PIAGGIO XEVO 250 IE Service Manual X EVO Workshop 250IE

SERVICE STATION MANUAL 664719 IT-664720 EN-664721 FR-664722 DE-664723 ES-664724 PT-664725 OL-664726 EL XEVO 250ie

SERVICE STATION MANUAL XEVO 250ie The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of single models 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 XEVO 250ie 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

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 spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections. XEVO 250ie Characteristics CHAR - 7

Vehicle identification Frame Prefix M36401 Engine Prefix M36AM Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 171 ± 5 kg Maximum weight allowed 360 kg Height 1370 mm Width (handlebar) 760 mm Wheelbase 1490 mm Overall length 2070 mm Characteristics XEVO 250ie CHAR - 8

Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke Cubic capacity 244 cm³ Bore x Stroke 72 x 60 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 Inlet: 0.10 mm Outlet: 0.15 mm Max. Power 16.0 Nm at 8,500 rpm Max. Torque 20.5 Nm at 6,750 rpm LUBRICATION Engine lubrication with lobe pump (inside crankcase) controlled by a chain and double filter: mesh and paper. Lubrication pressure 4 bar Minimum lubrication pressure (100° C) 0.8 bar Fuel supply Electronic injection with Ø 32-mm throttle body and electric fuel pump. Cooling Forced-circulation coolant system. Fuel Unleaded petrol (95 RON) Exhaust muffler Absorption-type exhaust muffler with a 3-way catalytic convert- er and lambda probe. Emission regulations EURO 3 Transmission T RANSMISSION Specification Desc./Quantity TRANSMISSION Automatic expandable pulley variator with torque server, V- belt, self-ventilating dry automatic centrifugal clutch and transmission housing with forced-circulation air cooling. XEVO 250ie Characteristics CHAR - 9

Specification Desc./Quantity Final reduction Gear reduction unit in oil bath. Capacities CAPACITY Specification Desc./Quantity Engine oil 1.3 l Transmission oil 250 cm³ Cooling system fluid ~ 2 l Fuel tank (reserve) ~ 12 l (~ 2.5 l) Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Start-up Electric Ignition Electronic inductive discharge ignition, high efficiency, with separate HV coil. Ignition advance α/N three-dimensional map managed by control unit Spark plug CHAMPION RG 4 PHP Alternative spark plug - Battery 12V-12Ah Generator Alternating current Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Chassis Tubular and sheet steel. Front suspension Hydraulic telescopic fork with Ø 35-mm stem Front suspension travel 90 mm Rear suspension Two double-acting shock absorbers, adjustable to four posi- tions at preloading. Rear suspension travel 90 mm Brakes BRAKES Specification Desc./Quantity Front brake Ø 260-mm disc brake with hydraulic control activated by handlebar 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 rims. Front rim 14'' x 3.50 Rear rim 12'' x 3.00 Front tyre Tubeless 120/70 - 14'' 55P Characteristics XEVO 250ie CHAR - 10

PIAGGIO XEVO 250 IE Service Manual X EVO Workshop 250IE

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