PIAGGIO X9 Evolution 125 2008 Service Station Manual
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PIAGGIO X9 Evolution 125 2008 Service Station Manual

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

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  • Page 1 SERVICE STATION MANUAL 664627 IT-664628 EN-664629 FR-664630 DE-664631 ES-664632 PT-664633 OL-664634 EL X9 Evolution 125...
  • Page 2 Not all versions shown in this publication are available in all countries. The availability of single models should be checked at the official Piaggio sales network. "© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 SERVICE STATION MANUAL X9 Evolution 125 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

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.

  • Page 8: Vehicle Identification

    X9 Evolution 125 Characteristics Vehicle identification Chassis prefix: ZAPM481000000 ÷ 1001 Engine prefix: M482M Dimensions and mass EIGHT AND DIMENSIONS Specification Desc./Quantity Kerb weight 172±5 kg Saddle height 790 mm Wheelbase 1500 mm Overall length 2130 mm Overall height 1450 mm Overall width 910 mm CHAR - 8...
  • Page 9 X9 Evolution 125 Characteristics Engine ECHNICAL DATA Specification Desc./Quantity Type Single-cylinder, 4-stroke Timing system 4 valves, single overhead camshaft, chain-driven. Cubic capacity 124 cm³ Bore x stroke 57 x 48.6 mm Compression ratio 12 ± 0.5: 1 Carburettor KEIHIN CVK 29 ignition advance (before TDC) 10°...

  • Page 10: Wheels And Tyres

    X9 Evolution 125 Characteristics Capacities APACITY Specification Desc./Quantity Rear hub 150 cm³ Cooling system ~ 1.2 l Engine oil ~ 1000 cm³ Fuel tank (including a ~ 2.5 l reserve) ~ 14.5 l Electrical system LECTRICAL COMPONENTS Specification Desc./Quantity Generator Three-phase alternating current Battery 12V -10 Ah...

  • Page 11: Secondary Air

    X9 Evolution 125 Characteristics Secondary air The SAS for 125cc leader engines operates in a similar manner to the SAS for 2T engines. The differences are the following: instead of entering through the muffler as for 2T engine, the secondary air enters directly in the discharge pipe on the head.
  • Page 12 X9 Evolution 125 Characteristics The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reac- tion of the catalytic converter. 125cc Version ble border="1"...
  • Page 13 X9 Evolution 125 Characteristics Carburettor Keihin Walbro Max. air jet Minimum air jet Throttle valve spring 100 ± 160 g 100 g Minimum mixture set screw initial open- 2 ± 1/4 2 5/8 ± 1/2 Tapered pin stamping NDYA Tapered pin notches position from top Fixed position Diffuser nozzle Ø...
  • Page 14 X9 Evolution 125 Characteristics Specification Desc./Quantity Diffuser nozzle Ø 2.7 Tapered pin notches from above Tapered pin stamping Minimum mixture set screw initial opening 2 5/8 ± 1/2 Throttle valve spring 100 g Minimum air jet Max. air jet Minimum jet Max.

  • Page 15: Tightening Torques

    X9 Evolution 125 Characteristics Specification Desc./Quantity Stamping 303A Tapered pin notches position from top Fixed position Max. air jet Diffuser nozzle Ø 2.8 Starter jet ~ 20 Ω Starter device resistance Diffuser Ø 29 Tapered pin stamping NDWA Minimum mixture set screw initial opening ±...

  • Page 16: Front Suspension

    X9 Evolution 125 Characteristics Name Torque in Nm Brake fluid pump-hose fitting 16 ÷ 20 Tightening screw for calliper support to the fork 45 ÷ 55 REAR SUSPENSION Name Torque in Nm Upper shock absorber clamp 33 ÷ 41 Lower shock absorber clamp 33 ÷...
  • Page 17 X9 Evolution 125 Characteristics ENGINE - CYLINDER HEAD Name Torque in Nm Manifold-silencer retaining bolt 15 ÷ 20 Nut fixing muffler to cylinder head 16 ÷ 18 Camshaft retention plate screw 4 ÷ 6 Timing chain tensioner central screw 5 ÷ 6 Timing chain tensioner support screw 11 ÷...
  • Page 18 X9 Evolution 125 Characteristics ENGINE 200 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder / piston 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 Cylinder / piston 72.004 ÷...
  • Page 19 X9 Evolution 125 Characteristics ENGINE 125 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059 Piston 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059 Piston 57.018 ÷...
  • Page 20 X9 Evolution 125 Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, transmission 16,6 +0-0,05 D = 0.20 ÷ 0.50 side Flywheel-side half shaft 16,6 +0-0,05 D = 0.20 ÷ 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 ÷ 0.50 Spacer tool 51.4 +0.05 D = 0.20 ÷...
  • Page 21 X9 Evolution 125 Characteristics Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
  • Page 22 X9 Evolution 125 Characteristics ENGINE 200 SHIMMING Name Measure A Thickness 1.40 ÷ 1.30 0.8 ± 0.05 1.60 ÷ 1.40 0.6 ± 0.05 1.70 ÷ 1.60 0.4 ± 0.05 ENGINE 125 SHIMMING Name Measure A Thickness 2.2 ÷ 2.4 0.4 ± 0.05 CHAR - 22...
  • Page 23 X9 Evolution 125 Characteristics Name Measure A Thickness 2.4 ÷ 2.6 0.6 ± 0.05 N.B. 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.
  • Page 24 X9 Evolution 125 Characteristics ENGINE 200 OVERSIZE Name Description Dimensions Initials Quantity Oil scraper ring 72 x 2.5 0.20 ÷ 0.40 Oil scraper ring 72 x 1 0.20 ÷ 0.40 Compression ring 72 x 1.5 0.15 ÷ 0.30 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications...

  • Page 25: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 26 X9 Evolution 125 Tooling APPROPRIATE TOOLS Stores code Description 020151Y Air heater 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 001467Y014 Pliers to extract ø 15-mm bearings TOOL - 26...
  • Page 27 X9 Evolution 125 Tooling Stores code Description 020412Y 15 mm guide 020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47-mm Adaptor TOOL - 27...
  • Page 28 X9 Evolution 125 Tooling Stores code Description 020363Y 20 mm guide 020459Y Punch for fitting bearing on steering tube 020458Y Puller for lower bearing on steering tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Oil pressure control fitting TOOL - 28...
  • Page 29 X9 Evolution 125 Tooling Stores code Description 020382Y011 adapter for valve removal tool 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch for assembling valve sealing rings 020360Y 52x55-mm Adaptor TOOL - 29...
  • Page 30 X9 Evolution 125 Tooling Stores code Description 020364Y 25-mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020444Y Tool for fitting/ removing the driven pulley clutch 020330Y Stroboscopic light to check timing 001467Y035 Belle for OD 47-mm bearings TOOL - 30...
  • Page 31 X9 Evolution 125 Tooling Stores code Description 020368Y driving pulley lock wrench 020319Y Immobilizer check tester 020287Y Clamp to assemble piston on cylinder 020263Y Driven pulley assembly sheath 020262Y Crankcase splitting strip 020430Y Pin lock fitting tool TOOL - 31...
  • Page 32 X9 Evolution 125 Tooling Stores code Description 020428Y Piston position check support 020426Y Piston fitting fork 020425Y Punch for flywheel-side oil seal 020423Y Driven pulley lock wrench 020414Y 28-mm guide 020393Y Piston assembly band TOOL - 32...
  • Page 33 X9 Evolution 125 Tooling Stores code Description 020382Y Valve cotters equipped with part 012 re- moval tool 020455Y 10-mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum-operated pump 020357Y 32x35-mm Adaptor TOOL - 33...
  • Page 34 X9 Evolution 125 Tooling Stores code Description 020409Y Multimeter adaptor - Peak voltage detec- tion 020456Y Ø 24 mm adaptor 020332Y Digital rev counter 020074Y Support base for checking crankshaft alignment 020055Y Wrench for steering tube ring nut TOOL - 34...
  • Page 35 X9 Evolution 125 Tooling Stores code Description 002465Y Pliers for circlips 001330Y Tool for fitting steering seats 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020444Y011 adapter ring 020444Y009 wrench 46 x 55 001467Y Extractor for bearings for holes TOOL - 35...
  • Page 36 X9 Evolution 125 Tooling Stores code Description 001467Y013 Pliers to extract ø 15-mm bearings 020444Y010 adapter ring TOOL - 36...
  • Page 37 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 38: Maintenance Chart

    X9 Evolution 125 Maintenance Maintenance chart VERY YEARS Action Coolant - change Brake fluid - change Secondary air filter (external / internal) - Clean EVERY 3000 KM Action Engine oil - level check/ top-up 1,000 FTER KM OR MONTHS Action Engine oil - replacement Hub oil - change Engine oil - change...
  • Page 39 X9 Evolution 125 Maintenance Action Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test Driving Belt - replacement (*) See instructions in the «Idle speed adjustment»...
  • Page 40 X9 Evolution 125 Maintenance Action Tyre pressure and wear - check Vehicle and brake test - road test Engine oil - change Oil filter -Replacement 36000 FTER Action Engine oil - replacement Hub oil level - check Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change valve clearance - check...

  • Page 41: Checking The Spark Advance

    X9 Evolution 125 Maintenance Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condition. - The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due to wear.
  • Page 42 X9 Evolution 125 Maintenance - The brand new control unit prevents that the engine rotation exceeds 2000 rpm. - The programmed control unit allows the engine to rotate within the prescribed limits. Specific tooling 020330Y Stroboscopic light to check timing Spark advance variation REVOLUTION LIMITER Specification...

  • Page 43: Spark Plug

    X9 Evolution 125 Maintenance Spark plug To service the spark plug the engine must be cold, proceed as follows: - Undo the knob located inside the rear boot and remove the saddle. - Remove the spark plug cap. - Use the supplied spanner (with retaining rubber ring) to remove the spark plug.

  • Page 44: Air Filter

    X9 Evolution 125 Maintenance Check - Rest the vehicle on its centre stand on an even surface. - Unscrew the oil dipstick, dry it with a clean cloth and reinsert it, screwing it in thoroughly.- Take out the dipstick and check that the oil level reaches the 2nd notch from the bottom.- Screw the dipstick back into place completely.

  • Page 45: Engine Oil

    X9 Evolution 125 Maintenance Remove the air cleaner cap after undoing the re- tainer screws, then extract the filter. - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of com- pressed air. -Saturate with a 50% mixture of gasoline and oil. -Drip dry the filtering element and then squeeze it between your hands without wringing.

  • Page 46: Level Check

    X9 Evolution 125 Maintenance - The MAX level reference indicates ~ 1000 cm³ in the engine. - When the oil level is below the MAX mark, top-up with oil but without exceeding the MAX level. Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications Level check SAS filters inspection and cleaning...
  • Page 47 X9 Evolution 125 Maintenance WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART. Insert the filter into its housing. Fit the valve support with the 3 screws Insert the rubber spacer on the valve and proceed with the assembly on the support.
  • Page 48 X9 Evolution 125 Maintenance Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4 MAIN - 48...
  • Page 49 X9 Evolution 125 Maintenance MAIN - 49...

  • Page 50: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 51: Poor Performance

    X9 Evolution 125 Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re- place Excess of encrustations in the combustion chamber Descale the cylinder, the piston, the head and the valves...
  • Page 52 X9 Evolution 125 Troubleshooting Possible Cause Operation Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight- ened Defective floating valve Check the proper sliding of the float and the functioning of the valve Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air...
  • Page 53 X9 Evolution 125 Troubleshooting Excessive exhaust noise EXCESSIVE EXHAUST NOISE Possible Cause Operation Secondary air device cut-off valve not working Replace the secondary air device Depression intake pipe of the secondary air device disconnec- Replace the pipe ted or dented Reed valve of the secondary air device does not close correctly Replace the device and the coupling and wears out the rubber coupling between the device and the...
  • Page 54 X9 Evolution 125 Troubleshooting Insufficient braking NSUFFICIENT BRAKING Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits;...
  • Page 55 X9 Evolution 125 Troubleshooting Controls STEERING CONTROLS AND SUSPENSIONS Possible Cause Operation Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu- larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: if they are recessed or if the balls are squashed, replace them.
  • Page 56 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 57 X9 Evolution 125 Electrical system This section is devoted to the description of the electrical system components. 1. Electronic ignition device 2. Immobilizer aerial 3. Magneto flywheel Pick-up 4. Relay for disabling start-up 5.Relay engine stop 6. Voltage regulator 7. Engine stop switch 8.
  • Page 58 X9 Evolution 125 Electrical system 11. Starter motor 12. Relay for start-up 13. Secondary fuses 14. Stop button on rear brake 15. Stop button on front brake 16. Start-up button 17. Reset 18. Saddle opening control unit wiring 19. Helmet compartment light switch 20.
  • Page 59 X9 Evolution 125 Electrical system 41. Digital instrument panel A. Preset warning light B. ABS wiring warning light C. Stop light bulb burned warning light D. Disabled engine warning light E. Oil warning light F. Low fuel warning light G. Headlight warning light H.
  • Page 60 X9 Evolution 125 Electrical system Conceptual diagrams Ignition 1. Electronic ignition device 2. Immobilizer aerial 5.Relay engine stop 7. Engine stop switch 8. Main fuses 10. Battery 49. Key switch 50. Side stand button 58. Spark plug 59. HV coil ELE SYS - 60...
  • Page 61 X9 Evolution 125 Electrical system Headlights and automatic starter section 1. Electronic ignition device 5.Relay engine stop 7. Engine stop switch 8. Main fuses 10. Battery 13. Secondary fuses 21. Light switch 22. Relay for headlight 23. Diode 25. License plate light 26.
  • Page 62 X9 Evolution 125 Electrical system 31. Right headlight A. Low-beam light B. Tail light 41. Digital instrument panel G. Headlight warning light H. High-beam warning light 42. Analogue instrument panel B. Instrument panel bulb 49. Key switch 50. Side stand button 51.
  • Page 63 X9 Evolution 125 Electrical system 8. Main fuses 10. Battery 11. Starter motor 12. Relay for start-up 13. Secondary fuses 14. Stop button on rear brake 15. Stop button on front brake 16. Start-up button 27. Rear stop light 49. Key switch 50.
  • Page 64 X9 Evolution 125 Electrical system 10. Battery 13. Secondary fuses 35. Oil pressure sensor 38.Wheel turning sensor 39. Fuel level transmitter 40. Thermistor 41. Digital instrument panel A. Preset warning light B. ABS wiring warning light C. Stop light bulb burned warning light D.

  • Page 65: Devices And Accessories

    X9 Evolution 125 Electrical system Devices and accessories 1. Electronic ignition device 5.Relay engine stop 7. Engine stop switch 8. Main fuses 9. 12V-180W socket 10. Battery 13. Secondary fuses 17. Reset 18. Saddle opening control unit wiring 19. Helmet compartment light switch 20.

  • Page 66: Checks And Inspections

    X9 Evolution 125 Electrical system 32. Front right turn indicator 33. Horn button 34. Horn 36. Accessories wiring 37. Reset button 41. Digital instrument panel I. Left turn indicator warning light L. Emergency flashing warning light M. Right turn indicator warning light 43.
  • Page 67 X9 Evolution 125 Electrical system -The diagnostic LED also works as a deterring blinker. This function is activated every time the key switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process.

  • Page 68: Diagnostic Codes

    X9 Evolution 125 Electrical system - Key switch contacts. Virgin circuit If the ignition system has not been programmed, the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evi- dent loss of power may be felt. Program the system with the MASTER (Brown) and SERVICE (Black) keys as follows: - Insert the MASTER key, turn it to "ON"...
  • Page 69 X9 Evolution 125 Electrical system That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table: 2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial.

  • Page 70: Ignition Circuit

    X9 Evolution 125 Electrical system Diagnostic code - 3 flashes If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the key switch. - If the failure disappears when the MASTER key is used, encode the service keys (Blue) again.

  • Page 71: Specific Tooling

    X9 Evolution 125 Electrical system Pick-up resistance value: 105 ÷ 124 Ohm If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine manual). If non-conforming values are measured, replace the Pick-Up; otherwise, repair the cable harness.
  • Page 72 X9 Evolution 125 Electrical system Electric characteristic Resistance value: ~ 3000 ± 300 Ohm - Pick-Up Disconnect the control unit connector and connect the positive wire to connector No. 2 and the neg- ative wire to connector No. 8 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up.

  • Page 73: Stator Check

    X9 Evolution 125 Electrical system The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed. Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger...
  • Page 74 X9 Evolution 125 Electrical system Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further rep- etitions of incorrect values replace the stator or repair the wiring.
  • Page 75 X9 Evolution 125 Electrical system Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive terminal, measure the bat- tery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V.
  • Page 76 X9 Evolution 125 Electrical system tive one to terminal No. 7 (White/Black) (see figure). If there is no voltage, replace the control unit after making sure that the fuses are not blown; other- wise, check the cable harness between the starter and the control unit and, as a last resource, re- place the starter.
  • Page 77 X9 Evolution 125 Electrical system The tables show the position and characteristics of the fuses on the scooter. CAUTION BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).
  • Page 78 X9 Evolution 125 Electrical system The X9 model has an instrument panel subdivided into 2 sections: the analogue section fastened to the windshield, and the digital section integral to the handlebar. The analogue section comprises: - A speedometer with double scale (MPH/KMH) controlled by the tone wheel; - An rpm indicator controlled by the signal coming from the HV coil.
  • Page 79 X9 Evolution 125 Electrical system The display provides 3 icons with the words: - Oil - Service - Belt - The "Oil" icon flashes when a distance of 1000 km has been covered, and then every 3000 km. - The "Service" icon flashes for the first time at 1000 km or after 1 year. After that, every 6000 km or after 1 year. - The "Belt"...
  • Page 80 X9 Evolution 125 Electrical system At the end of the operation above, the normal warning light bulbs check is carried out. Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary.
  • Page 81 X9 Evolution 125 Electrical system Dry-charge battery - Remove the battery air pipe cap and each single cell caps. - 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. - Incline the battery slightly to remove any air bubbles formed during filling.
  • Page 82 X9 Evolution 125 Electrical system Pump electrics check Connect the tester positive probe to pin 4 of the connector of the fuel pump control device, and the negative probe to pin 3, making sure there is bat- tery voltage as indicated in the table. PUMP SUPPLY Specification Desc./Quantity...

  • Page 83: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 84 X9 Evolution 125 Engine from vehicle Removal of the engine from the vehicle - Carry out the removal operations but in reverse order, observing the prescribed tightening torques. Locking torques (N*m) Lower shock absorber clamp 33 ÷ 41 Engine-swinging arm bolt 33 ÷ 41 - Remove the nut shown in the figure, then take out the pin.
  • Page 85 X9 Evolution 125 Engine from vehicle - Remove the nut shown in the figure, then take out the pin. ENG VE - 85...
  • Page 86 INDEX OF TOPICS NGINE...

  • Page 87: Automatic Transmission

    X9 Evolution 125 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 88: Removing The Driven Pulley Shaft Bearing

    X9 Evolution 125 Engine Air duct filter To remove the intake throat on the transmission cover, remove the 2 fixing screws indicated in the figure. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by means of: Specific tooling...
  • Page 89 X9 Evolution 125 Engine - Slightly heat the crankcase from the inside so as not to damage the painted surface. - Insert the bearing in its seat. - Refit the Seeger ring. CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM- AGING THE COVER PAINT.
  • Page 90 X9 Evolution 125 Engine - Refit the roller with the special screw. - Tighten to the specified torque. - Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing. Locking torques (N*m) Anti-flapping roller 12 - 16 - Heat the roller and insert the bearing using the specific punch: Specific tools:...

  • Page 91: Removing The Driven Pulley

    X9 Evolution 125 Engine Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.

  • Page 92: Removing The Clutch

    X9 Evolution 125 Engine Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft unit on the support to check the crankshaft alignment.
  • Page 93 X9 Evolution 125 Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 94 X9 Evolution 125 Engine Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - Replace with a new one if there are. - Remove the retaining ring using two flat blade screwdrivers. - Support the pulley bushing adequately from the threaded side using a wooden surface.
  • Page 95 X9 Evolution 125 Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. Characteristic Movable driven half-pulley max. diameter Max. diameter admitted: Ø 41.08 mm Movable driven half-pulley standard diameter Standard diameter: Ø...

  • Page 96: Refitting The Driven Pulley

    X9 Evolution 125 Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings (A) shown in the figure. - Fit the half-pulley over the bushing using the ap- propriate tool - Check that the pins are not worn and proceed to refitting them in their slots.
  • Page 97 X9 Evolution 125 Engine Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 106 mm acceptable limit after use: 101 mm Refitting the clutch - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis.
  • Page 98 X9 Evolution 125 Engine - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action until it reaches the pul- leys maximum opening and place the belt on the minimum rolling diameter.

  • Page 99: Removing The Driving Pulley

    X9 Evolution 125 Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Driving belt - minimum width: 21.5 mm Driving belt - standard width: 22.5 ± 0.2 mm During the wear checks foreseen in the scheduled maintenance services at 6,000 km;...
  • Page 100 X9 Evolution 125 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. - Check that the rollers are not damaged or worn.
  • Page 101 X9 Evolution 125 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 102 X9 Evolution 125 Engine - Correctly refit the previously removed Bendix back to its position. - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread Loctite 243 Quick Set threadlock on the thread and tighten the nut to the prescribed torque. - Avoid the half-pulley rotation with the appropriate stop key tool..
  • Page 103 X9 Evolution 125 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 104 X9 Evolution 125 Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Support the hub cover and expel the bearing. By means of the appropriate tools, remove the oil guard as in the figure. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm...
  • Page 105 X9 Evolution 125 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. - Remove the oil guard using a screwdriver, work- ing from inside the bearing and being careful not to damage the housing, make it come out of the...
  • Page 106 X9 Evolution 125 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. - Fit the Seeger ring.
  • Page 107 X9 Evolution 125 Engine Refitting the hub cover bearings - To fit the hub housing bearings, the engine crank- case and the cover must be heated with the spe- cial heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
  • Page 108 X9 Evolution 125 Engine 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. - Fit the gearbox cover, making sure the breather pipe is in the correct position.

  • Page 109: Flywheel Cover

    X9 Evolution 125 Engine Flywheel cover - Remove the two clamps, the two couplings and empty the cooling system. - Remove the 4 retainers and the flywheel cover. Removing the hub cover - Remove the two clamps, the two couplings and empty the cooling system.

  • Page 110: Removing The Stator

    X9 Evolution 125 Engine Removing the stator - Remove the electric terminal of the minimum oil pressure switch. - Remove the two Pick-Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure. - Remove the stator and its wiring.
  • Page 111 X9 Evolution 125 Engine - Place the flywheel with the top dead centre mark aligned with the crankcase. - Place the flywheel cover by aligning the reference marks of the drive and the crankcase cover. - Reassemble the cover on the engine, placing the three connectors in the drive for the water pump. - Carry out the steps in the reverse order from the dismantling procedure.
  • Page 112 X9 Evolution 125 Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate. Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly. - Lock the flywheel nut to the prescribed torque - Check that the Pick-Up air gap is between 0.34 ÷...

  • Page 113: Removing The Intake Manifold

    X9 Evolution 125 Engine Removing the intake manifold - Remove the flywheel cover completely as de- scribed in the flywheel cover section. - Loosen the 3 crews and remove the intake mani- fold. N.B. TAMPERPROOF SCREWS ARE SUPPLIED WITH 125 CC MODELS.
  • Page 114 X9 Evolution 125 Engine ENG - 114...

  • Page 115: Removing The Cam Shaft

    X9 Evolution 125 Engine Removing the cam shaft - Remove the 2 screws and the camshaft retainer shown in the diagram. - Remove the camshaft. - Remove the pins and the rocking levers from the flywheel side holes. N.B. IN NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKING LEVER PINS AND FIXING BRACK- ET.

  • Page 116: Removing The Cylinder Head

    X9 Evolution 125 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket.
  • Page 117 X9 Evolution 125 Engine Removing the cylinder - piston assy. - Remove the chain guide pad. - Pull out the cylinder. - Remove the cylinder base gasket. - Remove the two stop rings, the wrist pin and the piston. - Remove the piston seals. CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.
  • Page 118 X9 Evolution 125 Engine ENG - 118...

  • Page 119: Inspecting The Small End

    X9 Evolution 125 Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING. Characteristic Rod small end check-up: Maximum diameter 15.030 mm...
  • Page 120 X9 Evolution 125 Engine - If the clearance is greater than that indicated in the table, replace the piston. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.

  • Page 121: Removing The Piston

    X9 Evolution 125 Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin stop ring onto the appropriate tool. - With opening in the position indicated on the tool S = left D = right - Place the wrist pin stop ring into position using a punch...
  • Page 122 X9 Evolution 125 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket. - Assemble a dial gauge on the specific tool Support to check piston position 020428Y - Set the dial gauge to zero placing the tool on a contrasting surface. Keeping the zero position, as- semble the tool on the cylinder and lock it with 2 supplied nuts as shown in the figure.
  • Page 123 X9 Evolution 125 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 124: Inspecting The Cylinder Head

    X9 Evolution 125 Engine Inspecting the cylinder head - Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocking lever pin capacities exhibit no wear.
  • Page 125 X9 Evolution 125 Engine - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn. Standard diameter A Ø 12.000 ÷ 12.018 mm B Ø 20.000 ÷ 20.021 mm C Ø 37.000 ÷ 37.025 mm Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out.
  • Page 126 X9 Evolution 125 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 127 X9 Evolution 125 Engine Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the fay- ing surface with the articulated set screw terminal.
  • Page 128 X9 Evolution 125 Engine Inlet: 4.96 mm Valve check Standard diameter: Inlet: 4.972 ÷ 4.987 mm Valve check Standard diameter: Exhaust: 4.96 ÷ 4.975 mm - Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between valve and valve guide.
  • Page 129 X9 Evolution 125 Engine will prevent the lapping compound residues from penetrating between the valve stem and the guide (see figure). CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COM- POUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
  • Page 130 X9 Evolution 125 Engine or more points, or curved, replace the valve with a new one. CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT). Characteristic Valve wear check Standard: Intake and dis- charge: 0.99 - 1.27 mm Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear.

  • Page 131: Inspecting The Cam Shaft

    X9 Evolution 125 Engine Inspecting the cam shaft - Inspect the camshaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the camshaft retaining plate and its associated groove on the camshaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new...
  • Page 132 X9 Evolution 125 Engine Camshaft check: Minimum admissible diame- Bearing B diameter: 19.950 mm Camshaft check: Minimum admissible diame- Bearing A Ø: 36.94 mm Camshaft check: Standard diameter Bearing B diameter: 19.959 ÷ 19.98 mm Camshaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm Refitting the head and timing system components - Fit the timing chain guide pad.
  • Page 133 X9 Evolution 125 Engine - Refit the lower timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft. - Fit the chain tensioner slider from the cylinder head side.
  • Page 134 X9 Evolution 125 Engine - Tighten the clamping screw to the prescribed tor- que. - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the pre- scribed torque.

  • Page 135: Crankcase - Crankshaft

    X9 Evolution 125 Engine Refitting the intake manifold Fit the intake manifold and do up the three screws. N.B. USE COMMERCIALLY AVAILABLE INSERTS AND INSERT HOLDERS FOR THE SPECIAL SCREWS FOR 125 CM³ MODELS. Crankcase - crankshaft Splitting the crankcase halves First remove the following units: transmission cover, driving pulley, driven pulley and belt, rear hub cover, gears, bearings and oil seals as described in the transmission chapter.
  • Page 136 X9 Evolution 125 Engine Remove the 11 coupling screws to the crankcase. - Separate the crankcase while keeping the crank- shaft in one of the two halves of the crankcase. Remove the crankshaft. CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT.
  • Page 137 X9 Evolution 125 Engine Check the radial clearance on the connecting rod. Standard clearance: 0.036 ÷ 0.054 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
  • Page 138 X9 Evolution 125 Engine Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
  • Page 139 X9 Evolution 125 Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take particular care when handling the oil pump com- partment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the trans- mission side (see diagram).
  • Page 140 X9 Evolution 125 Engine 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 shown in the diagram, could cause a drop in the oil pressure lubricating the main bearings and con- nection rod.

  • Page 141: Specific Tooling

    X9 Evolution 125 Engine For the 200 models reposition the shim washers as in the original fitting. - Fit the 11 screws and tighten them to the pre- scribed torque. - Lubricate the flywheel oil seal. - Using the appropriate tool, assemble the oil seal. - Fit a new O-ring on the pre-filter and lubricate it.
  • Page 142 X9 Evolution 125 Engine ENG - 142...

  • Page 143: Oil Pressure Check

    X9 Evolution 125 Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure is between 0.5 ÷...

  • Page 144: Crankshaft Oil Seals

    X9 Evolution 125 Engine Crankshaft oil seals Removal - Remove the transmission cover and the com- plete drive pulley beforehand - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.
  • Page 145 X9 Evolution 125 Engine - Orientate the oil seal by inserting the bracket which is part of the specific tool. - Tighten the threaded bar onto the crankshaft as far as it will go. - Use the nut to move the base of the tool until you can feel the end of the oil seal driving stroke.

  • Page 146: Oil Pump

    X9 Evolution 125 Engine For 125 models, fit a new oil seal on the flywheel side using the specific tool as shown in the photo- graph N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE- QUENCE IN INADEQUATE OIL SEALING.
  • Page 147 X9 Evolution 125 Engine - Remove the oil pump by undoing the two screws in the figure. - Remove the oil pump seal. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
  • Page 148 X9 Evolution 125 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 149 X9 Evolution 125 Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete driving pulley assembly with belt and the sprocket wheel, as described in the "Trans- mission" chapter. - Drain the oil as described above. - Remove the 7 screws, shown in the diagram, and the 2 rear brake fluid pipe fixing brackets.
  • Page 150 X9 Evolution 125 Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.
  • Page 151 X9 Evolution 125 Engine - Switch the pump to pressure mode (PRES- SURE). - Operate the pump slowly and check if there is an increase of pressure. A small leakage is consid- ered to be normal. If anomalies are detected, replace the pump. N.B.

  • Page 152: Fuel Supply

    X9 Evolution 125 Engine the valve opens and the depression is suddenly set to zero. Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it. N.B. LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS IN EXHAUST NOISE (EXPLOSIONS IN THE MUFFLER).
  • Page 153 X9 Evolution 125 Engine Kehin - To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connection, the clamps anchoring the carburettor to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, and the intake fitting.
  • Page 154 X9 Evolution 125 Engine - Remove the clamp and cover with the airing filter of the diaphragm chamber. - Remove the 4 fixing screws shown in the figure and the vacuum chamber cover. WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
  • Page 155 X9 Evolution 125 Engine - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure. - Remove the chamber with the accelerating pump, its control and gasket.
  • Page 156 X9 Evolution 125 Engine Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side. - Remove the float and the plunger. - Remove the maximum nozzle -Remove the maximum nozzle. ENG - 156...
  • Page 157 X9 Evolution 125 Engine -Remove diffuser. - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT. -Remove the minimum nozzle.
  • Page 158 X9 Evolution 125 Engine - Remove the minimum flow set screw and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR PROGRESSIONS AND INLET NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL SHAFT.
  • Page 159 X9 Evolution 125 Engine - For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by flow screw, progression holes near the throttle valve. - For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations.
  • Page 160 X9 Evolution 125 Engine - Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the noz- zle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser. - Assemble the diffuser making sure the sprayer is being adequately inserted and lock it.
  • Page 161 X9 Evolution 125 Engine - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air. - Reassemble the acceleration pump valves fol- lowing this order: INTAKE VALVE (A) •...
  • Page 162 X9 Evolution 125 Engine Inspecting the valve and needle Kehin - Check that the tapered pin of the vacuum valve does not show wear. - Check that the depression valve does not show threads on the external surfaces. - Check that the vacuum intake hole is not clogged. - Check that the diaphragm is not damaged or has hardened, otherwise replacement the whole valve.
  • Page 163 X9 Evolution 125 Engine Inspecting the automatic choke device ENG - 163...
  • Page 164 X9 Evolution 125 Engine Kehin - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the piston sealing gasket is not de- formed.

  • Page 165: Adjusting The Idle

    X9 Evolution 125 Engine Starter resistance 20 Ω Check the automatic starter: Keihin maximum time 5 min Adjusting the idle - The engine does not require frequent idle speed adjustments, but it is essential to strictly follow cer- tain rules when adjusting the idle speed. - Before adjusting the carburettor make sure to re- spect the lubrication requirements, valve clear- ance, and complying timing, spark plug should be...

  • Page 166: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 167: Removing The Front Wheel

    X9 Evolution 125 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel Remove the two callipers according to what is de- scribed in the "Braking system" chapter. - Unscrew the wheel axle fixing nut; - Loosen the fork-wheel axle retainer clamp by slightly unscrewing the two screws located on the fork...
  • Page 168 X9 Evolution 125 Suspensions Refitting Carry out the above operations by working in the reverse order from those of the removal. Locking torques (N*m) Handlebar fixing screw (*) 43 ÷ 47 Removal After removing the upper seat, lean the vehicle on one side and extract the steering tube completely from the fork.
  • Page 169 X9 Evolution 125 Suspensions Recommended products SELENIA FORK 10W Oil for front fork SAE 10 W hydraulic oil Refitting Insert the two ring nuts and the special washer in- dicated in the figure Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Upper steering ring nut 30 ÷...
  • Page 170 X9 Evolution 125 Suspensions Lubricate the seats and the balls. Lock in place and turn the wrench anticlockwise Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GREASE PV2 Grease for steering bear- ings, bolt seatings for swinging arms and fay- ing surface of driven pulley spring (only pulley side) Soap-based lithium and zinc oxide grease con-...
  • Page 171 X9 Evolution 125 Suspensions Removal Remove upper bearing with an appropriate tool. N.B. USE THE APPROPRIATE TOOL AGAIN TO REMOVE THE LOWER HOUSING OF THE STEERING LOWER BEARING Specific tooling 020004Y Punch for removing fifth wheels from headstock SUSP - 171...
  • Page 172 X9 Evolution 125 Suspensions Refitting Insert the lower and upper bearing on the chassis using an appropriate tool. N.B. ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION OF AN ADEQUATE DIAME- TER. Specific tooling 001330Y Tool for fitting steering seats Rear SUSP - 172...

  • Page 173: Removing The Rear Wheel

    X9 Evolution 125 Suspensions Removing the rear wheel Removal - Unscrew the four fixing screws and remove the muffler and the relevant bracket; - Unscrew the central retaining nut. Reassembly Carry out the previous operations in reverse order. Locking torques (N*m) Rear wheel axle Rear wheel fixing 104 ÷...
  • Page 174 X9 Evolution 125 Suspensions Removal Proceed as follows: - Undo the screw fixing the shock absorber spring unit to the engine (A) on one side and the corre- sponding support (B) on the other; - remove the saddle and the helmet compartment; - undo the two upper nuts (one on each side) fixing the shock absorber spring unit to the chassis and remove the shock absorbers.

  • Page 175: Centre-Stand

    X9 Evolution 125 Suspensions Centre-stand Removal - Unhook the springs. - Loosen the nut. - Pull out the screw. Reassembly - Install the sealing rings on the support tube of the stand; - Carry out the operations described above in re- verse order, then insert the sealing rings into their seats.
  • Page 176 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 177 X9 Evolution 125 Braking system This section è is devoted to the description of the braking system components. Interventions rules General rules for maintenance operations on the hydraulic braking system. WARNING HYDRAULIC OIL IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THE CONTACT AREA WELL WITH COPIOUS AMOUNTS OF WATER.

  • Page 178: Front Brake Calliper

    X9 Evolution 125 Braking system Front brake calliper N.B. Minimise difficulty for this operation by re- moving the callipers from their supports without removing the oil pipe. Front brake pad removal: Proceed as follows: - disassemble the front wheel. - remove the two screws indicated in the figure. - remove the stop ring and withdraw the pin.
  • Page 179 X9 Evolution 125 Braking system Overhaul Proceed as follows: 1) remove the two male hexagonal screws (1) and take out the two pads (10); 2) remove the two male hexagonal screws (2) and remove the reaction plate (3); 3) take out the fixed plate (4) from the guide; 4) remove the internal elements from the floating body (5) with the help of short blows of com- pressed air through the brake fluid pipe in order to...
  • Page 180 X9 Evolution 125 Braking system The body and the reaction plate body work inte- grally and can move axially with respect of the fixed plate that is integral to the strut. The pistons, forced by pressure to push the pad to the disk, cause the reaction plate to push in turn the other pad towards the disc.
  • Page 181 X9 Evolution 125 Braking system N.B. THE SURFACE OF THE DISC WITH THE STAMPED AR- ROW INDICATING THE DIRECTION OF ROTATION MUST FACE THE SHOCK ABSORBER. Recommended products (°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength threadlock Characteristic Brake discs check: Max. axial deviat. 0.1 mm Locking torques (N*m) Disc tightening screw (°)
  • Page 182 X9 Evolution 125 Braking system Front - Rest the scooter on its stand on level ground. - Refill the brake circuit reservoir to the maximum level with the recommended fluid; - Connect the bleed fitting to the appropriate tool pipe (Mityvac manual pump); - Actuate the tool at the bleed fitting, at the same time constantly top up the brake reservoir to pre- vent air being drawn into the system, until no more...
  • Page 183 X9 Evolution 125 Braking system Front brake pump Removal 1) remove the front and rear handlebar covers; 2) placing a suitable container to catch the oil, dis- connect the oil pipe from the calliper and work the brake lever until no more oil comes out; 3) disconnect the oil pipe from the pump then un- screw the two u-bolt clamping screws and remove the pump.
  • Page 184 X9 Evolution 125 Braking system ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED. BRAK SYS - 184...
  • Page 185 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 186: Circuit Diagram

    X9 Evolution 125 Cooling system Circuit diagram COOL SYS - 186...
  • Page 187 X9 Evolution 125 Cooling system COOL SYS - 187...
  • Page 188 X9 Evolution 125 Cooling system Water pump - overhaul With a hot air gun heat the flywheel cover on the inner side. - Place the flywheel cover on the ring base follow- ing the same procedure as for removal. - Place the two bearings on the specific punch. - Use grease to keep the bearings on the appro- priate tool.
  • Page 189 X9 Evolution 125 Cooling system N.B. DO NOT LUBRICATE THE O-RING. FAILURE TO RESPECT THIS RULE RESULTS IN RING DISTORTION. Specific tooling 020440Y Water pump service tool Locking torques (N*m) Water pump rotor cover 3 ÷ 4 - Check that the rotor does not show abnormal wear or dents; - Check that the rotor shaft is not rusty;...
  • Page 190 X9 Evolution 125 Cooling system - Check the water pump if noise in the bearings or liquid leaking from the drainage hole inside the cover is detected. - Remove the flywheel cover together with the wa- ter pump from the engine (see chapter 4). - Remove the rotor cover by unscrewing the 3 re- tainers indicated in the figure.
  • Page 191 X9 Evolution 125 Cooling system With the hot air gun, drw. No. 20151y, heat the in- ner side of the flywheel cover . N.B.: Avoid overheating as this may alter the painted surface. - Place the flywheel cover on the ring base follow- ing the same procedure as for removal.
  • Page 192 X9 Evolution 125 Cooling system Insert the drive on the guide plug on the support base which forms part of the specific tool drw. No. 020440Y, being careful to check that the convex part faces upwards. - Insert the flywheel cover with bearings on the ap- propriate tool.
  • Page 193 X9 Evolution 125 Cooling system - Remove the flywheel cover together with the water pump from the engine (see chapter 4). - Remove the rotor cover by unscrewing the 3 retainers indicated in the figure. - Place the flywheel cover on the ring base forming part of the drw. No. 020440Y tool. N.B.: To avoid damaging the cover surface that retains the coolant, use de ring base with the accurately machined surface facing the flywheel cover.
  • Page 194 X9 Evolution 125 Cooling system COOL SYS - 194...
  • Page 195 X9 Evolution 125 Cooling system Removal - Loosen the two screws indicated in the figure and remove the thermostat cover. - Remove the thermostat with its gasket. Check - Visually check that the thermostat is not dam- aged. - Prepare a metal container with approx. 1 litre of water.
  • Page 196 X9 Evolution 125 Cooling system - Replace the thermostat if it does not work prop- erly. CAUTION TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI- THER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER. Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check: opening travel 3.5 mm at 80°C...
  • Page 197 X9 Evolution 125 Cooling system Refitting - Place the thermostat with the bleeding hole at the highest point. - Make sure that the rubber gasket is positioned properly. - Fit the thermostat cover with the connection for the carburettor heating pipe facing the flywheel. - Tighten the two screw to the torque indicated be- low.
  • Page 198 INDEX OF TOPICS CHAS HASSIS...
  • Page 199 X9 Evolution 125 Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat Helmet bay - Remove all electrical devices, the fuse box and release the wires fixed to the chassis with the rel- ative clamps;...

  • Page 200: Radiator Fan

    X9 Evolution 125 Chassis Radiator fan - Prepare a container for the coolant. - Remove the delivery and reverse pipes of both the expansion tank and the radiator coolant; - Disconnect the connector from the thermostat pipe; - Unscrew the fixing screws and release the radi- ator and the electrical fan.

  • Page 201: Expansion Tank

    X9 Evolution 125 Chassis Expansion tank - Unscrew the fixing screws from the expansion tank support and remove the support; - Slide off the expansion tank downwards with the relative gasket after removing momentarily the cap; - Prepare a container for the coolant. - Close the cap again and remove the coolant de- livery and reverse pipes.
  • Page 202 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 203 X9 Evolution 125 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning - Be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting plastic parts - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks...
  • Page 204 X9 Evolution 125 Pre-delivery - Horn - Starter CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.

  • Page 205: Static Test

    X9 Evolution 125 Pre-delivery - Abnormal noise Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
  • Page 206 INDEX OF TOPICS TIME...
  • Page 207 X9 Evolution 125 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 Crankcase RANKCASE REPAIR TIME Code Action Duration 003056 Head/Cylinder - Nut tightening 001153 Crankcase halves gasket - Replace- ment...
  • Page 208 X9 Evolution 125 Time Crankshaft RANKSHAFT REPAIR TIME Code Action Duration 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement 001100 Oil seal, clutch side - Replacement TIME - 208...

  • Page 209: Cylinder Head Assy

    X9 Evolution 125 Time Cylinder assy. IN PISTON CYLINDER ASSEMBLY REPAIR TIME Code Action Duration 001002 Cylinder / Piston - Replacement Cylinder head assy. YLINDER HEAD ASSEMBLY REPAIR TIME Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056...
  • Page 210 X9 Evolution 125 Time Code Action Duration 001057 Thermostat - Replacement 001083 Thermistor - Replacement Rocker arms support assy. OCKING LEVER SUPPORT ASSEMBLY REPAIR TIME Code Action Duration 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement TIME - 210...

  • Page 211: Cylinder Head Cover

    X9 Evolution 125 Time Cylinder head cover YLINER HEAD COVER REPAIR TIME Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment TIME - 211...

  • Page 212: Chain Tensioner

    X9 Evolution 125 Time Chain tensioner HAIN TENSIONER REPAIR TIME Code Action Duration 001124 By pass lubrica- tion - Replace- ment 001129 Chain tightener - Service and re- placement HAIN TENSIONER REPAIR TIME Code Action Duration 001129 Chain tightener - Overhaul and re- placement 001124 By pass lubrication - Replacement...

  • Page 213: Oil Filter

    X9 Evolution 125 Time Oil filter IL FILTER REPAIR TIME Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Replacement TIME - 213...

  • Page 214: Driven Pulley

    X9 Evolution 125 Time Driven pulley RIVEN PULLEY REPAIR TIME Code Action Duration 001022 Clutch - Replacement 003072 Clutch - replacement Clutch assem- bly - Wear check 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement TIME - 214...
  • Page 215 X9 Evolution 125 Time Oil pump IL PUMP UNIT REPAIR TIME Code Action Duration 001125 Chain guide pads - Replacement 001051 Belt/ Timing chain - Replacement 001042 Oil pump - Service 001112 Oil pump - change 001122 Oil pump chain - Replacement 001121 Chain cover oil seal - Replacement 001130...

  • Page 216: Driving Pulley

    X9 Evolution 125 Time Driving pulley RIVING PULLEY REPAIR TIME Code Action Duration 001086 Driving half-pulley - Replacement 001011 rear-view belt - Replacement 001006 rear-view pulley - Service 001066 driving pulley - Replacement 001141 Belt anti-vibration roller - Replace- ment TIME - 216...

  • Page 217: Starter Motor

    X9 Evolution 125 Time Code Action Duration 001175 Anti-vibration roller - Service Starter motor LECTRIC START UP REPAIR TIME Code Action Duration 001020 Starter motor - Replacement 001017 Starter sprocket wheel - Replace- ment TIME - 217...

  • Page 218: Flywheel Magneto

    X9 Evolution 125 Time Flywheel magneto AGNETO FLYWHEEL REPAIR TIME Code Action Duration 001087 Flywheel cover - replace 001113 Water pump - Replacement 001058 Flywheel - Replacement 001067 Stator - Replacement 001173 Rotor - Replacement 001161 Secondary air filters - Replacement / Cleaning 001162 Secondary air housing - Replace-...
  • Page 219 X9 Evolution 125 Time Belt cooling duct ELT COOLING PIPE REPAIR TIME Code Action Duration 001132 Transmission air inlet pipe - Replace- ment 001131 Transmission air intake - Replace- ment TIME - 219...
  • Page 220 X9 Evolution 125 Time TIME - 220...
  • Page 221 X9 Evolution 125 Time Carburettor ARBURETTOR REPAIR TIME Code Action Duration 001013 Intake manifold - change 001081 Automatic choke - Replacement 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heat piping. - Replace- ment 003058 Carburettor - Adjustment TIME - 221...

  • Page 222: Exhaust Pipe

    X9 Evolution 125 Time Exhaust pipe UFFLER REPAIR TIME Code Action Duration 001095 Muffler guard - Replacement 001092 Exhaust manifold - Replacement 001009 Muffler - Replacement Air cleaner IR CLEANER REPAIR TIME Code Action Duration 001014 Air filter - Replacement/Cleaning 001015 Air filter box - Replacement 004122...
  • Page 223 X9 Evolution 125 Time Frame HASSIS REPAIR TIME Code Action Duration 004148 footboard support bracket two sides - Replacement 004147 Footrest support bracket, one side - Replacement 004116 Rear frame - Replacement 004146 Front frame - Replacement 004001 Frame - replace TIME - 223...
  • Page 224 X9 Evolution 125 Time Centre-stand TAND REPAIR TIME Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement TIME - 224...
  • Page 225 X9 Evolution 125 Time Legshield spoiler POILER FRONT SHIELD REPAIR TIME Code Action Duration 004066 Rear view mirrors - Replacement 004028 Windshield glass - Replacement 006012 Front shield - Paintwork 006006 Headstock cover - Paintwork 004149 Shield central cover - Replacement 004064 Front shield - front section - Replace- ment...
  • Page 226 X9 Evolution 125 Time Side fairings 43 REAR COVERS Description Code Minutes Rear mudguard - Replace- 004009 ment Licence plate holder - Re- 005048 placement TIME - 226...

  • Page 227: Rear Cover

    X9 Evolution 125 Time Rear cover EAR SHIELD REPAIR TIME Code Action Duration 002082 Fuel tank door opening drive - Re- placement 004081 Glove box door - Replacement 004065 Front shield, rear part - Removal and refitting TIME - 227...
  • Page 228 X9 Evolution 125 Time Fuel tank ANK REPAIR TIME Code Action Duration 004089 Tank-pump hose - Replacement 004086 Petrol pump depression tube - Re- placement 004137 Carburettor - pump hose - Replace- ment 004073 Fuel pump - Replacement 004005 Fuel tank - replace 004109 Fuel tank breather - change 005010...
  • Page 229 X9 Evolution 125 Time Expansion tank XPANSION TANK REPAIR TIME Code Action Duration 001052 Coolant and air bleed - Replacement 007013 Expansion tank connection pipe - Replacement 007001 Expansion tank - Replacement TIME - 229...
  • Page 230 X9 Evolution 125 Time TIME - 230...
  • Page 231 X9 Evolution 125 Time Radiator ADIATOR REPAIR TIME Code Action Duration 007003 Coolant delivery and return pipe - Re- placement 007016 Fan with support - replace 007002 Radiator - Replacement 007014 Radiator thermal switch - Replace- ment Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration...
  • Page 232 X9 Evolution 125 Time Steering column bearings TEERING FIFTH WHEEL REPAIR TIME Code Action Duration 003073 Steering clearance - Adjust 003002 Steering fifth wheel - Replacement 004119 Bearing / Steering support fifth wheel - Replacement TIME - 232...

  • Page 233: Handlebar Covers

    X9 Evolution 125 Time Handlebar covers ANDLEBAR COVER Code Action Duration 004152 Board computer cover - Replace- ment 006014 Handlebar rear part - Painting 006013 Handlebar front part - Painting 004019 Handlebar rear section - Replace- ment 004018 Front handlebar cover - Replace- ment 004151 Instrument panel support - Replace-...

  • Page 234: Handlebar Components

    X9 Evolution 125 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 002088 Integral brake pump - Replacement 003061 Accelerator transmission - Adjust- ment 002059 Right hand grip - Replacement 002063 Throttle control transmission - Re- placement 003001 Handlebar - Removal and refitting 002024 Front brake pump - replace 002071...
  • Page 235 X9 Evolution 125 Time Swing-arm WINGING ARM REPAIR TIME Code Action Duration 003081 Swinging arm supporting flange - Re- placement 004058 Silent block - Replacement 001072 Engine / frame swinging arm fitting - Replacement TIME - 235...

  • Page 236: Brake Hoses

    X9 Evolution 125 Time Brake hoses RAKE PIPING Code Action Duration 002021 Front brake piping - Replacement 002090 Integral brake fluid and system bleeding - Change 002086 Integral brake front rigid pipe- Re- placement 002087 Integral brake rear rigid pipe- Re- placement 002089 Integral braking device - Replace-...
  • Page 237 X9 Evolution 125 Time Code Action Duration 002085 Integral brake device pipe- front cal- liper - Replacement 002084 Integral brake pump pipe, device - Replacement Seat ADDLE REPAIR TIME Code Action Duration 004067 Rider backrest - Replacement 004150 Saddle shock absorber - Replace- ment TIME - 237...

  • Page 238: Instrument Panel

    X9 Evolution 125 Time Code Action Duration 004144 Port and/or saddle cover - Replace- ment 004054 Saddle lock catch - Replacement 004003 Saddle - Replacement Instrument panel NSTRUMENT PANEL REPAIR TIME Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine Instrument panel repair time TIME - 238...
  • Page 239 X9 Evolution 125 Time Locks OCKS Code Action Duration 004010 Antitheft lock - Replacement 005016 Key switch - Replacement TIME - 239...
  • Page 240 X9 Evolution 125 Time TIME - 240...

  • Page 241: Turn Signal Lights

    X9 Evolution 125 Time Turn signal lights EAR LIGHTS Code Action Duration 005032 Transparent licence plate cover - re- place 005031 Licence plate light bulb - Replace- ment 004141 Cat's eye - Replacement 005066 Rear light bulbs - replace 005030 Rear telltale light and headlamp ca- ble assembly - Replacement 005005...

  • Page 242: Front Wheel

    X9 Evolution 125 Time Front wheel RONT WHEEL Code Action Duration 005089 Tone wheel - Replacement 002041 Front brake disc - Replacement 003040 Tyre pressure - Check 003063 Tyre pressure - Check 006018 Wheel rim - Paintwork 004123 Front wheel - Replacement 003047 Front tyre - Replacement 003037...

  • Page 243: Electric Devices

    X9 Evolution 125 Time Electric devices 40 HEADLIGHT Description Code Minutes Front headlamp - replace 005002 Front turn indicator bulb - Re- 005067 placement Front lights cable unit - replace 005044 Headlight bulbs - Replace- 005008 ment Front direction indicators - Re- 005012 placement TIME - 243...
  • Page 244 X9 Evolution 125 Time LECTRICAL WIRING Code Action Duration 005087 Side stand remote control - Replace- ment 005085 Reset button - Replacement 005088 Emergency stop remote control - Re- placement 005011 Start-up remote control switch - change TIME - 244...
  • Page 245 X9 Evolution 125 Time ATTERY Code Action Duration 005075 Stop remote control - Replacement 005024 Battery fuse - Replacement 001069 HV coil - Replacement 001094 Spark plug cap - Replacement 005035 Headlight remote control - Replace- ment 001023 Control unit - Replacement 005009 Voltage regulator - Replacement 005007...
  • Page 246 X9 Evolution 125 Time EADLIGHT Code Action Duration 005067 Front turn indicator bulb - Replace- ment 005044 Front lights cable unit- Replacement 005008 Front headlamp bulbs - Replacement 005012 Front direction indicators - Replace- ment 005002 Front headlamp - replace TIME - 246...
  • Page 247 X9 Evolution 125 Time 49 ELECTRICAL DEVICES Description Code Minutes Start-up remote control switch 005011 - Replacement Emergency stop remote con- 005088 trol - Replacement Reset button - Replacement 005085 Side stand remote control - 005087 Replacement TIME - 247...
  • Page 248 X9 Evolution 125 Time 48 BATTERY Description Code Minutes Battery - change 005007 Voltage regulator - replace 005009 Control unit - Replacement 001023 Headlight remote control - Re- 005035 placement Spark plug cap - Replacement 001094 TIME - 248...
  • Page 249 X9 Evolution 125 Time H.V. coil - replace 001069 Battery fuse - Replacement 005024 Stop remote control - Replace- 005075 ment ABLE HARNESS Code Action Duration 005025 Battery fuse box - Replacement 005001 Electrical system - Removal and re- fitting TIME - 249...
  • Page 250 X9 Evolution 125 Time LECTRICAL DEVICES Code Action Duration 005084 Emergency light switch - Replace- ment 005077 Emergency stop switch - Replace- ment 005003 Horn - Replacement 005006 Light switch or turn indicators - re- place 005039 Lights switch - Replacement 005041 Starter button - Replacement 005040...
  • Page 251 X9 Evolution 125 Time 41 REAR LIGHT Description Code Minutes Rear turn indicator bulb - Re- 005068 placement Taillight - change 005005 Rear telltale light and head- 005030 lamp cable assembly - Re- placement Rear light bulbs - replace 005066 Cat's eye - Replacement 004141 Licence plate light bulb - Re-...

  • Page 252: Brake Callipers

    X9 Evolution 125 Time Transparent licence plate cov- 005032 er - replace Brake callipers ALLIPERS Code Action Duration 003071 Rear brake pads - Wear check 002002 Rear brake pads - Replacement 002048 Rear brake calliper - Replacement 002039 Front brake calliper - Replacement 003070 Front brake pads - Wear check 002007...
  • Page 253 X9 Evolution 125 Time Fuel tank filler flap OOTREST DOOR TANK REPAIR TIME Code Action Duration 004011 Central frame cover - replace 004135 Fuel tank lid - Replacement TIME - 253...
  • Page 254 X9 Evolution 125 Time Footrests ATS REPAIR TIME Code Action Duration 006008 Rear fairing - Paintwork 006005 Two side covers - Paintwork 004129 Rear fairing - Replacement 004012 Rear fairing - Replacement 004059 Spark plug inspection flap - Replace- ment 004068 One passenger grab handle - Re- placement...

  • Page 255: Front Mudguard

    X9 Evolution 125 Time Front mudguard RONT MUDGUARD REPAIR TIME Code Action Duration 006003 Front mudguard - Paintwork 004002 Front mudguard - change 006027 Spoiler - Paintwork 005081 Temperature sensor - Replacement 004053 Spoiler - Replacement TIME - 255...

  • Page 256: Steering Column

    X9 Evolution 125 Time Steering column TEERING REPAIR TIME Code Action Duration 003048 Fork oil seal - Replacement 003079 Fork stem - Replacement 003051 Fork assembly - Replacement TIME - 256...
  • Page 257 X9 Evolution 125 Time TIME - 257...
  • Page 258 X9 Evolution 125 Time Helmet bay ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 002083 Saddle opening transmission - Re- placement 004142 electric socket - Replacement 005027 Helmet compartment bulb support - Replacement 005026 Helmet compartment light - Replace- ment 005033 Glove-box light switch - Replace-...
  • Page 259 X9 Evolution 125 Time Rear side fairings EAR COVERS Code Action Duration 005048 Licence plate holder - Replacement 004009 Rear mudguard - Replacement TIME - 259...

  • Page 260: Rear Wheel Axle

    X9 Evolution 125 Time Rear wheel axle EAR WHEEL AXLE EPAIR TIME Code Action Duration 004125 Rear wheel axle - Replacement 003065 Gear box oil - Replacement 001156 Gear reduction unit cover - Replace- ment 001010 Gear reduction unit - Inspection TIME - 260...
  • Page 261 X9 Evolution 125 Time TIME - 261...
  • Page 262 Air filter: 44 Battery: 54, 62, 72, 80, 81 Brake: 178, 183, 236, 252 Carburettor: 41, 152, 158, 221 Engine oil: 45 Engine stop: Fuel: 53, 152, 199, 228, 253 Fuses: 76 Headlight: Hub oil: 43 Identification: 8 Instrument panel: 238 Maintenance: 7, 38 Oil filter: 213 Saddle:...

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