PIAGGIO 2005 XEVO 400ie Instruction manual

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.
"©Copyright2005-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
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