Piaggio X9 evolution 125 2008 Guide

SERVICE STATION MANUAL

664627 IT-664628 EN-664629 FR-664630 DE-664631

ES-664632 PT-664633 OL-664634 EL

X9 Evolution 125

SERVICE STATION

MANUAL

X9 Evolution 125

The descriptions and illustrations given in this publication are not binding. While the basic specifications

as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

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.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - 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. 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. Any

significant changes to vehicle characteristics or to specific repair operations will be communicated by

updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment

and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special

tools, along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sectionsmarked with this symbol indicatethe correct use of thevehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well-

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. 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.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English measurement. Using unsuitable

coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.

X9 Evolution 125 Characteristics

CHAR - 7

Vehicle identification

Chassis prefix: ZAPM481000000 ÷ 1001

Engine prefix: M482M

Dimensions and mass

WEIGHT 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

Characteristics X9 Evolution 125

CHAR - 8

Engine

TECHNICAL 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° at 2000 rpm

Valve clearance intake: 0.10 mm discharge: 0.15 mm

Spark plug CHAMPION RG4HC

Alternative spark plug NGK CR8EB

Idle speed 1650 ± 100 rpm

Max. power 11 kW at 10,000 rpm

Max. torque 12 Nm at 8000 rpm

Maximum speed 105 km/h

Transmission

TRANSMISSIONS

Specification Desc./Quantity

Transmission With automatic expandable pulley variator, V belt, automatic

clutch, gear reduction unit and transmission housing with

forced-circulation air cooling.

X9 Evolution 125 Characteristics

CHAR - 9

Capacities

CAPACITY

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

ELECTRICAL COMPONENTS

Specification Desc./Quantity

Generator Three-phase alternating current

Battery 12V -10 Ah

Ignition type Electronic capacitive discharge ignition (CDI) and variable ad-

vance, with separate HV coil.

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification Desc./Quantity

Rear wheel max. travel 90 mm.

Rear suspension Engine with oscillating fork articulated to the chassis by means

of a double swinging arm. Double-acting hydraulic shock ab-

sorbers, coaxial helicoidal spring with variable step, adjustable

at preloading on 4 positions.

Front fork stroke 90 mm

Front suspension Hydraulic telescopic fork with Ø 35-mm stem

Type of chassis Welded tubular steel chassis with stamped sheet reinforce-

ments.

Brakes

BRAKES

Specification Desc./Quantity

Rear Ø 240 mm stainless steel disc with Brembo "Serie Oro" floating

calliper with Ø 34 mm twin plungers

Integral braking system Left lever acts on the left front and rear discs, through a valve

that distributes the pressure; the right lever acts on the right

front disc only

Front Ø 240 mm stainless steel double disc with Ø 34 mm Brembo

"Serie Oro" floating calliper (front Right) / Ø 32 (front Left)

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Tyre pressure (when cold) Front: 2.1 bar Rear: 2.3 bar (2.5 bar with driver and luggage)

Front tyre Without inner tube: 120/70-14" 55P

Rear tyre Without inner tube: 140/60-14" 64P

Front wheel alloy rim: 14'' x 3.50

Rear wheel alloy rim: 14'' x 3.50

Characteristics X9 Evolution 125

CHAR - 10

Secondary air

The SAS for 125cc leader engines operates in a similar manner to the SAS for 2T engines.

The differences are the following:

insteadofenteringthroughthemufflerasfor2Tengine,thesecondaryairentersdirectlyinthedischarge

pipe on the head.

The2Treed valvehasadiaphragm.Theunit,indicated byanarrowinthefigure,hasacut-off connected

to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions

in the muffler.

Air is drawn through the opening «A», goes through the first filter and is channelled through the opening

«B».

Air gets to the second filter «B» through the opening shown in the figure. Now, the filtered air enters

the diaphragm device, and then is channelled to the head.

X9 Evolution 125 Characteristics

CHAR - 11

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" cellpadding="5" cellspacing="1" class="piag_tabella2">

Carburettor Keihin Walbro

Vacuum type CVK 30 WVF-7G*

Body stamping CVK 7G

Stamping 303A

Max. jet 105 108

Minimum jet 35 36

Characteristics X9 Evolution 125

CHAR - 12

Carburettor Keihin Walbro

Max. air jet 70 115

Minimum air jet 130 100

Throttle valve spring 100 ± 160 g 100 g

Minimum mixture set screw initial open-

ing

2 ± 1/4 2 5/8 ± 1/2

Tapered pin stamping NDYA 51C

Tapered pin notches position from top Fixed position 2

Diffuser nozzle Ø 2.8 Ø 2.7

Starter air jet Ø 1.5 (body) 200

Starter diffuser jet 130

Starter jet 42 50

Starter device resistance ~ 20 Ω~ 40 Ω

Diffuser Ø 29 Ø 29 (30.3x27.0)

* The identification letter can vary with each carburettor update.

Kehin

KEHIN CARBURETTOR

Specification Desc./Quantity

Depression carburettor CVEK-30

Body stamping CVEK

Stamping 303A

Max. jet 105

Minimum jet 35

Max. air jet 70

Throttle valve spring 100 ÷ 160 g

Minimum mixture set screw initial opening 2 ± ¼

Tapered pin stamping NDYA

Tapered pin notches position from top Fixed position

Diffuser nozzle Ø 2.8

Starter diffuser jet

Starter jet 42

Starter device resistance ~ 20 Ω

Diffuser Ø 29

125 keihn - Minimum air jet 130

125 keihn - Maximum air jet 70

N.B.

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

Walbro

WALBRO CARBURETTOR

Specification Desc./Quantity

Venturi diffuser Ø 29 (30.3x27)

Starter device resistance ~ 40 Ω

Starter jet 50

Starter diffuser jet 130

Starter air jet 200

X9 Evolution 125 Characteristics

CHAR - 13

Specification Desc./Quantity

Diffuser nozzle Ø 2.7

Tapered pin notches from above 2

Tapered pin stamping 51C

Minimum mixture set screw initial opening 2 5/8 ± 1/2

Throttle valve spring 100 g

Minimum air jet 100

Max. air jet 115

Minimum jet 36

Max. jet 108

Stamping

Body stamping 7GO

125 Walbro: Minimum jet 100

125 Walbro: Max. jet 115

N.B.

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

200cc Version

Carburettor Keihin Walbro

Vacuum type CVK30 WVF-7H*

Body stamping CVK 7H

Stamping 303A

Max. jet 100 118

Minimum jet 38 34

Max. air jet 70 150

Minimum air jet 115 50

Throttle valve spring 150 ÷ 250 g 120 g

Minimum mixture set screw initial open-

ing

± 1/4 3 ± 1/4

Tapered pin stamping NDWA 465

Tapered pin notches position from top Fixed position 3

Diffuser nozzle Ø 2.8 Ø 2.7

Starter air jet 200

Starter diffuser jet Ø 1.5 (body) 130

Starter jet 42 50

Starter device resistance ~ 20 Ω~ 40 Ω

Diffuser Ø 29 Ø 29 (30.3x27.0)

ò The identification letter can vary with each carburettor update.

Kehin

KEHIN CARBURETTOR

Specification Desc./Quantity

Depression carburettor CVEK-30

Body stamping CVEK

Characteristics X9 Evolution 125

CHAR - 14

Specification Desc./Quantity

Stamping 303A

Tapered pin notches position from top Fixed position

Max. air jet 70

Diffuser nozzle Ø 2.8

Starter jet 42

Starter device resistance ~ 20 Ω

Diffuser Ø 29

Tapered pin stamping NDWA

Minimum mixture set screw initial opening ± ¼

Throttle valve spring 150 ÷ 250 g

Minimum air jet 115

Minimum jet 38

Max. jet 100

Starter air jet Ø 1.5 (body)

Starter diffuser nozzle Ø 1.5 (body)

N.B.

THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE

Walbro

WALBRO CARBURETTOR

Specification Desc./Quantity

Tapered pin notches position from top 3

Tapered pin stamping 465

Minimum mixture set screw initial opening 3 ± 1/4

Throttle valve spring 120 g

Minimum air jet 50

Max. air jet 150

Minimum jet 34

Max. jet 118

Body stamping 7HO

Vacuum type WVF-7H*

Diffuser Ø 29 (30.3x27.0)

Starter jet 50

Starter diffuser jet 130

Starter air jet 200

Diffuser nozzle Ø 2.7

Stamping

N.B.

THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE

Tightening Torques

TECHNICAL SERVICE NOTES

For correct tightening, the expansion tank cap locking torque has been standardised to 2.5 Nm

REAR BRAKE

Product Description Specifications

(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength

threadlock

FRONT BRAKE

Name Torque in Nm

Oil bleed screw 8 ÷ 12

Disc tightening screw (°) 5 ÷ 6

Brake fluid pipe-calliper fitting 16 ÷ 20

X9 Evolution 125 Characteristics

CHAR - 15

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 ÷ 41

Rear wheel axle 104 ÷ 126

FRONT SUSPENSION

Name Torque in Nm

Fork leg screw 6 ÷ 7

Front wheel axle 45 ÷ 50

Fork plate screw 25 ÷ 34

CHASSIS

Name Torque in Nm

Centre stand bolt 25 ÷ 30

Frame arm-engine arm bolt 60 ÷ 64

Swinging arm buffer nut 20 ÷ 25

Frame-swinging arm bolt 66 ÷ 80

Engine-swinging arm bolt 33 ÷ 41

STEERING

Name Torque in Nm

Upper steering ring nut 30 ÷ 36

Steering lower ring nut 10 ÷ 13 then loosen by 90°

Handlebar fixing screw (*) 45 ÷ 50

Fixing screws for the handlebar control unit U-bolts 7 ÷ 10

ENGINE - COOLING

Product Description Specifications

(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength

threadlock

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmission-side half

shaft) screws 4 ÷ 6

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing system cover screws (°) 3.5 ÷ 4.5

ENGINE - FLYWHEEL

Name Torque in Nm

Pick-Up clamping screws 3 ÷ 4

Stator assembly screws (°) 3 ÷ 4

Flywheel cover fixing screws 5 - 6

Flywheel nut (250) 94 ÷ 102

Screw fixing freewheel to flywheel 13 ÷ 15

ENGINE - TRANSMISSION

Name Torque in Nm

Rear hub cover screws 24 ÷ 27

Driven pulley shaft nut 54 ÷ 60

Transmission cover screws 11 ÷ 13

Drive pulley nut 75 ÷ 83

Clutch unit nut on driven pulley 55 ÷ 60

Belt support roller screw 11 ÷ 13

Characteristics X9 Evolution 125

CHAR - 16

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 ÷ 13

Start up counterweight support screw 11 ÷ 15

Timing chain tensioner slider screw 10 ÷ 14

Inlet manifold screws 11 ÷ 13

Tappet set screw lock nut 6 ÷ 8

Starter ground screw 7 ÷ 8.5

Head fixing side screws 11 ÷ 12

Nuts fixing head to cylinder (*) 27 ÷ 29

Tappet cover screws 6 ÷ 7

Spark plug 12 ÷ 14

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 0.7 ÷ 0.9

Screws fixing oil pump to crankcase 5 - 6

Oil pump command crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

N.B.

Before fitting the nuts, lubricate them with engine oil

N.B.

Use new nuts

Cylinder - piston assy.

ENGINE 125 COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059

Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059

Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059

Cylinder 1st Oversize A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059

Cylinder 1st Oversize B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059

Piston 1st Oversize C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059

Piston 1st Oversize D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059

Cylinder 2nd Oversize A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059

Cylinder 2nd Oversize B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059

Piston 2nd Oversize C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059

Piston 2nd Oversize D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059

Cylinder 3rd Oversize A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059

Cylinder 3rd Oversize B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059

Piston 3rd Oversize C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059

Piston 3rd Oversize D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

X9 Evolution 125 Characteristics

CHAR - 17

ENGINE 200 COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting

Cylinder / piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044

Cylinder / piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044

Cylinder / piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044

Cylinder / piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044

Characteristics X9 Evolution 125

CHAR - 18