SERVICE STATION MANUAL

xxxxxx (IT), xxxxxx (EN), xxxxxx (FR), xxxxxx (DE),

xxxxxx (ES), xxxxxx (PT), xxxxxx (NL), xxxxxx (EL)

X7 EVO 300 i.e.

 SERVICE STATION
MANUAL

X7 EVO 300 i.e.

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/models shown in this publication are available in all countries. The availability of each
model should be checked at the official Piaggio sales network.
"© Copyright 2008 - 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
X7 EVO 300 i.e.
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

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
X7 EVO 300 i.e. Characteristics

This section describes the general specifications of the vehicle.

Rules

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

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.

CHAR - 7
Characteristics X7 EVO 300 i.e.

Vehicle identification

To read the chassis prefix, lift the saddle and re-

move the lid «A».

The engine prefix «B» is stamped near the rear left

shock absorber lower support.

VEHICLE IDENTIFICATION
Specification Desc./Quantity
Chassis prefix M62201
Engine prefix M624M

Dimensions and mass

VEHICLE EARTHING
Specification Desc./Quantity
Kerb weight 161 ± 7 kg
Maximum weight allowed 360 kg
VEHICLE EARTHING

CHAR - 8
X7 EVO 300 i.e. Characteristics

Engine

ENGINE
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Cubic capacity 278 cm³
Bore x Stroke 75 X 63 mm
Compression ratio 11 ± 0.5 : 1
Engine idle speed 1,700 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm
Max. power 16 kW at 7500 rpm
MAX. torque 23.8 Nm at 5750 rpm
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Lubrication pressure 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel system Electronic injection with Ø 32-mm throttle body and electric fuel
pump.
Cooling Forced coolant circulation system.
Fuel Unleaded petrol (95 RON)
Exhaust silencer Absorption-type exhaust silencer with a 3-way catalytic con-
verter and lambda probe.
Emissions compliance EURO 3

Transmission

TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque server, V-
belt, self-ventilating dry automatic centrifugal clutch and trans-
mission housing with forced-circulation air cooling.
Final reduction gear Gear reduction unit in oil bath.

Capacities

CAPACITY
Specification Desc./Quantity
Engine oil 1.3 l
Transmission oil 250 cm³
Cooling system fluid ~2l
Fuel tank (reserve) ~ 12 l (~ 2.5 l)
Fork oil (quantity per stem) 133 cm³

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Starter starter
Ignition Electronic inductive discharge ignition, high efficiency, with
separate HV coil.
Ignition advance α/N three-dimensional map managed by control unit
Spark plug NGK CR8EKB
Alternative spark plug -
Battery 12V-12Ah
Alternator alternating current

CHAR - 9
Characteristics X7 EVO 300 i.e.

Frame and suspensions

CHASSIS AND SUSPENSION

Specification Desc./Quantity
Chassis Tubular and steel sheets.
Front suspension Hydraulic telescopic fork with Ø 35-mm stem
Front suspension travel 94 mm
Rear suspension Two double-acting shock absorbers, adjustable to four posi-
tions at preloading.
Rear suspension travel 89 mm

Brakes

BRAKES
Specification Desc./Quantity
Front brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar right-side lever.
Rear brake Ø 240-mm disc brake with hydraulic control operated by the
handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity
Wheel rim type Light alloy wheel rims.
Front rim 14'' x 3.50
Rear rim 13'' x 3.50
Front tyre Tubeless, 120/70-14'' 55P
Rear tyre Tubeless, 140/60 - 13'' 63P
Front tyre pressure (with passenger) 2 bar (2 bar)
Rear tyre pressure (with passenger) 2.2 bar (2.5 bar)

Tightening Torques

STEERING
Name Torque in Nm
Fixing screws for the handlebar control unit U-bolts 7 to 10
Steering tube upper ring nut 40 ÷ 45
Steering tube lower ring nut 14 ÷ 17
Handlebar fixing screw 43 ÷ 47

CHASSIS
Name Torque in Nm
Stand fixing bolt 40 ÷ 45
Engine and vehicle side swinging arm junction bolt 33 to 41
Engine-swinging arm pin 64 ÷ 72
Body shell - Swinging arm pin 76 ÷ 83
Screw fixing the silent-block support plate to the body 42 ÷ 52

FRONT SUSPENSION
Name Torque in Nm
Fork leg screw 6÷7
Front wheel axle 45 to 50
Fork plate screw 25 ÷ 34
Hydraulic rod fixing screw 25 ÷ 35* (apply LOCTITE 242 medium-strength threadlock)

CHAR - 10
X7 EVO 300 i.e. Characteristics

Name Torque in Nm
Stem support clamp tightening screws 20 to 25
Fork locking screws cap 15 ÷ 30

REAR SUSPENSION
Name Torque in Nm
Upper shock absorber retainer 33 to 41
Shock absorber lower clamping 33 to 41
Shock absorber-crankcase attachment bracket 20 to 25
Rear wheel axle 104 to 126
Silencer arm clamping screws 27 - 30
Silencer - muffler supporting arm fixing screws 24 to 27
Lambda probe tightening on exhaust manifold 40 to 50
Manifold - silencer diaphragm tightening clamp 16 to 18

FRONT BRAKE
Name Torque in Nm
Oil bleed screw 12 - 16
Brake disc screws 8 ÷ 10 (apply LOCTITE 243 medium-strength threadlock)
Brake fluid pipe-calliper fitting 20 to 25
Brake fluid pump-hose fitting 16 - 20
Screw tightening calliper to support 20 to 25
Tightening screw for calliper support to the fork 41 ÷ 51

REAR BRAKE
Name Torque in Nm
Oil bleed screw 12 - 16
Brake disc screws 8 ÷ 10 (apply LOCTITE 243 medium-strength threadlock)
Rear brake calliper-pipe fitting 20 to 25
Rear brake pump-pipe fitting 16 - 20
Screw tightening calliper to support 42 ÷ 52

FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 to 13
Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock)
Flywheel nut 94 - 102
Pickup fixing screws 3 to 4
Screw fixing freewheel to flywheel 13 - 15

LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 to 17
Oil filter on crankcase fitting 27 to 33
Engine oil drainage plug/ mesh filter 24 to 30
Oil filter 4 to 6
Oil pump cover screws 7-9
Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 to 14
Oil pump cover plate screws 4 to 6
Oil sump screws 10 to 14
Minimum oil pressure sensor 12 to 14

CYLINDER HEAD
Name Torque in Nm
Spark plug 12 to 14
Head cover screws 6-7
Nuts fixing head to cylinder 7±1 + 10±1 + 270°
Head fixing side screws 11 - 12
Starter ground screw 7 to 8.5

CHAR - 11
Characteristics X7 EVO 300 i.e.

Name Torque in Nm
Tappet adjustment check nut 6-8
Intake manifold screws 11 to 13
Timing chain tensioner slider screw 10 to 14
Starter counterweight support screw 11 to 15
Timing chain tensioner support screw 11 to 13
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4 to 6
Nut fixing muffler to cylinder head 16 ÷ 18

TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 to 13
Clutch unit nut on driven pulley 45 to 50
Drive pulley nut 75 to 83
Transmission cover screws 11 to 13
Driven pulley shaft nut 54 to 60
Rear hub cap screws 24 to 27

CRANKCASE AND CRANKSHAFT

Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half 4 to 6
shaft) screws
Engine-crankcase coupling screws 11 to 13
Starter screws 11 to 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)

COOLING
Name Torque in Nm
Water pump rotor cover 3 to 4
Thermostat cover screws 3 to 4
Bleed screw 3

Overhaul data

Assembly clearances

CHAR - 12
X7 EVO 300 i.e. Characteristics

Cylinder - piston assy.

CYLINDER - PISTON
Specification Desc./Quantity
Plunger diameter 74.967 +0.014 -0.014 mm
Cylinder diameter 75 +0.038 +0.01 mm

COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
cylinder-piston M 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064
cylinder-piston N 75.017 ÷ 75.024 74.960 ÷ 74.967 0.050 ÷ 0.064
cylinder-piston O 75.024 ÷ 75.031 74.967 ÷ 74.974 0.050 ÷ 0.064
cylinder-piston P 75.031 ÷ 75.038 74.974 ÷ 74.981 0.050 ÷ 0.064
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.

- Measure the outer diameter of the gudgeon pin.

Characteristic
Pin outside diameter
16 +0 -0.004 mm

CHAR - 13
Characteristics X7 EVO 300 i.e.

- Measure the diameter of the bearings on the pis-

ton.

Characteristic
Standard diameter
16 +0.006 +0.001 mm

- Calculate the piston pin coupling clearance.

N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 - 0.010 mm

- Carefully clean the sealing ring housings.

- Measure the coupling clearance between the
sealing rings and the piston grooves using suitable
sensors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.

Fitting clearance
Top piston ring - standard coupling clearance
0.015 - 0.06 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance 0.015 - 0.06 mm
Middle piston ring - maximum clearance al-
lowed after use 0.07 mm oil scraper ring - stand-
ard coupling clearance 0.015 - 0.06 mm oil scraper
ring - maximum clearance allowed after use
0.07 mm

CHAR - 14
X7 EVO 300 i.e. Characteristics

- Check that the head coupling surface is not worn

or misshapen.
- Pistons and cylinders are classified according to
their diameter. The coupling must be made with
those of the same type (M-M, N-N, O-O, P-P).

Characteristic
Maximum allowable run-out:
0.05 mm

Crankcase - crankshaft - connecting rod

CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Axial clearance between
crankshaft and connecting rod
Axial clearance between crankshaft and connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Transmissionside half- 16.6 +0-0.05 A D = 0.20 to 0.50
shaft
Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 to 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 to 0.50
Spacer tool 51.4 +0.05 E D = 0.20 to 0.50

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

CHAR - 15
Characteristics X7 EVO 300 i.e.

CRANKSHAFT
Specification Desc./Quantity
Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm
Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm

CHAR - 16
X7 EVO 300 i.e. Characteristics

MAX. ADMISSIBLE DISPLACEMENT

Specification Desc./Quantity
A= 0.15 mm
B= 0.010 mm
C= 0.010 mm
D= 0.10 mm

CHAR - 17
Characteristics X7 EVO 300 i.e.

Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm

- Using a bore gauge, measure the connecting rod

small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANK-
SHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.

Characteristic
Standard diameter
16 +0.025 +0.015 mm

- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure 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 half-bearings, 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 shutters in the oil feeding channels, the matching surface of the two half-bearings must be
perfectly orthogonal 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 BLUE bushings, with YELLOW bushings and with GREEN
bushings.
- 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 classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
- The main bushings are available in three thickness categories, identified by colour markings, as shown
in the table below.

BUSHINGS
TYPE IDENTIFICATION CRANKSHAFT HALF-BEARING
B BLUE 1.973 to 1.976
C YELLOW 1.976 to 1.979

CHAR - 18
X7 EVO 300 i.e. Characteristics

TYPE IDENTIFICATION CRANKSHAFT HALF-BEARING

E GREEN 1.979 to 1.982

COUPLINGS
BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING
HALVES CATEGORY
B 2 29.024 ÷ 29.054
C 1 29.024 ÷ 29.054
2 29.018 ÷ 29.048
E 1 29.018 ÷ 29.048

Combine the shaft with two category 1 crankwebs 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.

CATEGORIES
CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 E
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 C
Cat. 2 Cat. 1 C
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED 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 C BUSHINGS (YEL-
LOW)

Characteristic
Crankshaft-bushing maximum clearance ad-
mitted:
0.08 mm
Diameter of crankcase without bushing
CAT. 1: 32.959 ÷ 32.965 mm
CAT. 2: 32.953 ÷ 32.959 mm

THE CRANKSHAFT is available in two CATEGO-

RIES:

Characteristic
Crankshaft category:
CAT. 1 - CAT. 2

CRANKSHAFT CATEGORY IDENTIFICATION:

CHAR - 19
Characteristics X7 EVO 300 i.e.

The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.
Otherwise, «1 - 2» if done manually with an electric pen. The spare part identification is located on the
package with a drawing number plus FC1/FC2 or (001/002).
If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both
crankcase halves, combining the two components (Shaft and Crankcase) featuring the same category.

Cylinder Head

Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting

- Using a trued bar and a feeler gauge check that

the cylinder head surface is not worn or distorted.

Characteristic
Maximum allowable run-out:
0.1 mm

- In case of faults, replace the head.

- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the camshaft and the rocking lever pin capacities exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant seal plug exhibits no oxidation.

- 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.

CHAR - 20
X7 EVO 300 i.e. Characteristics

Measure the camshaft bearing seats and rocking

lever support pins with a bore meter

HEAD BEARINGS
Specification Desc./Quantity
bearing «A» Diameter 12.000 - 12.018 mm
bearing «B» Ø 20.000 ÷ 20.021 mm
bearing «C» Ø 37.000 - 37.025 mm

- Measure the unloaded valve spring length.

Characteristic
Standard length
40.2 mm
Allowable limit after use:
38.2 mm

- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the
impression on the valve seat "V".

Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm

- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damage, replace the head.

STANDARD VALVE LENGTH

Specification Desc./Quantity
Valve check Standard length Intake: 94.6 mm
Valve check Standard length Exhaust: 94.4 mm

CHAR - 21
Characteristics X7 EVO 300 i.e.

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

STANDARD DIAMETER
Specification Desc./Quantity
Intake: 4.987 - 4.972 mm
Exhaust: 4.975 - 4.960 mm

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity
Intake: 4.96 mm
Exhaust: 4.945 mm

- Calculate the clearance between valve and valve guide.

- Check the deviation of the valve stem by resting

it on a «V» shaped abutment and measuring the
extent of the deformation with a dial gauge.

Characteristic
Limit values admitted:
0.1 mm

CHAR - 22
X7 EVO 300 i.e. Characteristics

- Check the concentricity of the valve head by ar-

ranging a dial gauge at right angle relative to the
valve head and rotate it on a "V" shaped abutment.

Characteristic
Admissible limit:
0.03 mm

Measure the valve guide.

Characteristic
Valve guide:
5 +0.012 mm

- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.

INTAKE
Specification Desc./Quantity
Standard clearance: 0.013 - 0.04 mm
Admissible limit: 0.08 mm

EXHAUST
Specification Desc./Quantity
Standard clearance: 0.025 to 0.052 mm
Admissible limit: 0.09 mm

- Check that there are no signs of wear on the surface of contact with the articulated register terminal.

CHAR - 23
Characteristics X7 EVO 300 i.e.

- If no faults are found during the above checks,

you can use the same valves. To obtain better
sealing performance, grind the valve seats. Grind
the valves gently with a fine-grained lapping com-
pound. During the grinding, keep the cylinder head
with the valve axes in a horizontal position. This
will prevent the 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.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

- Check that the camshaft bearings exhibit no scores or abnormal wear.

- Using a micrometer, measure the camshaft bearings.

STANDARD DIAMETER
Specification Desc./Quantity
Camshaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm
Camshaft check: Standard diameter Bearing B diameter: 19.959 ÷ 19.98 mm

MINIMUM DIAMETER PERMITTED

Specification Desc./Quantity
Camshaft check: Minimum admissible diameter Bearing A Ø: 36.94 mm
Camshaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm

CHAR - 24
X7 EVO 300 i.e. Characteristics

-Using a gauge, measure the cam height.

STANDARD HEIGHT
Specification Desc./Quantity
Camshaft check: Standard height Intake: 30.285 mm
Camshaft check: Standard height Exhaust: 29.209 mm

Check the axial clearance of the camshaft

CAMSHAFT AXIAL CLEARANCE

Specification Desc./Quantity
Camshaft check: Standard axial clearance: 0.11 - 0.41 mm
Camshaft check: Maximum admissible axial clearance 0.42 mm

- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.
- Measure the internal diameter of each rocking lever.

CHAR - 25
Characteristics X7 EVO 300 i.e.

Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment
plate.

ROCKING LEVERS AND PIN DIAMETER:

Specification Desc./Quantity
Rocking lever inside diameter: Standard diameter Diameter 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter Diameter 11.977 - 11.985 mm

Slot packing system

Characteristic
Compression ratio
10.5 ÷ 11.5 : 1

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed
by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls

CHAR - 26
X7 EVO 300 i.e. Characteristics

inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice
versa.
N.B.
MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK-
CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON
A GROUND PLANE

ENGINE 300 SHIMMING

Name Measure A Thickness
SHIMMING 3.70 - 3.60 0.4 ± 0.05
SHIMMING 3.60 - 3.40 0.6 ± 0.05
SHIMMING 3.40 - 3.30 0.8 ± 0.05

Products

RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 4-stroke engines
(throttle control)
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP GP 330 Grease for brake lever, gas White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
AGIP PERMANENT SPECIAL coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
AGIP GREASE PV2 Grease for steering bearings, pin seats Soap-based lithium and zinc oxide
and swinging arm grease containing NLGI 2; ISO-L-
XBCIB2 of the swinging arm

CHAR - 27
INDEX OF TOPICS

TOOLING TOOL
X7 EVO 300 i.e. Tooling

SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats

001467Y014 Calliper to extract ø 15-mm bearings

005095Y Engine support

002465Y Calliper for circlips

006029Y Punch for fitting fifth steering bearing on

steering tube

020004Y Punch for removing steering bearings

from headstock

020055Y Wrench for steering tube ring nut

TOOL - 29
Tooling X7 EVO 300 i.e.

Stores code Description

020074Y Support base for checking crankshaft
alignment

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure check gauge

020201Y Spacer bushing driving tube

020262Y Crankcase splitting plate

020263Y Driven pulley assembly sheath

TOOL - 30
X7 EVO 300 i.e. Tooling

Stores code Description

020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020332Y Digital rpm indicator

TOOL - 31
Tooling X7 EVO 300 i.e.

Stores code Description

020648Y Single battery charger

020335Y Magnetic mounting for dial gauge

020357Y 32x35-mm Adaptor

020358Y 37x40-mm Adaptor
020359Y 42x47-mm Adaptor

020360Y 52x55-mm Adaptor

020363Y 20-mm guide

TOOL - 32
X7 EVO 300 i.e. Tooling

Stores code Description

020375Y 28 x 30 mm adaptor

020376Y Adaptor handle

020382Y Valve cotters equipped with part 012 re-

moval tool

020382Y011 adapter for valve removal tool

020393Y Piston assembly band

020412Y 15-mm guide

TOOL - 33
Tooling X7 EVO 300 i.e.

Stores code Description

020423Y Driven pulley lock wrench

020424Y Driven pulley roller casing fitting punch

020426Y Piston fitting fork

020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

TOOL - 34
X7 EVO 300 i.e. Tooling

Stores code Description

020439Y 17-mm guide

020444Y Tool for fitting/ removing the driven pulley

clutch

020456Y Ø 24 mm adaptor
020477Y 37 mm adaptor

020483Y 30-mm guide

020489Y Hub cover support stud bolt kit

TOOL - 35
Tooling X7 EVO 300 i.e.

Stores code Description

020428Y Piston position check mounting

020680Y Diagnosis Tool

020621Y HV cable extraction adaptor

020481Y Control unit interface wiring

001467Y035 Bearing housing, outside ø 47 mm

020626Y Driving pulley lock wrench

TOOL - 36
X7 EVO 300 i.e. Tooling

Stores code Description

001467Y013 Calliper to extract ø 15-mm bearings

020627Y Flywheel lock wrench

020467Y Flywheel extractor

020454Y Tool for fitting piston pin stops (200 - 250)

020622Y Transmission-side oil seal punch

020480Y Petrol pressure check kit

TOOL - 37
Tooling X7 EVO 300 i.e.

Stores code Description

020244Y 15-mm diameter punch

020115Y Ø 18 punch

020271Y Tool for removing-fitting silent bloc

020469Y Reprogramming kit for vehicle diagnostic

tester

020487Y Fork oil seal extractor

020458Y Puller for lower bearing on steering tube

TOOL - 38
X7 EVO 300 i.e. Tooling

TOOL - 39
INDEX OF TOPICS

MAINTENANCE MAIN
X7 EVO 300 i.e. Maintenance

Maintenance chart

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Replace every 2 years

Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Valve clearance A A A
Driving belt R R R R
Sliding shoes / CVT rollers R R R R R R
Spark plug R R R R R R
Air filter C C C C C C
Belt compartment air filter I I I I I I
Engine oil R I R I R I R I R I R I R
Oil filter R R R R R R R
Oil filter (mesh) C
Hub oil R I R I R I R
Coolant * I I I I I I I
Radiator (external cleaning) I I I I
Brake fluid * I I I I I I I
Brake pads I I I I I I I I I I I I I
Brake levers L L L L L L L
Throttle control A A A A A A A
Electrical system and battery I I I I I I I
Suspension I I I I I I
Steering A A A A A A A
Headlight direction adjustment A A A A
Transmission L L L L
Centre stand L L
Safety fasteners I I I I I
Tyre pressure and wear I I I I I I I
Vehicle road test I I I I I I I

Checking the spark advance

The ignition advance is determined electronically

on the basis of parameters known by the control
unit. For this reason it is not possible to interpret
the reference values based on the engine rpm.
The ignition advance value is detectable at any
time using the diagnostic tester. It is possible to
check whether the ignition advance determined by
the injection system matches the value actually
activated on the engine, by means of the strobo-
scopic light.
Proceed as follows:
- Remove the spark plug.
- Remove the transmission crankcase.

MAIN - 41
Maintenance X7 EVO 300 i.e.

- Rotate the driving pulley fan until the reference

marks between the flywheel and flywheel cover
coincide as shown in the photograph.
- Bring the reference mark onto the transmission
side between the fan and the transmission cover
as shown in the picture.
- Refit the spark plug.
- Refit the plastic cap on the flywheel cover.
- Adjust the spark gap to the contact position (no
reference mark visible) and install it on the engine
between the spark plug and spark plug cap
- Connect the induction clamp on the spark gap
cable respecting the proper polarity (the arrow on
the clamp must be pointing at the spark plug).
- Connect the diagnostic tester.
- Start the engine.
- Select the «Parameters» function in this menu.
- Set the stroboscopic light control to the traditional
four-stroke engine position (1 spark, 2 revs).
- Check that the real values of rpm and ignition
advance match those measured using the diag-
nostic tester.
If the values do not correspond, check:
- distribution timing
- revolution timing sensor
- injection control unit

Specific tooling
020680Y Diagnosis Tool
020330Y Stroboscopic light to check timing
020621Y HV cable extraction adaptor

MAIN - 42
X7 EVO 300 i.e. Maintenance

Spark plug

To service the spark plug the engine must be cold;

proceed as follows:
- Remove the spark plug inspection lid placed on
the right side of the vehicle by undoing the speci-
fied screw.

- Remove the spark plug cap by turning it clock-

wise until it is released from the head retainer.
- Remove the spark plug with the supplied wrench.
- 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 bend-
ing the outer electrode forward or away.
- Make sure the sealing washer is in good condi-
tions.
- Fit the spark plug, screw it manually and lock it
to the prescribed torque with a spark plug spanner.
- Refit the spark plug inspection lid.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE EN-
GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-
TED IN THE SCHEDULED MAINTENANCE TABLE. USING
NON-COMPLYING IGNITION CONTROL UNITS OR SPARK
PLUGS OTHER THAN THOSE PRESCRIBED MAY SERI-
OUSLY DAMAGE THE ENGINE.

Characteristic
Spark plug
NGK CR8EKB
Electrode gap
0.7 to 0.8 mm

Locking torques (N*m)

Spark plug 12 to 14

Hub oil

MAIN - 43
Maintenance X7 EVO 300 i.e.

Check

-Park the vehicle on its centre stand on flat ground;

- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;
- Remove the dipstick and check that the oil level
is slightly over the notch; if the level is below the
notch indicated by the arrow, refill the hub with the
right amount of oil.
-Screw up the oil dipstick again and make sure it
is locked properly into place.

Replacement

- Remove the oil filler plug "A".

- Remove the rear wheel.

- Unscrew the oil drainage cap «B» and drain out

all the oil.
- Screw in the drainage plug again and fill the hub
with the recommended 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
250 cm³

Locking torques (N*m)

Hub oil drainage plug 15 to 17

MAIN - 44
X7 EVO 300 i.e. Maintenance

Air filter

To reach the air filter:

- Undo the nine screws «A».
- Remove the air-box cover «B»

Cleaning:
- Wash the sponge with water and mild soap.
- Dry it with a clean cloth and short blasts of com-
pressed air.
- Soak it in a mixture of 50% petrol and 50% speci-
fied oil.
- Gently squeeze the filtering element with your
hands but do not wring it; allow it to drip dry and
then refit.
CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NEC-

ESSARY TO CARRY OUT MAINTENANCE CHECKS OF
THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE
ENGINE.

Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad-
hesiveness

MAIN - 45
Maintenance X7 EVO 300 i.e.

Engine oil

In four stroke engines, the engine oil is used to lubricate the distribution elements, the bench bearings
and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should
be considered normal, especially if during the run-in period. Consumption levels in particular can be
influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Change oil and replace filter as indicated in the

scheduled maintenance table.
- In order to facilitate oil drainage, unscrew the cap/
dipstick «A».

- Unscrew the mesh pre-filter drainage plug «B»

on the flywheel side and let the oil drain off.
- Once all the oil has drained through the drainage
hole, unscrew and remove the oil cartridge filter
«C ».

Make sure the pre-filter and drainage plug O-rings

are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing
them up to the prescribed torque.
Refit the new cartridge filter being careful to lubri-
cate the O-ring before fitting it.
Add the recommended engine oil through plug
«A». Then start up the vehicle, let it run for a few
minutes and shut 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.

MAIN - 46
X7 EVO 300 i.e. Maintenance

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 require-
ments of API SL, ACEA A3, JASO MA specifica-
tions

Characteristic
Engine oil
1.3 l

Check
This operation must be carried out with the en-
gine cold and following the procedure below:
- Place the vehicle on its centre stand and on flat
ground.
- Make sure the adjustment of the rear suspension
is set to the minimum preloading position.
- Unscrew the cap/dipstick «A», dry it with a clean
cloth and reinsert it, by screwing it in complete-
ly.
-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 cor-
rect check, wait at least 10 minutes after the en-
gine has been stopped so as to get the correct
level.
Oil top-up
The oil should be topped up after having checked the level and in any case by adding oil without ex-
ceeding the MAX level indicated on the cap/ dipstick.Restoring the level from MIN to MAX requires
approximately 400 cm³ of oil.

Engine oil filter

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.

MAIN - 47
Maintenance X7 EVO 300 i.e.

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

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

Oil pressure warning light

The vehicle is equipped with a telltale light on the

dashboard that lights up when the key is turned to
the «ON» position. However, this light should
switch off once the engine has started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication sys-
tem.

Checking the ignition timing

- Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark «T» on
the rotor matches the reference mark on the fly-
wheel cover 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 ref-
erence is opposite the indicator on the head, turn
the crankshaft once more.
For the use of this reference mark, remove the
spark plug and turn the engine in the direction that
is the reverse of the normal direction using a cal-
liper spanner applied to the camshaft command
pulley casing.

MAIN - 48
X7 EVO 300 i.e. Maintenance

Cooling system

If noise or liquid leaks through the drain bore of the water pump are detected, the pump must be replaced
as described in the «Flywheel cover» Chapter.
CAUTION
FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM, SEE CHAPTER "COOLING
SYSTEM".

Level check

Check coolant when the engine is cold and as in-

dicated in the scheduled maintenance tables, fol-
lowing the steps below.
- Set the vehicle upright on the stand and remove
the cover by undoing screw «A».

- Remove the expansion tank cover «B» by turning

it anticlockwise.

- Look inside the expansion tank and check that

the level is between MIN and MAX. Top up if the
coolant is below the MIN level.
If the level is not correct, proceed to top-up when
the engine is cold. If it is necessary to top up the
coolant frequently, or if the expansion tank is com-
pletely dry, you should look for the cause in the
cooling system.
WARNING

TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW

THE EXPANSION TANK COVER WHILE THE ENGINE IS
STILL HOT.
WARNING

MAIN - 49
Maintenance X7 EVO 300 i.e.

IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RID-

ING, IT IS IMPORTANT TO MAKE SURE THAT THE LEVEL
DOES NOT EXCEED THE REFERENCE TONGUE TOO
MUCH.
TO ENSURE CORRECT ENGINE OPERATION, KEEP THE
RADIATOR GRILLE CLEAN.

Recommended products
AGIP PERMANENT SPECIAL coolant
Monoethylene glycol-based antifreeze fluid, CU-
NA NC 956-16

Braking system

Level check

The front and rear brake fluid reservoirs are both

positioned on the handlebar. 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 brake pads.

Top-up

Proceed as follows:
- Remove the rear-view mirrors.
- Working from both sides of the vehicle, undo the
three screws «A» and remove the front frame.

MAIN - 50
X7 EVO 300 i.e. Maintenance

- Remove the windshield.

- Undo the screw «B» and remove the front han-
dlebar cover «C» partially.

- Remove the cap «E» by loosening the two

screws «D» and restore the fluid level by adding
prescribed fluid type only, without exceeding the
maximum level.
This operation applies to top up the rear brake
pump. Follow the same procedure for the front
one.
WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. BRAKING CIR-

CUIT FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE
THAT IT DOES NOT COME INTO CONTACT WITH THE
PAINTWORK.
CAUTION

AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN,

AND CLOTHING. IN CASE OF CONTACT, RINSE WITH WA-
TER. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC,
THAT IS, IT ABSORBS HUMIDITY FROM THE SURROUND-
ING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EX-
CEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFI-
CIENT BRAKING. NEVER USE BRAKING FLUID KEPT IN
CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR
PARTIALLY USED.

Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid

MAIN - 51
Maintenance X7 EVO 300 i.e.

Headlight adjustment

Proceed as follows:
- Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pres-
sure, onto a flat surface, 10 m away from a half-lit
white screen; make sure the vehicle axis is per-
pendicular to the screen.
- Turn on the headlight and check that the border-
line 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.
- Otherwise, adjust the headlight.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.

In order to adjust the light beams:

- Remove the PIAGGIO clip-on badge and undo
the screw «A».

- Working on both sides of the vehicle, undo the

screw «B» and remove the front headlight cover.

MAIN - 52
X7 EVO 300 i.e. Maintenance

- Act on the screws «C» in order to aim the light

properly.

MAIN - 53
INDEX OF TOPICS

TROUBLESHOOTING TROUBL
X7 EVO 300 i.e. Troubleshooting

This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.

Engine

Poor performance

POOR PERFORMANCE
Possible Cause Operation
Fuel pump Check the injection load relay
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Silencer 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.
Oil level exceeds maximum Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Drive 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 neces-
sary
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 unit

Starting difficulties

DIFFICULT STARTING
Possible Cause Operation
Rpm too low at start-up or engine and start-up system dam- Check the starter motor, the system and the torque limiter
aged
Incorrect valve sealing or valve adjustment 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 engine 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.
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
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 tightened Replace the intake coupling and check the clamps are tight-
ened

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves

TROUBL - 55
Troubleshooting X7 EVO 300 i.e.

Possible Cause Operation

Misshapen/worn valve seats Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil seal Replace the valve oil seal
Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

LOW LUBRICATION PRESSURE

Possible Cause Operation
By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation
Faulty clutch Check that there is no grease on the masses. Check that the
clutch mass faying surface with the bell 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

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation
Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check 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.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
vehicle.

Brakes overheating

BRAKE OVERHEAT
Possible Cause Operation
Defective plunger sliding Replace the calliper.
Brake disc slack or distorted 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.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace the calliper.

TROUBL - 56
X7 EVO 300 i.e. Troubleshooting

Electrical system

Battery

BATTERY
Possible Cause Operation
Battery 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

Heavy steering

STEERING HARDENING
Possible Cause Operation
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation
Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.

Noisy suspension

NOISY SUSPENSION
Possible Cause Operation
Malfunctions in the suspension system If the front suspension is noisy, check: tightening torques,
headstock components, inspect forks.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation
Faulty or broken seals Replace the shock absorber

TROUBL - 57
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

X7 EVO 300 i.e. Electrical system

Key:
1. Magneto flywheel
2. Voltage regulator
3. Fuse F1 - 30A
4. Battery 12V-12Ah
5. Starter remote control switch
6. Starter motor
7. Starter button
8. Stop light remote control
9. Stop buttons
10. Stop light bulb (12V - 21/5W)
11.Fuse F10 - 7.5A
12. Turn indicator control device
13. Turn indicator switch
14. Pre-installation for anti-theft device
15. Horn button
16. Horn
17. Turn indicator warning light bulb (12V - 2W)
18. Turn indicator bulb (12V - 10W)
19. Light switch

ELE SYS - 59
Electrical system X7 EVO 300 i.e.

20. High-beam light flashing switch

21.Fuse F11 - 7.5A
22.Fuse F12 - 7.5A
23. High-beam warning light bulb (12V - 2W)
24. High beam bulb (12V - 55W)
25. Low beam bulb (12V - 55W)
26. Front and rear daylight bulbs and license plate light (12V - 5W)
27. Instrument panel lighting bulbs (12V - 1.2W)
28.Fuse F3 - 15A
29. Light solenoid
30.Fuse F2 - 15A
31. Key switch contacts
32.Fuse F7 - 3A
33.Fuse F8 - 7.5A
34.Fuse F9 - 7.5A
35.Fuse F6 - 3A
36.Digital clock
37.Preinstallation for satellite navigation system
38. Oil pressure warning light bulb (12V - 2W)
39. Oil pressure sensor
40. Low fuel warning light bulb (12V - 2W)
41. Fuel level transmitter
42. Fuel gauge
43. Water temperature gauge
44.Immobilizer Aerial
45.Engine control warning light
46. Injection electronic control unit
47. Diagnostics socket
48.Coolant temperature sensor:
49.Engine stop switch
50. Fuel supply pump
51. Fuel injector
52. Lambda probe
53. HV coil
54. Engine rpm sensor
55. Immobilizer LED
56. Injection load remote control
57.Fuse F5 - 15A

ELE SYS - 60
X7 EVO 300 i.e. Electrical system

58.Fuse F4 - 15A
59. Electric fan remote control
60. Radiator electric fan
61. Fuel port opening switch
62. Fuel port actuator

Key
Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr:Grey
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Components arrangement

1. Injection ECU: Remove the inspection flap

placed in the helmet compartment to reach it.

ELE SYS - 61
Electrical system X7 EVO 300 i.e.

2. Stator: Remove the left side fairing to reach the

connector.

3. Remote control switches: Remove the shield

back plate to reach them.
KEY
A. Injection load remote control switch
B. Stop light remote control switch
C. Remote control switch for electric fan
D. Headlight remote control switch

4. Turn indicators control device: Remove the leg-

shield to reach it.

5. Horn: Remove the left footrest to reach it.

ELE SYS - 62
X7 EVO 300 i.e. Electrical system

6. Fuel level transmitter: Remove the central cover

to reach it.

7. Spark plug: Remove the lid placed on the right

side fairing to reach it.

Characteristic
Spark plug
CHAMPION RG 4 PHP

8. HV coil: remove the right side fairing in order to

reach it.

Characteristic
HV coil resistance primary value:
~ 0.9 Ω
HV coil secondary resistance value
~ 3.4 kΩ

9.Oil pressure sensor: On the engine, on the low

right-hand side.

ELE SYS - 63
Electrical system X7 EVO 300 i.e.

10. Start-up remote control switch: Remove the

right side fairing to reach it.

11. Voltage regulator: Remove the side fairings to

reach it.

12. Battery: Remove the battery cover placed in

the helmet compartment to reach it.

Electric characteristic
Battery
12V 12Ah

13. Diagnostics socket: Remove the battery cover

placed in the helmet compartment to reach it.

ELE SYS - 64
X7 EVO 300 i.e. Electrical system

14. Fuses: Remove the battery cover placed in the

helmet compartment to reach them.

15. Fuel port actuator: Remove the left footrest to reach them.

16.Immobilizer Aerial: Remove the legshield to

reach it. The aerial is placed on the key switch.

Ground points

There are three ground points in the electrical system:

A. Ground point on the chassis. Remove the left

footrest to reach it.

B. Ground point on the chassis. Remove the left

footrest to reach it.

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Electrical system X7 EVO 300 i.e.

C. Ground point on the engine. Placed at the bot-

tom at the back of the left side fairing.

Conceptual diagrams

Ignition

Key:
4. 12V-12Ah Battery
30.Fuse F2 - 15A
31. Key switch contacts
33.Fuse F8 - 7.5A
44.Immobilizer Aerial
45.Engine control warning light
46. Injection electronic control unit

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X7 EVO 300 i.e. Electrical system

47. Diagnostics socket

49.Engine stop switch
53. HV coil
55. Immobilizer LED
56. Injection load remote control
57.Fuse F5 - 15A
KEY
Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red
Gre: Green Pr: Purple

Battery recharge and starting

Key:
1. Magneto flywheel
2. Voltage regulator
3. Fuse F1 - 30A
4. 12V-12Ah Battery
5. Start-up remote control switch
6. Starter motor
7. Starter button
8. Stop light remote control

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Electrical system X7 EVO 300 i.e.

9. Stop buttons
10. Stop light bulb (12V - 21/5W)
11.Fuse F10 - 7.5A
30.Fuse F2 - 15A
31. Key switch contacts
33.Fuse F8 - 7.5A
46. Injection electronic control unit
57.Fuse F5 - 15A
KEY
Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red
Gre: Green Pr: Purple

Level indicators and enable signals section

Key:
4. 12V-12Ah Battery
29. Light solenoid
30.Fuse F2 - 15A
31. Key switch contacts
32.Fuse F7 - 3A
33.Fuse F8 - 7.5A

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X7 EVO 300 i.e. Electrical system

37.Preinstallation for satellite navigation system

38. Oil pressure warning light bulb (12V - 2W)
39. Oil pressure sensor
40. Low fuel warning light bulb (12V - 2W)
41. Fuel level transmitter
42. Fuel gauge
43. Water temperature gauge
44.Immobilizer Aerial
46. Injection electronic control unit
48.Coolant temperature sensor:
49.Engine stop switch
50. Fuel supply pump
51. Fuel injector
52. Lambda probe
54. Engine speed sensor
56. Injection load remote control
57.Fuse F5 - 15A

KEY
Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red
Gre: Green Pr: Purple

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Electrical system X7 EVO 300 i.e.

Devices and accessories

Key:
11.Fuse F10 - 7.5A
12. Turn indicator control device
13. Turn indicator switch
14. Pre-installation for anti-theft device
15. Horn button
16. Horn
17. Turn indicator warning light bulb (12V - 2W)
18. Turn indicator bulb (12V - 10W)
30.Fuse F2 - 15A
31. Key switch contacts
32.Fuse F7 - 3A
33.Fuse F8 - 7.5A
35.Fuse F6 - 3A
36.Digital clock
46. Injection electronic control unit
50. Fuel supply pump
53. HV coil

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X7 EVO 300 i.e. Electrical system

56. Injection load remote control

57.Fuse F5 - 15A
58.Fuse F4 - 15A
60. Radiator electric fan
61. Fuel port opening switch
62. Fuel port actuator
KEY
Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red
Gre: Green Pr: Purple

Lights and turn indicators

Key:
4. 12V-12Ah Battery
11.Fuse F10 - 7.5A
12. Turn indicator control device
13. Turn indicator switch
17. Turn indicator warning light bulb (12V - 2W)
18. Turn indicator bulb (12V - 10W)
19. Light switch
20. High-beam light flashing switch

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Electrical system X7 EVO 300 i.e.

21.Fuse F11 - 7.5A

22.Fuse F12 - 7.5A
23. High-beam warning light bulb (12V - 2W)
24. High beam bulb (12V - 55W)
25. Low beam bulb (12V - 55W)
26. Front and rear daylight bulbs and license plate light (12V - 5W)
27. Instrument panel lighting bulbs (12V - 1.2W)
28.Fuse F3 - 15A
29. Light solenoid
30.Fuse F2 - 15A
31. Key switch contacts
33.Fuse F8 - 7.5A
34.Fuse F9 - 7.5A
46. Injection electronic control unit
57.Fuse F5 - 15A

KEY
Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red
Gre: Green Pr: Purple

Checks and inspections

This section is dedicated to the checks on the electrical system components.

Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system.
The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with
coded keys recognised by the control unit. The code is integrated in a transponder in the key block.
This allows the driver clear operation without having to do anything other than just turning the key. The
Immobilizer system consists of the following components:
- an electronic control unit
- immobilizer aerial
- master key with built-in transponder
- service key with built-in transponder
- HV coil
- diagnosis LED
The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the key
switch is set to «OFF» or the engine emergency cut-off switch is set to «OFF». It remains activated for
48 hours in order not to affect the battery charge. When the ignition switch is turned to «ON», the

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X7 EVO 300 i.e. Electrical system

deterring blinker function is deactivated. Subsequently, a flash confirms the switching to « ON». The
duration of the flash depends on the programming of the electronic control unit If the LED is off regard-
less of the position of the ignition-key switch and/or the instrument panel is not initiated, check if:
- there is battery voltage
- fuses F2 and F8 efficiency
- there is power to the control unit as specified below:

With the key switch set to OFF:

- if there is battery voltage between terminals 6-26
and terminal 6-chassis ground (fixed power sup-
ply). If there is no voltage, check that fuse F5 and
its cable harness are in working order.

With the key switch in the OFF position:

- if there is battery voltage between terminals 5-26
and terminals 5-chassis ground (fixed power sup-
ply). If there is no voltage, check the key switch
contacts, and that fuses F2 and F8 and their cable
harnesses are in working order.

- There is continuity between terminals 12-18 with

the emergency cut-off switch set to «RUN». If
there is no continuity, check their contacts.

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Electrical system X7 EVO 300 i.e.

After removing the leg shield back plate, remove

the electrical connection from the aerial as shown
in the picture.

Remove the protective base from the connector.

With the ignition key switch set to ON, check there

is battery voltage between the Red-Green and
Black cables

With MIU connector disconnected, check the con-

tinuity between the Orange-White cable and pin 7
of the interface wiring.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

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X7 EVO 300 i.e. Electrical system

Virgin circuit

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The
keys can only be recognised if the control unit has been programmed properly. The data storage pro-
cedure for a previously not programmed control unit provides for the recognition of the Master as the
first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The Master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3
seconds).
- Insert the service key and turn it to «ON» for 2 seconds.
- If you have copies of the key, repeat the operation with each key.
- 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 service keys can be programmed at one time.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, the Master key transponder is strictly matched with the control
unit. With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore
necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key
becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In
any case it is advisable to use resistive spark plugs.

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Electrical system X7 EVO 300 i.e.

Diagnostic codes

The Immobilizer system is tested each time the

key switch is turned from «OFF» to «ON». During
this diagnosis phase a number of control unit sta-
tuses can be identified and various light codes
displayed. Regardless of the code transmitted, if
at the end of the diagnosis the LED remains off
permanently, the ignition is enabled. If, however,
the LED remains on permanently, it means the ig-
nition is inhibited:
1. Previously unused control unit - key inser-
ted: a single 2 second flash is displayed, after
which the LED remains off permanently. The keys
can be stored to memory, the vehicle can be star-
ted but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transpond-
er absent or cannot be used: The LED is per-
manently ON; in this condition, no operations are
possible, including starting of the vehicle.

3. Programmed control unit - the service key in

(normal condition of use): a single 0.7-second
flash is displayed, after which the LED remains off
steadily. The engine can be started.
4. Programmed control unit - Master key in: a
0.7 sec. flash is displayed followed by the LED re-
maining off for 2 sec. and then by short 0.46 sec.
flashes the same number of times as there are
keys stored in the memory including the Master
key. When the diagnosis has been completed, the
LED remains permanently OFF. The engine can
be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be trans-
mitted are:
- 1-flash code
- 2-flash code

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X7 EVO 300 i.e. Electrical system

- 3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the se-

rial line is not present or is not detected. Check the
Immobilizer aerial wiring and change it if necessa-
ry.

Diagnostic code - 2 flashes

A two-flash code shows a system where the con-

trol unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
Turn the switch to «ON» using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. If this
is not the case, replace the defective key and/or
reprogram the control unit.

Diagnostic code - 3 flashes

A three-flash code indicates a system where the

control unit does not recognise the key. Turn the
switch to «ON» using several keys: if the error
code is repeated even with the Master key, replace
the control unit. If this is not the case, reprogram
the decoder.

Ignition circuit

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Electrical system X7 EVO 300 i.e.

No spark plug
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
HV coil primary resistance value:
Disconnect the connector of the HV coil and meas-
ure the resistance between the two terminals.

Characteristic
HV coil resistance primary value:
~ 0.9 Ω

HV coil secondary resistance value:

1) Disconnect the HV cable from the spark plug
and measure the resistance between the spark
plug cap and the HV coil negative terminal.
2)Disconnect the spark plug cap from the HV cable
and measure the resistance between the HV cable
end and the HV coil negative terminal (see figure).
3) Measure the resistance between the 2 ends of
the spark plug cap.

Characteristic
HV coil secondary resistance value with spark
plug cap
~ 8.4 kΩ
HV coil secondary resistance value:
~ 3.4 kΩ
Spark plug cap resistance value
~ 5 kΩ

Battery recharge circuit

The recharge circuit is provided with a three-phase generator with permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
This, in its turn, is connected directly to the ground and the battery positive terminal passing through
the 30A protection fuse F1.
The three-phase generator provides good recharge power and at low revs, a good compromise is ach-
ieved between generated power and idle stability.

ELE SYS - 78
X7 EVO 300 i.e. Electrical system

Remote controls check

To check the operation of a solenoid:

1) Check that, given regular conditions, there is no
continuity between terminals 87 and 30.
2) Apply a 12V voltage to power terminals 86 and
85 of the solenoid.
3) With the solenoid fed, check that there is con-
tinuity between terminals 87 and 30.
4) If these conditions are not met, the solenoid is
surely damaged and, therefore, it should be re-
placed.

Switches check

To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.

KEY
Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red
Gre: Green Pr: Purple

ENGINE STOP SWITCH

STARTER BUTTON

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Electrical system X7 EVO 300 i.e.

LIGHT SWITCH

IGNITION KEY

TURN INDICATOR SWITCH

HORN BUTTON

ELE SYS - 80
X7 EVO 300 i.e. Electrical system

FUEL PORT OPENING SWITCH

Stator check
WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Disconnect the connector between stator and
regulator with the three yellow cables as shown in
the photograph.
2) Measure the resistance between each of the
yellow terminals and the other two.

Characteristic
Stator phase resistance value
~ 0.6 Ω

3) Check that there is insulation between the each yellow cable and the ground.

Voltage regulator check

With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high
running engine.
Voltage should not exceed 15 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.

Electric characteristic
Control voltage
14÷15 V to 1500÷12000 rpm

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Electrical system X7 EVO 300 i.e.

Recharge system voltage check

Connect the ammeter induction clamp to the volt-

age regulator positive terminal, measure the bat-
tery voltage and turning on the vehicle lights with
the engine off, wait for the voltage to settle at about
12 Volt. Start the engine and measure the current
generated by the system with the 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.

Starter motor

KEY
1. Battery
2. Fuse F2
3. Key switch contacts
4. Fuse F10
5. Stop button on rear brake
6. Stop button on front brake
7. Injection ECU

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X7 EVO 300 i.e. Electrical system

8. Starter button
9. Starter remote control switch
10. Starter motor
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If the starter motor does not operate correctly, proceed as follows:
1) Check the continuity of the Red cable between the battery and the start-up remote control switch.
Also check continuity between the latter and the starter motor.
2) Check the starter motor ground connection.
3) Check fuses F2 and F10.
4) Check key switch contacts.
5) Check stop buttons and the starter button.
6) Check the start-up remote control switch.
7) Check wiring continuity.

Horn control

KEY
1. Battery
2. Fuse F2
3. Key switch contacts
4. Fuse F10
5. Horn button

ELE SYS - 83
Electrical system X7 EVO 300 i.e.

6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
In case the horn does not operate correctly, proceed as follows:
1) Check fuses F2 and F10.
2) Check key switch contacts and horn button.
3) Check wiring continuity.
4) Check the horn ground connection.

Turn signals system check

KEY
1. Battery
2. Fuse F2
3. Key switch contacts
4. Fuse F10
5. Turn indicators control device
6. Turn indicator switch
7. Left turn indicator bulbs
8. Right turn indicator bulbs
9. Turn indicator warning light bulb
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.

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X7 EVO 300 i.e. Electrical system

If the circuit does not work properly, proceed as follows:

1) Check that bulbs operate properly.
2) Check fuses F2 and F10.
3) Check key switch contacts.
4) With the key switch set to «ON», check if there is intermittent voltage between the output Blue-Black
cable from the turn indicator control device and the ground lead.
5) If no voltage is detected, check cable harness continuity and, if necessary, restore it. If it is not
damaged, replace the turn indicator control device.
6) Check the turn indicator switch.
7) Check turn indicator switch cable harness continuity.
8) Check the bulbs ground connection.

level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If faults are detected:
1) With a multimeter, check resistance values be-
tween the White-Green cable and the Black cable
of the fuel level transmitter by moving the arm with
the float.
2) If the transmitter operates correctly but the in-
dication on the instrument panel is not exact,
check that the cable harnesses between them are
not interrupted.

Electric characteristic
Resistance value when the tank is full
<= 7 Ω
Resistance value when the tank is empty
90 +13/-3 Ω

Lights list

LIGHT BULBS TABLE

Specification Desc./Quantity
1 High-beam light bulb Type: HALOGEN (H7)
Power: 12V - 55W
Quantity: 1
2 Low-beam bulb Type: HALOGEN (H7)
Power: 12V - 55W
Quantity: 1
3 Front side light bulb Type: Incandescent (W2.1x9.5d)

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Electrical system X7 EVO 300 i.e.

Specification Desc./Quantity
Power: 12V - 5W
Quantity: 2
4 Front turn indicator light bulb Type: Incandescent (BAU 15s)
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
5 Rear turn indicator light bulb Type: Incandescent (BAU 15s)
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
6 Tail light and stop light bulb Type: Incandescent (BAY 15d)
Power: 12V - 5/21W
Quantity: 2
7 License plate bulb Type: Incandescent (W2.1x9.5 d)
Quantity: 1
Power: 12V - 5W

Fuses

The electrical system is fitted with twelve fuses

divided between two fuse boxes, located in the
battery compartment, for the protection of the var-
ious circuits in the system.
The chart shows the position and specifications of
the fuses in the vehicle.
CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE

THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).

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X7 EVO 300 i.e. Electrical system

FUSES
Specification Desc./Quantity
1 Fuse F1 Capacity: 30 A
Protected circuits: Battery recharge circuit.
2 Fuse F2 Capacity: 15A
Protected circuits (live):Headlight remote control,
fuses F 7-8-9-10-11 and fuel port actuator.
Battery-powered immobilizer LED.
3 Fuse F3 Capacity:15A
Protected circuits: Light switch (via remote control)
4 Fuse F4 Capacity: 15A
Protected circuits:Electric fan (via remote control)
5 Fuse F5 Capacity: 15A
Protected circuits:Injection load (via remote control),
injection ECU.
6 Fuse F6 Capacity:3A
Protected circuits: Clock, pre-installation for antitheft
device.
7 Fuse F7 Capacity:3A
Protected circuits (live): Anti-theft device, satellite nav-
igation system, warning lights and instrument panel in-
dicators.
8 Fuse F8 Capacity: 7.5 A
Protected circuits (live): Injection load remote control,
injection ECU, electric fan remote control, immobilizer
aerial.
9 Fuse F9 Capacity: 7.5 A
Protected circuits (live): Position lights, license plate
light, instrument panel lighting.
10 Fuse F10 Capacity: 7.5 A
Protected circuits (live): Stop lights, start-up circuit,
horn, turn indicators.
11 Fuse F11 Capacity: 7.5 A
Protected circuits (live): High-beam light.
12 Fuse F12 Capacity:7.5 A
Protected circuits (live):Low-beam light.

ELE SYS - 87
Electrical system X7 EVO 300 i.e.

Dashboard

A = Coolant temperature gauge

B = Engine control telltale light and injection system failure warning light
F = Low oil pressure warning light
D = Left turn indicator warning light
E = Speedometer with twin scale (km/h and mph)
F = Odometer
G = Right turn indicator warning light
H = High-beam warning light
I = Low fuel warning light
L = Fuel gauge
M = Immobilizer LED
N = Digital clock

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.

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X7 EVO 300 i.e. Electrical system

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 re-
quired, before storing the vehicle and afterwards every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a standard 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 to 14.70V
- Initial charge voltage equal to 0.3 to 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 battery rated capacity
- Charge time: Maximum 5 h

Battery installation

VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO
CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN.
AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN

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Electrical system X7 EVO 300 i.e.

1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.

2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulfuric
acid.

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
5) Take out the container.
Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Now, gently pull the container out from the battery, only do this when the
container is completely empty, and proceed immediately to the next point.
6) Battery closing.
Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure
that the strip is levelled with the top part of the battery.

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X7 EVO 300 i.e. Electrical system

Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Place the battery down for 1 to 2 hours prior to the charging from the battery.

7) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
The dry charge battery MF like the completely loa-
ded YTX, must have a no-load voltage between
12.8 - 13.15 V Bring the battery to full charge, us-
ing the 020648Y battery charger:
a - select the type of battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
c - connect the clamps of the battery charger to the
battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

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Electrical system X7 EVO 300 i.e.

e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.

f - Check the ignition of the green LED indicated

with a red arrow in figure.

g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place

h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge pro-
cedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

ELE SYS - 92
X7 EVO 300 i.e. Electrical system

Connectors

INSTRUMENT PANEL CONNECTOR «A»

1. Low fuel warning light (Yellow-Green)
2. Live supply (White-Red)
3. High-beam warning light (Purple)
4. Right turn indicator warning light (White-Blue)
5. Fuel level indicator (White-Green)
6. Instrument panel lighting (Yellow-Black)

INSTRUMENT PANEL CONNECTOR «B»

1. Ground (Black)
2. Left turn indicator warning light (Pink)
3. Coolant temperature signal (Blue-Black)
4. Live supply (White-Red)
5. Injection telltale light (Brown-Black)

OIL WARNING LIGHT CONNECTOR

1. Minimum oil pressure signal (White-Pink)
2. Live supply (White-Red)

CLOCK CONNECTOR
1. Battery positive (Blue-Red)
2. Ground (Black)

ELE SYS - 93
Electrical system X7 EVO 300 i.e.

IMMOBILIZER LED CONNECTOR

1. Negative from control unit (Yellow)
2. Battery positive (Red-Black)

FUEL PUMP CONNECTOR

1. Not connected
2. Ground lead (Black)
3. Not connected
4. Not connected
5. Power from solenoid (Black-Green)

ELECTRIC FAN CONNECTOR

1. Power via remote control (Red)
2. Ground (Black)

MAGNETO FLYWHEEL CONNECTOR

1. Engine revolution sensor ECU positive (Red)
2. Engine revolution sensor ECU negative (Brown)
3. Oil pressure sensor (White-Pink)

ELE SYS - 94
X7 EVO 300 i.e. Electrical system

ANTI-THEFT DEVICE PRE-INSTALLATION

CONNECTOR
1. LHS Turn indicator bulbs (Pink)
2. RHS Turn indicator bulbs (White-Blue)
3. Ground (Black)
4. Battery-powered (Blue-Red)
5. Live supply (White-Red)
6. Not connected
7. Not connected
8. Not connected

LAMBDA PROBE CONNECTOR

1. Lambda probe ECU positive (Sky blue-Yellow)
2. Lambda probe ECU negative (Sky blue-Black)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red)
2. Ground (Black)
3. Battery positive (Red)
4. Ground (Black)

INJECTION ELECTRONIC CONTROL UNIT

CONNECTOR
1. Injection telltale light (Brown-Black)
2. Not connected
3. Not connected
4. Lambda probe negative (Sky blue-Black)
3. Live supply (Red-Green)
6. Battery-powered (Orange-Blue)
7. Immobilizer Aerial (Orange-White)

ELE SYS - 95
Electrical system X7 EVO 300 i.e.

8. Electric fan remote control (Green-White)

9. Coolant temperature sensor (Yellow-Pink)
10. Not connected
11. Lambda probe positive (Light blue-Yellow)
12. Engine stop switch (Orange)
13. Engine speed sensor positive (Red)
14. Injector negative (Yellow-Red)
15. Engine speed sensor negative (Brown)
16. Diagnostics socket (Orange-Black)
17. Immobilizer LED (Yellow)
18. Ground lead (Grey-Green)
19. Lights remote control (Black-Green)
20. Injection load remote control (Black-Purple)
21. Not connected
22. HV coil negative (Pink-Black)
23. Not connected
24. Start-up remote control switch (Blue-Green)
25. Not connected
26. Ground lead (Black)

INJECTOR CONNECTOR
1. Power from solenoid (Black-Green)
2. Negative from control unit (Yellow-Red)

HV COIL CONNECTOR
1. Control unit negative (Pink-Black)
2. Power via remote control (Black-Green)

ELE SYS - 96
X7 EVO 300 i.e. Electrical system

FUEL LEVEL TRANSMITTER CONNECTOR

1. Fuel level indicator (White-Green)
2. Ground (Black)
3. Low fuel warning light (Yellow-Green)

COOLANT TEMPERATURE SENSOR CON-

NECTOR
1. Ground (Grey-Green)
2. Ground (Black)
3. Injection ECU (Yellow-Pink)
4. Instrument panel (Sky blue-Black)

IMMOBILIZER AERIAL CONNECTOR

1. Live power supply (Red-Green)
2. Ground (Black)
3. Electronic control unit (Orange-White)

FUEL PORT ACTUATOR CONNECTOR

1. Ground lead (Black)
2. Switch signal (Orange-Black)

ELE SYS - 97
Electrical system X7 EVO 300 i.e.

FUEL PORT OPENING SWITCH CONNECTOR

A. Live power supply (Orange-White)
B. Actuator (Orange-Black)

ELE SYS - 98
INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle X7 EVO 300 i.e.

This section describes the operations to carry out when removing the engine from the vehicle.

Exhaust assy. Removal

- Remove the Lambda probe from its support and

disconnect it.

- Undo the two exhaust manifold fixings on the

head. To unscrew the nuts that fix the silencer
flange to the head properly, use a jointed wrench
that allows, according to the travel direction, to get
also at the right nut. That is difficult to do with a
traditional straight wrench.

- Undo the three screws that fix the silencer to the

supporting arm.
- Remove the full silencer unit.

Remove the lambda probe from the manifold.

ENG VE - 100
X7 EVO 300 i.e. Engine from vehicle

CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS RE-
PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

Removal of the engine from the vehicle

Disconnect the battery.

- Remove the engine cover inside the helmet compartment
- Remove the side panels
Remove the full muffler assembly.
CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Remove the pipe feeding coolant into the pump
as shown in the photograph and then empty the
system.

- Remove the engine-chassis ground lead.

- Disconnect the fuel delivery and return pipes from

the injector by removing the screw locking the re-
taining clamp.
- Disconnect the injector wiring and the throttle
body control unit wiring.

ENG VE - 101
Engine from vehicle X7 EVO 300 i.e.

- Remove the coolant outlet pipe from the engine

as indicated.

- Remove the spark plug cap.

- Remove the coolant temperature sensor con-
nector indicated in the picture.

- Remove the throttle cables from the throttle body

by undoing the nuts indicated in the picture.

- Remove the positive and negative wiring from the

starter motor as shown in the picture.

ENG VE - 102
X7 EVO 300 i.e. Engine from vehicle

- Disconnect the connectors from the flywheel wir-

ing as shown in the photo.
- Remove the cable from the retaining clip on the
flywheel cover.

- Undo the fixing screw of the locking clamps of the

brake pipe from the muffler supporting arm.

Muffler supporting arm removal

- Unscrew and remove the screw fixing the right-
hand shock absorber to the supporting plate.

- Remove the cotter pin, the cap and unscrew the

wheel axle nut. Operate the rear brake by pulling
the left lever on the handlebar so that the axle does
not turn.

ENG VE - 103
Engine from vehicle X7 EVO 300 i.e.

- Undo the 2 screws fixing the rear brake calliper.

- Remove the calliper and its pipes from the muffler
supporting arm.

- Undo the 2 screws fixing the swinging arm to the

engine.
- Remove the muffler support arm

- Slide off the entire wheel with its disc from the wheel axle. Move the right shock absorber backwards
to facilitate removing the wheel.

- Use a jack to support the vehicle properly. Re-

move the engine-swinging arm fixing pin by undo-
ing the nut and the head of the pin as shown in the
photograph.
- The engine is now free.

ENG VE - 104
X7 EVO 300 i.e. Engine from vehicle

When refitting the engine onto the vehicle, carry

out the removal operations but in reverse order
and respect the tightening torques shown in the
Specifications Chapter.
- Check that there is a small clearance when the
valve is in abutment against the set screw.
-Check the engine oil level and if necessary top it
up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct
functioning.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE
THROTTLE CONTROL TRANSMISSION PROPERLY.

ENG VE - 105
INDEX OF TOPICS

ENGINE ENG
X7 EVO 300 i.e. Engine

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.
- Remove the ten screws.

ENG - 107
Engine X7 EVO 300 i.e.

- Remove the transmission cover.

N.B.
WHEN YOU ARE REMOVING THE TRANSMISSION COVER
YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH
BELL.

Air duct

- Remove the transmission compartment air intake

cover shown in the picture.

- Remove the 5 screws, found on two different lev-

els, as well as the small casing.

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 28 x 30 mm adaptor
020412Y 15-mm guide

ENG - 108
X7 EVO 300 i.e. Engine

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 DAM-
AGING THE COVER PAINT.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.

Specific tooling
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020412Y 15-mm guide

Baffle roller

Plastic roller

- Check that the roller does not show signs of wear

and that it turns freely.
- Remove the special clamping screws as indica-
ted in the picture

- Check the outer diameter of the roller does not

have defects that could jeopardise belt functioning
- For refitting, place the roller with the belt contain-
ment edge on the engine crankcase side
- Tighten the wrench to the prescribed torque.

Locking torques (N*m)

Anti-flapping roller 12 - 16

ENG - 109
Engine X7 EVO 300 i.e.

Removing the driven pulley

- Remove the clutch bell housing and the driven

pulley assembly.
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 (inside diameter: 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft unit on the support to check
the crankshaft alignment.

ENG - 110
X7 EVO 300 i.e. Engine

- Using a feeler dial 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 mounting 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
«C» on the tool internal side.
- Introduce the adapter ring 11 with the chamfering
facing the inside of the tool.
- Fit the driven pulley unit on the tool with the in-
sertion of the 3 pins in the ventilation holes in the
mass holder support.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tight-
en the clutch nut.
- Use the special 46x55 wrench component 9 to
remove the nut fixing the clutch in place.
- Dismantle the driven pulley components (Clutch
and spring with its plastic holder)
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CON-
TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.

Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 wrench 46 x 55

ENG - 111
Engine X7 EVO 300 i.e.

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 CEN-
TRAL FAYING 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 ANY DIFFICUL-
TY.
N.B.
BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO
FAR TO AVOID DAMAGE THAT COULD COMPROMISE
THE O-RING SEAL.

- Remove the 4 torque server pins and pull the

pulley halves apart.

ENG - 112
X7 EVO 300 i.e. Engine

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisi-

ness; - Replace with a new one if there are.
- Remove the retainer 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 Bearing housing, outside ø 47 mm

- 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 outside diameter of the pulley bush-

ing.
- 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 contact surface.

Characteristic
Half-pulley minimum diameter
Minimum admissible diameter: Ø 40.96 mm
Half-pulley standard diameter

ENG - 113
Engine X7 EVO 300 i.e.

Standard diameter: Ø 40.985 mm

Wear limit
0.3 mm

Inspecting the driven sliding half-pulley

- Remove the two seal rings and the two O-rings.

- Measure the movable half-pulley bushing inside
diameter.
- 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 contact surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Specification Desc./Quantity
Wear limit 0.3 mm
standard diameter Ø 41.000 - 41.035 mm
maximum allowable diameter Ø 41.08 mm

ENG - 114
X7 EVO 300 i.e. Engine

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the

threaded side using a wooden surface.
- Fit a new roller bearing as shown in the figure.
- For the fitting of the new ball bearing, follow the
example in the figure using a modular punch.
Fit the retainer ring
WARNING
N.B.
FIT THE BALL BEARING WITH THE VISIBLE SHIELDING

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020424Y Driven pulley roller casing fitting
punch

Refitting the driven pulley

- Insert the new oil seals and O-rings on the mov-

able half-pulley.
- Lightly grease the O-rings «A» shown in the fig-
ure.
- Fit the half-pulley over the bushing using the spe-
cific 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 unit with approximately 6 grams of
grease. Apply 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 O-rings.
N.B.

ENG - 115
Engine X7 EVO 300 i.e.

THE TORQUE SERVER CAN BE GREASED WHETHER

WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-
PLACED; UNDERTAKING THE OPERATION WHEN THE
BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling
020263Y Driven pulley assembly sheath

Recommended products
AGIP GREASE SM 2 Grease for the C-ring of
the tone wheel
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20

Inspecting the clutch spring

- Measure the length of the spring when it is re-

laxed.

Characteristic
Standard length
123 mm
Acceptable limit after use:
118 mm

Refitting the clutch

- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring No. 11 with the cham-
fering facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the torque server closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the drive belt into the pulley unit according
to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.

ENG - 116
X7 EVO 300 i.e. Engine

- 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 accord-
ing 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 and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED IN CONTACT WITH THE CLUTCH.

Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 wrench 46 x 55

Locking torques (N*m)

Clutch unit nut on driven pulley 45 to 50

ENG - 117
Engine X7 EVO 300 i.e.

Refitting the driven pulley

- Refit the clutch bell.

Drive-belt

- Make sure the drive belt is not damaged and does not show abnormal wear.
- Replace as indicated in the scheduled maintenance table.

Removing the driving pulley

- Turn the crankshaft until the ropes of the pulley

are on a horizontal axis

- Insert the adaptor sleeve of the appropriate tool

in the hole shown in the picture

ENG - 118
X7 EVO 300 i.e. Engine

- Insert the tool in the hollows and apply the reten-

tion ring
- Bring in the ring's clamping screws while keeping
the tool to support the pulley

Specific tooling
020626Y Driving pulley lock wrench

- Remove the fixing nut and the washer

- Remove the stationary drive pulley half.

Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter A.
- Measure outer diameter B of the pulley sliding
bushing 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
movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm

ENG - 119
Engine X7 EVO 300 i.e.

movable driving half-pulley bushing: Maxi-

mum allowable diameter
Ø 26.12 mm
Sliding bushing: Standard Diameter
Ø 25.959 - 25.98 mm
Sliding bushing: Minimum admissible diame-
ter
Ø 25.95 mm
Roller: Standard Diameter
Diameter 20.5 - 20.7 mm
Roller: Minimum diameter allowed
Ø 20 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 crank-
shaft.
- Fit the driven pulley/Clutch/belt unit on the en-
gine.

ENG - 120
X7 EVO 300 i.e. Engine

- Fit the steel shim in contact with the bushing and

the stationary drive pulley.
- Install the appropriate tool as described in the re-
moval phase.
-Tighten the nut with washer to the prescribed tor-
que.

Specific tooling
020626Y Driving pulley lock wrench

Locking torques (N*m)

Drive pulley nut 75 - 83

Refitting the transmission cover

- Check that there are 2 alignment dowels and that

the sealing gasket for the oil sump on the trans-
mission cover is adequately fitted.
- Replace the cover and tighten the 10 screws to
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.
- Refit the plastic cover.

Specific tooling
020423Y Driven pulley lock wrench

Locking torques (N*m)

Transmission cover screws 11 to 13 Driven pul-
ley shaft nut 54 to 60

ENG - 121
Engine X7 EVO 300 i.e.

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.

Removing the wheel axle

- Remove the wheel axis complete with gear.

- Remove the intermediate gear.

ENG - 122
X7 EVO 300 i.e. Engine

Removing the hub bearings

- Check the state of the bearings being examined

(wear, clearance and noisiness). If faults are de-
tected, 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 Calliper to extract ø 15-mm bear-
ings

Removing the wheel axle bearings

- Take out the clip on the outside of the gearbox

cover.
- Support the hub cover and expel the bearing.
By means of the appropriate tools, remove the oil
seal as in the figure.

Specific tooling
020376Y Adaptor handle
020477Y 37 mm adaptor
020483Y 30-mm guide
020359Y 42x47-mm Adaptor
020489Y Hub cover support stud bolt kit

ENG - 123
Engine X7 EVO 300 i.e.

Removing the driven pulley shaft bearing

- As you need to remove the driven pulley shaft, its

bearing and oil guard, remove the transmission
cover as described above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, work-
ing 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
- Remove the driven pulley shaft bearing using the
modular punch.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20-mm guide

Inspecting the hub shaft

- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- If faults are found, replace the damaged compo-
nents.

ENG - 124
X7 EVO 300 i.e. Engine

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.
- In case of faults, replace the damaged components.

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat
gun.
- Fit the wheel shaft bearing with a modular punch
as shown in the figure.
- Fit the Seeger ring.
- Fit the oil seal 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 to-
wards the bearing.

Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020483Y 30-mm guide

ENG - 125
Engine X7 EVO 300 i.e.

Refitting the hub cover bearings

In order to fit the hub box 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.

Specific tooling
020150Y Air heater mounting
020151Y Air heater
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020412Y 15-mm guide

N.B.
TO FIT THE BEARING ON THE COVER, ADEQUATELY SUPPORT THE COVER WITH THE STUD
BOLT KIT.
- Refit the driven pulley shaft bearing with a mod-
ular punch as shown in the figure.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-
ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020363Y 20-mm guide
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.
- Refit the Seeger ring with the opening facing the bearing and fit a new oil seal flush with the crankcase
from the pulley side.

ENG - 126
X7 EVO 300 i.e. Engine

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 dow-

els.
- 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.
- Position the shorter screw that can also be rec-
ognised from the different colour as shown in the
figure.
- Fix the breather tube support by means of the
lower screw.
- Fit the remaining screws and tighten the seven
screws to the prescribed torque.

Flywheel cover

ENG - 127
Engine X7 EVO 300 i.e.

Removing the hub cover

- Remove the clamp fixing the sleeve to the cylin-

der and detach the sleeve.
- Remove the 10 clamps
- Remove the flywheel cover.

Removing the stator

- Remove the two pickup screws and the screw

holding the wiring support and the three stator
clamping screws shown in the figure.
- Remove the stator and its wiring.

ENG - 128
X7 EVO 300 i.e. Engine

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.

Locking torques (N*m)

Stator assembly screws (°) 3 to 4

Refitting the flywheel cover

- Position the spline clip on the crankshaft and ori-

ent the end as shown in the figure.

- Orient the water pump shaft with reference to the

transmission gear seat as shown in the picture.

- Refit the cover over the engine and tighten the screws to the prescribed torque.
- Carry out the removal steps but in the reverse order.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-
TRING DOWELS ARE PRESENT.
Locking torques (N*m)
Flywheel cover screws 11 - 13

Flywheel and starting

ENG - 129
Engine X7 EVO 300 i.e.

Removing the starter motor

- Remove the two screws indicated in the figure

- Take the starter motor out of its seat

Removing the flywheel magneto

- Remove the water pump shaft and crankshaft

spline clip

- Line up the two holes in the flywheel as shown in

the picture

- Screw in the guide bushing that is part of the

special flywheel stop tool on the flywheel as shown
in the picture

ENG - 130
X7 EVO 300 i.e. Engine

- Insert the special flywheel stop tool on the fly-

wheel as shown in the picture

Specific tooling
020627Y Flywheel lock wrench

Remove the plate indicated in the picture.

- Remove the flywheel nut with its washer

- Do up the flywheel nut by three or four threads
so that the flywheel does not fall accidentally on
extraction
- Screw the extractor onto the flywheel and extract
it as shown in the picture

Specific tooling
020467Y Flywheel extractor

Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.

Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

ENG - 131
Engine X7 EVO 300 i.e.

- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-
wheel itself, i.e. with wheel Seeger ring visible.
- Lock the six clamping screws in criss-cross fash-
ion to the prescribed torque.

Locking torques (N*m)

Screw fixing freewheel to flywheel 13 - 15

- Oil the free wheel "rollers".

Refitting the flywheel magneto

- Remove the freewheel retaining plate indicated

in the picture
- Remove the transmission gear and the freewheel

- Insert the free wheel on the flywheel as shown in

the picture
- Then refit the flywheel with free wheel and trans-
mission gear

ENG - 132
X7 EVO 300 i.e. Engine

- Using the special flywheel lock wrench, tighten

up the flywheel fixing nut to the prescribed torque
- Refit the retention plate

Specific tooling
020627Y Flywheel lock wrench

Locking torques (N*m)

Flywheel nut 94 - 102

Refitting the starter motor

- Fit a new O-ring on the starter motor and lubricate

it.
- Fit the starter motor on the crankcase and lock
the 2 screws to the prescribed torque.

Locking torques (N*m)

Starter screws 11 to 13

Cylinder assy. and timing system

Removing the intake manifold

Loosen the 3 screws and remove the air intake

manifold.
- Upon refitting, secure to the specified torque.

ENG - 133
Engine X7 EVO 300 i.e.

Removing the rocker-arms cover

- Remove the 5 screws indicated in the figure

Removing the timing system drive

- First remove the parts listed below: transmission

cover, drive pulley with belt, oil sump with spring
and by-pass piston, oil pump pulley cover, O-ring
on the crankshaft and the sprocket wheel separa-
tion washer.
- Remove the tappet cover.
- Remove the central screw fastener and the au-
tomatic 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.

ENG - 134
X7 EVO 300 i.e. Engine

- Loosen the central screw on the tensioner first.

- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.

- Remove the internal hex screw and the counter-

weight 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 tensioner slider must be removed from
the transmission side. As regards the lower chain
guide slider, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.

ENG - 135
Engine X7 EVO 300 i.e.

Removing the cam shaft

- Remove the 2 screws and the camshaft retainer

shown in the diagram.
- Remove the pins and the rocking levers from the
flywheel side holes.
- Remove the cam shaft.
N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

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 alignment dowels and
the gasket.
N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

ENG - 136
X7 EVO 300 i.e. Engine

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 RECOG-
NISE THEIR ORIGINAL POSITION ON THE HEAD.

Specific tooling
020382Y011 adapter for valve removal tool
020382Y Valve cotters equipped with part 012
removal tool
020431Y Valve oil seal extractor

Removing the cylinder - piston assy.

Removing cylinder and piston

- Remove the chain guide slider.
- Remove the 4 O-rings on the stud bolts.
- Pull out the cylinder.
- Remove the cylinder base gasket.
- Remove the two stop rings, the wrist pin and the
piston.
- Remove the piston seals.
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 - 137
Engine X7 EVO 300 i.e.

Inspecting the small end

- Measure the internal diameter of the 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.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

See also
Crankcase - crankshaft - connecting rod

Inspecting the wrist pin

- Measure the outer diameter of the gudgeon pin.

- Calculate the coupling clearance between pin and connecting rod end.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

See also
Cylinder - piston assy.

ENG - 138
X7 EVO 300 i.e. Engine

Inspecting the piston

- Measure the diameter of the wrist pin seat on the

piston.
- Calculate the piston pin coupling clearance.
- Measure the outside diameter of the piston, per-
pendicular to the gudgeon pin axis.
- Take the measurement at 5 mm from the base in
the position shown in the figure.
- Carefully clean the seal housings.
- Measure the coupling clearance between the
sealing rings and the grooves using suitable sen-
sors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.
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.

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

See also
Cylinder - piston assy.

Inspecting the cylinder

- 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 coupling surface is not worn or misshapen.
- Pistons and cylinders are classified according to their diameter. The coupling must be made with those
of the same type (M-M, N-N, O-O, P-P).

ENG - 139
Engine X7 EVO 300 i.e.

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

See also
Cylinder - piston assy.

Inspecting the piston rings

sealing rings
- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di-
ameter. 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.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

ENG - 140
X7 EVO 300 i.e. Engine

Removing the piston

- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards the exhaust.
- Fit the wrist pin snap 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 snap ring using the plug as shown
in the figure
N.B.
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST
BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-
ING.

Specific tooling
020454Y Tool for fitting piston pin stops (200 -
250)

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 mounting

- Using an abutment plane, reset the dial gauge

with a preload of a few millimetres.
- Finally fix the dial gauge.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the dial gauge position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inver-
sion point of the dial gauge rotation)
- Measure the deviation from the reset value.

ENG - 141
Engine X7 EVO 300 i.e.

- By means of the table, see 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 compres-
sion ratio.
- Remove the special tool and the cylinder.
N.B.
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY
ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.
See also
Slot packing system

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.
- It is advisable to use a fitter to facilitate the installation of the linings.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS-SEC-
TION. THIS IS TO ACHIEVE A BETTER BEDDING.

ENG - 142
X7 EVO 300 i.e. Engine

- 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.
- The top piston ring on the engine has an L-sha-
ped cross-section.

Refitting the cylinder

- Insert the cylinder base gasket with the thickness

determined above.
- Using the fork support and the piston ring retain-
ing 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
020426Y Piston fitting fork
020393Y Piston assembly band

ENG - 143
Engine X7 EVO 300 i.e.

Inspecting the cylinder head

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.
- Ensure that the camshaft control pulley chain as-
sembly and the sprocket wheel are not worn.
- If you detect wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn, replace
the whole unit.
- 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
unit.

Inspecting the valve sealings

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the valves

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

ENG - 144
X7 EVO 300 i.e. Engine

Inspecting the springs and half-cones

- Check that the upper and lower supporting spring

washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component
when worn.

- Measure the unloaded spring length.

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

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 spring retaining
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

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

ENG - 145
Engine X7 EVO 300 i.e.

See also
Cylinder Head

Refitting the head and timing system components

- Fit the timing chain guide slider.

- 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 an initial pre-torque of 7±1
N·m
- Tighten up the nuts to a second pre-torque of 10
±1 N·m
- Rotate by an angle of 270°
- To carry out the operations described above, fol-
low 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 COM-
PRESSED AIR JET.

Locking torques (N*m)

Timing chain tensioner support screw 11 to 13

- Refit 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.

ENG - 146
X7 EVO 300 i.e. 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 camshaft
in the cylinder head with the cams corresponding
to the rocking levers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed tor-
que.
- Refit the spacer on the camshaft.
- 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 cam-
shaft control pulley.
- Insert the pulley on the camshaft while keeping
the reference 4V in correspondence with the ref-
erence mark on the head.
- Fit the counterweight and tighten the clamping
screw to the prescribed torque.
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
camshaft.
- Fit the automatic valve-lifter return spring.
- During this operation the spring must be loaded
by approximately 180°.
- Fit the automatic valve-lifter retaining dish, using
the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed tor-
que.
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a
new gasket, and tight the two screws to the pre-
scribed torque.
- Insert the chain tensioning screw, together with
the spring and washer, tightening it to the prescri-
bed torque.
- Adjust the valve clearance.

ENG - 147
Engine X7 EVO 300 i.e.

- Fit the spark plug.

Electrode distance 0.8 mm
N.B.
GREASE THE END STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.

Locking torques (N*m)

Timing chain tensioner support screw 11 to 13
Spark plug 12 to 14 Starter ground screw 7 to 8.5
Timing chain tensioner slider screw 10 to 14
Starter counterweight support screw 11 to 15
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4 to 6

ENG - 148
X7 EVO 300 i.e. Engine

Refitting the rocker-arms cover

- Refit the cylinder head cover and tighten the 5

clamping screws to the prescribed torque.
- Make sure the gasket is positioned properly.

Locking torques (N*m)

Tappet cover screws 6 - 7 Nm

Refitting the intake manifold

- Fit the intake manifold and do up the three

screws.

Locking torques (N*m)

Intake manifold screws 11 to 13

Crankcase - crankshaft

Splitting the crankcase halves

- Before opening the crankcase, it is advisable to

check the axial clearance of the crankshaft. To do
this, use a plate and a support with appropriate tool
dial gauge.
- Upper clearances are an indication of wear on
the surfaces of the crankshaft casing support.
- Remove the 10 crankshaft coupling screws.
- Separate the crankcase while keeping the crank-
shaft in one of the two halves of the crankcase.
- Remove the crankshaft.
- Remove the half crankcase coupling gasket.

ENG - 149
Engine X7 EVO 300 i.e.

- Remove the two screws and the internal cover

shown in the diagram.
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram.
- Check the axial clearance on the connecting rod.
- 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 crank-
shaft between these surfaces, as shown in the
diagram.
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
- Check the diameters of both the bearings of the
crankshaft in accordance with the axes and surfa-
ces shown in the figure. The half-shafts are clas-
sified in two categories Cat. 1 and Cat. 2 as shown
the chart below.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE CRANKSHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
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.
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.

Specific tooling
020262Y Crankcase splitting plate
020335Y Magnetic mounting for dial gauge

ENG - 150
X7 EVO 300 i.e. Engine

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

See also
Crankcase - crankshaft - connecting rod

Inspecting the crankshaft alignment

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

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 com-
partment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the trans-
mission 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 piston, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.
- Inspect the coupling surfaces on the crankcase
halves for scratches or deformation, taking partic-

ENG - 151
Engine X7 EVO 300 i.e.

ular care with the cylinder/crankcase surfaces and

the crankcase halves surfaces.
- Defects in the crankcase coupling gasket be-
tween the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bushings and
connecting 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 di-
mensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES PIS-
TON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-
ERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD.
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 CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.

Inspecting the crankshaft plain bearings

8

- To 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 half-bearings, one with holes and channels for lubrication
whereas the other is solid.
Characteristic
Lubrication pressure
3.5 to 4 bar
- 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 shutters in the oil feeding channels, the matching surface of the two half-bearings must be
perfectly orthogonal to the cylinder axis, as shown in the figure.

ENG - 152
X7 EVO 300 i.e. Engine

- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

See also
Crankcase - crankshaft - connecting rod

Refitting the crankcase halves

- Fit the internal bulkhead and lock the 2 screws to

the prescribed torque.
- Fit the oil filter fitting and tighten it to the prescri-
bed torque.
- Position the oil pre-filter element as shown in the
picture.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, to-
gether with the centring dowels.
- Lubricate the main bushings and insert the crank-
shaft in the transmission side crankcase half.
- Reassemble both crankcase halves.
- Fit the 10 screws and tighten them to the speci-
fied torque.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the filter on the engine with the relative cap.
Tighten to the prescribed torque.

Locking torques (N*m)

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 to 6 Engine-crank-
case coupling screws 11 to 13 Oil filter on
crankcase fitting 27 to 33 Engine oil drainage
plug/ mesh filter 24 to 30

ENG - 153
Engine X7 EVO 300 i.e.

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 picture. If it varies significantly
from the driving depth indicated, it means that the
stud bolt has yielded.
In this case, replace it.

ENG - 154
X7 EVO 300 i.e. Engine

By working on two fitted cylinder head fixing nuts,

nut and lock nut, as shown in the picture, remove
the stud bolt from its seat.
Clean the threaded seat on the carter thoroughly.
Refit a new stud bolt and apply the special product
on the threading crankcase side.
Tighten up to the depth of the driving indicated.

Recommended products
Loctite Quick Set Loctite 270 high strength
threadlock
Loctite 270 high strength threadlock

Lubrication

Conceptual diagrams

LUBRICATION CIRCUIT

ENG - 155
Engine X7 EVO 300 i.e.

ENG - 156
X7 EVO 300 i.e. Engine

1. Engine throttle recovery

2. Tappet cover
3. Crankshaft
4. By-pass valve
5. Oil load
6. Oil level in the sump
7. oil pump
8. Mesh pre-filter
9. Cartridge filter
10. Minimum pressure switch

Oil pressure check

- Remove the electrical minimum oil pressure

switch connection and remove the switch.
- Connect the coupling and the pressure gauge to
check the oil pressure to the hole on the minimum
pressure sensor.
- Check that the oil pressure reading is between
0.5 and 1.2 atm with the engine idling at 1650 rpm
and the oil at the required temperature (wait for at
least one electric ventilation).
- Check that the oil pressure is between 3.2 and
4.2 atm with the engine running at 6000 rpm and
the oil at the required temperature.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the specified torque
and fit the fan 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 PROPER
CONDITION.

Specific tooling
020193Y Oil pressure check gauge

ENG - 157
Engine X7 EVO 300 i.e.

Characteristic
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.

Locking torques (N*m)

Minimum oil pressure sensor 12 to 14

Crankshaft oil seals

Removal

- Remove the transmission cover and the com-

plete drive pulley beforehand

- Install the base of the appropriate tool on the oil

seal using the screws provided.

Specific tooling
020622Y Transmission-side oil seal punch

- Screw the threaded bar onto the base of the tool

and extract the oil seal.

Specific tooling
020622Y Transmission-side oil seal punch

ENG - 158
X7 EVO 300 i.e. Engine

Refitting

- Always use a new oil seal upon refitting

- Prepare the new oil seal by lubricating the sealing
lip.
- Preassemble the oil seal with the appropriate tool
by positioning the screws.
- Insert the sheath over the crankshaft.
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase.
- Insert the adaptor bushing of the tool in the hole
on the crankcase.
- Orientate the oil guard by inserting the bracket
which is part of the appropriate 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 see the end of the oil seal driving stroke
- Remove all the tool components following the
procedure but in reverse order
CAUTION
DO NOT LUBRICATE THE KEYING SURFACE ONTO THE
ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL SEAL BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
SEAL. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL SEAL
SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP CONTROL
CHAIN.

Specific tooling
020622Y Transmission-side oil seal punch

ENG - 159
Engine X7 EVO 300 i.e.

Oil pump

Removal

- Undo the two clamping screws in the figure and

remove the cover over the pump control sprocket.

- Block the rotation of the oil pump control pulley

with a screwdriver inserted through one of its two
holes.
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the sprocket.
- Remove the control sprocket wheel with relative
O-ring.
- Remove the oil pump by undoing the two screws
in the figure.
- Remove the oil pump seal.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.

ENG - 160
X7 EVO 300 i.e. Engine

Inspection

- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
retainer ring.
- Check the clearance between the rotors in the
position shown in the diagram using a feeler
gauge.
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 - 161
Engine X7 EVO 300 i.e.

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 clamping 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 CUP WASHER SO THAT ITS OUTER RIM TOUCH-
ES THE PULLEY. MAKE SURE THAT THE PUMP TURNS
FREELY.

Locking torques (N*m)

Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 to 14 Oil
pump cover screws 0.7 - 0.9

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 "Trans-
mission" chapter.
- Drain the oil as described above.
- Remove the 7 screws, shown in the diagram, and
the 2 rear brake fluid pipe fixing brackets.
- Remove the screw, the by-pass piston, the gas-
ket and the centring dowels shown in the figure.

ENG - 162
X7 EVO 300 i.e. Engine

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 defec-
tive parts.

Characteristic
By-pass check up: Standard length
54.2 mm

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 de-
scribed in the "Transmissions" chapter.
N.B.
WHEN CHECKING THE LUBRICATION SYSTEM, REFER
TO THE «CRANKCASE AND CRANKSHAFT» CHAPTER

ENG - 163
Engine X7 EVO 300 i.e.

ON LUBRICATING THE CRANKSHAFT AND CONNECTING

ROD.

Locking torques (N*m)

Oil sump screws 10 to 14

ENG - 164
INDEX OF TOPICS

INJECTION INJEC
Injection X7 EVO 300 i.e.

INJECTION COMPONENTS
Specification Desc./Quantity
1 Throttle body and electronic injection control unit (MIU)
2 Fuel injector
3 Injection load solenoid
4 Electric fan solenoid
5 HV coil
6 Lambda probe
7 Water temperature sensor
8 Instrument panel
9 Battery 12V - 12 Ah
10 Diagnostics socket connector
11 Engine Speed sensor
12 Fuel pump
13 Electric fan

MIU injection system

This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the
crankshaft (24-2 teeth) and pick-up sensor.
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature.
- Intake air temperature
- Lambda probe strength

INJEC - 166
X7 EVO 300 i.e. Injection

The system implements an idle feeding correction with cold engine through a Stepper motor on a by-
pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening
time, thereby ensuring the idle steadiness and the proper combustion.
In all conditions of use, mixture preparation is managed by modifying the injector opening time.

The fuel system circuit consists of:

- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by a delivery pipe.
The fuel pump is controlled by the MIU control unit; this ensures the vehicle safety

The ignition circuit consists of:

- HV coil
- HV cable
- Shielded cap
- MIU control unit
- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector

The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-
strument panel.

INJEC - 167
Injection X7 EVO 300 i.e.

Failures are detected and restored by the diag-

nostic tester.
In any case, when the fault is no longer present,
the data storage is automatically cleared after 16
cycles of use (cold start, running at regular engine
temperature, stop).
The diagnostic tester is also required to adjust the
idle mixture.

Specific tooling
020680Y Diagnosis Tool
The MIU injection-ignition system carries out
checks on the rpm indicator and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the anti-
theft immobilizer system.
The MIU control unit is connected to a diagnostic
LED (M) on the instrument panel that also carries
out the deterrent flashing functions.
The MIU control unit power supply is furthermore controlled by the emergency switch; to allow further
safety of the scooter.

Precautions
Troubleshooting hints
1 - A failure of the EMS system is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
c. Remote controls
d. Connectors
B: Chassis earthing
C: Fuel supply
a. Broken fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Broken coil
c. Broken shielded cap

INJEC - 168
X7 EVO 300 i.e. Injection

E: Intake circuit
a. Dirty air filter
b. Dirty by-pass circuit
c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing
b. Wrong idle mixture
c.Incorrect reset of the throttle valve position sensor
2 - MIU system faults may be caused by loose connectors. Make sure that all connections are properly
implemented.
Check the connectors taking into consideration the following point:
- check that the terminals are not bent.
- check that the connectors have been connected up properly.
- check whether the failure changes making the connector vibrate slightly.
3 - check the entire system thoroughly before replacing the MIU control unit. If the fault is fixed by
replacing the MIU control unit, install the original control unit again and check if the fault occurs again.
4 - Use a multimeter with an internal resistance of more than 10K Ohm/V when troubleshooting. In-
struments that are not suitable might damage the MIU central control unit. Use instruments with
definitions over 0.1V and 0.5W, the precision must be greater than 2%.

1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel supply system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release
fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to
avoid spraying fuel to your eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before any attempt to start the vehicle, check to make sure there is at least two litres of fuel in the
tank. Failure to respect this norm will damage the fuel pump.
6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and cable harnesses.
8. When an ignition problem is detected, start the checks from the battery and the injection system
connections.
9. Before disconnecting the MIU ECU connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.

INJEC - 169
Injection X7 EVO 300 i.e.

10. Do not invert the poles when fitting the battery.

11. To avoid causing any damage, disconnect and reconnect the MIU system connectors only if re-
quired. Before reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, remember to protect the system
connector with its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.

Terminals setup

TERMINAL LAYOUT
Specification Desc./Quantity
1 Injection telltale light
2 -
3 -
4 Lambda probe negative
5 Live supply
6 Battery-powered
7 Immobilizer aerial
8 Electric fan solenoid
9 Water temperature sensor
10 -
11 Lambda probe positive
12 Engine stop switch
13 Engine speed sensor (+)
14 Fuel injector
15 Engine speed sensor (-)

INJEC - 170
X7 EVO 300 i.e. Injection

Specification Desc./Quantity
16 Diagnostics socket output
17 Immobilizer LED
18 Ground lead
19 Headlight remote control
20 Injection load solenoid
21 -
22 HV coil
23 -
24 Start up enabling
25 -
26 Ground lead Engine stop switch connected.

EMS circuit diagram

SYSTEM DIAGRAM
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse F10 7.5 A
3 Fuse F5 15 A
4 Fuse F2 15 A
5 Engine Speed sensor
6 Water temperature sensor
7 Water temperature gauge
8 Engine stop switch
9 Ignition key contacts
10 Fuse F8 7.5 A
11 Injection load solenoid
12 Fuse F4 15 A
13 Stop button
14 Starter button
15 Electric fan solenoid
16 Start-up solenoid
17 Starter motor
18 Electric fan
19 Fuel pump
20 HV coil

INJEC - 171
Injection X7 EVO 300 i.e.

Specification Desc./Quantity
21 Fuel injector
22 Lambda probe
23 Engine control warning light
24 Diagnostics socket connector
25 Injection ECU
26 Immobilizer aerial
27 Immobilizer LED

Troubleshooting procedure

Engine does not start

ENGINE DOES NOT START IF ONLY PULLED

Possible Cause Operation
Immobiliser enabling signal System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Fuel system Fuel in the tank
Fuel pump activation
Fuel pressure (low)
Injector capacity (low)
Power to the spark plug Shielded spark plug cap HV coil (secondary insulation)
Parameter reliability Coolant temperature
Distribution timing - injection ignition
Intake air temperature
End of compression pressure End of compression pressure

Starting difficulties

ENGINE START-UP PROBLEMS

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Start-up speed Starter motor and remote control
Battery
Ground connections
Stepper
End of compression pressure End of compression pressure
Power to the spark plug Spark plug
Shielded cap
HV coil
Speed-timing sensor
Ignition advance
Fuel system Fuel in the tank
Fuel pressure (low)
Injector capacity (low)
Injector sealing (poor)
Correctness of the parameters Coolant temperature
Stepper throttle valve position intake air temperature (steps
and actual opening)
Cleaning the throttle valve, air filter efficiency

INJEC - 172
X7 EVO 300 i.e. Injection

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Stepper
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Air cleaner joint
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity

Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Air cleaner joint
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity

Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATING

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature

INJEC - 173
Injection X7 EVO 300 i.e.

Possible Cause Operation

Coolant temperature
Lambda probe
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Air cleaner joint
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Exhaust system sealing (infiltrations) Manifold - head
Manifold - silencer
silencer welding

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN

Possible Cause Operation
Intake system cleaning Air filter
Diffuser and throttle valve
Stepper
Intake system sealing Air cleaner joint
Filter box
Ignition system Spark plug wear check
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
TPS reset successful TPS reset successful
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe

Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-

ANCE ON PICKUP
Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Spark plug power supply Spark plug
Shielded cap
HV cable
HV coil
Intake system Air filter
Filter box (sealing)
Air cleaner joint (sealing)
Parameter reliability Throttle valve position signal
Coolant temperature indicator

INJEC - 174
X7 EVO 300 i.e. Injection

Possible Cause Operation

Intake air temperature indicator
Ignition advance
Fuel system Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity

Engine knocking

PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Ignition efficiency Spark plug
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Intake system sealing Air cleaner joint
Filter box
TPS reset successful TPS reset successful
Fuel system Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

Fuel supply system

The fuel system circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.

INJEC - 175
Injection X7 EVO 300 i.e.

Removing the butterfly valve

Remove the helmet compartment cover.

Remove the fuel piping clamping screw indicated
in the figure.

Remove the fast-release fitting from the injector

support

INJEC - 176
X7 EVO 300 i.e. Injection

Remove the injector connector.

Remove the three screws fixing the manifold to the

cylinder head and the clip fixing the throttle body
to the manifold.

Remove the MIU ECU connector.

INJEC - 177
Injection X7 EVO 300 i.e.

Remove the clip fixing the throttle body to the air

cleaner joint.

Remove the gas control retainers as indicated in

the photograph

Refitting the butterfly valve

To refit, perform the operations in the reverse or-

der from the removal operations being careful to
position the clip fixing the throttle body to the air
filter joint at 45°, as shown in the picture.

INJEC - 178
X7 EVO 300 i.e. Injection

Pump supply circuit

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse F5 15 A
3 Fuse F2 15 A
4 Ignition key contacts
5 Fuse F8 7.5 A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda probe
11 Electric fan solenoid

When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine
starts up, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA

• Pump winding resistance ~ 1.5 Ohm

• Input current during normal functioning 1.4 ÷ 1.8 A
• Input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel
pressure control, choking the circuit on the return pipe)

Check efficiency of the fuse F2 of 15 A (battery-powered key switch and immobilizer LED).
Check the efficiency of 15A fuse F5 (injection load).
Check the efficiency of 7.5A fuse F8 (live ECU power).

INJEC - 179
Injection X7 EVO 300 i.e.

Check the efficiency of the injection load remote

control: measure the resistance of the drive coil
between pins 86 and 85.

Characteristic
Drive coil resistance
40 ÷ 80 Ω

Apply a voltage of 12V to pins 86 and 85; make

sure that there is continuity between pins 30 and
87 of the remote control.

Check the power supply line of the injection load

remote control energising coil: after switching to
«ON », make sure there is battery voltage, for 2
seconds, between the Red-Green cable and the
Black-Purple cable of the remote control base. If
there is not, check the continuity of the Red-Green
cable between the fuse box (fuse F8) and the re-
mote control base and of the Black-Purple cable
between pin 20 of the ECU and the remote control
base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

INJEC - 180
X7 EVO 300 i.e. Injection

Check if there is steady voltage between the Or-

ange-Blue cable of the remote control base and
the ground lead. If there is not, check the continuity
of the Orange-Blue cable between the fuse box
(15A fuse F5) and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

After switching to «ON», check that there is battery

voltage, for about 2 seconds, between the Black-
Green cable of the pump connector and the
ground lead with the pump connector disconnec-
ted. Otherwise, check the continuity of the Black-
Green cable (5, positive) between the pump
connector and the remote control base.
Check the efficiency of the ground line of the fuel
pump by measuring the continuity between the
pump connector Black cable (2, negative), system
side, and the ground lead.

INJEC - 181
Injection X7 EVO 300 i.e.

If, when switching to «ON», the pump continues to

turn after 2 seconds of activation, check, with the
control unit disconnected and the injection load re-
mote control disconnected, that the Black-Purple
cable (pin 20 on the interface wiring) is insulated
from the ground.

Specific tooling
020331Y Digital multimeter
020481Y Control unit interface wiring

Circuit leak test

Install the appropriate tool for fuel pressure control

with the pipe fitted with the pressure gauge on the
delivery pipe..

Check during regular operation by placing the ap-

propriate tool between the pump and the injector.
With the battery voltage> 12 V check that the fuel
pressure is 2.5 BAR and that the input current is
1.4 to 1.8 A

With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Get a graded burette with a flow rate of
approximately 1 L. Rotate the pump using the active diagnoses of the palm top computer. Using a pair

INJEC - 182
X7 EVO 300 i.e. Injection

of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 BAR.
Check that within 15 seconds the pump has a flow rate of approx. 110 cm³.

Specific tooling
020480Y Petrol pressure check kit

Fuel filter check

Disconnect the terminals from the electric pump

Remove the screw shown in the picture

Remove the clip fixing the piping to the filter shown

in the picture

INJEC - 183
Injection X7 EVO 300 i.e.

Separate the lower part of the pump mounting as

shown in the picture.

Remove the filter from the pump mounting

Inspecting the injector circuit

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse F5 15 A
3 Fuse F2 15 A

INJEC - 184
X7 EVO 300 i.e. Injection

Specification Desc./Quantity
4 Ignition key contacts
5 Fuse F8 7.5 A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda probe
11 Electric fan solenoid

Check the resistance at the injector ends: 14.5 ± 5% Ohm

Check efficiency of the fuse F2 of 15 A (battery-powered key switch and immobilizer LED).
Check the efficiency of 15A fuse F5 (injection load).
Check the efficiency of 7.5A fuse F8 (live ECU power).

Check the efficiency of the injection load remote

control: measure the resistance of the drive coil
between pins 86 and 85.

Characteristic
Drive coil resistance
40 ÷ 80 Ω

Apply a voltage of 12V to pins 86 and 85; make

sure that there is continuity between pins 30 and
87 of the remote control.

INJEC - 185
Injection X7 EVO 300 i.e.

Check the power supply line of the injection load

remote control energising coil: after switching to
«ON », make sure there is battery voltage, for 2
seconds, between the Red-Green cable and the
Black-Purple cable of the remote control base. If
there is not, check the continuity of the Red-Green
cable between the fuse box (fuse F8) and the re-
mote control base and of the Black-Purple cable
between pin 20 of the ECU and the remote control
base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

Check if there is steady voltage between the Or-

ange-Blue cable of the remote control base and
the ground lead. If there is not, check the continuity
of the Orange-Blue cable between the fuse box
(15A fuse F5) and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

INJEC - 186
X7 EVO 300 i.e. Injection

With the control unit and the injector disconnected,

check the continuity of the Red-Yellow cable be-
tween pin 14 of the interface wiring and the injector
connector

Switch to «ON» and check if there is voltage, with

injector disconnected and control unit connected,
between the Black-Green cable of the injector con-
nector and the ground lead

With injector disconnected and the injector load

remote control disconnected, check the continuity
of the Black-Green cable between the injector con-
nector and remote control base.

Specific tooling
020331Y Digital multimeter
020481Y Control unit interface wiring

INJEC - 187
Injection X7 EVO 300 i.e.

Inspecting the injector hydraulics

To carry out the injector check, remove the intake

manifold by removing the three clamping screws
at the head and the clip connecting the control unit
to the manifold.

Install the appropriate tool for checking fuel pres-

sure and position the manifold over a container
graduated by at least 100 cm³. Connect the injec-
tor with the cable making up part of the supply for
the injection tester. Connect the clamps of the ca-
ble to an auxiliary battery. Activate the fuel pump
with the active diagnosis. Check that, within fifteen
seconds, approximately 40 cm³ of fuel is dis-
pensed with an adjustment pressure of approxi-
mately 2.5 BAR.

Specific tooling
020480Y Petrol pressure check kit

INJEC - 188
X7 EVO 300 i.e. Injection

Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute

Tachometer

With wiring disconnected from the control unit and

connected to the system, check that the sensor
resistance between pins 13 - 15 is between 100
and 150 Ohm at an engine temperature of approx-
imately 20°

INJEC - 189
Injection X7 EVO 300 i.e.

Disconnect the fuel pipe connector. Start up the

engine and wait for it to stop. With the wiring con-
nected to the control unit and system try to start up
the engine and check that the voltage between
pins 13 and 15 is around 2.8 V

With the interface cable harness disconnected

from the control unit, check continuity between pin
13 and the red cable of the engine speed sensor
connector and between pin 15 and the brown ca-
ble of the engine speed sensor connector

With the interface wiring and rpm sensor connec-

tor disconnected from the control unit, check that
the Red and Brown cables (pin 13 - 15) are isola-
ted from each other and insulated from the ground.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

INJEC - 190
X7 EVO 300 i.e. Injection

HT coil

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse F5 15 A
3 Fuse F2 15 A
4 Ignition key contacts
5 Fuse F8 7.5 A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda probe
11 Electric fan solenoid

The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
The control unit manages two important parameters:
- Ignition advance
This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure
With the engine at idle, the ignition advance is optimised to stabilise the speed at 1700 ± 100 rpm.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The ignition power is increased during the
engine start-up phase.
The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during
compression.

Specific tooling
020331Y Digital multimeter
020481Y Control unit interface wiring

INJEC - 191
Injection X7 EVO 300 i.e.

Check efficiency of the fuse F2 of 15 A (battery-powered key switch and immobilizer LED).
Check the efficiency of 15A fuse F5 (injection load).
Check the efficiency of 7.5A fuse F8 (live ECU power).

Check there is voltage between pins 22 and 26 of

the interface wiring for around two seconds when
switching to «ON».

Check the resistance of the primary coil between

pin 22 of the interface wiring and the Black-Green
cable of the injection load remote control base,
with the control unit disconnected and the remote
control disconnected.

Characteristic
HV coil resistance primary value:
~ 0.9 Ω

Check the efficiency of the injection load remote

control: measure the resistance of the drive coil
between pins 86 and 85.

Characteristic
Drive coil resistance
40 ÷ 80 Ω

INJEC - 192
X7 EVO 300 i.e. Injection

Apply a voltage of 12V to pins 86 and 85; make

sure that there is continuity between pins 30 and
87 of the remote control.

Check the power supply line of the injection load

remote control energising coil: after switching to
«ON », make sure there is battery voltage, for 2
seconds, between the Red-Green cable and the
Black-Purple cable of the remote control base. If
there is not, check the continuity of the Red-Green
cable between the fuse box (fuse F8) and the re-
mote control base and of the Black-Purple cable
between pin 20 of the ECU and the remote control
base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

INJEC - 193
Injection X7 EVO 300 i.e.

Check if there is steady voltage between the Or-

ange-Blue cable of the remote control base and
the ground lead. If there is not, check the continuity
of the Orange-Blue cable between the fuse box
(15A fuse F5) and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

Coolant temperature sensor

TEMPERATURE SENSOR 1
Specification Desc./Quantity
1 Water temperature sensor
2 Engine stop switch
3 Water temperature gauge

INJEC - 194
X7 EVO 300 i.e. Injection

Specification Desc./Quantity
4 Injection ECU

With the connector on the control unit side discon-

nected and the coolant temperature sensor con-
nector connected, check that the resistance val-
ues between pins 9 and 26 correspond to the
engine temperature.
20° = 2500 ± 100 Ω
80° = 308 ± 6 Ω
With the connector on the control unit side discon-
nected and the coolant temperature sensor con-
nector disconnected, check the insulation be-
tween the two Grey-Green and Yellow-Pink
cables.

With the connector on the control unit side discon-

nected and the coolant temperature sensor con-
nector disconnected, check the continuity be-
tween pin 9 of the interface wiring and the Yellow-
Pink cable of the connector, and between pin 26
of the interface wiring and the Grey-Green cable
of the connector.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

INJEC - 195
Injection X7 EVO 300 i.e.

Zeroing the throttle

Resetting the throttle valve position signal (TPS reset)

The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.

Connect the diagnostic tester.

Switch to «ON».
Select the functions of the diagnostic tester on
«TPS RESET».

Specific tooling
020680Y Diagnosis Tool

INJEC - 196
X7 EVO 300 i.e. Injection

Make sure that the throttle valve with the control is

supporting the stop screw.

Guaranteeing that this position will be kept, send

a confirmation for the TPS reset procedure.

Reset should be performed in the following cases:

- on first fitting.
- if the injection control unit is replaced.
N.B.

INJEC - 197
Injection X7 EVO 300 i.e.

THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Given that the TPS resetting is also done when the
control unit is replaced, place the control unit - filter
box joint retainer clamp at 45° during the refitting
operation, as shown in the picture.

Lambda probe

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse F5 15 A
3 Fuse F2 15 A
4 Ignition key contacts
5 Fuse F8 7.5 A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda probe
11 Electric fan solenoid
The Lambda probe or oxygen sensor is a sensor which provides indications concerning the oxygen
content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type,

INJEC - 198
X7 EVO 300 i.e. Injection

i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic
converter in an area where the gas temperature is always high. The temperature at which the sensor
works is at least 350°C at 600°C and it has a reaction time of just 50 milliseconds. The signal generated
passes from a high value to a low value with a mixture with lambda =1.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

Check efficiency of the fuse F2 of 15 A (battery-powered key switch and immobilizer LED).
Check the efficiency of 15A fuse F5 (injection load).
Check the efficiency of 7.5A fuse F8 (live ECU power).

Check the efficiency of the injection load remote

control: measure the resistance of the drive coil
between pins 86 and 85.

Characteristic
Drive coil resistance
40 ÷ 80 Ω

Apply a voltage of 12V to pins 86 and 85; make

sure that there is continuity between pins 30 and
87 of the remote control.

INJEC - 199
Injection X7 EVO 300 i.e.

Check the power supply line of the injection load

remote control energising coil: after switching to
«ON », make sure there is battery voltage, for 2
seconds, between the Red-Green cable and the
Black-Purple cable of the remote control base. If
there is not, check the continuity of the Red-Green
cable between the fuse box (fuse F8) and the re-
mote control base and of the Black-Purple cable
between pin 20 of the ECU and the remote control
base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

Check if there is steady voltage between the Or-

ange-Blue cable of the remote control base and
the ground lead. If there is not, check the continuity
of the Orange-Blue cable between the fuse box
(15A fuse F5) and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

SIGNAL CONTROL

INJEC - 200
X7 EVO 300 i.e. Injection

Install the electronic control unit interface wiring.

Start the engine and warm up until the electric fan
switches on.
Use an analogue multimeter with a direct voltage
scale measuring down to 2 V.
Place the tips of the multimeter between pins 4 (-)
and 11 (+)

With the engine running at idle speed, check that

the voltage oscillates between 0V and 1V
With the throttle valve completely open, the volt-
age is approx. 1V.
During the closing phase, the voltage is approx.
0V.
If the voltage remains constant, the sensor may be
damaged. Remove the sensor and check that
there are no oil or carbon deposits inside it..

Specific tooling
020331Y Digital multimeter
020481Y Control unit interface wiring

INJEC - 201
INDEX OF TOPICS

SUSPENSIONS SUSP
X7 EVO 300 i.e. Suspensions

This section is dedicated to operations that can be carried out on the suspensions.

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 two bearings on the brake disc side
using pliers 14 and the special bell 9.
- Remove the internal spacer.

SUSP - 203
Suspensions X7 EVO 300 i.e.

- 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 brake
disc side to permit the removal of the opposite 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 opposite the
brake disc with the heat gun.

- Insert the bearing using the punch consisting of

adaptor handle, 40x37 mm adaptor and 15 mm
guide, and take it to the stop.

SUSP - 204
X7 EVO 300 i.e. 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

- Refit the cap and tighten the five fixing screws.

- 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.

SUSP - 205
Suspensions X7 EVO 300 i.e.

- Heat the bearing seat on the side the brake disc

with the heat gun.

2 - Insert the two bearings one at a time using the

punch consisting of adaptor handle, 32x35 mm
adaptor and 15 mm guide, and take it to the stop.

Specific tooling
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020412Y 15-mm guide

Refitting the front wheel

- Carry out the operations described in the «re-

moval» section but in reverse order.

Locking torques (N*m)

Wheel axle nut 45 to 50 Wheel axle clamp
screws 6 - 7 Nm

Handlebar

SUSP - 206
X7 EVO 300 i.e. Suspensions

Removal

- Remove the handlebar covers as explained in the

«Bodywork» Chapter.
- Remove the handlebar wiring retaining straps
and disconnect the electric connectors from the
brake levers.

- Unscrew the clamps of the U-bolts and release

the brake pumps.
- Remove the flexible transmissions of the throttle
grip and remove the throttle control.
- Loosen the clamp fixing the handlebar to the
steering tube and remove the handlebar by pulling
it upwards.
N.B.
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 following the

removal steps but in reverse order, respecting the
handlebar-steering tube alignment as shown in the
figure.

Locking torques (N*m)

Handlebar fixing screw (*) 43 ÷ 47

Front fork

Removal

See also
Removal

SUSP - 207
Suspensions X7 EVO 300 i.e.

Overhaul

- Support the fork in a vice.

- Loosen the two tightening screws of the stem
supporting clamp.
- Unscrew the stem closing cap and slide off the
complete fork leg from the corresponding support.
CAUTION
THE STEM CLOSING CAP KEEPS THE MAIN SPRING PRE-
LOADED. KEEP THE CAP PROPERLY FITTED DURING
THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS.

- Support the fork leg properly, remove the main

spring and drain off the fork leg oil.

- Remove the hydraulic rod fixing screw with the

corresponding sealing gasket:
- With a 19-mm hexagonal spanner, lock hydraulic
rod rotation.
- Undo the fixing screw and collect the copper
washer.

SUSP - 208
X7 EVO 300 i.e. Suspensions

- Remove the stem dust guard with a screwdriver.

- Remove the circlip retaining the oil seal.

- Take out the stem.

- Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace
the damaged parts.

Characteristic
Maximum fork leg diameter
35.10 mm
Minimum stem diameter
34.90 mm

SUSP - 209
Suspensions X7 EVO 300 i.e.

- Take out the oil seal using the appropriate tools.

- Fit the tie rod into the oil seal.
- Insert in sequence the two half-rings per Ø 35-
mm stems.

Specific tooling
020487Y Fork oil seal extractor

- Hold the tie rod manually so that it does not fall

into the fork leg and/or that both half-rings are not
in their position.
- Fit the bell.
- Tighten the nut until it stops.
- Act on the tool until the oil seal is completely re-
moved.

Specific tooling
020487Y Fork oil seal extractor

- Remove the hydraulic rod with the corresponding

sealing gasket, the spring and the stop bushing.

COMPONENT CHECK
CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.

SUSP - 210
X7 EVO 300 i.e. Suspensions

- Check that the fork leg is not cracked or broken

in the attachments.
- Check that the stem is not scored, dented or dis-
torted.
- Check that the stop bushing for the hydraulic rod
is correctly fixed through caulking.

- Check that hydraulic rod caulkings, the return

spring to the unloaded the end of stroke and the
hydraulic rod sealing ring are in good conditions.

- Check that the main spring exhibits no signs of

yielding or abnormal wear.

SUSP - 211
Suspensions X7 EVO 300 i.e.

- Check that the closing cap O-ring of the stem is

in good conditions.

Refitting

- First grease the splitting chamber of the two seal-

ing lips of a new oil seal.
- Fit the sealing ring on the stem and keep the
identification words facing upwards.
- Drive the oil seal as far as it will go using the ap-
propriate tool.

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
- Pre-fit the stem with the hydraulic rod, the spring
and the stop bushing.
- Fit the pre-assembled components inside the fork
leg.

- Fit the hydraulic rod fixing screw with the copper

sealing washer and tighten to the prescribed tor-
que using the recommended product.
CAUTION
ALWAYS USE NEW COPPER WASHER.

Locking torques (N*m)

Hydraulic rod fixing screw 25 ÷ 35*

(°) Apply LOCTITE 243 threadlock

SUSP - 212
X7 EVO 300 i.e. Suspensions

- Lock hydraulic rod rotation using a 19-mm hex-

agonal spanner.

- Fit the oil seal retaining circlip.

- Grease and fit a new dust guard.

- Fit the fork leg together with the stem on the fork
supporting clamp until it stops.
- Tighten the two screws to the prescribed torque
in the sequence indicated in the picture.

Locking torques (N*m)

Stem support clamp tightening screws 20 to 25

SUSP - 213
Suspensions X7 EVO 300 i.e.

- Refill the fork leg with the recommended product

to the prescribed amount.

Recommended products
AGIP FORK 7.5 W Oil for front fork
Hydraulic fluid SAE 7.5 W

Characteristic
Oil quantity per stem
133 ± 3 cm³

- Bleed the hydraulic rod by actuating the stem re-

peatedly.
- Fit the spring into the stem.

- Lubricate the closing cap O-ring of the stem.

- Preload the spring, fit the closing cap and tighten
to the prescribed torque.

Locking torques (N*m)

Fork locking screws cap 15 ÷ 30

- Repeat the procedure for the other fork leg.

N.B.
IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME, BE CAREFUL NOT TO INVERT THE
RIGHT FORK LEG WITH THE LEFT ONE.

SUSP - 214
X7 EVO 300 i.e. Suspensions

Steering column

Removal

- Remove the front wheel.

- Remove the handlebar and tip it onto the shield
back plate being careful not to damage the plate.
- Release the front brake pipe from the fork by un-
doing the screws indicated.

- 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
Removal

Refitting

- Fit the lower steering fifth wheel on the steering

tube.
- Fit the fork together with the lower steering fifth
wheel on the headstock and hold it so that it does
not fall.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, bolt seatings for swinging arms and fay-
ing surface of driven pulley spring (only pulley
side)
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2

SUSP - 215
Suspensions X7 EVO 300 i.e.

- Fit the upper steering fifth wheel.

CAUTION
INSERT THE UPPER FIFTH WHEEL WITH THE CAGE FAC-
ING UPWARDS.

- Fit the steering fifth wheel upper seat.

- Fit the cover plate.

SUSP - 216
X7 EVO 300 i.e. Suspensions

- Insert the spacer.

- Insert the lower tightening ring nut, screw until it

stops and, with the specific tool, tighten to the pre-
scribed torque.

Specific tooling
020055Y Wrench for steering tube ring nut

Locking torques (N*m)

Steering tube lower ring nut 14 ÷ 17

- Fit the spacer between the two ring nuts on the

steering tube in the position indicated.

SUSP - 217
Suspensions X7 EVO 300 i.e.

- Insert the upper tightening ring nut, screw until it

stops and, with the specific tool, tighten to the in-
dicated torque.

Specific tooling
020055Y Wrench for steering tube ring nut

Locking torques (N*m)

Steering tube upper ring nut 40 ÷ 45

- Fasten the two retainer clamps of the front brake

pipe to the fork plate.

Locking torques (N*m)

Screw fixing the front brake pipe to the fork
plate 5 ÷ 7

- Fit the front wheel.

Steering bearing

SUSP - 218
X7 EVO 300 i.e. Suspensions

Removal

- Clean thoroughly and visually inspect if the com-

ponents are in good conditions.
- Check the upper steering fifth wheel for wear.

- Check the lower steering fifth wheel for wear.

- Visually inspect that the steering fifth wheel

tracks, the headstock and the steering tube exhibit
no scores or abnormal wear. Otherwise, replace
them.
STEERING FIFTH WHEEL TRACK REMOVAL
- Remove the steering fifth wheel tracks on the
chassis with the specific tool, following the indica-
ted procedure.
- Fit the specific tool from the lower part of the
headstock until it makes contact with the upper
track.
- Hit with force the specific tool, placing it at differ-
ent points diametrically opposed so as to remove
the upper track.

Specific tooling
020004Y Punch for removing steering bearings
from headstock

SUSP - 219
Suspensions X7 EVO 300 i.e.

- Repeat the procedure for the lower steering fifth wheel track by using the appropriate tool.

Specific tooling
020458Y Puller for lower bearing on steering tube

- Remove the lower fifth wheel seat on the steering

tube using the specific tool.

Specific tooling
020004Y Punch for removing steering bearings
from headstock

SUSP - 220
X7 EVO 300 i.e. Suspensions

Refitting

STEERING FIFTH WHEEL TRACK FITTING

- Thoroughly clean the track seats on the head-
stock and the steering tube.
- Fit the new tracks of the headstock with the spe-
cific tool.
- Screw the nut until the tracks are fully inserted.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.

Specific tooling
001330Y Tool for fitting steering seats
001330Y014 Tool for fitting steering seats
001330Y015 Tool for fitting steering seats

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, bolt seatings for swinging arms and fay-
ing surface of driven pulley spring (only pulley
side)
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2

- Fit the lower fifth wheel seat on the steering tube.

- With a tube of the indicated sizes, fit the lower
seat until it stops. Inside Ø: 35.5 mm; Outside Ø:
38 mm; Length: 350 mm.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, bolt seatings for swinging arms and fay-
ing surface of driven pulley spring (only pulley
side)

SUSP - 221
Suspensions X7 EVO 300 i.e.

Soap-based lithium and zinc oxide grease con-

taining NLGI 2; ISO-L-XBCIB2

Rear

Removing the rear wheel

- Remove the muffler supporting bracket.

- Remove the rear mudguard.
- Remove the tapered spacer.

- Remove the rear wheel.

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 picture.

Locking torques (N*m)

Silencer arm clamping screws 27 - 30 Rear
wheel axle nut 104 to 126 Shock absorber-crank-
case attachment bracket 20 to 25 Lower shock
absorber clamping screw 33 - 41 Nm Rear brake
calliper fixing screws 25 - 30 Nm

Swing-arm

SUSP - 222
X7 EVO 300 i.e. Suspensions

Removal

- Place the vehicle on its centre stand;

- Remove the swinging arm/engine fitting shown in
the picture
- Move the engine back

- remove the spring anchoring the swinging arm to

the chassis as shown in the picture

- Remove the two screws fixing the buffer support

bracket to the chassis

- Undo the nut on the LHS shown in the figure and

remove the corresponding bolt from the opposite
side.
- Remove the swinging arm.

SUSP - 223
Suspensions X7 EVO 300 i.e.

- Check the entire swinging arm assembly.

- Check all the centring bushing components and
silent block rubber buffers.
- Replace the work components that cause exces-
sive 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 chassis 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

- To check the clearance on the chassis-side arm,

mount the retainer using the pin fixing the swinging
arm to the chassis 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 chassis side

Characteristic
Standard clearance
0.40 - 0.60 mm
Allowable limit after use:
1.5 mm

SUSP - 224
X7 EVO 300 i.e. Suspensions

- Separate the swinging arm on the engine side

from the vehicle side arm.
- Remove the plastic bushings and the internal
spacer shown in the picture.

- Using a suitable pin remove the roller casings as

shown in the pictures

- Using an appropriate tool plant new roller cas-

ings, 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
Chassis side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the chassis side:
290 ± 0.1 mm

SUSP - 225
Suspensions X7 EVO 300 i.e.

Length of the swinging arm tube on the chas-

sis 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 picture
- Adjust the bolt as shown in the picture
- Position the chassis side swinging arm with the
most protruding part pointing towards the silent
block side as shown in the picture

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2 of the swinging arm

- Make sure the silent bloc is not broken. If it is,

replace the coupling.
- Remove the Seeger ring shown in the picture

- Remove the full silent bloc bracket

- Undo the silent bloc ring shown in the picture

SUSP - 226
X7 EVO 300 i.e. Suspensions

- 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

- 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 picture

Refitting

- To refit, perform the removal operations in reverse.

- Grease the bearings and the rolling parts with the recommended grease.

SUSP - 227
Suspensions X7 EVO 300 i.e.

-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

- Rest the scooter on its centre stand.

- Slightly lift the engine using a jack to free both
shock absorbers.
- Remove the silencer.
- Unscrew the shock absorber spring unit fixing
screw from the support fixed to the engine on one
side, and from that fixed to the muffler support on
the other.
- Undo the two upper nuts (one on each side) fixing
the shock absorber spring unit to the chassis and
remove the shock absorbers themselves.

Refitting

Carry out the previous operations but in reverse order.

Locking torques (N*m)

SUSP - 228
X7 EVO 300 i.e. Suspensions

Shock absorber lower clamping 33 to 41 Upper shock absorber retainer 33 to 41

Exhaust bracket

Removal

- Remove the exhaust silencer.

- Remove the rear brake calliper, release the rear
brake pipes from the retainer clamp and undo the
screw fixing the rear mudguard.

- Release the cotter pin and remove the cap.

- Unscrew the rear wheel fixing nut and remove the

spacer.

SUSP - 229
Suspensions X7 EVO 300 i.e.

- Undo the two fixing screws to the engine crank-

case.

- Remove the muffler supporting bracket.

Overhaul

- Remove the Seeger ring.

- With the appropriate tools, remove the bearing

from the inside.

Specific tooling
020376Y Adaptor handle
020439Y 17-mm guide
020358Y 37x40-mm Adaptor

SUSP - 230
X7 EVO 300 i.e. Suspensions

- Check that the bearing seat is not abnormally

worn.
- Heat the bearing seat with the appropriate tool.

Specific tooling
020151Y Air heater

- Drive a new bearing as far as it will go using the

appropriate tool.

Specific tooling
020376Y Adaptor handle
020439Y 17-mm guide
020359Y 42x47-mm Adaptor

- Fit the Seeger ring.

Refitting

- Follow the removal procedures but in reverse order and tighten to the prescribed torques.
- Lubricate the rear wheel axle with the recommended product.

Recommended products
AGIP GREASE PV2 Grease for steering bearings and spindle seats
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2 of the swinging arm

Locking torques (N*m)

Silencer arm clamping screws 27 - 30 Rear wheel axle 104 to 126
See also
Refitting
Refitting the rear wheel
Refitting

SUSP - 231
Suspensions X7 EVO 300 i.e.

Centre-stand

REMOVAL
- Use a jack to support the vehicle properly.
- Remove the two stand return springs.
- 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 re-
verse order, then insert the sealing rings into their
seats.
CAUTION
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 fixing bolt 40 ÷ 45

SUSP - 232
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Braking system X7 EVO 300 i.e.

This section è is dedicated to the description of the brake system components.

Rear brake calliper

Removal

- Remove the muffler.

- Remove the two rear brake calliper devices fas-
tening them to the support as shown in the picture.
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

- Follow the removal procedures but in reverse order and tighten to the prescribed torques with the
recommended product.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Screw tightening calliper to support 42 ÷ 52
If the calliper is replaced:
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
Locking torques (N*m)
Rear brake calliper-pipe fitting 20 to 25
See also
Rear - combined

Front brake calliper

BRAK SYS - 234

X7 EVO 300 i.e. Braking system

Removal

- Remove the two retainers fastening the front

brake calliper to the support as shown in the pic-
ture.
N.B.
SHOULD IT BE NECESSARY TO REPLACE THE CALLIP-
ER, 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)

Screw tightening calliper to support 24 to 27
If the calliper is replaced:
CAUTION
ALWAYS USE NEW COPPER WASHERS.
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
Locking torques (N*m)
Brake fluid pipe-calliper fitting 20 to 25
See also
Front

Rear brake disc

Removal

- Remove the rear wheel.

- Act on the disc five fixing screws shown in the
picture.

BRAK SYS - 235

Braking system X7 EVO 300 i.e.

Refitting

For fitting, position the disc correctly using the ar-

row stamped on it as reference.
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE
RUNNING DIRECTION MUST BE FITTED TOWARDS THE
OUTSIDE OF THE VEHICLE.

- Tighten the screws to the prescribed torque and

apply the recommended product.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Brake disc screws 8 to 10

Disc Inspection

- Remove the rear brake calliper

- Check disc thickness with a micrometer, repeat
the measurement at no fewer than six points on
the disc.

Characteristic
Standard thickness:
5 ± 0.2 mm
Disc thickness at wear limit
4.5 mm

- Check the brake disc rotates regularly using the appropriate tool fixed onto the brake calliper support.

BRAK SYS - 236

X7 EVO 300 i.e. Braking system

- In order to be able to anchor the specific tool

properly use a metal plate with an M8 threaded
hole and fix it to one of the two rear brake calliper
attachment points.
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 mounting for dial gauge

Characteristic
Max. deviation allowed:
0.1 mm

- If you detect incorrect values, replace the disc.

- If the fault continues, repeat the test.
- If the problem persists, replace the wheel.

Front brake disc

Removal

- Remove the front wheel.

- Undo the five clamping screws shown in the pho-
tograph

BRAK SYS - 237

Braking system X7 EVO 300 i.e.

Refitting

For fitting, position the disc correctly using the ar-

row stamped on it as reference.
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE
RUNNING DIRECTION MUST BE FITTED TOWARDS THE
OUTSIDE OF THE VEHICLE.

- Tighten the screws to the prescribed torque and

apply the recommended product.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Brake disc screws 8 to 10

Disc Inspection

- Remove the front brake calliper.

- Check disc thickness with a micrometer, repeat
the measurement at no fewer than six points on
the disc.

Characteristic
Standard thickness:
5 ± 0.2 mm
Disc thickness at wear limit
4.5 mm

- Check the brake disc rotates regularly using the appropriate tool fixed onto the brake calliper support.

BRAK SYS - 238

X7 EVO 300 i.e. Braking system

- In order to secure the specific tool adequately use

a metal plate with an M8 threaded hole and fix it to
one of the two front brake calliper attachment
points.

Specific tooling
020335Y Magnetic mounting for dial gauge

Characteristic
Max. deviation allowed:
0.1 mm

- If you detect incorrect values, replace the disc.

- If the fault continues, repeat the test.
- If the problem persists, replace the wheel.

Front brake pads

Removal

Proceed as follows:
- Remove the front brake 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 re-
sidual 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

BRAK SYS - 239

Braking system X7 EVO 300 i.e.

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.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE
CALLIPER ON THE DISC DURING FITTING, GENTLY EX-
PAND THE PADS.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Screw tightening calliper to support 24 to 27 Pad
fixing pin 19.6 ÷ 24.5

BRAK SYS - 240

X7 EVO 300 i.e. Braking system

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 re-
sidual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.

See also
Rear

BRAK SYS - 241

Braking system X7 EVO 300 i.e.

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.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE
CALLIPER ON THE DISC DURING FITTING, GENTLY EX-
PAND THE PADS.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Screw tightening calliper to support 24 to 27 Pad
fixing pin 19.6 ÷ 24.5

Fill

Rear - combined
- Remove the rubber cap 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

BRAK SYS - 242

X7 EVO 300 i.e. Braking system

FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)

System bleed calliper fitting: 12 ÷ 16 Nm

Front

- Remove the rubber cap 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 OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)

System bleed calliper fitting: 12 ÷ 16 Nm

BRAK SYS - 243

Braking system X7 EVO 300 i.e.

Brake fluid level check

The front and rear brake fluid reservoirs are both

positioned on the handlebar. 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 brake pads.

Front brake pump

Removal

- Remove the front and rear handlebar cover.

- Place a suitable container to collect the oil, dis-
connect the oil pipe from the calliper and operate
the brake lever until no more oil comes out.

- Disconnect the oil pipe from the pump.

BRAK SYS - 244

X7 EVO 300 i.e. Braking system

- Unscrew the two clamps of the U-bolt and re-

move 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
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF 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 DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
Locking torques (N*m)
Oil bleed screw 12 - 16 Rear brake calliper-pipe fitting 20 to 25 Rear brake pump-pipe fitting 16
- 20 Fixing screws for the handlebar control unit U-bolts 7 to 10
See also
Front

Rear brake pump - combined

BRAK SYS - 245

Braking system X7 EVO 300 i.e.

Removal

- Remove the front and rear handlebar cover.

- Place a suitable container to collect the oil, dis-
connect the oil pipe from the calliper and operate
the brake lever until no more oil comes out.

- Disconnect the oil pipe from the pump.

- Unscrew the two clamps of the U-bolt and re-

move 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
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.
CAUTION

BRAK SYS - 246

X7 EVO 300 i.e. Braking system

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 DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
Locking torques (N*m)
Oil bleed screw 12 - 16 Rear brake calliper-pipe fitting 20 to 25 Rear brake pump-pipe fitting 16
- 20 Fixing screws for the handlebar control unit U-bolts 7 to 10
See also
Rear - combined

BRAK SYS - 247

INDEX OF TOPICS

COOLING SYSTEM COOL SYS

X7 EVO 300 i.e. Cooling system

Circuit diagram

KEY
A = Expansion tank
B = Radiator
C = Radiator intake pipe
D = Water pump
E = Delivery pipe to cylinder
F = By-Pass pipe
G = Thermostat
H = Radiator delivery pipe

COOL SYS - 249

Cooling system X7 EVO 300 i.e.

TECHNICAL SPECIFICATIONS
Specification Desc./Quantity
Cooling system capacity: ~2l
Recommended fluid AGIP PERMANENT SPEZIAL (ready for use)
Sealing pressure Cap calibrated at 0.9 bar

THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening at 85 ± 2°C

ELECTRIC VENTILATION
Specification Desc./Quantity
Electric ventilation starts at 100° C
Electric ventilation stops at 90° C

WATER PUMP
Specification Desc./Quantity
Type Centrifugal
Control Coaxial to crankshaft

RADIATOR
Specification Desc./Quantity
Type Aluminium, with horizontal circulation

EXPANSION TANK
Specification Desc./Quantity
Calibration Automatic bleeding, in parallel with the radiator

Electric fan check

- Check and, if necessary, restore the correct battery voltage.

Characteristic
Battery voltage
12V

- Check that the electric ventilation relay is working

properly.

COOL SYS - 250

X7 EVO 300 i.e. Cooling system

- If the relay is not working, replace it.

- If the relay is working, remove it and jump the
Purple - White and Red - Green (85 - 86) wires.
The electric ventilation starts if the key switch is set
to «ON» and all components are working.

- In order to check the coolant temperature sensor, see the «Injection» chapter.

See also
Remote controls check

System bleed

- Start up the engine until the operating tempera-

ture 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 commu-
nication hole is revealed with the head as shown
in the picture
- 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

COOL SYS - 251

Cooling system X7 EVO 300 i.e.

Removal

- Remove the helmet compartment inspection cov-

er.
- Place a + 2.0 l container under the vehicle to col-
lect the coolant.
- Undo the two screws indicated, lift the cover and
remove the thermostat.

Check

- Visually check that the thermostat is not dam-

aged.
- 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:
- Warm up until the thermostat opens completely.
- Replace the thermostat if it does not work prop-
erly.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-
THER THE THERMOSTAT NOR THE THERMOMETER
TOUCHES THE CONTAINER.

Specific tooling

COOL SYS - 252

X7 EVO 300 i.e. Cooling system

020331Y Digital multimeter

020151Y Air heater

Characteristic
Thermostat check: Opening start temperature
85 ÷ 1.5°C

Refitting

- Follow the removal steps but in reverse order; be careful to tighten screws to the prescribed torque.

Locking torques (N*m)

Thermostat cover screws 3 to 4
- Once the cooling circuit is restored, refill using the recommended product and purge the circuit as
expressly indicated in the «Cooling System» chapter.

COOL SYS - 253

INDEX OF TOPICS

CHASSIS CHAS
X7 EVO 300 i.e. Chassis

Seat

- Lift the saddle and undo the three screws indica-

ted.

Driving mirrors

- Unscrew the lock-nut and slide off the rear-view

mirror stem.

Rear handlebar cover

- Remove the front handlebar cover.

- Undo the two screws indicated.

CHAS - 255
Chassis X7 EVO 300 i.e.

- Undo the two screws and disconnect the con-

nections of the electrical controls.

See also
Front handlebar cover

Instrument panel

- Remove the rear handlebar cover.

- Disconnect the odometer transmission cable.

- Undo the two screws indicated.

- Undo the two screws indicated and disconnect

the connectors.

See also

CHAS - 256
X7 EVO 300 i.e. Chassis

Rear handlebar cover

Front handlebar cover

- Remove the windshield and the front central cov-

er.
- Undo the screw indicated from both sides of the
vehicle.

- Undo the screw indicated and remove the front

handlebar cover.

See also
Front central cover
Flyscreen

Headlight assy.

- Remove the front central cover.

- Undo the three screws indicated.

CHAS - 257
Chassis X7 EVO 300 i.e.

- Undo the screw indicated in the front wheel hous-

ing on both sides.
- Disconnect the connectors from the low-beam,
high-beam and turn indicators bulbs.
- Slide off the tail light rubber bulb holders.

See also
Front central cover

Frame central cover

- Remove the saddle.

- Undo and remove the screw indicated from both
sides of the vehicle and free the retainers.

- Unscrew the fuel tank cap.

- Undo the two screws indicated.

- Free the central cover from its retainers.

- Disconnect the fuel tank cap opening transmis-
sion.

See also

CHAS - 258
X7 EVO 300 i.e. Chassis

Seat

Legshield

- Remove the shield back plate.

- Remove the headlight assembly.
- Undo the four screws indicated.

- Undo the screw indicated in the front wheel hous-

ing on both sides.

- Undo the two screws indicated on both sides of

the vehicle.

See also
Knee-guard

Headlight assy.

CHAS - 259
Chassis X7 EVO 300 i.e.

Knee-guard

- Remove the footrest.

- Undo the four screws on both sides.

- Undo the upper screw on both sides of the vehi-

cle.

See also
Footrest

- Undo the screw indicated.

- Remove the lid and unscrew the expansion tank
cap.

- Undo the screw indicated.

See also

CHAS - 260
X7 EVO 300 i.e. Chassis

Footrest

- Undo the screw indicated on both sides of the

vehicle.

See also
Footrest

Front wheel housing

- Remove the legshield.

- Remove the fork
- Undo the screw indicated.

- Undo the screw indicated from both sides of the

vehicle.

See also
Legshield

CHAS - 261
Chassis X7 EVO 300 i.e.

Taillight assy.

- Undo the two screws indicated.

- With the aid of a flat screwdriver, remove the

cover indicated.

- Undo the two screws indicated.

- Extract the light units and disconnect the bulb

connectors.

CHAS - 262
X7 EVO 300 i.e. Chassis

License plate light

- Undo the screw indicated and slide off the rubber

bulb holder.

- Remove the rear light unit and disconnect the electrical connection indicated.

See also
Taillight assy.

Footrest

- Remove the side fairing.

- Undo the three screws indicated.

- Remove the two screws indicated in the front

wheel housing.

CHAS - 263
Chassis X7 EVO 300 i.e.

- Undo the two screws indicated.

See also
Side fairings

Side fairings

- Remove the chassis central cover.

- Remove the rear light assembly.
- Undo the screw indicated.

- Undo the four screws indicated and remove the

passenger grab handles.

- Undo the two screws indicated.

CHAS - 264
X7 EVO 300 i.e. Chassis

- Undo the screw indicated and remove the in-

spection door.

- Undo the two screws indicated.

See also
Frame central cover
Taillight assy.

License plate holder

- Remove the side fairings.

- Undo the two screws indicated on both sides of
the vehicle.
- Disconnect the license plate light connection.

See also
Side fairings

CHAS - 265
Chassis X7 EVO 300 i.e.

Air filter

- Undo the two screws indicated.

- Loosen the tightening screw of the throttle body

sleeve to the filter.

Rear mudguard

- From the right side of the vehicle, undo the screw

indicated.

- Undo the two screws indicated from the right side

and collect the washers.
- Remove the rear mudguard.

CHAS - 266
X7 EVO 300 i.e. Chassis

Helmet bay

- Remove the chassis central cover.

- Remove the side fairings.
- Remove the battery and disconnect the fuses box
from the helmet compartment.
- Disconnect the fuel port opening cable from the
lever on the helmet compartment.
- Undo the three screws indicated on both sides of
the vehicle.
- Release the wiring from the helmet compartment.

See also
Side fairings
Frame central cover

Fuel tank

- Remove the footrests.

- Disconnect the fuel delivery pipe.

- Disconnect the power connector from the fuel

pump.

CHAS - 267
Chassis X7 EVO 300 i.e.

- Disconnect the connector of the probe checking

fuel level.

- Undo the screw indicated.

- Undo the screw indicated, placed under the ve-

hicle at the back of the tank.

- Undo the screw indicated, placed under the ve-

hicle at the front of the tank.

See also
Footrest

CHAS - 268
X7 EVO 300 i.e. Chassis

Front mudguard

- Undo the rear and front screws by working inside

the mudguard.
- Slide up the entire mudguard.

Radiator fan

- Remove the wheel housing.

- Disconnect the connector of the electric fan.
- Get a container of suitable capacity and discon-
nect the feeding and return cooling circuit pipes.

- Disconnect the feeding and return pipes from the

expansion tank.

- Undo the fixing screw to the chassis.

CHAS - 269
Chassis X7 EVO 300 i.e.

- Disconnect the radiator together with the electric

fan from the chassis retainers.
- Once the radiator is removed, undo the three fix-
ing screws to remove the electric fan.

Expansion tank

- Remove the shield back plate.

- Disconnect the circuit de-aeration pipe.

- Disconnect the circuit refill pipe.

See also
Knee-guard

CHAS - 270
X7 EVO 300 i.e. Chassis

Front central cover

- Undo the screw indicated from both sides of the

vehicle.

- Remove the PIAGGIO clip-on badge and undo

the screw indicated.

Flyscreen

- Remove both rear-view mirrors.

- Undo both rear-view mirrors supports.

- Undo the screws indicated on both sides of the

handlebar and remove the front frame.

CHAS - 271
Chassis X7 EVO 300 i.e.

- Undo the four screws indicated and remove the

windshield.

See also
Driving
mirrors

CHAS - 272
INDEX OF TOPICS

PRE-DELIVERY PRE DE
Pre-delivery X7 EVO 300 i.e.

Carry out the listed tests before delivering the vehicle.

Warning - Handle fuel with care.

Aesthetic inspection

Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt

Tightening torques inspection

- Check visually that the following clamps are marked in yellow:

FRONT SUSPENSION
• Front wheel pin nut
• Screw fixing wheel pin on right fork leg

FRONT BRAKE
• Screws fixing front brake callipers to forks
• Brake pipes to front brake callipers couplings

REAR SUSPENSION
• Shock absorbers lower fixing screw
• Shock absorbers upper fixing screw

REAR BRAKE
• Screws fixing rear brake calliper to supporting plate
• Brake pipe / rear brake calliper coupling

SWINGING ARM
• Swinging arm to engine pin locknut

STAND
• Central stand bolt nuts
• Screw fixing muffler to muffler supporting arm

Electrical system

• Battery
• Main switch
• Lights: high-beam lights, low-beam lights, taillights (front and rear) and relevant warning lights
- Headlight adjustment according to the regulations currently in force

PRE DE - 274
X7 EVO 300 i.e. Pre-delivery

• Front and rear stop light buttons and bulb

• Turn indicators and their warning lights
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electrical start up
• Engine stopping with emergency stop switch
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.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
- BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC 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 ACCIDENTALLY 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. VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF 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 brake system liquid level.
- Rear hub oil level
- Engine coolant level
- Engine oil level

Road test

Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency

PRE DE - 275
Pre-delivery X7 EVO 300 i.e.

- Rear and front suspension efficiency

- Abnormal noise

Static test

Static control after the test ride:

• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
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 Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting,
lock check, tyre pressure check, rear-view mirror and any accessory fitting

PRE DE - 276
INDEX OF TOPICS

TIME TIME
Time X7 EVO 300 i.e.

This section is dedicated to the time necessary to carry out repairs.

For each operation, the description, code and time envisages are specified.

Engine

ENGINE
Code Action Duration
1 001001 Engine from chassis - Removal and
refit.
2 003064 Engine oil - change
3 001127 Engine - Complete service
4 003057 Engine retainer - Tighten nuts

TIME - 278
X7 EVO 300 i.e. Time

Crankcase

CRANKCASE
Code Action Duration
1 001153 Crankcase halves gasket - Replace-
ment
2 001133 Engine crankcase - Replacement
3 001124 Lubrication by pass - Replacement
4 002028 Rear wheel hub - Replacement

TIME - 279
Time X7 EVO 300 i.e.

Crankshaft

CRANKSHAFT
Code Action Duration
1 001117 Crankshaft - Replacement

TIME - 280
X7 EVO 300 i.e. Time

Cylinder assy.

CYLINDER - PISTON
Code Action Duration
1 001002 Cylinder / Piston - Replacement
2 001154 Pistonsrings-pin assembly - Service
3 001176 Rings / Pin - Replacement

TIME - 281
Time X7 EVO 300 i.e.

Cylinder head assy.

VALVE HEAD
Code Action Duration
1 001126 Head - Replacement
2 001045 Valves - Replacement
3 001049 Valves - adjust
4 001056 Head gasket - change
5 000235 Coolant temperature sensor - Repl.
6 001057 Thermostat - Replacement
7 007012 Coolant bleed valve - Replacement

TIME - 282
X7 EVO 300 i.e. Time

Rocker arms support assy.

CAMSHAFT
Code Action Duration
1 001148 Rockers valves - Replacement
2 001044 Camshaft - Replacement
3 001169 Pressure reducer - Replacement

TIME - 283
Time X7 EVO 300 i.e.

Cylinder head cover

HEAD COVER
Code Action Duration
1 001093 Spark plug - Replacement
2 001089 Head cover - Replacement
3 001088 Head cover gasket - Replacement
4 001074 Oil vapour recovery pipe - Replace-
ment

TIME - 284
X7 EVO 300 i.e. Time

Oil filter

OIL FILTER
Code Action Duration
1 001123 Oil filter -Replacement
2 001160 Oil pressure sensor - change
3 001102 Net oil filter - change / Cleaning

TIME - 285
Time X7 EVO 300 i.e.

Flywheel cover

FLYWHEEL COVER
Code Action Duration
1 001087 Flywheel cover - Replacement
2 001150 Flywheel cover gasket - change
3 007007 Water pump rotor - Replacement
4 001113 Water pump / Pump rotor - Replace-
ment
5 001099 Flywheel-side oil seal - Replacement

TIME - 286
X7 EVO 300 i.e. Time

Driven pulley

DRIVEN PULLEY
Code Action Duration
1 001022 Clutch - Replacement
2 001012 Driven pulley - overhaul
3 001110 Driven pulley- Replacement
4 001155 Clutch bell - Replacement

TIME - 287
Time X7 EVO 300 i.e.

Oil pump

OIL PUMP
Code Action Duration
1 001125 Chain guide pads - Replacement
2 001051 Distribution belt - chain - Replace-
ment
3 001042 Oil pump - overhaul
4 001112 Oil pump - change
5 001122 Oil pump chain - Replacement
6 001172 Chain cover flap - change
7 001130 Oil sump - change
8 001129 Chain tensioner - Service and Re-
placement
9 888133 Chain cover flap - Check / replace-
ment

TIME - 288
X7 EVO 300 i.e. Time

Final gear assy.

FINAL REDUCTION GEAR

Code Action Duration
1 001010 Reduction gear - Replacement
2 003065 Gear box oil - Replacement
3 001156 Reduction gear cover - Replacement
4 004125 Rear wheel axle - Replacement
5 004180 Reduction gear pipe - replace

TIME - 289
Time X7 EVO 300 i.e.

Driving pulley

DRIVING PULLEY
Code Action Duration
1 001086 Driving half-pulley - Replacement
2 001011 Drive belt - Replacement
3 001066 Driving pulley - Removal and refitting
4 001177 CVT rollers / sliders - Replacement
5 001141 Belt anti-flapping roller - Replace-
ment
6 001006 Driving pulley - Service
7 001175 Anti-flapping roller/ Belt - Service

TIME - 290
X7 EVO 300 i.e. Time

Transmission cover

TRANSMISSION COVER
Code Action Duration
1 001096 Transmission crankcase cover - Re-
placement
2 001135 Transmission cover bearing - Re-
placement
3 001170 Air deflector - Replacement

TIME - 291
Time X7 EVO 300 i.e.

Water pump

WATER PUMP
Code Action Duration
1 007017 Water pump cover - Replacement
2 007003 Coolant delivery and return pipe -
change

TIME - 292
X7 EVO 300 i.e. Time

Starter motor

ELECTRICAL START-UP
Code Action Duration
1 001020 Starter motor - Replacement
2 001151 Starter driven gearing - Replacement
3 001017 Start-up pinion - Replacement

TIME - 293
Time X7 EVO 300 i.e.

Flywheel magneto

MAGNETO FLYWHEEL
Code Action Duration
1 001067 Stator - Removal and Refitting
2 001173 Rotor - Replacement
3 001058 Complete flywheel - change
4 001104 Start-up freewheel - Replacement

TIME - 294
X7 EVO 300 i.e. Time

Butterfly valve

THROTTLE BODY
Code Action Duration
1 001166 Throttle body - Replacement
2 001047 Injector - Replacement
3 001013 Intake manifold - change

TIME - 295
Time X7 EVO 300 i.e.

Exhaust pipe

MUFFLER
Code Action Duration
1 001009 Silencer - Replacement
2 001092 Exhaust manifold - Replacement
3 001095 Silencer heatshield - Replacement
4 005138 Lambda probe - Replacement

TIME - 296
X7 EVO 300 i.e. Time

Air cleaner

AIR CLEANER
Code Action Duration
1 001015 Air filter box - Replacement
2 001014 Air filter - Replacement / cleaning
3 004122 Air cleaner/ carburettor union - Re-
placement

TIME - 297
Time X7 EVO 300 i.e.

Frame

CHASSIS
Code Action Duration
1 004001 Chassis - Replacement
2 004147 footboard support bracket one side -
Replacement
3 004148 Footrest support bracket, both sides
- Replacement
4 004146 Front chassis - Replacement

TIME - 298
X7 EVO 300 i.e. Time

Centre-stand

STAND
Code Action Duration
1 004004 Stand - Replacement
2 001053 Stand pin - Replacement
3 004179 Stand bumper - Replacement

TIME - 299
Time X7 EVO 300 i.e.

Legshield spoiler

LEGSHIELD
Code Action Duration
1 004020 Headlight frame - Replacement
2 004064 Legshield, front section - Replace-
ment

TIME - 300
X7 EVO 300 i.e. Time

Code Action Duration

3 004066 Driving mirror - Replacement

Side fairings

SIDE COVERS
Code Action Duration
1 004068 Passenger handgrip - Replacement
2 004085 Fairing (1) - Replacement
3 004053 Spoiler - Replacement
4 004036 Chassis cover - Replacement

TIME - 301
Time X7 EVO 300 i.e.

Rear cover

SHIELD BACK PLATE

Code Action Duration
1 004065 Shield back plate - Replacement
2 004156 Glove box flap and/or support - Re-
placement
3 004145 Glove box - Replacement
4 007024 Expansion tank cap - Replacement

TIME - 302
X7 EVO 300 i.e. Time

Central cover

CENTRAL COVER
Code Action Duration
1 004135 Fuel tank port - Replacement
2 004011 Central chassis cover - Replacement
3 004059 Spark plug inspection flap - Replace-
ment
4 004015 Footrest - Replacement

TIME - 303
Time X7 EVO 300 i.e.

Mudguard

MUDGUARDS
Code Action Duration
1 004002 Front mudguard - change
2 004167 Grille / radiator cover - Replacement
3 004009 Rear mudguard - Replacement

TIME - 304
X7 EVO 300 i.e. Time

Fuel tank

FUEL TANK
Code Action Duration
1 004005 Fuel tank - Replacement
2 005010 Tank float - Replacement
3 004109 Fuel tank breather - change

TIME - 305
Time X7 EVO 300 i.e.

Rear shock-absorber

REAR SHOCK ABSORBER

Code Action Duration
1 003007 Rear shock absorber - Replacement

TIME - 306
X7 EVO 300 i.e. Time

Handlebar covers

HANDLEBAR COVERS
Code Action Duration
1 004018 Front handlebar covers - Replace-
ment
2 004019 Rear handlebar covers - Replace-
ment
3 004101 Windscreen - Replacement

TIME - 307
Time X7 EVO 300 i.e.

Handlebar components

HANDLEBAR COMPONENTS
Code Action Duration
1 003001 Handlebar - Replacement
2 002063 Complete throttle transmission - Re-
placement
3 003061 Accelerator transmission - adjust
4 003059 Counterweight - Replacement
5 004162 Mirror mounting and/or brake pump
fitting U-bolt - Replacement
6 002024 Front brake pump - Replacement
7 002067 Rear brake pump - Replacement
8 002037 Brake lever - Replacement
9 002071 Left knob - Replacement
10 002059 Right-hand knob - Replacement
11 002060 Complete throttle control - Replace-
ment
12 002047 Front brake fluid and air bleed sys-
tem - Replacement
13 002080 Rear brake oil bleed system -
Change

TIME - 308
X7 EVO 300 i.e. Time

Swing-arm

SWINGING ARM
Code Action Duration
1 003081 Swinging arm support flange - Re-
placement
2 004058 Silent block - Replacement
3 001072 Engine/chassis swinging arm attach-
ment - Replacement
4 003080 Swinging arm on chassis - Replace-
ment
5 003077 Muffler supporting arm/ rear shock
absorber - Replacement

TIME - 309
Time X7 EVO 300 i.e.

Seat

SADDLE
Code Action Duration
1 004003 Saddle - Replacement

TIME - 310
X7 EVO 300 i.e. Time

Instrument panel

INSTRUMENT PANEL
Code Action Duration
1 005014 Odometer - Replacement

TIME - 311
Time X7 EVO 300 i.e.

Locks

LOCKS
Code Action Duration
1 004010 Anti-theft lock - Replacement
2 005099 Electric saddle opening device - Re-
placement
3 004054 Saddle lock catch - Replacement

Turn signal lights

Rear lights

TIME - 312
X7 EVO 300 i.e. Time

REAR LIGHTS
Code Action Duration
1 005005 Taillight - change
2 005031 number plate light bulb - Replace-
ment
3 005032 number plate light glass - Replace-
ment
4 005022 Rear turning indicators - Replace-
ment
5 005066 Rear light bulbs - Replacement
6 005068 Rear turning indicator bulb - Re-
placement

Front lights

TIME - 313
Time X7 EVO 300 i.e.

INDICATOR LIGHTS
Code Action Duration
1 005002 Front light - replacement
2 005008 Headlight bulbs - Replacement
3 005044 Front lights cable unit - replace
4 005067 Front turning indicator bulb - replace-
ment

TIME - 314
X7 EVO 300 i.e. Time

Front wheel

FRONT WHEEL
Code Action Duration
1 002041 Front brake disc - Replacement
2 003037 Front wheel rim - Replacement
3 003038 Front wheel axle - Replacement
4 003040 Front wheel bearings - Replacement
5 003047 Front tyre - Replacement
6 004123 Front wheel - Replacement
7 002011 Odometer drive - Replacement

TIME - 315
Time X7 EVO 300 i.e.

Rear wheel

REAR WHEEL
Code Action Duration
1 001016 Rear wheel - Replacement
2 001071 Rear wheel rim - Replacement
3 004126 Rear wheel tyre - Replacement
4 002070 Rear brake disc - Replacement

TIME - 316
X7 EVO 300 i.e. Time

Fuel pump

FUEL PUMP
Code Action Duration
1 004073 Fuel pump - Replacement
2 004137 Pump/ injector pipe - Replacement

TIME - 317
Time X7 EVO 300 i.e.

Electric devices

REMOTE CONTROLS
Code Action Duration
1 005003 Horn - Replacement
2 005007 Battery - change
3 005075 Stop solenoid - Replacement
4 005035 Headlight solenoid - Replacement
5 005011 Starter relay - Replacement

TIME - 318
X7 EVO 300 i.e. Time

VOLTAGE REGULATOR
Code Action Duration
1 005009 Voltage regulator - Replacement
2 001069 HV coil - Replacement
3 001094 Spark plug cap - Replacement
4 005119 Fuel pump remote control - Replace-
ment

TIME - 319
Time X7 EVO 300 i.e.

WIRE UNIT
Code Action Duration
1 005001 Electrical system - Replacement

Electronic controls

TIME - 320
X7 EVO 300 i.e. Time

ELECTRIC CONTROLS
Code Action Duration
1 005006 Light or turning indicator switch - Re-
placement
2 005039 Lights switch - Replacement
3 005040 Horn button - Replacement
4 005041 Starter button - Replacement
5 005077 Emergency stop switch - Replace-
ment
6 005016 Key switch - Replacement

Transmissions

TRANSMISSIONS
Code Action Duration
1 002082 Fuel tank door opening drive - Re-
placement
2 002083 Saddle opening transmission - Re-
placement
3 002049 Odometer cable - Replacement

TIME - 321
Time X7 EVO 300 i.e.

Helmet bay

HELMET COMPARTMENT
Code Action Duration
1 004016 Helmet compartment - Replacement
2 005046 Battery cover - change

TIME - 322
X7 EVO 300 i.e. Time

Rear side fairings

REAR COVERS
Code Action Duration
1 005048 number plate holder - Replacement

TIME - 323
Time X7 EVO 300 i.e.

Front suspension

FRONT SUSPENSION
Code Action Duration
1 003051 Complete fork - Replacement
2 003010 Front suspension - Service
3 003076 Fork sheath - Replacement
4 003079 Fork stem - Replacement
5 003048 Fork oil seal - Replacement
6 003002 Steering fifth wheels - Replacement
7 003073 Steering clearance - Adjustment

TIME - 324
X7 EVO 300 i.e. Time

Cooling system

COOLING SYSTEM
Code Action Duration
1 007002 Water radiator - replacement
2 007016 Fan with support - Replacement
3 007001 Expansion tank - Replacement
4 007022 Coolant delivery pipe - Replacement
5 007013 Radiator expansion tank connection
pipe - change
6 001052 Coolant and air bleed - Replacement
7 007019 Connection water pump pipe / return
pipe - Replacement

TIME - 325
Time X7 EVO 300 i.e.

Braking system

BRAKING SYSTEM
Code Action Duration
1 002007 Front brake pads - Replacement
2 002039 Front brake calliper - Replacement
3 002021 Front brake piping - Replacement
4 002002 Rear brake pads - Replacement
5 002048 Rear brake calliper - Replacement
6 002020 Rear brake disc piping - Replace-
ment

TIME - 326
X7 EVO 300 i.e. Time

Windscreen

WINDSCREEN
Code Action Duration
1 004101 Windscreen - Replacement

TIME - 327
Time X7 EVO 300 i.e.

Stickers

TRANSFERS
Code Action Duration
1 004159 Plates / Stickers - Replacement

TIME - 328
A
Air filter: 45, 266

B
Battery: 57, 67, 78, 88, 89
Brake: 234, 235, 237, 239–242, 244, 245
Brake fluid: 244
Bulbs:

C
Checks: 72
Coolant: 194

E
Electric: 250, 318
Engine oil: 46

F
Fuel: 175, 183, 267, 305, 317
Fuses: 86

H
Headlight: 52, 257, 259
Horn: 83
Hub oil: 43

I
Identification: 8
Instrument panel: 256, 311

M
Maintenance: 7, 41
Mirrors: 255, 272

O
Oil filter: 47, 285

R
Recommended products:

S
Saddle:
Shock absorbers: 228
Spark plug: 43, 78
Stand:
Start-up:
Suspension: 57, 324

T
Tank: 267, 270, 305
Transmission: 9, 56, 107, 121, 291
Turn indicators: 71
Tyres: 10

V
Vehicle: 8, 100, 101