Page 1 SERVICE STATION MANUAL xxxxxx X7 250ie...
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 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 SERVICE STATION MANUAL X7 250ie This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8: Safety Rules
Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 9: Vehicle Identification
X7 250ie Characteristics Vehicle identification To read the chassis prefix, lift the saddle and re- move the lid «A». The engine prefix «B» is stamped near the lower support of the rear left shock absorber. VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix...
Page 10 X7 250ie Characteristics Dimensions and mass VEHICLE EARTHING Specification Desc./Quantity Kerb weight 162 kg Maximum weight allowed 360 kg Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke Cubic capacity 244 cm³ Bore x Stroke 72 x 60 mm Compression ratio 11 ± 0.5 : 1 Engine idle speed 1,700 ±...
Page 11: Electrical System
X7 250ie Characteristics Specification Desc./Quantity Minimum lubrication pressure (100° C) 0.8 bar Fuel supply Electronic injection with Ø 32-mm throttle body and electric fuel pump. Cooling Forced coolant circulation system. Fuel Unleaded petrol (95 RON) Exhaust muffler Absorption-type exhaust muffler with 3-way cata- lytic converter and lambda probe.
Page 12: Wheels And Tyres
X7 250ie Characteristics Specification Desc./Quantity Front suspension Hydraulic telescopic fork with Ø 35 mm stem Front suspension travel 94 mm Rear suspension Two double-acting shock absorbers, adjustable to four positions at preloading. Rear suspension travel 89 mm Brakes BRAKES Specification Desc./Quantity...
Page 13 X7 250ie Characteristics Name Torque in Nm Front wheel shaft 45 ÷ 50 Fork plate screw 25 ÷ 34 Hydraulic rod fixing screw 25 ÷ 35* Stem support clamp tightening screws 20 ÷ 25 Fork locking screws cap 15 ÷ 30...
Page 14 X7 250ie Characteristics LUBRICATION Name Torque in Nm Hub oil drainage plug 15 ÷ 17 Oil filter on crankcase fitting 27 ÷ 33 Engine oil drainage plug/mesh filter 24 ÷ 30 Oil filter 4 ÷ 6 Oil pump cover screws 7 ÷...
Page 15: Assembly Clearances
X7 250ie Characteristics Overhaul data Assembly clearances Cylinder - piston assy. ENGINE COUPLING CATEGORY Name Initials Cylinder Piston Play on fitting Cylinder 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064 Piston 72.024 ÷...
Page 16 X7 250ie Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05 D = 0.20 - 0.50 mission side Flywheel-side half- 16.6 +0-0.05 D = 0.20 - 0.50 shaft Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05...
Page 17 X7 250ie Characteristics Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
Page 18 X7 250ie Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifi- cations AGIP CITY HI TEC 4T Oil to lubricate flexible transmis- Oil for 4-stroke engines...
Page 19 INDEX OF TOPICS TOOL OOLING...
Page 20 X7 250ie Tooling APPROPRIATE TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y014 Pliers to extract ø 15-mm bear- ings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y...
Page 21 X7 250ie Tooling Stores code Description 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting TOOL - 3...
Page 22 X7 250ie Tooling Stores code Description 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol 020331Y Digital multimeter 020332Y Digital rev counter TOOL - 4...
Page 23 X7 250ie Tooling Stores code Description 020648Y Single battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide TOOL - 5...
Page 24 X7 250ie Tooling Stores code Description 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool 020393Y Piston fitting band 020412Y 15 mm guide TOOL - 6...
Page 25 X7 250ie Tooling Stores code Description 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driv- en pulley clutch...
Page 26 X7 250ie Tooling Stores code Description 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020489Y Hub cover support stud bolt set 020428Y Piston position check support 020460Y Scooter diagnosis and tester TOOL - 8...
Page 27 X7 250ie Tooling Stores code Description 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Belle for OD 47-mm bearings 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15-mm bear- ings 020627Y Flywheel lock wrench TOOL - 9...
Page 28 X7 250ie Tooling Stores code Description 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020480Y Petrol pressure check set 020244Y 15-mm diameter punch 020115Y Ø 18 punch TOOL - 10...
Page 29 X7 250ie Tooling Stores code Description 020271Y Tool for removing-fitting silent bloc 020638Y 250 I. E. ENGINE - ABS SOFT- WARE 020469Y Reprogramming kit for scooter diagnosis tester 020487Y Fork oil seal extractor 020458Y Puller for lower bearing on steer-...
Page 30 X7 250ie Tooling TOOL - 12...
Page 31 INDEX OF TOPICS MAIN AINTENANCE...
Page 32: Maintenance Chart
X7 250ie Maintenance Maintenance chart EVERY 2 YEARS Action Coolant - change Brake fluid - change AFTER 5,000 KM; 25,000 KM; 35,000 KM; 55,000 KM; 65,000 KM Action Engine oil - level check/ top-up Brake pads - check condition and wear AFTER 10,000 KM;...
Page 33 X7 250ie Maintenance Action Coolant level - check Brake fluid level - check Engine oil - replacement Brake pads - check condition and wear Sliding block / variable speed rollers - change Tyre pressure and wear - check Vehicle and brake test - road test...
Page 34: Checking The Spark Advance
X7 250ie Maintenance Checking the spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to declare the reference values based on the engine rpm. The ignition timing value is detectable any time using the diagnostic tester.
Page 35: Spark Plug
X7 250ie Maintenance - Check that the real values of rpm and ignition advance match those measured using the diag- nostic tester. If the values do not correspond, check: - distribution timing - revolution-timing sensor - Injection control unit Specific tooling...
Page 36 X7 250ie Maintenance SPARK PLUGS OTHER THAN THOSE PRE- SCRIBED MAY SERIOUSLY DAMAGE THE EN- GINE. Characteristic Spark plug CHAMPION RG 4 PHP Electrode gap 0.7-0.8 mm Locking torques (N*m) Spark plug 12 ÷ 14 Hub oil Check -Park the vehicle on its centre stand on flat ground;...
Page 37: Air Filter
X7 250ie Maintenance Replacement - Unscrew the oil drainage cap "B" and drain out all the oil. - Screw in the drainage plug again and fill the hub with the recommended oil. Recommended products AGIP ROTRA 80W-90 Rear hub oil...
Page 38: Engine Oil
X7 250ie Maintenance IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTE- NANCE CONTROLS OF THE AIR FILTER TO AVOID DAMAGING THE ENGINE. Recommended products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased ad-...
Page 39 X7 250ie Maintenance minutes and shut it off. After five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
Page 40: Checking The Ignition Timing
X7 250ie Maintenance The oil should be topped up after having checked the level and in any case by adding oil without ex- ceeding the MAX level indicated on the cap/ dipstick.Restoring the level from MIN to MAX requires approximately 400 cm³ of oil.
Page 41: Cooling System
X7 250ie Maintenance For the use of this reference mark, remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a cal- liper spanner applied to the camshaft command pulley casing.
Page 42: Braking System
X7 250ie Maintenance IN ORDER TO AVOID BURNS, DO NOT UN- SCREW THE EXPANSION TANK CAP WHILE THE ENGINE IS STILL HOT. WARNING IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RIDING, IT IS IMPORTANT TO MAKE SURE THAT THE LEVEL DOES NOT EXCEED THE REFERENCE TONGUE TOO MUCH.
Page 43 X7 250ie Maintenance - Remove the windshield. - Undo the screw «B» and remove the front han- dlebar cover «C» partially. - Remove the cap «E» by loosening the two screws «D» and restore the fluid level by adding prescribed fluid type only, without exceeding the maximum level.
Page 44: Headlight Adjustment
LATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED. In order to adjust the light beams: - Remove the PIAGGIO clip-on badge and undo the screw «A». - Working on both sides of the vehicle, undo the screw «B» and remove the front headlight cover.
Page 45 X7 250ie Maintenance - Act on the screws «C» in order to aim the light properly. MAIN - 15...
Page 46 X7 250ie Maintenance MAIN - 16...
Page 47 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 48 X7 250ie Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance OOR PERFORMANCE Possible Cause Operation Fuel pump...
Page 49 X7 250ie Troubleshooting Possible Cause Operation Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components Battery flat Check the charge of the battery, if there are any sulphur marks, replace and use the new battery...
Page 50 X7 250ie Troubleshooting Insufficient braking INEFFICIENT BRAKING SYSTEM Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and replace brake fluid if necessary.
Page 51 X7 250ie Troubleshooting Noisy suspension NOISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy, check: locking tor- ques, headstock components, inspect forks. Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Seal fault or breakage...
Page 52 X7 250ie Troubleshooting TROUBL - 6...
Page 53 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 54 X7 250ie Electrical system Components arrangement 1. Injection ECU: Remove the inspection flap placed in the helmet compartment to reach it. 2. Stator: Remove the left side fairing to reach the connector. ELE SYS - 2...
Page 55 X7 250ie Electrical system 3. Remote control switches: Remove the shield back plate to reach them. A. Injection load remote control switch B. Stop light remote control switch C. Remote control switch for electric fan D. Headlight remote control switch 4.
Page 56 X7 250ie Electrical system 7. Spark plug: Remove the lid placed on the right side fairing to reach it. Characteristic Spark plug CHAMPION RG 4 PHP 8. HV coil: Remove the right side fairing to reach Characteristic HV coil resistance primary value: ~ 0.9 Ω...
Page 57 X7 250ie Electrical system 11. Voltage regulator: Remove the side fairings to reach it. 12. Battery: Remove the battery cover placed in the helmet compartment to reach it. Electric characteristic Battery 12V 12Ah 13. Diagnostics socket: Remove the battery cover placed in the helmet compartment to reach it.
Page 58 X7 250ie Electrical system A. Ground point on the chassis. Remove the left footrest to reach it. B. Ground point on the chassis. Remove the left footrest to reach it. C. Ground point on the engine. Placed at the bot- tom at the back of the left side fairing.
Page 59 X7 250ie Electrical system HV coil primary resistance value: Disconnect the connector of the HV coil and meas- ure the resistance between the two terminals. Characteristic HV coil resistance primary value: ~ 0.9 Ω HV coil secondary resistance value: 1) Disconnect the HV cable from the spark plug and measure the resistance between the spark plug cap and the HV coil negative terminal.
Page 60 X7 250ie Electrical system 1) Disconnect the connector between stator and regulator with the three yellow cables as shown in the photograph. 2) Measure the resistance between each of the yellow terminals and the other two. Characteristic Stator phase resistance value ~ 0.6 Ω...
Page 61: Starter Motor
X7 250ie Electrical system Starter motor 1. Battery 2. Fuse No. 2 3. Key switch contacts 4. Fuse No. 10 5. Stop button on rear brake 6. Stop button on front brake 7. Injection ECU 8. Starter button 9. Start-up remote control switch 10.
Page 62 X7 250ie Electrical system 6) Check the start-up remote control switch. 7) Check wiring continuity. Horn control 1. Battery 2. Fuse No. 2 3. Key switch contacts 4. Fuse No. 10 5. Horn button 6. Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
Page 63 X7 250ie Electrical system Turn signals system check 1. Battery 2. Fuse No. 2 3. Key switch contacts 4. Fuse No. 10 5. Turn indicators control device 6. Turn indicator switch 7. Left turn indicator bulbs 8. Right turn indicator bulbs...
Page 64 X7 250ie Electrical system 7) Check turn indicator switch cable harness continuity. 8) Check the bulbs ground connection. level indicators WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If faults are detected: 1) With a multimeter, check resistance values be-...
Page 65 X7 250ie Electrical system Specification Desc./Quantity Power: 12V - 5/21W Quantity: 2 License plate light bulb Type: ALL GLASS Power: 12V - 5W Quantity: 1 Fuses The electrical system is fitted with twelve fuses divided between two fuse boxes, located in the battery compartment, for the protection of the var- ious circuits in the system.
Page 66 X7 250ie Electrical system Specification Desc./Quantity Protected circuits: Light switch (via remote control) Fuse No. 4 Capacity: 15A Protected circuits:Electric fan (via remote control) Fuse No. 5 Capacity: 15A Protected circuits:Injection load (via remote control), injection ECU. Fuse No. 6...
Page 67 X7 250ie Electrical system A = Coolant temperature gauge B = Engine control telltale light and injection system failure warning light F = Low oil pressure warning light D = Left turn indicator warning light E = Speedometer with twin scale (km/h and mph)
Page 68 X7 250ie Electrical system - Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an am- bient temperature not below 15°C, until it reaches the upper level indicated on the block. - Tilt the battery slightly to remove any air bubbles formed during filling.
Page 69 X7 250ie Electrical system Controllo teleruttori To check the operation of a remote control: 1) Check that, given regular conditions, there is no continuity between terminals 87 and 30. 2) Apply a 12V voltage to power terminals 86 and 85 of the remote control.
Page 70 X7 250ie Electrical system LIGHT SWITCH TURN INDICATOR SWITCH HORN BUTTON Connectors INSTRUMENT PANEL CONNECTOR «A» 1. Low fuel warning light (Yellow-Green) 2. Live supply (White-Red) 3. High-beam warning light (Purple) 4. Right turn indicator warning light (White-Blue) 5. Fuel level indicator (White-Green) 6.
Page 71 X7 250ie Electrical system INSTRUMENT PANEL CONNECTOR «B» 1. Ground (Black) 2. Left turn indicator warning light (Pink) 3. Coolant temperature signal (Blue-Black) 4. Live supply (White-Red) 5. Injection telltale light (Brown-Black) FUEL PUMP CONNECTOR 1. Not connected 2. Ground (Black) 3.
Page 72 X7 250ie Electrical system ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. LHS Turn indicator bulbs (Pink) 2. RHS Turn indicator bulbs (White-Blue) 3. Ground (Black) 4. Battery-powered (Blue-Red) 5. Live supply (White-Red) 6. Not connected 7. Not connected 8. Not connected LAMBDA PROBE CONNECTOR 1.
Page 73 X7 250ie Electrical system 11. Lambda probe positive (Sky blue-Yellow) 12. Engine stop switch (Orange) 13. Engine revolution sensor positive (Red) 14. Injector negative (Yellow-Red) 15. Engine revolution sensor negative (Brown) 16. Diagnostics socket (Orange-Black) 17. Not connected 18. Ground (Black) 19.
Page 74 X7 250ie Electrical system FUEL LEVEL TRANSMITTER CONNECTOR 1. Low fuel warning light (Yellow-Green) 2. Ground (Black) 3. Fuel level indicator (White-Green) COOLANT TEMPERATURE SENSOR CON- NECTOR 1. Ground (Grey-Green) 2. Ground (Black) 3. Injection ECU (Yellow-Pink) 4. Instrument panel (Sky blue-Black)
Page 75 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 76 X7 250ie Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the Lambda probe from its support and disconnect it. - Undo the two exhaust manifold fixings on the head.
Page 77 X7 250ie Engine from vehicle CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE- PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. Removal of the engine from the vehicle - Disconnect the battery - Remove the engine cover inside the helmet compartment - Remove the side panels Remove the full muffler assembly.
Page 78 X7 250ie Engine from vehicle - Remove the coolant outlet pipe from the motor as indicated. - Remove the spark plug cap. - Remove the coolant temperature sensor con- nector indicated in the photo. - Remove the throttle cables from the throttle body by undoing the nuts indicated in the photograph.
Page 79 X7 250ie Engine from vehicle - Disconnect the connectors from the flywheel wir- ing as shown in the photo. - Remove the cable from the retaining clip on the flywheel cover. - Undo the fixing screw of the locking clamps of the brake pipe from the muffler supporting arm.
Page 80 X7 250ie Engine from vehicle - Undo the 2 screws fixing the rear brake calliper. - Remove the calliper and its pipes from the muffler supporting arm. - Undo the 2 screws fixing the swinging arm to the engine. - Remove the muffler support arm - Slide off the entire wheel with its disc from the wheel axle.
Page 81 X7 250ie Engine from vehicle - Fill and bleed the cooling circuit. - Check the functioning of the accelerator and the electrical devices. CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY. ENG VE - 7...
Page 82 X7 250ie Engine from vehicle ENG VE - 8...
Page 83 INDEX OF TOPICS NGINE...
Page 84: Automatic Transmission
X7 250ie Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
Page 85 X7 250ie Engine - Remove the transmission cover. N.B. WHEN YOU ARE REMOVING THE TRANSMIS- SION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH BELL. Air duct - Remove the transmission compartment air intake cover shown in the photograph.
Page 86 X7 250ie Engine Refitting the driven pulley shaft bearing - Slightly heat the crankcase from the inside so as not to damage the painted surface. - Insert the bearing in its seat. - Refit the seeger ring. CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.
Page 87: Removing The Driven Pulley
X7 250ie Engine Removing the driven pulley - Remove the clutch bell housing and the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.
Page 88: Removing The Clutch
X7 250ie Engine - Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft...
Page 89 X7 250ie Engine 020444Y Tool for fitting/ removing the driven pulley clutch Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.
Page 90 X7 250ie Engine - Remove the four torque server pins and pull the pulley halves apart. Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - Replace with a new one if there are.
Page 91 X7 250ie Engine Inspecting the driven fixed half-pulley - Measure the outer diameter of the pulley bushing. - Check the contact surface with the belt to make sure there are no flaws. - Check the riveted joints are functional. - Check the evenness of the belt contact surface.
Page 92: Refitting The Driven Pulley
X7 250ie Engine MOVABLE DRIVEN HALF-PULLEY DIMENSIONS Specification Desc./Quantity Wear limit 0.3 mm standard diameter Diameter 41.000 - 41.035 mm maximum allowable diameter Ø 41.08 mm Refitting the driven half-pulley bearing - Support the pulley bushing adequately from the threaded side using a wooden surface.
Page 93 X7 250ie Engine grease. Apply the grease through one of the holes in the bushing until it comes out through the hole on the opposite side. This operation is necessary to avoid the presence of grease beyond the O- rings.
Page 94 X7 250ie Engine Refitting the clutch - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position "C" on the inside. - Introduce the adapter ring No. 11 with the cham- fering facing upwards.
Page 95 X7 250ie Engine SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH. Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 46x55 Wrench Locking torques (N*m) Clutch unit nut on driven pulley 45 ÷ 50 Refitting the driven pulley - Refit the clutch bell.
Page 96: Removing The Driving Pulley
X7 250ie Engine Removing the driving pulley - Turn the crankshaft until the ropes of the pulley are on a horizontal axis - Insert the adaptor sleeve of the appropriate tool in the hole shown in the photograph - Insert the tool in the hollows and apply the reten-...
Page 97 X7 250ie Engine Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure outer diameter B of the pulley sliding bushing shown in the figure.
Page 98 X7 250ie Engine Refitting the driving pulley - Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation. - Check that the roller contact plate does not have flaws and is not damaged on the grooved edge.
Page 99 X7 250ie Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque.
Page 100 X7 250ie Engine Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket. Removing the wheel axle - Remove the wheel axis complete with gear.
Page 101 X7 250ie Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
Page 102 X7 250ie Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil guard, remove the transmission cover as described above. - Extract the driven pulley shaft from its bearing.
Page 103 X7 250ie Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
Page 104 X7 250ie Engine Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the special heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
Page 105 X7 250ie Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Seal the gasket of the breather pipe using black silicone sealant.
Page 106: Removing The Stator
X7 250ie Engine Removing the hub cover - Remove the clamp fixing the sleeve to the cylin- der and detach the sleeve. - Remove the 10 fixings - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
Page 107 X7 250ie Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4 Refitting the flywheel cover - Position the spline clip on the crankshaft and ori- ent the end as shown in the figure.
Page 108 X7 250ie Engine Removing the starter motor - Remove the two screws indicated in the figure. - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft spline clip - Line up the two holes in the flywheel as shown in...
Page 109 X7 250ie Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling 020627Y Flywheel lock wrench - Remove the plate indicated in the photo. - Remove the flywheel nut with its washer...
Page 110 X7 250ie 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 111 X7 250ie Engine - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque -Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut 94 ÷ 102 Refitting the starter motor...
Page 112 X7 250ie Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separa- tion washer.
Page 113 X7 250ie Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.
Page 114: Removing The Cylinder Head
X7 250ie Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the pins and the rocker arms from the flywheel side holes. - Remove the cam shaft.
Page 115: Removing The Valves
X7 250ie Engine MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool.
Page 116: Inspecting The Small End
X7 250ie Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAME- TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Page 117: Inspecting The Piston
X7 250ie Engine Inspecting the piston - Measure the diameter of the wrist pin seat on the piston. - Calculate the piston pin coupling clearance. - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis.
Page 118 X7 250ie Engine Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the head coupling surface is not worn or misshapen.
Page 119: Removing The Piston
X7 250ie Engine scraper ring Standard opening: 0.20 ÷ 0.40 mm Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin stop ring onto the appropriate tool...
Page 120 X7 250ie Engine Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder. The further the piston travels into the cylinder, the thinner the thickness «B»...
Page 121 X7 250ie Engine Refitting the piston rings Fitting the sealing rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston.
Page 122: Inspecting The Cylinder Head
X7 250ie Engine 020393Y Piston fitting band Inspecting the cylinder head - Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocker pin ca- pacities exhibit no wear.
Page 123 X7 250ie 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 124 X7 250ie Engine Sealing surface length: after use: Intake and exhaust: 1.6 mm - If any of the sealing surfaces on the valves is wider than the specified limit or is damaged in one or more points, or curved, replace the valve with a new one.
Page 125 X7 250ie Engine Outlet: 4.95 mm Valve check Minimum admissible diameter Inlet: 4.96 mm Valve check Standard diameter: Inlet: 4.972 ÷ 4.987 mm Valve check Standard diameter: Outlet: 4.96 ÷ 4.975 mm ENG - 43...
Page 126 X7 250ie Engine Inspecting the springs and half-cones - Check that the upper and lower supporting wash- ers of the springs, the cotters and the oil seal do not show signs of abnormal wear. - Replace the components when worn.
Page 127 X7 250ie Engine wear, replace the defective components with new ones. - Check there are no signs of wear on the auto- matic valve-lifter cam, or the end-of stroke roller, or the rubber buffer on the automatic valve-lifter retaining cover.
Page 128 X7 250ie Engine Bearing A Ø: 36.95 ÷ 36.975 mm Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head.
Page 129 X7 250ie Engine - Lubricate the two rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que.
Page 130 X7 250ie Engine Electrode distance 0.8 mm N.B. GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE EN- GINE. Locking torques (N*m) Timing chain tensioner support screw 11 ÷ 13 Spark plug 12 ÷ 14 Starter ground screw 7 ÷...
Page 131 X7 250ie Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
Page 132 X7 250ie Engine - Remove the two screws and the internal cover shown in the diagram. - Remove the oil guard on the flywheel side. - Remove the oil filter fitting shown in the diagram. - Check the axial clearance on the connecting rod.
Page 133 X7 250ie Engine 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Axial crankshaft/crankcase clearance: Stand- ard clearance 0.15 - 0.40 mm (when cold) Axial connecting rod - crankshaft clearance Standard clearance 0.20 ÷ 0.50 mm Radial connecting rod - crankshaft clearance Standard clearance 0.036 ÷...
Page 134 X7 250ie Engine crankshaft, be very careful that no impurities get in through the shaft's lubrication holes. In order to prevent damaging the connecting rod bushings, do not attempt cleaning the lubrication duct with compressed air. - Make sure that the 2 caps on the crankpin are properly fitted.
Page 135 X7 250ie Engine - Inspect the coupling surfaces on the crankcase halves for scratches or deformation, taking partic- ular care with the cylinder/crankcase surfaces and the crankcase halves surfaces. - Defects in the crankcase coupling gasket be- tween the crankcase halves or the mating surfaces...
Page 136 X7 250ie Engine Inspecting the crankshaft plain bearings o obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure (3,2 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
Page 137 X7 250ie Engine TYPE IDENTIFICATION BLUE YELLOW Type "A" Type "B" Type "C" - RED - BLUE - YEL- Main half- 1.970 ÷ 1.9703 ÷ 1.976 ÷ bearing 1.973 1.976 1.979 Bush- Crank- Internal bush- Possible ing cat- case ing diameter...
Page 138 X7 250ie Engine N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. N.B. CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED...
Page 139 X7 250ie Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.
Page 140 X7 250ie Engine By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the photograph, re- move the stud bolt from its seat. Clean the threaded seat on the carter thoroughly. Refit a new stud bolt and apply the special product on the threading crankcase side.
Page 141 X7 250ie Engine ENG - 59...
Page 142: Oil Pressure Check
X7 250ie Engine 1. Engine throttle recovery 2. Tappet cover 3. Crankshaft 4. By-pass valve 5. Oil filler 6. Oil level in the sump 7. Oil pump 8. Mesh pre-filter 9. Cartridge filter 10. Minimum pressure switch Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch.
Page 143 X7 250ie Engine Characteristic Oil pressure Minimum pressure admitted at 6000 rpm: 3.2 atm. Locking torques (N*m) Minimum oil pressure sensor 12 ÷ 14 Crankshaft oil seals Removal - Remove the transmission cover and the com- plete driving pulley beforehand - Install the base of the appropriate tool on the oil guard using the screws provided.
Page 144 X7 250ie Engine Refitting - Use a new oil guard for the refitting - Prepare the new oil guard, lubricating the sealing lip. - Preassemble the oil seal with the specific tool, positioning the screws. - Insert the sheath over the crankshaft.
Page 145: Oil Pump
X7 250ie Engine Oil pump Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
Page 146 X7 250ie Engine Inspection - Remove the two screws and the oil pump cover. - Remove the clip retaining the innermost rotor. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible Replace the clip.
Page 147 X7 250ie Engine Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
Page 148 X7 250ie Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defec- tive parts.
Page 149 X7 250ie Engine CRANKSHAFT» CHAPTER ON LUBRICATING THE CRANKSHAFT AND CONNECTING ROD. Locking torques (N*m) Oil sump screws 10 ÷ 14 ENG - 67...
Page 150 X7 250ie Engine ENG - 68...
Page 151 INDEX OF TOPICS INJEC NJECTION...
Page 152 X7 250ie Injection INJECTION COMPONENTS Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Fuel injector Injection load remote control INJEC - 2...
Page 153 X7 250ie Injection Specification Desc./Quantity Electric fan starter HV coil Lambda sensor Water temperature sensor Instrument panel Battery 12V - 12 Ah Diagnostics socket connector Engine rpm sensor Fuel pump Electric fan MIU injection system This vehicle is fitted with an integrated injection and ignition system.
Page 154 X7 250ie Injection The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only in the compression phase) at the same time. The MIU injection-ignition system controls engine functions by means of a pre-set program. Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to reach a service station.
Page 155 X7 250ie Injection A: Electrical power supply a. Battery voltage b. Blown fuse c. Remote controls d. Connectors B: Chassis earthing C. Fuel supply a. Broken fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Broken coil c.
Page 156 X7 250ie Injection 3. When fixing electric components, operate with battery connected only when actually required. 4. When functional checks are performed, check that the battery voltage is more than 12V. 5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to respect this norm will damage the fuel pump.
Page 157 X7 250ie Injection Terminals setup TERMINAL LAYOUT Specification Desc./Quantity Injection warning light Lambda probe negative Live supply Battery-powered Electric fan starter Water temperature sensor Lambda probe positive Engine stop switch R.P.M. sensor (+) Fuel injector R.P.M. sensor (-) Diagnostics socket output...
Page 158 X7 250ie Injection Specification Desc./Quantity Ground lead Connected with: water temperature sensor, engine stop switch. EMS circuit diagram SYSTEM SCHEMATIC Specification Desc./Quantity Battery 12V - 12 Ah Fuse 7.5 A Fuse Fuse Engine rpm sensor Water temperature sensor Water temperature gauge...
Page 159 X7 250ie Injection Specification Desc./Quantity "WARNING" light Diagnostics socket connector Injection ECU Troubleshooting procedure Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil...
Page 160 X7 250ie Injection Possible Cause Operation Stepper throttle valve position intake air tempera- ture (steps and actual opening) Cleaning of the auxiliary air pipe and throttle valve; air filter efficiency Engine stops at idle ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW...
Page 161 X7 250ie Injection Possible Cause Operation Fuel feed (low pressure) Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil...
Page 162 X7 250ie Injection Possible Cause Operation Coolant temperature Lambda sensor Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PROGRESS ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil...
Page 163 X7 250ie Injection Possible Cause Operation Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness Fuel supply system The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector and the fuel delivery pipes.
Page 164 X7 250ie Injection Remove the fast-release fitting from the injector support Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. INJEC - 14...
Page 165 X7 250ie Injection Remove the MIU connector Remove the clip fixing the throttle body to the pu- rifier bellows Remove the gas control retainers as indicated in the photograph Refitting the butterfly valve To refit, perform the operations in the reverse or-...
Page 166 X7 250ie Injection Pump supply circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan starter When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts up, in the presence of rpm timing signal the pump is continuously supplied.
Page 167 X7 250ie Injection Check the efficiency of the injection load remote control: measure the resistance of the drive coil between pins 86 and 85. Characteristic Drive coil resistance 40 ÷ 80 Ω Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 168 X7 250ie Injection Check if there is steady voltage between the Or- ange-Blue cable of the remote control base and the ground lead. If there is not, check the continuity of the Orange-Blue cable between the fuse box (15A fuse No. 5) and the remote control base.
Page 169 X7 250ie Injection control unit disconnected and the injection load re- mote control disconnected, that the Black-Purple cable (pin 20 on the interface wiring) is insulated from the ground. Specific tooling 020331Y Digital multimeter Circuit leak test Install the appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the delivery pipe..
Page 170 X7 250ie Injection a pair of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 BAR. Check that, in fifteen seconds, the pump has a flow rate of around 110 cm³. Specific tooling 020480Y Petrol pressure check set...
Page 171 X7 250ie Injection Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah INJEC - 21...
Page 172 X7 250ie Injection Specification Desc./Quantity Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan starter Check the resistance at the injector ends: 14.5 ± 5% Ohm Check the efficiency of 15A fuse No. 5 (injection load).
Page 173 X7 250ie Injection Check the power supply line of the injection load remote control energising coil: after switching to «ON », make sure there is battery voltage, for 2 seconds, between the Red-Green cable and the Black-Purple cable of the remote control base. If there is not, check the continuity of the Red-Green cable between the fuse box (fuse No.
Page 174 X7 250ie Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to "ON" and check if there is voltage, with...
Page 175 X7 250ie Injection Inspecting the injector hydraulics To carry out the injector check, remove the intake manifold by removing the three clamping screws at the head and the clip connecting the control unit to the manifold. Install the appropriate tool for checking fuel pres- sure and position the manifold over a container graduated by at least 100 cm³.
Page 176 X7 250ie Injection Proceed with the injector seal test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector. Slight oozing is normal.
Page 177 X7 250ie Injection INJECTION COMPONENTS Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Fuel injector Injection load remote control Electric fan starter HV coil Lambda sensor Water temperature sensor Instrument panel Battery 12V - 12 Ah Diagnostics socket connector...
Page 178 X7 250ie Injection Tachometer With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20°...
Page 179 X7 250ie Injection With the interface cable harness disconnected from the control unit, check continuity between pin 13 and the red cable of the rpm sensor connector and between pin 15 and the brown cable of the rpm sensor connector...
Page 180 X7 250ie Injection Specification Desc./Quantity Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan starter The ignition system is integrated with the injection and is of the inductive high efficiency type.
Page 181 X7 250ie Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the Black-Green cable of the injection load remote control base, with the control unit disconnected and the remote control disconnected. Characteristic HV coil resistance primary value: ~ 0.9 Ω...
Page 182 X7 250ie Injection Check the power supply line of the injection load remote control energising coil: after switching to «ON », make sure there is battery voltage, for 2 seconds, between the Red-Green cable and the Black-Purple cable of the remote control base. If there is not, check the continuity of the Red-Green cable between the fuse box (fuse No.
Page 183 X7 250ie Injection Coolant temperature sensor EMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor Engine stop switch INJEC - 33...
Page 184 X7 250ie Injection With the connector on the control unit side discon- nected and the coolant temperature sensor con- nector connected, check that the resistance val- ues between pins 9 and 18 correspond to the engine temperature. 20° = 2500 ± 100 Ω...
Page 185 X7 250ie Injection Zeroing the throttle Resetting the throttle valve position signal (TPS reset) The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated. Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre-set reference conditions.
Page 186 X7 250ie Injection Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure. Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Page 187 X7 250ie Injection Given that the TPS resetting is also done when the control unit is replaced, place the control unit - filter box bellows at 45° during the refitting operation as shown in the photograph. Lambda probe INJECTION LOADS Specification Desc./Quantity...
Page 188 X7 250ie Injection i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic converter in an area where the gas temperature is always high. The temperature at which the sensor works is at least 350°C at 600°C and it has a reaction time of just 50 milliseconds. The signal generated passes from a high value to a low value with a mixture with lambda =1.
Page 189 X7 250ie Injection Check the efficiency of the injection load remote control: measure the resistance of the drive coil between pins 86 and 85. Characteristic Drive coil resistance 40 ÷ 80 Ω Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 190 X7 250ie Injection Check if there is steady voltage between the Or- ange-Blue cable of the remote control base and the ground lead. If there is not, check the continuity of the Orange-Blue cable between the fuse box (15A fuse No. 5) and the remote control base.
Page 191 X7 250ie Injection With the engine running at idle speed, check that the voltage oscillates between 0V and 1V With the throttle valve completely open, the volt- age is approx. 1V. During the closing phase, the voltage is approx. If the voltage remains constant, the sensor may be damaged.
Page 192 X7 250ie Injection INJEC - 42...
Page 193 INDEX OF TOPICS SUSP USPENSIONS...
Page 194: Removing The Front Wheel
X7 250ie 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. - Loosen the two screws fixing the wheel axle clamp and remove the clamp.
Page 195 X7 250ie 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 196 X7 250ie 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 197 X7 250ie 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 198: Front Fork
X7 250ie Suspensions Removal - Remove the handlebar covers as explained in the «Bodywork» Chapter. - Remove the handlebar wiring retaining straps and disconnect the electric connectors from the brake levers. - Unscrew the clamps of the U-bolts and release the brake pumps.
Page 199 X7 250ie Suspensions Removal Overhaul - Support the fork in a vice. - Loosen the two tightening screws of the stem supporting clamp. - Unscrew the stem closing cap and slide off the complete fork leg from the corresponding support.
Page 200 X7 250ie Suspensions - Remove the stem dust guard with a screwdriver. - Remove the circlip retaining the oil seal. - Take out the stem. - Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace the damaged parts.
Page 201 X7 250ie Suspensions - Take out the oil seal using the appropriate tools. - Fit the tie rod into the oil seal. - Insert in sequence the two half-rings per Ø 35- mm stems. Specific tooling 020487Y Fork oil seal extractor...
Page 202 X7 250ie Suspensions - Check that the fork leg is not cracked or broken in the attachments. - Check that the stem is not scored, dented or dis- torted. - Check that the stop bushing for the hydraulic rod is correctly fixed through caulking.
Page 203 X7 250ie Suspensions - Check that the closing cap O-ring of the stem is in good conditions. Refitting - First grease the splitting chamber of the two seal- ing lips of a new oil seal. - Fit the sealing ring on the stem and keep the identification words facing upwards.
Page 204 X7 250ie Suspensions - Lock hydraulic rod rotation using a 19-mm hex- agonal spanner. - Fit the oil seal retaining circlip. - Grease and fit a new dust guard. - Fit the fork leg together with the stem on the fork supporting clamp until it stops.
Page 205 X7 250ie Suspensions - Refill the fork leg with the recommended product to the prescribed amount. Recommended products AGIP FORK 7.5 W Oil for front fork Hydraulic fluid SAE 7.5 W Characteristic Oil quantity per stem 133 ± 3 cm³...
Page 206: Steering Column
X7 250ie Suspensions Steering column Removal - Remove the front wheel. - Remove the handlebar and tip it onto the shield back plate being careful not to damage the plate. - Release the front brake pipe from the fork by un- doing the screws indicated.
Page 207 X7 250ie Suspensions Soap-based lithium and zinc oxide grease con- taining NLGI 2; ISO-L-XBCIB2 - Fit the upper steering fifth wheel. CAUTION INSERT THE UPPER FIFTH WHEEL WITH THE CAGE FACING UPWARDS. - Fit the steering fifth wheel upper seat.
Page 208 X7 250ie Suspensions - Insert the spacer. - Insert the lower tightening ring nut, screw until it stops and, with the specific tool, tighten to the pre- scribed torque. Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Steering tube lower ring nut 14 ÷...
Page 209 X7 250ie Suspensions - Insert the upper tightening ring nut, screw until it stops and, with the specific tool, tighten to the in- dicated torque. Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Steering tube upper ring nut 40 ÷ 45 - Fasten the two retainer clamps of the front brake pipe to the fork plate.
Page 210 X7 250ie Suspensions Removal - Clean thoroughly and visually inspect if the com- ponents are in good conditions. - Check the upper steering fifth wheel for wear. - Check the lower steering fifth wheel for wear. - Visually inspect that the steering fifth wheel tracks, the headstock and the steering tube exhibit no scores or abnormal wear.
Page 211 X7 250ie Suspensions - Repeat the procedure for the lower steering fifth wheel track. - Remove the lower fifth wheel seat on the steering tube using the specific tool. Specific tooling 020004Y Punch for removing fifth wheels from headstock SUSP - 19...
Page 212 X7 250ie Suspensions Refitting STEERING FIFTH WHEEL TRACK FITTING - Thoroughly clean the track seats on the head- stock and the steering tube. - Fit the new tracks of the headstock with the spe- cific tool. - Screw the nut until the tracks are fully inserted.
Page 213: Removing The Rear Wheel
X7 250ie Suspensions Soap-based lithium and zinc oxide grease con- taining NLGI 2; ISO-L-XBCIB2 Rear Removing the rear wheel - Remove the muffler supporting bracket. - Remove the rear mudguard. - Remove the tapered spacer. - Remove the rear wheel.
Page 214 X7 250ie Suspensions Removal - Place the scooter on its centre stand; - Remove the swinging arm/engine fitting shown in the photo - Move the engine back - remove the spring anchoring the swinging arm to the frame as shown in the photo...
Page 215 X7 250ie Suspensions - Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause exces- sive clearance on the rear suspension. Overhaul - Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side.
Page 216 X7 250ie Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo. - Using a suitable pin remove the roller casings as...
Page 217 X7 250ie Suspensions Length of the swinging arm tube on the frame side: 283 ± 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in...
Page 218 X7 250ie Suspensions - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the...
Page 219: Shock Absorbers
X7 250ie Suspensions -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque. Locking torques (N*m) Engine and vehicle side swinging arm junction bolt 33 ÷ 41 Nm Swinging arm pin - Engine 64 - 72 Body shell - Swinging arm pin 76 ÷...
Page 220 X7 250ie Suspensions Shock absorber lower clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41 Exhaust bracket Removal - Remove the exhaust silencer. - Remove the rear brake calliper, release the rear brake pipes from the retainer clamp and undo the screw fixing the rear mudguard.
Page 221 X7 250ie Suspensions - Undo the two fixing screws to the engine crank- case. - Remove the muffler supporting bracket. Overhaul - Remove the seeger ring. - With the appropriate tools, remove the bearing from the inside. Specific tooling 020376Y Adaptor handle...
Page 222 X7 250ie Suspensions - Check that the bearing seat is not abnormally worn. - Heat the bearing seat with the appropriate tool. Specific tooling 020151Y Air heater - Drive a new bearing as far as it will go using the appropriate tool.
Page 223 X7 250ie Suspensions Centre-stand REMOVAL - Use a jack to support the vehicle properly. - Remove the two stand return springs. - Undo the nut shown in the figure. - Remove the bolt from the right side. - Remove the centre stand.
Page 224: Side Stand
X7 250ie Suspensions Side stand REMOVAL - Uncouple the centre stand return spring; Remove the screw shown in the photograph FITTING To refit, carry out the removal operations in re- verse order and comply with the specified torque. Locking torques (N*m) Side stand fixing bolt 35 ÷...
Page 225 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 226: Rear Brake Calliper
X7 250ie Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the muffler. - Remove the two rear brake calliper devices fas- tening them to the support as shown in the photo- graph.
Page 227 X7 250ie Braking system Removal - Remove the two retainers fastening the front brake calliper to the support as shown in the pho- tograph. N.B. SHOULD IT BE NECESSARY TO REPLACE THE CALLIPER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CAL- LIPER.
Page 228 X7 250ie Braking system Refitting For fitting, position the disc correctly using the ar- row stamped on it as reference. N.B. THE ARROW STAMPED ON THE DISC INDI- CATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VE- HICLE.
Page 229: Front Brake Disc
X7 250ie Braking system - In order to be able to anchor the specific tool properly use a metal plate with an M8 threaded hole and fix it to one of the two rear brake calliper attachment points. N.B. SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN IN ORDER TO ROTATE THE DISC.
Page 230 X7 250ie Braking system Refitting For fitting, position the disc correctly using the ar- row stamped on it as reference. N.B. THE ARROW STAMPED ON THE DISC INDI- CATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VE- HICLE.
Page 231: Front Brake Pads
X7 250ie Braking system - In order to secure the specific tool adequately use a metal plate with an M8 threaded hole and fix it to one of the two front brake calliper attachment points. Specific tooling 020335Y Magnetic support for dial gauge Characteristic Max.
Page 232 X7 250ie Braking system See also Front brake calliper Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
Page 233 X7 250ie Braking system Removal - Remove the rear brake calliper - Loosen the two pins shown in the figure that lock the two pads; be careful with the pad spring clamp. - Remove the brake pad and check there are no faults or warping.
Page 234 X7 250ie Braking system IF IT IS NOT POSSIBLE TO CORRECTLY PO- SITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Screw tightening calliper to the support 24 ÷...
Page 235 X7 250ie 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 brake lever, load the system and bring it up to the required pressure.
Page 236 X7 250ie Braking system Removal - Remove the front and rear handlebar cover. - Place a suitable container to collect the oil, dis- connect the oil pipe from the calliper and operate the brake lever until no more oil comes out.
Page 237 X7 250ie Braking system WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE- GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Page 238 X7 250ie Braking system Refitting - Upon refitting, perform the operation but in reverse order. - Tighten the hydraulic line to the prescribed torque and purge the system. - When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
Page 239 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 240: Circuit Diagram
X7 250ie Cooling system Circuit diagram A = Expansion tank B = Radiator C = Radiator intake pipe D = Water pump E = Delivery pipe to cylinder F = By-Pass pipe G = Thermostat H = Radiator delivery pipe Electric fan check - Check the correct battery voltage and restore, if necessary.
Page 241 X7 250ie Cooling system Characteristic Battery voltage - Check that the electric ventilation relay is working properly. - If the relay is not working, replace it. - If the relay is working, remove it and jump the red - red black (85 - 86) wires. The electric ventilation starts if the key switch is set to «ON»...
Page 242 X7 250ie Cooling system - Tighten the bleed valve respecting the maximum torque. - Bring the coolant up to the correct level inside the expansion tank Locking torques (N*m) Bleed screw: 3 Removal - Loosen the two screws indicated in the figure and remove the thermostat cover.
Page 243 X7 250ie Cooling system Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check: Opening start temperature 85 ÷ 1.5°C Refitting - Place the thermostat with the bleeding hole at the highest point. - Make sure that the rubber gasket is positioned properly.
Page 244 X7 250ie Cooling system COOL SYS - 6...
Page 245 INDEX OF TOPICS CHAS HASSIS...
Page 246 X7 250ie Chassis Seat - Lift the saddle and undo the three screws indica- ted. Driving mirrors - Unscrew the lock-nut and slide off the rear-view mirror stem. Rear handlebar cover - Remove the front handlebar cover. - Undo the two screws indicated.
Page 247: Instrument Panel
X7 250ie Chassis - Undo the two screws and disconnect the con- nections of the electrical controls . See also Front handlebar cover Instrument panel - Remove the rear handlebar cover. - Disconnect the odometer transmission cable. - Undo the two screws indicated.
Page 248 X7 250ie Chassis Rear handlebar cover Front handlebar cover - Remove the windshield and the front central cov- - Undo the screw indicated from both sides of the vehicle. - Undo the screw indicated and remove the front handlebar cover.
Page 249 X7 250ie Chassis - Undo the screw indicated in the front wheel hous- ing on both sides. - Disconnect the connectors from the low-beam, high-beam and turn indicators bulbs. - Slide off the tail light rubber bulb holders. See also...
Page 250 X7 250ie Chassis Seat Legshield - Remove the shield back plate. - Remove the headlight assembly. - Undo the four screws indicated. - Undo the screw indicated in the front wheel hous- ing on both sides. - Undo the two screws indicated on both sides of the vehicle.
Page 251 X7 250ie Chassis Knee-guard - Remove the footrest. - Undo the four screws on both sides. - Undo the screw indicated on both sides of the vehicle. - Undo the screw indicated. - Remove the lid and unscrew the expansion tank cap.
Page 252 X7 250ie Chassis - Undo the screw indicated on both sides of the vehicle. See also Footrest Front wheel housing - Remove the front shield. - Remove the fork - Undo the screw indicated. - Undo the screw indicated from both sides of the vehicle.
Page 253 X7 250ie Chassis Taillight assy. - Undo the two screws indicated. - With the aid of a flat screwdriver, remove the cover indicated. - Undo the two screws indicated. - Extract the light units and disconnect the bulb connectors. CHAS - 9...
Page 254: License Plate Light
X7 250ie Chassis License plate light - Undo the screw indicated and slide off the rubber bulb holder. - Remove the rear light unit and disconnect the electrical connection indicated. See also Taillight assy. Footrest - Remove the side fairing.
Page 255 X7 250ie Chassis - Undo the two screws indicated. See also Side fairings Side fairings - Remove the central frame cover. - Remove the rear light assembly. - Undo the screw indicated. - Undo the four screws indicated and remove the passenger grab handles.
Page 256 X7 250ie Chassis - Undo the screw indicated and remove the in- spection door. - Undo the two screws indicated. See also Frame central cover Taillight assy. License plate holder - Remove the side fairings. - Undo the two screws indicated on both sides of the vehicle.
Page 257: Rear Mudguard
X7 250ie Chassis Air filter - Undo the two screws indicated. - Loosen the tightening screw of the carburettor sleeve to the filter. Rear mudguard - From the right side of the vehicle, undo the screw indicated. - Undo the two screws indicated from the right side and collect the washers.
Page 258: Fuel Tank
X7 250ie Chassis Helmet bay - Remove the central frame cover. - Remove the side fairings. - Undo the three screws indicated on both sides of the vehicle. - Release the wiring from the helmet compartment. See also Side fairings...
Page 259 X7 250ie Chassis - Disconnect the connector of the probe checking fuel level. - Undo the screw indicated. - Undo the screw indicated, placed under the ve- hicle at the back of the tank. - Undo the screw indicated, placed under the ve- hicle at the front of the tank.
Page 260: Front Mudguard
X7 250ie Chassis Front mudguard - Undo the three screws indicated inside the mud- guard. Radiator fan - Remove the wheel housing. - Disconnect the connector of the electric fan. - Get a container of suitable capacity and discon- nect the feeding and return cooling circuit pipes.
Page 261 X7 250ie Chassis - Disconnect the radiator together with the electric fan from the chassis retainers. - Once the radiator is removed, undo the three fix- ing screws to remove the electric fan. Expansion tank - Remove the shield back plate.
Page 262 X7 250ie Chassis Front central cover - Undo the screw indicated from both sides of the vehicle. - Remove the PIAGGIO clip-on badge and undo the screw indicated. Flyscreen - Remove both rear-view mirrors. - Undo both rear-view mirrors supports.
Page 263 X7 250ie Chassis - Undo the four screws indicated and remove the windshield. See also Driving mirrors Battery - Lift the saddle - Undo the two screws and remove the battery cover. - Unscrew the two terminals and remove the bat- tery.
Page 264 X7 250ie Chassis CHAS - 20...
Page 265 INDEX OF TOPICS PRE DE DELIVERY...
Page 266 X7 250ie Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance checks: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection - Check visually that the following clamps are marked in yellow: FRONT SUSPENSION •...
Page 267 X7 250ie Pre-delivery • Turn indicators and their warning lights • Instrument lighting • instruments: fuel and temperature indicator •Instrument panel lights • Horn • electric start up • Engine stopping with emergency stop switch CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
Page 268 X7 250ie Pre-delivery - Abnormal noise Static test Static control after the test ride: • Hot engine restart • Minimum seal (turning the handlebar) • Uniform steering rotation • Possible losses • electric radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Page 269 INDEX OF TOPICS TIME...
Page 270 X7 250ie Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and refit. 003064...
Page 271 X7 250ie Time Crankcase CRANKCASE Code Action Duration 001153 Crankcase halves gasket - Replacement 001133 Engine crankcase- Replace- ment 001124 Lubrication by-pass - Re- placement 002028 Rear wheel hub - Replace- ment TIME - 3...
Page 272 X7 250ie Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 4...
Page 273 X7 250ie Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replace- ment 001154 Pin ring piston unit - Service 001176 Rings / Pin - Replacement TIME - 5...
Page 274 X7 250ie Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 000235 Coolant temperature sensor - Replac. 001057 Thermostat - Replacement 007012 Coolant bleed valve - Re-...
Page 275 X7 250ie Time Rocker arms support assy. CAM SHAFT Code Action Duration 001148 Rocking lever valve - Re- placement 001044 Camshaft - Replacement 001169 Decompressor - Replace- ment TIME - 7...
Page 276: Cylinder Head Cover
X7 250ie Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replace- ment 001074 Oil vapour recovery pipe - Re- placement TIME - 8...
Page 277: Oil Filter
X7 250ie Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - Re- placement 001102 Net oil filter - Replacement / Cleaning TIME - 9...
Page 278 X7 250ie Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - replace 001150 Flywheel cover gasket - Re- placement 007007 Water pump rotor cover 001113 Water pump / Pump rotor - Replacement 001099 Oil seal, flywheel side - Re-...
Page 279 X7 250ie Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement TIME - 11...
Page 280 X7 250ie Time Oil pump OIL PUMP Code Action Duration 001125 Chain guide pads - change 001051 Belt - Distribution chain - Re- placement 001042 Oil pump - overhaul 001112 Oil pump - change 001122 Oil pump chain - Replace-...
Page 281 X7 250ie Time Final gear assy. FINAL REDUCTION Code Action Duration 001010 Reduction gear - Replace- ment 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Replacement 004125 Rear wheel axle - Replace- ment 004180 Reduction gear pipe - Re-...
Page 282 X7 250ie Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001066 Driving pulley - Removal and Refitting 001177 Variator rollers / shoes - Re- placement 001141 Belt anti-flapping roller - Re-...
Page 283 X7 250ie Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cov- er - Replacement 001135 Transmission cover bearing - Replacement 001170 Air duct - Replacement TIME - 15...
Page 284: Water Pump
X7 250ie Time Water pump WATER PUMP Code Action Duration 007017 Water pump cover - Replace- ment 007003 Coolant delivery and return pipe - Replacement TIME - 16...
Page 285: Starter Motor
X7 250ie Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001151 Start-up driven gearing - Re- placement 001017 Start-up pinion - Replace- ment TIME - 17...
Page 286: Flywheel Magneto
X7 250ie Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refit- ting 001173 Rotor - Replacement 001058 Complete flywheel - Replace- ment 001104 Start-up freewheel - Replace- ment TIME - 18...
Page 287 X7 250ie Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - change TIME - 19...
Page 288 X7 250ie Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replace- ment 001095 Muffler guard - Replacement 005138 Lambda probe - Replace- ment TIME - 20...
Page 289: Air Cleaner
X7 250ie Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor fitting - Replacement TIME - 21...
Page 290 X7 250ie Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004147 Footrest support bracket, one side - Replacement 004148 footrest support bracket, both sides - Replacement 004146 Front frame - Replacement TIME - 22...
Page 291 X7 250ie Time Centre-stand STAND Code Action Duration 004004 Stand - Replacement 001053 Stand bolt - Replacement 004179 Stand buffer - Replacement TIME - 23...
Page 292 X7 250ie Time Legshield spoiler FRONT SHIELD Code Action Duration 004020 Headlight frame - Replace- ment TIME - 24...
Page 293 X7 250ie Time Code Action Duration 004064 Front shield, front section - Replacement 004066 Driving mirror - Replacement Side fairings SIDE COVERS Code Action Duration 004068 Passenger handgrip - Re- placement 004085 Fairing (1) - Replacement 004053 Spoiler - Replacement...
Page 294 X7 250ie Time Rear cover SHIELD BACK PLATE Code Action Duration 004065 Shield back plate - Replace- ment 004156 Glove box flap and/or support - Replacement 004145 Glove box - Replacement 007024 Expansion tank cap - Re- placement TIME - 26...
Page 295 X7 250ie Time Central cover CENTRAL COVER Code Action Duration 004135 Fuel tank port - Replacement 004011 Central chassis cover - Re- placement 004059 Spark plug inspection flap - Replacement 004015 Footrest - Replacement TIME - 27...
Page 296 X7 250ie Time Mudguard UDGUARDS Code Action Duration 004002 Front mudguard - Replace- ment 004167 Grill / radiator cover - Re- placement 004009 Rear mudguard - Replace- ment TIME - 28...
Page 297 X7 250ie Time Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - Replace- ment TIME - 29...
Page 298 X7 250ie Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Re- placement TIME - 30...
Page 299: Handlebar Covers
X7 250ie Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Re- placement 004019 Rear handlebar covers - Re- placement 004101 Windshield - Replacement TIME - 31...
Page 300 X7 250ie Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002063 Complete throttle control - Replacement 003061 Accelerator transmission - Adjustment 003059 Counterweight - Replace- ment 004162 Mirror support and/or brake pump fitting U-bolt - Replace-...
Page 301 X7 250ie Time Swing-arm SWINGING ARM Code Action Duration 003081 Swinging arm support flange - replace 004058 Silent-block - replace 001072 Engine /frame swinging arm attachment - replace 003080 Swinging arm on frame - Re- placement 003077 Muffler supporting arm/ rear...
Page 302 X7 250ie Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 34...
Page 303 X7 250ie Time Instrument panel INSTRUMENT PANEL Code Action Duration 005014 Odometer - Replacement TIME - 35...
Page 304 X7 250ie Time Locks LOCKS Code Action Duration 004010 Anti-theft lock - Replacement 005099 Electric saddle opening de- vice - Replacement 004054 Saddle lock catch - Replace- ment Turn signal lights Rear lights TIME - 36...
Page 305 X7 250ie Time REAR LIGHTS Code Action Duration 005005 Taillight - Replacement 005031 Licence plate light bulb - Re- placement 005032 Transparent licence plate cover - replace 005022 Rear turn indicators - Re- placement 005066 Rear light bulbs - Replace-...
Page 306 X7 250ie Time TURN INDICATOR LIGHTS Code Action Duration 005002 Front light - Replacement 005008 Light bulbs - Replacement 005044 Front lights cable unit- Re- placement 005067 Front direction indicator bulb - Replacement TIME - 38...
Page 307: Front Wheel
X7 250ie Time Front wheel RONT WHEEL Code Action Duration 002041 Front brake disc - Replace- ment 003037 Front wheel rim- Replace- ment 003038 Front wheel axle - Replace- ment 003040 Front wheel bearings - Re- placement 003047 Front tyre - replace...
Page 308: Rear Wheel
X7 250ie Time Rear wheel EAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001071 Rear wheel rim - replace 004126 Rear wheel tyre - Replace- ment 002070 Rear brake disc - Replace- ment TIME - 40...
Page 309 X7 250ie Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Pump/ injector pipe - Re- placement TIME - 41...
Page 310 X7 250ie Time Electric devices REMOTE CONTROLS Code Action Duration 005003 Horn - Replacement 005007 Battery - Replacement 005075 Stop remote control - Re- placement 005035 Headlight remote control - Replacement 005011 Start-up remote control switch - Replacement TIME - 42...
Page 311 X7 250ie Time VOLTAGE REGULATOR Code Action Duration 005009 Voltage regulator - Replace- ment 001069 HV coil - Replacement 001094 Spark plug cap - Replace- ment 005119 Fuel pump remote control - Replacement TIME - 43...
Page 312 X7 250ie Time WIRE UNIT Code Action Duration 005001 Electrical system - Replace- ment Electronic controls TIME - 44...
Page 313 X7 250ie Time LECTRIC CONTROLS Code Action Duration 005006 Light switch or turn indicators - Replacement 005039 Headlight switch - replace 005040 Horn button - Replacement 005041 Starter button - Replacement 005077 Emergency stop switch - Re- placement 005016 Key switch - Replacement...
Page 314 X7 250ie Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Re- placement 005046 Battery cover - change TIME - 46...
Page 315 X7 250ie Time Rear side fairings EAR COVERS Code Action Duration 005048 Licence plate holder - Re- placement TIME - 47...
Page 316: Front Suspension
X7 250ie Time Front suspension FRONT SUSPENSION Code Action Duration 003051 Complete fork - replace 003010 Front suspension - Service 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003002 Steering thrust washer - Re-...
Page 317 X7 250ie Time Cooling system COOLING SYSTEM Code Action Duration 007002 Water radiator - replacement 007016 Fan with support - Replace- ment 007001 Expansion tank - Replace- ment 007022 Coolant delivery pipe - Re- placement 007013 Radiator expansion tank con-...
Page 318 X7 250ie Time Braking system BRAKE SYSTEM Code Action Duration 002007 Front brake pads - Replace- ment 002039 Front brake calliper - Re- placement 002021 Front brake piping - Replace- ment 002002 Rear brake pads - Replace- ment 002048 Rear brake calliper - Re-...
Page 319 X7 250ie Time Windscreen INDSHIELD Code Action Duration 004101 Windshield - Replacement TIME - 51...
Page 320 X7 250ie Time Stickers TRANSFERS Code Action Duration 004159 Plates / Stickers - Replace- ment TIME - 52...

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