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PIAGGIO
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X7 250ie
PIAGGIO X7 250ie User Manual
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Studs
Check that the stud bolts have not worked loose
from their seat in the crankcase.
Check the depth of stud bolt driving with a gauge,
as indicated in the photograph. If it varies signifi-
cantly from the driving depth indicated, it means
that the stud bolt has yielded.
In this case, replace it.
X7 250ie
Engine
ENG - 57
138
140
Table of Contents
Vehicle View
4
Index of Topics
5
Safety Rules
8
Maintenance Rules
8
Characteristics
9
Vehicle Identification
9
Dimensions and Mass
10
Engine Specifications
10
Transmission Data
11
Capacities
11
Electrical System Data
11
Frame and Suspensions Data
11
Brakes Data
12
Wheels and Tyres Data
12
Tightening Torques
12
Cylinder Head
14
Crankcase and Crankshaft
14
Overhaul Data
15
Assembly Clearances
15
Recommended Products Table
18
Tooling
20
Maintenance
31
Maintenance Chart
32
Every 2 Years
32
Checking the Spark Advance
34
Spark Plug
35
Hub Oil Check
36
Hub Oil Replacement
37
Air Filter
37
Engine Oil Replacement
38
Engine Oil Check
39
Engine Oil Filter
40
Oil Pressure Warning Light
40
Checking the Ignition Timing
40
Cooling System
41
Coolant Level Check
41
Braking System Maintenance
42
Brake Fluid Level Check
42
Brake Fluid Top-Up
42
Headlight Adjustment
44
Index of Topics
47
Troubleshooting
47
Troubleshooting
48
Engine Troubles
48
Poor Engine Performance
48
Starting Difficulties
48
Excessive Oil Consumption/Exhaust Smoke
49
Insufficient Lubrication Pressure
49
Transmission and Brakes Troubles
49
Clutch Grabbing or Performing Inadequately
49
Insufficient Braking
50
Brakes Overheating
50
Steering and Suspensions Troubles
50
Heavy Steering/Excessive Steering Play
50
Noisy Suspension
51
Suspension Oil Leakage
51
Electrical System
53
Electrical System Components Arrangement
54
Ground Points
57
Ignition Circuit Check
58
No Spark Plug
58
Checks and Inspections
58
Battery Recharge Circuit
59
Stator Check
59
Voltage Regulator Check
60
Recharge System Voltage Check
60
Starter Motor
61
Horn Control
62
Turn Signals System Check
63
Level Indicators
64
Lights List
64
Fuses
65
Dashboard
66
Sealed Battery
67
Dry-Charge Battery
67
To Check the Operation of a Remote Control
69
Switch Control
69
Engine Stop Switch
69
Starter Button
69
Connectors
70
Instrument Panel Connector "A"
70
Light Switch
70
Turn Indicator Switch
70
Horn Button
70
Instrument Panel Connector "B"
71
Fuel Pump Connector
71
Electrical Fan Connector
71
Magneto Flywheel Connector
71
Antitheft Device Pre-Installation Connector
72
Lambda Probe Connector
72
Voltage Regulator Connector
72
Injection Electronic Control Unit
72
Injector Connector
73
HV Coil Connector
73
Fuel Level Transmitter Connector
74
Coolant Temperature Sensor Connector
74
Index of Topics
75
Engine from Vehicle
76
Exhaust Assy. Removal
76
Removal of the Engine from the Vehicle
77
Engine
84
Automatic Transmission
84
Transmission Cover
84
Air Duct
85
Removing the Driven Pulley Shaft Bearing
85
Refitting the Driven Pulley Shaft Bearing
86
Baffle Roller
86
Plastic Roller
86
Removing the Driven Pulley
87
Inspecting the Clutch Drum
87
Removing the Clutch
88
Inspecting the Clutch
89
Pin Retaining Collar
89
Removing the Driven Half-Pulley Bearing
90
Inspecting the Driven Fixed Half-Pulley
91
Inspecting the Driven Sliding Half-Pulley
91
Refitting the Driven Half-Pulley Bearing
92
Refitting the Driven Pulley
92
Inspecting the Clutch Spring
93
Refitting the Clutch
94
Drive-Belt
95
Removing the Driving Pulley
96
Inspecting the Rollers Case
97
Refitting the Driving Pulley
98
Refitting the Transmission Cover
99
End Gear
99
Removing the Hub Cover
100
Removing the Wheel Axle
100
Removing the Hub Bearings
101
Removing the Wheel Axle Bearings
101
Inspecting the Hub Shaft
102
Inspecting the Hub Cover
102
Refitting the Wheel Axle Bearing
103
Refitting the Hub Cover Bearings
104
Refitting the Hub Bearings
105
Refitting the Hub Cover
105
Flywheel Cover
105
Removing the Stator
106
Refitting the Stator
107
Refitting the Flywheel Cover
107
Flywheel and Starting
107
Removing the Starter Motor
108
Removing the Flywheel Magneto
108
Inspecting the Flywheel Components
109
Refitting the Free Wheel
109
Refitting the Flywheel Magneto
110
Refitting the Starter Motor
111
Cylinder Assy. and Timing System
111
Removing the Intake Manifold
111
Removing the Rocker-Arms Cover
112
Removing the Timing System Drive
112
Removing the Cam Shaft
114
Removing the Cylinder Head
114
Removing the Valves
115
Removing the Cylinder - Piston Assy.
115
Inspecting the Small End
116
Inspecting the Wrist Pin
116
Inspecting the Piston
117
Inspecting the Cylinder
118
Inspecting the Piston Rings
118
Removing the Piston
119
Choosing the Gasket
119
Refitting the Piston Rings
121
Refitting the Cylinder
121
Inspecting the Cylinder Head
122
Inspecting the Timing System Components
122
Inspecting the Valve Sealings
123
Inspecting the Valve Housings
123
Inspecting the Valves
123
Inspecting the Springs and Half-Cones
126
Refitting the Valves
126
Inspecting the Cam Shaft
126
Refitting the Head and Timing System Components
128
Refitting the Rocker-Arms Cover
131
Refitting the Intake Manifold
131
Crankcase - Crankshaft
131
Splitting the Crankcase Halves
131
Inspecting the Crankshaft Alignment
133
Inspecting the Crankcase Halves
134
Inspecting the Crankshaft Plain Bearings
136
Refitting the Crankcase Halves
138
Studs
139
Lubrication Circuit
140
Engine Lubrication Diagram
141
Oil Pressure Check
142
Crankshaft Oil Seals Removal
143
Crankshaft Oil Seals Refitting
144
Oil Pump Removal
145
Oil Pump Inspection
146
Oil Pump Refitting
147
Removing the Oil Sump
147
Inspecting the By-Pass Valve
148
Refitting the Oil Sump
148
Index of Topics
151
Injection Components View
152
MIU Injection System
153
Injection System Troubleshooting Hints
154
Terminals Setup (Injection System)
157
Terminal Layout
157
EMS Circuit Diagram
158
Injection System Troubleshooting
159
Engine Does Not Start
159
Troubleshooting Procedure
159
Engine Stops at Idle
160
Engine Does Not Rev down
160
Exhaust Backfires in Deceleration
161
Engine Revs Irregularly
161
Poor Performance at Full Throttle
162
Engine Knocking
162
Fuel Supply System
163
Removing the Butterfly Valve
163
Refitting the Butterfly Valve
165
Pump Supply Circuit
166
Electrical Data
166
Circuit Leak Test
169
Fuel Filter Check
170
Inspecting the Injector Circuit
171
Inspecting the Injector Hydraulics
175
Injection Components Location
176
Tachometer
178
HT Coil
179
Coolant Temperature Sensor
183
Zeroing the Throttle
185
Lambda Probe
187
Signal Control
190
Index of Topics
193
Suspensions
194
Front Suspension
194
Removing the Front Wheel
194
Front Wheel Hub Overhaul
194
Refitting the Front Wheel
197
Handlebar Removal
198
Handlebar Refitting
198
Front Fork
198
Front Suspension Overhaul
199
Component Check
201
Steering Column Removal
206
Steering Column Refitting
206
Steering Bearing
209
Steering Bearing Removal
210
Steering Bearing Refitting
212
Rear Suspension
213
Removing the Rear Wheel
213
Refitting the Rear Wheel
213
Swing-Arm Removal
214
Swing-Arm Overhaul
215
Swing-Arm Refitting
218
Shock Absorbers Removal
219
Shock Absorbers Refitting
219
Exhaust Bracket Removal
220
Exhaust Bracket Overhaul
221
Exhaust Bracket Refitting
222
Centre-Stand Removal and Fitting
223
Side Stand Removal and Fitting
224
Index of Topics
225
Braking System
225
Braking System
226
Rear Brake Calliper Removal
226
Rear Brake Calliper Refitting
226
Front Brake Calliper Removal
227
Front Brake Calliper Refitting
227
Rear Brake Disc Removal
227
Rear Brake Disc Refitting
228
Rear Brake Disc Inspection
228
Front Brake Disc Removal
229
Front Brake Disc Refitting
230
Front Brake Disc Inspection
230
Front Brake Pads Removal
231
Front Brake Pads Refitting
232
Rear Brake Pads
232
Rear Brake Pads Removal
233
Rear Brake Pads Refitting
233
Fill - Rear, Combined
234
Fill - Front Brake
235
Brake Fluid Level Check
235
Front Brake Pump Removal
236
Front Brake Pump Refitting
236
Rear Brake Pump - Combined, Removal
237
Rear Brake Pump - Combined, Refitting
238
Index of Topics
239
Cooling System Circuit Diagram
240
Cooling System Bleeding
241
Thermostat Removal
242
Thermostat Check
242
Thermostat Refitting
243
Chassis
246
Seat
246
Driving Mirrors
246
Rear Handlebar Cover
246
Instrument Panel
247
Front Handlebar Cover
248
Headlight Assy
248
Frame Central Cover
249
Legshield
250
Knee-Guard
251
Front Wheel Housing
252
Taillight Assy
253
License Plate Light
254
Footrest
254
Side Fairings
255
License Plate Holder
256
Rear Mudguard
257
Helmet Bay
258
Fuel Tank
258
Front Mudguard
260
Radiator Fan
260
Expansion Tank
261
Front Central Cover
262
Flyscreen
262
Battery
263
Index of Topics
265
Pre-Delivery
266
Aesthetic Inspection
266
Tightening Torques Inspection
266
Electrical System Check
266
Levels Check
267
Road Test
267
Static Test
268
Functional Inspection
268
Time to Carry out Repairs
270
Engine Repair Time
270
Crankcase Repair Time
271
Crankshaft Repair Time
272
Cylinder Assy Repair Time
273
Cylinder Head Assy Repair Time
274
Rocker Arms Support Assy Repair Time
275
Cylinder Head Cover Repair Time
276
Oil Filter Repair Time
277
Flywheel Cover Repair Time
278
Driven Pulley Repair Time
279
Oil Pump Repair Time
280
Final Gear Assy Repair Time
281
Final Reduction
281
Driving Pulley Repair Time
282
Transmission Cover Repair Time
283
Water Pump Repair Time
284
Starter Motor Repair Time
285
Electrical Start-Up
285
Flywheel Magneto Repair Time
286
Butterfly Valve Repair Time
287
Throttle Body
287
Exhaust Pipe Repair Time
288
Air Cleaner Repair Time
289
Frame Repair Time
290
Centre-Stand Repair Time
291
Legshield Spoiler Repair Time
292
Side Fairings Repair Time
293
Side Covers
293
Rear Cover Repair Time
294
Central Cover Repair Time
295
Mudguard Repair Time
296
Fuel Tank Repair Time
297
Rear Shock-Absorber Repair Time
298
Handlebar Covers Repair Time
299
Handlebar Components Repair Time
300
Swing-Arm Repair Time
301
Swinging Arm
301
Seat Repair Time
302
Instrument Panel Repair Time
303
Locks Repair Time
304
Turn Signal Lights
304
Rear Lights Repair Time
305
Turn Indicator Lights Repair Time
306
Front Wheel Repair Time
307
Rear Wheel Repair Time
308
Fuel Pump Repair Time
309
Electric Devices Repair Time
310
Remote Controls
310
Voltage Regulator Repair Time
311
Wire Unit Repair Time
312
Electronic Controls Repair Time
312
Transmissions Repair Time
313
Helmet Bay Repair Time
314
Helmet Compartment
314
Rear Side Fairings Repair Time
315
Front Suspension Repair Time
316
Cooling System Repair Time
317
Braking System Repair Time
318
Brake System
318
Windscreen Repair Time
319
Stickers Repair Time
320
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PIAGGIO X7 250ie Specifications
General
Brand
PIAGGIO
Model
X7 250ie
Category
Scooter
Language
English
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