service station manual

service station manual
SERVICE STATION MANUAL
664711 IT-664712 EN-664713 FR-664714 DE-664715
ES-664716 PT-664717 OL-664718 EL
XEVO 125 Euro 3
SERVICE STATION
MANUAL
XEVO 125 Euro 3
The descriptions and illustrations given in this publication are not binding. While the basic features as
described and illustrated in this manual 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 accessory supplies, 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 individual
versions should be confirmed with the official Piaggio sales network.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
SERVICE STATION MANUAL
XEVO 125 Euro 3
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio
vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. 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 Sections marked with this symbol indicate the correct use of the vehicle
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
PRE-DELIVERY
TIME
CHAS
PRE DE
TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
XEVO 125 Euro 3
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 wellventilated, 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 solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.
- 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 scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 2
XEVO 125 Euro 3
Characteristics
Vehicle identification
Chassis prefix: M36601
Engine prefix: M368M
Dimensions and mass
CHAR - 3
XEVO 125 Euro 3
Characteristics
WEIGHTS AND DIMENSIONS
Specification
Kerb weight
Maximum weight allowed
Height
Width (handlebar)
Wheelbase
Overall length
Desc./Quantity
161 ± 5 kg
360 kg
1370 mm
760 mm
1490 mm
2070 mm
Engine
ENGINE
Specification
Type
Cubic capacity
Bore x stroke
Compression ratio
Engine idle speed
Timing system
Valve clearance
Max. power
MAX. torque
Lubrication
Lubrication pressure
Minimum lubrication pressure (100° C)
Fuel supply
Cooling
Fuel
Exhaust muffler
Emission regulations
Desc./Quantity
Single-cylinder, 4-stroke
124 cm³
57 x 48.6 mm
12 ± 0.5: 1
1650 ± 100 rpm
4 valves, single overhead camshaft, chain-driven.
Inlet: 0.10 mm Outlet: 0.15 mm
11 kW at 10,000 rpm
12 Nm at 8,000 rpm
Engine lubrication with lobe pump (inside crankcase) controlled by a chain with double filter: mesh
and paper.
4 bar
0.8 bar
KEIHIN CVEK 30 carburettor and electrical fuel
pump.
Forced coolant circulation system.
Unleaded petrol (95 RON)
absorption-type exhaust muffler with catalytic converter.
EURO 3
Transmission
TRANSMISSION
CHAR - 4
Specification
Main drive
Desc./Quantity
Automatic expandable pulley variator with torque
server, V-belt, automatic self-ventilating centrifugal dry clutch
Final reduction
Gear reduction unit in oil bath.
XEVO 125 Euro 3
Characteristics
Capacities
CAPACITY
Specification
Engine oil
Transmission oil
Cooling system fluid
Fuel tank (reserve)
Desc./Quantity
1.1 l
150 cm³
~2l
~ 12 l (~ 2.5 l)
Electrical system
ELECTRICAL SYSTEM
Specification
Start-up
Ignition
Ignition advance
Spark plug
Alternative spark plug
Battery
Generator
Desc./Quantity
Electric
Capacitive discharge ignition, with variable advance and separate HV coil.
10° ± 1° at 2,000 rpm
CHAMPION RG4HC
NGK CR8EB
12V-12Ah
In alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Chassis
Front suspension
Front suspension travel
Rear suspension
Rear suspension travel
Desc./Quantity
Tubular and sheet steel.
Hydraulic telescopic fork with Ø 35 mm stem
90 mm
Two double-acting shock absorbers, adjustable to
four positions at preloading.
90 mm
Brakes
BRAKES
Specification
Front brake
Rear brake
Desc./Quantity
Ø 260-mm disc brake with hydraulic control activated by the handlebar right-side lever.
Ø 240 mm disc brake with hydraulic control activated by the handlebar left-side lever.
Wheels and tyres
WHEELS AND TYRES
Specification
Wheel rim type
Desc./Quantity
Light alloy rims.
CHAR - 5
XEVO 125 Euro 3
Characteristics
Specification
Front rim
Rear rim
Front tyre
Rear tyre
Front tyre pressure (with passenger)
Rear tyre pressure (with passenger)
Desc./Quantity
14'' x 3.50
12'' x 3.00
Tubeless 120/70 - 14'' 55P
Tubeless 130/70 12'' 62P
2.3 bar (-)
2.6 bar (-)
Carburettor
125cc Version
Kehin
CARBURETTOR KEIHIN
Specification
Type
Model
Body stamping
Tapered pin stamping
CUT-OFF device
Diffuser
Max. jet
Minimum jet
Max. air jet
Minimum air jet
Throttle valve spring
Minimum mixture set screw initial opening
Tapered pin
Diffuser nozzle
Starter air jet
Starter jet
Starter device resistance
Starter pin travel
Desc./Quantity
Depression carburettor
CVK 30
CVK
305D
Not present
Ø 29
105
38
70
130
100 ÷ 160 g
1½
Ø 2.49
Ø 2.8
Ø 1.5
42
~ 20 Ω
10
Tightening Torques
REAR BRAKE
Name
Rear brake disc screws(°)
Rear brake calliper-pipe fitting
Rigid / flexible pipe fitting
Rear brake pump-pipe fitting
Rear brake calliper fixing screws
Torque in Nm
5 ÷ 6.5
20 ÷ 25
13 ÷ 18
16 ÷ 20
20 ÷ 25
REAR BRAKE
Product
(°) Loctite 243
CHAR - 6
Description
Medium strength threadlock
Specifications
Apply LOCTITE 243 mediumstrength threadlock
XEVO 125 Euro 3
Characteristics
FRONT BRAKE
Name
Oil bleed screw
Disc tightening screw (°)
Brake fluid pipe-calliper fitting
Brake fluid pump - hose fitting
Tightening screw for calliper support to the fork
Screw tightening calliper to the support
Torque in Nm
8÷12
5 ÷ 6.5
20 ÷ 25
16 ÷ 20
20 ÷ 25
42 ÷ 52
REAR SUSPENSION
Name
Upper shock absorber clamp
Shock absorber lower clamp
Shock absorber-crankcase attachment bracket
Rear wheel axle
Muffler arm clamping screws
Torque in Nm
33 ÷ 41
33 ÷ 41
20 ÷ 25
104 ÷ 126
27 ÷ 30
FRONT SUSPENSION
Name
Fork leg screw
Front wheel shaft
Fork plate screw
Torque in Nm
6÷7
45 ÷ 50
25 ÷ 34
CHASSIS
Name
Centre stand bolt
Side stand bolt (°)
Engine arm bolt - frame arm
Swinging arm buffer nut
Frame-swinging arm bolt
Engine-swinging arm bolt
Torque in Nm
25 ÷ 30
35 ÷ 40
33 ÷ 41
64 - 72
64 - 72
64 - 72
CHASSIS
Product
(°) Loctite 243
Description
Medium strength threadlock
Specifications
Apply LOCTITE 243 mediumstrength threadlock
STEERING
Name
Upper steering ring nut
Steering lower ring nut
Handlebar fixing screw
Fixing screws for handlebar control assembly Ubolts
Torque in Nm
30 ÷ 33
10 ÷ 13 then loosen by 90°
50 ÷ 55
7 ÷ 10
ENGINE - COOLING
Product
(°) Loctite 243
Description
Medium strength threadlock
Specifications
Apply LOCTITE 243 mediumstrength threadlock
CHAR - 7
XEVO 125 Euro 3
Characteristics
CRANKCASE AND CRANKSHAFT
Name
Internal engine crankcase bulkhead (transmission-side half shaft) screws
Engine-crankcase coupling screws
Starter motor screws
Crankcase timing system cover screws (°)
Torque in Nm
4÷6
11 ÷ 13
11 ÷ 13
3.5 ÷ 4.5
ENGINE - FLYWHEEL
Name
Pick-Up clamping screws
Stator assembly screws (°)
Flywheel cover fixing screws
Flywheel nut (250)
Screw fixing freewheel to flywheel
Torque in Nm
3÷4
3÷4
5-6
94 ÷ 102
13 ÷ 15
ENGINE - TRANSMISSION
Name
Rear hub cover screws
Driven pulley shaft nut
Transmission cover screws
Drive pulley nut
Clutch unit nut on driven pulley
Belt support roller screw
Torque in Nm
24 ÷ 27
54 ÷ 60
11 ÷ 13
75 ÷ 83
55 ÷ 60
11 ÷ 13
ENGINE - CYLINDER HEAD
Name
Manifold-silencer retaining bolt
Nut fixing muffler to cylinder head
Camshaft retention plate screw
Timing chain tensioner central screw
Timing chain tensioner support screw
Starter ground support screw
Timing chain tensioner slider screw
Inlet manifold screws
Tappet set screw lock nut
Starter ground screw
Head fixing side screws
Nuts fixing head to cylinder (*)
Tappet cover screws
Spark plug
Torque in Nm
15 ÷ 20
16 ÷ 18
4÷6
5-6
11 ÷ 13
11 ÷ 15
10 ÷ 14
11 ÷ 13
6÷8
7 ÷ 8.5
11 ÷ 12
27 ÷ 29
6÷7
12 ÷ 14
LUBRICATION
Name
Hub oil drainage plug
Oil filter on crankcase fitting
Engine oil drainage plug/mesh filter
Oil filter
Oil pump cover screws
Screws fixing oil pump to the crankcase
Oil pump control crown screw
Oil pump cover plate screws
CHAR - 8
Torque in Nm
15 ÷ 17
27 ÷ 33
24 ÷ 30
4÷6
0.7 ÷ 0.9
5-6
10 ÷ 14
4÷6
XEVO 125 Euro 3
Characteristics
Name
Oil sump screws
Minimum oil pressure sensor
Torque in Nm
10 ÷ 14
12 ÷ 14
Overhaul data
Assembly clearances
Cylinder - piston assy.
ENGINE COUPLING CATEGORIES
Name
Cylinder
Cylinder
Piston
Piston
Cylinder 1st Oversize
Cylinder 1st Oversize
Piston 1st Oversize
Piston 1st Oversize
Cylinder 2nd Oversize
Cylinder 2nd Oversize
Initials
A
B
C
D
A1
Cylinder
56.997 ÷ 57.004
57.004 ÷ 57.011
57.011 ÷ 57.018
57.018 ÷ 57.025
57.197 ÷ 57.204
Piston
56.945 ÷ 56.952
56.952 ÷ 56.959
56.959 ÷ 56.966
56.966 ÷ 56.973
57.145 ÷ 57.152
Play on fitting
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
B1
57.204 ÷ 57.211
57.152 ÷ 57.159
0.045 - 0.059
C1
57.211 ÷ 57.218
57.159 ÷ 57.166
0.045 - 0.059
D1
57.218 ÷ 57.225
57.166 ÷ 57.173
0.045 - 0.059
A2
57.397 ÷ 57.404
57.345 ÷ 57.352
0.045 - 0.059
B2
57.404 ÷ 57.411
57.352 ÷ 57.359
0.045 - 0.059
CHAR - 9
XEVO 125 Euro 3
Characteristics
Name
Piston 2nd Oversize
Piston 2nd Oversize
Cylinder 3rd Oversize
Cylinder 3rd Oversize
Piston 3rd Oversize
Piston 3rd Oversize
Initials
C2
Cylinder
57.411 ÷ 57.418
Piston
57.359 ÷ 57.366
Play on fitting
0.045 - 0.059
D2
57.418 ÷ 57.425
57.366 ÷ 57.373
0.045 - 0.059
A3
57.597 ÷ 57.604
57.545 ÷ 57.552
0.045 - 0.059
B3
57.604 ÷ 57.611
57.552 ÷ 57.559
0.045 - 0.059
C3
57.611 ÷ 57.618
57.559 ÷ 57.566
0.045 - 0.059
D3
57.618 ÷ 57.625
57.566 ÷ 57.573
0.045 - 0.059
Crankcase - crankshaft - connecting rod
CRANKSHAFT HALF-BEARINGS
Name
Crankshaft halfbearing
Crankshaft halfbearing
Crankshaft halfbearing
Description
Dimensions
Initials
Category B - blue
Quantity
1.973 ÷ 1.976
Type C - yellow
1.976 ÷ 1.979
Category E - green
1.979 ÷ 1.982
CRANKCASE - CRANKSHAFT COUPLINGS
Name
Crankshaft category 1 - Crankcase
category 1
Crankshaft category 1 - Crankcase
category 2
Crankshaft class 2
- Crankcase class
1
Crankshaft category 2 - Crankcase
category 2
Description
Dimensions
Initials
E-E
Quantity
C-C
C-C
B-B
CRANKSHAFT - CRANKCASE
Name
Crankshaft
Crankshaft
Crankcase
Crankcase
CHAR - 10
Description
Dimensions
Initials
Category 1
Class 2
Category 1
Class 2
Quantity
28.998 ÷ 29.004
29.004 ÷ 29.010
32.959 ÷ 32.965
32.953 ÷ 32.959
XEVO 125 Euro 3
Characteristics
Fitting clearances
Crankshaft/crankcase axial clearance (H):
0.15 ÷ 0.40 mm (when cold)
CHAR - 11
XEVO 125 Euro 3
Characteristics
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name
Half-shaft, transmission side
Flywheel-side halfshaft
Connecting rod
Spacer tool
Description
Dimensions
16.6 +0-0.05
Initials
A
Quantity
D = 0.20 - 0.50
16.6 +0-0.05
B
D = 0.20 - 0.50
18 -0.10 -0.15
51.4 +0.05
C
E
D = 0.20 - 0.50
D = 0.20 - 0.50
Slot packing system
Characteristic
Compression ratio
12 ± 0.5: 1
Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR
MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
CHAR - 12
XEVO 125 Euro 3
Characteristics
MODELS WITH FIBRE HEAD GASKET (1.1)
Name
Shimming - Cylinder 67 - Head
gasket 1.1 - Base gasket 0.4
Shimming - Cylinder 67 - Head
gasket 1.1 - Base gasket 0.6
Measure A
2.20 ÷ 2.45
Thickness
0.4 ± 0.05
2.45 ÷ 2.70
0.6 ± 0.05
Characteristic
Compression ratio
12 ± 0.5: 1
Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR
MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
MODELS WITH METAL HEAD GASKET (0.3)
Name
Shimming - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.4
Shimming - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.6
Measure A
1.40 ÷ 1.65
Thickness
0.4 ± 0.05
1.65 ÷ 1.90
0.6 ± 0.05
CHAR - 13
XEVO 125 Euro 3
Characteristics
Oversizes
OVERSIZES
Name
Compression ring
Oil scraper ring
Oil scraper ring
Compression ring
1st oversize
Oil scraper ring 1st
Oversize
Oil scraper ring 1st
Oversize
Compression ring
2nd Oversize
Oil scraper ring
2nd Oversize
Oil scraper ring
2nd Oversize
Compression ring
3rd Oversize
Oil scraper ring 3rd
Oversize
Oil scraper ring 3rd
Oversize
CHAR - 14
Description
Dimensions
57 x 1
57 x 1
57 x 2.5
57.2 x 1
Initials
A
A
A
A
Quantity
0.15 ÷ 0.30
0.10 ÷ 0.30
0.15 ÷ 0.35
0.15 ÷ 0.30
57.2 x 1
A
0.10 ÷ 0.30
57.2 x 2.5
A
0.15 ÷ 0.35
57.4 x 1
A
0.15 ÷ 0.30
57.4 x 1
A
0.10 ÷ 0.30
57.4 x 2.5
A
0.15 ÷ 0.35
57.6 x 1
A
0.15 ÷ 0.30
57.6 x 1
A
57.6 x 2.5
A
0.15 ÷ 0.35
XEVO 125 Euro 3
Characteristics
Products
RECOMMENDED PRODUCTS TABLE
Product
AGIP ROTRA 80W-90
AGIP CITY HI TEC 4T
AGIP FILTER OIL
AGIP GP 330
AGIP CITY HI TEC 4T
AGIP BRAKE 4
SPECIAL AGIP PERMANENT
fluid
Description
Rear hub oil
Specifications
SAE 80W/90 Oil that exceeds the
requirements of API GL3 specifications
Oil to lubricate flexible transmisOil for 4-stroke engines
sions (throttle control)
Oil for air filter sponge
Mineral oil with specific additives
for increased adhesiveness
Grease for brake levers, throttle White calcium complex soapbased spray grease with NLGI 2;
ISO-L-XBCIB2
Engine oil
SAE 5W-40, API SL, ACEA A3,
JASO MA Synthetic oil
Brake fluid
FMVSS DOT 4 Synthetic fluid
coolant
Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16
CHAR - 15
Characteristics
CHAR - 16
XEVO 125 Euro 3
INDEX OF TOPICS
TOOLING
TOOL
XEVO 125 Euro 3
Tooling
APPROPRIATE TOOLS
TOOL - 2
Stores code
020151Y
Description
Air heater
020331Y
Digital multimeter
020333Y
Single battery charger
020334Y
Multiple battery charger
001467Y014
Pliers to extract ø 15-mm bearings
XEVO 125 Euro 3
Tooling
Stores code
020412Y
Description
15 mm guide
020335Y
Magnetic support for dial gauge
020565Y
Flywheel lock calliper spanner
020439Y
17 mm guide
020359Y
42x47-mm adaptor
TOOL - 3
XEVO 125 Euro 3
Tooling
TOOL - 4
Stores code
020363Y
Description
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
XEVO 125 Euro 3
Tooling
Stores code
020382Y011
Description
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 seal
rings
020360Y
Adaptor 52 x 55 mm
TOOL - 5
XEVO 125 Euro 3
Tooling
TOOL - 6
Stores code
020364Y
Description
25-mm guide
020375Y
Adaptor 28 x 30 mm
020376Y
Adaptor handle
020444Y
Tool for fitting/ removing the driven pulley clutch
020330Y
Stroboscopic light for timing control
001467Y035
Belle for OD 47-mm bearings
XEVO 125 Euro 3
Tooling
Stores code
020368Y
Description
driving pulley lock wrench
020319Y
Immobilizer check tester
020287Y
Clamp to assemble piston on cylinder
020263Y
Sheath for driven pulley fitting
020262Y
Crankcase splitting strip
020430Y
Pin lock fitting tool
TOOL - 7
XEVO 125 Euro 3
Tooling
TOOL - 8
Stores code
020428Y
Description
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 fitting band
XEVO 125 Euro 3
Tooling
Stores code
020382Y
Description
Valve cotters equipped with part
012 removal tool
020455Y
10-mm guide
020442Y
Pulley lock wrench
020440Y
Water pump service tool
020329Y
MityVac vacuum-operated pump
020357Y
32 x 35 mm adaptor
TOOL - 9
XEVO 125 Euro 3
Tooling
TOOL - 10
Stores code
020409Y
Description
Multimeter adaptor - Peak voltage detection
020456Y
Ø 24 mm adaptor
020332Y
Digital rev counter
020074Y
Support base for checking crankshaft alignment
020055Y
Wrench for steering tube ring nut
XEVO 125 Euro 3
Tooling
Stores code
002465Y
Description
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
46x55 Wrench
001467Y
Extractor for bearings for holes
TOOL - 11
XEVO 125 Euro 3
Tooling
TOOL - 12
Stores code
001467Y013
Description
Pliers to extract ø 15-mm bearings
020444Y010
adapter ring
INDEX OF TOPICS
MAINTENANCE
MAIN
XEVO 125 Euro 3
Maintenance
Follow these steps to reset the service icons:
1. With the key set to OFF, hold down the
"SET" button and turn the key to ON : the
"BELT" and "SERVICE" icons start flashing.
2. Push the "CLOCK" button for less than 1
second and the icons are displayed sequentially. The icon selected remains ON and the
other is no longer displayed.
3. Press the "CLOCK" button again for more
than 3 seconds to reset the relative maintenance step and the icon is no longer displayed.
Maintenance chart
EVERY 2 YEARS
Action
Coolant - change
Brake fluid - change
secondary air filter (outside) - cleaning
EVERY 3,000 KM
10'
Action
Engine oil - level check/ top-up
AFTER 1,000 KM
65'
Action
Engine oil - replacement
Hub oil - change
Idle speed (*) - adjustment
Throttle lever - adjustment
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
AFTER 6,000 KM
120'
MAIN - 2
XEVO 125 Euro 3
Maintenance
Action
Engine oil - replacement
Hub oil level - check
Spark plug/ electrode gap - check
Valve clearance - check
Air filter - clean
Engine oil - change
Driving belt - check
Sliding blocks / variable speed rollers - check
Coolant level - check
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
AFTER 12,000 KM; 60,000 KM
130'
Action
Engine oil - replacement
Hub oil level - check
Air filter - clean
Engine oil - change
Spark plug - replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Driven pulley roller casing - Greasing
Driving belt - replacement
Sliding blocks / variable speed rollers - check
Coolant level - check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
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
(*) See instructions in the «Idle speed adjustment» section
AT 18000 KM AND AT 54000 KM
120'
Action
Engine oil - change
Engine oil - change
Hub oil level - check
Spark plug/ electrode gap - check
Air filter - clean
Sliding blocks / variable speed rollers - check
Driving belt - Check
Coolant level - check
MAIN - 3
XEVO 125 Euro 3
Maintenance
Action
Radiator - external cleaning/ check
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
AT 24000 KM AND AT 48000 KM
130'
Action
Engine oil - replacement
Engine oil - change
Hub oil - change
Air filter - clean
Spark plug - replacement
Valve clearance - Check
Idle speed (*) - adjustment
Sliding block / variable speed rollers - change
Driving Belt - replacement
Driven pulley roller casing - Greasing
Throttle lever - adjustment
Coolant level - check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
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
(*) See instructions in «Idle speed adjustment» section
AFTER 30,000 KM; 42,000 KM; 66,000 KM
90'
Action
Engine oil - change
Engine oil - change
Hub oil level - check
Spark plug/ electrode gap - check
Air filter - clean
Driving belt - check
Sliding blocks / variable speed rollers - check
Coolant level - check
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
MAIN - 4
XEVO 125 Euro 3
Maintenance
AFTER 36000 KM
270'
Action
Engine oil - replacement
Hub oil level - check
Air filter - clean
Engine oil - change
Spark plug - replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Driving belt - replacement
Sliding blocks / variable speed rollers - check
Driven pulley roller casing - Greasing
Coolant level - check
Radiator - external cleaning/ check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
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
(*) See instructions in «Idle speed adjustment» section
AFTER 72,000 KM
270'
Action
Engine oil - replacement
Engine oil - change
Hub oil - change
Spark plug / electrode gap - check / replacement
Valve clearance - check
Air filter - clean
Idle speed (*) - adjustment
Throttle lever - adjustment
Driving belt - replacement
Sliding block / variable speed rollers - change
Coolant level - check
Radiator - external cleaning/ check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Driven pulley roller casing - Greasing
MAIN - 5
XEVO 125 Euro 3
Maintenance
Action
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
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.
- If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it
is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
Checking the spark advance
- To check ignition advance, use the stroboscopic
light with induction pincers connected to the spark
plug power wire.
- Connect the induction pincers being careful to
respect the proper polarity (the arrow stamped on
the pincers must be pointing at the spark plug).
- Place the light selector in central position (1 spark
= 1 crankshaft turn as in 2-T engines).
- Start the engine and check that the light works
properly and the rpm indicator can read also the
high rpm (e.g. 8000 rpm).
- If flash unsteadiness or revolution reading error
is detected (e.g. half values), increase the resistive
load on the spark plug power line (10 ÷ 15 KΩ in
series to HV wire).
- Remove the plastic cover from the slot on the flywheel cover.
- Operating on the flash corrector displacement of
the bulb, make the reference on the flywheel cover
coincide with level on the water pump drive. Read
MAIN - 6
XEVO 125 Euro 3
Maintenance
the advance degrees indicated by the stroboscopic light.
- Check that the advance degrees corresponds
with the rotation speed as indicated in the table.
- If failures are found, check the Pick-Up and the
control unit power supply (positive-negative), replace the control unit if necessary.
- The unprogrammed control unit prevents that the
engine rotation exceeds 2000 rpm.
- The programmed control unit allows the engine
to rotate within the prescribed limits.
Characteristic
Variable ignition advance (before TDC)
10°±1° at 2000 rpm
Spark plug
To service the spark plug the engine must be cold,
proceed as follows:
- Undo the fixing screw of the right side lid on the
right rear fairing and remove it.
- Remove the spark plug cap.
- Use the supplied spanner (with retaining rubber
ring) to remove the spark plug.
- Disconnect and remove the spark plug cable.
- Examine it carefully and replace it if the insulator
is chipped or cracked.
- Measure electrode gap with a thickness gauge
and, if necessary, adjust the gap by carefully bending the outer electrode forward or away.
- Make sure the sealing washer is in good condition.
- Fit the spark plug, screw it manually and lock it
to the prescribed torque with a spark plug spanner.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN
THE ENGINE IS COLD. REPLACE THE SPARK
PLUG AS INDICATED IN THE SCHEDULED
MAINTENANCE TABLE. USING NON-COMPLYING IGNITION CONTROL UNITS OR
MAIN - 7
Maintenance
SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap
0.7-0.8 mm
Electric characteristic
Recommended spark plug
CHAMPION RG4HC
Locking torques (N*m)
Spark plug 12 ÷ 14
Hub oil
Check the oil in the rear hub. To check the rear hub
oil level, proceed as follows:
1) Park the scooter on level ground and place it on
the centre stand.
2) Unscrew the dipstick "A", dry it with a clean rag
and then reinsert it, screwing it tightly into
place;
3) Pull out the dipstick and check that the oil level
is above the first notch from the bottom. If the oil
level is below the Max notch, refill the hub with the
adequate amount of oil.
4) Screw the dipstick back in, checking that it is
locked in place.
N.B.
THE REFERENCE MARKS ON THE HUB OIL
LEVEL DIPSTICK, EXCEPT FOR THE ONE INDICATING THE "MAX" LEVEL, REFER TO OTHER MODELS BY THE MANUFACTURER AND
HAVE NO SPECIFIC FUNCTION FOR THIS
MODEL.
CAUTION
RIDING THE VEHICLE WITH INSUFFICIENT
HUB LUBRICATION OR WITH CONTAMINATED OR IMPROPER LUBRICANTS ACCELERATES THE WEAR AND TEAR OF THE MOVING
PARTS AND CAN CAUSE SERIOUS DAMAGE.
CAUTION
MAIN - 8
XEVO 125 Euro 3
XEVO 125 Euro 3
Maintenance
USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR OIL REPLACEMENT, CONTACT AN AUTHORISED
SERVICE CENTRE, WHICH IS EQUIPPED TO
DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY.
CAUTION
UPON REPLACING HUB OIL, AVOID THE OIL
COMING INTO CONTACT WITH THE REAR
BRAKE DISC.
Recommended products
AGIP ROTRA 80W-90 rear oil hub
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Transmission oil
150 cm³
Replacement
-Remove the oil cap «A».
- Unscrew the oil drainage cap "B" and drain out
all the oil.
- Screw in the drainage cap again and fill the hub
with the prescribed oil.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Transmission oil
150 cm³
Locking torques (N*m)
Hub oil drainage plug 15 ÷ 17
MAIN - 9
Maintenance
XEVO 125 Euro 3
Air filter
Remove cleaner cover after unscrewing the two
knob screws «A» and the six screws «B», then remove the filtering element.
- Wash with water and neutral soap.
-Dry with a clean cloth and short blasts of compressed air.
- Soak with a mixture 50 % petrol and 50 % specific
oil.
- Drip dry the filtering element and then squeeze it
with your hands without wringing.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR
FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE
AIR FILTER MUST BE CLEANED MORE OFTEN
THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.
Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased adhesiveness
Engine oil
In 4T engines, engine oil is used to lubricate the distribution elements, main bearings and thermal group.
An insufficient quantity of oil can cause serious damage to the engine itself. In all four-stroke
engines, a loss of efficiency in oil performance and consumption should be considered normal. Consumption can particularly reflect the conditions of use (i.e. when driving at "full acceleration" all the time,
oil consumption increases). The replacement frequencies provided for by the maintenance programme
are defined, depending on the total contents of oil in the engine and average consumption measured
following standardised methods. In order to prevent any problems, we recommend checking oil
level more frequently than indicated in the Scheduled Maintenance table or before setting off
on long journeys. The vehicle is, however, equipped with an oil pressure warning light on the
instrument panel.
MAIN - 10
XEVO 125 Euro 3
Maintenance
Replacement
Replace oil and filter as indicated in the scheduled
maintenance table. The engine must be emptied
by draining the oil through the drainage plug «B»
of the mesh pre-filter, flywheel side. furthermore,
to facilitate oil drainage, loosen the cap/dipstick
«A». Once all the oil has drained through the drainage opening, unscrew and remove the oil cartridge
filter «C ».
Make sure the pre-filter and discharge tap O-rings
are in good condition.
Lubricate them and refit the mesh filter and oil
drainage plug, screwing them up to the specified
torque.
Refit the new cartridge filter being careful to lubricate the O-ring before fitting it.
Change the engine oil.
Since a certain quantity of oil still remains in the
circuit, engine oil must be added through the plug
«A». Then start up the scooter, leave it running for
a few minutes and switch it off: after five minutes
check the level and if necessary top up without
exceeding the MAX level. The cartridge filter must
be replaced every time the oil is changed. Use new
oil of the recommended type for topping up and
changing purposes.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS
CHANGED.
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
MAIN - 11
Maintenance
Check
This operation must be carried out with the engine cold and following the procedure below:
1) Rest the vehicle on the central stand and on a
flat ground.
2) Make sure the adjustment of the rear suspension is set to the minimum preloading position.
3 ) Screw off the cap/dipstick «A», dry it off with a
clean cloth and reinsert it, screwing down completely.
4) Remove the cap/dipstick «A» again and check
that the level is between the MAX and MIN marks;
top up, if required.
If the check is carried out after the vehicle has
been used, and therefore with a hot engine, the
level line will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct
level.
Oil top up
Always check the oil level before topping up in order to avoid exceeding the MAX level. Restoring
the level from Min to Max requires approx. 400 cm³
of oil.
Characteristic
Engine oil
1.1 l
MAIN - 12
XEVO 125 Euro 3
XEVO 125 Euro 3
Maintenance
Checking the ignition timing
-Remove the 4 fixing screws and move away from
the engine the flywheel cover fitted with the water
pump and cooling sleeves.
- Rotate the flywheel until the reference matches
the crankcase operation end as shown in the figure
(TDC). Make sure that the 4V reference point on
the camshaft control pulley is aligned with the reference point on the head as shown in the second
figure. If the reference is opposite the indicator on
the head, turn the crankshaft once more.
N.B.
TIME THE TIMING SYSTEM UNIT IF IT IS NOT
IN PHASE.
Checking the valve clearance
-To check valve clearance, centre the reference
marks of the timing system
- Use a thickness gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve
clearance values, intake and drainage respectively, are different from the ones indicated below,
adjust them by loosening the lock nut and operate
on the register with a screwdriver as shown in the
figure.
Characteristic
Valve clearance
Inlet: 0.10 mm Outlet: 0.15 mm
MAIN - 13
Maintenance
Cooling system
Adding engine coolant.
Check coolant level when the engine is cold as indicated in the scheduled maintenance table, following the steps below.
Place the scooter on its centre stand and on flat
ground.
- Undo the screw shown in the figure and remove
the expansion tank cap on RHS.
- Top up if the fluid level is near or below the MIN
level edge. The liquid level must always be between the MIN and MAX level.
CAUTION
DO NOT EXCEED THE MAX. LEVEL WHEN
FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN
THE vehicle IS IN USE.
Recommended products
SPECIAL AGIP PERMANENT fluid coolant
Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16
Braking system
Level check
The front and rear brake fluid reservoirs are both
positioned on the handlebars. Proceed as follows:
- Rest the vehicle onto the centre stand, with the
handlebar centred.
- Check the fluid level through the sight glass
«A».
A certain lowering of the level is caused by wear
on the pads.
MAIN - 14
XEVO 125 Euro 3
XEVO 125 Euro 3
Maintenance
Top-up
Proceed as follows: Loosen the screw «B» and lift
the plastic cover «A» in order to access the brake
fluid reservoir. Loosen the two fixing screws and
remove the reservoir cover; top-up with the recommended fluid without exceeding the 'MAX.'
mark.
This procedure applies to the rear brake pump topup operation; follow the same procedure for the
front brake pump.
Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance
table.
WARNING
ONLY USE DOT 4 CLASS BRAKE FLUIDS.
COOLING SYSTEM FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT
COME INTO CONTACT WITH THE PAINTWORK.
CAUTION
MAKE SURE THE BRAKE FLUID DOES NOT
GET INTO YOUR EYES OR ON YOUR SKIN OR
CLOTHES. IF THIS HAPPENS ACCIDENTALLY,
WASH WITH WATER.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Headlight adjustment
MAIN - 15
Maintenance
Proceed as follows:
1. Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a half-lit
white screen; ensure that the longitudinal axis of
the vehicle is perpendicular to the screen;
2. Turn on the headlight and check that the borderline of the projected light beam should be lower
than 9/10 of the distance from the ground to the
centre of the vehicle's headlight, and higher than
7/10;
3. If not, adjust the headlight by turning the central
screw «A» underneath the Piaggio badge.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH
THE EUROPEAN STANDARDS REGARDING
MAXIMUM AND MINIMUM HEIGHT OF LIGHT
BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.
SAS filters inspection and cleaning
Remove the secondary air filter cover after undoing the 3 fixing screws «A», then remove the filtering element «B».
- Wash with water and mild soap.
-Dry with a clean cloth and short blasts of compressed air.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE
AIR FILTER MUST BE CLEANED MORE OFTEN
THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.
MAIN - 16
XEVO 125 Euro 3
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
XEVO 125 Euro 3
Troubleshooting
This section makes it possible to find what solutions to apply when troubleshooting.
For each breakdown, a list of the possible causes and respective interventions is given.
Engine
Poor performance
POOR PERFORMANCE
Possible Cause
Operation
The carburettor is dirty; fuel pump or vacuum valve Remove, wash with solvent and dry with comdamaged
pressed air or replace
Excess of encrustations in the combustion cham- Descale the cylinder, the piston, the head and the
ber
valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Muffler obstructed
Replace
Air filter blocked or dirty.
Remove the sponge, wash with water and car
shampoo, then soak it in a mixture of 50% petrol
and 50% specific oil. Press with your hand without
squeezing, allow it to drip dry and refit.
Automatic starter failure
Check: mechanical movement, electric connection and fuel supply, replace if required.
Oil level exceeds maximum
Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valves
Replace the worn parts
worn
Transmission belt worn
Replace
Inefficient automatic transmission
Check the rollers, the pulley movement and make
sure the drive belt is in good conditions; replace
the damaged parts and lubricate the moveable
driven pulley with specific grease.
Clutch slipping
Check the clutch system and/or the bell and replace if necessary
Overheated valves
Remove the head and the valves, grind or replace
the valves
Wrong valve adjustment
Adjust the valve clearance properly
Valve seat distorted
Replace the head assembly
Defective floating valve
Check the proper sliding of the float and the functioning of the valve
Rear wheel spins at idle
Starting difficulties
DIFFICULT STARTING
Possible Cause
Altered fuel characteristics
Rpm too low at start-up or engine and start-up
system damaged
TROUBL - 2
Operation
Drain off the fuel no longer up to standard; then,
refill
Check the starter motor, the system and the torque
limiter
XEVO 125 Euro 3
Troubleshooting
Possible Cause
Incorrect valve sealing or valve adjustment
Operation
Inspect the head and/or restore the correct clearance
Engine flooded
Try starting-up with the throttle fully open. If the
engine fails to start, remove the spark plug, dry it
and before refitting, make the motor turn so as to
expel the fuel excess taking care to connect the
cap to the spark plug, and this in turn to the ground.
If the fuel tank is empty, refuel and start up.
Automatic starter failure
Check: mechanical movement, electric connection and fuel supply, replace if required.
Air filter blocked or dirty.
Remove the sponge, wash with water and car
shampoo, then soak it in a mixture of 50% petrol
and 50% specific oil. Press with your hand without
squeezing, allow it to drip dry and refit.
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit
components
The carburettor is dirty; fuel pump or vacuum valve Remove, wash with solvent and dry with comdamaged
pressed air or replace
Flat battery
Check the charge of the battery, if there are any
sulphur marks, replace and use the new battery
following the instructions shown in the chapter
Intake coupling cracked or clamps incorrectly
Replace the intake coupling and check the clamps
tightened
are tightened
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
Fuel pump fault
Check the pump control device
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST
Possible Cause
Operation
Worn valve guides
Check and replace the head unit if required
Worn valve oil guard
Replace the valve oil guard
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn or broken piston rings or piston rings that Replace the piston cylinder unit or just the piston
have not been fitted properly
rings
Insufficient lubrication pressure
LOW LUBRICATION PRESSURE
Possible Cause
By-Pass remains open
Oil pump with excessive clearance
Oil filter too dirty
Oil level too low
Operation
Check the By-Pass and replace if required. Carefully clean the By-Pass area.
Perform the dimensional checks on the oil pump
components
Replace the cartridge filter
Restore the level adding the recommended oil
type
TROUBL - 3
XEVO 125 Euro 3
Troubleshooting
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE
Possible Cause
Faulty fuel supply
Incorrect float level
Water in the carburettor
Maximum nozzle dirty - lean mixture
Operation
Check or replace the pump and the vacuum valve,
check the vacuum intake and the pipe sealing
Restore the level in the tank by bending on the float
the thrusting reed of the petrol inlet rod so as to
have the float parallel to the tank level with the
carburettor inverted.
Empty the tank through the appropriate bleed nipple.
Wash the nozzle with solvent and dry with compressed air
Engine tends to cut-off at idle
ENGINE STOP IDLING
Possible Cause
Incorrect timing
Cut off device failure
Incorrect idle adjustment
Pressure too low at the end of compression
Faulty spark plug or incorrect ignition advance
The starter remains on
Minimum nozzle dirty
Operation
Time the system and check the timing system
components
Check that the following parts work properly:
valve; diaphragm; spring; and that the air calibration elements are clean; check if the sponge filter
is clean too
Adjust using the rpm indicator
Check the thermal group seals and replace worn
components
Replace the spark plug or check the ignition circuit
components
Check: electric wiring, circuit not interrupted, mechanical movement and power supply; replace if
necessary
Wash the nozzle with solvent and dry with compressed air
Excessive exhaust noise
EXCESSIVE EXHAUST NOISE
Possible Cause
Secondary air device cut-off valve not working
Depression intake pipe of the secondary air device
disconnected or dented
Reed valve of the secondary air device does not
close correctly and wears out the rubber coupling
between the device and the head pipe
TROUBL - 4
Operation
Replace the secondary air device
Replace the pipe
Replace the device and the coupling
XEVO 125 Euro 3
Troubleshooting
High fuel consumption
HIGH FUEL CONSUMPTION
Possible Cause
Float level
Operation
Restore the level in the tank by bending on the float
the thrusting reed of the petrol inlet rod so as to
have the float parallel to the tank level with the
carburettor inverted.
Check the maximum and minimum nozzles are
adequately fixed in their fittings
Check that there is no fuel in the low-pressure duct
Check: electric wiring, circuit continuity, mechanical sliding and power supply
Remove the sponge, wash with water and car
shampoo, then soak it in a mixture of 50% petrol
and 50% specific oil. Press with your hand without
squeezing, allow it to drip dry and refit.
Loose nozzles
Fuel pump failure
Starter inefficient
Air filter blocked or dirty.
SAS malfunctions
ANOMALIES IN THE SECONDARY AIR DEVICE
Possible Cause
Secondary air device cut-off valve not working
Depression intake pipe of the secondary air device
disconnected or dented
Reed valve of the secondary air device does not
close correctly and wears out the rubber coupling
between the device and the head pipe
Operation
Replace the secondary air device
Replace the pipe
Replace the device and the coupling
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Faulty clutch
Operation
Check that there is no grease on the masses.
Check that the clutch mass contact surface with
the casing is mainly in the centre with equivalent
characteristics on the three masses. Check that
the clutch casing is not scored or worn in an anomalous way
Insufficient braking
INSUFFICIENT BRAKING
Possible Cause
Inefficient braking system
Operation
Check the pad wear (1.5 min). Check that the
brake discs are not worn, scored or warped. Check
TROUBL - 5
XEVO 125 Euro 3
Troubleshooting
Possible Cause
Fluid leakage in hydraulic braking system
Operation
the correct level of fluid in the pumps and replace
brake fluid if necessary. Check there is no air in
the circuits; if necessary, bleed the air. Check that
the front brake calliper moves in axis with the disc.
Failing elastic fittings, plunger or brake pump
seals, replace
Brakes overheating
BRAKES OVERHEATING
Possible Cause
Rubber gaskets swollen or stuck
Compensation holes on the pump clogged
Brake disc slack or distorted
Defective piston sliding
Operation
Replace gaskets.
Clean carefully and blast with compressed air
Check the brake disc screws are locked; use a dial
gauge and a wheel mounted on the vehicle to
measure the axial shift of the disc.
Check calliper and replace any damaged part.
Electrical system
Battery
BATTERY
Possible Cause
Battery
Operation
This is the device in the system that requires the
most frequent attention and the most thorough
maintenance. If the vehicle is not used for some
time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 3 months. If the battery is
fitted on a motorcycle, be careful not to invert the
connections, keeping in mind that the black ground
wire is connected to the negative terminal while the
red wire is connected to the terminal marked+.
Steering and suspensions
Rear wheel
REAR WHEEL ROTATES WITH ENGINE AT IDLE
Possible Cause
Idling rpm too high
Clutch fault
TROUBL - 6
Operation
Adjust the engine idle speed.
Check the springs / clutch masses
XEVO 125 Euro 3
Troubleshooting
Controls
STEERING CONTROLS AND SUSPENSIONS
Possible Cause
Torque not conforming
Steering hardening
Malfunctions in the suspension system
Seal fault or breakage
Operation
Check the tightening of the top and bottom ring
nuts. If irregularities 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.
Check the tightening of the top and bottom ring
nuts. If irregularities 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.
If the front suspension is noisy, check: the efficiency of the front shock absorbers; the condition of
the ball bearings and relevant lock-nuts, the limit
switch rubber buffers and the movement bushings.
In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber
disk in the attachment to the hub and the steering
tube.
Replace the shock absorber Check the condition
of wear of the steering covers and the adjustments.
TROUBL - 7
Troubleshooting
TROUBL - 8
XEVO 125 Euro 3
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
KEY
1. Electronic ignition device
2. Immobilizer aerial
3. Magneto flywheel - Pick-up
4. Diagnosis connector
5. Engine stop switch
6. Voltage regulator
7. Main fuses
8. Plug socket
9. Battery
10. Starter motor
11. Start-up remote control switch
12. Start-up button
13. Secondary fuses
14. Stop button on rear brake
15. Stop button on front brake
16. Boot opening switch
17. Rear boot actuator
18. Saddle opening actuator
19.Electrical actuators control unit
ELE SYS - 2
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Electrical system
20. Wiring for antitheft device
21. Hazard button
22. Turn indicator switch
23. Turn indicator control device
24.Helmet compartment light switch
25.Rear case light switch
26. Light switch
27. Helmet compartment internal light
28. Licence plate light bulb
29. Rear left turn indicator
30. Rear light
A. Stop light bulbs B. Tail light bulbs
31. Rear right turn indicator
32. Front left turn indicator
33. Front light
A. Tail light bulbs B. Low-beam light bulb C. High-beam light bulb
34. Front right turn indicator
35.Ambient temperature sensor
36. Remote control headlight
37. Engine oil pressure sensor
38. Horn
39. Horn button
40. MODE button
41. Thermistor
42. Instrument panel
43.Wheel turning sensor
44. Fuel level transmitter
45. Light switch remote control
46. Thermoswitch
47. Electric fan
48. Fuel electric pump control device
49. Key switch
50. Fuel pump
51. Spark plug
52. HV coil
53. Automatic starter
Key
Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey
ELE SYS - 3
Electrical system
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple
Conceptual diagrams
Ignition
KEY
1. Electronic ignition device
2. Immobilizer aerial
5. Engine stop switch
7. Main fuses
9. Battery
49. Key switch
51. Spark plug
52. HV coil
ELE SYS - 4
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Electrical system
Headlights and automatic starter section
KEY
1. Electronic ignition device
5. Engine stop switch
7. Main fuses
9. Battery
13. Secondary fuses
26. Light switch
28. Licence plate light bulb
30. Rear light
B. Tail light bulbs
33. Front light
A. Tail light bulbs B. Low-beam light bulb C. High-beam light bulb
36. Remote control headlight
42. Instrument panel
49. Key switch
53. Automatic starter
ELE SYS - 5
Electrical system
Battery recharge and starting
KEY
1. Electronic ignition device
3. Magneto flywheel - Pick-up
5. Engine stop switch
6. Voltage regulator
7. Main fuses
9. Battery
10. Starter motor
11. Start-up remote control switch
12. Start-up button
13. Secondary fuses
14. Stop button on rear brake
15. Stop button on front brake
30. Rear light
A. Stop light bulbs
49. Key switch
ELE SYS - 6
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XEVO 125 Euro 3
Electrical system
Level indicators and enable signals section
KEY
1. Electronic ignition device
2. Immobilizer aerial
5. Engine stop switch
7. Main fuses
9. Battery
13. Secondary fuses
35.Ambient temperature sensor
37. Engine oil pressure sensor
41. Thermistor
42. Instrument panel
43.Wheel turning sensor
44. Fuel level transmitter
49. Key switch
ELE SYS - 7
Electrical system
Devices and accessories
KEY
1. Electronic ignition device
4. Diagnosis connector
5. Engine stop switch
7. Main fuses
8. Plug socket
9. Battery
13. Secondary fuses
16. Boot opening switch
17. Rear boot actuator
18. Saddle opening actuator
19.Electrical actuators control unit
20. Wiring for antitheft device
21. Hazard button
22. Turn indicator switch
23. Turn indicator control device
24.Helmet compartment light switch
25.Rear case light switch
ELE SYS - 8
XEVO 125 Euro 3
XEVO 125 Euro 3
Electrical system
27. Helmet compartment internal light
29. Rear left turn indicator
31. Rear right turn indicator
32. Front left turn indicator
34. Front right turn indicator
38. Horn
39. Horn button
40. MODE button
42. Instrument panel
45. Light switch remote control
46. Thermoswitch
47. Electric fan
48. Fuel electric pump control device
49. Key switch
50. Fuel pump
Checks and inspections
This section is devoted to the checks on the electrical system components.
Immobiliser
The electric ignition system is fed with direct current and is protected by an antitheft immobilizer
integrated to the control unit.
The ignition system consists of:
- electronic control unit
- immobilizer aerial
- master and service keys with built-in transponder
- H.V. coil
- diagnosis LED
The diagnosis LED also works as a theft deterring
blinker. This function is activated every time the
key switch is turned to «OFF», and it remains activated for 48 hours so as not to affect the battery
charge.
When the ignition switch is turned to «ON», the
deterring blinker function is deactivated. Subsequently, a flash confirms the switching to « ON».
ELE SYS - 9
Electrical system
The duration of the flash depends on the electronic
control unit program (see figure).
If the LED turns off and remains so when switching
to «ON», check whether there is battery voltage in
the electric control unit.
Connect the immobilizer tester to the diagnosis
socket (see ET4 125 manual) located inside the
battery compartment.
If the serial LED remains off, proceed to check the
control unit supply as follows:
- Disconnect the control unit connector and check
if:
- There is battery voltage between the terminal No.
3 (Red) and the ground connection.
- There is battery voltage between terminal No. 3
(Red) and terminal No. 6 (Negative) as shown in
the figure.
If no voltage is detected, check the wiring to the
battery positive lead and see if the 15A fuse is in
good conditions.
- There is battery voltage between terminals No. 1
and No. 6 with the key switch set to «ON » and the
emergency switch set to «RUN»
If no faults are found, replace the control unit; otherwise, check the wiring and the following components:
- Emergency cut-off switch;
- Key switch contacts.
ELE SYS - 10
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XEVO 125 Euro 3
Electrical system
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 evident loss of power may be felt.
Program the system with the MASTER (Red) and
SERVICE (Black) keys as follows:
- Insert the MASTER key, turn it to "ON" and keep
it in that position for 2 seconds (limit values: 1 ÷ 3
seconds).
- Alternately insert all the available black keys and
turn each one of them to "ON" for 2 seconds.
- Insert the MASTER key again and turn it to "ON"
for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 (Black) service keys can be programmed at one time.
Sequence and times must be strictly observed or
it will be necessary to repeat the procedure from
the start.
Once the control unit has been programmed, the
control unit is inseparably matched with the MASTER key transponder.
This matching allows programming further service
keys in case of loss, replacement, etc. Each new
time new data is programmed the previously stored one is deleted.
If a service key setting is lost, it is essential to
carefully check the efficiency of the high voltage
system:
Shielded cap resistance ~ 5000 Ω.
In any case it is advisable to use resistive spark
plugs.
Diagnostic codes
The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings.
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:
ELE SYS - 11
Electrical system
XEVO 125 Euro 3
2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial.
Ignition disabled-Vehicle immobilised
3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown transponder code. Ignition disabled-Vehicle immobilised
Diagnostic code - 2 flashes
When the 2-flash code is detected, carry out the following checks:
- Check if the failure continues after changing key (MASTER key included). If the failure persists with
any key, disconnect the aerial connector from the control unit and check the aerial continuity with the
020331Y multimeter.
If non-conforming values are measured, replace the aerial.
If no failures are found in the aerial, replace the control unit.
CAUTION
BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE
CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT
Electric characteristic
immobilizer aerial
~ 7 ÷ 9 Ohm
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, proceed to encode the service keys
(Black).
ELE SYS - 12
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Electrical system
- If the failure persists, it means that the MASTER
key and the control unit are not linked; in this case,
replace the control unit and then encode the keys.
The immobilizer system is efficient when, after
switching over to "ON", only a 0.7-second flash is
detected (see diagram).
In this case, the engine can be started.
Example with programmed control unit, transponder, programmed key and aerial working properly.
Ignition is enabled (regular conditions of use)
Ignition circuit
Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a
spark in the spark plug.
The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control
unit is connected to the Pick-Up by the chassis and the engine ground lead.
To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding is efficient.
No spark plug
Once the lack of power to the spark plug has been
detected and the LED indicates it can be ignited,
follow this procedure:
- Pick-Up check.
Disconnect the control unit connector and check
that the cable between terminal No. 8 (Green) and
terminal No. 6 (Black) is not interrupted. Check the
Pick-Up and its power line:
Electric characteristic
Pick-up resistance value
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 detected, replace the Pick-Up, otherwise check the cable harELE SYS - 13
Electrical system
XEVO 125 Euro 3
ness and the connections. In case conforming values are measured and the wiring and connections
check is OK, try replacing the control unit (without programming) and make sure the failure has been
solved by checking sparks are produced in the spark plug; only then program the control unit. If no
sparks are produced with the new control unit, proceed as follows.
- HV primary coil check
Disconnect the two connectors on the HV coil and
check continuity (see figure). If non-conforming
values are measured, replace the HV coil. If conforming values are measured, check the wiring. If
failures are detected, check the HV coil secondary.
Electric characteristic
High voltage coil primary resistance value
High voltage coil primary resistance value: 0.4 ÷
0.5 Ohm
HV coil secondary check
Disconnect the spark plug cap from the HV cable
and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see
figure). If non-conforming values are measured,
replace the HV coil. To carry out a more complete
diagnosis, check the peak voltage with the multimeter adaptor.
Electric characteristic
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~
3000 ± 300 Ohm
ELE SYS - 14
XEVO 125 Euro 3
Electrical system
- Pick-Up.
Disconnect the control unit connector and connect
the positive terminal to connector No. 8 and the
negative terminal to connector No. 6 (see figure).
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
Replace Pick-Up if non-conforming values are
measured.
Electric characteristic
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- HV coil
With the control unit and HV coil connected, measure the voltage of the coil primary during the startup test with the voltage peak adaptor and connecting the positive terminal to the ground one and
the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
N.B.
THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE HV COIL PRIMARY IS BLACK
AND THE NEGATIVE TERMINAL ONE IS
GREEN.
Electric characteristic
High voltage coil voltage value
High voltage coil voltage value: > 100 Volt
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any yellow
cable and the other two cables.
Electric characteristic
Ohm value:
0.7 ÷ 0.9 Ohm
ELE SYS - 15
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 repetitions of incorrect values replace the stator or
repair the wiring.
- With a tester, check the circuit between connections 5-3 and 5-1 is not interrupted.
- Check the earth isolation on the three phases of
stators 5-earth, 3-earth, 1-earth.
Stage indicative resistance: 0.7 - 0.9 Ω
Minimum oil pressure switch check
- With a tester, check the circuit between connections 4 and ground (with engine off) is not interrupted.
Pick-Up check
- Check that there is a resistance of approx. 105 ÷
124 Ω at 20° C between connection 6 and the
ground lead.
- In case values different from the ones stated are
detected, replace the defective parts.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN
VALUES HIGHER THAN THOSE STATED.
ELE SYS - 16
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XEVO 125 Euro 3
Electrical system
Voltage regulator check
With a perfectly charged battery and lights off,
measure voltage at the battery poles with a high
running engine.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
Recharge system voltage check
Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with
engine off, wait for the voltage to set at about 12
V. Start the engine and measure the current generated by the system with lights on and a high
running engine.
In case the generated current value is lower than
10A, repeat the test using a new regulator and/
stator alternatively.
Choke Inspection
Refer to the engine section to check the resistance
and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals
receive battery voltage when the engine is on (see
figure).
If voltage is detected, replace the automatic starter
as it is surely failing.
If no voltage is detected, connect the multimeter
negative terminal to the ground lead and the positive terminal to the automatic starter orange cable;
with the key switch set to «ON» check whether
there is battery voltage; if there is no voltage,
ELE SYS - 17
Electrical system
XEVO 125 Euro 3
check the wiring connections to the key switch and
that the 15A fuse works properly.
If there is voltage, check again the ignition control
unit connector. After disconnecting the starter,
start up the engine and keep it at idle speed; then
check whether there is voltage connecting the multimeter positive probe to terminal No. 5 (Orange),
and the negative one to terminal No. 7 (Brown)
(see figure).
Replace the control unit if there is no voltage; otherwise, check the wiring connections between the
starter and the control unit.
Turn signals system check
The turn indicator circuit is controlled by the specific management device. If it does not work, it is necessary to:
- Check if light bulbs are working properly and the corresponding wiring harness is not interrupted.
- Check if there is voltage in the blue-black cable of the turn indicator switch. Keep the switch activated
to the right and the key switch set to «ON».
- Also check the white-pink cable of the turn indicator switch for voltage. Keep the switch activated to
the left.
If there is voltage, check the turn indicator management device; otherwise, check the orange-white
cable of the switch again.
If there is voltage in the cable, replace the turn indicator switch because it is faulty; otherwise, check
cable harness and repeat the procedure.
Check the turn indicator management device
Check the cable harness between the turn indicator switch and the management device; restore it if
damaged. Then check power supply:
- Check if there is voltage between terminals 6-9 and terminal 6-chassis ground.
- Repeat the procedure for terminals 8-9 and terminal 8-chassis ground with the key switch set to «ON».
If there is no voltage, check if fuses 2, 6 and 7, their cable harness and the key switch contacts are in
working order. Otherwise:
- Check if there is intermittent voltage between terminals 4-9 and 5-9 with the key switch set to «ON»
and the turn indicator switch activated.
If there is no voltage, replace the management device because it is damaged.
ELE SYS - 18
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Electrical system
Lights list
LIGHT BULB TABLE
1
Specification
High-beam light bulb
2
Low-beam bulb
3
Front tail light bulb
4
Instrument panel bulb
5
Front turn indicator bulb
6
Helmet compartment light bulb
7
Rear turn indicator bulb
8
Rear tail light bulb
9
Stop light bulb
10
License plate light bulb
Desc./Quantity
Type: HALOGEN (H7)
Power: 12V - 55W
Quantity: 1
Type: HALOGEN (H1)
Power: 12V - 55W
Quantity: 1
Type: ALL GLASS
Power: 12V - 5W
Quantity: 2
Type: ALL GLASS
Power: 12V - 2W
Quantity: 4
Type: ALL GLASS
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
Type: CYLINDRIC
Power: 12V - 5W
Quantity: 1
Type: ALL GLASS
Power: 12V - 5W
Quantity: 2 RHS + 2 LHS
Type: ALL GLASS
Power: 12V - 5W
Quantity: 2
Type: SPHERICAL
Power: 12V - 10W
Quantity: 2
Type: ALL GLASS
Power: 12V - 5W
Quantity: 1
Fuses
The electrical system is equipped with 12 protective fuses for the various circuits on the vehicle,
subdivided into two fuse boxes «A» and «B» located alongside the battery.
The chart shows the position and characteristics
of the fuses in the vehicle.
CAUTION
NEVER TRY TO REPLACE A BLOWN FUSE
WITH A FUSE OF A DIFFERENT RATING THAN
THAT SPECIFIED OR USING OTHER MATERIELE SYS - 19
XEVO 125 Euro 3
Electrical system
AL (FOR EXAMPLE, A PIECE OF ELECTRICAL
WIRE).
BESIDES, IF AFTER REPLACING A FUSE, THE
NEW FUSE ALSO BLOWS, THE VEHICLE
NEEDS TO BE TAKEN TO AN AUTHORISED
SERVICE CENTRE TO IDENTIFY THE CAUSE
OF THE FAULT AND AVOID FURTHER DAMAGE TO THE ELECTRIC SYSTEM COMPONENTS OR THE VEHICLE ITSELF.
CAUTION
MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE
TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING
AND RISK OF FIRE.
FUSE TABLE
1
Specification
Fuse No. 1
2
Fuse No. 2
3
Fuse No. 3
4
Fuse No. 4
5
Fuse No. 5
ELE SYS - 20
Desc./Quantity
Capacity:20A
Protected circuits:Battery recharge circuit
Location:Battery compartment on left side of
the vehicle
Capacity:15A
Protected circuits:
Electric fan, battery powered electronic ignition device.
Live power supply to load fuses no.
7-8-10-12, light remote control, engine stop
switch, automatic starter, electronic ignition
device.
Location:Battery compartment on left side of
the vehicle
Capacity:15A
Protected circuits:
Battery powered plug socket, helmet compartment lighting, electric actuator control
unit, antitheft device installation.
Live power supply to boot opening switch.
Location:Battery compartment on left side of
the vehicle
Capacity:10 A
Protected circuits:Load fuses no.9, battery
powered light switch
Location:Battery compartment on left side of
the vehicle
Capacity:5 A
XEVO 125 Euro 3
Electrical system
Specification
6
Fuse No. 6
7
Fuse No. 7
8
Fuse No. 8
9
Fuse No. 9
10
Fuse No. 10
11
Fuse No. 11
12
Fuse No. 12
Desc./Quantity
Protected circuits:Battery powered immobilizer warning light, digital display
Location:Battery compartment on left side of
the vehicle
Capacity:5 A
Protected circuits:Battery powered turn indicator control device
Location:Battery compartment on left side of
the vehicle
Capacity:10 A
Protected circuits:Live power supply to antitheft device installation, electric actuator
control unit, turn indicators
Location:Battery compartment on vehicle
RHS
Capacity:7.5 A
Protected circuits:Live power supply to
horn, switch light
Location:Battery compartment on vehicle
RHS
Capacity:7.5 A
Protected circuits:Live power supply to tail
lights, license plate light, instrument panel
lightning
Location:Battery compartment on vehicle
RHS
Capacity:7.5 A
Protected circuits:Live power supply to
wheel revolution sensor, digital display, instrument panel warning lights
Location:Battery compartment on vehicle
RHS
Capacity:5 A
Protected circuits:Live power supply to stop
lights, start-up circuit
Location:Battery compartment on vehicle
RHS
Capacity:3A
Protected circuits:Live power supply to
electric pump control device
Location:Battery compartment on vehicle
RHS
ELE SYS - 21
Electrical system
Dashboard
A = Immobilizer / anti-theft LED
B= Speedometer with twin scale (Km/h and Mph)
C = CLOCK switch
D = Digital display
E = Emergency turn indicator warning light
F= SET switch
G = Rpm indicator
H = Fuel gauge
I = Warning light for helmet compartment courtesy
light on
L = Engine control telltale light
M = Low fuel warning light
N = Engine stop warning light
O= Turn indicator warning light
P = Low oil pressure warning light
Q = High beam warning light
Pushing the «CLOCK» button for less than 1 second displays the following sequence:
•
TIME
•
DATE
To set the clock push and hold the «CLOCK» button longer than 3 seconds.
The numbers showing the hours will begin flashing.
Set the hour using the «SET» button. Push the
«CLOCK» button again and the minutes numbers
start flashing.
Set the minutes using the «SET»button. Push the
«CLOCK» button again and the day numbers start
flashing.
Set the day with the «SET» button. Push the
«CLOCK» button again and the month numbers
start flashing.
Set the month with the «SET» button. Push the
«CLOCK» button again and the year numbers
start flashing.
ELE SYS - 22
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XEVO 125 Euro 3
Electrical system
Set the year with the «SET» button. Press the
«CLOCK » button again for 4 seconds to exit the
adjustment menu.
During the reset process, not pressing any buttons
for a period longer than 8 seconds ends the process automatically and the display shows the modified time.
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.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
- Charge time: 5 h
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED
SHORTENS THE LIFE OF THE BATTERY.
IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS
TO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THE
COURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE,
BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE
GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL
ELE SYS - 23
Electrical system
XEVO 125 Euro 3
WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL
MARKED WITH THE +POSITIVE SIGN
WARNING
WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS
OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Dry-charge battery
COMMISSIONING A NEW DRY-CHARGED BATTERY
- Remove the battery air pipe stop cap and each single element caps.
- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an ambient temperature not below 15°C, until it reaches the upper level indicated on the block.
- Tilt the battery slightly to remove any air bubbles formed during filling.
- Place the caps on each single element filling holes without screwing them and leave the battery to
rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases.
- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).
- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level
using the same filling electrolyte
Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled
water;
- Before 24 hours elapse, recharge the battery following these steps:
- Connect the battery charger terminals observing the correct polarity;
- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by
selecting the position corresponding to that capacity;
- Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with
a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge.
Note: Batteries that have been stored for a long time may take a longer charging time. The battery
chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge
after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the
activation of the safety system and not the end of the charge.
- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a
standard tester.
- If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake
or tilt the battery to eliminate any air bubbles formed during recharging.
- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary,
clean battery properly, close each single cell cap tightly and install it on the vehicle.
- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.
ELE SYS - 24
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Electrical system
Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the
Check function. The value indicated on the display must be higher than the value indicated on the chart;
otherwise, recharge the battery again in the same way indicated above.
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 battery voltage as indicated in the table.
PUMP SUPPLY
Specification
Key set to «KEY ON»
Engine revs from 0 to 200 rpm
Engine revs from 200 to 1200 rpm
Engine revs from 1200 to 2000 rpm
Engine rpm ] 2000 r.p.m.
Desc./Quantity
Supply to the pump for 13 seconds
Always «OFF»
Always «ON»
0.2 seconds «ON»
9 seconds «OFF»
Always «ON»
Connectors
FUEL PUMP CONNECTOR
1. Ground (White-Black)
2. Live supply (Blue-Black)
ELE SYS - 25
Electrical system
FUEL ELECTRIC PUMP CONTROL DEVICE
CONNECTOR
1. Live supply (Blue-Red)
2. Not connected
3. Pump Ground (White-Black)
4. Pump supply (Blue-Black)
5. Ground (Black)
6. Engine revs (Purple)
VOLTAGE REGULATOR CONNECTOR
1. Battery positive (Red-Blue)
2. Magneto flywheel (Yellow)
3. Not connected
4. Magneto flywheel (Yellow)
5. Ground (Black)
6. Magneto flywheel (Yellow)
AUTOMATIC STARTER CONNECTOR
1. Live positive (Orange)
2. Ground (Brown)
TURN INDICATOR CONTROL DEVICE CONNECTOR
1. Hazard switch (Brown)
2. LHS Turn indicator switch (White-Pink)
3. RHS Turn indicator switch (Blue-Black)
4. LHS Turn indicator bulbs (Pink)
5. RHS Turn indicator bulbs (White-Blue)
6. Battery powered (Grey-Green)
7. Light switch remote control (Purple-White)
8. Live (Orange-White)
9. Ground (Black)
10. Not connected
11. Not connected
ELE SYS - 26
XEVO 125 Euro 3
XEVO 125 Euro 3
Electrical system
12. Not connected
ELECTRONIC CONTROL UNIT CONNECTOR
1. Engine stop switch (Sky Blue)
2. Not connected
3. Battery powered (Red)
4. Diagnosis Connector (Purple-White) v5. Live
(Orange)
6. Ground (Black)
7. Automatic starter negative (Brown)
8. Pick-up (Green)
9. Engine revs signal (Blue)
10. Engine check warning light (Brown-Black)
11. Not connected
12. Not connected
13. Immobilizer LED (Yellow)
14. HV coil (Purple)
INSTRUMENT PANEL CONNECTOR «A»
1. Not connected
2. Not connected
3. Not connected
4. Not connected
5. Instrument panel lighting (Yellow-Black)
6. Battery powered (Red-Green)
7. Not connected
8. Not connected
9. Not connected
10. Not connected
11. Ground (Black)
12. Live (Grey-Black)
INSTRUMENT PANEL CONNECTOR «B»
1. Speed sensor (Green)
2. Fuel level indicator (White-Green)
3. Thermistor (Yellow-Green)
4. Water temperature sensor negative (Black)
5. MODE button (Green-Blue)
6. Oil pressure warning light (Pink-White)
7. Left turn indicator warning light (Pink)
ELE SYS - 27
Electrical system
8. Right turn indicator warning light (White-Blue)
9. High-beam warning light (Purple)
10. Boot open warning light (Red-Yellow)
11. Rpm indicator (Blue)
12. Ambient temperature sensor (White-Yellow)
13. Ambient temperature sensor negative (YellowBlue)
14. Engine stop switch (Sky Blue)
15. Immobilizer LED (Yellow)
16. Engine check warning light (Brown-Black)
17. Ground (Black)
18. Hazard warning light (Purple-Black)
19. Ground (Ground)
20. Not connected
ELE SYS - 28
XEVO 125 Euro 3
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Engine from vehicle
XEVO 125 Euro 3
This section describes the operations to carry out when removing the engine from the vehicle.
Exhaust assy. Removal
•
Unscrew the 3 screws fixing the muffler
to the engine crankcase and the supporting arm;
•
Loosen the bolt holding the muffler to
the exhaust manifold; after that, remove the muffler backwards.
•
Unscrew the 2 nuts that fix the exhaust
manifold to the head and remove it.
Removal of the engine from the vehicle
•
Remove the side panels
•
Undo the 2 screws fixing the rear brake
calliper to the supporting arm and remove it.
•
Keep the pipes connected to the calliper and move it aside towards the
vehicle front part so as not to hinder the
next removal operations.
ENG VE - 2
XEVO 125 Euro 3
•
Empty the cooling system.
•
Remove the clamps and disconnect
Engine from vehicle
the coolant feeding (engine compartment) and return (water pump) pipes.
•
Remove the holding spring and remove the coolant out pipes;
•
Remove the holding spring and remove the petrol pump low-pressure
pipe from the inlet manifold;
•
Move the accelerator wire from the
throttle control rocking lever; unscrew
the set screw and disconnect the transmission from the carburettor.
ENG VE - 3
Engine from vehicle
•
Disconnect the HV wire from the spark
plug;
•
Disconnect the thermistor electrical
connection after removing the rubber
cap.
•
Remove the holding spring and move
the petrol feed pipe to carburettor;
•
Cut the plastic clamp and disconnect
the starter supply connection.
•
Remove the lower screws fastening
the rear shock absorbers to the engine
crankcase and the supporting arm;
ENG VE - 4
XEVO 125 Euro 3
XEVO 125 Euro 3
•
Engine from vehicle
Cut the clamp on the transmission
crankcase duct; after that, disconnect
the pipe connected to the air intake on
the chassis.
•
Disconnect the electric connector linking the magneto flywheel to the vehicle
cable harness.
•
Remove the starter motor electrical
connections acting on the two screws.
•
Remove the footrest and the left side
fairing; move the lower central cover
slightly to the outside and remove the
three screws fixing the supporting plate
of the swinging arm buffer.
•
Remove the buffer sealing seeger ring
and remove the supporting plate of the
swinging arm buffer.
•
Support the vehicle adequately with
the jack. Remove the engine-swinging
arm fixing pin by acting on the nut and
the pin head as shown in the figure.
•
The engine is now free.
ENG VE - 5
Engine from vehicle
Locking torques (N*m)
Engine swinging arm pin nut 33 ÷ 41 Shock absorber lower clamp 33 ÷ 41 Rear brake calliper
tightening screws 20 ÷ 25
ENG VE - 6
XEVO 125 Euro 3
INDEX OF TOPICS
ENGINE
ENG
Engine
XEVO 125 Euro 3
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. Using the clutch
bell lock wrench shown in the figure, remove the
driven pulley shaft locking nut and washer.
Specific tooling
020423Y driven pulley lock wrench
- Remove the cap/dipstick from the engine oil filling
hole «A».
- Remove the ten screws.
- Remove the transmission cover.
If this operation is carried out directly on the vehicle, remove the cooling air supply coupling of the
transmission housing.
Air duct
- Remove the 4 screws and the housing.
ENG - 2
XEVO 125 Euro 3
Engine
- To remove the intake throat on the transmission
cover, just 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
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020412Y 15 mm guide
Refitting the driven pulley shaft bearing
- Slightly heat the crankcase from the inside so as
not to damage the painted surface.
- Insert the bearing in its seat.
- Refit the Seeger ring.
CAUTION
USE AN APPROPRIATE REST SURFACE TO
AVOID DAMAGING THE COVER PAINT.
N.B.
ALWAYS REPLACE THE BEARING WITH A
NEW ONE UPON REFITTING.
Specific tooling
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
ENG - 3
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.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
Checking the bell working surface eccentricity
- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft assembly on the support to
check the crankshaft alignment.
ENG - 4
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
- Using a feeler pin gauge and the magnetic base,
measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central,
internal, external).
- If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
Removing the clutch
Fit the driven pulley spring compressor specific
tool with medium length pins screwed in position
F from the tool internal side.
- Insert the adapter ring No. 8 in the pins.
- Assemble the driven pulley unit on the tool introducing the rivets heads in the adapter ring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tighten the clutch nut.
- Use the special 46x55 wrench component No. 9
to remove the nut fixing the clutch in place.
- Separate the driven pulley components (Clutch,
fan and spring with plastic fitting).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE
CLAMP AND THE CENTRAL SCREW MUST BE
BROUGHT INTO CONTACT WITH THE TOOL.
EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE.
Specific tooling
020444Y009 46x55 Wrench
020444Y010 adapter ring
ENG - 5
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 CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS
TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Simultaneously turn and pull the collar manually
to remove it.
N.B.
USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY.
N.B.
BE CAREFUL NOT TO PUSH THE SCREW
DRIVERS IN TOO FAR TO AVOID DAMAGE
THAT COULD ENDANGER THE O-RING SEAL.
- Remove the four torque server pins and pull the
pulley halves apart.
ENG - 6
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Removing the driven half-pulley bearing
- Check there are no signs of wear and/or noisiness; - 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.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Support the pulley properly using the bell as shown in the figure.
Specific tooling
001467Y035 Belle for OD 47-mm bearings
- Remove the roller bearing using the modular
punch.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
Inspecting the driven fixed half-pulley
- Measure the outer diameter of the pulley bushing.
- Check the faying surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt faying surface.
Characteristic
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Half-pulley minimum diameter
Minimum admissible diameter Ø 40.96 mm
Wear limit
0.3 mm
ENG - 7
XEVO 125 Euro 3
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.
- Check that the faying surface with the belt is not
abnormally worn.
- Check the riveted joints are functional.
- Check the evenness of the belt faying surface.
MOVABLE DRIVEN HALF-PULLEY DIMENSIONS
Specification
Wear limit
standard diameter
maximum allowable diameter
Refitting the driven half-pulley bearing
- Support the pulley bushing adequately from the
threaded side using a wooden surface.
- Fit a new roller sleeve as in the figure.
- For the fitting of the new ball bearing, follow the
example in the figure using a modular punch.
- Fit the retention ring
WARNING
N.B.
FIT THE BALL BEARING WITH THE VISIBLE
SHIELD
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
ENG - 8
Desc./Quantity
0.3 mm
Diameter 41.000 - 41.035 mm
Ø 41.08 mm
XEVO 125 Euro 3
Engine
020424Y Driven pulley roller casing fitting
punch
Refitting the driven pulley
- Insert the new oil guards and O-rings on the movable half-pulley.
- Lightly grease the O-rings «A» shown in the figure.
- Fit the half-pulley over the bushing using the appropriate tool
- Check that the pins are not worn and proceed to
refitting them in their slots.
- Refit the torque server closure collar.
Using a curved-spout grease gun, lubricate the
driven pulley assembly with approximately 6 g of
grease. Apply the grease through one of the holes
in the bushing until it comes out through the hole
on the opposite side. This operation is necessary
to avoid the presence of grease beyond the Orings.
N.B.
THE TORQUE SERVER CAN BE GREASED
WHETHER WITH BEARINGS FITTED OR
WHEN THEY ARE BEING REPLACED; UNDERENG - 9
Engine
TAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER.
Specific tooling
020263Y Sheath for driven pulley fitting
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
Inspecting the clutch spring
- Measure the length of the spring, while it is relaxed.
Characteristic
Standard length
106 mm
acceptable limit after use:
101 mm
Refitting the clutch
- Support the driven pulley spring compressor appropriate tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed on the inside.
- Insert the adapter ring No. 8 in the pins.
- Preassemble the cooling fan to the clutch in such
a way that the keying facets are aligned and the 3
pin heads «A» of the fulcrum axis can be seen in
full.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the servo-system closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the pulley unit with the belt into the tool.
ENG - 10
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
- Slightly preload the spring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.
- Loosen the tool clamp and insert the belt according 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 pulleys maximum opening and place the belt on the
minimum rolling diameter.
- Remove the driven pulley /belt unit from the tool.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE
SHOULD BE MOUNTED IN CONTACT WITH
THE CLUTCH.
N.B.
DURING THE SPRING PRELOADING PHASE,
BE CAREFUL NOT TO DAMAGE THE PLASTIC
SPRING STOP AND THE BUSHING THREADING.
N.B.
AN EXCESSIVE QUANTITY CAN DAMAGE THE
CLUTCH OPERATION.
Specific tooling
020444Y011 adapter ring
020444Y009 46x55 Wrench
Locking torques (N*m)
Clutch unit nut on driven pulley 55 ÷ 60
ENG - 11
Engine
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
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 check foreseen in the scheduled
maintenance, check that the rim bottom of the
toothing does not show signs of scores or cracking
(see figure); otherwise, replace the belt.
ENG - 12
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Removing the driving pulley
- With the appropriate tool, remove the nut with the
built-in belleville washer, the drive and the steel
washer.
- Remove the fixed driving half-pulley.
- Remove the steel washer separating from the
bushing.
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative
guide pads.
Specific tooling
020368Y driving pulley lock wrench
Inspecting the rollers case
- Check that the internal bushing shown in the figure is not abnormally worn and measure inner
diameter A.
- Measure the pulley sliding bushing outside diameter shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt faying surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
- Check that the O-ring is not pushed out of shape.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED
BUSHINGS
Characteristic
Roller: Standard Diameter
ENG - 13
Engine
Ø 18.9 ÷ 19.1 mm
Sliding bushing: Minimum admissible diameter
Ø 25.95 mm
Movable driving half-pulley bushing: Maximum allowable diameter
Ø 26.12 mm
roller: Standard Diameter
Ø 18.9 ÷ 19.1 mm
Sliding bushing: Standard Diameter
Ø 25.959 ÷ 25.98 mm
Movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
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.
- Mount the complete bushing unit on the driving
shaft.
- Fit the driven pulley/Clutch/belt unit on the engine.
ENG - 14
XEVO 125 Euro 3
XEVO 125 Euro 3
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..
- Rotate the engine manually until the belt is slightly taut.
CAUTION
IT IS EXTREMELY IMPORTANT THAT THE
BELT IS PERFECTLY FREE WHEN THE FIXED
DRIVING HALF-PULLEY IS ASSEMBLED. THIS
IS TO AVOID CARRYING OUT A WRONG
TIGHTENING OF THE DRIVING HALF-PULLEY.
Specific tooling
020368Y driving pulley lock wrench
Locking torques (N*m)
Drive pulley nut 75 ÷ 83
ENG - 15
Engine
Refitting the transmission cover
- Check the presence of the 2 centring dowels and
the correct installation of the sealing gasket for the
oil sump on the transmission cover.
- Replace the cover tightening the 10 screws at the
specified torque.
- Refit the oil loading cap/bar.
- refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Replace the plastic cover.
Specific tooling
020423Y driven pulley lock wrench
Locking torques (N*m)
Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60
End gear
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.
ENG - 16
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Removing the wheel axle
- Remove the wheel axis complete with gear.
- Remove the intermediate gear.
Removing the hub bearings
- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are detected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
001467Y013 Pliers to extract ø 15-mm bearings
ENG - 17
Engine
Removing the wheel axle bearings
Hold up the hub cover and take out the bearing.
Specific tooling
020376Y Adaptor handle
020477Y Adaptor 37 mm
020483Y 30 mm guide
With the appropriate tools, remove the oil seal as
shown in the figure.
Specific tooling
020359Y 42x47-mm adaptor
Removing the driven pulley shaft bearing
When removing the driven pulley shaft, the corresponding bearing and oil seal, remove the transmission cover and the clutch group as explained
above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not
to damage the housing, make it come out of the
belt transmission side.
- Remove the seeger ring shown in the figure
With the sectional punch, remove the driven pulley shaft bearing.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide
ENG - 18
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Inspecting the hub shaft
- Check the three shafts for wear or distortion of
the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged components.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.
- Check the bearing bearings.
- In case of anomalies, replace the damaged components.
Refitting the wheel axle bearing
Support the hub cover on a wooden surface.
- Heat the cover crankcase with special heat gun.
- Fit the wheel shaft bearing with a modular punch
as shown in the figure.
Specific tooling
020150Y Air heater support
020151Y Air heater
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
020483Y 30 mm guide
Assemble the seeger ring.
ENG - 19
Engine
XEVO 125 Euro 3
- Fit the oil guard with seal lip towards the inside
of the hub and place it flush with the internal surface by means of the appropriate tool used from
the 52 mm side.
The 52 mm side of the adapter must be turned towards the bearing.
Refitting the hub cover bearings
To fit the hub housing bearings, the engine crankcase and the cover must be heated with the special heat gun.
- The three 15 mm bearings must be fitted using
the appropriate tools.
- The 42-mm side of the adapter must be turned
towards the bearing.
- Refit the seeger ring with the opening facing the
bearing and the new oil seal flush with the crankcase on the pulley side.
- Refit the driven pulley shaft bearing with a modular punch as shown in the figure.
Specific tooling
020150Y Air heater support
020151Y Air heater
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
020363Y 20 mm guide
N.B.
TO FIT THE BEARING ON THE COVER, SUPPORT THE COVER WITH THE STUD BOLT SET.
ENG - 20
XEVO 125 Euro 3
Engine
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS
ARE VISIBLE FROM THE HUB INNER SIDE.
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE
PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
Refitting the hub bearings
- Install the three shafts in the engine crankcase as shown in the figure.
Refitting the ub cover
- Fit a new gasket together with the centring dowels.
- 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.
- Place the 3 shortest screws, identifiable by their different colour, as shown in the figure.
- Fasten the breather pipe support bracket with the lower short screw.
- Assemble the remaining 4 screws and tighten the 7 screws to the prescribed torque.
Locking torques (N*m)
Rear hub cover screws 24 ÷ 27
ENG - 21
Engine
Flywheel cover
Removing the hub cover
- Remove the two clamps, the two couplings and
empty the cooling system.
- Remove the 4 retainers and the flywheel cover
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.
ENG - 22
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
- Place the cable harness as shown in the figure.
- Stator screws and Pick-Up
N.B.
THE PICK-UP WIRE SHOULD BE POSITIONED
BETWEEN THE UPPER SCREW AND THE REFERENCE PIN AS SHOWN IN THE DETAIL
DRAWING.
Locking torques (N*m)
Stator assembly screws (°) 3 ÷ 4
Refitting the flywheel cover
- 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.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE
FLYWHEEL CONNECTOR. MAKE SURE THE
CENTRING DOWELS ARE PRESENT.
Flywheel and starting
ENG - 23
Engine
XEVO 125 Euro 3
Removing the flywheel magneto
- Lock the rotation of the Flywheel with the calliper
spanner.
- Remove the nut.
- Take out the flywheel.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER
THAN THE ONE SUPPLIED COULD DAMAGE
THE STATOR COILS
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
÷ 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up support.
N.B.
A VARIATION IN THE AIR GAP DISTANCE
MODIFIES THE IGNITION SYSTEM IDLE
SPEED
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 24
XEVO 125 Euro 3
Engine
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, locking the two
screws to the prescribed torque.
Locking torques (N*m)
Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
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.
SCREWS AGAINST ACCIDENTAL OPERATION ARE PROVIDED.
ENG - 25
Engine
Removing the rocker-arms cover
- Remove the 5 screws indicated in the figure
Removing the timing system drive
- First remove the following units:
transmission cover, driving pulley with belt, oil
sump with spring and by-pass piston, oil pump
pulley cover, O-ring on the crankshaft and the
sprocket wheel separation washer.
- Remove the tappet cover.
- 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 tensioner with its gasket.
ENG - 26
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the camshaft control pulley with its
washer.
- Remove the command sprocket wheel and the
timing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner slider.
The chain tensioning pad must be removed from
the transmission side. As regards the lower chain
guide pad, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Removing the cam shaft
- Remove the two screws and the cam shaft retainer shown in the diagram.
ENG - 27
Engine
- Remove the cam shaft.
- Remove the pins and the rocker arms from the
flywheel side holes.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING
SHAFT CHAIN TIGHTENER.
ENG - 28
XEVO 125 Euro 3
XEVO 125 Euro 3
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.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING
SHAFT CHAIN TIGHTENER.
Removing the valves
- Using the appropriate tool fitted with an adaptor,
remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool.
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS
TO RECOGNISE THEIR ORIGINAL POSITION
ON THE HEAD.
Specific tooling
020382Y011 adapter for valve removal tool
020382Y Valve cotters equipped with part 012
removal tool
020306Y Punch for assembling valve seal
rings
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.
ENG - 29
Engine
XEVO 125 Euro 3
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.
ENG - 30
XEVO 125 Euro 3
Engine
Inspecting the small end
- Measure the internal diameter of the rod 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
Rod small end check-up: Standard diameter
15 +0.015+0.025 mm
Inspecting the wrist pin
- Measure the outer diameter of the gudgeon pin.
- Calculate the coupling clearance between pin
and connecting rod end.
- Measure the capacity diameter on the piston.
- Calculate the piston pin coupling clearance.
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
- Carry out the measurement as shown in the figure.
41.1 mm (from the crown)
- Using a bore meter, measure the inner cylinder
diameter at three different points according to the
directions shown in the figure.
- Check that the head matching surface exhibits no
deformations or wear.
Maximum admissible displacement: 0.05 mm
- Pistons and cylinders are classified according to
diameter (0.2 - 0.4 - 0.6 m). The coupling is carried
out in pairs (A-A, B-B, C-C, D-D).
- The cylinder rectifying operation should be carried out with a surfacing that respects the original
angle.
ENG - 31
Engine
- The cylinder surface roughness should be 0.9
micron.
- This is indispensable for a good seating of the
sealing rings, which in turn minimises oil consumption and guarantees optimum performance.
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.
Characteristic
Pin diameter Standard diameter:
56.997 ÷ 57.025
piston diameter
56.945 ÷ 56.973 mm
Pin diameter: Standard clearance
0.015 ÷ 0.029 mm
Pin diameter Standard diameter
14.996 - 15.000 mm
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
ENG - 32
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Inspecting the piston
- Carefully clean the seal housings.
- Measure the coupling clearance between the
seal rings and the grooves using suitable sensors,
as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
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 - 33
Engine
XEVO 125 Euro 3
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 - 34
XEVO 125 Euro 3
Engine
Choosing the gasket
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool.
Specific tooling
020428Y Piston position check support
- 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.
- By means of the table shown in the specifications
chapter identify the cylinder base gasket thickness
to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct
compression ratio.
- Remove the specific tool and the cylinder.
N.B.
MEASURE PISTON PROTRUSION.
ENG - 35
Engine
XEVO 125 Euro 3
Refitting the piston 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.
The chamfered side of the oil scraper ring should
always be facing the piston crown.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'TOP' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A
TAPERED CYLINDRICAL CONTACT CROSSSECTION. THIS IS TO ACHIEVE A BETTER
BEDDING.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL
THE CYLINDER BARREL.
Specific tooling
020393Y Piston fitting band
020287Y Clamp to assemble piston on cylinder
ENG - 36
XEVO 125 Euro 3
Engine
Inspecting the cylinder head
- Using a trued bar and feeler gauge check that the
cylinder head surface is not worn or distorted.
Maximum allowable run-out: 0.05 mm
- Check that the camshaft and the rocker pin capacities exhibit no wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
bearing «A»
Ø 12.000 - 12.018 mm
bearing «B»
Ø 20.000 ÷ 20.021 mm
bearing «C»
Ø 37.000 - 37.025 mm
ENG - 37
Engine
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Ensure that the camshaft control pulley chain assembly and the sprocket wheel are not worn.
- If you encounter wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn replace
the whole assembly.
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
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.
ENG - 38
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Inspecting the valve housings
- Check the width of the mark on the seat of valve
«V».
- Remove any carbon formation from the valve
guides.
- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights
in the rocker arm push direction.
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the specified limits, replace the cylinder head.
Characteristic
Max. wear limit
1.6 mm
Valve seat wear Intake guide
limit accepted: 5.022
Valve seat wear Intake guide
Standard diameter: 5.000 ÷ 5.012 mm
Valve seat wear Exhaust guide
Accepted limit 5.022
Valve seat wear Exhaust guide
Standard diameter: 5.000 ÷ 5.012 mm
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 surface of contact with the articulated register terminal.
- If the checks above give no failures, you can use
the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently
with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the
ENG - 39
Engine
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 COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE
VALVES WITH A SUITABLE PRODUCT FOR
THE TYPE OF LAPPING COMPOUND BEING
USED.
N.B.
DO NOT CHANGE THE POSITIONS THE
VALVES ARE FITTED IN
Characteristic
Valve check standard length
Outlet: 94.4 mm
Valve check standard length
Inlet: 94.6 mm
Valve check Maximum admissible clearance
Outlet: 0.072 mm
Valve check Maximum admissible clearance
Inlet: 0.062 mm
Valve check standard clearance
Outlet: 0.025 ÷ 0.052 mm
Valve check standard clearance
Inlet: 0.013 ÷ 0.040 mm
Valve check Minimum admissible diameter
Outlet: 4.95 mm
Valve check Minimum admissible diameter
Inlet: 4.96 mm
Valve check Standard diameter:
Inlet: 4.972 ÷ 4.987 mm
Valve check Standard diameter:
Outlet: 4.96 ÷ 4.975 mm
ENG - 40
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Inspecting the springs and half-cones
- Check that the upper and lower supporting washers of the springs, the cotters and the oil seal do
not show signs of abnormal wear.
- Replace the components when worn.
ENG - 41
Engine
Refitting the valves
- Lubricate the valve guides with engine oil.
- Place the valve spring supports on the head.
- Using the special punch, fit the four valve seals.
- Fit the valves, the springs and the caps. Using
the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE
REFERENCE COLOUR ON COTTER SIDE
(TURNS WITH GREATER PITCH).
Specific tooling
020306Y Punch for assembling valve seal
rings
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear
on the cams.
- Check the cam height.
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- Check there are no signs of wear on the automatic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check the rocker pins do not show signs of wear
or scoring.
ENG - 42
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
- Measure the internal diameter of each rocker
arm.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
Characteristic
Internal rocker arm diameter: Standard diameter
Diameter 12.000 - 12.011 mm
Rocker arm pin diameter: Standard diameter
Diameter 11.977 - 11.985 mm
Cam shaft check: Maximum admissible axial
clearance
0.42 mm
Cam shaft check: Standard axial clearance:
0.11 - 0.41 mm
Cam shaft check: Standard height
Outlet: 29.209 mm
Cam shaft check: Standard height
Inlet: 30.285 mm
Cam shaft check: Minimum admissible diameter
Bearing B diameter: 19.950 mm
Cam shaft check: Minimum admissible diameter
Bearing A Ø: 36.94 mm
Cam shaft check: Standard diameter
Bearing B diameter: 19.959 ÷ 19.98 mm
Cam shaft check: Standard diameter
Bearing A Ø: 36.95 ÷ 36.975 mm
ENG - 43
Engine
XEVO 125 Euro 3
Refitting the head and timing system components
- Fit the timing chain guide pad.
- Insert the centring dowel between the cylinder
head to the cylinder, fit the cylinder head gasket
and the cylinder head.
- Lubricate the stud bolt threading.
- Tighten up the nuts to a pre-torque of 7±1 N·m
- Rotate by a 180° angle (2 rotations of 90° each)
- To carry out the operations described above, follow the tightening sequence in the figure.
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE
SURE THAT THE LUBRICATION CHANNEL IS
CLEAN USING A COMPRESSED AIR JET.
Locking torques (N*m)
Timing chain tensioner support screw 11 ÷ 13
Assemble 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.
- Fit the spacer and the screw fastener.
- Tighten the screws to the prescribed torque.
Locking torques (N*m)
Slider screw 10 ÷ 14 Nm
ENG - 44
XEVO 125 Euro 3
Engine
Fit the pins and rocking levers.
- Lubricate the two rocking levers through the
holes at the top.
- Lubricate the 2 bearings and insert the cam shaft
in the cylinder head with the cams corresponding
to the rockers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed torque.
Locking torques (N*m)
Plate screws 4 ÷ 6 Nm
ENG - 45
Engine
Insert the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- Holding this position insert the chain on the camshaft control pulley.
- Insert the pulley on the cam shaft while keeping
the reference 4V in correspondence with the reference mark on the head.
- Assemble the counterweight with the corresponding fixing screw and tighten to the prescribed
torque.
Locking torques (N*m)
Counterweight screw 7 ÷ 8.5
Fit the end-of stroke ring on the valve-lifting mass
and fit the automatic valve-lifting cam to the camshaft.
N.B.
LUBRICATE WITH GREASE THE END-OFSTROKE RING IN ORDER TO AVOID ACCIDENTAL LEAKS THAT MAY FALL INTO THE
ENGINE. ASSEMBLE THE AUTOMATIC
VALVE-LIFTER RETURN SPRING. DURING
THIS OPERATION THE SPRING MUST BE LOADED AT APPROXIMATELY 180°.
Assemble the limiting bell using the counterweight
fixing screw as a reference.
- Tighten the clamping screw to the prescribed torque.
Locking torques (N*m)
Limiting bell screw 11 ÷ 15 Nm
ENG - 46
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Set the tensioner cursor to the rest position.
- Fit the chain tensioner on the cylinder, using a
new gasket, and tight the two screws to the prescribed torque.
Insert the chain tensioning screw, together with the
spring and washer, tightening it to the prescribed
torque.
Locking torques (N*m)
Tensioner screws 11 ÷ 13 Tensioner cover 5 ÷
6 Nm
Adjust valve clearance
- Fit the spark plug.
Locking torques (N*m)
Spark plug 12 ÷ 14
Characteristic
Electrode distance
0.8 mm
Refit the cylinder head cover, tightening the 5 screws to the prescribed torque. Make sure the gasket
is positioned properly.
Remove the flywheel cover completely as already described in the flywheel chapter.
- Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as
described in the lubrication chapter.
- Reassemble the driving pulley, the belt and the transmission cover as described in the transmission
chapter.
Locking torques (N*m)
Tappet cover screws 6 - 7 Nm
TIMING SYSTEM COMPONENTS ASSEMBLY
Name
Tappet cover screws
Spark plug
Tensioner cover
Tensioner screws
Limiting bell screw
Counterweight screw
Plate screws
Slider screw
Torque in Nm
6 - 7 Nm
12 ÷ 14
5 ÷ 6 Nm
11 ÷ 13
11 ÷ 15 Nm
7 ÷ 8.5
4 ÷ 6 Nm
10 ÷ 14 Nm
ENG - 47
Engine
XEVO 125 Euro 3
Refitting the intake manifold
- Fit the intake manifold and tighten the three
screws.
N.B.
FOR SPECIAL SCREWS USE COMMERCIALLY
AVAILABLE INSERTS AND INSERT HOLDERS.
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.
- Remove the oil sump, the by-pass, the chain
compartment cover and the oil pump as in the lubrication chapter.
- Remove the flywheel cover together with the water pump, the flywheel and the stator as described in
the magneto flywheel chapter.
- Remove the oil filter and the oil pressure switch.
- Remove the cylinder/piston/head unit as described in the cylinder head timing system chapter.
- Remove the two retainers indicated in the figure and the starter motor.
Before opening the engine crankcase, it is advisable to check axial clearance of the crankshaft. To
do this, use a plate and a support with appropriate
tool dial gauge.
Higher clearances are signs of wear on the supporting surfaces of the crankshaft casing.
Characteristic
Standard clearance:
0.15 ÷ 0.40 mm
ENG - 48
XEVO 125 Euro 3
Engine
- Remove the eleven crankshaft coupling screws.
- Separate the crankcase while keeping the crankshaft 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. IF YOU FAIL TO DO THIS, THE
CRANKSHAFT MIGHT ACCIDENTALLY FALL.
- Remove the coupling gasket of the crankcase
halves.
- Remove the two screws and the internal cover
shown in the diagram.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING THE DRIVING SHAFT, CHECK THAT
THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE
TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS.
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram
Fitting clearance
Connecting rod axial clearance 0.20 - 0.50
ENG - 49
XEVO 125 Euro 3
Engine
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
N.B.
WHEN MEASURING THE WIDTH OF THE
CRANKSHAFT, MAKE SURE THAT THE MEASUREMENTS ARE NOT MODIFIED BY THE RADIUSES OF FITTINGS WITH THE CRANKSHAFT
BEARINGS.
Characteristic
Standard clearance:
0.036 ÷ 0.054 mm
Standard dimensions:
55.75 ÷ 55.90 mm
The crankshaft can be reused when the width is
within the standard values and the surfaces show
no signs of scoring.
N.B.
IN CASE OF NEW UTILISATION, MAINTAIN
THE FIRST FITTING POSITION.
If the axial clearance between crankshaft and crankcase exceeds the standard and the crankshaft does
not have any defect, the problem must be due to either excessive wear or wrong machining on the
engine crankcase.
Check the diameters of both bearings of the crankshaft according to the axes and surfaces shown in
the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart
below.
STANDARD DIAMETER
Specification
Standard diameter - Category 1
Standard diameter - Category 2
ENG - 50
Desc./Quantity
28.994 ÷ 29.000
29.004 ÷ 29.010
XEVO 125 Euro 3
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.
- In case of failures, replace the crankshaft.
The connecting rod head bushings cannot be replaced. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
ENG - 51
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 compartment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the transmission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the flywheel side oil seal.
- Inspect the coupling surfaces on the crankcase
halves for scratches or deformation, taking particular care with the cylinder/crankcase surfaces and
the crankcase halves surfaces.
- Defects in the crankcase coupling gasket between the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bearings and connection rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and dimensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE PISTON TOP COOLING.
CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE
INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING
ENG - 52
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
AND CONNECTING ROD LUBRICATION PRESSURE.
N.B.
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A
"LOW PRESSURE" HEAD LUBRICATION; THIS
CHOICE WAS MADE TO REDUCE THE OIL
TEMPERATURE IN THE SUMP. THE JET
CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET
FAILURE CAUSES A DECREASE OF THE MAIN
BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.
Inspecting the crankshaft plain bearings
-T
o obtain a good bushing lubrication it is necessary
to have both an optimal lubricating pressure (3,2
bar) and a good oil flow rate; the bushings must be
correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one with holes and channels for lubrication whereas the other is solid.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason
it is arranged opposite the cylinder.
- To prevent obstructions in the oil feeding channels, the matching surface of the two half-bearings
must be perfectly perpendicular to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected
by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings
in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing
half. see diagram.
- There are three crankcase versions: with RED
main bushings, with BLUE main bushings and with
YELLOW main bushings.
ENG - 53
XEVO 125 Euro 3
Engine
- There is only one type of main bushing housing
hole in the crankcase
The standard bushing diameter after driving is variable on the basis of a coupling selection.
- The bushing housings in the crankcase are available in two categories, Cat. 1 and Cat. 2, as are
the crankshafts.
- The main bushings are available in three thickness categories, identified by colour markings, as
shown in the table below.
TYPE
IDENTIFICATION
A
RED
B
BLUE
C
YELLOW
Type "A" Type "B" Type "C"
- RED
- BLUE
- YELLOW
Crankshaft
1.970 ÷
1.9703 ÷
1.976 ÷
half-bearing
1.973
1.976
1.979
Bush-
Crank-
Internal bush-
Possible
ing cat-
case
ing diameter
fitting
egory
halves
after fitting
category
A
1
29.025 ÷
Original
29.040
B
1
2
29.019 ÷
Original
29.034
and spare
29.028 ÷
29.043
C
2
29.022 ÷
Original
29.037
Match the shaft with two category 1 crank webs
with the category 1 crankcase (or cat. 2 with cat.
2) Furthermore a spare crankcase cannot be
matched with a crankshaft with mixed categories.
The spare crankshaft has half shafts of the same
category.
ENG - 54
XEVO 125 Euro 3
Engine
Crankcase
Engine half
Bushing
halves
shaft
Cat. 1
Cat. 1
B
Cat. 2
Cat. 2
B
Cat. 1
Cat. 2
A
Cat. 2
Cat. 1
C
N.B.
TO KEEP THIS POSITION OF THE BUSHINGS
ON THE CRANKCASE, FITTING IS FORCED ON
STEEL RINGS INSERTED IN THE CASTING OF
BOTH CRANKCASE HALVES.
N.B.
DO NOT TAKE THE MEASUREMENT ON THE
TWO HALF-SHELL COUPLING SURFACE
SINCE THE ENDS ARE RELIEVED TO ALLOW
BENDING DURING THE DRIVING OPERATION.
N.B.
CRANKCASES FOR REPLACEMENTS ARE
SELECTED WITH CRANKCASE HALVES OF
THE SAME CATEGORY AND ARE FITTED
WITH CATEGORY B BUSHINGS (BLUE)
Characteristic
Standard driving depth
1.35 ÷ 1.6
Diameter of crankcase without bushing
32.953 ÷ 32.963
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two
screws to the prescribed torque.
- Fit the oil filter fitting and tighten it to the specified
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, together with the locating dowels.
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
- Fit the 10 screws and tighten them to the prescribed torque.
- Fit a new O-ring on the pre-filter and lubricate it.
ENG - 55
Engine
- Insert the filter on the engine with the relative cap.
Tighten to the prescribed torque.
Locking torques (N*m)
Internal engine crankcase bulkhead (transmission-side half shaft) screws 4 ÷ 6 Enginecrankcase coupling screws 11 ÷ 13 Oil filter on
crankcase fitting 27 ÷ 33 Engine oil drainage
plug/mesh filter 24 ÷ 30
Lubrication
Conceptual diagrams
LUBRICATION CIRCUIT
ENG - 56
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
ENG - 57
Engine
1. Engine throttle recovery
2. Tappet cover
3. Crankshaft
4. By-pass valve
5. Oil filler
6. Oil level in the sump
7. Oil pump
8. Mesh pre-filter
9. Cartridge filter
10. Minimum pressure switch
Oil pressure check
- After removing the flywheel cover as described
in the "Flywheel" chapter, remove the electric connexion of the minimum oil pressure switch and
then remove the switch.
- Install the special tool.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 ÷ 1.2 atm.
- With the engine idling at 6000 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 3.2 ÷ 4.2 atm.
- Remove the specific tool once the check is complete, refit the oil pressure switch and its washer,
tighten the washer to the prescribed torque and fit
the flywheel cover.
- If the oil pressure is not within the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH
OIL AT THE CORRECT LEVEL AND WITH AN
OIL FILTER IN GOOD CONDITION.
Specific tooling
020193Y Oil pressure gauge
Characteristic
ENG - 58
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.
Locking torques (N*m)
Minimum oil pressure sensor 12 ÷ 14
Crankshaft oil seals
Removal
- First remove the transmission cover and the complete driving pulley
- Install the base of the appropriate tool on the oil
guard using the screws provided.
Specific tooling
020622Y Transmission-side oil guard punch
ENG - 59
Engine
- Screw the threaded bar onto the base of the tool
and extract the oil guard.
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
- Use a new oil seal upon refitting.
- Prepare the new oil seal, lubricating the sealing
lip.
- Preassemble the oil seal with the specific tool,
positioning the screws.
- Place the sheath over the crankshaft.
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase.
- 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.
- Remove all of the tool components following the
inverse procedure
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO THE ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL GUARD BY POSITIONING
THE CHAIN HOUSING CHANNEL FACING
DOWNWARDS. WHEN THE POSITION IS
REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS
RULE CAN CAUSE A WRONG POSITIONING
OF THE OIL GUARD SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY
PROCEDURE CAN SERIOUSLY DAMAGE THE
ENGINE DUE TO THE WRONG TENSIONING
OF THE OIL PUMP CONTROL CHAIN.
ENG - 60
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Specific tooling
020622Y Transmission-side oil guard punch
Removal
- Remove the cover of the pump control pulley using the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley
inserting a screwdriver through one of its two
holes.
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain.
- Remove the control sprocket with relative O-ring.
- Remove the oil pump by unscrewing the two
screws in the figure.
ENG - 61
Engine
- Remove the oil pump seal.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.
- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the
clip.
- Check the clearance between the rotors in the
position shown in the diagram.
Measure the distance between the outer rotor and
the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.
Characteristic
Axial rotor clearance
Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm
ENG - 62
XEVO 125 Euro 3
XEVO 125 Euro 3
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.
- Fit the pump cover in the position that permits the
crankcase fixing screws to be aligned.
- Make sure the gasket is positioned properly and
refit the pump on the engine crankcase. The pump
can only be fitted in one position. - Tighten the
screws to the prescribed torque.
- Fit the sprocket wheel with a new O-ring.
- Fit the chain.
- Fit the central screw and the belleville washer.
Tighten to the prescribed torque.
- Fit the oil pump cover by tightening the two
screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS
OUTER RIM TOUCHES THE PULLEY. MAKE
SURE THAT THE PUMP TURNS FREELY.
Locking torques (N*m)
Screws fixing oil pump to the crankcase 5 - 6
Oil pump control crown screw 10 ÷ 14 Oil pump
cover screws 0.7 ÷ 0.9
ENG - 63
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 "Transmission" chapter.
- Drain the oil as described previously.
- Remove the seven screws, shown in the diagram, and the two rear brake fluid pipe fixing
brackets.
- Remove the screw, the by-pass piston, the gasket and centring dowels shown in the figure.
Inspecting the by-pass valve
- Check the unloaded spring length.
- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defective parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 64
XEVO 125 Euro 3
XEVO 125 Euro 3
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.
- Refit the rear brake cable brackets and the
screws in the reverse order from which they were
removed.
- Tighten the screws to the prescribed torque.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as described in the "Transmissions" chapter.
- When testing the lubrication system, refer to
chapter "Crankcase and Crankshaft", regarding lubrication of the crankshaft and connecting rod
Locking torques (N*m)
Oil sump screws 10 ÷ 14
SAS valve
Inspecting the one-way valve
- Remove the SAS valve.
- Provisionally assemble the rubber coupling of the
SAS valve outlet to ensure tightness.
- Connect the MITYVAC vacuum pump to the rubber coupling as shown in the photograph.
- Set the pump to the low-pressure position (VACUUM).
- Operate the pump slowly.
- Check that the one way valve allows the air to
pass through causing a slight vibration.
ENG - 65
Engine
- Switch the pump to pressure mode (PRESSURE).
- Operate the pump slowly and check if there is an
increase of pressure. A small leakage is considered to be normal.
If anomalies are detected, replace the pump.
N.B.
A MALFUNCTIONING ONE-WAY VALVE CAN
RESULT IN RUBBER COUPLING AND FILTER
OVERHEATING
N.B.
ABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING
Specific tooling
020329Y MityVac vacuum-operated pump
Inspecting the cut-off
- Remove the SAS valve.
- Connect the MITYVAC pump in low-pressure
mode (VACUUM) to the CUT-OFF valve vacuum
intake.
- Apply a vacuum value higher than 0.5 BAR.
- Check that this value is kept all the time.
- If a worn seal is detected, replace it.
- With a "T" bypass and flexible rubber hoses make
a parallel connection between the rubber coupling
and the vacuum intake of the CUT-OFF valve.
- Connect the bypass to the MITYVAC pump.
- Set the pump set to the low-pressure mode
(VACUUM).
- Using a pair of long flat pliers, choke the rubber
hose next to the valve.
- Operate the pump until vacuum is higher than 0.5
BAR.
- Release the hose and check how the vacuum reacts. - Under normal functioning conditions the
vacuum undergoes a slight fall and then readjusts.
There follows a slow and continuous loss of depression up to approximately 0.4 BAR. At this point
ENG - 66
XEVO 125 Euro 3
XEVO 125 Euro 3
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). INCORRECT CUT-OFF
VALVE CALIBRATION CAN RESULT IN CATALYTIC CONVERTER MALFUNCTIONING
N.B.
A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES JEOPARDISING THE CORRECT OPERATION OF THE CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING
Specific tooling
020329Y MityVac vacuum-operated pump
Fuel supply
- To clean the filtering element proceed as follows: remove the cover and take out the paper filtering
element, clean with compressed air and refit.
- Make sure the filtering element is in the correct position.
- Check that the air passage sections are not damaged or deformed.
- Check the correct sealing of the coupling between the filter housing and the cover.
N.B.
FAILURE TO OBSERVE THESE INSTRUCTIONS MAY RESULT IN WRONG VACUUM INSIDE THE
FILTER HOUSING, WHICH IN TURN MAY PRODUCE VARIATIONS IN CARBURETION.
Removing the carburettor
ENG - 67
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.
- Take out the carburettor and rotate it so as to
remove the screw with the water joint and the
pipes.
N.B.
THIS LAST OPERATION IS NECESSARY SO
AS NO TO EMPTY THE COOLING SYSTEM.
- Remove the protection, the bracket and the starter acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with
the gasket.
ENG - 68
XEVO 125 Euro 3
XEVO 125 Euro 3
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.
- Remove the vacuum valve together with the diaphragm.
ENG - 69
Engine
- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle
- Remove the 4 screws indicated in the figure.
- Remove the chamber with the accelerating
pump, its control and gasket.
ENG - 70
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
- Remove the oil pump seal.
- Remove the intake and outlet valves of the intake
pump from the tank
N.B.
CAUTION, THE ACCELERATION PUMP
VALVES ARE MADE UP OF NOZZLES, SPRING
AND BALL.
N.B.
AVOID REMOVING THE PISTON OF THE PUMP
AND ITS CONTROL.
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.
ENG - 71
Engine
-Remove diffuser.
- Remove the sprayer.
N.B.
WHEN CLEANING THE CARBURETTOR BODY
REMOVE THE SPRAYER TO AVOID LOSING
PARTS. IF THE SPRAYER IS FORCED IN ITS
HOUSING DO NOT ATTEMPT TO REMOVE IT
AS THIS WILL ONLY DAMAGE IT.
ENG - 72
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
-Remove the minimum nozzle.
- 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. DO NOT REMOVE
THROTTLE-SHAFT CONNECTION SCREWS.
THE FIXING SCREWS ARE CAULKED AFTER
ASSEMBLY AND THEIR REMOVAL DAMAGES
THE SHAFT.
Refitting the carburettor
Kehin
- Before refitting, wash the carburettor body accurately with petrol and compressed air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
ENG - 73
Engine
XEVO 125 Euro 3
- For maximum circuit, check the air adjustment is
correct as shown in the figure.
- 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.
- Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
- Check that the coupling surfaces, the tank and the diaphragm are not dented.
-Check that the depression valve housing pipe is not scratched.
- Check that the throttle valve and the shaft do not show abnormal wear.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
ENG - 74
XEVO 125 Euro 3
Engine
- Wash and blow the minimum nozzle properly and
reassemble it.
- Properly wash and blow the components of the
sprayer maximum circuit, the diffuser and the nozzle.
- 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.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs
of wear on the sealing surfaces of the shock absorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
- Replace it in case of anomalies.
- Introduce the float with the rod on the fuel feeding tube side.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
ENG - 75
XEVO 125 Euro 3
Engine
- Remove the drainage screw from the tank, wash
and blow it properly and make sure the acceleration pump pipes are clean.
- Operate the acceleration pump piston repeatedly
and blow with compressed air.
- Reassemble the acceleration pump valves following this order:
INTAKE VALVE (A)
•
Spring
•
Ball
•
Nozzle
IN VALVE (M)
•
Ball
•
Spring
•
Nozzle
N.B.
THE IN VALVE NOZZLE, CORRESPONDING
TO THE ACCELERATION PUMP, IS MILLED.
-Check the screw tightness introducing a small
amount of fuel in the tank.
- Assemble a new gasket on the tank.
- Assemble the tank on the carburettor body fastening the 4 screws.
- Check that the control roller is free to rotate in its
own seat.
N.B.
MAKE SURE THE TANK GASKET IS CORRECTLY INTRODUCED
N.B.
AVOID DEFORMING THE ACCELERATION
PUMP CONTROL ROCKING LEVER.
- Wash and blow the flow screw properly.
- Check that screw is not deformed and/or rusty.
- Assemble the spring on the screw.
- Screw the flow screw on the carburettor body.
- The screw final position should be determined by an exhaust fume analysis.
ENG - 76
XEVO 125 Euro 3
Engine
- Adjust the carburettor by turning the screw twice from the close position.
Level check
Kehin
- Place the carburettor inclined as shown in the
figure.
- Check that the float reference is parallel to the tank coupling surface
- If different positions are detected, change the plunger control metal plate direction to obtain the position
described above.
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.
- Insert the tapered pin into the vacuum valve
housing.
- Reassemble the vacuum valve on the carburettor
body taking care that the tapered pin is inserted
into the sprayer.
N.B.
THE VALVE CAN BE INSERTED IN ONLY ONE
POSSIBLE POSITION.
ENG - 77
Engine
- Reassemble the spring with the pin lock.
- Remove the cover of the vacuum chamber being
careful to correctly insert the spring in its place on
the cover.
- Tighten the screws.
- Wash and blow dry the filter sponge of the ambient pressure intake.
ENG - 78
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
- Reassemble the filter with its clamp.
- Wash and blow dry the starter support.
Assemble a new gasket on the carburettor body
and tighten the 2 fixing screws.
Inspecting the automatic choke device
Kehin
- Check that the automatic starter piston is not deformed or rusty.
- Check that the piston slides freely from the seat
to the support.
- Check that the piston sealing gasket is not deformed.
- The starter must be more or less functional depending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the ambient temperature.
- The starter should disconnect progressively by
means of electric heating.
ENG - 79
Engine
- Check the starter resistance when adjusted to the
ambient temperature.
With a 12V battery power the automatic starter and
check that the piston protrudes as much as possible.
- The correct warm up time depends on the ambient temperature.
- If protrusion, resistance or timing values are different from the ones prescribed, replace the starter.
- Assemble the starter to the carburettor being
careful to position the O-Ring correctly, insert the
plate with the machined side contacting the starter,
tighten the fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
N.B.
TO CARRY OUT THIS CHECK PAY SPECIAL
ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE
STARTER.
Characteristic
Starter pin travel
10
Starter device resistance
~ 20 Ω
Check the automatic starter: Keihin maximum
time
5 min
ENG - 80
XEVO 125 Euro 3
XEVO 125 Euro 3
Engine
Adjusting the idle
- The engine does not require frequent idle speed
adjustments, but it is essential to strictly follow certain rules when adjusting the idle speed.
- Before adjusting the carburettor make sure to respect the lubrication requirements, valve clearance, and complying timing, spark plug should be
in optimum conditions, air filter clean and sealed,
and the exhaust system tight.
- Warm up the engine by running it at least 5 minutes at approximately 50 kph.
- Connect a millimetre thermometer (020331y) on
the sump, using a cover with oil expressly prepared for probes.
- Start the engine and before adjusting the idle
speed, make sure that the oil temperature is between 70÷80 °C.
- Using the rpm indicator of the analyser or an independent one (020332y), adjust the idle set
screw until 1600 ÷ 1700 rpm is obtained.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS
MAY NOT BE ACCURATE IF INADEQUATE
RPM INDICATORS ARE USED. CORRECT
COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN READ RPM OVER
6000 ÷ 8000
ENG - 81
Engine
ENG - 82
XEVO 125 Euro 3
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
XEVO 125 Euro 3
This section is devoted to operations that can be carried out on the suspension.
Front
Removing the front wheel
- Remove the fixing nut from the wheel axle on the
left side of the vehicle.
- Loosen the two screws fixing the wheel axle
clamp and remove the clamp.
Front wheel hub overhaul
Check that the wheel bearings do not show signs
of wear.
If you have to replace the wheel bearings, proceed
as follows:
- Remove the plastic cover facing the disc brake
side to avoid causing damages, by loosening the
five fixing screws.
- Remove the two bearings using pliers 14 or 34
and the special bell 9.
- Remove the internal spacer.
SUSP - 2
XEVO 125 Euro 3
Suspensions
- Support the front wheel with two wooden shims
that make it possible to avoid scratching in the
case of contact with the rim.
- Insert the punch, consisting of adaptor handle,
24-mm adaptor and 15-mm guide, from the opposite side to the brake disc to facilitate removing the
disc-brake side bearing and the spacer bushing.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020412Y 15 mm guide
- Heat the bearing seat on the side the brake disc
with the heat gun.
- Insert the bearing using the punch consisting of
adaptor handle, 42x47 mm adaptor and 15 mm
guide, and drive it up to the stop.
SUSP - 3
Suspensions
- Reinsert the spacer bushing on the brake disc
side using the appropriate tool and take it to the
stop.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
020201Y Spacer bushing driving tube
- Turn over the wheel and insert the internal spacer
with the part fitted with the Seeger ring facing the
bearing on the brake disc side installed previously.
- Heat the bearing seat on the side opposite the
brake disc with the heat gun.
- Insert the two bearings using the punch consisting of adaptor handle, 32x35 mm adaptor and 15
mm guide, and drive it up to the stop.
Specific tooling
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
SUSP - 4
XEVO 125 Euro 3
XEVO 125 Euro 3
Suspensions
- Refit the cap and tighten the five fixing screws.
Refitting the front wheel
- Carry out the operations described in the «removal» section but in reverse order.
Locking torques (N*m)
Wheel axle nut 45 ÷ 50 Wheel axle clamp
screws 6 - 7 Nm
Handlebar
Removal
•
Remove the 3 handlebar covers as explained in the «Bodywork» Chapter.
•
Remove the handlebar wiring fixing
clips and disconnect the electric connectors from the brake levers.
•
Unscrew the fittings, then remove the
front and rear brake pump piping.
•
Remove the flexible transmission of
the accelerator and remove the throttle.
•
Loosen the clamp fixing the handlebar
to the steering tube and pulling upwards, remove the handlebar, then remove the lower plastic cover.
N.B.
SUSP - 5
Suspensions
XEVO 125 Euro 3
IF THE HANDLEBAR IS BEING REMOVED TO
REMOVE THE STEERING, IT IS ONLY NECESSARY TO TILT THE HANDLEBAR FORWARD
ONTO THE FRONT PART OF THE VEHICLE
WITHOUT REMOVING THE PARTS FITTED SO
AS TO AVOID DAMAGING THE SHAFTS.
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
Front fork
Removal
- Remove the front wheel.
- Remove the handlebar and tip it onto the shield back plate being careful not to damage the plate.
- Using the appropriate tool, loosen and remove
the upper ring nut, the space washer, the counter
ring nut and the spacer ring.
- Extract the fork.
N.B.
TAKE CARE TO SUPPORT THE FORK SO AS
TO PREVENT IT FROM COMING OFF ABRUPTLY
Specific tooling
020055Y Wrench for steering tube ring nut
See also
Removing the front wheel
Overhaul
- With the 10 mm hexagonal wrench for internal
parts loosen the upper stem closing cap.
SUSP - 6
XEVO 125 Euro 3
Suspensions
- Loosen the stem support clamp and remove fork
leg and stem.
- Remove the first spring consisting of 15 windings.
- Remove the spring support plate.
- Remove the second spring consisting of 21 windings.
- Drain the oil.
- Separate the stem from the leg by removing the
screws with copper washer shown in the figure. To
prevent the rotation of the pumping insert a 12 mm
hexagonal wrench for internal parts in the stem.
- Remove the dust guard ring using a screwdriver
as shown in the figure.
- Remove the oil guard safety lock using a screwdriver.
- Using the appropriate special tool, remove the oil
seal.
- Insert the tie rod complete with cable into the oil
guard.
- Insert the two half rings for diameter 35 mm
stems.
SUSP - 7
XEVO 125 Euro 3
Suspensions
- Keeping the tie rod in vertical position, insert the
bell for the Ø 35 mm stems.
- Insert the nut in the thread and take out the oil
guard
Specific tooling
020487Y Fork oil seal extractor
SPRING LENGTH CHECK
Specification
Standard length
Standard length
Allowable limit after use:
Allowable limit after use:
Desc./Quantity
15 winding spring: 116.3 + 2-1 mm
21 winding spring: 175.7 + 2-1 mm
15 winding spring: 114.3 mm
21 winding spring: 173.7 mm
Check there are no signs of wear or seizing up between the stem and the leg. If there are, replace the
damaged part.
Characteristic
Maximum leg diameter
35.10 mm
Minimum stem diameter
34.90 mm
Check that the oil holes on the pumping element
are not clogged. - Check that the O-ring shows no
sign of damage.
SUSP - 8
XEVO 125 Euro 3
Suspensions
- Insert a new oil guard with the special adaptor
handle and take it to the stop.
- Insert the safety clip.
- Insert a new dust guard.
- Insert the contrast spring into the pumping member.
- Insert the pumping element inside the stem.
- Insert the pumping element guide bushing at the
lower stem end.
- Insert the stem in the leg being careful not to let
the stem guide bushing come out.
- Inset and screw up the copper washer to the prescribed torque. To prevent the pumping member
from rotating, insert a 12 mm Allen key into the
stem.
- Pour 125 ± 1 cm³ of oil into the stem.
Recommended products
AGIP FORK 7.5 W Fork oil
Grade 7.5 W
- Insert the 21 winding springs, the support plate
with the chamfer facing downwards and then the
15 winding spring.
SUSP - 9
Suspensions
XEVO 125 Euro 3
- Insert the stem into the fork clamp.
- Do up the clamp once to allow the stem closure
upper cap to be tightened.
- Check that the sealing ring on the cap is in good
working order, then tighten the cap on the stem to
the prescribed torque.
- Loosen the fork clamp screws and ensure the
stem closure cap is fitted properly on the clamp.
- Tighten the clamp screws to the prescribed torque.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
Locking torques (N*m)
Fork clamp screws 20 ÷ 25 Stem upper cap 15
÷ 30 Lower screw with copper washer 25 - 35
Refitting
- Grease using lithium soap grease on the roller
bearings.
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
- Insert the fork into the headstock.
- Insert the spacer ring.
- Using an appropriate tool do up the first ring nut in the steering tube (upper steering ball bearing). Lock
with a torque of 10 ÷ 13 Nm and rotate the wrench anticlockwise by 90°.
- Install the space washer.
- Using the appropriate tool tighten the second locking ring in the steering tube to a torque of 30 ÷ 36
Nm.
SUSP - 10
XEVO 125 Euro 3
Suspensions
- Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on
the handlebar with that on the steering tube as
shown in the figure.
- Tighten the handlebar fixing screw on the steering tube to the prescribed torque.
- Refit the three handlebar covers as described in
the «Bodywork» Chapter.
- Install the front wheel.
- Refit the brake calliper on the fork leg.
Specific tooling
020055Y Wrench for steering tube ring nut
Locking torques (N*m)
screw fixing handlebar to the steering tube 45
÷ 50 Upper steering ring nut 30 ÷ 36 Steering
lower ring nut 10 ÷ 13 then loosen by 90° Tightening screw for calliper support to the fork 45
÷ 55 Front wheel shaft 45 ÷ 50
See also
Refitting the front wheel
Steering bearing
Removal
- Remove the fork
- Check that the upper ball bearing and the seat of
the lower roller bearings do not show signs of wear
or pricking.
In case of replacement, proceed as follows:
- Using a punch to remove the bearings, insert it
from the bottom and remove the ball bearing
above the headstock. Then remove the lower seat
of the roller bearing by inserting the punch from the
top of the headstock.
N.B.
ONLY REMOVE THE UPPER BALL BEARING IF
YOU REALLY NEED TO.
SUSP - 11
Suspensions
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
- Check that the roller bearing does not show signs
of wear or pricking.
In case of replacement, proceed as follows:
- Support the fork in a vice.
- Insert the contrast plate in the upper end of the
steering tube
N.B.
ONLY REMOVE THE UPPER BALL BEARING IF
YOU REALLY NEED TO.
SUSP - 12
XEVO 125 Euro 3
XEVO 125 Euro 3
Suspensions
- Insert the special tool as shown in the figure.
- Insert the retaining band of the two half-rings.
- Using a 19 mm hexagonal spanner, extract the
roller bearing.
Specific tooling
020458Y Puller for lower bearing on steering
tube
For the version with steering fifth wheel remove the
seat on the steering tube by means of the special
punch as indicated in the photograph
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
SUSP - 13
Suspensions
Refitting
Using the appropriate tool, refit the upper ball bearing and the seat of the lower roller bearings on the
headstock as described below:
- Place a new ball bearing on the headstock and a
roller bearing seat on the lower part.
- Insert the tie rod screw of the appropriate tool
fitted out with the adaptors for planting the bearing
and seat it in the headstock as in the photograph.
- Using two 24 mm wrenches, tighten the screw
until the seat and the bearing are fully set in place.
N.B.
ALWAYS USE A NEW BEARING AND A NEW
SEAT.
Specific tooling
001330Y Tool for fitting steering seats
SUSP - 14
XEVO 125 Euro 3
XEVO 125 Euro 3
Suspensions
- Insert the a new plate and a new dust guard in
the steering tube
- Insert a new roller bearing in the roller tube.
- Using the special tool and a mallet to move the
dust guard and the bearing in abutment.
Specific tooling
006029Y Punch for fitting fifth wheel seat on
steering tube
Rear
Removing the rear wheel
Remove the full muffler assembly.
- Remove the screw fixing the right-hand shock
absorber to the bracket
- Remove the two screws supporting the brake
calliper on the bracket
- Remove the cotter pin, the cap, the wheel axle
fixing nut and the outer one of the two spacers.
- Remove the screws fixing the mudguard and the
brake pipe to the bracket.
- Remove the screw fixing the brake pipe to the
bracket.
- Remove the two screws fixing the bracket to the
engine.
- Disconnect the connector from the wheel turning
sensor.
SUSP - 15
Suspensions
- Undo the wheel axle bracket, using the heat gun if necessary.
Refitting the rear wheel
To fit, follow the removal steps but in the reverse
sequence, being careful to fit the spacers on the
wheel axle as shown in the photograph.
Locking torques (N*m)
Muffler arm clamping screws 27 ÷ 30 Rear
wheel axle nut 104 ÷ 126 Shock absorbercrankcase attachment bracket 20 ÷ 25 Lower
shock absorber clamping screw 33 ÷ 41 Nm
Rear brake calliper fixing screws 25 ÷ 30 Nm
Swing-arm
Removal
- Place the scooter on its centre stand;
- Remove the swinging arm/engine fitting shown in
the photo
- Move the engine back
- remove the spring anchoring the swinging arm to
the frame as shown in the photo
SUSP - 16
XEVO 125 Euro 3
XEVO 125 Euro 3
Suspensions
- Remove the two screws fixing the buffer support
bracket to the frame
- Undo the nut on the LHS shown in the figure and
remove the corresponding bolt from the opposite
side.
- Remove the swinging arm.
- Check the entire swinging arm assembly.
- Check all the centring bushing components and
silent block rubber buffers.
- Replace the work components that cause excessive clearance on the rear suspension.
Overhaul
- Check there is no sticking in the movement of the
connection of the swinging arm on the engine side
to the swinging arm on the frame side.
- Check the axial clearance between the two
swinging arms using a feeler gauge
Characteristic
Standard clearance
0.40 ÷ 0.60 mm
Allowable limit after use:
1.5 mm
SUSP - 17
Suspensions
- To check the clearance on the frame-side arm,
mount the retainer using the pin fixing the swinging
arm to the frame and two adaptor rings of the appropriate tool 020229Y. Alternatively use two
washers with inner diameter for 12-mm pins, min.
outer diameter: 30 mm: min. thickness: 4 mm.
- Check there is no sticking in the rotation.
- Check the axial clearance of the swinging arm on
the frame side
Characteristic
Standard clearance
0.40 ÷ 0.60 mm
Allowable limit after use:
1.5 mm
- Separate the swinging arm on the engine side
from the vehicle side arm.
- Remove the plastic bushings and the internal
spacer shown in the photo.
- Using a suitable pin remove the roller casings as
shown in the photographs
SUSP - 18
XEVO 125 Euro 3
XEVO 125 Euro 3
Suspensions
- Using an appropriate tool plant new roller casings, being careful to position the bearings with the
O-rings facing outwards
Specific tooling
020244Y 15 mm diameter punch
020115Y Ø 18 punch
Characteristic
Length of the swinging arm tube on the engine
side:
175.3 ± 0.3 mm
Length of the internal swinging arm spacer on
the engine side:
183 ± 0.3 mm
Engine side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Frame-side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the frame side:
290 ± 0.1 mm
Length of the swinging arm tube on the frame
side:
283 ± 0.1 mm
- Lubricate roller casings and the plastic bushings
with grease
- Insert the spacers
- Assemble the two arms with the relative bolt in
the position shown in the photograph
- Adjust the bolt as shown in the photograph
- Position the frame side swinging arm with the
most protruding part pointing towards the silent
block side as shown in the photograph
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2 of the swinging arm
SUSP - 19
Suspensions
- Make sure the silent bloc is not broken. If there
is, replace it.
- Remove the seeger ring shown in the photograph
- Remove the full silent bloc bracket
- Undo the silent bloc ring shown in the photograph
- Hold the full silent bloc bracket in the clamp
- Using the appropriate tool, remove the silent bloc
from the bracket from the side corresponding to
the inside of the vehicle. This is to guarantee the
tool is centred properly on the support
SUSP - 20
XEVO 125 Euro 3
XEVO 125 Euro 3
Suspensions
- Install a new silent bloc, making sure it aligns
properly with the reference tooth.
- Fit the silent blocs, making sure the chamfered
part of the silent bloc matches the chamfered part
of the bracket
- Using the appropriate tool, fit the silent bloc as
shown in the photo
Refitting
- To refit, perform the removal operations in reverse.
- Grease the bearings and the rolling parts with the recommended grease.
-Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque.
Locking torques (N*m)
Engine and vehicle side swinging arm junction bolt 33 ÷ 41 Nm Swinging arm pin - Engine 64 72 Body shell - Swinging arm pin 76 ÷ 83 Screw fixing the silent-block support plate to the
body 42 ÷ 52
Shock absorbers
Removal
Proceed as follows:
- place the scooter on its centre stand;
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the muffler
- undo the shock absorber spring assembly clamping screw from the support fixed to the engine on
SUSP - 21
Suspensions
XEVO 125 Euro 3
the one side and from that fixed to the muffler on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.
Refitting
Carry out the previous operations but in reverse order.
Locking torques (N*m)
Shock absorber lower clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41
Centre-stand
REMOVAL
- Use a jack to support the vehicle properly.
- Remove the two return springs from the centre
stand.
- Undo the nut shown in the figure.
- Remove the bolt from the right side.
- Remove the centre stand.
FITTING
- Install the sealing rings on the support tube of the
stand;
- Carry out the operations described above in reverse order, then insert the sealing rings into their
seats.
CAUTION
SUSP - 22
XEVO 125 Euro 3
Suspensions
LUBRICATE THE FOLLOWING PARTS WITH
GREASE: SPRING COUPLING PINS, BUSHINGS ON STAND FIXING BRACKETS.
Recommended products
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2
Locking torques (N*m)
stand retaining bolt 20 ÷ 25
Side stand
REMOVAL
- Uncouple the centre stand return spring;
Remove the screw shown in the photograph
FITTING
To refit, carry out the removal operations in reverse order and comply with the specified torque.
Locking torques (N*m)
Side stand fixing bolt 35 ÷ 40
SUSP - 23
Suspensions
SUSP - 24
XEVO 125 Euro 3
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
XEVO 125 Euro 3
This section è is devoted to the description of the braking system components.
Rear brake calliper
Removal
- Remove the muffler.
- Remove the two rear brake calliper devices fastening them to the support as shown in the photograph.
N.B.
SHOULD THE BRAKE CALLIPER BE REPLACED, BEFORE REMOVING THE FITTINGS
FIXING THE CALLIPER TO THE SUPPORTING
BRACKET, FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM
OF THE CIRCUIT BEING INSPECTED.
Refitting
- To fit the calliper, follow the above operations but in reverse order.
Locking torques (N*m)
Rear brake calliper fixing screws 20 ÷ 25 Rear brake calliper-pipe fitting 20 ÷ 25
Front brake calliper
Removal
- Remove the two retainers fastening the front
brake calliper to the support as shown in the photograph.
N.B.
SHOULD IT BE NECESSARY TO REPLACE
THE CALLIPER, FIRST LOOSEN THE FITTING
CONNECTING THE PIPE TO THE BRAKE CALLIPER.
Refitting
- To fit the calliper, follow the above operations but in reverse order.
Locking torques (N*m)
BRAK SYS - 2
XEVO 125 Euro 3
Braking system
Screw tightening calliper to the support 42 ÷ 52 Brake fluid pipe-calliper fitting 20 ÷ 25
Rear brake disc
Removal
- Remove the rear wheel.
- Undo the five clamping screws shown in the photograph
Refitting
For the fitting, position the disc correctly using the arrow stamped on it as reference.
- Do up the screws to the prescribed torque and apply the recommended product
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED
TOWARDS THE OUTSIDE OF THE VEHICLE.
Recommended products
Loctite 243 Medium-strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Brake disc fixing screw 5 ÷ 6.5
Disc Inspection
- Remove the rear brake calliper
- Check the disc thickness with a micrometer.
Characteristic
Standard thickness:
5 ± 0.2 mm
BRAK SYS - 3
Braking system
XEVO 125 Euro 3
- Repeat the measurement at no fewer than six
points on the disc.
- Check the regular nature of the rotation of the
brake disc assembly using the appropriate tool
fixed onto the brake calliper as shown in the photo.
- In order to be able to anchor the appropriate tool properly use a metal plate with M8 threaded hole
and fix it to one of the two rear brake calliper attachment points.
- Suitably fix the flange to the wheel axle with the original nut and spacer and a Ø 17-mm bearing
N.B.
SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN
IN ORDER TO ROTATE THE DISC.
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Max. deviation allowed:
0.1 mm
- If you detect incorrect values, replace the disc. If the anomaly persists, replace the hub.
Front brake disc
Removal
- Remove the front wheel.
- Undo the five clamping screws shown in the photograph
BRAK SYS - 4
XEVO 125 Euro 3
Braking system
Refitting
For the fitting, position the disc correctly using the
arrow stamped on it as reference.
- Do up the screws to the prescribed torque and
apply the recommended product
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE
FITTED TOWARDS THE OUTSIDE OF THE VEHICLE.
Recommended products
Loctite 243 Medium-strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Brake disc fixing screw 5 ÷ 6.5
Disc Inspection
Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt
and must not show signs of deep scoring.
Characteristic
New rear disc thickness
4.0 mm
Disc thickness at wear limit (front)
3.5 mm
•
Using the appropriate tool, measure
how much the disc protrudes when the
wheel is fitted properly. The protrusion,
measured near the external edge of
the disc, must be less than 0.1 mm.
•
If a value is measured other than the
specified value, remove the front wheel
(Front/Rear Suspension chapter) and
check the protrusion of the disc. Maximum permissible out of true is 0.1 mm.
If the value measured is greater, replace the disc and repeat the check.
•
If the problem persists, check and replace the wheel hub if necessary.
BRAK SYS - 5
Braking system
XEVO 125 Euro 3
Specific tooling
020335Y Magnetic support for dial gauge
Front brake pads
Removal
Proceed as follows:
- Remove the front calliper.
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the friction material of the
pads.
- Replace the pads if the thickness is below the
minimum value.
- The replacement must be made with greater residual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.
Characteristic
Minimum value
1.5 mm
See also
Front brake calliper
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
BRAK SYS - 6
XEVO 125 Euro 3
Braking system
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium-strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Screw tightening calliper to the support 24 ÷ 27 Pad fastening pin 19.6 ÷ 24.5
Rear brake pads
Removal
- Remove the rear brake calliper
- Loosen the two pins shown in the figure that lock
the two pads; be careful with the pad spring clamp.
- Remove the brake pad and check there are no
faults or warping. Replace it if such anomalies are
present.
- Check the thickness of the friction material is
more than 1.5 mm. If it is not , replace it
- The replacement must be made with greater residual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.
See also
Rear brake calliper
BRAK SYS - 7
Braking system
XEVO 125 Euro 3
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium-strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Screw tightening calliper to the support 24 ÷ 27 Pad fastening pin 19.6 ÷ 24.5
Fill
Rear - combined
- Remove the rubber hood from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the brake lever, load the system and bring
it up to the required pressure.
- Keeping the brake lever pulled, loosen the bleed
screw to purge the air in the system. Then tighten
the bleed screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y MityVac vacuum-operated pump
Locking torques (N*m)
BRAK SYS - 8
XEVO 125 Euro 3
Braking system
System bleed calliper fitting: 12 ÷ 16 Nm
Front
- Remove the rubber hood from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the brake lever, load the system and bring
it up to the required pressure.
- Keeping the brake lever pulled, loosen the bleed
screw to purge the air in the system. Then tighten
the bleed screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y MityVac vacuum-operated pump
Locking torques (N*m)
System bleed calliper fitting: 12 ÷ 16 Nm
Brake fluid level check
- Position the vehicle on a flat surface and on the
centre stand
- Remove the brake pump cover as indicated in the
photo
BRAK SYS - 9
Braking system
XEVO 125 Euro 3
- Use the appropriate spyglass on the pump to
check the level of the brake fluid, as shown in the
photograph
- If the level is below the minimum, fill using the two
screws shown in the figure
- Remove the gasket and fill with DOT 4 until the
spyglass is completely covered
CAUTION
MAKE SURE THE BRAKE FLUID DOES NOT
GET INTO YOUR EYES OR ON YOUR SKIN OR
CLOTHES. IF THIS HAPPENS ACCIDENTALLY,
WASH WITH WATER.
CAUTION
THE BRAKING CIRCUIT FLUID IS HIGHLY
CORROSIVE. THEREFORE, WHEN TOPPING
IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, WHICH MEANS THAT IT
ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF MOISTURE CONTAINED IN
THE BRAKE FLUID EXCEEDS A CERTAIN
VALUE, THIS WILL RESULT IN INEFFICIENT
BRAKING.
Coppie di bloccaggio (N*m)
Viti vaschetta pompa freno 1,5 ÷ 2
Never use brake liquid in open or partially used containers.
Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance table.
For refitting purposes carry out the operations in the reverse order from the removal operation and
respect the tightening torque of the tank cover screws.
Front brake pump
BRAK SYS - 10
XEVO 125 Euro 3
Braking system
Removal
- Remove the front and rear handlebar covers;
- Place a suitable container to collect the oil, disconnect the oil pipe from the calliper and actuate
on the brake lever until no more oil comes out;
- Disconnect the oil pipe from the pump, then unscrew the two U-bolt clamping screws and remove
the pump.
Refitting
- Upon refitting, perform the operation but in reverse order.
- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE,
BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED
CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE
THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH
CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Locking torques (N*m)
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 ÷ 20 Fixing screws for handlebar control
assembly U-bolts 7 ÷ 10
See also
Front
Rear brake pump - combined
Removal
- Remove the front and rear handlebar covers;
- Place a suitable container to collect the oil, disconnect the oil pipe from the calliper and actuate on
the brake lever until no more oil comes out;
- Disconnect the oil pipe from the pump, then unscrew the two U-bolt clamping screws and remove the
pump.
BRAK SYS - 11
Braking system
XEVO 125 Euro 3
Refitting
- Upon refitting, perform the operation but in reverse order.
- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE,
BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED
CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE
THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH
CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Locking torques (N*m)
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 ÷ 20 Fixing screws for handlebar control
assembly U-bolts 7 ÷ 10
See also
Rear - combined
BRAK SYS - 12
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
XEVO 125 Euro 3
Cooling system
Circuit diagram
COOLING CIRCUIT
Specification
A
COOL SYS - 2
Desc./Quantity
Carburettor heating circuit
XEVO 125 Euro 3
Specification
B
C
D
E
Cooling system
Desc./Quantity
Thermostat with by-pass
Expansion tank
Radiator
Circuit air bleeding
System bleed
- Start up the engine until the operating temperature is reached.
- Remove the rubber hood over the bleed valve
- Obtain a rubber tube that is of the right length to
connect the valve to the expansion tank
- Place one end of the pipe on the bleed valve and
the other in the expansion tank
- Loosen the screw by two turns until the communication hole is revealed with the head as shown
in the photo
- Wait until only coolant comes out of the rubber
pipe so as to eliminate any air bubbles inside the
circuit.
- Tighten the bleed valve respecting the maximum
torque.
- Bring the coolant up to the correct level inside the
expansion tank
Locking torques (N*m)
Bleed screw: 3
Thermostat
Removal
- Loosen the two screws indicated in the figure and
remove the thermostat cover.
- Remove the thermostat with its gasket.
COOL SYS - 3
Cooling system
Check
- Visually check that the thermostat is not damaged.
- Prepare a metal container with approx. 1 litre of
water.
- Immerse the thermostat, keeping it in the centre
of the container.
- Immerse the multimeter temperature probe, near
the thermostat.
- Warm up the container using the heat gun.
- Check the temperature when the thermostat
starts to open:
- Heat up until the thermostat is completely open
- Replace the thermostat if it does not work properly.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE
SURE NEITHER 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
Thermostat check: Opening start temperature
69.5 ÷ 72.5°C
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 below.
COOL SYS - 4
XEVO 125 Euro 3
XEVO 125 Euro 3
Cooling system
Locking torques (N*m)
Thermostat cover screws 3 ÷ 4
COOL SYS - 5
Cooling system
COOL SYS - 6
XEVO 125 Euro 3
INDEX OF TOPICS
CHASSIS
CHAS
XEVO 125 Euro 3
Chassis
This section è is devoted to the operations that can be carried out on the vehicle's bodywork.
Seat
•
Raise the saddle
•
Undo the three screws fixing the plate
to the central cover and remove the
saddle.
Side fairings
•
Remove the side panel
•
Undo the three clamping screws of the
bumper band and remove it.
See also
Side fairings
Driving mirrors
•
Remove the joint rubber of the mirror
housing from the bottom;
•
Unscrew the two screws, then remove
the covering from the support arm;
•
Remove the 2 lower retainers fixings
the mirror to the frame.
CHAS - 2
XEVO 125 Euro 3
Chassis
Rear handlebar cover
•
- Remove the front handlebar cover
•
Undo the 3 screws fixing the rear handlebar cover and remove the cover
once the connectors of the controls
have been disconnected.
See also
Front handlebar cover
Instrument panel
•
Remove the instrument panel support
and tip it.
•
Undo the six fixing screws «A» to remove the instrument panel.
See also
Analogue instrument panel support
Front handlebar cover
•
Undo the three screws«A» fixing the
handlebar upper cover and slide it off
upwards.
CHAS - 3
XEVO 125 Euro 3
Chassis
•
Undo the screw «B», then remove the
cover «C» on both sides of the handlebar.
•
Undo the two fixing screws at the bottom part.
•
Take out the cover by pulling it upwards.
Headlight assy.
•
Remove the upper cover of the headlight
•
Undo the two upper fixing screws «A»,
the lower screw «B» and remove the
headlight assembly once the connector has been removed.
CHAS - 4
XEVO 125 Euro 3
Chassis
For the front turn indicators:
•
Undo the screw «C» and remove the
plastic cover.
•
Undo the screw «D» and remove the
turn indicator once the connector has
been removed.
See also
Flyscreen
Frame central cover
•
Remove the saddle.
•
Remove the shield back plate.
•
Remove the side panels
•
Undo the two rear fixing screws and
free the coupling teeth.
•
Remove the two front screws «A».
•
Unscrew the fuel tank cap temporarily.
•
Disconnect the opening contacts of the
central compartment and the boot
opening lever.
•
Take out the cover and then screw up
the fuel tank cap.
See also
Seat
CHAS - 5
XEVO 125 Euro 3
Chassis
Knee-guard
Side fairings
Legshield
•
Remove the front headlight.
•
Remove the three upper retainers.
•
Remove the mats on the footrest.
•
Remove the ten fixing screws «A» (five
per side) on the shield back plate.
•
Remove the front mudguard.
•
Remove the six screws «B» (four per
side) fixing the shield with the radiator
grille and the spoiler.
•
Remove the shield.
See also
Headlight assy.
Front mudguard
CHAS - 6
XEVO 125 Euro 3
Chassis
Knee-guard
•
- Remove the front shield.
•
Remove the expansion tank from the
shield back plate by undoing the two
screws «A» and fix it to the small front
frame in such a way that it does not turn
over.
•
Disconnect the connectors of the
MODE button and the plug socket.
•
Undo the screw fixing the caps of the
two lower screws and remove them.
•
Remove the three fixing screws to the
frame.
•
Remove the instrument panel support.
•
Remove the shield back plate by removing the lower part.
•
To make the operation easier it might
be necessary to turn the steering alternately to right and left to free the upper
appendages.
See also
Legshield
Analogue instrument panel support
CHAS - 7
XEVO 125 Euro 3
Chassis
Front wheel housing
•
- Remove the front shield.
•
Remove the front fork.
•
Undo the central screw fixing the wheel
house to the frame.
•
Disconnect the brake pipe to the pump
and slide it off.
See also
Legshield
Taillight assy.
•
After accessing the rear glove box, undo two rear light clamping screws «D».
•
Once you have removed the rear light, remove screw «E» and remove the turn indicator.
CHAS - 8
XEVO 125 Euro 3
•
Central lights: parking lights;
•
Side lights: stop lights.
Chassis
License plate light
•
Remove the two screws «G», then remove the side panels and light support
junction after disconnecting the electrical connection.
Footrest
•
Remove the frame central cover.
•
Undo the four screws fixing the footrest, two of which are underneath the
mat, and remove the footrest.
•
Undo the two screws «A» on the internal side of the footrest.
•
Undo the four fixing screws «B » on the
edge of the footrest and remove the
lower cover.
The diagram illustrates what to do on the righthand footrest; follow the same procedure to remove the left-hand footrest.
CHAS - 9
XEVO 125 Euro 3
Chassis
See also
Central cover
Side fairings
•
Remove the passenger grab handle.
•
Remove the two upper screws «A» fixing the side fairings.
•
Remove the license plate light support
then undo the two fairing fixing screws
«H» underneath it.
•
Remove the rear light unit.
•
Undo the screw «C» under the turn indicator.
CHAS - 10
XEVO 125 Euro 3
•
Chassis
Remove the five screws «D», then
slide off the side panel by pulling it
backwards to free the teeth hooking it
to the central cover.
See also
Taillight assy.
License plate light
Handles and top side fairings
License plate holder
•
Remove the rear and side fittings and
the pipe above the helmet compartment retaining frame;
•
Remove the two side licence plate support clamping screws;
•
Lift the helmet compartment to allow
the licence plate support to free itself
from the two threaded appendages on
the rear frame tube.
See also
Helmet bay
CHAS - 11
XEVO 125 Euro 3
Chassis
Air filter
•
Remove the left-hand side panel;
•
Undo the three screws fixing the box to
the crankcase;
•
Loosen the hose tightening screw on
the carburettor and remove the hose;
•
Push the box upwards to free it from
the appendages on the crankcase and
remove it ;
•
Undo the clamping screws «A» (two of
which are on the knob-type head) and
remove the air-box cover.
See also
Side fairings
CHAS - 12
XEVO 125 Euro 3
Chassis
Helmet bay
- Remove the side fairings;
- Remove the frame central cover;
- Remove the saddle opening receiver from its
support by undoing the two screws «A» on the left
fairing;
- Undo the four screws fixing the frame upper pipe
and remove it once the boot light connector has
been removed.
- Open the glove box flap;
- Undo the 2 screws two on the bottom of the helmet compartment.
- Undo the 2 screws located in the front part of the
helmet compartment.
CHAS - 13
Chassis
- Undo the 4 screws (2 per side) on the sides of
the helmet compartment.
- Raise the helmet compartment as much as possible;
- Disconnect the electrical connection of the two
light buttons;
- Remove the glove box flap hook;
- Remove the saddle hook;
- Disconnect the spark plug HV wire.
- Pull the right and left fuse box out downwards
freeing the tooth with a screwdriver from above;
- Slide off the battery positive and negative leads
and the diagnostics socket from the side slots.
See also
Side fairings
Frame central cover
Fuel tank
- Remove the central chassis cover.
- Remove the footrest.
- Remove the three tank retainers.
- Disconnect the electric wiring and the fuel pipes.
CHAS - 14
XEVO 125 Euro 3
XEVO 125 Euro 3
Chassis
See also
Footrest
Front mudguard
•
Remove the four fixing screws
«A» (two per side) on the mudguard
internal side.
CHAS - 15
Chassis
Top-case
Rear
- Open the case;
- Undo the four screws «A» to remove the case
cover;
- Undo the eight screws «B» to remove the plastic
cover;
In order to remove the case support:
- Remove the side fairings;
- Remove the frame upper pipe;
- Undo the ten screws «C» (five per side) fixing the
helmet compartment;
- First slide off the rubber rim and then remove the
upper cover;
- Undo the four screws «D» (two per side) on the
lower part of the case support;
- Pull up the case support to remove it.
See also
Side fairings
Helmet bay
CHAS - 16
XEVO 125 Euro 3
XEVO 125 Euro 3
Chassis
Handles and top side fairings
•
Remove the passenger grab handle by
undoing the two upper screws «A» and
the two lower screws «B» in the compartment under the saddle.
Flyscreen
•
Remove the driving mirrors;
•
Undo the four fixing screws «A» and
the screw «B», then take out the cover.
•
Remove the four screws «C» fixing the
windshield;
•
Remove the windshield being careful
to collect the washers supporting the
rubber support blocks.
See also
CHAS - 17
XEVO 125 Euro 3
Chassis
Driving mirrors
Analogue instrument panel support
•
Remove the windscreen;
•
- Remove the front shield.
•
Undo the two front screws.
•
Undo the two screws «A » at the side
of the handlebar cover and the two
screws «B» on the upper part of the
shield back plate;
•
Detach the cover from the front frame;
•
Remove the two instrument panel connectors;
•
See also
Flyscreen
Legshield
CHAS - 18
Remove the entire assembly.
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
XEVO 125 Euro 3
Carry out the listed tests before delivering the vehicle.
Warning- be very careful when handling fuel.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Lock check
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system
- Main switch
- Headlamps: high beam, low beam, position and parking lights and the respective warning lights
- Adjusting the headlights according to the regulations currently in force
- Tail light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument lighting
- Instrument panel: fuel and temperature indicator
- Instrument panel warning lights
PRE DE - 2
XEVO 125 Euro 3
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.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
PRE DE - 3
Pre-delivery
XEVO 125 Euro 3
- 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.
Functional inspection
Functional check up:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 4
INDEX OF TOPICS
TIME
TIME
XEVO 125 Euro 3
Time
This section is devoted to the time necessary to carry out repairs.
For each operation, the description, code and time envisages are specified.
Engine
ENGINE
1
2
3
TIME - 2
Code
001001
003064
001127
Action
Engine - Replacement
Engine oil - Change
Engine - Complete service
Duration
XEVO 125 Euro 3
Time
Crankcase
CRANKCASE
1
Code
001153
2
001133
3
001124
4
001099
5
002028
Action
Crankcase halves gasket Replacement
Engine crankcase- Replacement
Lubrication by-pass - Replacement
Oil seal, flywheel side - Replacement
Rear wheel hub - Replacement
Duration
TIME - 3
XEVO 125 Euro 3
Time
Crankshaft
CRANKSHAFT
1
TIME - 4
Code
001117
Action
Crankshaft - Replacement
Duration
XEVO 125 Euro 3
Time
Cylinder assy.
CYLINDER UNIT - PISTON
1
Code
001002
2
3
001176
001154
Action
Cylinder / Piston - Replacement
Rings / Pin - Replacement
Pin-ring-piston assembly Service
Duration
TIME - 5
XEVO 125 Euro 3
Time
Cylinder head assy.
HEAD UNIT
1
2
3
4
5
Code
001126
001045
001049
001056
007009
6
7
8
001057
001083
007012
TIME - 6
Action
Head - Replacement
Valves - Replacement
Valves - Adjustment
Head gasket - Replacement
Cylinder / pump rubber coupling - Replacement
Thermostat - Replacement
Thermistor - Replacement
Coolant bleed valve - Replacement
Duration
XEVO 125 Euro 3
Time
Rocker arms support assy.
ROCKING LEVER UNIT
1
Code
001148
2
3
001044
001169
Action
Valve rocking levers - Replacement
Camshaft - Replacement
Decompressor - Replacement
Duration
TIME - 7
XEVO 125 Euro 3
Time
Cylinder head cover
HEAD COVER
1
2
3
Code
001093
001089
001088
4
001074
TIME - 8
Action
Spark plug - Replacement
Head cover - Replacement
Head cover gasket - Replacement
Oil vapour recovery pipe - Replacement
Duration
XEVO 125 Euro 3
Time
Oil filter
OIL FILTER
1
2
Code
001123
001160
3
001102
Action
Oil filter - Replacement
Oil pressure sensor - Replacement
Oil mesh filter - Change /
Cleaning
Duration
TIME - 9
XEVO 125 Euro 3
Time
Driven pulley
DRIVEN PULLEY
1
2
3
4
TIME - 10
Code
001022
001012
001110
001155
Action
Clutch - Replacement
Driven pulley - Service
Driven pulley - Replacement
Clutch bell - Replacement
Duration
XEVO 125 Euro 3
Time
Oil pump
OIL PUMP
1
Code
001125
2
001051
3
4
5
001042
001112
001122
6
001172
7
8
001130
001129
9
888133
Action
Chain guide sliders - Replacement
Distribution belt - chain - Replacement
Oil pump - Service
Oil pump - Replacement
Oil pump chain - Replacement
Chain cover flap - Replacement
Oil sump - Replacement
Chain tightener - Service and
replacement
Chain cover flap - Check / replacement
Duration
TIME - 11
XEVO 125 Euro 3
Time
Final gear assy.
FINAL REDUCTION
1
Code
001010
2
3
003065
001156
4
004125
TIME - 12
Action
Geared reduction unit - Service
Gearcase oil - Replacement
Reduction gear cover - Replacement
Rear wheel axle - Replacement
Duration
XEVO 125 Euro 3
Time
Driving pulley
DRIVING PULLEY REPAIR TIME
1
Code
001086
2
3
4
5
001011
001006
001066
001177
Action
Driving half-pulley - Replacement
Driving belt - Replacement
Driving pulley - Service
driving pulley - Replacement
Variator rollers / shoes - Replacement
Duration
TIME - 13
XEVO 125 Euro 3
Time
Transmission cover
TRANSMISSION COVER
1
Code
001096
2
001135
3
4
001170
001132
5
001131
TIME - 14
Action
Transmission crankcase cover - Replacement
Transmission cover bearing Replacement
Air deflector - Replacement
Transmission air inlet pipe Replacement
Transmission air intake - Replacement
Duration
XEVO 125 Euro 3
Time
Starter motor
STARTER MOTOR
1
2
Code
001020
001017
3
005045
Action
Starter motor - Replacement
Start-up pinion - Replacement
Starter motor cable assembly
- Replacement
Duration
TIME - 15
XEVO 125 Euro 3
Time
Flywheel magneto
MAGNETO FLYWHEEL AND SECONDARY AIR
1
TIME - 16
Code
001087
Action
Flywheel cover - Replacement
Duration
XEVO 125 Euro 3
2
Code
001113
3
4
5
6
001058
001173
001067
001161
7
001162
8
9
001174
001163
Time
Action
Water pump / Pump rotor Replacement
Flywheel - Replacement
Rotor - Replacement
Stator - Replacement
Secondary air filter - Replacement / Cleaning
Secondary air housing - Replacement
SAS valve - Replacement
SAS valve / Head connection
- Replacement
Duration
Carburettor
TIME - 17
XEVO 125 Euro 3
Time
CARBURETTOR
1
Code
001013
2
001081
3
4
5
001008
001063
007020
6
003058
TIME - 18
Action
Intake manifold - Replacement
Automatic choke - Replacement
Carburettor - Inspection
Carburettor - Replacement
Carburettor heating tubing replacement
Carburettor - Adjustment
Duration
XEVO 125 Euro 3
Time
Exhaust pipe
MUFFLER
1
2
Code
001009
001092
3
001095
Action
Muffler - Replacement
Exhaust manifold - Replacement
Muffler guard - Replacement
Duration
TIME - 19
XEVO 125 Euro 3
Time
Air cleaner
AIR CLEANER
1
2
Code
001015
001014
3
004122
TIME - 20
Action
Air filter box - Replacement
Air filter - Replacement /
cleaning
Air cleaner/ carburettor union
- Replacement
Duration
XEVO 125 Euro 3
Time
Frame
CHASSIS
1
2
3
Code
004001
004146
004147
4
004148
5
004116
Action
Chassis - Replacement
Front frame - Replacement
Footrest support bracket, one
side - Replacement
Footrest support bracket,
both sides - Replacement
Rear frame - Replacement
Duration
TIME - 21
XEVO 125 Euro 3
Time
Centre-stand
STAND REPAIR TIME
1
2
3
TIME - 22
Code
004004
004102
001053
Action
Stand - Replacement
Side stand - Replacement
Stand bolt - Replacement
Duration
XEVO 125 Euro 3
Time
Legshield spoiler
FRONT SHIELD
1
Code
004020
Action
Headlight frame - Replacement
Duration
TIME - 23
XEVO 125 Euro 3
Time
2
Code
004064
3
004066
Action
Legshield, front section - Replacement
Rear-view mirror - Replacement
Duration
Side fairings
SIDE COVERS
1
Code
004068
2
3
004085
004012
4
5
004036
004013
TIME - 24
Action
Passenger handgrip - Replacement
Fairing (1) - Replacement
Rear side panels - Replacement
Frame cover - Replacement
Side bumper- Replacement
Duration
XEVO 125 Euro 3
Time
Rear cover
SHIELD BACK PLATE
1
Code
004065
2
004156
3
4
004145
007024
Action
Shield back plate - Replacement
Glove box flap and/or support
- Replacement
Glove box - Replacement
Expansion tank cap - Replacement
Duration
TIME - 25
XEVO 125 Euro 3
Time
Central cover
CENTRAL COVER
1
2
Code
004135
004011
3
4
004075
004059
5
004015
TIME - 26
Action
Fuel tank port - Replacement
Frame central cover - Replacement
Front mat - Replacement
Spark plug inspection flap Replacement
Footrest - Replacement
Duration
XEVO 125 Euro 3
Time
Mudguard
PARAFANGHI
1
Code
004002
2
004167
3
004009
4
004053
Action
Front mudguard - Replacement
Grill / radiator cover - Replacement
Rear mudguard - Replacement
Spoiler - Replacement
Duration
TIME - 27
XEVO 125 Euro 3
Time
Fuel tank
FUEL TANK
1
2
3
4
Code
004005
004007
005010
004089
5
004109
6
888141
TIME - 28
Action
Fuel tank - Replacement
Fuel valve - Replacement
Tank float - Replacement
Tank / petrol pump pipe - Replacement
Fuel tank breather - Replacement
Fuel tank coupling check
Duration
XEVO 125 Euro 3
Time
Rear shock-absorber
REAR SHOCK ABSORBER
1
Code
003007
Action
Rear shock absorber - Replacement
Duration
TIME - 29
XEVO 125 Euro 3
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
004018
2
004019
3
004099
4
004026
5
003043
TIME - 30
Action
Front handlebar cover - Replacement
Rear handlebar cover - Replacement
Odometer housing - Replacement
Handlebar cover - Replacement
Steering tube dust guard Replacement
Duration
XEVO 125 Euro 3
Time
Handlebar components
HANDLEBAR COMPONENTS
1
2
Code
003001
002063
3
003061
4
003059
5
004162
6
002024
7
002067
8
9
10
002037
002071
002059
11
002060
12
002047
13
002080
Action
Handlebar - Replacement
Throttle control transmission
- Replacement
Accelerator transmission Adjustment
Counterweight - Replacement
Mirror support and/or brake
pump fitting U-bolt - Replacement
Front brake pump - Replacement
Rear brake pump - Replacement
Brake lever - Replacement
Left knob - Replacement
Right-hand knob - Replacement
Complete throttle control Replacement
Front brake fluid and air
bleeding system - Replacement
Rear brake oil bleeding system - Replacement
Duration
TIME - 31
XEVO 125 Euro 3
Time
Swing-arm
BRACCIO OSCILLANTE
1
Code
003081
2
3
004058
001072
4
003080
TIME - 32
Action
Swinging arm supporting
flange - Replacement
Silent-block - Replacement
Engine/frame swinging arm
attachment - Replacement
Swinging arm on frame - Replacement
Duration
XEVO 125 Euro 3
Time
Seat
SADDLE
1
Code
004003
Action
Saddle - Replacement
Duration
TIME - 33
XEVO 125 Euro 3
Time
Instrument panel
GRUPPO STRUMENTI + COMANDI AL MANUBRIO
1
Code
005078
2
3
005014
005038
TIME - 34
Action
Odometer glass - Replacement
Odometer - Replacement
Dashboard warning/telltale
lights - Replacement
Duration
XEVO 125 Euro 3
Time
Locks
SERRATURE + TRASMISSIONI SERRATURE
1
2
Code
004010
005099
3
005133
4
004054
5
004173
6
004158
7
004172
8
005072
Action
Antitheft lock - Replacement
Electric saddle opening activator - Replacement
Electric glove box activator Replacement
Saddle lock catch - Replacement
Trunk opening splitter - Replacement
Saddle opening splitter - Replacement
Rear case closure hook - Replacement
Immobilizer aerial - Replacement
Duration
Turn signal lights
Rear lights
TIME - 35
XEVO 125 Euro 3
Time
REAR LIGHTS
1
2
Code
005005
005048
3
005031
4
005032
5
005022
6
005066
7
005068
8
005030
Front lights
TIME - 36
Action
Taillight - Replacement
Licence plate holder - Replacement
Licence plate light bulb - Replacement
Licence plate light glass - Replacement
Rear turn indicators - Replacement
Rear light bulbs - Replacement
Rear turn indicator bulb - Replacement
Rear headlight cable unitReplacement
Duration
XEVO 125 Euro 3
Time
INDICATOR LIGHTS
1
2
Code
005002
005008
3
005044
4
005012
5
005067
Action
Front light - replacement
Headlight bulbs - Replacement
Front lights cable unit- Replacement
Front turn indicators - Replacement
Front turn indicator bulb - Replacement
Duration
TIME - 37
XEVO 125 Euro 3
Time
Front wheel
RUOTA ANTERIORE
1
Code
002041
2
003037
3
003038
4
003040
5
6
003047
004123
TIME - 38
Action
Front brake disc - Replacement
Front wheel rim - Replacement
Front wheel axle - Replacement
Front wheel bearings - Replacement
Front tyre - Replacement
Front wheel - Replacement
Duration
XEVO 125 Euro 3
Time
Rear wheel
REAR WHEEL
1
2
Code
001016
001071
3
004126
4
002070
5
003077
Action
Rear wheel - Replacement
Rear wheel rim - Replacement
Rear wheel tyre - Replacement
Rear brake disc - Replacement
muffler/rear shock absorber
support arm - Service
Duration
TIME - 39
XEVO 125 Euro 3
Time
Fuel pump
FUEL PUMP
1
2
3
Code
004073
004072
004086
4
004087
5
004137
TIME - 40
Action
Fuel pump - Replacement
Fuel filter - Replacement
Petrol pump depression tube
- Replacement
Filter / petrol pump pipe - Replacement
Pump / carburettor hose - Replacement
Duration
XEVO 125 Euro 3
Time
Electric devices
TIME - 41
XEVO 125 Euro 3
Time
DISPOSITIVI ELETTRICI
1
2
3
4
5
6
Code
005001
005114
005003
001069
001023
005035
7
8
005007
005011
9
10
11
005009
005052
001094
12
002011
13
002051
TIME - 42
Action
electric system - change
Electrical system - Service
Horn - Replacement
HV coil - replace
Control unit - Replacement
Headlight remote control Replacement
Battery - Replacement
Start-up remote control
switch - change
Voltage regulator - replace
Fuse (1) - Replacement
Spark plug cap - Replacement
Odometer movement sensor
- Replacement
Odometer transmission assembly - Replacement
Duration
XEVO 125 Euro 3
Time
Electronic controls
COMANDI ELETTRICI
1
Code
005006
2
005039
3
4
005040
005132
5
6
005041
005077
7
8
9
10
11
005016
004142
005085
005017
003074
12
003075
Action
Light or turn indicator switch Replacement
Headlight switch - Replacement
Horn button - Replacement
Trunk opening button - Replacement
Starter button - Replacement
Emergency stop switch - Replacement
Key switch - Replacement
Plug socket - Replacement
Reset button - Replacement
Stop switch - Replacement
Handlebar right control - Replacement
Handlebar left control - Replacement
Duration
TIME - 43
XEVO 125 Euro 3
Time
Transmissions
TRASMISSIONI
1
Code
002082
2
002092
3
002093
4
002094
TIME - 44
Action
Fuel tank cap opening drive Replacement
Transmission splitter/ hook
transmission - Replacement
Trunk opening transmission Replacement
Trunk splitter/ hook transmission - Replacement
Duration
XEVO 125 Euro 3
Time
Helmet bay
PORTACASCO
1
Code
004016
2
005033
3
4
004082
005026
5
005027
Action
Helmet compartment - Replacement
Glove-box light switch - Replacement
Trunk gasket - Replacement
Helmet compartment bulb Replacement
Helmet compartment bulb
support - Replacement
Duration
TIME - 45
XEVO 125 Euro 3
Time
Rear side fairings
COPERTURE POSTERIORI
1
Code
005048
2
005033
3
004081
4
5
004174
004080
6
005131
TIME - 46
Action
Licence plate holder - Replacement
Glove-box light switch - Replacement
Glove box door - Replacement
Trunk levers - Replacement
Trunk flap support - Replacement
Licence plate light support Replacement
Duration
XEVO 125 Euro 3
Time
Front suspension
SOSPENSIONE ANTERIORE
1
2
3
4
5
6
Code
003051
003010
003076
003079
003048
003002
7
004119
8
003073
Action
Complete fork - replace
Front suspension - Service
Fork sheath - Replacement
Fork stem - Replacement
Fork oil seal - Replacement
Steering thrust washer - Replacement
Upper steering bearing Housing
Steering clearance - Adjustment
Duration
TIME - 47
XEVO 125 Euro 3
Time
Cooling system
IMPIANTO DI RAFFREDDAMENTO
1
2
Code
007002
007016
3
007001
4
007022
5
007013
6
001052
7
007019
8
007014
TIME - 48
Action
Water radiator - replacement
Fan with support - Replacement
Expansion tank - Replacement
Coolant delivery pipe - Replacement
Expansion tank - radiator
connection pipe - Replacement
Coolant and air bleed - Replacement
Connection water pump
pipe / return pipe - Replacement
Radiator thermal switch - Replacement
Duration
XEVO 125 Euro 3
Time
Braking system
BRAKE SYSTEM
1
Code
002007
2
002039
3
002021
4
002002
5
002048
6
002081
7
8
002025
002020
Action
Front brake pads - Replacement
Front brake calliper - Replacement
Front brake piping - Replacement
Rear brake pads - Replacement
Rear brake calliper - Replacement
Rear brake rigid pipes - Replacement
Brake piping - Replacement
Rear brake disc piping - Replacement
Duration
TIME - 49
XEVO 125 Euro 3
Time
Windscreen
WINDSHIELD
1
TIME - 50
Code
004101
Action
Windshield - Replacement
Duration
XEVO 125 Euro 3
Time
Stickers
TRANSFERS
1
Code
004159
Action
Plates / Stickers - Replacement
Duration
TIME - 51
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