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

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.
Piston rings
*Fit rings «2» and «3» with the word «TOP» facing upwards.
** Position the port of the rings as shown here.
***Value «A» of sealing ring inside the cylinder.
Check the size of the sealing ring opening:
Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Rings/housing coupling clearances:
Carefully clean the sealing ring housings.
Place a thickness gauge between the ring and the
housing as shown in the drawing and check the
coupling clearances.
Top ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
XEVO 400ie Characteristics
CHAR - 11

Intermediate ring Standard coupling clear-
ance:0.02÷0.07 mm
Maximum clearances allowed after use: 0.10
mm
Oil scraper ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Replace the piston if clearances exceed the max-
imum limits specified in the table.
Crankcase - crankshaft - connecting rod
Diameter of crankshaft bearings.
Measure the bearings on both axes x-y.
CRANKSHAFT
Specification Desc./Quantity
Cat. 1 Standard diameter: 40.020÷40.026
Cat. 2 Standard diameter: 40.026÷40.032
Crankshaft alignment
Specific tooling
020335Y Magnetic support for dial gauge
MAX. ADMISSIBLE DISPLACEMENT
Specification Desc./Quantity
A = 0.15 mm
B = 0.010 mm
C = 0.010 mm
D = 0.10 mm
Characteristics XEVO 400ie
CHAR - 12

Characteristic
crankshaft / crankcase axial clearance:
0.1 ÷ 0.405 mm
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Description Dimensions Initials Quantity
Transmission-side
shoulder 1±0.025 A D = 0.20 - 0.50
Half-shaft, transmission
side 20.9 -0.05 B D = 0.20 - 0.50
Connecting rod 22 -0.10 -0.15 C D = 0.20 - 0.50
Flywheel-side shoulder 1.8±0.025 F D = 0.20 - 0.50
Flywheel-side half-shaft 19.6 -0.05 E D = 0.20 - 0.50
Complete crankshaft 65.5 +0.10 -0.05 G D = 0.20 - 0.50
Crankcase / countershaft coupling
Besides considering it should match the crankshaft, the crankcase is chosen according to the centre
to centre distance between the seat of the crankshaft and that of the contra-rotating shaft.
Both the centre to centre distance and the pair of gears driving the contra-rotating shaft are divided into
two types (A and B) to be matched (Awith Aand Bwith B).
XEVO 400ie Characteristics
CHAR - 13

This selection is useful to keep the difference between the working distance of the gears and their
distance without clearance at a given value in order to avoid abnormal noise.
TYPE A
Specification Desc./Quantity
Centre to centre distance of the gears without clearance 76.937 ÷ 76.867
Centre to centre distance on the crankcase 77.022 ÷ 76.992
TYPE B
Specification Desc./Quantity
Centre to centre distance of the gears without clearance 76.907 ÷ 76.837
Centre to centre distance on the crankcase 76.992 ÷ 76.962
The gears with centre to centre distance without clearance between 76.867 and 76.907 are considered
universal and can be fitted to either crankcase type.
Either the pair of gears or the crankcase is identified with the letter referring to the type (on the crank-
case, this mark is found at the cylinder mouth, flywheel side).
Slot packing system
Shimmingsystem for keeping the compressionra-
tio
DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF
THE PISTON CROWN WITH RESPECT TO THE CYLINDER
PLANE.
DISTANCE «A» HELPS DETERMINE THE THICKNESS OF
GASKET«B»THAT HASTOBE FITTED TOTHE CYLINDER
HEAD IN ORDER TO RESTORE COMPRESSION RATIO.
BASE GASKET «B» MUST BE THICKER THE MORE THE
PLANE FORMED BY THE PISTON TOP PROTRUDES
FROMTHEPLANE FORMEDBY THECYLINDERHEAD. ON
THE OTHER HAND, THE MORE THE PISTON TOP IS RE-
CESSED INTO THE CYLINDER TOP PLANE, THE SMALL-
ER THE GASKET THICKNESS.
Characteristic
Compression ratio
10.6 ± 0.5 :1
BASE GASKET THICKNESS
Name Measure A Thickness
«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05
«A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05
«A» MEASURE TAKEN + 0.10 ÷ + 0.185 0.8 ± 0.05
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE
CYLINDER PLANE.
N.B.
DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»
Characteristics XEVO 400ie
CHAR - 14

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
(throttle control) Oil for 4-stroke engines
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP GP 330 Calcium complex soap-based grease
with NLGI 2; ISO-L-XBCIB2 Grease (brake control levers, throttle grip)
AGIP CITY HI TEC 4T Engine oil SAE5W-40,APISL,ACEAA3,JASOMA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
AGIP FORK 7.5 W Fork oil Grade 7.5 W
AGIP GREASE PV2 Grease for the steering bearings, pin
seats and swinging arm White anhydrous-calcium based grease to protect roller bearings; temperature
range between -20 C and +120 C; NLGI
2; ISO-L-XBCIB2.
XEVO 400ie Characteristics
CHAR - 15

INDEX OF TOPICS
MAINTENANCE MAIN

Follow these steps to reset the service icons:
1. With the key set to OFF, hold down the
"SET" button and turn the key to ON : the
"BELT" and "SERVICE" icons start flashing.
2. Push the "CLOCK" button for less than 1
second and the icons are displayed sequen-
tially. The icon selected remains ON and the
other is no longer displayed.
3. Press the "CLOCK" button again for more
than 3 seconds to reset the relative mainte-
nance step and the icon is no longer dis-
played.
Maintenance chart
EVERY 2 YEARS
60' Action
Coolant - change
Brake fluid - change
AFTER 1,000 KM
60' Action
Safety locks - check
Throttle lever - adjustment
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - change
Steering - Check
AFTER 5,000 KM; 25,000 KM; 35,000 KM; 55,000 KM; 65,000 KM
10' Action
Engine oil - level check/ top-up
Brake pads - check condition and wear
Centre stand - lubrication
AFTER 10,000 KM; 50,000 KM; 70,000 KM
120' Action
Safety locks - check
Driving belt - replacement
Throttle lever - adjustment
XEVO 400ie Maintenance
MAIN - 17

Action
Air filter - clean
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - check
Suspensions - check
Steering - Check
Centre stand - lubrication
Spark plugs - replacement
AFTER 15,000 KM; 45,000 KM; 75,000 KM
10' Action
Engine oil - level check/ top-up
Brake pads - check condition and wear
Centre stand - lubrication
AFTER 20,000 KM; 40,000 KM; 60,000 KM AND 80,000 KM
190' Action
Spark plugs - replacement
Driving belt - replacement
Throttle lever - adjustment
Air filter - check
Engine oil - change
Valve clearance - check
Electrical system and battery - check
Coolant level - check
Engine oil - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - change
Suspensions - check
Steering - Check
Centre stand - lubrication
Brake fluid level - check
30,000 KM
200' Action
Safety locks - check
Driving Belt - replacement
Throttle lever - adjustment
Air filter - cleaning
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Hub oil - check
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Suspensions - check
Maintenance XEVO 400ie
MAIN - 18

Action
Steering - Check
Centre stand - lubrication
Spark plugs - replacement
Spark plug
Remove the port on the left-hand side panel of the
vehicle by undoing the fixing screw and using a
small screwdriver in the rear recess shown in the
figure, then do the following:
-Disconnect the HV wire cap «A» of the spark
plug;
-Unscrew the spark plug using the wrench sup-
plied;
-Upon refitting, place the spark plug at the re-
quired angle and tighten by hand until it is finger
tight;
-Use the wrench only for final tightening of the
spark plug;
-Place cap «A» fully over the spark plug.
-Refit the port making sure the rear hook is inser-
ted.
WARNING
THE SPARK PLUG MUST BE REMOVED WHEN THE EN-
GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-
TED IN THE SCHEDULED MAINTENANCE TABLE. THE
USE OF ELECTRONIC CENTRAL UNITS AND OF NON-
COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGS
OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY
DAMAGE THE ENGINE.
N.B.
USING SPARK PLUGS OTHER THAN THE INDICATED
TYPE OR SHIELDLESS SPARK PLUG CAPS CAN CAUSE
ELECTRICAL SYSTEM FAILURES.
Characteristic
Spark plug
CHAMPION RG 6 YC
Alternative spark plug
NGK CR7EKB
Electric characteristic
Electrode gap
0.7 ÷ 0.8 mm
XEVO 400ie Maintenance
MAIN - 19

Locking torques (N*m)
Spark plug 12 ÷ 14
Hub oil
Check
-Parkthevehicle onitscentrestand onflatground;
- 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 second notch starting from the
lower end; if the level is below the MAX mark, it
needs to be filled up with the right amount of hub
oil.
-Screw up the oil dipstick again and make sure it
is locked properly into place.
Replacement
-Remove the oil filler cap «A».
- Unscrew the oil drainage cap "B" and drain out
all the oil.
- Screw in the drainage cap again and fill the hub
with the prescribed oil.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Rear hub oil
Capacity approximately 250 cc
Maintenance XEVO 400ie
MAIN - 20