PIAGGIO X8 400 Euro 3 Guida

SERVICE STATION MANUAL

633779 ÷ 633786

X8 400 Euro 3

SERVICE STATION

MANUAL

X8 400 Euro 3

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

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

required for manufacturing or construction reasons.

Not all versions shown in this publication are available in all countries. The availability of single versions

should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

www.piaggio.com

SERVICE STATION MANUAL

X8 400 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, completely satisfactory work cannot be carried out without the

necessary equipment and tools. It is therefore advisable to read the sections of this manual relating to

appropriate tools, along with the appropriate tool catalogue.

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

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

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

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

injury.

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

to prevent damaging the environment.

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

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

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

Safety rules

•Should it be necessary to keep the engine running while servicing, make sure that the area

or room is well ventilated, and use special exhaust fans, if required. 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. Sul-

phuricacidis highly corrosive; in the event of contact with your eyesorskin, 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 in some conditions it can be explosive. Do not smoke in the

working area, and avoid open flames or sparks.

•Clean the brake pads in a well ventilated environment, directing the compressed air jet so

as to not inhale the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, dust inhalation 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 special tools designed for this scooter.

•Always use new gaskets, sealing rings and split pins upon reassembly.

•After removal, clean the components using non-flammable or low fire-point solvent. Lubri-

cate all the work surfaces except the tapered couplings before refitting.

•After reassembly, check that all components have been installed properly and that they are

in good working order.

•Forremoval, overhaul and reassemblyoperations use only tools provided with metric meas-

ures. Metric bolts, nuts and screws are not interchangeable with coupling members with

English measurement. Using unsuitable coupling members and tools may damage the

scooter.

•Should any interventions to the scooter electrical system be required, check that the elec-

trical connections - especially earth and battery connections - have been implemented

properly.

X8 400 Euro 3 Characteristics

CHAR - 7

Vehicle identification

Chassis prefix

ZAPM52100÷1001

Engine prefix

M521M÷1001

Dimensions and mass

WEIGHT

Specification Desc./Quantity

Kerb weight 206 kg

Overall width 750 mm

Overall length 2190 mm

Wheelbase 1540 mm

Saddle height 790 mm

Overall height 1360 mm

Characteristics X8 400 Euro 3

CHAR - 8

Engine

ENGINE

Specification Desc./Quantity

Engine single-cylinder, four-stroke

Bore x stroke 85.8 X 69 mm

Cubic capacity 399 cm³

Compression ratio 10.6 ± 0.5 :1

Timing system Single overhead camshaft with integrated tone wheel, control

from flywheel side chain, 4 valves and automatic start-up valve

lifting device.

Valve clearance: intake 0.15 mm (when cold)

Valve clearance: discharge 0.15 mm (when cold)

Valve clearance adjustment By threaded adjuster on the rockers

Engine idle speed 1500 ± 50 rpm

Air filter sponge, impregnated with mixture (50% petrol and 50% oil)

CO % value (measured at the intake manifold) 1 - 1.5%

Starting system Electric starter system with freewheel.

Lubrication By trochoidal pump (inside the crankcase), pressure adjust-

ment by-pass and oil filter.

Lubrication pressure 4 bar

Minimum allowed (at 100° C) 0.8 bar

Fuel supply Electronic injection system with electric fuel pump, Ø 38 mm

throttle body and single injector.

Maximum power (to the crankshaft) 24.5 kW at 7250 rpm

Maximum torque (to the crankshaft) 36 Nm at 5500 rpm

Cooling system Fluid circulation through a motor-driven pump, 3-way thermo-

stat and electric fan.

Transmission

TRANSMISSIONS

Specification Desc./Quantity

Transmission With automatic expandable pulley variator with torque server,

V belt, automatic clutch, gear reduction unit and transmission

housing with forced air circulation cooling.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil (empty) 1.7 lt.

Engine oil (at oil and filter change) 1.5 lt.

Fuel tank capacity Tank capacity: ~12 l (approximate value)

Rear hub approx. 250 cc.

Cooling system approx. 1.8 litres

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Electronic ignition inductive, high efficiency integrated with the injection system,

with variable timing and separate HV coil.

Spark plug NGK CR7EKB

Spark plug CHAMPION RG6YC

Battery Dry-cell lead-acid battery, 12V-14Ah

Generator Three-phase alternating current

X8 400 Euro 3 Characteristics

CHAR - 9

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Chassis Welded steel pipes with pressed sheet metal stiffening

Front suspension DoubleeffecthydraulictelescopicforkwithØ35mmstemsand

pin backwards with connections for double brake calliper

Front fork max. stroke 104 mm

Rear suspension Engine with swinging fork attached to the frame by means of

an arm with one degree of freedom and a pair of double effect

hydraulic shock absorbers with 4 adjustable preload positions.

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 240mm double disk brake with hydraulic control activated by

the handlebar right-hand lever.

Rear brake Ø 240 mm disc brake with hydraulic control activated by han-

dlebar left lever.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Tyre pressure (cold) front 2.1 bar

Tyre pressure (cold) rear 2.3 bar (2.5 bar with passenger)

Front wheel rim Die-cast aluminium alloy, 3.50"x14''

Rear wheel rim Die-cast aluminium alloy 4.50"x14"

Front tyre Tubeless 120/70 - 14'' - Michelin Gold Standard M/C 55S

Rear tyre Tubeless 140/70 - 14'' - Michelin Gold Standard M/C 68S

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST

PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

CAUTION

IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE COR-

RECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER

TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES REC-

OMMENDED BY PIAGGIO.

Tightening Torques

FRAME

Name Torque in Nm

Electric pump locking ring nut 20

BRAKE SYSTEM

Name Torque in Nm

Brake calliper coupling 20 - 24

Front brake disc mounting 5 ÷ 6 •

Characteristics X8 400 Euro 3

CHAR - 10

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