PIAGGIO XEVO 125 Euro 3 Service Station Manual
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PIAGGIO XEVO 125 Euro 3 Service Station Manual

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SERVICE STATION MANUAL
664711 IT-664712 EN-664713 FR-664714 DE-664715
ES-664716 PT-664717 OL-664718 EL
XEVO 125 Euro 3

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  • Page 1 SERVICE STATION MANUAL 664711 IT-664712 EN-664713 FR-664714 DE-664715 ES-664716 PT-664717 OL-664718 EL XEVO 125 Euro 3...
  • Page 2 Not all versions shown in this publication are available in all Countries. The availability of individual versions should be confirmed with the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 XEVO 125 Euro 3 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.
  • 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 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: 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 9 XEVO 125 Euro 3 Characteristics Vehicle identification Chassis prefix: M36601 Engine prefix: M368M Dimensions and mass CHAR - 3...
  • Page 10 XEVO 125 Euro 3 Characteristics WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 161 ± 5 kg Maximum weight allowed 360 kg Height 1370 mm Width (handlebar) 760 mm Wheelbase 1490 mm Overall length 2070 mm Engine ENGINE Specification Desc./Quantity Type...
  • Page 11 XEVO 125 Euro 3 Characteristics Capacities CAPACITY Specification Desc./Quantity Engine oil 1.1 l Transmission oil 150 cm³ Cooling system fluid ~ 2 l Fuel tank (reserve) ~ 12 l (~ 2.5 l) Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Start-up Electric...

  • Page 12: Tightening Torques

    XEVO 125 Euro 3 Characteristics Specification Desc./Quantity Front rim 14'' x 3.50 Rear rim 12'' x 3.00 Front tyre Tubeless 120/70 - 14'' 55P Rear tyre Tubeless 130/70 12'' 62P Front tyre pressure (with passenger) 2.3 bar (-) Rear tyre pressure (with passenger) 2.6 bar (-)
  • Page 13 XEVO 125 Euro 3 Characteristics FRONT BRAKE Name Torque in Nm Oil bleed screw 8÷12 Disc tightening screw (°) 5 ÷ 6.5 Brake fluid pipe-calliper fitting 20 ÷ 25 Brake fluid pump - hose fitting 16 ÷ 20 Tightening screw for calliper support to the fork 20 ÷...

  • Page 14: Table Of Contents

    XEVO 125 Euro 3 Characteristics CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead (transmis- 4 ÷ 6 sion-side half shaft) screws Engine-crankcase coupling screws 11 ÷ 13 Starter motor screws 11 ÷ 13 Crankcase timing system cover screws (°) 3.5 ÷...
  • Page 15 XEVO 125 Euro 3 Characteristics Name Torque in Nm Oil sump screws 10 ÷ 14 Minimum oil pressure sensor 12 ÷ 14 Overhaul data Assembly clearances Cylinder - piston assy. ENGINE COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 ÷...
  • Page 16 XEVO 125 Euro 3 Characteristics Name Initials Cylinder Piston Play on fitting Piston 2nd Over- 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059 size Piston 2nd Over- 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059 size Cylinder 3rd Over- 57.597 ÷...
  • Page 17 XEVO 125 Euro 3 Characteristics Fitting clearances Crankshaft/crankcase axial clearance (H): 0.15 ÷ 0.40 mm (when cold) CHAR - 11...
  • Page 18 XEVO 125 Euro 3 Characteristics AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05 D = 0.20 - 0.50 mission side Flywheel-side half- 16.6 +0-0.05 D = 0.20 - 0.50 shaft Connecting rod 18 -0.10 -0.15...
  • Page 19 XEVO 125 Euro 3 Characteristics (1.1) ODELS WITH FIBRE HEAD GASKET Name Measure A Thickness Shimming - Cylinder 67 - Head 2.20 ÷ 2.45 0.4 ± 0.05 gasket 1.1 - Base gasket 0.4 Shimming - Cylinder 67 - Head 2.45 ÷ 2.70 0.6 ±...
  • Page 20 XEVO 125 Euro 3 Characteristics Oversizes OVERSIZES 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 57.2 x 1...
  • Page 21 XEVO 125 Euro 3 Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifi- cations AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-...
  • Page 22 XEVO 125 Euro 3 Characteristics CHAR - 16...
  • Page 23 INDEX OF TOPICS TOOL OOLING...
  • Page 24 XEVO 125 Euro 3 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 bear- ings TOOL - 2...
  • Page 25 XEVO 125 Euro 3 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 - 3...
  • Page 26 XEVO 125 Euro 3 Tooling Stores code Description 020363Y 20 mm guide 020459Y Punch for fitting bearing on steer- ing tube 020458Y Puller for lower bearing on steer- ing tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Oil pressure control fitting...
  • Page 27 XEVO 125 Euro 3 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 seal rings 020360Y Adaptor 52 x 55 mm...
  • Page 28 XEVO 125 Euro 3 Tooling Stores code Description 020364Y 25-mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020444Y Tool for fitting/ removing the driv- en pulley clutch 020330Y Stroboscopic light for timing con- trol 001467Y035 Belle for OD 47-mm bearings...
  • Page 29 XEVO 125 Euro 3 Tooling Stores code Description 020368Y driving pulley lock wrench 020319Y Immobilizer check tester 020287Y Clamp to assemble piston on cyl- inder 020263Y Sheath for driven pulley fitting 020262Y Crankcase splitting strip 020430Y Pin lock fitting tool...
  • Page 30 XEVO 125 Euro 3 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 fitting band TOOL - 8...
  • Page 31 XEVO 125 Euro 3 Tooling Stores code Description 020382Y Valve cotters equipped with part 012 removal tool 020455Y 10-mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum-operated pump 020357Y 32 x 35 mm adaptor TOOL - 9...
  • Page 32 XEVO 125 Euro 3 Tooling Stores code Description 020409Y Multimeter adaptor - Peak volt- age detection 020456Y Ø 24 mm adaptor 020332Y Digital rev counter 020074Y Support base for checking crank- shaft alignment 020055Y Wrench for steering tube ring nut...
  • Page 33 XEVO 125 Euro 3 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 46x55 Wrench 001467Y...
  • Page 34 XEVO 125 Euro 3 Tooling Stores code Description 001467Y013 Pliers to extract ø 15-mm bear- ings 020444Y010 adapter ring TOOL - 12...
  • Page 35 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 36: Maintenance Chart

    XEVO 125 Euro 3 Maintenance Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequen- tially.

  • Page 37: Spark Plug

    XEVO 125 Euro 3 Maintenance Action Engine oil - replacement Hub oil level - check Spark plug/ electrode gap - check Valve clearance - check Air filter - clean Engine oil - change Driving belt - check Sliding blocks / variable speed rollers - check...
  • Page 38 XEVO 125 Euro 3 Maintenance Action Radiator - external cleaning/ check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test...
  • Page 39 XEVO 125 Euro 3 Maintenance 36000 FTER 270' Action Engine oil - replacement Hub oil level - check Air filter - clean Engine oil - change Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Driving belt - replacement...

  • Page 40: Checking The Spark Advance

    XEVO 125 Euro 3 Maintenance Action Tyre pressure and wear - check Vehicle and brake test - road test (*) See instructions in the «Idle speed adjustment» section Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning.
  • Page 41 XEVO 125 Euro 3 Maintenance the advance degrees indicated by the stroboscop- ic light. - Check that the advance degrees corresponds with the rotation speed as indicated in the table. - If failures are found, check the Pick-Up and the control unit power supply (positive-negative), re- place the control unit if necessary.
  • Page 42 XEVO 125 Euro 3 Maintenance SPARK PLUGS OTHER THAN THOSE PRE- SCRIBED MAY SERIOUSLY DAMAGE THE EN- GINE. Characteristic Electrode gap 0.7-0.8 mm Electric characteristic Recommended spark plug CHAMPION RG4HC Locking torques (N*m) Spark plug 12 ÷ 14 Hub oil Check the oil in the rear hub.
  • Page 43 XEVO 125 Euro 3 Maintenance USED OILS CONTAIN SUBSTANCES HARM- FUL TO THE ENVIRONMENT. FOR OIL RE- PLACEMENT, CONTACT AN AUTHORISED SERVICE CENTRE, WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMEN- TALLY FRIENDLY AND LEGAL WAY. CAUTION...
  • Page 44 XEVO 125 Euro 3 Maintenance Air filter Remove cleaner cover after unscrewing the two knob screws «A» and the six screws «B», then re- move the filtering element. - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of com- pressed air.
  • Page 45 XEVO 125 Euro 3 Maintenance Replacement Replace oil and filter as indicated in the scheduled maintenance table. The engine must be emptied by draining the oil through the drainage plug «B» of the mesh pre-filter, flywheel side. furthermore, to facilitate oil drainage, loosen the cap/dipstick «A».
  • Page 46 XEVO 125 Euro 3 Maintenance Check This operation must be carried out with the en- gine cold and following the procedure below: 1) Rest the vehicle on the central stand and on a flat ground. 2) Make sure the adjustment of the rear suspen- sion is set to the minimum preloading position.

  • Page 47: Checking The Ignition Timing

    XEVO 125 Euro 3 Maintenance Checking the ignition timing -Remove the 4 fixing screws and move away from the engine the flywheel cover fitted with the water pump and cooling sleeves. - Rotate the flywheel until the reference matches the crankcase operation end as shown in the figure (TDC).
  • Page 48 XEVO 125 Euro 3 Maintenance Cooling system Adding engine coolant. Check coolant level when the engine is cold as in- dicated in the scheduled maintenance table, fol- lowing the steps below. Place the scooter on its centre stand and on flat ground.

  • Page 49: Headlight Adjustment

    XEVO 125 Euro 3 Maintenance Top-up Proceed as follows: Loosen the screw «B» and lift the plastic cover «A» in order to access the brake fluid reservoir. Loosen the two fixing screws and remove the reservoir cover; top-up with the rec- ommended fluid without exceeding the 'MAX.'...
  • Page 50 9/10 of the distance from the ground to the centre of the vehicle's headlight, and higher than 7/10; 3. If not, adjust the headlight by turning the central screw «A» underneath the Piaggio badge. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS.
  • Page 51 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 52: Rear Wheel Spins At Idle

    XEVO 125 Euro 3 Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty;...
  • Page 53 XEVO 125 Euro 3 Troubleshooting Possible Cause Operation Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clear- ance Engine flooded Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it...
  • Page 54 XEVO 125 Euro 3 Troubleshooting Engine tends to cut-off at full throttle ENGINE STOP FULL THROTTLE Possible Cause Operation Faulty fuel supply Check or replace the pump and the vacuum valve, check the vacuum intake and the pipe sealing Incorrect float level...
  • Page 55 XEVO 125 Euro 3 Troubleshooting High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Float level Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted.
  • Page 56 XEVO 125 Euro 3 Troubleshooting Possible Cause Operation the correct level of fluid in the pumps and replace brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the front brake calliper moves in axis with the disc.
  • Page 57 XEVO 125 Euro 3 Troubleshooting Controls STEERING CONTROLS AND SUSPENSIONS Possible Cause Operation Torque not conforming Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steer- ing even after making the above adjustments,...
  • Page 58 XEVO 125 Euro 3 Troubleshooting TROUBL - 8...
  • Page 59 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 60 XEVO 125 Euro 3 Electrical system 1. Electronic ignition device 2. Immobilizer aerial 3. Magneto flywheel - Pick-up 4. Diagnosis connector 5. Engine stop switch 6. Voltage regulator 7. Main fuses 8. Plug socket 9. Battery 10. Starter motor 11. Start-up remote control switch 12.
  • Page 61 XEVO 125 Euro 3 Electrical system 20. Wiring for antitheft device 21. Hazard button 22. Turn indicator switch 23. Turn indicator control device 24.Helmet compartment light switch 25.Rear case light switch 26. Light switch 27. Helmet compartment internal light 28. Licence plate light bulb 29.
  • Page 62 XEVO 125 Euro 3 Electrical system Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple Conceptual diagrams Ignition 1. Electronic ignition device 2. Immobilizer aerial 5. Engine stop switch 7. Main fuses 9. Battery 49. Key switch 51. Spark plug 52.
  • Page 63 XEVO 125 Euro 3 Electrical system Headlights and automatic starter section 1. Electronic ignition device 5. Engine stop switch 7. Main fuses 9. Battery 13. Secondary fuses 26. Light switch 28. Licence plate light bulb 30. Rear light B. Tail light bulbs 33.
  • Page 64 XEVO 125 Euro 3 Electrical system Battery recharge and starting 1. Electronic ignition device 3. Magneto flywheel - Pick-up 5. Engine stop switch 6. Voltage regulator 7. Main fuses 9. Battery 10. Starter motor 11. Start-up remote control switch 12. Start-up button 13.
  • Page 65 XEVO 125 Euro 3 Electrical system Level indicators and enable signals section 1. Electronic ignition device 2. Immobilizer aerial 5. Engine stop switch 7. Main fuses 9. Battery 13. Secondary fuses 35.Ambient temperature sensor 37. Engine oil pressure sensor 41. Thermistor 42.
  • Page 66 XEVO 125 Euro 3 Electrical system Devices and accessories 1. Electronic ignition device 4. Diagnosis connector 5. Engine stop switch 7. Main fuses 8. Plug socket 9. Battery 13. Secondary fuses 16. Boot opening switch 17. Rear boot actuator 18. Saddle opening actuator 19.Electrical actuators control unit...
  • Page 67 XEVO 125 Euro 3 Electrical system 27. Helmet compartment internal light 29. Rear left turn indicator 31. Rear right turn indicator 32. Front left turn indicator 34. Front right turn indicator 38. Horn 39. Horn button 40. MODE button 42. Instrument panel 45.
  • Page 68 XEVO 125 Euro 3 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», check whether there is battery voltage in the electric control unit.
  • Page 69 XEVO 125 Euro 3 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 70 XEVO 125 Euro 3 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...
  • Page 71 XEVO 125 Euro 3 Electrical system - If the failure persists, it means that the MASTER key and the control unit are not linked; in this case, replace the control unit and then encode the keys. The immobilizer system is efficient when, after switching over to "ON", only a 0.7-second flash is...
  • Page 72 XEVO 125 Euro 3 Electrical system ness and the connections. In case conforming values are measured and the wiring and connections check is OK, try replacing the control unit (without programming) and make sure the failure has been solved by checking sparks are produced in the spark plug; only then program the control unit. If no sparks are produced with the new control unit, proceed as follows.
  • Page 73 XEVO 125 Euro 3 Electrical system - Pick-Up. Disconnect the control unit connector and connect the positive terminal to connector No. 8 and the negative terminal to connector No. 6 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up.
  • Page 74 XEVO 125 Euro 3 Electrical system 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 75 XEVO 125 Euro 3 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 76 XEVO 125 Euro 3 Electrical system check the wiring connections to the key switch and that the 15A fuse works properly. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed; then check whether there is voltage connecting the mul- timeter positive probe to terminal No.
  • Page 77 XEVO 125 Euro 3 Electrical system Lights list LIGHT BULB TABLE Specification Desc./Quantity High-beam light bulb Type: HALOGEN (H7) Power: 12V - 55W Quantity: 1 Low-beam bulb Type: HALOGEN (H1) Power: 12V - 55W Quantity: 1 Front tail light bulb...
  • Page 78 XEVO 125 Euro 3 Electrical system AL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE). BESIDES, IF AFTER REPLACING A FUSE, THE NEW FUSE ALSO BLOWS, THE VEHICLE NEEDS TO BE TAKEN TO AN AUTHORISED SERVICE CENTRE TO IDENTIFY THE CAUSE...
  • Page 79 XEVO 125 Euro 3 Electrical system Specification Desc./Quantity Protected circuits:Battery powered immo- bilizer warning light, digital display Location:Battery compartment on left side of the vehicle Fuse No. 6 Capacity:5 A Protected circuits:Battery powered turn in- dicator control device Location:Battery compartment on left side of the vehicle Fuse No.
  • Page 80 XEVO 125 Euro 3 Electrical system Dashboard A = Immobilizer / anti-theft LED B= Speedometer with twin scale (Km/h and Mph) C = CLOCK switch D = Digital display E = Emergency turn indicator warning light F= SET switch G = Rpm indicator...
  • Page 81 XEVO 125 Euro 3 Electrical system Set the year with the «SET» button. Press the «CLOCK » button again for 4 seconds to exit the adjustment menu. During the reset process, not pressing any buttons for a period longer than 8 seconds ends the proc- ess automatically and the display shows the modi- fied time.
  • Page 82 XEVO 125 Euro 3 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 83 XEVO 125 Euro 3 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 84 XEVO 125 Euro 3 Electrical system FUEL ELECTRIC PUMP CONTROL DEVICE CONNECTOR 1. Live supply (Blue-Red) 2. Not connected 3. Pump Ground (White-Black) 4. Pump supply (Blue-Black) 5. Ground (Black) 6. Engine revs (Purple) VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Blue) 2.
  • Page 85 XEVO 125 Euro 3 Electrical system 12. Not connected ELECTRONIC CONTROL UNIT CONNECTOR 1. Engine stop switch (Sky Blue) 2. Not connected 3. Battery powered (Red) 4. Diagnosis Connector (Purple-White) v5. Live (Orange) 6. Ground (Black) 7. Automatic starter negative (Brown) 8.
  • Page 86 XEVO 125 Euro 3 Electrical system 8. Right turn indicator warning light (White-Blue) 9. High-beam warning light (Purple) 10. Boot open warning light (Red-Yellow) 11. Rpm indicator (Blue) 12. Ambient temperature sensor (White-Yellow) 13. Ambient temperature sensor negative (Yellow- Blue) 14.
  • Page 87 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 88 XEVO 125 Euro 3 Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal • Unscrew the 3 screws fixing the muffler to the engine crankcase and the sup- porting arm;...
  • Page 89 XEVO 125 Euro 3 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 spring and re- move the coolant out pipes;...
  • Page 90 XEVO 125 Euro 3 Engine from vehicle • Disconnect the HV wire from the spark plug; • Disconnect the thermistor electrical connection after removing the rubber cap. • Remove the holding spring and move the petrol feed pipe to carburettor;...
  • Page 91 XEVO 125 Euro 3 Engine from vehicle • Cut the clamp on the transmission crankcase duct; after that, disconnect the pipe connected to the air intake on the chassis. • Disconnect the electric connector link- ing the magneto flywheel to the vehicle cable harness.
  • Page 92 XEVO 125 Euro 3 Engine from vehicle Locking torques (N*m) Engine swinging arm pin nut 33 ÷ 41 Shock ab- sorber lower clamp 33 ÷ 41 Rear brake calliper tightening screws 20 ÷ 25 ENG VE - 6...
  • Page 93 INDEX OF TOPICS NGINE...

  • Page 94: Automatic Transmission

    XEVO 125 Euro 3 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 95 XEVO 125 Euro 3 Engine - To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover.

  • Page 96: Removing The Driven Pulley

    XEVO 125 Euro 3 Engine Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.

  • Page 97: Removing The Clutch

    XEVO 125 Euro 3 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 98 XEVO 125 Euro 3 Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EX-...
  • Page 99 XEVO 125 Euro 3 Engine Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - Replace with a new one if there are. - Remove the retaining ring using two flat blade screwdrivers.
  • Page 100 XEVO 125 Euro 3 Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check that the faying surface with the belt is not abnormally worn.
  • Page 101 XEVO 125 Euro 3 Engine 020424Y Driven pulley roller casing fitting punch Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure.
  • Page 102 XEVO 125 Euro 3 Engine TAKING THE OPERATION WHEN THE BEAR- INGS ARE BEING SERVICED MIGHT BE EAS- IER. Specific tooling 020263Y Sheath for driven pulley fitting Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide;...

  • Page 103: Clutch Unit Nut On Driven Pulley

    XEVO 125 Euro 3 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 104 XEVO 125 Euro 3 Engine Refitting the driven pulley - Reassemble the clutch bell and spacer. Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Driving belt - minimum width: 21.5 mm Driving belt - standard width: 22.5 ±...

  • Page 105: Removing The Driving Pulley

    XEVO 125 Euro 3 Engine Removing the driving pulley - With the appropriate tool, remove the nut with the built-in belleville washer, the drive and the steel washer. - Remove the fixed driving half-pulley. - Remove the steel washer separating from the bushing.
  • Page 106 XEVO 125 Euro 3 Engine Ø 18.9 ÷ 19.1 mm Sliding bushing: Minimum admissible diame- Ø 25.95 mm Movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm roller: Standard Diameter Ø 18.9 ÷ 19.1 mm Sliding bushing: Standard Diameter Ø...

  • Page 107: Drive Pulley Nut

    XEVO 125 Euro 3 Engine - 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 108 XEVO 125 Euro 3 Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque.
  • Page 109 XEVO 125 Euro 3 Engine Removing the wheel axle - Remove the wheel axis complete with gear. - Remove the intermediate gear. Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following.
  • Page 110 XEVO 125 Euro 3 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 111 XEVO 125 Euro 3 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents.
  • Page 112 XEVO 125 Euro 3 Engine - Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal sur- face by means of the appropriate tool used from the 52 mm side.
  • Page 113 XEVO 125 Euro 3 Engine N.B. IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE. N.B. WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.

  • Page 114: Removing The Stator

    XEVO 125 Euro 3 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 115: Stator Assembly Screws (°)

    XEVO 125 Euro 3 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.
  • Page 116 XEVO 125 Euro 3 Engine Removing the flywheel magneto - Lock the rotation of the Flywheel with the calliper spanner. - Remove the nut. - Take out the flywheel. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE...

  • Page 117: Starter Motor Screws

    XEVO 125 Euro 3 Engine Locking torques (N*m) 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, locking the two screws to the prescribed torque.
  • Page 118 XEVO 125 Euro 3 Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the following units: transmission cover, driving pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separation washer.
  • Page 119 XEVO 125 Euro 3 Engine - Remove the internal hex screw and the counter- weight shown in the figure. - Remove the camshaft control pulley with its washer. - Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider.
  • Page 120 XEVO 125 Euro 3 Engine - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes. N.B. IN CASE OF NEED, THE HEAD MAY BE RE- MOVED WITH THE CAMSHAFT, PINS, ROCK- ING LEVERS AND FIXING BRACKET. THE...

  • Page 121: Removing The Cylinder Head

    XEVO 125 Euro 3 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.
  • Page 122 XEVO 125 Euro 3 Engine CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. ENG - 30...

  • Page 123: Inspecting The Small End

    XEVO 125 Euro 3 Engine Inspecting the small end - Measure the internal diameter of the rod small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAME- TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
  • Page 124 XEVO 125 Euro 3 Engine - The cylinder surface roughness should be 0.9 micron. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consump- tion and guarantees optimum performance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.

  • Page 125: Inspecting The Piston

    XEVO 125 Euro 3 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 126: Removing The Piston

    XEVO 125 Euro 3 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 127 XEVO 125 Euro 3 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket. - Assemble a dial gauge on the specific tool. Specific tooling 020428Y Piston position check support - Set the dial gauge to zero placing the tool on a contrasting surface.
  • Page 128 XEVO 125 Euro 3 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 129: Inspecting The Cylinder Head

    XEVO 125 Euro 3 Engine Inspecting the cylinder head - Using a trued bar and feeler 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 rocker pin ca- pacities exhibit no wear.
  • Page 130 XEVO 125 Euro 3 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
  • Page 131 XEVO 125 Euro 3 Engine Inspecting the valve housings - Check the width of the mark on the seat of valve «V». - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
  • Page 132 XEVO 125 Euro 3 Engine lapping compound residues from penetrating be- tween the valve stem and the guide (see figure). CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFUL-...
  • Page 133 XEVO 125 Euro 3 Engine Inspecting the springs and half-cones - Check that the upper and lower supporting wash- ers of the springs, the cotters and the oil seal do not show signs of abnormal wear. - Replace the components when worn.
  • Page 134 XEVO 125 Euro 3 Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head. - Using the special punch, fit the four valve seals. - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
  • Page 135 XEVO 125 Euro 3 Engine - Measure the internal diameter of each rocker arm. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. Characteristic Internal rocker arm diameter: Standard diame- Diameter 12.000 - 12.011 mm...

  • Page 136: Timing Chain Tensioner Support Screw

    XEVO 125 Euro 3 Engine Refitting the head and timing system components - 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 137 XEVO 125 Euro 3 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 138 XEVO 125 Euro 3 Engine Insert the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the cam- shaft control pulley.

  • Page 139: Tappet Cover Screws

    XEVO 125 Euro 3 Engine Set the tensioner cursor to the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the pre- scribed torque. Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque.
  • Page 140 XEVO 125 Euro 3 Engine Refitting the intake manifold - Fit the intake manifold and tighten the three screws. N.B. FOR SPECIAL SCREWS USE COMMERCIALLY AVAILABLE INSERTS AND INSERT HOLDERS. Crankcase - crankshaft Splitting the crankcase halves First remove the following units:...
  • Page 141 XEVO 125 Euro 3 Engine - Remove the eleven crankshaft coupling screws. - Separate the crankcase while keeping the crank- shaft in one of the two halves of the crankcase. - Remove the crankshaft. CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPA- RATING IT.
  • Page 142 XEVO 125 Euro 3 Engine - Check the radial clearance on the connecting rod. -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 143 XEVO 125 Euro 3 Engine Inspecting the crankshaft alignment 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 144 XEVO 125 Euro 3 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 145 XEVO 125 Euro 3 Engine AND CONNECTING ROD LUBRICATION PRES- SURE. N.B. THE HEAD LUBRICATION CHANNEL IS PRO- VIDED 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 CLOGGING IMPAIRS THE HEAD LUBRICA- TION AND THE TIMING MECHANISMS.
  • Page 146 XEVO 125 Euro 3 Engine - There is only one type of main bushing housing hole in the crankcase The standard bushing diameter after driving is var- iable on the basis of a coupling selection. - The bushing housings in the crankcase are avail- able in two categories, Cat.
  • Page 147 XEVO 125 Euro 3 Engine Crankcase Engine half Bushing halves shaft Cat. 1 Cat. 1 Cat. 2 Cat. 2 Cat. 1 Cat. 2 Cat. 2 Cat. 1 N.B. TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.

  • Page 148: Engine Oil Drainage Plug/Mesh Filter

    XEVO 125 Euro 3 Engine - Insert the filter on the engine with the relative cap. Tighten to the prescribed torque. Locking torques (N*m) Internal engine crankcase bulkhead (transmis- sion-side half shaft) screws 4 ÷ 6 Engine- crankcase coupling screws 11 ÷ 13 Oil filter on crankcase fitting 27 ÷...
  • Page 149 XEVO 125 Euro 3 Engine ENG - 57...

  • Page 150: Oil Pressure Check

    XEVO 125 Euro 3 Engine 1. Engine throttle recovery 2. Tappet cover 3. Crankshaft 4. By-pass valve 5. Oil filler 6. Oil level in the sump 7. Oil pump 8. Mesh pre-filter 9. Cartridge filter 10. Minimum pressure switch Oil pressure check - After removing the flywheel cover as described in the "Flywheel"...
  • Page 151 XEVO 125 Euro 3 Engine Oil pressure Minimum pressure admitted at 6000 rpm: 3.2 atm. Locking torques (N*m) Minimum oil pressure sensor 12 ÷ 14 Crankshaft oil seals Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided.
  • Page 152 XEVO 125 Euro 3 Engine - Screw the threaded bar onto the base of the tool and extract the oil guard. Specific tooling 020622Y Transmission-side oil guard punch Refitting - Use a new oil seal upon refitting. - Prepare the new oil seal, lubricating the sealing lip.
  • Page 153 XEVO 125 Euro 3 Engine Specific tooling 020622Y Transmission-side oil guard punch Removal - Remove the cover of the pump control pulley us- ing the two retainers, as shown in the figure. - Block the rotation of the oil pump control pulley inserting a screwdriver through one of its two holes.
  • Page 154 XEVO 125 Euro 3 Engine - Remove the oil pump seal. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN OR- DER TO ENSURE THAT THE INITIAL DIREC- TION OF ROTATION IS MAINTAINED. Inspection - Remove the two screws and the oil pump cover.

  • Page 155: Oil Pump Cover Screws 0.7 ÷

    XEVO 125 Euro 3 Engine Refitting - 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 156 XEVO 125 Euro 3 Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete driving pulley assembly with belt and the sprocket wheel, as described in the "Trans- mission" chapter. - Drain the oil as described previously.
  • Page 157 XEVO 125 Euro 3 Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.
  • Page 158 XEVO 125 Euro 3 Engine - Switch the pump to pressure mode (PRES- SURE). - Operate the pump slowly and check if there is an increase of pressure. A small leakage is consid- ered to be normal. If anomalies are detected, replace the pump.

  • Page 159: Fuel Supply

    XEVO 125 Euro 3 Engine the valve opens and the depression is suddenly set to zero. Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it.
  • Page 160 XEVO 125 Euro 3 Engine Kehin - To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connection, 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 161 XEVO 125 Euro 3 Engine - Remove the clamp and cover with the airing filter of the diaphragm chamber. - Remove the 4 fixing screws shown in the figure and the vacuum chamber cover. WARNING DURING THE REMOVAL OF THE CARBURET- TOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
  • Page 162 XEVO 125 Euro 3 Engine - 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. - Remove the chamber with the accelerating pump, its control and gasket.
  • Page 163 XEVO 125 Euro 3 Engine - 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. N.B.
  • Page 164 XEVO 125 Euro 3 Engine -Remove diffuser. - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
  • Page 165 XEVO 125 Euro 3 Engine -Remove the minimum nozzle. - Remove the minimum flow set screw and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EM- BEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR PRO-...
  • Page 166 XEVO 125 Euro 3 Engine - For maximum circuit, check the air adjustment is correct as shown in the figure. - For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by flow screw, progression holes near the throttle valve.
  • Page 167 XEVO 125 Euro 3 Engine - Wash and blow the minimum nozzle properly and reassemble it. - Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the noz- zle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser.
  • Page 168 XEVO 125 Euro 3 Engine - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air.
  • Page 169 XEVO 125 Euro 3 Engine - Adjust the carburettor by turning the screw twice from the close position. 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 170 XEVO 125 Euro 3 Engine - 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. - Tighten the screws. - Wash and blow dry the filter sponge of the am- bient pressure intake.
  • Page 171 XEVO 125 Euro 3 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. Inspecting the automatic choke device Kehin - Check that the automatic starter piston is not de- formed or rusty.
  • Page 172 XEVO 125 Euro 3 Engine - Check the starter resistance when adjusted to the ambient temperature. With a 12V battery power the automatic starter and check that the piston protrudes as much as possi- ble. - The correct warm up time depends on the ambi- ent temperature.
  • Page 173 XEVO 125 Euro 3 Engine Adjusting the idle - The engine does not require frequent idle speed adjustments, but it is essential to strictly follow cer- tain rules when adjusting the idle speed. - Before adjusting the carburettor make sure to re-...
  • Page 174 XEVO 125 Euro 3 Engine ENG - 82...
  • Page 175 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 176: Removing The Front Wheel

    XEVO 125 Euro 3 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the fixing nut from the wheel axle on the left side of the vehicle.
  • Page 177 XEVO 125 Euro 3 Suspensions - Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch, consisting of adaptor handle, 24-mm adaptor and 15-mm guide, from the oppo- site side to the brake disc to facilitate removing the disc-brake side bearing and the spacer bushing.
  • Page 178 XEVO 125 Euro 3 Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube...
  • Page 179 XEVO 125 Euro 3 Suspensions - Refit the cap and tighten the five fixing screws. Refitting the front wheel - Carry out the operations described in the «re- moval» section but in reverse order. Locking torques (N*m) Wheel axle nut 45 ÷ 50 Wheel axle clamp...

  • Page 180: Front Fork

    XEVO 125 Euro 3 Suspensions IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING, IT IS ONLY NECES- SARY TO TILT THE HANDLEBAR FORWARD ONTO THE FRONT PART OF THE VEHICLE WITHOUT REMOVING THE PARTS FITTED SO AS TO AVOID DAMAGING THE SHAFTS.
  • Page 181 XEVO 125 Euro 3 Suspensions - Loosen the stem support clamp and remove fork leg and stem. - Remove the first spring consisting of 15 windings. - Remove the spring support plate. - Remove the second spring consisting of 21 wind- ings.
  • Page 182 XEVO 125 Euro 3 Suspensions - Keeping the tie rod in vertical position, insert the bell for the Ø 35 mm stems. - Insert the nut in the thread and take out the oil guard Specific tooling 020487Y Fork oil seal extractor...
  • Page 183 XEVO 125 Euro 3 Suspensions - Insert a new oil guard with the special adaptor handle and take it to the stop. - Insert the safety clip. - Insert a new dust guard. - Insert the contrast spring into the pumping mem- ber.
  • Page 184 XEVO 125 Euro 3 Suspensions - Insert the stem into the fork clamp. - Do up the clamp once to allow the stem closure upper cap to be tightened. - Check that the sealing ring on the cap is in good working order, then tighten the cap on the stem to the prescribed torque.
  • Page 185 XEVO 125 Euro 3 Suspensions - Install the handlebars on the steering tube, pay- ing attention to the centring, aligning the recess on the handlebar with that on the steering tube as shown in the figure. - Tighten the handlebar fixing screw on the steer- ing tube to the prescribed torque.
  • Page 186 XEVO 125 Euro 3 Suspensions Specific tooling 020004Y Punch for removing fifth wheels from headstock - Check that the roller bearing does not show signs of wear or pricking. In case of replacement, proceed as follows: - Support the fork in a vice.
  • Page 187 XEVO 125 Euro 3 Suspensions - Insert the special tool as shown in the figure. - Insert the retaining band of the two half-rings. - Using a 19 mm hexagonal spanner, extract the roller bearing. Specific tooling 020458Y Puller for lower bearing on steering...
  • Page 188 XEVO 125 Euro 3 Suspensions Refitting Using the appropriate tool, refit the upper ball bear- ing and the seat of the lower roller bearings on the headstock as described below: - Place a new ball bearing on the headstock and a roller bearing seat on the lower part.

  • Page 189: Removing The Rear Wheel

    XEVO 125 Euro 3 Suspensions - Insert the a new plate and a new dust guard in the steering tube - Insert a new roller bearing in the roller tube. - Using the special tool and a mallet to move the dust guard and the bearing in abutment.
  • Page 190 XEVO 125 Euro 3 Suspensions - Undo the wheel axle bracket, using the heat gun if necessary. Refitting the rear wheel To fit, follow the removal steps but in the reverse sequence, being careful to fit the spacers on the wheel axle as shown in the photograph.
  • Page 191 XEVO 125 Euro 3 Suspensions - Remove the two screws fixing the buffer support bracket to the frame - Undo the nut on the LHS shown in the figure and remove the corresponding bolt from the opposite side. - Remove the swinging arm.
  • Page 192 XEVO 125 Euro 3 Suspensions - To check the clearance on the frame-side arm, mount the retainer using the pin fixing the swinging arm to the frame and two adaptor rings of the ap- propriate tool 020229Y. Alternatively use two washers with inner diameter for 12-mm pins, min.
  • Page 193 XEVO 125 Euro 3 Suspensions - Using an appropriate tool plant new roller cas- ings, being careful to position the bearings with the O-rings facing outwards Specific tooling 020244Y 15 mm diameter punch 020115Y Ø 18 punch Characteristic Length of the swinging arm tube on the engine side: 175.3 ±...
  • Page 194 XEVO 125 Euro 3 Suspensions - Make sure the silent bloc is not broken. If there is, replace it. - Remove the seeger ring shown in the photograph - Remove the full silent bloc bracket - Undo the silent bloc ring shown in the photograph...

  • Page 195: Shock Absorbers

    XEVO 125 Euro 3 Suspensions - Install a new silent bloc, making sure it aligns properly with the reference tooth. - Fit the silent blocs, making sure the chamfered part of the silent bloc matches the chamfered part of the bracket...
  • Page 196 XEVO 125 Euro 3 Suspensions the one side and from that fixed to the muffler on the other; - unscrew the two upper nuts (one on each side) fixing the shock absorber spring assembly to the frame and remove the shock absorbers.

  • Page 197: Side Stand

    XEVO 125 Euro 3 Suspensions LUBRICATE THE FOLLOWING PARTS WITH GREASE: SPRING COUPLING PINS, BUSH- INGS ON STAND FIXING BRACKETS. Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °...
  • Page 198 XEVO 125 Euro 3 Suspensions SUSP - 24...
  • Page 199 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 200: Rear Brake Calliper

    XEVO 125 Euro 3 Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the muffler. - Remove the two rear brake calliper devices fas- tening them to the support as shown in the photo- graph.
  • Page 201 XEVO 125 Euro 3 Braking system Screw tightening calliper to the support 42 ÷ 52 Brake fluid pipe-calliper fitting 20 ÷ 25 Rear brake disc Removal - Remove the rear wheel. - Undo the five clamping screws shown in the pho-...

  • Page 202: Front Brake Disc

    XEVO 125 Euro 3 Braking system - Repeat the measurement at no fewer than six points on the disc. - Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed onto the brake calliper as shown in the photo.
  • Page 203 XEVO 125 Euro 3 Braking system Refitting For the fitting, position the disc correctly using the arrow stamped on it as reference. - Do up the screws to the prescribed torque and apply the recommended product N.B. THE ARROW STAMPED ON THE DISC INDI-...

  • Page 204: Front Brake Pads

    XEVO 125 Euro 3 Braking system Specific tooling 020335Y Magnetic support for dial gauge Front brake pads Removal Proceed as follows: - Remove the front calliper. - Loosen the two pins shown in the figure that lock the two pads.
  • Page 205 XEVO 125 Euro 3 Braking system N.B. IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT- TING, GENTLY EXPAND THE PADS. Recommended products Loctite 243 Medium-strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Screw tightening calliper to the support 24 ÷...
  • Page 206 XEVO 125 Euro 3 Braking system Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
  • Page 207 XEVO 125 Euro 3 Braking system System bleed calliper fitting: 12 ÷ 16 Nm Front - Remove the rubber hood from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered.
  • Page 208 XEVO 125 Euro 3 Braking system - Use the appropriate spyglass on the pump to check the level of the brake fluid, as shown in the photograph - If the level is below the minimum, fill using the two screws shown in the figure...
  • Page 209 XEVO 125 Euro 3 Braking system Removal - Remove the front and rear handlebar covers; - Place a suitable container to collect the oil, dis- connect the oil pipe from the calliper and actuate on the brake lever until no more oil comes out;...
  • Page 210 XEVO 125 Euro 3 Braking system Refitting - Upon refitting, perform the operation but in reverse order. - Tighten the hydraulic line to the prescribed torque and purge the system. - When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
  • Page 211 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 212 XEVO 125 Euro 3 Cooling system Circuit diagram COOLING CIRCUIT Specification Desc./Quantity Carburettor heating circuit COOL SYS - 2...
  • Page 213 XEVO 125 Euro 3 Cooling system Specification Desc./Quantity Thermostat with by-pass Expansion tank Radiator Circuit air bleeding System bleed - Start up the engine until the operating tempera- ture is reached. - Remove the rubber hood over the bleed valve...
  • Page 214 XEVO 125 Euro 3 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.
  • Page 215 XEVO 125 Euro 3 Cooling system Locking torques (N*m) Thermostat cover screws 3 ÷ 4 COOL SYS - 5...
  • Page 216 XEVO 125 Euro 3 Cooling system COOL SYS - 6...
  • Page 217 INDEX OF TOPICS CHAS HASSIS...
  • Page 218 XEVO 125 Euro 3 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 219: Instrument Panel

    XEVO 125 Euro 3 Chassis Rear handlebar cover • - Remove the front handlebar cover • Undo the 3 screws fixing the rear han- dlebar cover and remove the cover once the connectors of the controls have been disconnected. See also...
  • Page 220 XEVO 125 Euro 3 Chassis • Undo the screw «B», then remove the cover «C» on both sides of the handle- bar. • Undo the two fixing screws at the bot- tom part. • Take out the cover by pulling it up- wards.
  • Page 221 XEVO 125 Euro 3 Chassis For the front turn indicators: • Undo the screw «C» and remove the plastic cover. • Undo the screw «D» and remove the turn indicator once the connector has been removed. See also Flyscreen Frame central cover •...
  • Page 222 XEVO 125 Euro 3 Chassis Knee-guard Side fairings Legshield • Remove the front headlight. • Remove the three upper retainers. • Remove the mats on the footrest. • Remove the ten fixing screws «A» (five per side) on the shield back plate.
  • Page 223 XEVO 125 Euro 3 Chassis Knee-guard • - Remove the front shield. • Remove the expansion tank from the shield back plate by undoing the two screws «A» and fix it to the small front frame in such a way that it does not turn over.
  • Page 224 XEVO 125 Euro 3 Chassis Front wheel housing • - Remove the front shield. • Remove the front fork. • Undo the central screw fixing the wheel house to the frame. • Disconnect the brake pipe to the pump and slide it off.

  • Page 225: License Plate Light

    XEVO 125 Euro 3 Chassis • Central lights: parking lights; • Side lights: stop lights. License plate light • Remove the two screws «G», then re- move the side panels and light support junction after disconnecting the electri- cal connection.
  • Page 226 XEVO 125 Euro 3 Chassis See also Central cover Side fairings • Remove the passenger grab handle. • Remove the two upper screws «A» fix- ing the side fairings. • Remove the license plate light support then undo the two fairing fixing screws «H»...
  • Page 227 XEVO 125 Euro 3 Chassis • Remove the five screws «D», then slide off the side panel by pulling it backwards to free the teeth hooking it to the central cover. See also Taillight assy. License plate light Handles and top side fairings License plate holder •...
  • Page 228 XEVO 125 Euro 3 Chassis Air filter • Remove the left-hand side panel; • Undo the three screws fixing the box to the crankcase; • Loosen the hose tightening screw on the carburettor and remove the hose; • Push the box upwards to free it from the appendages on the crankcase and remove it ;...
  • Page 229 XEVO 125 Euro 3 Chassis Helmet bay - Remove the side fairings; - Remove the frame central cover; - Remove the saddle opening receiver from its support by undoing the two screws «A» on the left fairing; - Undo the four screws fixing the frame upper pipe and remove it once the boot light connector has been removed.
  • Page 230 XEVO 125 Euro 3 Chassis - Undo the 4 screws (2 per side) on the sides of the helmet compartment. - Raise the helmet compartment as much as pos- sible; - Disconnect the electrical connection of the two light buttons;...
  • Page 231 XEVO 125 Euro 3 Chassis See also Footrest Front mudguard • Remove the four fixing screws «A» (two per side) on the mudguard internal side. CHAS - 15...
  • Page 232 XEVO 125 Euro 3 Chassis Top-case Rear - Open the case; - Undo the four screws «A» to remove the case cover; - Undo the eight screws «B» to remove the plastic cover; In order to remove the case support: - Remove the side fairings;...
  • Page 233 XEVO 125 Euro 3 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 com- partment under the saddle. Flyscreen • Remove the driving mirrors;...
  • Page 234 XEVO 125 Euro 3 Chassis Driving mirrors Analogue instrument panel support • Remove the windscreen; • - Remove the front shield. • Undo the two front screws. • Undo the two screws «A » at the side of the handlebar cover and the two screws «B»...
  • Page 235 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 236 XEVO 125 Euro 3 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check...
  • Page 237 XEVO 125 Euro 3 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 238 XEVO 125 Euro 3 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 239 INDEX OF TOPICS TIME...
  • Page 240 XEVO 125 Euro 3 Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine NGINE Code Action Duration 001001 Engine - Replacement 003064 Engine oil - Change...
  • Page 241 XEVO 125 Euro 3 Time Crankcase CRANKCASE Code Action Duration 001153 Crankcase halves gasket - Replacement 001133 Engine crankcase- Replace- ment 001124 Lubrication by-pass - Re- placement 001099 Oil seal, flywheel side - Re- placement 002028 Rear wheel hub - Replace-...
  • Page 242 XEVO 125 Euro 3 Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 4...
  • Page 243 XEVO 125 Euro 3 Time Cylinder assy. YLINDER UNIT ISTON Code Action Duration 001002 Cylinder / Piston - Replace- ment 001176 Rings / Pin - Replacement 001154 Pin-ring-piston assembly - Service TIME - 5...
  • Page 244 XEVO 125 Euro 3 Time Cylinder head assy. HEAD UNIT Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 007009 Cylinder / pump rubber cou- pling - Replacement 001057...
  • Page 245 XEVO 125 Euro 3 Time Rocker arms support assy. OCKING LEVER UNIT Code Action Duration 001148 Valve rocking levers - Re- placement 001044 Camshaft - Replacement 001169 Decompressor - Replace- ment TIME - 7...
  • Page 246 XEVO 125 Euro 3 Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replace- ment 001074 Oil vapour recovery pipe - Re- placement TIME - 8...

  • Page 247: Oil Filter

    XEVO 125 Euro 3 Time Oil filter IL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Re- placement 001102 Oil mesh filter - Change / Cleaning TIME - 9...
  • Page 248 XEVO 125 Euro 3 Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement TIME - 10...

  • Page 249: Oil Pump

    XEVO 125 Euro 3 Time Oil pump OIL PUMP Code Action Duration 001125 Chain guide sliders - Re- placement 001051 Distribution belt - chain - Re- placement 001042 Oil pump - Service 001112 Oil pump - Replacement 001122 Oil pump chain - Replace-...
  • Page 250 XEVO 125 Euro 3 Time Final gear assy. FINAL REDUCTION Code Action Duration 001010 Geared reduction unit - Serv- 003065 Gearcase oil - Replacement 001156 Reduction gear cover - Re- placement 004125 Rear wheel axle - Replace- ment TIME - 12...
  • Page 251 XEVO 125 Euro 3 Time Driving pulley RIVING PULLEY REPAIR TIME Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001006 Driving pulley - Service 001066 driving pulley - Replacement 001177 Variator rollers / shoes - Re-...
  • Page 252 XEVO 125 Euro 3 Time Transmission cover RANSMISSION COVER Code Action Duration 001096 Transmission crankcase cov- er - Replacement 001135 Transmission cover bearing - Replacement 001170 Air deflector - Replacement 001132 Transmission air inlet pipe - Replacement 001131 Transmission air intake - Re-...

  • Page 253: Starter Motor

    XEVO 125 Euro 3 Time Starter motor TARTER MOTOR Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replace- ment 005045 Starter motor cable assembly - Replacement TIME - 15...

  • Page 254: Flywheel Magneto

    XEVO 125 Euro 3 Time Flywheel magneto AGNETO FLYWHEEL AND SECONDARY AIR Code Action Duration 001087 Flywheel cover - Replace- ment TIME - 16...
  • Page 255 XEVO 125 Euro 3 Time Code Action Duration 001113 Water pump / Pump rotor - Replacement 001058 Flywheel - Replacement 001173 Rotor - Replacement 001067 Stator - Replacement 001161 Secondary air filter - Replace- ment / Cleaning 001162 Secondary air housing - Re-...
  • Page 256 XEVO 125 Euro 3 Time ARBURETTOR Code Action Duration 001013 Intake manifold - Replace- ment 001081 Automatic choke - Replace- ment 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replacement 003058 Carburettor - Adjustment TIME - 18...
  • Page 257 XEVO 125 Euro 3 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replace- ment 001095 Muffler guard - Replacement TIME - 19...

  • Page 258: Air Cleaner

    XEVO 125 Euro 3 Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Replacement TIME - 20...
  • Page 259 XEVO 125 Euro 3 Time Frame HASSIS 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...
  • Page 260 XEVO 125 Euro 3 Time Centre-stand TAND REPAIR TIME Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 001053 Stand bolt - Replacement TIME - 22...
  • Page 261 XEVO 125 Euro 3 Time Legshield spoiler FRONT SHIELD Code Action Duration 004020 Headlight frame - Replace- ment TIME - 23...
  • Page 262 XEVO 125 Euro 3 Time Code Action Duration 004064 Legshield, front section - Re- placement 004066 Rear-view mirror - Replace- ment Side fairings IDE COVERS Code Action Duration 004068 Passenger handgrip - Re- placement 004085 Fairing (1) - Replacement 004012...
  • Page 263 XEVO 125 Euro 3 Time Rear cover SHIELD BACK PLATE Code Action Duration 004065 Shield back plate - Replace- ment 004156 Glove box flap and/or support - Replacement 004145 Glove box - Replacement 007024 Expansion tank cap - Re- placement...
  • Page 264 XEVO 125 Euro 3 Time Central cover ENTRAL COVER Code Action Duration 004135 Fuel tank port - Replacement 004011 Frame central cover - Re- placement 004075 Front mat - Replacement 004059 Spark plug inspection flap - Replacement 004015 Footrest - Replacement...
  • Page 265 XEVO 125 Euro 3 Time Mudguard ARAFANGHI Code Action Duration 004002 Front mudguard - Replace- ment 004167 Grill / radiator cover - Re- placement 004009 Rear mudguard - Replace- ment 004053 Spoiler - Replacement TIME - 27...
  • Page 266 XEVO 125 Euro 3 Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement 005010 Tank float - Replacement 004089 Tank / petrol pump pipe - Re- placement 004109 Fuel tank breather - Replace-...
  • Page 267 XEVO 125 Euro 3 Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Re- placement TIME - 29...

  • Page 268: Handlebar Covers

    XEVO 125 Euro 3 Time Handlebar covers ANDLEBAR COVERS Code Action Duration 004018 Front handlebar cover - Re- placement 004019 Rear handlebar cover - Re- placement 004099 Odometer housing - Replace- ment 004026 Handlebar cover - Replace- ment 003043 Steering tube dust guard -...
  • Page 269 XEVO 125 Euro 3 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002063 Throttle control transmission - Replacement 003061 Accelerator transmission - Adjustment 003059 Counterweight - Replace- ment 004162 Mirror support and/or brake pump fitting U-bolt - Replace-...
  • Page 270 XEVO 125 Euro 3 Time Swing-arm BRACCIO OSCILLANTE Code Action Duration 003081 Swinging arm supporting flange - Replacement 004058 Silent-block - Replacement 001072 Engine/frame swinging arm attachment - Replacement 003080 Swinging arm on frame - Re- placement TIME - 32...
  • Page 271 XEVO 125 Euro 3 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 33...
  • Page 272 XEVO 125 Euro 3 Time Instrument panel GRUPPO STRUMENTI + COMANDI AL MANUBRIO Code Action Duration 005078 Odometer glass - Replace- ment 005014 Odometer - Replacement 005038 Dashboard warning/telltale lights - Replacement TIME - 34...

  • Page 273: Turn Signal Lights

    XEVO 125 Euro 3 Time Locks SERRATURE + TRASMISSIONI SERRATURE Code Action Duration 004010 Antitheft lock - Replacement 005099 Electric saddle opening acti- vator - Replacement 005133 Electric glove box activator - Replacement 004054 Saddle lock catch - Replace- ment...
  • Page 274 XEVO 125 Euro 3 Time EAR LIGHTS Code Action Duration 005005 Taillight - Replacement 005048 Licence plate holder - Re- placement 005031 Licence plate light bulb - Re- placement 005032 Licence plate light glass - Re- placement 005022 Rear turn indicators - Re-...
  • Page 275 XEVO 125 Euro 3 Time NDICATOR LIGHTS Code Action Duration 005002 Front light - replacement 005008 Headlight bulbs - Replace- ment 005044 Front lights cable unit- Re- placement 005012 Front turn indicators - Re- placement 005067 Front turn indicator bulb - Re-...

  • Page 276: Front Wheel

    XEVO 125 Euro 3 Time Front wheel UOTA ANTERIORE Code Action Duration 002041 Front brake disc - Replace- ment 003037 Front wheel rim - Replace- ment 003038 Front wheel axle - Replace- ment 003040 Front wheel bearings - Re- placement...
  • Page 277 XEVO 125 Euro 3 Time Rear wheel EAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001071 Rear wheel rim - Replace- ment 004126 Rear wheel tyre - Replace- ment 002070 Rear brake disc - Replace- ment 003077 muffler/rear shock absorber...

  • Page 278: Fuel Pump

    XEVO 125 Euro 3 Time Fuel pump UEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004072 Fuel filter - Replacement 004086 Petrol pump depression tube - Replacement 004087 Filter / petrol pump pipe - Re- placement 004137 Pump / carburettor hose - Re-...
  • Page 279 XEVO 125 Euro 3 Time Electric devices TIME - 41...
  • Page 280 XEVO 125 Euro 3 Time ISPOSITIVI ELETTRICI Code Action Duration 005001 electric system - change 005114 Electrical system - Service 005003 Horn - Replacement 001069 HV coil - replace 001023 Control unit - Replacement 005035 Headlight remote control - Replacement...
  • Page 281 XEVO 125 Euro 3 Time Electronic controls OMANDI ELETTRICI Code Action Duration 005006 Light or turn indicator switch - Replacement 005039 Headlight switch - Replace- ment 005040 Horn button - Replacement 005132 Trunk opening button - Re- placement 005041 Starter button - Replacement...
  • Page 282 XEVO 125 Euro 3 Time Transmissions RASMISSIONI Code Action Duration 002082 Fuel tank cap opening drive - Replacement 002092 Transmission splitter/ hook transmission - Replacement 002093 Trunk opening transmission - Replacement 002094 Trunk splitter/ hook transmis- sion - Replacement TIME - 44...
  • Page 283 XEVO 125 Euro 3 Time Helmet bay ORTACASCO Code Action Duration 004016 Helmet compartment - Re- placement 005033 Glove-box light switch - Re- placement 004082 Trunk gasket - Replacement 005026 Helmet compartment bulb - Replacement 005027 Helmet compartment bulb support - Replacement...
  • Page 284 XEVO 125 Euro 3 Time Rear side fairings OPERTURE POSTERIORI Code Action Duration 005048 Licence plate holder - Re- placement 005033 Glove-box light switch - Re- placement 004081 Glove box door - Replace- ment 004174 Trunk levers - Replacement 004080...

  • Page 285: Front Suspension

    XEVO 125 Euro 3 Time Front suspension OSPENSIONE ANTERIORE Code Action Duration 003051 Complete fork - replace 003010 Front suspension - Service 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003002 Steering thrust washer - Re-...
  • Page 286 XEVO 125 Euro 3 Time Cooling system MPIANTO DI RAFFREDDAMENTO Code Action Duration 007002 Water radiator - replacement 007016 Fan with support - Replace- ment 007001 Expansion tank - Replace- ment 007022 Coolant delivery pipe - Re- placement 007013 Expansion tank - radiator...
  • Page 287 XEVO 125 Euro 3 Time Braking system RAKE SYSTEM Code Action Duration 002007 Front brake pads - Replace- ment 002039 Front brake calliper - Re- placement 002021 Front brake piping - Replace- ment 002002 Rear brake pads - Replace- ment...
  • Page 288 XEVO 125 Euro 3 Time Windscreen INDSHIELD Code Action Duration 004101 Windshield - Replacement TIME - 50...
  • Page 289 XEVO 125 Euro 3 Time Stickers TRANSFERS Code Action Duration 004159 Plates / Stickers - Replace- ment TIME - 51...

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