 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 Cylinder / piston 72.004 ÷...
Page 16 X8 125-200 Characteristics ENGINE 125 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059 Piston 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059...
Page 17 X8 125-200 Characteristics Slot packing system 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.
Page 18 X8 125-200 Characteristics 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.
Page 19 X8 125-200 Characteristics Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
Page 20 X8 125-200 Characteristics Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
Page 21 X8 125-200 Characteristics Oversizes ENGINE 125 OVERSIZE Name Description Dimensions Initials Quantity Compression ring 57 x 1 0.15 ÷ 0.30 Oil scraper ring 57 x 1 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 0.15 ÷ 0.35 Compression ring 1st 57.2 x 1...
Page 22 X8 125-200 Characteristics Products PRODUCTS Product Description Specifications AGIP GREASE PV2 Grease for steering bearings and spindle Soap-based lithium and zinc oxide seats grease containing NLGI 2; ISO-L- XBCIB2 of the swinging arm MONTBLANC MOLYBDENUM Grease for driven pulley shaft adjusting...
Page 23 INDEX OF TOPICS TOOL OOLING...
Page 24 X8 125-200 Tooling APPROPRIATE TOOLS Stores code Description 020151Y Air heater 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 001467Y014 Pliers to extract ø 15-mm bearings TOOL - 24...
Page 25 X8 125-200 Tooling Stores code Description 020412Y 15 mm guide 020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47-mm Adaptor TOOL - 25...
Page 26 X8 125-200 Tooling Stores code Description 020363Y 20 mm guide 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 TOOL - 26...
Page 27 X8 125-200 Tooling Stores code Description 020382Y011 adapter for valve removal tool 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 TOOL - 27...
Page 28 X8 125-200 Tooling Stores code Description 020364Y 25-mm guide 020375Y Adaptor 28 x 30 mm 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 TOOL - 28...
Page 29 X8 125-200 Tooling Stores code Description 020368Y driving pulley lock wrench 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 TOOL - 29...
Page 30 X8 125-200 Tooling Stores code Description 020428Y Piston position check support 020426Y Piston fitting fork 020425Y Punch for flywheel-side oil seal 020423Y Driven pulley lock wrench 020414Y 28-mm guide 020393Y Piston assembly band TOOL - 30...
Page 31 X8 125-200 Tooling Stores code Description 020382Y Valve cotters equipped with part 012 re- moval tool 020455Y 10-mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum-operated pump 020357Y 32x35-mm Adaptor TOOL - 31...
Page 32 X8 125-200 Tooling Stores code Description 020409Y Multimeter adaptor - Peak voltage detec- tion 020456Y Ø 24 mm adaptor 020332Y Digital rev counter 020074Y Support base for checking crankshaft alignment 020055Y Wrench for steering tube ring nut TOOL - 32...
Page 33 X8 125-200 Tooling Stores code Description 002465Y Pliers for circlips 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...
Page 34 X8 125-200 Tooling Stores code Description 001467Y013 Pliers to extract ø 15-mm bearings 020444Y010 adapter ring TOOL - 34...
Page 35 INDEX OF TOPICS MAIN AINTENANCE...
Page 36: Maintenance Chart
X8 125-200 Maintenance Maintenance chart VERY YEARS Action Coolant - change Brake fluid - change Secondary air filter (external/internal) - cleaning (125) EVERY 3,000 KM Action Engine oil - level check/ top-up 1,000 FTER Action Engine oil - replacement Hub oil - change...
Page 37 X8 125-200 Maintenance Action Driven pulley roller casing - Greasing Driving belt - replacement Sliding blocks / variable speed rollers - check Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear...
Page 38 X8 125-200 Maintenance Action 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...
Page 39 X8 125-200 Maintenance Action Engine oil - change 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...
Page 40: Checking The Spark Advance
X8 125-200 Maintenance Action Coolant level - check 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...
Page 41 X8 125-200 Maintenance load on the spark plug power line (10 ÷ 15 KΩ in 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.
Page 42 X8 125-200 Maintenance ERSION Specification Desc./Quantity Spark elimination First threshold : 1 spark on 7 Second threshold : 2 sparks on 3 Version 200 : Operation threshold First threshold : 9900 ±50 Second threshold : 10100 ±50 Version 200 : Reactivation threshold First threshold : 9800 ±50 Second threshold: 10000 ±50...
Page 43 X8 125-200 Maintenance Spark plug MAIN - 43...
Page 44 X8 125-200 Maintenance Hub oil Make sure that there is oil in the rear hub (amount 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.
Page 45 X8 125-200 Maintenance DISPOSE OF USED OILS IN AN ENVIRONMENTALLY 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...
Page 46 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.
Page 47 X8 125-200 Maintenance RUNNING THE ENGINE WITH INSUFFICIENT LUBRICA- 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.
Page 48: Checking The Ignition Timing
X8 125-200 Maintenance This operation must be carried out with the en- 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.
Page 49: Checking The Valve Clearance
X8 125-200 Maintenance To use this reference mark, remove the spark plug 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.
Page 50 X8 125-200 Maintenance Proceed as follows: 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;...
Page 51 X8 125-200 Maintenance - Insert a conical plug into the vacuum feeding 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.
Page 52 X8 125-200 Maintenance SAS filters inspection and cleaning 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.
Page 53 X8 125-200 Maintenance MAIN - 53...
Page 54 X8 125-200 Maintenance Undo the 3 fixing screws "A", remove the secon- 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.
Page 55 X8 125-200 Maintenance MAIN - 55...
Page 56 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 57: Troubleshooting
X8 125-200 Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-...
Page 58 X8 125-200 Troubleshooting 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 Battery flat Check the charge of the battery, if there are any sulphur marks,...
Page 59 X8 125-200 Troubleshooting Possible Cause Operation The starter remains on Check: electric wiring, circuit not interrupted, mechanical movement and power supply; replace if necessary Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air Excessive exhaust noise...
Page 60 X8 125-200 Troubleshooting Insufficient braking NSUFFICIENT BRAKING Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits;...
Page 61 X8 125-200 Troubleshooting Rear wheel REAR WHEEL ROTATES WITH ENGINE AT IDLE 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...
Page 62 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 63: Electric System
X8 125-200 Electrical system ELECTRIC SYSTEM Specification Desc./Quantity Horn button Indicators switch Light switch Stop button on rear brake Instrument panel Open saddle button Horn Headlight remote control switch Radio display preset Front left turn signal lamp N°2 lamps 12V - 5W Complete headlamp N°2 lamps (H7), n°2 front position lamps 12V - 5W...
Page 64 X8 125-200 Electrical system Specification Desc./Quantity Electronic ignition device Thermistor Thermal switch Electric fan motor Fuel level sender HV coil Voltage regulator Engine oil pressure sensor Automatic starter Output for immobilizer diagnostic instrument Magneto flywheel Pick - up Starter motor...
Page 65 X8 125-200 Electrical system Ignition IGNITION Specification Desc./Quantity Pick - up Magneto flywheel Fuse Electronic controller Spark plug HV coil Voltage regulator Battery 12V-12Ah ELE SYS - 65...
Page 66 X8 125-200 Electrical system Headlights and automatic starter section HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity Number-plate light bulb 12V 5W Four (4) light dashboard lighting bolbs 12V - 1.2W Headlight warning light 12V - 1.2W Two front parking light bulbs...
Page 67 X8 125-200 Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP SECTION Specification Desc./Quantity Engine stop switch Key switch contacts Fuse Front and rear brake light button Start up button Starter motor Remote starter switch Two (2) stop light bulbs...
Page 68 X8 125-200 Electrical system Level indicators and enable signals section ENABLE SIGNALS Specification Desc./Quantity Coolant temperature gauge Fuel gauge Fuel level sender Thermistor Low fuel warning light 12V - 2W Low oil pressure warning light 12V - 2W Oil pressure sensor Fuse (Rear position light protection, number plate light, 7.5A...
Page 69 X8 125-200 Electrical system We inform you that a new thermal switch has been introduced starting with frame number ZAPM2300003507739 (X9) ZAPM3620000003383 (X8) ZAPM2850000001025 (Beverly), in order to prevent possible malfunctioning of the thermal switch. Turn signal lights FLASHING LIGHTS Specification Desc./Quantity...
Page 70 X8 125-200 Electrical system Specification Desc./Quantity Fuse 10 A PICS prewiring Boot opening button Key switch contacts Key switch contacts Anti-theft alarm fitting Fuses Clock reset push button Immobilizer LED Analogue clock Antenna Fuse Output for immobilizer diagnostic instrument Boot button...
Page 71 X8 125-200 Electrical system The duration of the flash depends on the electronic control unit program (see figure). If the led turns off and remains so when switching to "ON", it is necessary to check if there is battery voltage in the electric control unit.
Page 72 X8 125-200 Electrical system Virgin circuit If the ignition system has not been programmed, the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evi- dent loss of power may be felt.
Page 73 X8 125-200 Electrical system 2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial. Ignition disabled-Vehicle immobilised 3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans- ponder code. Ignition disabled-Vehicle immobilised Diagnostic code - 2 flashes...
Page 74 X8 125-200 Electrical system Diagnostic code - 3 flashes If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the key switch. - If the failure disappears when the MASTER key is used, proceed to encode the service keys (Black).
Page 75 X8 125-200 Electrical system No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure: - Pick-Up check. Disconnect the control unit connector and check that the cable between terminal No.
Page 76 X8 125-200 Electrical system High voltage coil secondary resistance value 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.
Page 77 X8 125-200 Electrical system Electric characteristic Ohm value: 0.7 ÷ 0.9 Ohm 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.
Page 78 X8 125-200 Electrical system Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator.
Page 79 X8 125-200 Electrical system If no voltage is detected, connect the multimeter 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.
Page 80 X8 125-200 Electrical system Fuses The electric system is equipped with: - 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.
Page 81 X8 125-200 Electrical system Dashboard A = Twin scale speedometer (km/h and mph) B = Fuel gauge C = Antitheft device LED D = Coolant temperature gauge E = Right turn indicator warning light E = Left turn indicator warning light...
Page 82 X8 125-200 Electrical system The clock, powered directly by the vehicle's bat- 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;...
Page 83 X8 125-200 Electrical system WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL MARKED WITH THE +POSITIVE SIGN WARNING WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
Page 84 X8 125-200 Electrical system Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the Check function. The value indicated on the display must be higher than the value indicated on the chart;...
Page 85 X8 125-200 Electrical system Specification Desc./Quantity ANTITHEFT DEVICE LED OUTPUT ANTITHEFT DEVICE LED OUTPUT ANALOGUE CARD SERIAL DATE OUTPUT ANALOGUE CARD SERIAL DATE OUTPUT LIGHTS ON OUTPUT LIGHTS ON OUTPUT (Not connected) (Not connected) WAY INSTRUMENT CONNECTOR Specification Desc./Quantity GENERAL USE WARNING LIGHT INPUT...
Page 86 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 87 X8 125-200 Engine from vehicle This section describes the operations to make to separate of the motor of the vehicle. Exhaust assy. Removal • Unscrew the 3 screws fixing the muffler to the engine crankcase and the sup- porting arm;...
Page 88 X8 125-200 Engine from vehicle • Empty the cooling system. • 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; •...
Page 89 X8 125-200 Engine from vehicle • Remove the holding spring and move 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;...
Page 90 X8 125-200 Engine from vehicle and remove the supporting plate from 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. •...
Page 91 INDEX OF TOPICS NGINE...
Page 92: Automatic Transmission
X8 125-200 Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
Page 93 X8 125-200 Engine - Remove the 5 screws, found on two different lev- 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.
Page 94 X8 125-200 Engine Refitting the driven pulley shaft bearing - Slightly heat the crankcase from the inside so as not to damage the painted surface. - Insert the bearing in its seat. - Refit the Seeger ring. CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM- AGING THE COVER PAINT.
Page 95: Removing The Driven Pulley
X8 125-200 Engine - Refit the roller with the special screw. - Tighten to the specified torque. - Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing. Locking torques (N*m) Anti-flapping roller 12 - 16...
Page 96: Removing The Clutch
X8 125-200 Engine - Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft...
Page 97 X8 125-200 Engine - Fit the special driven pulley spring compressor 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.
Page 98 X8 125-200 Engine Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL- N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.
Page 99 X8 125-200 Engine - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide Inspecting the driven fixed half-pulley - Measure the outer diameter of the pulley bushing.
Page 100 X8 125-200 Engine - Misurare il diametro esterno del boccolo della 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;...
Page 101 X8 125-200 Engine MOVABLE DRIVEN HALF-PULLEY DIMENSIONS Specification Desc./Quantity Wear limit 0.3 mm standard diameter Diameter 41.000 - 41.035 mm maximum allowable diameter Ø 41.08 mm - Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling free assembled rollers.
Page 102 X8 125-200 Engine Refitting the driven pulley - Inserire i nuovi paraoli ed anelli O-R sulla semi- puleggia mobile. - Lubrificare leggermente di grasso gli anelli O-R (A) indicati in figura. - Insert the new oil guards and O-rings on the mov- able half-pulley.
Page 103 X8 125-200 Engine Specific tooling 020263Y Driven pulley assembly sheath Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Misurare la lunghezza libera della molla della semipuleggia condotta mobile.
Page 104 X8 125-200 Engine - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut. - Place the tool in the clamp with the control screw on the horizontal axis.
Page 105 X8 125-200 Engine - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position "C" on the inside. - Introduce the adapter ring 11 with the chamfering facing upwards.
Page 106 X8 125-200 Engine 020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55 Locking torques (N*m) Nut locking clutch unit on pulley 55 ÷ 60 Nm Refitting the driven pulley - Reassemble the clutch bell and spacer.
Page 107: Removing The Driving Pulley
X8 125-200 Engine During the wear checks foreseen in the scheduled maintenance services at 6,000 km; 18,000 km; etc., check that the rim bottom of the toothing does not show signs of incisions or cracking (see figure): The rim bottom of the tooth must not have incisions or cracking;...
Page 108 X8 125-200 Engine - Remove the entire start-up crown unit with the torque limiter. - Remove the fixed driving half-pulley together with the O-ring and the steel washer touching the bush- ing. Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A.
Page 109 X8 125-200 Engine Diameter 20.5 - 20.7 mm roller (125): Standard Diameter Ø 18.9 ÷ 19.1 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm movable driving half-pulley bushing: Standard Diameter 26.000 - 26.021 mm Refitting the driving pulley...
Page 110 X8 125-200 Engine - Correctly reassemble the previously removed Bendix back to its position. - Fit the steel shim washer in contact with the bushing and the fixed driving pulley together with the O-ring on the outside of the fan blades.
Page 111 X8 125-200 Engine Locking torques (N*m) Drive pulley nut 75 ÷ 83 - Correctly refit the previously removed Bendix back to its position. - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread Loctite 243 Quick Set threadlock on the thread and tighten the nut to the prescribed torque.
Page 112 X8 125-200 Engine End gear Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket. Removing the wheel axle - Remove the wheel axis complete with gear.
Page 113 X8 125-200 Engine Removing the wheel axle bearings Hold up the hub cover and take out the bearing. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide With the appropriate tools, remove the oil seal as shown in the figure.
Page 114 X8 125-200 Engine Removing the driven pulley shaft bearing When removing the driven pulley shaft, the corre- sponding bearing and oil seal, remove the trans- mission cover and the clutch group as explained above. - Extract the driven pulley shaft from its bearing.
Page 115 X8 125-200 Engine Refitting the wheel axle bearing Support the hub cover on a wooden surface. - Heat the cover crankcase with special heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
Page 116 X8 125-200 Engine Refitting the hub cover bearings In order to fit the hub box bearings, the engine crankcase and the cover must be heated with the special heat gun. - The three 15-mm bearings must be fitted using the appropriate tools: - The 42-mm side of the adapter must be turned towards the bearing.
Page 117 X8 125-200 Engine Refitting the ub cover - Fit a new gasket together with the centring dowels. - Seal the gasket of the breather pipe using black silicone sealant. - Fit the gearbox cover, making sure the breather pipe is in the correct position.
Page 118: Removing The Stator
X8 125-200 Engine Flywheel cover Removing the hub cover - Remove the two clamps, the two couplings and empty the cooling system. - Remove the 4 retainers and the flywheel cover Removing the stator - Remove the electric terminal of the minimum oil pressure switch.
Page 119 X8 125-200 Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. - Place the cable harness as shown in the figure. - Stator screws and Pick-Up N.B.
Page 120 X8 125-200 Engine Removing the flywheel magneto - Lock the rotation of the Flywheel with the calliper spanner tool. - Remove the nut. - Take out the flywheel. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS N.B.
Page 121 X8 125-200 Engine Flywheel nut 54 ÷ 60 Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate - Fit the starter on the crankcase and lock the 2 screws to the prescribed torque. Locking torques (N*m) Starter motor screws 11 ÷...
Page 122 X8 125-200 Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: transmission cover, drive pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separa- tion washer.
Page 123 X8 125-200 Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.
Page 124 X8 125-200 Engine Removing the cam shaft - Remove the 2 screws and the camshaft retainer shown in the diagram. - Remove the camshaft. - Remove the pins and the rocking levers from the flywheel side holes. N.B. IN NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKING LEVER PINS AND FIXING BRACK- ET.
Page 125: Removing The Cylinder Head
X8 125-200 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket.
Page 126 X8 125-200 Engine TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. ENG - 126...
Page 127: Inspecting The Small End
X8 125-200 Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Page 128 X8 125-200 Engine Inspecting the wrist pin - Check the pin outside diameter. - Calculate the coupling clearance between pin and connecting rod end. - Measure the capacity diameter on the piston. - Calculate the coupling clearance between pin and piston.
Page 129 X8 125-200 Engine MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON. Characteristic Piston pin diameter: Standard diameter: 200 - 250 cc 68,990 ÷ 69,018 Pin diameter Standard diameter: 125 cc 56.997 ÷ 57.025 Piston pin diameter: Piston 200 - 250 68,933 ÷...
Page 130: Inspecting The Piston
X8 125-200 Engine Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
Page 131: Removing The Piston
X8 125-200 Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin stop ring onto the appropriate tool. - With opening in the position indicated on the tool...
Page 132 X8 125-200 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, with- out any base gasket. - Assemble a dial gauge on the specific tool Support to check piston position 020428Y - Set the dial gauge to zero placing the tool on a contrasting surface.
Page 133 X8 125-200 Engine Refitting the piston rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston.
Page 134: Inspecting The Cylinder Head
X8 125-200 Engine Inspecting the cylinder head - Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocking lever pin capacities exhibit no wear.
Page 135 X8 125-200 Engine Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn. - If you detect wear, replace the parts or, if the chain, sprocket wheel and pulley are worn, replace the whole unit.
Page 136 X8 125-200 Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
Page 137 X8 125-200 Engine CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COM- POUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
Page 138 X8 125-200 Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.
Page 139 X8 125-200 Engine Inspecting the cam shaft - Inspect the camshaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the camshaft retaining plate and its associated groove on the camshaft.
Page 140 X8 125-200 Engine Camshaft check: Maximum admissible axial clearance 0.42 mm Camshaft check: Standard axial clearance: 0.11 - 0.41 mm Camshaft check: Standard height Exhaust: 29.209 mm Camshaft check: Standard height Inlet: 30.285 mm Camshaft check: Minimum admissible diame- Bearing B diameter: 19.950 mm Camshaft check: Minimum admissible diame- Bearing A Ø: 36.94 mm...
Page 141 X8 125-200 Engine Fit the pins and rocking levers. - Lubricate the two rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers.
Page 142 X8 125-200 Engine Assemble the limiting bell using the counterweight fixing screw as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Limiting bell screw 11 ÷ 15 Nm Set the tensioner cursor to the rest position.
Page 143 X8 125-200 Engine Name Torque in Nm Slider screw 10 ÷ 14 Nm - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head.
Page 144 X8 125-200 Engine Refitting the rocker-arms cover - Refit the cylinder head cover and tighten the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
Page 145 X8 125-200 Engine - Remove the two retainers indicated in the figure and the starter motor. Before opening the engine crankcase, it is advis- able to check axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge.
Page 146 X8 125-200 Engine Fitting clearance Connecting rod axial clearance 0.20 - 0.50 Check the radial clearance on the connecting rod. Standard clearance: 0.036 ÷ 0.054 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
Page 147 X8 125-200 Engine Check the diameters of both the driving shaft ends according to the axes and planes shown in the fig- ure. Half-shafts are classified into two categories, Cat. 1 and Cat. 2. The table is shown below. Characteristic Standard diameter (125 - 200) Cat.
Page 148 X8 125-200 Engine To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
Page 149 X8 125-200 Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take particular care when handling the oil pump com- partment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the trans- mission side (see diagram).
Page 150 X8 125-200 Engine THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG- GING IMPAIRS THE HEAD LUBRICATION AND THE TIM- ING MECHANISMS.
Page 151 X8 125-200 Engine - The bushing housings in the crankcase are avail- able in two categories, Cat. 1 and Cat. 2, as are the crankshafts. - The main bushings are available in three thick- ness categories, identified by colour markings, as shown in the table below.
Page 152 X8 125-200 Engine LIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. N.B. CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS (BLUE) Characteristic Standard driving depth 1.35 ÷ 1.6 Diameter of crankcase without bushing 32.953 ÷...
Page 153 X8 125-200 Engine ENG - 153...
Page 154: Oil Pressure Check
X8 125-200 Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure...
Page 155 X8 125-200 Engine Crankshaft oil seals Refitting - Fit the internal bulkhead by locking the two screws to the prescribed torque. - Fit the oil filter fitting and tighten it to the specified torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, to- gether with the locating dowels.
Page 156 X8 125-200 Engine Oil pump - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
Page 157 X8 125-200 Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defective parts.
Page 158 X8 125-200 Engine ing lubrication of the crankshaft and connect- ing rod Locking torques (N*m) Oil sump screws 10 ÷ 14 SAS valve Inspecting the one-way valve - Remove the SAS valve. - Provisionally assemble the rubber coupling of the SAS valve outlet to ensure tightness.
Page 159 X8 125-200 Engine Inspecting the cut-off - Remove the SAS valve. - Connect the MITYVAC pump in low-pressure mode (VACUUM) to the CUT-OFF valve vacuum intake. - Apply a vacuum value higher than 0.5 BAR. - Check that this value is kept all the time.
Page 160: Fuel Supply
X8 125-200 Engine Fuel supply - To clean the filtering element proceed as follows: remove the 4 filter cover fixing screws indicated in the figure; remove the cover and take out the pa- per filtering element, clean with compressed air and refit.
Page 161 X8 125-200 Engine - Remove the protection, the bracket and the start- er acting on the screw shown in the figure. - Remove the 2 screws and the starter support with the gasket. - Remove the clamp and cover with the airing filter of the diaphragm chamber.
Page 162 X8 125-200 Engine - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure.
Page 163 X8 125-200 Engine - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
Page 164 X8 125-200 Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 164...
Page 165 X8 125-200 Engine - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
Page 166 X8 125-200 Engine Walbro To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connexion, the clamps anchoring the carburettor to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, and the intake fitting.
Page 167 X8 125-200 Engine Remove the 4 fixing screws indicated in the figure and the vacuum chamber cover. N.B. DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY. Remove the vacuum valve together with the dia- phragm.
Page 168 X8 125-200 Engine Unscrew the bayonet joint 1/8 of a turn, remove it, take out the spring and vacuum valve plunger Remove the 4 screws shown in the figure. Remove the tank with the intake pump, its control and gasket.
Page 169 X8 125-200 Engine Remove the acceleration pump piston with the ring nut, the hood, the O-Ring and the spring from the tank as shown in the figure. Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side.
Page 170 X8 125-200 Engine Remove the cover of the duct from the carburettor to the starter nozzle as shown in the figure. -Remove the maximum nozzle. -Remove diffuser. Remove the sprayer. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY.
Page 171 X8 125-200 Engine Remove the minimum flow screw with the O-ring, the washer and the spring. -Remove the 2 fixing screws, the cover, the spring, and the cut-off device diaphragm. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,...
Page 172 X8 125-200 Engine Kehin - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
Page 173 X8 125-200 Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear.
Page 174 X8 125-200 Engine - Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean.
Page 175 X8 125-200 Engine - The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position. Walbro - Before refitting, wash the carburettor body accu- rately with petrol and compressed air.
Page 176 X8 125-200 Engine - For the starter circuit, blow the connection pipe properly with the jet.This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly. N.B. THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE.
Page 177 X8 125-200 Engine Level check Kehin - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
Page 178 X8 125-200 Engine - Remove the drainage screw from the tank, wash and blow the tank properly and make sure the ac- celeration pump intake and supply valve are clean. - Being the valves unidirectional, blow them care- fully with compressed air, at the inner side of the tank for the intake valve and at the pump piston housing for the supply valve.
Page 179 X8 125-200 Engine - Prepare the carburettor for adjustment by rotating the screw 3 turns from the close position. - Check that the rocking lever control of the accel- erating pump does not show abnormal wear. - Check that the end of stroke screw of the rocking lever protrudes 3.2 mm.
Page 180 X8 125-200 Engine N.B. THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION. - Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover.
Page 181 X8 125-200 Engine - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Walbro - Check that the pin does not show signs of wear and that the lock is in the 3rd of the 3 notches.
Page 182 X8 125-200 Engine - Check that the diaphragm is not worn or has hardened. If it does, replace it. - Refit the tapered pin on the vacuum valve. - Make sure the spring is in the correct position on the plunger and inserted in its housing.
Page 183 X8 125-200 Engine Inspecting the automatic choke device - Check that the piston of the automatic starter is not deformed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the sealing gasket of the piston is not deformed.
Page 184 X8 125-200 Engine 5 min Electric characteristic Check the automatic starter: Resistance around 30 Ω Kehin - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support.
Page 185 X8 125-200 Engine TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNEC- TED TO THE STARTER. Characteristic Check the automatic starter: Kehin: Protrusion value XX ÷ XX mm at approx. 20°C...
Page 186 X8 125-200 Engine Characteristic Check the auto starter: Protrusion Value for Walbro 12.5 ÷ 13 mm at approx. 20°C Check the automatic starter: Walbro maximum protrusion 18.5 ÷ 19 mm Check the automatic starter: Walbro max. time 5 min Electric characteristic Walbro Resistance approx.
Page 187 X8 125-200 Engine loosened the CO value rises (rich mix). Tightening the screw decreases the CO (lean mix). - If the adjustment of the flow screw causes a rpm increase readjust the revs again and if necessary, the flow screw to reach stable values.
Page 188 X8 125-200 Engine CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000 Characteristic Idle adjustment: Pipe sizes Ø 40 mm Idle adjustment: length 500 ÷- 600 mm ENG - 188...
Page 189 INDEX OF TOPICS SUSP USPENSIONS...
Page 190: Removing The Front Wheel
X8 125-200 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel • Remove the front brake calliper after undoing the screws fixing it to the leg. • Loosen the wheel axle locking nut.
Page 191 X8 125-200 Suspensions 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020412Y 15 mm guide - Heat the bearing seat on the side the brake disc with the heat gun. - Insert the bearing using the punch consisting of adaptor handle, 42x47 mm adaptor and 15 mm guide, and drive it up to the stop.
Page 192 X8 125-200 Suspensions - Heat the bearing seat on the odometer drive side with the heat gun. - Insert the two bearings using the punch consist- ing of adaptor handle, 32x35 mm adaptor and 15 mm guide, and drive it up to the stop.
Page 193 X8 125-200 Suspensions Wheel axle nut Safety screw on fork leg 45 ÷ 50 6 ÷ 7 Handlebar Removal • Remove the 3 handlebar covers as ex- plained in the «Bodywork» Chapter. • Remove the handlebar wiring fixing clips and disconnect the electric con- nectors from the brake levers.
Page 194: Front Fork
X8 125-200 Suspensions Front fork Removal - Remove the front wheel. - Remove the handlebar and tip it onto the shield back plate being careful not to damage the plate. - Using the appropriate tool, loosen and remove the upper ring nut, the space washer, the counter ring nut and the spacer ring.
Page 195 X8 125-200 Suspensions - Remove the first spring featuring 15 turns. - Remove the spring support plate. - Remove the second spring featuring 21 turns. - Drain the oil. - Separate the stem from the leg by removing the screws with copper washer shown in the figure. To prevent the rotation of the pumping insert a 12 mm hexagonal wrench for internal parts in the stem.
Page 196 X8 125-200 Suspensions Check there are no signs of wear or seizing up between the stem and the leg. Otherwise, replace the damaged parts. Characteristic Maximum leg diameter 35.10 mm Minimum stem diameter 34.90 mm Check that the oil holes on the pumping element are not clogged.
Page 197 X8 125-200 Suspensions - Insert the contrast spring into the pumping mem- ber. - Insert the pumping element inside the stem. - Insert the pumping element guide bushing at the lower stem end. - Insert the stem in the leg being careful not to let the stem guide bushing come out.
Page 198 X8 125-200 Suspensions - Loosen the fork clamp screws and ensure the stem closure cap is fitted properly on the clamp. - Tighten the clamp screws to the prescribed tor- que. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm Adaptor Locking torques (N*m)
Page 199 X8 125-200 Suspensions - Refit the three handlebar covers as described in the «Bodywork» Chapter. - Install the front wheel. - Refit the brake calliper on the fork leg. Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m)
Page 200 X8 125-200 Suspensions Removal Remove upper bearing with an appropriate tool. N.B. USE THE APPROPRIATE TOOL AGAIN TO REMOVE THE LOWER HOUSING OF THE STEERING LOWER BEARING Specific tooling 020004Y Punch for removing fifth wheels from headstock SUSP - 200...
Page 201 X8 125-200 Suspensions Refitting Insert the lower and upper bearing on the chassis using an appropriate tool. N.B. ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION OF AN ADEQUATE DIAME- TER. Specific tooling 001330Y Tool for fitting steering seats...
Page 202: Removing The Rear Wheel
X8 125-200 Suspensions Removing the rear wheel Removal - Unscrew the four fixing screws and remove the muffler and the relevant bracket; - Unscrew the central retaining nut. Reassembly Carry out the previous operations in reverse order. Locking torques (N*m)
Page 203: Shock Absorbers
X8 125-200 Suspensions - Loosen the nut on the inside of the frame from the left-hand side (see figure) and remove the rel- evant spindle; - Remove the swinging arm. Shock absorbers Removal Proceed as follows: - Undo the screw fixing the shock absorber spring unit to the engine (A) on one side and the corre- sponding support (B) on the other;...
Page 204 X8 125-200 Suspensions - Carry out the operations described above in re- verse order, then insert the sealing rings into their seats. CAUTION Lubricate the following parts with grease: spring coupling pins, bushings on stand fixing bracket. Recommended products AGIP GREASE PV2 Grease for control levers...
Page 205 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 206: Rear Brake Calliper
X8 125-200 Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal Proceed as follows: - remove the exhaust pipe; - loosen fitting and detach brake lines, without spilling any brake fluid on the tyre;...
Page 207 X8 125-200 Braking system Removal Proceed as follows: - place a suitable container, then disconnect the oil pipe from the calliper; - Remove the two screws (indicated in the figure) fixing the calliper to the support and remove the calliper.
Page 208 X8 125-200 Braking system and then the pads, fixing them with the corre- sponding screws (1); 5) place the calliper on the disc and lock it to the strut by tightening the fixing screws; 6) fix the pipe joint on the calliper at the prescribed torque.
Page 209: Front Brake Disc
X8 125-200 Braking system Front brake disc Removal Remove the wheel and check that the axial devi- ation of the braking surface is within in the recom- mended values: - If this is not the case, replace the disc and repeat the test.
Page 210: Front Brake Pads
X8 125-200 Braking system Disc Inspection - Remove the front wheel - Use a micrometer to check the disc thickness as shown in the photograph - Repeat the measurement in at least 6 points on the disk - Remove the front brake calliper...
Page 211 X8 125-200 Braking system Rear brake pads Removal Proceed as follows: - remove the silencer. - loosen the two screws shown in the figure. - remove the lock ring and the pin. - extract the two pads from the bottom.
Page 212 X8 125-200 Braking system DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE DISC. Specific tooling 020329Y MityVac vacuum-operated pump Locking torques (N*m) Oil bleed screw 8 ÷ 12 Front brake pump Removal 1) remove the front and rear handlebar covers;...
Page 213 X8 125-200 Braking system 6. Piston 7. Gasket 8. Spring 9. Tank CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED. BRAK SYS - 213...
Page 214 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 215 X8 125-200 Cooling system Circuit diagram Water pump - overhaul Check components COOL SYS - 215...
Page 216 X8 125-200 Cooling system - Check that the rotor does not show abnormal wear or dents; - Check that the rotor shaft is not rusty; - Check that there is no rust on the bearing seats or the ceramic seal;...
Page 217 X8 125-200 Cooling system ALWAYS USE NEW CERAMIC RING AND GASKETS. AS- SEMBLING THE CERAMIC SEALING RING IN A MANNER OTHER THAN MANUALLY MAY DAMAGE THE RING. N.B. Centre the punch well on the rotor. Push the shaft in and check that the wheel flywheel cover is level.
Page 218 X8 125-200 Cooling system such cases we recommend cleaning the casing in order to be able to check again for leaks after a distance of more than 1500 km. If leaks continue or in the event of real losses, the ceramic seal should be replaced.
Page 219 X8 125-200 Cooling system Thermostat Removal - Loosen the two screws indicated in the figure and remove the thermostat cover. - Remove the thermostat with its gasket. COOL SYS - 219...
Page 220 X8 125-200 Cooling system Check - Visually check that the thermostat is not dam- aged. - Prepare a metal container with approx. 1 litre of water. - Immerse the thermostat, keeping it in the centre of the container. - Immerse the multimeter temperature probe, near the thermostat.
Page 221 X8 125-200 Cooling system Check the temperature when the thermostat starts to open: Opening start temperature: 69.5 ÷72.5°C Heat up until the thermostat is completely open. Opening travel: 3.5 mm at 80°C CAUTION - To execute the test correctly, make sure neither the thermostat nor the thermometer touches the container.
Page 222 INDEX OF TOPICS CHAS HASSIS...
Page 223 X8 125-200 Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat • Raise the saddle • Undo the three screws fixing the plate to the central cover and remove the saddle.
Page 224 X8 125-200 Chassis Driving mirrors • Remove the joint rubber of the mirror housing from the bottom; • Unscrew the two screws, then remove the covering from the support arm; • Remove the 2 lower retainers fixings the mirror to the frame.
Page 225 X8 125-200 Chassis Front handlebar cover • Undo the three clamping screws of the upper handlebar cover and pull it up- wards. • Undo screw «B», then remove cover «A». • Undo the two clamping screws at the bottom. Headlight assy.
Page 226 X8 125-200 Chassis See also Flyscreen Frame central cover • • Remove the saddle • - Remove the shield back plate • - Remove the side panels • Undo the two rear clamping screws • Detach the covering caps of the front...
Page 227 X8 125-200 Chassis Legshield • Remove the front headlight • Remove the upper three fixings • Remove the eight clamping screws (4 each side) on the shield back plate. • Remove the eight clamping screws (four per side) for fixing the shield with the radiator grille and the spoiler.
Page 228 X8 125-200 Chassis Knee-guard • - Remove the front shield. • Remove the expansion tank from the shield back plate and fix it to the small front frame in such a way that it does not turn over; • Disconnect the clock setting button and electrical socket connection;...
Page 229: License Plate Light
X8 125-200 Chassis Taillight assy. • After accessing the rear glove box, undo two rear light clamping screws «D». • Once you have removed the rear light, remove screw «E» and remove the turn indicator. • Central lights: parking lights;...
Page 230 X8 125-200 Chassis Footrest • - Remove the central cover of the frame. • Undo the four clamping screws of the footboard and remove it. • Undo the four clamping screws on the edge of the footboard and remove the lower cover.
Page 231 X8 125-200 Chassis • Undo screw «E» under the turn indica- tor. • Remove the four screws «F», then re- move the side panel by pulling it back- wards to free the teeth hooking it to the central cover. See also...
Page 232 X8 125-200 Chassis • Undo the clamping screws «A» (two of which are on the knob-type head) and remove the air-box cover. See also Side fairings Helmet bay • - Remove the central cover of the frame. • Remove the three clamping screws of the rear handlebar cover and remove - Open the glove box flap;...
Page 233 X8 125-200 Chassis - Undo the 2 screws located in the front part of the helmet compartment. - Undo the 4 screws (2 per side) on the sides of the helmet compartment. • Raise the helmet compartment as far as possible;...
Page 234 X8 125-200 Chassis Handles and top side fairings • Remove the passenger grab handle by undoing the two upper screws «A» and the two lower screws «B» in the helmet compartment. Flyscreen • Remove the driving mirrors; • Undo the four clamping screws «B»,...
Page 235 X8 125-200 Chassis Analogue instrument panel support • Remove the windscreen; • Undo the two front screws. • Undo the two screws at the side of the handlebar cover and the two on the up- per part of the shield back plate;...
Page 236 INDEX OF TOPICS PRE DE DELIVERY...
Page 237 X8 125-200 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning - Be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting plastic parts - Scratches - Dirt Tightening torques inspection Lock check - Safety locks...
Page 238 X8 125-200 Pre-delivery - Horn - Starter CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Page 239 X8 125-200 Pre-delivery - Abnormal noise Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Page 240 INDEX OF TOPICS TIME...
Page 241 X8 125-200 Time This section is devoted to the time necessary to carry out repairs. The description, code and predetermined time for each operation are specified. Engine NGINE Code Action Duration 001001 Engine - Replacement 001136 Exhaust emissions - Adjustment...
Page 242 X8 125-200 Time Crankcase RANKCASE Code Action Duration 001153 Crankcase gasket - Replacement 001133 Engine crankcase - Replacement TIME - 242...
Page 243 X8 125-200 Time Crankshaft RANKSHAFT Code Action Duration 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement 001100 Oil seal, clutch side - Replacement TIME - 243...
Page 244 X8 125-200 Time Cylinder assy. YLINDER UNIT ISTON Code Action Duration 001002 Cylinder / Piston - Replacement 001176 Rings / Pin - Replacement TIME - 244...
Page 245 X8 125-200 Time Cylinder head assy. YLINDER HEAD ASSEMBLY Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 007009 Cylinder / pump rubber coupling - Re- placement 001057 Thermostat - Replacement...
Page 246 X8 125-200 Time Rocker arms support assy. OCKING LEVER UNIT Code Action Duration 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement 001169 Decompressor - Replacement TIME - 246...
Page 247: Cylinder Head Cover
X8 125-200 Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment TIME - 247...
Page 248 X8 125-200 Time Chain tensioner HAIN TIGHTENER Code Action Duration 001124 Lubrication by-pass - Replacement 001129 Chain tightener - Replacement TIME - 248...
Page 249: Oil Filter
X8 125-200 Time Oil filter IL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Replacement 001102 Oil mesh filter - Change / Cleaning TIME - 249...
Page 250: Driven Pulley
X8 125-200 Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement TIME - 250...
Page 251 X8 125-200 Time Oil pump OIL PUMP Code Action Duration 001125 Chain guide sliders - Replacement 001051 Distribution belt - chain - Replace- ment 001042 Oil pump - Service 001112 Oil pump - Replacement 001122 Oil pump chain 001172 Chain cover flap - Replacement...
Page 252: Final Reduction
X8 125-200 Time Final gear assy. FINAL REDUCTION Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Re- placement 004125 Rear wheel axle - Replacement TIME - 252...
Page 253 X8 125-200 Time Driving pulley RIVING PULLEY REPAIR TIME Code Action Duration 001086 Driving half-pulley - Replacement 001011 rear-view belt - Replacement 001006 rear-view pulley - Service 001066 driving pulley - Replacement 001177 Variator rollers / shoes - Replace- ment...
Page 254 X8 125-200 Time Transmission cover RANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001135 Transmission cover bearing - Re- placement 001170 Air deflector - Replacement TIME - 254...
Page 255: Starter Motor
X8 125-200 Time Starter motor TARTER MOTOR Code Action Duration 001020 Starter motor - Replacement 001017 Starter sprocket wheel - Replace- ment 001141 Anti-flapping roller - belt - Replace- ment 001175 Anti-vibration roller - Service 005045 Starter motor cable assembly - Re-...
Page 256: Flywheel Magneto
X8 125-200 Time Flywheel magneto AGNETO FLYWHEEL AND SECONDARY AIR Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump / Pump rotor - Replace- ment 001058 Flywheel - Replacement 001173 Rotor - Replacement 001067 Stator - Replacement 001161...
Page 257 X8 125-200 Time Belt cooling duct ELT COOLING TUBE Code Action Duration 001131 Transmission air inlet - Replacement 001132 Transmission air inlet tube - Replace- ment TIME - 257...
Page 258 X8 125-200 Time Carburettor ARBURETTOR Code Action Duration 001013 Intake manifold - Replacement 001081 Automatic choke - Replacement 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replace- ment 003058 Carburettor - Adjustment TIME - 258...
Page 259 X8 125-200 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 259...
Page 260 X8 125-200 Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Re- placement TIME - 260...
Page 261 X8 125-200 Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004146 Front frame - Replacement 004147 Footrest support bracket, one side - Replacement 004148 Footrest support bracket, both sides - Replacement 004116 Rear frame - Replacement TIME - 261...
Page 262 X8 125-200 Time Centre-stand TAND REPAIR TIME Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 001053 Stand bolt - Replacement TIME - 262...
Page 263 X8 125-200 Time Legshield spoiler RONT SHIELD Code Action Duration 004101 Windshield - Replacement 004066 Rear-view mirror - Replacement 004020 Headlight frame - Replacement 004064 Legshield - Replacement TIME - 263...
Page 264 X8 125-200 Time Side fairings IDE COVERS Code Action Duration 004068 One passenger grab handle - Re- placement 004085 Fairing (1) - Replacement 004012 Rear side panels - Replacement 004053 Spoiler - Replacement 004036 Frame cover - Replacement 004075 Front mat - Replacement...
Page 265 X8 125-200 Time Rear cover HIELD BACK PLATE Code Action Duration 004065 Shield back plate - Replacement 004156 Glove box flap and/or support - Re- placement 004145 Glove box - Replacement 007024 Expansion tank cap - Replacement 004142 electric socket - Replacement...
Page 266 X8 125-200 Time Central cover ENTRAL COVER Code Action Duration 002082 Fuel tank cap opening drive - Re- placement 004135 Fuel tank lid - Replacement 004011 Frame central cover - Replacement TIME - 266...
Page 267 X8 125-200 Time Mudguard UDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004167 Grille / radiator cover - Replacement 004009 Rear mudguard - Replacement TIME - 267...
Page 268: Fuel Tank
X8 125-200 Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement 005010 Tank float - Replacement TIME - 268...
Page 269 X8 125-200 Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Replacement TIME - 269...
Page 270 X8 125-200 Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar cover - Replace- ment 004019 Rear handlebar cover - Replacement 004099 Odometer housing - Replacement 004026 Handlebar cover - Replacement 003043 Steering tube dust guard - Replace-...
Page 271 X8 125-200 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002063 Throttle control transmission - Re- placement 003061 Accelerator transmission - Adjust- ment 003059 Counterweight - Replacement 005017 Stop switch - Replacement 004162 Mirror support and/or brake pump fit-...
Page 272 X8 125-200 Time Swing-arm WINGING ARM Code Action Duration 003081 Swinging arm supporting flange - Re- placement 004058 Silent-block - Replacement 001072 Engine/frame swinging arm attach- ment - Replacement TIME - 272...
Page 273 X8 125-200 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 273...
Page 274 X8 125-200 Time Instrument panel NSTRUMENT PANEL COMMANDS ON HANDLEBAR Code Action Duration 005078 Odometer glass - Replacement 005014 Odometer - Replacement 005006 Light switch or turn indicators - Re- placement 005039 Light switch - Replacement 005040 Horn button - Replacement...
Page 275 X8 125-200 Time Locks OCKS LOCK TRANSMISSIONS Code Action Duration 005016 Key switch - Replacement 004010 Anti-theft lock - Replacement 005099 Electric saddle opening activator - Replacement 005133 Electric glove box activator - Re- placement 004054 Saddle lock catch - Replacement...
Page 276 X8 125-200 Time REAR LIGHTS Code Action Duration 005005 Taillight - Replacement 005048 number plate holder - Replacement 005031 number plate light bulb - Replace- ment 005032 number plate light glass - Replace- ment 005022 Rear turning indicators - Replace-...
Page 277 X8 125-200 Time NDICATOR LIGHTS Code Action Duration 005002 Front light - replacement 005008 Headlight bulbs - Replacement 005044 Front lights cable unit- Replacement 005012 Front turning indicators - Replace- ment 005067 Front turning indicator bulb - replace- ment TIME - 277...
Page 278: Front Wheel
X8 125-200 Time Front wheel RONT WHEEL Code Action Duration 002011 Odometer movement sensor - Re- placement 002041 Front brake disc - Replacement 003037 Front wheel rim- Replacement 003038 Front wheel axle - Replacement 003040 Front wheel bearings - Replacement...
Page 279 X8 125-200 Time Rear wheel EAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001071 Rear wheel rim - Replacement 004126 Rear wheel tyre - Replacement 002070 Rear brake disc - Replacement 003077 muffler/rear shock absorber support arm - Service...
Page 280: Fuel Pump
X8 125-200 Time Fuel pump UEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004072 Fuel filter - Replacement 004086 Petrol pump depression tube - Re- placement 004087 Filter / petrol pump pipe - Replace- ment 004137 Pump / carburettor hose - Replace-...
Page 281 X8 125-200 Time Electric devices LECTRICAL DEVICES Code Action Duration 005001 Electrical system - Replacement 005114 Electrical system - Service 005003 Horn - Replacement 001069 HV coil - replace 001023 Control unit - Replacement 005035 Headlight remote control - Replace-...
Page 282 X8 125-200 Time Helmet bay ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 005033 Glove-box light switch - Replace- ment 004036 Frame cover - Replacement 004082 Trunk gasket - Replacement 005026 Helmet compartment light - Replace- ment 005027...
Page 283 X8 125-200 Time Rear side fairings EAR COVERS Code Action Duration 005048 number plate holder - Replacement 005033 Glove-box light switch - Replace- ment 004081 Top box lid - Replacement 004159 Plates / Stickers - Replacement 004174 Top box leverage...
Page 284 X8 125-200 Time Front suspension RONT SUSPENSION Code Action Duration 003051 Complete fork - Replacement 003010 Front suspension - Service 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003002 Steering thrust washer - Replace-...
Page 285: Cooling System
X8 125-200 Time Cooling system OOLING SYSTEM Code Action Duration 007002 Water radiator - replacement 007016 Fan with support - Replacement 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007019 Connection water pump pipe / return pipe - Replacement...
Page 286: Braking System
X8 125-200 Time Braking system RAKE SYSTEM Code Action Duration 002007 Front brake pads - Replacement 002039 Front brake calliper - Replacement 002021 Front brake piping - Replacement 002002 Rear brake pads - Replacement 002048 Rear brake calliper - Replacement...
Page 287 Air filter: 46, 231 Battery: 60, 67, 82, 83 Brake: 206, 209–212 Carburettor: 10, 40, 160, 171, 258 Engine oil: 46 Engine stop: Fuel: 59, 160, 268, 280 Fuses: 80 Headlight: 49, 225, 227 Hub oil: 44 Identification: 7 Instrument panel: 224, 235, 274 Maintenance: 7, 36 Mirrors: 224, 234 Oil filter: 249...

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