PIAGGIO XEVO 400 Workshop Repair Manual 2005 ONWARD

MANUALE STAZIONE DI SERVIZIO ****** - ****** XEVO 400ie

MANUALE STAZIONE DI SERVIZIO XEVO 400ie The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2005 - 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. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) www.piaggio.com

MANUALE STAZIONE DI SERVIZIO XEVO 400ie This service station manual has been drawn up by Piaggio & C. S.p.A. 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 change 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 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

Maintenance rules • Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non- original or non-conforming spares may damage the vehicle. • Use only the special tools designed for this scooter. • Always use new gaskets, sealing rings and split pins upon reassembly. • After removal, clean the components using non-flammable or low fire-point solvent. Lubri- cate all the work surfaces except the tapered couplings before refitting. • After reassembly, check that all components have been installed properly and that they are in good working order. • For removal, overhaul and reassembly operations use only tools provided with metric meas- ures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter. • Should any interventions to the scooter electrical system be required, check that the electrical connections - especially earth and battery connections - have been implemented properly. Vehicle identification Chassis prefix ZAPM52101 Engine prefix M521M XEVO 400ie Characteristics CHAR - 7

Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 171 ± 6 kg Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke Bore x stroke 85.8 X 69 mm Cubic capacity 399 cm³ Compression ratio 10.6 ± 0.5 : 1 Timing system Four valves, single overhead camshaft, chain-driven. Valve clearance Inlet: 0.15 mm Outlet: 0.15 mm Engine idle speed 1,500 ± 100 rpm Start-up Electric LUBRICATION Engine lubrication with trochoidal pump (inside the crankcase), oil filter and pressure adjustment by-pass. FINAL REDUCTION GEAR Gear reduction unit in oil bath. Muffler Absorption-type exhaust muffler with catalytic converter and lambda probe. Fuel supply Electronic injection with Ø 38-mm throttle body and electric fuel pump. MAX Power 24 kW at 7,250 rpm MAX torque 38 Nm at 5,250 rpm Cooling Forced coolant circulation system. Characteristics XEVO 400ie CHAR - 8

Transmission TRANSMISSION Specification Desc./Quantity TRANSMISSION Automatic expandable pulley variator with torque server, V- belt, automatic clutch. Capacities CAPACITY Specification Desc./Quantity Engine oil 1.7 l Transmission oil 250 cm³ Cooling system fluid ~ 1.8 l Fuel tank (reserve) approx. 12 l (approx. 2 l) Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Ignition Electronic, inductive, high efficiency ignition, integrated with the injection system, with variable advance and separate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug CHAMPION RG 6 YC Alternative spark plug NGK CR7EKB Battery 12V-12Ah Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity Frame Tubular and steel sheets. Front suspension Hydraulic telescopic fork with Ø 35-mm stem Rear suspension Two double-acting shock absorbers, adjustable to four posi- tions at preloading. Brakes BRAKES Specification Desc./Quantity Front brake Ø 240-mm double disc brake with hydraulic control operated by the handlebar right-hand 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 tyre Tubeless 120/70 - 14'' 55P XEVO 400ie Characteristics CHAR - 9

Specification Desc./Quantity Rear tyre Tubeless 140/70 - 14'' 68S Front tyre pressure (with passenger) 2.3 bar (-) Rear tyre pressure (with passenger) 2.6 bar (-) N.B. CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES. CAUTION IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE COR- RECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES REC- OMMENDED BY PIAGGIO. Overhaul data Assembly clearances Cylinder - piston assy. HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED Specification Desc./Quantity A 43.2 mm B 43 mm CYLINDER- PISTON Specification Desc./Quantity Cylinder diameter C 85.8 - +0.018 -0.01 mm Piston Ø P 85.768 ± 0.014 mm CYLINDER - PISTON COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder- Piston A 85.790÷85.797 85.754÷85.761 0.029÷0.043 Cylinder- Piston B 85.797÷85.804 85.761 ÷ 85.768 0.029÷0.043 Cylinder- Piston C 85.804÷85.811 85.768÷85.775 0.029÷0.043 Cylinder- Piston D 85.811÷85.818 85.775÷85.782 0.029÷0.043 CATEGORIES OF COUPLING N.B. Characteristics XEVO 400ie CHAR - 10

PIAGGIO XEVO 400 Workshop Repair Manual 2005 ONWARD

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