PIAGGIO X8 400 Euro 3 Service Station Manual

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SERVICE STATION MANUAL

633779 ÷ 633786

X8 400 Euro 3

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Page 1 SERVICE STATION MANUAL 633779 ÷ 633786 X8 400 Euro 3...
Page 2 Not all versions shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2005 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 X8 400 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 ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION 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
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 special tools designed for this scooter.
Page 8: Vehicle Identification
X8 400 Euro 3 Characteristics Vehicle identification Chassis prefix ZAPM52100÷1001 Engine prefix M521M÷1001 Dimensions and mass WEIGHT Specification Desc./Quantity Kerb weight 206 kg Overall width 750 mm Overall length 2190 mm Wheelbase 1540 mm Saddle height 790 mm Overall height...
Page 9: Electrical System
X8 400 Euro 3 Characteristics Engine ENGINE Specification Desc./Quantity Engine single-cylinder, four-stroke Bore x stroke 85.8 X 69 mm Cubic capacity 399 cm³ Compression ratio 10.6 ± 0.5 : 1 Timing system Single overhead camshaft with integrated tone wheel, control from flywheel side chain, 4 valves and automatic start-up valve lifting device.
Page 10: Wheels And Tyres
X8 400 Euro 3 Characteristics Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Chassis Welded steel pipes with pressed sheet metal stiffening Front suspension Double effect hydraulic telescopic fork with Ø 35 mm stems and pin backwards with connections for double brake calliper Front fork max.
Page 11: Front Suspension
X8 400 Euro 3 Characteristics Name Torque in Nm Rear brake disc mounting 11 ÷ 13 Front brake calliper mounting on fork 20 ÷ 25 Rear calliper support on crankcase retainer 20 ÷ 25 Pipe / brake calliper coupling 20 ÷ 25 Pipe / brake pump coupling 20 ÷...
Page 12: Table Of Contents
X8 400 Euro 3 Characteristics Name Torque in Nm Engine oil drainage plug 24 ÷ 30 Engine-crankcase coupling screws 11 ÷ 13 Oil pump screws 5 - 6 Gear mounting on crankshaft screws 10 -12 Bulkhead screws for oil pump housing cover...
Page 13 X8 400 Euro 3 Characteristics Cylinder - piston assy. HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED Specification Desc./Quantity 43.2 mm 43 mm CYLINDER- PISTON Specification Desc./Quantity Cylinder diameter C 85.8 - +0.018 -0.01 mm Piston Ø P 85.768 ± 0.014 mm...
Page 14 X8 400 Euro 3 Characteristics SEAL RINGS Specification Desc./Quantity 1st compression ring 0.150 ÷0.300 2nd compression ring 0.250 ÷0.500 Oil scraper ring 0.250 ÷0.500 SEAL RINGS Crankcase - crankshaft - connecting rod Diameter of crankshaft bearings. Measure the bearings on both axes x-y.
Page 15 X8 400 Euro 3 Characteristics This selection is useful to keep the difference between the working distance of the gears and their distance without clearance at a given value in order to avoid abnormal noise. TYPE A Specification Desc./Quantity Centre to centre distance of the gears without clearance 76.937 ÷...
Page 16 X8 400 Euro 3 Characteristics Characteristic crankshaft / crankcase axial clearance: 0.1 ÷ 0.405 mm Slot packing system Shimming system for keeping the compression ra- DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE.
Page 17 X8 400 Euro 3 Characteristics Products PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-...
Page 18 INDEX OF TOPICS TOOL OOLING...
Page 19 X8 400 Euro 3 Tooling ATTREZZATURA SPECIFICA BUONA Stores code Description 001330Y Tool for fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings 001467Y008 Pliers to extract 17 mm ø bearings 001467Y014 Pliers to extract ø...
Page 20 X8 400 Euro 3 Tooling Stores code Description 001467Y031 Bell 001467Y034 Pliers to extract ø 15-mm bearings 001467Y035 Belle for OD 47-mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020004Y Punch for removing fifth wheels from...
Page 21 X8 400 Euro 3 Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020201Y Spacer bushing driving tube 020262Y Crankcase splitting strip 020306Y Punch for assembling valve sealing rings...
Page 22 X8 400 Euro 3 Tooling Stores code Description 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 22...
Page 23 X8 400 Euro 3 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32x35-mm Adaptor 020358Y 37x40-mm Adaptor 020359Y 42x47-mm Adaptor 020360Y 52x55-mm Adaptor 020364Y 25-mm guide 020376Y Adaptor handle 020382Y012 bush (valve removing tool) TOOL - 23...
Page 24 X8 400 Euro 3 Tooling Stores code Description 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020439Y 17 mm guide TOOL - 24...
Page 25 X8 400 Euro 3 Tooling Stores code Description 020444Y Tool for fitting/ removing the driven pulley clutch 020456Y Ø 24 mm adaptor 020458Y Puller for lower bearing on steering tube 020459Y Punch for fitting bearing on steering tube 020460Y Scooter diagnosis and tester...
Page 26 X8 400 Euro 3 Tooling Stores code Description 020468Y Piston fitting band 020469Y Reprogramming kit for scooter diagnostic tester 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench TOOL - 26...
Page 27 X8 400 Euro 3 Tooling Stores code Description 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020478Y Punch for driven pulley roller casing 020479Y Countershaft lock wrench 020480Y Petrol pressure check set TOOL - 27...
Page 28 X8 400 Euro 3 Tooling Stores code Description 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter 020565Y Flywheel lock calliper spanner TOOL - 28...
Page 29 X8 400 Euro 3 Tooling Stores code Description Marelli MIU diagnosis software Marelli MIU diagnosis software 020640y software euro 3 TOOL - 29...
Page 30 INDEX OF TOPICS MAIN AINTENANCE...
Page 31: Maintenance Chart
X8 400 Euro 3 Maintenance Maintenance chart EVERY 2 YEARS Action Coolant - change Brake fluid - change AFTER 1,000 KM Action Safety locks - check Throttle lever - adjustment Engine oil - change Electrical system and battery - check...
Page 32: Spark Plug
X8 400 Euro 3 Maintenance Action Crankcase breather - empty AFTER 20,000 KM AFTER 40,000 KM AFTER 60,000 KM AND AFTER 80,000 KM Action Safety locks - check Bushing of driven pulley Spark plug - replacement Driving belt - replacement...
Page 33 X8 400 Euro 3 Maintenance TIONS ARE DESCRIBED IN THE SCHEDULED MAINTE- NANCE TABLE THE USE OF ELECTRONIC CONTROL UNITS OR NON- COMPLIANT ELECTRONIC IGNITION SYSTEMS AND/OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE. IF THE SPARK PLUG NEEDS TO BE REMOVED AFTER A...
Page 34 X8 400 Euro 3 Maintenance - Pull out the dipstick and check that the oil level is between the MAX and MIN notches indicated on the dipstick; if the level is below the MIN value, re- store the proper amount of oil in the hub.
Page 35: Air Filter
X8 400 Euro 3 Maintenance Air filter Proceed as follows: 1. Unscrew the 9 fixing screws «A»; 2. Remove the air filter«B» CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NEC- ESSARY TO SERVICE THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
Page 36: Engine Oil Filter
X8 400 Euro 3 Maintenance Check This operation must be carried out with the engine cold and following the procedure below: 1) Rest the vehicle on the central stand and on a flat ground. 2) Unscrew the cap/dipstick "A", dry it with a clean cloth and reinsert it, screwing it thoroughly.
Page 37: Engine Oil Drainage Plug
X8 400 Euro 3 Maintenance - Remove and clean the mesh pre-filter of the drain cap with compressed air. - Use a belt spanner for filters to remove cartridge filter "C". - Make sure the pre-filter and drain cap O-rings are in good condition.
Page 38: Checking The Valve Clearance
X8 400 Euro 3 Maintenance Oil pressure warning light Warning light (low oil pressure) The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been star- ted.
Page 39: Braking System
X8 400 Euro 3 Maintenance CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD. - Remove the water pump cover as indicated in the figure by loosening the 6 retaining screws. - Proceeding as described in chapter "Engine", partially drain the system and overhaul the pump.
Page 40 X8 400 Euro 3 Maintenance Level check The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal; - Check the fluid level through the sight glass «C».
Page 41: Headlight Adjustment
9/10 and higher than 7/10 of the distance from the ground to the centre of the vehicle headlight; 3. If not, adjust the headlight by turning the central screw «A» placed behind the Piaggio badge. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO- PEAN STANDARDS REGARDING MAXIMUM AND MINI- MUM HEIGHT OF LIGHT BEAMS.
Page 42 X8 400 Euro 3 Maintenance If the end of compression pressure is lower than the standard, remove the test gauge connector and add some cc of oil to the combustion chamber, make the engine turn (preferably manually) to lubricate the cylinder.
Page 43 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 44 X8 400 Euro 3 Electrical system KEY: 1. Magneto flywheel 2. Voltage regulator 3. Revolution sensor 4. Throttle valve position sensor 5. Ambient temperature sensor 6. Stepper motor for idle jet 7. Electric fan 8. Engine temperature sensor 9. Remote control for electric fan 10.
Page 45 X8 400 Euro 3 Electrical system 20. Start up remote control switch 21. Starter button 22. Wiring for radio display 23. Wiring for radio 24. Stop button on rear brake 25. Stop button on front brake 26. Boot switch 27. Boot actuator 28.
Page 46 X8 400 Euro 3 Electrical system 53. Fuel pump 54. Fuel injector 55. Spark plug 56. High voltage coil 57. Lambda probe 58. Diagnostics socket 59. Injection ECU 60. Stand switch Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black,...
Page 47 X8 400 Euro 3 Electrical system 5. Ambient temperature sensor 6. Stepper motor for idle jet 7. Electric fan 8. Engine temperature sensor 9. Remote control for electric fan 10. Key switch 11. Injection load remote control 12. Fuse holder B 13.
Page 48 X8 400 Euro 3 Electrical system 41. Front headlight assembly A. Low-beam bulb B.A. Parking light C. High-beam headlight bulb 42. Right front turn indicator bulbs 43. Light switch 44. Turn indicator switch 45. Turn indicator remote control 46. Remote control headlight 47.
Page 49 X8 400 Euro 3 Electrical system H.V. coil In order to access the HV coil remove the chassis central cover; to remove it, loosen the screws in- side the battery compartment. Saddle opening remote control unit. In order to access the saddle opening control unit, remove the left side fairing.
Page 50 X8 400 Euro 3 Electrical system Immobilizer decoder In order to access the immobilizer decoder remove the front top fairing and the shield back plate. Relays and diode group In order to access the relays and the diode unit remove the front top fairing and the shield back plate.
Page 51 X8 400 Euro 3 Electrical system Ignition KEY: 3. Revolution sensor 10. Key switch 11. Injection load remote control 12. Fuse holder B 13. Fuse holder A 15. Engine stop remote control 16. Engine stop switch 17. Diode 18. Battery 49.
Page 52 X8 400 Euro 3 Electrical system Headlights and automatic starter section KEY: 10. Key switch 12. Fuse holder B 13. Fuse holder A 15. Engine stop remote control 16. Engine stop switch 17. Diode 18. Battery 35. Wiring for antitheft device 36.
Page 53 X8 400 Euro 3 Electrical system B. Parking light C. High-beam headlight bulb 42. Right front turn indicator bulbs 43. Light switch 44. Turn indicator switch 45. Turn indicator remote control 46. Remote control headlight 49. Instrument panel 60. Stand switch...
Page 54 X8 400 Euro 3 Electrical system 19. Starter motor 20. Start up remote control switch 21. Starter button 24. Stop button on rear brake 25. Stop button on front brake 37. Rear headlight assembly A. Tail light Bulb B. Stop light Bulb 60.
Page 55 X8 400 Euro 3 Electrical system 13. Fuse holder A 15 Engine stop remote control 16. Engine stop switch 17. Diode 18. Battery 47. Fuel level transmitter 49. Instrument panel 50. Oil pressure sensor 53. Fuel pump 54. Fuel injector 57.
Page 56 X8 400 Euro 3 Electrical system 12. Fuse holder B 13. Fuse holder A 14. 12V - 180W socket 15. Engine stop remote control 16. Engine stop switch 17. Diode 18. Battery 26. Boot switch 27. Boot actuator 28. Saddle opening switch 29.
Page 57 X8 400 Euro 3 Electrical system switch is turned to the "ON" position, the theft-deterrent blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or the instrument panel is not initiated, check if: •...
Page 58 X8 400 Euro 3 Electrical system Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised when the decoder has been correctly programmed. The procedure for programming a new decoder requires the rec- ognition of the "master"...
Page 59 X8 400 Euro 3 Electrical system oughly inspected: In any case it is advisable to use resistive spark plugs. Characteristic MASTER key: BROWN KEY SERVICE key. BLACK KEY Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During...
Page 60 X8 400 Euro 3 Electrical system pleted, the LED remains permanently OFF. The engine can be started. 5. Decoder programmed - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be trans- mitted are: •...
Page 61 X8 400 Euro 3 Electrical system Diagnostic code - 3 flashes The 3-flash code indicates a system where the de- coder does not recognise the key. Turn the switch to ON using several keys: If the error code is re- peated even with the Master key, replace the de- coder.
Page 62 X8 400 Euro 3 Electrical system 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator. Recharge system voltage check Maximum current output check. - With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.
Page 63 X8 400 Euro 3 Electrical system Turn signals system check The turn indicator circuit is controlled by the electronic control unit. In the case it does not work, it is necessary to: 1. Check that fuse 8 is in working order 2.
Page 64 BESIDES, IF AFTER REPLACING A FUSE, THE NEW FUSE ALSO BLOWS, THE SCOOTER NEEDS TO BE TAKEN TO AN AUTHORISED PIAGGIO/GILERA SERVICE CENTRE TO IDENTIFY THE CAUSE OF THE FAULT AND AVOID FUR- THER DAMAGE TO THE ELECTRIC SYSTEM COMPO- NENTS OR THE VEHICLE ITSELF.
Page 65 X8 400 Euro 3 Electrical system Specification Desc./Quantity Location: Battery compartment on the left side Protected circuits: Remote control for injection com- ponents (fuel pump, injector, h.v. coil.) Fuse No. 5 Threshold of operation: 10 A Location: Battery compartment on the left side...
Page 66 X8 400 Euro 3 Electrical system E: Engine stop remote control switch F: Turn indicator remote control G: Starter remote control Dashboard A = Twin scale speedometer (km/h and mph) B = Fuel gauge C = Antitheft device LED D = Coolant temperature gauge...
Page 67 X8 400 Euro 3 Electrical system INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a regular tester. - If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
Page 68 X8 400 Euro 3 Electrical system Dry-charge battery - Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corresponding to 30 Bé at a minimum tem- perature of 15°C until the upper level is reached.
Page 69: Battery Installation
X8 400 Euro 3 Electrical system The battery runs down completely in the course of three months. When refitting the battery onto the scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must be attached to the positive, + terminal.
Page 70 X8 400 Euro 3 Electrical system IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYS- TEM, NEVER DISCONNECT THE WIRING WHILE THE EN- GINE IS RUNNING. DO NOT TIP THE SCOOTER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BAT- TERY ELECTROLYTE.
Page 71 X8 400 Euro 3 Electrical system Specification Desc./Quantity Injector control (negative) Stepper motor Stepper motor Injection telltale light Decoder (serial) Overturn sensor Battery powered Air temperature sensor Fuel pump H.V. coil (negative control) Stepper motor Stepper motor Sensor power supply...
Page 72 X8 400 Euro 3 Electrical system Specification Desc./Quantity Immobilizer LED control (negative) Base power supply (positive) Negative Electronic control unit EMS (serial) Continuous power supply (positive) Immobilizer aerial Engine rev. sensor REV SENSOR Specification Desc./Quantity Male Female Shielding Dashboard ONNECTOR Specification Desc./Quantity...
Page 73: Battery Replacement
X8 400 Euro 3 Electrical system Remote seat opening The vehicle is equipped with a remote control to open the saddle. This remote control is supplied together with the keys and at the manufacturing stage, it has been programmed to work together with the ECU that control the opening device.
Page 74 X8 400 Euro 3 Electrical system Zeroing - To access the saddle opening control/reception unit, remove the left side fairing. - A white cable, that comes from pin 3 of the control unit, goes out from the wiring. - Earth the cable at least 10 seconds in order to delete all the remote controls stored in the control unit.
Page 75 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 76 X8 400 Euro 3 Engine from vehicle Exhaust assy. Removal - Remove the right-hand side fairing - Undo the two exhaust manifold fixings on the head. - Remove the Lambda probe from its support and disconnect it. Remove the screw indicated in the photograph.
Page 77 X8 400 Euro 3 Engine from vehicle N.B. DUE TO MUFFLER DIMENSIONS IT IS NOT POSSIBLE TO ACTUATE ON THE SCREW PERPENDICULARLY TO RE- MOVE IT; USE A COMMERCIALLY AVAILABLE «BON- DUS» MALE HEXAGONAL WRENCH. Remove the lambda probe from the manifold.
Page 78 X8 400 Euro 3 Engine from vehicle - Remove the electrical connections to the sensors and devices. - Remove the throttle control cable from the throttle body by undoing the nut "C". - Remove the positive and negative wiring from the starter motor.
Page 79 X8 400 Euro 3 Engine from vehicle Check that there is a small clearance when the valve is in abutment against the set screw. -Check the engine oil level and if necessary top it up with the recommended type. - Top-up the cooling circuit.
Page 80 INDEX OF TOPICS NGINE...
Page 81: Transmission Cover
X8 400 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 - Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap.
Page 82: Transmission Cover
X8 400 Euro 3 Engine - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely, otherwise replace it. - Loosen the 4 fastening screws - Extract the outside plastic transmission cover. Air duct - Remove the transmission cover.
Page 83: Transmission Cover
X8 400 Euro 3 Engine Air duct filter - Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the fig- ure to remove the conveyor filter. Removing the driven pulley shaft bearing - Remove the transmission cover.
Page 84: Transmission Cover
X8 400 Euro 3 Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little grease to prevent it from coming out.
Page 85: Inspecting The Clutch Drum
X8 400 Euro 3 Engine - Check that the roller does not show signs of wear and that it turns freely. - Loosen the retaining bolt using a 13 mm spanner. - Remove the complete roller with bearing. N.B. IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE THE COMPLETE ROLLER.
Page 86: Removing The Clutch
X8 400 Euro 3 Engine Removing the clutch - To remove the clutch with the driven pulley it is necessary to use the special tool; - Arrange the tool with the mean pins screwed in position "E" on the inside;...
Page 87 X8 400 Euro 3 Engine Removing the driven half-pulley bearing - Check that the bushing is free from wear and damage; otherwise replace the fixed driven half- pulley. - Remove the lock ring using pliers. - Using the special tool inserted through the roller bearing, pull out the ball bearing.
Page 88 X8 400 Euro 3 Engine Inspecting the driven fixed half-pulley - Check that the belt contact surface is free from wear. - Measure the outer diameter of the pulley bushing. Characteristic Minimum admissible diameter 49.91 mm Standard diameter: 50.00 -0.015 -0.035 mm...
Page 89: Refitting The Driven Pulley
X8 400 Euro 3 Engine Specific tooling 020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing - Install a new ball bearing using the special tool. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020363Y 20 mm guide - Insert the Seeger lock ring.
Page 90 X8 400 Euro 3 Engine Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring while it is unloaded. Characteristic Standard length: 125.5 mm...
Page 91: Clutch Ring Nut
X8 400 Euro 3 Engine Refitting the clutch Bell assembly - Install the bell and the spacer. - Prepare the special tool as for removal; - Preassemble the driven pulley unit with the drive belt according to its direction of rotation;...
Page 92: Removing The Driving Pulley
X8 400 Euro 3 Engine Refitting the driven pulley - Install the driven pulley assembly with belt. Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width: 25 mm Standard width: 26.2 mm...
Page 93 X8 400 Euro 3 Engine - First install the lock ring of the special tool onto the pulley so that the splines are completely en- gaged. - Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself.
Page 94 X8 400 Euro 3 Engine - Measure the pulley sliding bushing outside di- ameter shown in the figure. Characteristic Minimum admissible diameter Ø 29.95 mm Standard diameter: Ø 29.959 mm - Check that the rollers are not damaged or worn.
Page 95 X8 400 Euro 3 Engine Refitting the driving pulley Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley.
Page 96: Driving Pulley Nut
X8 400 Euro 3 Engine - Turn the central pulley nut to horizontally align the holes and install the special tool. N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY IN- SERTED INTO THE PULLEY AND IN THE ENGINE CRANK- CASE.
Page 97: External Transmission Cover Screws
X8 400 Euro 3 Engine - Assembly the half-pulley with the roller contrast plate and sliding blocks. - Insert the half-pulley on the crankshaft. - Insert the spacer bushing. Refitting the transmission cover - Install the driving pulley shaft cover, positioning the tooth gap on the lower part with the reference mark on the transmission crankcase.
Page 98: M8 Retainers For Transmission Cover
X8 400 Euro 3 Engine - Ensure the correct installation on the crankcase of the 2 centring dowels. - Insert the transmission cover with the bearing and install the relevant retainers. - Lock the four M8 retainers. Locking torques (N*m) M8 retainers for transmission cover 23 ÷...
Page 99 X8 400 Euro 3 Engine End gear Removing the hub cover - Drain the rear hub oil through the oil drainage cap located under the engine. - Drain the rear hub oil through the oil drainage cap located under the engine.
Page 100 X8 400 Euro 3 Engine - Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts. Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings 001467Y034 Pliers to extract ø...
Page 101 X8 400 Euro 3 Engine - Remove the oil guard using a screwdriver. Removing the driven pulley shaft bearing - If you have to remove the driven pulley shaft, the relevant bearing and the oil guard, remove the transmission cover and the clutch unit as descri- bed in the «...
Page 102 X8 400 Euro 3 Engine Connection diameter for countershaft: A = diameter 20 - 0.01 -0.02 mm Connection diameter for wheel shaft: B = diameter 30 - 0.010 -0.023 mm C = diameter 15 - 0.01 -0.02 mm Bearing diameter for driven pulley shaft: D = diameter 17 - 0.01 -0.02 mm...
Page 103 X8 400 Euro 3 Engine - Heat the intermediate gear bearing seat. - Insert the intermediate shaft bearing using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling...
Page 104 X8 400 Euro 3 Engine Refitting the hub cover bearings - Heat the bearing seats on the cover using the heat gun. - Support the hub cover using the stud bolt set. Specific tooling 020151Y Air heater 020476Y Stud bolt set - Insert the intermediate shaft bearing on the cover using the special tool.
Page 105 X8 400 Euro 3 Engine - Support the hub cover using the stud bolt set. - Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover. - Place the oil guard flush with the crankcase.
Page 106 X8 400 Euro 3 Engine Locking torques (N*m) Rear hub cover screws 24 ÷ 27 Flywheel cover - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.
Page 107 X8 400 Euro 3 Engine - Remove the oil filter using a filter tape or shaped cup wrench. - Loosen the 14 fastening screws. - Remove the flywheel cover with the relevant gas- ket and the cooling system sleeve support.
Page 108: Removing The Stator
X8 400 Euro 3 Engine - Remove the by-pass and the relevant spring. - Remove the oil pump seal. Removing the stator - Remove the two retaining screws and the cable guide bracket. - Unscrew the 3 fastening screws and remove sta- tor and its wiring.
Page 109: Water Pump Impeller
X8 400 Euro 3 Engine - Remove the blow-by reed valve with the relevant sealing gasket. - Unscrew the fastening screw and remove the gas outlet union with the relevant O-ring. - Remove the water pump impeller by unscrewing it from the relevant shaft.
Page 110: Minimum Oil Pressure Sensor
X8 400 Euro 3 Engine - Remove the sealing ring. - Remove the ceramic ring and the relevant gas- ket. - Remove the sealing ring for the pump shaft lu- brication using a suitably shaped tool. - Remove the engine oil filling cap/dipstick and the check hole cover for the distribution timing.
Page 111 X8 400 Euro 3 Engine Inspecting the cover components - Install a new oil filter, lubricate the gasket, screw on and finally tighten to the prescribed torque. Locking torques (N*m) Engine oil filter 12 - 16 - Install the supply hose to the cylinder and con- nect the return hose to the pump cover using 3 new clamps.
Page 112 X8 400 Euro 3 Engine - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Electric characteristic Resistance: 0.2 - 1 Ω...
Page 113: Blow-By Recovery Duct Fixing Screws
X8 400 Euro 3 Engine - Check that the oil filter union and matching sur- face exhibit no deformations or wear. Refitting the stator - Install the stator assembly together with the wir- ing harness, tightening the 3 screws to the pre- scribed torque.
Page 114 X8 400 Euro 3 Engine - Insert the spring and the by-pass piston on the flywheel cover. N.B. LUBRICATE THE BY-PASS VALVE. Refitting the flywheel cover components - Before reassembling, check that all components are perfectly clean. - For the cover, carefully check all lubrication chan- nels, in particular: - The 3 by-pass channels.
Page 115: Supporting Screws With Bulkhead 0.3 -
X8 400 Euro 3 Engine - Oil pressure sensor feeding duct. - Oil vapour decantation chamber - Reinstall the blow-by reed valve using a new sealing gasket. - Reinstall the support with head and tighten the screws to the prescribed torque.
Page 116 X8 400 Euro 3 Engine - Pre-assemble the ceramic seal and the relevant gasket. N.B. PLACE THE CHAMFERING TOWARDS THE GASKET BE- ING CAREFUL NOT TO FOUL THE CERAMIC RING WITH OIL OR GREASE, WHICH WOULD IMPAIR THE SEAL. - Insert the ceramic seal on the flywheel cover.
Page 117 X8 400 Euro 3 Engine - Install a new gasket on the engine crankcase. - Check the presence of the three centring dowels. - Turn the crankshaft in order to align the counter- shaft movement sensor with a reference point on the crankcase (see figure).
Page 118 X8 400 Euro 3 Engine N.B. - THE INTERMEDIATE BOLTS FOR THE REMAINING MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT FOR THE MANIFOLD SUPPORT (SHOWN IN THE FIGURE) ARE SLIGHTLY LONGER. Locking torques (N*m) Flywheel cover screws 11 - 13 Flywheel and starting The starter is sold as a complete part.
Page 119 X8 400 Euro 3 Engine 80 - 120 A Revolution speed = approx. 300-400 rpm YES go to 6 NO go to 7 NO go to 8 NO go to 9 5 - Restore the connections 6- The values are correct.
Page 120 X8 400 Euro 3 Engine N.B. IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE NOISE, CHECK THE FREEWHEEL OF THE TORQUE LIMITER (SEE THE "FLYWHEEL AND STARTER SYSTEM" CHAPTER). STARTER MOTOR Specification Desc./Quantity Type Mitsuba sm13d Power 0.9 kW...
Page 121 X8 400 Euro 3 Engine Removing the starter motor N.B. THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED. - Loosen the two fastening screws. - Extract the complete starter motor. Removing the flywheel magneto N.B. IF YOU MUST REMOVE THE FLYWHEEL, IT IS NECESSARY TO REMOVE THE CHAIN GUIDE SLIDING BLOCK RETAIN PLATE FIRST.
Page 122 X8 400 Euro 3 Engine - Tighten the bushing of the flywheel lock tool on the removing tool threading. - Insert the special tool as shown in the figure, making sure that the pins are perfectly inserted in- to the previously aligned holes and that it is per- fectly abutted and almost flush with the flywheel.
Page 123 X8 400 Euro 3 Engine - Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer. CAUTION THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS STRONGLY LOCKED; THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE, WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS.
Page 124 X8 400 Euro 3 Engine - Remove the freewheel from the flywheel by loos- ening the 6 fastening screws. SINCE THE FREEWHEEL MUST BE REMOVED, IT IS AD- VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT.
Page 125 X8 400 Euro 3 Engine Starter gear rim - Check that there is no wear or abnormal impres- sions on the "rollers" of the freewheel and on the surface of the starter ring gear hub. - Check the hub outside diameter.
Page 126 X8 400 Euro 3 Engine Also check the shaft diameter on the flywheel cov- er and on the engine crankcase. Characteristic Bearing diameter on the flywheel cover 12 + 0.034 -0.016 mm Bearing diameter on the engine crankcase: 12 + 0.034 -0.016 mm N.B.
Page 127: Screw Fixing Freewheel To Flywheel
X8 400 Euro 3 Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel Seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
Page 128 X8 400 Euro 3 Engine - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel turning it clockwise and inserting at the same time. Refitting the flywheel magneto - Insert the key on the crankshaft.
Page 129: Flywheel Fixing Nut
X8 400 Euro 3 Engine - Tighten thoroughly the guide bushing of the fly- wheel lock tool and loosen by 1/4 turn. N.B. FAILURE TO OBSERVE THIS PRECAUTION CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL. Specific tooling 020472Y Flywheel lock wrench - Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool.
Page 130 X8 400 Euro 3 Engine - Install the chain guide retain plate tightening the 3 screws to the prescribed torque. N.B. BEFORE TIGHTENING THE SCREWS, MOVE THE START- UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC- TION.
Page 131 X8 400 Euro 3 Engine Removing the intake manifold - Remove the 3 mounting screws. - Remove the intake manifold unit. Removing the rocker-arms cover - Loosen the 6 special screws with stop and the relevant rubber gaskets. - Remove the tappet cover with relevant gasket.
Page 132 X8 400 Euro 3 Engine - Remove the central screw and the valve lifting device mass stop bell using the special tool. Specific tooling 020565Y Flywheel lock calliper spanner - Remove the return spring and the valve lifting mass with relevant travel end washer.
Page 133 X8 400 Euro 3 Engine Remove the inside hexagon screw and the coun- terweight as shown in the figure. - Remove the timing belt rim from the camshaft. - Remove the timing belt rim. - Remove the tone wheel. - Remove the engine revolution timing sensor and...
Page 134: Removing The Cylinder Head
X8 400 Euro 3 Engine Removing the cam shaft - Unscrew the 3 fastening screws and remove camshaft retaining bracket. N.B. REMOVING THE FASTENING SCREWS MAY BE DIFFI- CULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEX- AGON. IF NECESSARY, SEPARATE THE THREADS IN ADVANCE.
Page 135 X8 400 Euro 3 Engine - Remove the coolant temperature sensor. N.B. THE SENSOR CONTROLS BOTH INJECTION AND THE AN- ALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS COMPONENT, SEE THE INJECTION CHAPTER. - Remove the 2 fastening nuts on the head, on the exhaust and on the intake side.
Page 136: Removing The Valves
X8 400 Euro 3 Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush (valve removing tool)
Page 137 X8 400 Euro 3 Engine Removing the cylinder - piston assy. - Remove the timing chain. - Loosen the fastening screw and remove the spacer and the tightening sliding block. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Page 138: Inspecting The Small End
X8 400 Euro 3 Engine Inspecting the small end - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANK- SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Page 139: Inspecting The Piston
X8 400 Euro 3 Engine Inspecting the piston - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis. - Take the measurement in the position shown in the figure. Characteristic Piston diameter: 85.768 ± 0.014 mm 42.2 mm...
Page 140: Removing The Piston
X8 400 Euro 3 Engine Fitting clearance (Cylindrin/Pison) Standard coupling clearance A 0.9 - 0.005 -0.030mm B 1.5 - 0.005 -0.03mm Maximum permissible clearance after use C 0.9 + 0.03 +0.01mm D 2 + 0.05 +0.02mm Standard coupling clearance </>...
Page 141 X8 400 Euro 3 Engine - Insert the locking ring into the special tool, with the opening in the position indicated on the tool. S = left D= right - Place the wrist pin stop ring into position using a...
Page 142 X8 400 Euro 3 Engine - Using an abutment plane, reset the comparator with a preload of a few millimetres. - Finally fix the comparator. - Check the perfect sliding of the feeler pin. - Install the tool on the cylinder without changing the comparator position.
Page 143: Inspecting The Cylinder Head
X8 400 Euro 3 Engine Refitting the piston rings - Place the scraper ring spring on the piston. - Install the scraper ring keeping the opening op- posed to the spring junction and with the writing "top" facing the piston top. The chamfered side of the oil scraper ring should always be facing the piston crown.
Page 144 X8 400 Euro 3 Engine Maximum allowable run-out: 0.1 mm - In case of irregularities, replace the head. - Check the sealing surfaces for the intake and ex- haust manifold. - Check that the camshaft and the rocker pin ca- pacities exhibit no wear.
Page 145 X8 400 Euro 3 Engine Inspecting the valve sealings - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
Page 146 X8 400 Euro 3 Engine Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity Inlet: 4.987 - 4.972 mm Outlet: 4.975 - 4.960 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity...
Page 147 X8 400 Euro 3 Engine Inspecting the valve stem guide clearance - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem. INLET Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm...
Page 148 X8 400 Euro 3 Engine - If the checks above give no failures, you can use the same valves. To obtain better sealing perform- ance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound. During the grinding, keep the cylinder head with the valve ax- es in a horizontal position.
Page 149 X8 400 Euro 3 Engine Refitting the valves - Place the valve spring support washers on the head. - Alternately insert the 4 oil guards using the spe- cial tool. - Lubricate the oil guards and the valve guides. Specific tooling...
Page 150 X8 400 Euro 3 Engine -Using a gauge, measure the cam height. STANDARD HEIGHT Specification Desc./Quantity Intake 33.988 mm Exhaust: 33.417 mm ADMISSIBLE LIMITS Specification Desc./Quantity Intake 33.740 mm Exhaust: 33.170 mm Standard axial clearance: 0 - 0.22 mm Maximum admissible axial clearance: 0.3 mm...
Page 151 X8 400 Euro 3 Engine - Check that the cam contact sliding block and the articulated register plate is free from wear. - In case of wear, replace the component. Refitting the head and timing system components - Insert the chain guide sliding block.
Page 152 X8 400 Euro 3 Engine - Tighten the 4 fastening columns crosswise to the prescribed torque as shown in the figure. - Tighten the 4 screws by 90° in the sequence shown in the figure. - Further tighten by 90° in the sequence shown in the figure.
Page 153 X8 400 Euro 3 Engine - Insert the timing control belt on the crankshaft according to the initial direction of rotation. - Install the tensioner shoe with its spacer, tight- ening the bolt to the prescribed torque, using the recommended product.
Page 154 X8 400 Euro 3 Engine - Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque, being careful not to damage the inside hexagon. Locking torques (N*m) Camshaft retaining bracket screws: 4 ÷ 6...
Page 155 X8 400 Euro 3 Engine - Install the intermediate gear with torque limiter, the flywheel and its cover, as described in Chapter "Flywheel and start-up system", and in Chapter "Flywheel cover". N.B. FOR MORE CONVENIENCE, INSTALL THE FLYWHEEL COVER WITHOUT THE COOLING SYSTEM SLEEVES.
Page 156 X8 400 Euro 3 Engine - Insert the belt on the camshaft control timing rim. - Insert the timing rim on the camshaft checking that the references are aligned. N.B. DURING THE STROKE CHECK, KEEP THE BELT TEN- SIONED BY PRESSING ON THE TIGHTENER COMPART- MENT SIDE.
Page 157 X8 400 Euro 3 Engine - Turn the engine to move the references to the top as shown in the figure (intake end). - Insert the valve lifting device mass stop bell. - Tighten the retaining screw to the prescribed torque, using the recommended product.
Page 158 X8 400 Euro 3 Engine Refitting the timing chain This section described the operations to be carried out on the manifold components. The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to interpret the reference values based on the engine rpm.
Page 159 X8 400 Euro 3 Engine - Repeat for the reference between driving pulley and transmission housing. - Refit the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the «parameters» function in this menu.
Page 160 X8 400 Euro 3 Engine - Repeat the check at 3 - 4 points. - Place the tightener cursor in the rest position, keeping the retain tab pressed. - Install a new tightener on the cylinder using a new gasket.
Page 161 X8 400 Euro 3 Engine Refitting the rocker-arms cover - Check that the gasket is in good working order. - Tighten the two screws indicated in the figure with «1» and «2» to limit the reciprocal sliding of the cover surface with the head surface.
Page 162 X8 400 Euro 3 Engine Refitting the intake manifold - Install the intake manifold on the engine. - Insert the 3 fastening screws, one of which with a support band for the cooling system sleeve, and tighten to the prescribed torque.
Page 163 X8 400 Euro 3 Engine - Remove the thermal group (cylinder, head, pis- ton) as described in the «Thermal group and timing system chapter». - Before opening the crankcase, check the crank- shaft axial clearance. For this purpose, use a plate (e.g. the special tool) and a support with special tool comparator.
Page 164 X8 400 Euro 3 Engine Splitting the crankcase halves - Remove the engine support retain screw on the flywheel side half-crankcase. - Remove the 14 crankcase coupling screws. N.B. THE FASTENING SCREWS ARE OF 3 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION.
Page 165 X8 400 Euro 3 Engine - Remove the crankshaft with the shim adjustment washer on the flywheel side. CAUTION WHILE OPENING THE CRANKCASE AND REMOVING THE CRANKSHAFT, CHECK THAT THE SHAFT THREADED ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS.
Page 166 X8 400 Euro 3 Engine - Remove the special tool and extract the counter- shaft with the control gear. Replacing the countershaft bearings - Check that the bearings are free from irregular noise or clearance. If it does, replace it.
Page 167 X8 400 Euro 3 Engine - Before installing a new bearing, heat the flywheel side half-crankcase using the special tool. - Place the half-crankcase on a wooden base. Specific tooling 020151Y Air heater - Insert a new bearing on the special tool after greasing the guide seat.
Page 168 X8 400 Euro 3 Engine - Insert a new bearing on the special tool after greasing the guide seat. - Install the new bearing on the engine crankcase using the special tool. N.B. IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE.
Page 169 X8 400 Euro 3 Engine CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VALUES AND THE SUR- FACES ARE FREE FROM SCRATCHES. Shimming - Check the overall height of the crankshaft - shoulders - gear assembly.
Page 170 X8 400 Euro 3 Engine MAX ADMISSIBLE DISPLACEMENT: Specification Desc./Quantity = 0.15 mm = 0.01 mm = 0.01 mm = 0.10 mm - 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 171 X8 400 Euro 3 Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - For the transmission-side half-crankcase, special attention should be given to the bushings, to the cooling jet on the transmission side (see figure) and to the lubrication duct.
Page 172 X8 400 Euro 3 Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
Page 173 X8 400 Euro 3 Engine CHECK THE BENCH BUSH Name Description Dimensions Initials Quantity Type A - Red 1.971 ÷ 1.974 Type B - Blue 1.974 ÷ 1.977 Type C - Yellow 1.977 ÷ 1.980 Type D - Green 1.980 ÷ 1.983...
Page 174 X8 400 Euro 3 Engine - Complete FC3 type crankcase equipped with bushings for housing a category 1 crankshaft and a countershaft with centre to centre distance B. - Complete FC4 type crankcase equipped with bushings for housing a category 2 crankshaft and a countershaft with centre to centre distance B.
Page 175: Gear Mounting On Crankshaft Screws
X8 400 Euro 3 Engine N.B. IF YOU HAVE TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NEC- ESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL. - Before installing the gear on the crankshaft, care- fully clean the two matching surfaces removing any residues of LOCTITE from the holes using a brush.
Page 176: Bulkhead Screws For Oil Pump Housing Cover
X8 400 Euro 3 Engine - Insert the crankshaft on the pin and into the bush- ing. - Before inserting thoroughly, make the oil pump gear align with the control gear. - Insert thoroughly and remove the special tool. N.B.
Page 177: Engine-Crankcase Coupling Screws
X8 400 Euro 3 Engine - Insert the gasket on the flywheel side half-crank- case. - Lubricate the main bearing on the transmission side half-crankcase. - Couple the 2 half-crankcases being careful not to damage the bushing on the transmis- sion side half-crankcase with the threaded tang of the crankshaft.
Page 178 X8 400 Euro 3 Engine - Install the flywheel with start-up control as de- scribed in the "Flywheel and start-up" chapter. - Install the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover chap- ter". - Install the complete driving pulley, the transmis-...
Page 179: Oil Pump
X8 400 Euro 3 Engine OIL PUMP Specification Desc./Quantity Type Trochoidal Rotor washers 8 mm Assembly clearances Lobe ends 0.05-0.008 mm External rotor radial clearance 0.05- 0.12 mm Rotor axial clearance 0.025 - 0.065 mm BY-PASS Specification Desc./Quantity Type with piston Plunger diameter 13.9 - 0.039 -0.057 mm...
Page 180 X8 400 Euro 3 Engine Conceptual diagrams PRINCIPLE DIAGRAM Specification Desc./Quantity Camshaft Cylinder-head plane Cylinder-crankcase plane Water pump impeller Minimum oil pressure sensor Oil filter cartridge To the oil sump By-pass valve Oil pump Mesh pre-filter Crankshaft Connecting rod General characteristics...
Page 181 X8 400 Euro 3 Engine The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the pressure of the circuit.
Page 182 X8 400 Euro 3 Engine 3 Check the actual oil pressure. AHEAD - go to 4 4 - Remove the switch and fit the special tool with the relevant gasket. Specific tooling 020193Y Oil pressure gauge 020434Y Oil pressure control fitting - Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied with the special tool.
Page 183: Oil Pressure Check
X8 400 Euro 3 Engine 8 - If pressure lower than 1.3 ÷ 1.5 bar is measured. AHEAD go to 9 9 - Replace the oil filter and repeat the pressure check with oil at 80°C. YES go to 10 NO go to 13 10 - The failure was fixed.
Page 184 X8 400 Euro 3 Engine 020434Y Oil pressure control fitting AHEAD go to 3 3 - Check the system pressure with cold engine and medium - high speed. Standard pressure < 6 bar YES go to 4 NO go to 5 4 - Replace the damaged components.
Page 185 X8 400 Euro 3 Engine - Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper. - Remove the gasket. - Remove the two screws and the oil pump cover.
Page 186 X8 400 Euro 3 Engine - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and free from wear. - Reassemble the rotors in the pump body, keep-...
Page 187 X8 400 Euro 3 Engine - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit values admitted: 0.1 mm Inspection - For tests on the oil pump, see the "Lubrication"...
Page 188 X8 400 Euro 3 Engine Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body. Locking torques (N*m) Screws fixing oil pump to crankcase 5 - 6 - Insert the countershaft with gearing into the fly- wheel-side half-crankcase.
Page 189 X8 400 Euro 3 Engine Oil pump cover screws 0.7 ÷ 0.9 ENG - 189...
Page 190 INDEX OF TOPICS INJEC NJECTION...
Page 191 X8 400 Euro 3 Injection EMS injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. Injection and ignition are timed on the 4-stroke cycle using a tonne wheel pivoted on the camshaft control and a reluctance variation sensor.
Page 192 X8 400 Euro 3 Injection - Fuel pump - HV coil - Injector The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel. Failures are detected and restored by the diag- nostic tester.
Page 193 X8 400 Euro 3 Injection Precautions 1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults. 2. The fuel supply system is pressurised at 300 kPa (3 BAR). Before disconnecting the quick coupler of a pipe in the fuel supply system, check that there are no naked flames.
Page 194 X8 400 Euro 3 Injection ELECTRONIC CONTROL UNIT SIDE SYSTEM SIDE Specification Desc./Quantity Throttle potentiometer power supply +5 V Oxygen sensor Engine temperature 86 electric fan remote control switch Stepper motor Stepper motor Engine rpm sensor Oxygen sensor EMS diagnostic connector...
Page 195 X8 400 Euro 3 Injection IMMOBILIZER DECODER Specification Desc./Quantity Immobilizer LED control (negative) Base power supply (positive) Negative Electronic control unit EMS (serial) Continuous power supply (positive) Immobilizer aerial EMS circuit diagram 3. Engine rev sensor 4. Throttle valve position sensor...
Page 196 X8 400 Euro 3 Injection 5. Ambient temperature sensor 6. Stepper motor for idle jet 8. Engine temperature sensor 10. Key switch 11. Injection load remote control 12. Fuse holder B 13. Fuse-box A 15. Engine stop remote control 16. Engine stop switch 17.
Page 197 X8 400 Euro 3 Injection Possible Cause Operation Fuel pressure (low) Injector capacity (low) Power to the spark plug Shielded spark-plug cap HV coil (secondary insulation) Parameter reliability Coolant temperature Distribution timing - injection ignition Intake air temperature End of compression pressure...
Page 198 X8 400 Euro 3 Injection Possible Cause Operation Fuel filter Injector capacity Analysis of exhaust fumes before the catalytic converter Trimmer value adjustment (CO % adjustment) Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH...
Page 199 X8 400 Euro 3 Injection Engine revs irregularly IRREGULAR PROGRESS OF THE ENGINE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature.
Page 200 X8 400 Euro 3 Injection Possible Cause Operation Coolant temperature. Atmospheric pressure Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake system sealing Intake sleeve Filter box TPS reset successful...
Page 201 X8 400 Euro 3 Injection 7 - Check that fuses 3 and 7 are in working order. YES go to 10 NO go to 8 8 - Fix any wiring short circuits and replace the fuse. YES go to 1 NO go to 9 9 - Check any short circuit on decoder or control unit and replace, if necessary.
Page 202 X8 400 Euro 3 Injection Key-switch power supply circuit check A failure of the constant power supply disables both ignition and injection functions. In case of power supply faults, the diagnostic tester gives the information "NO REPLY FROM THE CONTROL UNIT".
Page 203 X8 400 Euro 3 Injection 8 - Decoder with proper continuous power supply. Use the special tool to check the control unit con- tinuous power supply. Switch set to "ON", switch to "RUN" and side stand raised. Pin 26 = battery positive...
Page 204 X8 400 Euro 3 Injection - emergency switch and connector - side stand switch and connector YES go to 16 16 - Check the cable harness continuity. Check the utility control main remote control switch. Disconnect the master remote control switch.
Page 205 X8 400 Euro 3 Injection 2 - Check the control unit base and continuous power supplies. YES go to 4 3 - Restore 4 - Place the special tool between control unit and system. Keep the control unit disconnected. YES go to 5...
Page 206 X8 400 Euro 3 Injection Injection warning light circuit 3. Revolution sensor 10. Key switch 12. Fuse holder B 13. Fuse holder A 15. Engine stop remote control switch 16. Engine stop switch 17. Diode 18. Battery 49. Instrument panel 51.
Page 207 X8 400 Euro 3 Injection Specification Desc./Quantity STANDARD VALUES : O V TERMINAL: 15 - 23 CONDITIONS: AFTER THE CHECK - Switch set to "ON" - Side stand raised - Switch to "RUN" STANDARD VALUES : Battery voltage The injection telltale light is controlled upon every switching to "ON" by the 3-second timing generated by the digital instrument.
Page 208 X8 400 Euro 3 Injection goes back off, however, the related operating tests need to be carried out. The light can go on whether the engine is able to run or not. Self-diagnosis system The injection control unit is provided with an auto-diagnosis function.
Page 209 X8 400 Euro 3 Injection - Stepper and relevant circuit - Pump relay circuit - Electric fan relay circuit - RAM memory - ROM memory - EEPROM - Microprocessor - Signals panel (stroke - revolution signal - unsteady cycle) Underlined failures cause the engine to stop.
Page 210: Circuit Diagram
X8 400 Euro 3 Injection BEFORE WORKING ON THE FUEL SUPPLY SYSTEM, CAREFULLY CLEAN THE PARTS TO PREVENT DAMAGING THE FAST-RELEASE COUPLING SEAL OR TO PREVENT DIRT GETTING INTO THE DUCTS. CAUTION THE SYSTEM IS UNDER PRESSURE. DO NOT SMOKE DURING ANY OPERATION.
Page 211 X8 400 Euro 3 Injection 12. Fuse holder B 13. Fuse-box A 15. Engine stop remote control 16. Engine stop switch 17. Diode 18. Battery 47. Fuel level transmitter 49. Instrument panel 50. Oil pressure sensor 60. Stand switch 51. Immobilizer aerial 52.
Page 212 X8 400 Euro 3 Injection - Remove the injector from the manifold. - Once the engine is repaired check the CO% value again while idling to make sure it is within the prescribed limits. If the CO% is not in conformity, proceed with calibration as described in the "Carbu- retion adjustment"...
Page 213 X8 400 Euro 3 Injection - Remove the 3 retaining screws indicated in the figure. CAUTION THE THROTTLE BODY COMES PRE-CALIBRATED. TAMPERING WITH THE THROTTLE STOP REGISTER IS TO BE ABSOLUTELY AVOIDED. THIS REGISTER HAS BEEN SEALED FOR THIS PURPOSE. FOR PROBLEMS WITH IDLING SEE THE "INJECTION" CHAPTER.
Page 214 X8 400 Euro 3 Injection the scooter is used, weather conditions and idle speed adjustment. This phenomenon can be easily detected as a gradual poor idle signals it. Carry out a thorough check with a scooter diagnostic tester, drw. 020460y. With engine temperature of at least 90°, the parameters may be as follows:...
Page 215 X8 400 Euro 3 Injection The idle carburetion needs to be adjusted to compensate for the production tolerances and engine settlement. This adjustment is done by modifying the injector opening time with the engine running at idle. To adjust, proceed as follows: 1 - Idle carburetion adjustment must be performed on an engine ready for precision adjustment.
Page 216 X8 400 Euro 3 Injection 6 - Repair according to indications supplied. YES go to 4 7 - Start the engine and let it warm up until the following conditions are present: - coolant temperature = over 80°C - intake air temperature = 25 ÷ 30°C...
Page 217 X8 400 Euro 3 Injection AFTER ADJUSTMENT ENGINES CAN HAVE CARBURETION WITH BOTH POSITIVE AND NEG- ATIVE TRIMMER VALUES. THIS IS DUE TO NORMAL PRODUCTION TOLERANCES. 14 - After having modifying a trimmer value, wait until the CO value becomes steady.
Page 218 X8 400 Euro 3 Injection When the control unit is replaced, reset TPS and pre-program the trimmer value of the original control unit (if available) preventively. In any case, check the CO value again. Proceed as follows: 1 - Set the switch to "ON" with emergency switch to "RUN" and side stand raised. The pump rotates for 2 seconds.
Page 219 X8 400 Euro 3 Injection YES go to 13 12 - Check and restore the earth insulation of the control unit line 19 and of the pump remote control switch line 85. YES go to 14 13 - Install the special tool between control unit and the injection system.
Page 220 X8 400 Euro 3 Injection 21 - Fix the wiring and repeat the check from the beginning. 22 - Check the earth insulation of wiring 87 (pump remote control switch) - 23 = insulation (>1 MΩ) YES go to 24 NO go to 23 23 - Restore the wiring insulation and replace the fuse.
Page 221 X8 400 Euro 3 Injection The injection CPU manages the negative of the light. The light must go off after the initial check. The light goes on again when the CPU autodiagnosis detects a fault. When the fault disappears the light goes back off, however, the related operating tests need to be carried out.
Page 222: Yes Go To 4 No Go To 5
X8 400 Euro 3 Injection The system pressure check must be carried out, for practical reasons, by connecting on the pump side. Connect the manometer to the outlet duct (RHS) and the extension tube to the inlet duct (LHS). CAUTION BEFORE REASSEMBLING CHECK THE TOOL DUCTS ARE CLEAN.
Page 223: Yes Go To 2
X8 400 Euro 3 Injection 4 - The pressure regulator is efficient. 5 - Pressure too high Check that the return duct is not clogged or squashed YES go to 6 NO go to 7 6 - Replace the pressure regulator.
Page 224 X8 400 Euro 3 Injection 2 - Let bleed for a few seconds. Make sure that there are no leaks. Using pliers with flat and long tips, temporarily clamp the return duct by the extension of the spe- cial tool with pump power supply voltage higher than 12 V, check the system maximum pressure.
Page 225 X8 400 Euro 3 Injection 10 - There occur trend variations YES go to 11 NO go to 13 11 - Repeat the test clamping the pipe of the spe- cial tool in the portion between the branch and the injector.
Page 226 X8 400 Euro 3 Injection 17 - Introduce the return pipe into a graduated container. Using the diagnostic tester, start the fuel pump for 10 seconds. Make sure that the power supply voltage is more than 12V. Measure the amount of fuel delivered.
Page 227 X8 400 Euro 3 Injection Pump consumption check The pump power consumption may vary according - Power supply voltage - Pump running-in - Regulation pressure - Delivery filter cleaning To check the current consumption, proceed as fol- lows - Disconnect the pump remote control switch con- nector.
Page 228 X8 400 Euro 3 Injection Pump bracket overhaul To remove the pump support from the tank, pro- ceed as follows: - Disconnect the electric connector. - Start the engine and wait for the spontaneous stop. - Clean the tank and the pump support (wash and blow with compressed air, if necessary).
Page 229 X8 400 Euro 3 Injection Pass the wires through the hole found between fil- ter and pressure regulator. - Disconnect and extract the wires - Using a screwdriver on the retain tab as shown in the figure, extract the level indicator from the...
Page 230 X8 400 Euro 3 Injection - Lubricate the O-rings and repeat the operations in the reverse order for reassembly. (3) Fuel pump - Note the position of the power supply wires on the support pos 1 = positive (red) pos 4 = negative (black)
Page 231 X8 400 Euro 3 Injection - Remove the filter coupling pipe - Remove the pump with annular support and pre- filter. - If the pump requires replacement, remove the pre-filter and the annular support. - For reassembly, perform the removal operations but in the reverse order using a new clamp for the delivery pipe and a new pump mounting washer.
Page 232 X8 400 Euro 3 Injection Pump bracket installation - Before reassembling, carefully check that the tank is clean. In case of dirt or water, remove the tank. - Install the sealing gasket on the pump support. - Introduce the pump into the tank being careful not to deform the level indicator arm.
Page 233 X8 400 Euro 3 Injection Inspecting the injector circuit 3. Engine rev sensor 4. Throttle valve position sensor 5. Ambient temperature sensor 6. Stepper motor for idle jet 8. Engine temperature sensor 10. Key switch 11. Injection load remote control 12.
Page 234: Yes Go To 3
X8 400 Euro 3 Injection 51. Immobilizer aerial 52. Immobilizer decoder 53. Fuel pump 54. Fuel injector 55. Spark plug 56. HV coil 57. Lambda probe 58. Diagnostics socket 59. Injection ECU 60. Stand switch 2 - Enable the function with continuous power sup- ply on and engine off.
Page 235: Yes Point 12
X8 400 Euro 3 Injection 10 - There are also fault messages for: pump relay YES go to 13 NO go to 11 11 - There is also a fault message for the HV coil. YES point 12 12 - Check the power supply circuit with the fuse 12 and the remote control switch. Common feeding to the fuel pump.
Page 236 X8 400 Euro 3 Injection 18 - No continuity. Disconnect the connector and repeat the resistive check directly at the injector terminals. Resistance = 14.5 Ω ± 2% YES go to 21 NO go to 22 19 - Check the earth insulation of the injector negative line. Disconnected control unit and injector connectors.
Page 237 X8 400 Euro 3 Injection 2 - Prepare a graduated container with minimum capacity of 100 cm3 and a resolution of 10-20 cm3 Connect the injector to the wire supplied with the injection tester. The wire is provided with alligator clips for direct connection to the battery.
Page 238: Troubleshooting
X8 400 Euro 3 Injection about 80°. The jet thus formed impinges both in- take valves. N.B. - AN INJECTOR WITH LOW FLOW RATE AFFECTS THE MAXIMUM PERFORMANCE. - AN INJECTOR WITH POOR SEAL AFFECTS IDLING AND THE START-UP FEATURES AFTER A SHORT STOP WITH HOT ENGINE.
Page 239: System Components
X8 400 Euro 3 Injection Immobiliser circuit The EMS system is integrated with the immobiliser anti-theft device. Its functions are: - Start-up enabled by key recognition. - Deterrent flashing. System components The system consists of: -EMS system control unit - Decoder...
Page 240 X8 400 Euro 3 Injection Set the switch to "ON" and select the diagnostic tester menu to the immobiliser function. Scroll the pages to display the control unit data. N.B. AN UNPROGRAMMED SYSTEM CANNOT BE DETECTED UPON FIRST FITTING, OR IN CASE THE DECODER AND THE CONTROL UNIT ARE REPLACED CONCURRENTLY.
Page 241 X8 400 Euro 3 Injection • there is power to the control unit as specified below: Disconnect the connector from the control unit. Check the following conditions: With the key switch set to OFF: • Battery voltage between terminals 17-23 and terminals 17-chassis ground (continuous pow- er supply).
Page 242 X8 400 Euro 3 Injection - Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper lim- its 1 to 3 seconds). - Insert the service key and turn it to «ON» for 2 seconds.
Page 243 X8 400 Euro 3 Injection Checking master-box data Connect the diagnostic tester. Set to «ON» and select the immobilizer function. Scroll the pages the find the data. Specific tooling 020460Y Scooter diagnosis and tester The information will be as follows: - Unprogrammed control unit «OFF»...
Page 244 X8 400 Euro 3 Injection Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
Page 245 X8 400 Euro 3 Injection Code 1 A one-flash code indicates a system where the se- rial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessa- Code 2 A 2-flash code indicates a system where the de- coder does not recognise the transponder signal.
Page 246 X8 400 Euro 3 Injection STANDARD: approx. 0.8 - 4.5 V CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Engine rpm sensor The sensor allows the rotations and the angular position of the crankshaft to be recognised by reference to the TDC. Since the wheel speed sensor is pivoted on the camshaft it is also possible to recognise the 4-stroke cycle.
Page 247 X8 400 Euro 3 Injection Any faults discovered in this phase are signalled via the injection telltale light. The fault continues to be signalled, but the circuit is only checked when turning to "ON". Therefore faults which occur or disappear after turning to "ON" are not acknowledged.
Page 248 X8 400 Euro 3 Injection THE FAULT HAS BEEN RECORDED IN CUR- RENT STATUS: The control circuit gave a negative result when switching to "ON". AHEAD go to 8 3 Select the "PARAMETERS" function on the menu. Check the number of «lost synchronisations»: 1 TOOTH and >...
Page 249 X8 400 Euro 3 Injection RESISTANCE OF THE RPM TIMING SENSOR: ( 25°C) Specification Desc./Quantity 860 Ω ± 130 Ω Model with 1 clamp: 680 Ω ± 100 Ω Model with 2 clamps: YES go to 11 NO go to 12 11 - Check the earth isolation between a pole and the shielding.
Page 250 X8 400 Euro 3 Injection 15 - Check the connectors carefully. Disconnect and check the continuity between connector and pin 7-12 Electric characteristic Connector - 7 = Continuity Connector - 12 = Continuity Fix the connectors or replace the cable harness.
Page 251 X8 400 Euro 3 Injection -A POOR CABLE SHIELDING CAN IMPAIR THE ENGINE PERFORMANCE AT HIGH SPEED. HT coil This section describes the ignition system operation. Circuit diagram Electric characteristic TERMINALS: 20 - 23 CONDITIONS : During the pump timing with engine off.
Page 252 X8 400 Euro 3 Injection 15. Engine stop remote control 16. Engine stop switch 17. Diode 18. Battery 47. Fuel level transmitter 49. Instrument panel 50. Oil pressure sensor 60. Stand switch 51. Immobilizer aerial 52. Immobilizer decoder 53. Fuel pump 54.
Page 253 X8 400 Euro 3 Injection 1 - Connect the diagnostic tester. Select the menu on the "ACTIVE DIAGNOSIS" function. Start the HV coil check with switch set to «ON», switch to «RUN» and side stand raised. Wait for the tester to display: "TEST SUCCESSFUL"...
Page 254 X8 400 Euro 3 Injection Repeat the voltage check between the black-green wire and earth. Electric characteristic Black-green-23 = battery voltage (coupled to the pump rotation-2 seconds). YES go to 10 NO go to 9 9 - Check the black-green wire continuity.
Page 255 X8 400 Euro 3 Injection YES go to 12 NO go to 13 12 - Check the earth insulation of the negative line. Electric characteristic 20-23 = Ω infinite (>1MΩ) YES go to 15 NO go to 14 13 - Repair or replace the faulty system. Repeat the check with the menu on "ACTIVE DIAGNOSIS".
Page 256 X8 400 Euro 3 Injection Measure between one of the primary terminals and earth. Electric characteristic Primary-earth = Ω infinite (>1MΩ) YES go to 17 NO go to 1 9 17 - Check the secondary resistance. Measure the resistance between one of the primary terminals and the spark plug cable output...
Page 257 X8 400 Euro 3 Injection If different values are measured (<1; >20KΩ), re- place the shielded cap. N.B. A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM. FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTE- NANCE»...
Page 258 X8 400 Euro 3 Injection - By the driving pulley, turn the engine to find the alignment of the references to identify the TDC. - Repeat for the reference between driving pulley and engine crankcase. - Refit the inspection cap on the flywheel side.
Page 259 X8 400 Euro 3 Injection 3. Engine rev sensor 4. Throttle valve position sensor 5. Ambient temperature sensor 6. Stepper motor for idle jet 8. Engine temperature sensor 10. Key switch 11. Injection load remote control 12. Fuse holder B 13.
Page 260 X8 400 Euro 3 Injection 53. Fuel pump 54. Fuel injector 55. Spark plug 56. HV coil 57. Lambda probe 58. Diagnostics socket 59. Injection ECU 60. Stand switch The coolant temperature sensor is installed on the engine head and provides the indications for the digital instrument and for the injection.
Page 261 X8 400 Euro 3 Injection YES go to 5 5 - Check the following values: coolant temperature intake air temperature ambient temperature The three indications are equal or they are slightly different (e.g. 1° C). YES go to 6 NO go to 7 6 - The temperature sensor is providing probably correct information.
Page 262 X8 400 Euro 3 Injection If infinite resistance is detected (>1MW), check the continuity between the two lines with disconnected connectors. Electric characteristic Blue-white-4 = 0W (continuity) Light blue/green-22 = 0 ohm. (Continuity) YES point 12 12 - Repair or replace the cable harness.
Page 263 X8 400 Euro 3 Injection 14 - Repair or replace the wiring. Check the air temperature lines and the throttle valve position. YES go to 13 15 - Connect the special tool to the control unit. Set the switch to "ON" with switch to "RUN" and side stand raised.
Page 264 X8 400 Euro 3 Injection Repeat the sensor and circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector. Check the control unit power supply. Replace the control unit, if necessary.
Page 265 X8 400 Euro 3 Injection 3. Engine rev sensor 4. Throttle valve position sensor 5. Ambient temperature sensor 6. Stepper motor for idle jet 8. Engine temperature sensor 10. Key switch 11. Injection load remote control 12. Fuse holder B 13.
Page 266 X8 400 Euro 3 Injection 53. Fuel pump 54. Fuel injector 55. Spark plug 56. HV coil 57. Lambda probe 58. Diagnostics socket 59. Injection ECU 60. Stand switch The sucked air temperature sensor is installed in the bottom side of the throttle body on the filter box side.
Page 267 X8 400 Euro 3 Injection 5 - Check the following values: coolant temperature intake air temperature ambient temperature indicated by the digital instrument. The three indications are equal or they are slightly different (e.g. 1° C). YES go to 6 NO go to 7 6 - The intake air temperature sensor is providing an incorrect information.
Page 268 X8 400 Euro 3 Injection YES go to 13 NO go to 11 11 - If slightly higher values are detected, check the connectors. If infinite resistance is detected (>1MΩ), check the continuity of the two lines with disconnected con- nectors.
Page 269 X8 400 Euro 3 Injection YES go to 15 NO go to 14 14 - Repair or replace the wiring. Check the valve position and the fluid temp. lines. YES go to 13 15 - Connect the special tool to the control unit.
Page 270 X8 400 Euro 3 Injection YES go to 18 Electric characteristic Measured value = Repeat the sensor circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector. Check the control unit power supply. Replace the control unit, if necessary.
Page 271 X8 400 Euro 3 Injection YES go to 4 NO go to 5 4 - The ambient pressure signal is correct. 5 - Replace the injection control unit. Throttle valve opening sensor Throttle position sensor (t.p.s.) Electric characteristic TERMINALS: 1 - 22 CONDITIONS: Switch set to "ON"...
Page 272 X8 400 Euro 3 Injection CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Valve position sensor Air temperature sensor Fluid temperature sensor The throttle valve position sensor is not removable and is installed on the throttle body. This sensor receives a 5-V power supply from the...
Page 273 X8 400 Euro 3 Injection 2 - Select the diagnostic tester menu on the "PA- RAMETERS" function. Check whether the control unit recognises the ex- treme positions: Throttle valve to minimum Throttle valve to maximum YES go to 4 NO go to 3 3 - Check the adjustment of the throttle valve control flexible transmissions.
Page 274 X8 400 Euro 3 Injection 8 - Check the earth insulation of the three circuit lines. Electric characteristic 22-23 = Ω infinite (>1M) 1-23 = Ω infinite (>1M) 11-23 = Ω infinite (>1M) YES go to 10 NO go to 9...
Page 275 X8 400 Euro 3 Injection 12 - Connect the throttle valve position sensor connector. Repeat the voltage measurement between terminals 1 and 22 of the special tool. Electric characteristic 1-22 = 5±0.2 V YES go to 13 NO go to 14 13 - Measure voltage between terminals 11 and 22.
Page 276 X8 400 Euro 3 Injection Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre-set reference conditions. Pre-calibration ensures optimal air flow to control idling. This regulation must not be tampered with in any way whatsoever.
Page 277 X8 400 Euro 3 Injection Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure. Select the "PARAMETERS" function and check that the TPS reset "YES" is displayed. Reset should be performed in the following cases: - on first fitting.
Page 278 X8 400 Euro 3 Injection Step motor CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Stepper motor Stepper motor The throttle body is provided with an auxiliary air circuit. This is enabled by a piston valve controlled by a Stepper motor.
Page 279 X8 400 Euro 3 Injection travel and to open up again by a fixed number of steps (self-reset). When the control unit changes the Stepper open- ing "steps" it also changes the injection time to ensure proper ignition. The engine idle speed is practically stabilised at 1550-50 rpm.
Page 280 X8 400 Euro 3 Injection YES go to 3 NO go to 4 3 - Start the engine and let it warm up. With a coolant temperature of more than 70°C, the control unit must control the Stepper with about 45 «steps».
Page 281 X8 400 Euro 3 Injection Resistance = approx. 51 Ω YES go to 11 NO go to 10 9 - Test successful. No variations of revolutions. Remove the throttle body. Check the auxiliary air circuit cleaning. Switch from "ON" to "OFF" and again to "ON" and check wheth- er the piston valve moves.
Page 282 X8 400 Euro 3 Injection YES go to 12 NO go to 13 12 - Check the earth insulation of the 4 Stepper lines. Electric characteristic 14-23 = >1 MΩ (infinite) 6-23 = >1 MΩ (infinite) 21-23 = >1 MΩ (infinite) 24-23 = >1 MΩ...
Page 283 X8 400 Euro 3 Injection YES go to 16 NO go to 15 15 - Check cable harness and connectors more carefully. 16 - Connect the control unit connector. Set the switch to «ON» with switch to «RUN» and side stand raised. Repeat the «ON» «OFF» «ON»...
Page 284 X8 400 Euro 3 Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Connect the multimeter probes between pin 2 (-)
Page 285 X8 400 Euro 3 Injection 3. Engine rev sensor 4. Throttle valve position sensor 5. Ambient temperature sensor 6. Stepper motor for idle jet 8. Engine temperature sensor 10. Key switch 11. Injection load remote control 12. Fuse holder B 13.
Page 286 X8 400 Euro 3 Injection 53. Fuel pump 54. Fuel injector 55. Spark plug 56. HV coil 57. Lambda probe 58. Diagnostics socket 59. Injection ECU 60. Stand switch The electric fan system is powered by a remote control switch connected to the continuous power supply controlled by the electronic control unit of the injection system.
Page 287 X8 400 Euro 3 Injection 2 - Select the menu on the "ACTIVE DIAGNOSIS" function. Activate the electric fan diagnostic func- tion. Check acoustically for rotation of the electric fan. Wait for the exit from the diagnostic tester. YES go to 3 NO go to 4 3 - Test successful.
Page 288 X8 400 Euro 3 Injection 12 - Repair or replace the wiring. 13 - Leaving the remote control switch disconnec- ted, check for continuity between pin 86 of the remote control switch connector and pin 5 of the electronic control unit.
Page 289 INDEX OF TOPICS SUSP USPENSIONS...
Page 290: Removing The Front Wheel
X8 400 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 291 X8 400 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 brake disc side to permit the removal of the opposite side bearing and the spacer bushing.
Page 292 X8 400 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 - Refit the cap and tighten the five fixing screws.
Page 293: Front Fork
X8 400 Euro 3 Suspensions - Heat the bearing seat on the side the brake disc with the heat gun. 2 - Insert the two bearings one at a time using the punch consisting of adaptor handle, 32x35 mm adaptor and 15 mm guide, and take it to the stop.
Page 294 X8 400 Euro 3 Suspensions Using the special tool, loosen and remove the up- per ring nut, the spacer washer and the counter- ring nut. - Extract the fork. N.B. TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT...
Page 295 X8 400 Euro 3 Suspensions - Loosen the stem support clamp and remove fork leg and stem. - Remove the spring. - Drain the oil. - Remove the screw with copper washer shown in the figure. To prevent the pumping member rota- tion, insert an inside 22 mm hexagon spanner into the stem.
Page 296 X8 400 Euro 3 Suspensions - Extract the oil guard "D", the abutment washer "C" and the top bushing "B". - Widen and remove the bottom bushing "A". Servicing tapered bearing seats - Check that the seats and the tapered bearings exhibit no scratches or wear.
Page 297 X8 400 Euro 3 Suspensions - Insert the following from the top of the stem: 1 Bushing "B" 2 Abutment washer "C" 3 Oil guard "D" - Insert the pumping member guiding bushing at the bottom end of the stem.
Page 298 X8 400 Euro 3 Suspensions - Insert the contrast spring into the pumping mem- ber. - Insert the pumping member into the stem. - Insert the stem into the fork leg being careful not to let the guiding bushing come out of the stem.
Page 299 X8 400 Euro 3 Suspensions - Loosen the fork clamp screws and move the stem closing cap in abutment with the clamp. - Tighten the clamp screws to the prescribed tor- que. Locking torques (N*m) Fork clamp screws 20 ÷ 25 - Grease the tapered bearing using the specified product.
Page 300 X8 400 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 steering tube to the prescribed torque.
Page 301 X8 400 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 302: Removing The Rear Wheel
X8 400 Euro 3 Suspensions Reassembly of steering tapered bearing seats Using the special tool, reassemble the tapered bearing housings on the head as described below: - Place a new top housing on the head and a new bearing seat on the bottom side.
Page 303 X8 400 Euro 3 Suspensions - Remove the two screws fixing the bracket to the engine - Remove the two screws fixing the stand to the bracket - Slide off the wheel axle bracket, using the heat gun if necessary.
Page 304: Shock Absorbers
X8 400 Euro 3 Suspensions F = Chassis Removal - Support the engine adequately. - Remove the pin anchoring the engine to the chassis. - Move the engine backwards to take out spacers - Remove the left spacer highlighted in the figure.
Page 305 X8 400 Euro 3 Suspensions Removal Proceed as follows: - place the scooter on its centre stand; - lift the engine a little with a jack so as to free the two shock absorbers; - remove the muffler - undo the shock absorber spring assembly clamp-...
Page 306: Side Stand
X8 400 Euro 3 Suspensions Side stand - Unhook the springs. - Loosen the nut. - Pull out the screw. Fitting Carry out the previous operations but in reverse order. Locking torques (N*m) Side stand clamp 15 ÷ 20 SUSP - 306...
Page 307 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 308: Rear Brake Calliper
X8 400 Euro 3 Braking system Rear brake calliper Removal - Remove the left suspension bottom retainer and lift absorber upwards. - Remove the two rear brake calliper devices fas- tening them to the support as shown in the photo- graph.
Page 309 X8 400 Euro 3 Braking system - Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully - Fit the O-rings and new dust guards - Refit the pistons in their seats being careful to...
Page 310 X8 400 Euro 3 Braking system - Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. Front brake calliper Removal - Remove the two front brake calliper devices fas- tening them to the support as shown in the photo- graph.
Page 311 X8 400 Euro 3 Braking system Overhaul - Remove the brake calliper. - Suitably support the brake calliper in a vice - Remove the two pad fixing screws. - Remove the pads being careful with the stop spring. - Remove the fixed plate by undoing the screw shown in the photograph.
Page 312 X8 400 Euro 3 Braking system Refitting - Insert the O-rings and small pistons the floating body, lubricating all the components with brake fluid. - Fit the fixed plate being careful to grease guide A and to insert washer B as indicated in the photo.
Page 313 X8 400 Euro 3 Braking system Refitting - To reassemble the brake disc on the hub, carry out the removal operations in the reverse order ar- ranging the brake disc on the hub on the side opposed the wheel keying - Follow the direction of rotation shown by the ar- row and tighten to the prescribed torque.
Page 314: Front Brake Disc
X8 400 Euro 3 Braking system - Repeat the measurement at no fewer than six points on the disc. - Check that the measurements do not deviate over 0.1 mm - Remove the front calliper. - Place the magnetic base with the dial gauge on the brake calliper support bracket as shown in the photograph.
Page 315 X8 400 Euro 3 Braking system Loctite 243 Medium-strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Brake disc fixing screw 5 ÷ 6.5 - Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the six screws to the specified torque.
Page 316: Front Brake Pads
X8 400 Euro 3 Braking system 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. - Remove the pads, being careful with the pad spring clamp.
Page 317 X8 400 Euro 3 Braking system Removal - Remove the rear brake calliper. - Remove the brake pad and check there are no faults or warping. If there is, replace it. - Check the thickness of the friction material is more than 1.5 mm.
Page 318 X8 400 Euro 3 Braking system Rear brake calliper tightening screw 20 ÷ 25 Nm Fill Rear - combined - 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 319 X8 400 Euro 3 Braking system 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. - With the left-had brake lever, load the system and bring it up to the required pressure.
Page 320 X8 400 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 up by acting on the two screws shown in the figure.
Page 321 X8 400 Euro 3 Braking system Removal - Remove the front handlebar cover. - Drain off the braking system corresponding to the circuit being tested. - Remove the two fixing screws from the brake pump to the handlebar indicated in the photo- graph.
Page 322 X8 400 Euro 3 Braking system Removal - Remove the front handlebar cover. - Drain off the braking system corresponding to the circuit being tested. - Remove the two fixing screws from the brake pump to the handlebar indicated in the photo- graph.
Page 323 X8 400 Euro 3 Braking system - Tighten the screws fixing the valve to the chassis, but above all tighten the brake piping to the pre- scribed locking torques. - Fill and purge the braking system as described in the relevant section.
Page 324 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 325 X8 400 Euro 3 Cooling system Circuit diagram The cooling system is a forced circulation type system, with continuous venting and air pressurisation. Circulation takes places by a centrifugal pump driven by the countershaft. The pump delivers the coolant to the thermal group.
Page 326 X8 400 Euro 3 Cooling system For the system venting during the circuit filling step, there is a special union at the top of the head (see filling rules). To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection system.
Page 327 X8 400 Euro 3 Cooling system - Select the menu on the "ACTIVE DIAGNOSIS" function and start the electric fan operation simu- lation (see "Injection" chapter). - If the electric fan is certainly efficient, check the ventilation start and stop temperatures.
Page 328: Coolant Replacement
X8 400 Euro 3 Cooling system DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OB- SERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE SEALING GASKETS. Coolant replacement System filling instructions - Prepare the mixture of 50% water and 50% cool- ant.
Page 329: Water Pump Cover Screws
X8 400 Euro 3 Cooling system - Refit the water pump cover, tightening the 6 fixing screws to the prescribed torque. Locking torques (N*m) Water pump cover screws 3 ÷ 4 Water pump ceramic seal Our Leader, Quasar, and Master liquid cooled engines are equipped with water pumps fitted with the ceramic seal in the subject.
Page 330 X8 400 Euro 3 Cooling system - Check that the reed valve of blow-by circuit closes adequately. - Check that the water pump shaft does not show signs of wear and tear on the bearings in contact with the crankcase, in the oil seal area and on the motion sensor.
Page 331 X8 400 Euro 3 Cooling system - Check the free length of the spring. Characteristic Standard length: 65.2 mm Length limit after use: 64.0 mm Thermostat Check Before proceeding to disassemble, carry out a few checks: - Connect the diagnostic tester and select the «PA- RAMETERS»...
Page 332 X8 400 Euro 3 Cooling system - Visually check that the thermostat exhibits no mechanical faults. - 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 close to the thermostat.
Page 333 X8 400 Euro 3 Cooling system N.B. THE CAP IS EQUIPPED WITH A PRESSURE-RELIEF VALVE CALIBRATED AT 0.9 BAR. There is also a valve that must allow air inlet during the cooling step. YES go to 2 NO go to 3 2 - Check the head gasket seal (see «Thermal group and timing system»...
Page 334 INDEX OF TOPICS CHAS HASSIS...
Page 335 X8 400 Euro 3 Chassis This section is devoted to the operations that can be carried out on the vehicle bodywork. CAUTION WE STRONGLY RECOMMEND NOT TO CLEAN THE PAINTED PLASTIC PARTS WITH SOLVENTS CONTAINING PETROL OR PETROL BY-PRODUCTS. Seat •...
Page 336: Instrument Panel
X8 400 Euro 3 Chassis Instrument panel • Remove the instrument panel support and tip it. • Unscrew the two clamping screws to remove the instrument panel. Front handlebar cover • Undo the three clamping screws of the upper handlebar cover and pull it up- wards.
Page 337 X8 400 Euro 3 Chassis Headlight assy. • Remove the upper cover of the head- light • Undo the two upper clamping screws, the lower screw and remove the head- light assembly • Undo the two clamping screws of each...
Page 338 X8 400 Euro 3 Chassis Legshield • Remove the rear-view mirrors • Remove the two screws indicated in the figure. • Remove the front headlight • Remove the upper three fixings • Remove the eight clamping screws (4 each side) on the shield back plate.
Page 339 X8 400 Euro 3 Chassis • Remove the eight clamping screws (four per side) for fixing the shield with the radiator grille and the spoiler. See also Headlight assy. Knee-guard • - Remove the front shield. • Remove the expansion tank from the...
Page 340 X8 400 Euro 3 Chassis See also Legshield Front wheel housing • Remove the front fork; • Unscrew the central stud of the wheel well at the frame; • Disconnect the brake pipe to the pump and pull it out;;...
Page 341: License Plate Light
X8 400 Euro 3 Chassis • Central lights: parking lights; • Side lights: stop lights. License plate light - To replace the bulb remove the rubber cap from inside the helmet compartment, then slide the rub- ber bulb holder off its fitting.
Page 342 X8 400 Euro 3 Chassis • Undo the four clamping screws on the edge of the footboard and remove the lower cover. The diagram illustrate what to do on the right-hand footboard; follow the same procedure to remove the left-hand footboard.
Page 343 X8 400 Euro 3 Chassis - Remove the two screws indicated in the figure. - Unscrew the screw under the turn indicator. - Remove the plastic parts on the passenger foot- rest indicated in the figure. Remove the 4 screws indicated in the figure, then slide off the fairing by pulling it backwards to free the teeth hooking it to the central cover.
Page 344 X8 400 Euro 3 Chassis See also License plate light Handles and top side fairings License plate holder • Remove the rear and side fittings and the pipe above the helmet compart- ment retaining frame; • Remove the two side licence plate sup- port clamping screws;...
Page 345 X8 400 Euro 3 Chassis 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; - Undo the 2 screws two on the bottom of the hel- met compartment.
Page 346 X8 400 Euro 3 Chassis - Undo the 4 screws (2 per side) on the sides of the helmet compartment. • Raise the helmet compartment as far as possible; • Disconnect the electrical connection of the light and the two buttons for acti- vating it ;...
Page 347 X8 400 Euro 3 Chassis Flyscreen • Remove the driving mirrors; • Undo the four clamping screws «B», then extract the cover being careful with the 2 teeth coupling it to the turn indicators. • Remove the four clamping screws;...
Page 348 INDEX OF TOPICS PRE DE DELIVERY...
Page 349 X8 400 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 plastic parts - Scratches - Dirt Tightening torques inspection Lock check...
Page 350 X8 400 Euro 3 Pre-delivery 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. CAUTION WHEN INSTALLING THE BATTERY, CONNECT THE POSITIVE CABLE BEFORE CONNECTING THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
Page 351 X8 400 Euro 3 Pre-delivery - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks - Operation of the radiator electric fan Functional inspection Operating test: - Hydraulic brake system - Lever travel...
Page 352 INDEX OF TOPICS TIME...
Page 353 X8 400 Euro 3 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 ENGINE Code Action Duration 001001 Engine to chassis - Replacement TIME - 353...
Page 354 X8 400 Euro 3 Time Crankcase CRANKCASE Code Action Duration 001100 Oil seal, clutch side - Replacement 001133 Engine crankcase - Replacement 001153 Crankcase half gasket - Replace- ment TIME - 354...
Page 355 X8 400 Euro 3 Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001098 Countershaft - Replacement TIME - 355...
Page 356 X8 400 Euro 3 Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder / Piston - Replacement 001154 Pistonsrings-pin assembly - Service 001129 Chain tensioner - Service and Re- placement TIME - 356...
Page 357 X8 400 Euro 3 Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001049 Valves - Adjustments 001056 Head gasket - Replacement 001126 Head - Replacement 001083 Thermistor - Replacement 005116 Rpm timing sensor - Replacement...
Page 358 X8 400 Euro 3 Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Valve rocking levers - Replacement TIME - 358...
Page 359: Cylinder Head Cover
X8 400 Euro 3 Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement TIME - 359...
Page 360 X8 400 Euro 3 Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump - Replacement 001123 Oil filter - Replacement 001124 By-pass valve - Replacement 001057 Thermostat - Replacement 001062 Water pump command shaft - Re-...
Page 361: Driven Pulley
X8 400 Euro 3 Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement TIME - 361...
Page 362 X8 400 Euro 3 Time Oil pump OIL PUMP Code Action Duration 001042 Oil pump - Service 001051 Belt/ Timing chain - Replacement 001112 Oil pump - Replacement 001125 Chain guide sliders - Replacement 001071 Start-up pinion - Replacement 001020...
Page 363 X8 400 Euro 3 Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001010 Geared reduction unit - Service 001156 Gear reduction unit cover - Replace- ment 003065 Gearcase oil - Replacement 004125 Rear wheel axle - Replacement...
Page 364 X8 400 Euro 3 Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001006 rear-view pulley - Service 001141 Belt anti-flapping roller - Replace- ment 001066 rear-view pulley - Replacement TIME - 364...
Page 365 X8 400 Euro 3 Time Transmission cover TRANSMISSION COVER Code Action Duration 001065 Internal transmission cover - Re- placement 001096 External transmission cover - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement...
Page 366: Flywheel Magneto
X8 400 Euro 3 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001173 Rotor - Replacement 001067 Stator - Replacement 001058 Flywheel - Replacement 001104 Start-up freewheel - Replacement 001151 Start-up driven gearing - Replace- ment TIME - 366...
Page 367: Throttle Body
X8 400 Euro 3 Time Butterfly valve THROTTLE BODY Code Action Duration 001013 Intake manifold - Replacement 001047 Injector - Replacement 001166 Throttle body - Replacement 004122 Cleaner / Throttle body union - Re- placement 001171 Throttle body - Service/cleaning...
Page 368 X8 400 Euro 3 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 004169 Muffler guard - Replacement 005138 Lambda probe - Replacement TIME - 368...
Page 369: Air Cleaner
X8 400 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 - Re- placement 001027 Body / air cleaner union - Replace-...
Page 370 X8 400 Euro 3 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...
Page 371 X8 400 Euro 3 Time Centre-stand SIDE/CENTRAL STAND Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Side stand switch - Replacement 004171 Stand support plate - Replacement TIME - 371...
Page 372 X8 400 Euro 3 Time Legshield spoiler RONT SHIELD Code Action Duration 004101 Windshield - Replacement 004066 Rear-view mirror - Replacement 004020 Headlight frame - Replacement 004064 Legshield - Replacement TIME - 372...
Page 373 X8 400 Euro 3 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 - 373...
Page 374 X8 400 Euro 3 Time Mudguard UDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004167 Grille / radiator cover - Replacement 004009 Rear mudguard - Replacement TIME - 374...
Page 375: Fuel Tank
X8 400 Euro 3 Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - Replacement 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 375...
Page 376: Handlebar Covers
X8 400 Euro 3 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 377 X8 400 Euro 3 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 378: Turn Signal Lights
X8 400 Euro 3 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement Turn signal lights Front lights TIME - 378...
Page 379 X8 400 Euro 3 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-...
Page 380 X8 400 Euro 3 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 381: Front Wheel
X8 400 Euro 3 Time Front wheel FRONT WHEEL Code Action Duration 005089 Tone wheel - Replacement 002041 Front brake disc - Replacement 003037 Front wheel rim - Replacement 003038 Front wheel axle - Replacement 003040 Front wheel bearings - Replacement...
Page 382: Rear Wheel
X8 400 Euro 3 Time Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001017 Rear wheel rim - replace 002070 Rear brake disc - Replacement 003063 Tyre pressure - Check 003077 Muffler / rear shock absorber support...
Page 383: Fuel Pump
X8 400 Euro 3 Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 383...
Page 384 X8 400 Euro 3 Time Electric devices ELECTRIC DEVICES Code Action Duration 001023 Injection ECU - Replacement 005009 Voltage regulator - Replacement 005117 Electric fan remote control - Replace- ment 005088 Emergency stop remote control - Re- placement 005096 Injection components remote control...
Page 385 X8 400 Euro 3 Time ELECTRIC DEVICES Code Action Duration 005001 Electrical system - Replacement 005054 Fuse holder - Replacement 005052 Fuse (1) - Replacement 005114 Electrical system - Service 005130 Electric control management device - Replacement TIME - 385...
Page 386 X8 400 Euro 3 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-...
Page 387 X8 400 Euro 3 Time Rear side fairings REAR COVERS Code Action Duration 004053 Spoiler - Replacement 004085 Rear fairing - Replacement 004068 Passenger handgrip - Replacement 004159 Plates / Stickers - Replacement 004036 Lower chassis cover - Replacement 004012...
Page 388 X8 400 Euro 3 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 389 X8 400 Euro 3 Time Rear suspension REAR SUSPENSION Code Action Duration 003085 Suspension strut - Replacement 003007 Rear shock absorber - Replacement 004120 Rear suspension linkage - Replace- ment 003086 Suspension strut support - replace- ment TIME - 389...
Page 390 X8 400 Euro 3 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...
Page 391 X8 400 Euro 3 Time Braking system BRAKE SYSTEM Code Action Duration 002021 Front brake piping - Replacement 002047 Front brake fluid and air bleeding system - Replacement 002020 Rear brake disc piping - Replace- ment 002087 Rear integral braking system rigid...
Page 392 X8 400 Euro 3 Time Windscreen WINDSHIELD Code Action Duration 004028 Windshield glass - Replacement 004101 Windshield - Replacement 004117 Top fairing - Replacement TIME - 392...
Page 393 Air filter: 35, 344 Battery: 53, 61, 66, 68, 69, 73 Brake: 308, 310, 312, 314, 316, 319–321 Brake fluid: 319 Coolant: 258, 328 Engine oil: 35 Fuel: 209, 223, 227, 375, 383 Fuses: 64 Headlight: 41, 337, 339 Hub oil: 33 Identification: 8 Immobilizer: Instrument panel: 336...
Page 394 Tank: 375 Technical Data: Transmission: 9, 81, 97, 365 Tyres: 10...

PIAGGIO X8 400 Euro 3 Service Station Manual

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