PIAGGIO 2005 XEVO 400ie Manual de instrucciones

MANUALE STAZIONE DI SERVIZIO

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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.

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 Sectionsmarked with this symbol indicatethe correct use of thevehicle

to prevent damaging the environment.

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

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

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.

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

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

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

scooter.

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

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

properly.

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 ElectronicinjectionwithØ38-mmthrottlebodyandelectricfuel

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,highefficiencyignition,integratedwiththe

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

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