Mode d'emploi PIAGGIO X9

[. . . ] "© Copyright 2008 - PIAGGIO & C. Reproduction of this publication in whole or in part is prohibited. " PIAGGIO & C. - After-Sales V. le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) 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. [. . . ] A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED Specific tooling 020565Y Flywheel lock calliper spanner Locking torques (N*m) Flywheel nut 54 ÷ 60 Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate it. - Fit the starter on the crankcase and lock the 2 screws to the prescribed torque. Locking torques (N*m) Starter motor screws 11 ÷ 13 Cylinder assy. and timing system ENG - 112 X9 Evolution 125 Engine Removing the intake manifold - Remove the flywheel cover completely as described in the flywheel cover section. - Loosen the 3 crews and remove the intake manifold. N. B. TAMPERPROOF SCREWS ARE SUPPLIED WITH 125 CC MODELS. Removing the timing system drive - Remove the parts listed below first: transmission cover, driving pulley with belt, start-up piston, oil sump with spring and by-pass piston, oil pump pulley cover, the O-ring on the crankshaft and the pinion separation washer. - Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the figure. - Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer. - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the internal hex screw and the counterweight shown in the figure. - Remove the camshaft command pulley and its washer. 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. Characteristic Wrist pin seat on the piston: Standard diameter 15. 001 ÷ 15. 006 mm Diameter of the wrist pin seat on the piston: Standard clearance 0. 001 ÷ 0. 010 mm piston diameter 56. 945 ÷ 56. 973 mm Fitting clearance Top piston ring - standard coupling clearance 0. 025 ÷ 0. 07 mm Top piston ring - maximum clearance allowed after use 0. 08 mm Middle piston ring - standard coupling clearance 0. 015 - 0. 06 mm Middle piston ring - maximum clearance allowed after use 0. 07 mm oil scraper ring - standard coupling clearance 0. 015 - 0. 06 mm oil scraper ring - maximum clearance allowed after use 0. 07 mm Inspecting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening (see figure) of the sealing rings using a feeler gauge. - If any measurements are greater than specified, replace the piston rings. N. B. BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD. ENG - 120 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 - Fit the wrist pin stop using the plug as shown in the figure CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING. N. B. THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY. Specific tooling 020430Y Pin lock fitting tool ENG - 121 Engine X9 Evolution 125 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, assemble the tool on the cylinder and lock it with 2 supplied nuts as shown in the figure. - Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation) - Position the dial gauge on the piston as shown in the figure and measure how much the piston protrudes. [. . . ] - 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 below. Locking torques (N*m) Thermostat cover screws 3 ÷ 4 COOL SYS - 197 INDEX OF TOPICS CHASSIS CHAS 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 relative clamps; - Remove the battery after removing the elastic belt; - Undo the screws fixing the rear frame to the chassis and to the helmet compartment and remove compartment by lifting the front part and sliding it backwards; - Remove the saddle; - Unscrew the remaining fixing screws, remove the rubber cover and the helmet compartment light switch and then slide the helmet compartment off and upwards Fuel tank - Remove both footrests, the central cover and the tunnel cover as described before; - Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank breather; - Remove the horn after unscrewing its fixing screws indicated in the figure and after disconnecting the electrical connections. - Unscrew the four fixing screws of the holding bracket indicated in the figure and remove it; - Unscrew the two fuel tank fixing screws, located on the upper part; - Slide off the tank downward after tilting it slightly. N. B. this operation should be preferably be carried out with the tank empty. CHAS - 199 Chassis X9 Evolution 125 Radiator fan - Prepare a container for the coolant. [. . . ]