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. Nonoriginal 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. Lubricate 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 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.
•
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 CORRECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER
TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES RECOMMENDED 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 clearance: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 maximum 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 (A with A and B with 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 crankcase, this mark is found at the cylinder mouth, flywheel side).
Slot packing system
Shimming system for keeping the compression ratio
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 HAS TO BE FITTED TO THE CYLINDER
HEAD IN ORDER TO RESTORE COMPRESSION RATIO.
BASE GASKET «B» MUST BE THICKER THE MORE THE
PLANE FORMED BY THE PISTON TOP PROTRUDES
FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON
THE OTHER HAND, THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER 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 SAE 5W-40, API SL, ACEA A3, JASO MA
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 sequentially. 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 maintenance step and the icon is no longer displayed.
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 ENGINE IS COLD. REPLACE THE SPARK PLUG AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE. THE
USE OF ELECTRONIC CENTRAL UNITS AND OF NONCOMPLIANT 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
-Park the vehicle on its centre stand on flat ground;
- 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
Air filter
Proceed as follows:
1. From the inside of the rear wheel housing, undo
the three screws «A».
2. Undo the six screws «B».
3. Remove the air filter cover «C».
4.Remove the air filter «D».
XEVO 400ie Maintenance
MAIN - 21
- Wash the sponge with water and mild soap.
- Dry it with a clean cloth and short blasts of compressed air.
- Soak it in a mixture of 50% petrol and 50% specified oil.
- Gently squeeze the filtering element with your
hands but do not wring it; allow it to drip dry and
then refit.
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NECESSARY TO SERVICE THE AIR FILTER MORE OFTEN TO
AVOID DAMAGING THE ENGINE.
Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased adhesiveness
Engine oil
In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the
thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced
by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Maintenance XEVO 400ie
MAIN - 22
Replacement
Change oil and replace filter as indicated in the
scheduled maintenance table. Empty the engine
by draining the oil through drainage plug «B».
To facilitate oil drainage, loosen the cap/dipstick
«A».
Once all the oil has drained through the drainage
hole, unscrew and remove the oil cartridge filter
«C ».
Make sure the pre-filter and drainage plug O-rings
are in good conditions.
Lubricate them and refit the mesh filter and the oil
drainage plug, screwing them up to the prescribed
torque.
Refit the new cartridge filter being careful to lubricate the O-ring before fitting it.
Change the engine oil.
Since a certain quantity of oil still remains in the
circuit, engine oil must be added through plug
«A». Then start the scooter, leave it running for a
XEVO 400ie Maintenance
MAIN - 23
few minutes and switch it off: after five minutes
check the level and if necessary top up without
exceeding the MAX level. The cartridge filter must
be replaced every time the oil is changed. Use new
oil of the recommended type for topping up and
changing purposes.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
Locking torques (N*m)
Engine oil filter 12 - 16 Engine oil drainage plug
24 ÷ 30
Check
This operation must be carried out with the engine
cold and following the procedure below:
- Place the vehicle on its centre stand and on flat
ground.
- Unscrew the cap/dipstick «A», dry it with a clean
cloth and reinsert it, screwing it all the way
down.
- Remove the cap/dipstick again and check that
the level is between the min and max reference
marks; top-up, if required.
If the check is carried out after the vehicle has
been used, and therefore with a hot engine, the
level line will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct
level.
Maintenance XEVO 400ie
MAIN - 24
Oil top up
The oil should be topped up after having checked
the level and in any case by adding oil without
ever exceeding the MAX. level.
Restoring the level from the MIN to the MAX marks
requires approx. 400 m³ of oil.
Engine oil filter
CAUTION
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. OIL, GASKET AND FILTER SHOULD BE DISPOSED OF ACCORDING TO THE REGULATIONS IN FORCE.
WARNING
AVOID TOUCHING PARTS OF THE ENGINE WHEN HOT, AS THIS MAY CAUSE BURNS.
The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.
Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
Oil pressure warning light
The vehicle is equipped with a warning light on the
instrument panel that lights up when the key is
turned to the «ON» position. However, this light
should switch off once the engine has been started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication system.
XEVO 400ie Maintenance
MAIN - 25
Checking the ignition timing
- Remove the plastic cap on the flywheel cover
-Turn the flywheel until the reference mark «T» on
the rotor matches the reference mark on the flywheel cover as shown in the figure (TDC). Make
sure that the 4V reference point on the camshaft
control pulley is aligned with the reference point on
the head as shown in the second figure. If the reference is opposite the indicator on the head, turn
the crankshaft once more.
For the use of this reference mark, remove the
spark plug and turn the engine in the direction that
is the reverse of the normal direction using a calliper spanner applied to the camshaft command
pulley casing.
Checking the valve clearance
- To check the clearance in the valves collimate
the references between the cam shaft control pulley and head.
- Use a feeler to make sure the clearance between
the valve and register screw correspond to the indicated values. If the clearance does not correspond, adjust it by loosening the lock nut using a
screwdriver on the set screw as shown in the figure.
Characteristic
Valve clearance
Inlet: 0.15 mm
Outlet: 0.15 mm
Maintenance XEVO 400ie
MAIN - 26
Cooling system
Adding engine coolant.
Check coolant level when the engine is cold as indicated in the scheduled maintenance table, following the steps below:
Place the scooter on its centre stand and on flat
ground.
- Undo the screw shown in the figure and remove
the expansion tank cap on RHS.
- Top up if the fluid level is near or below the MIN
level edge. The liquid level must always be between the MIN and MAX level.
-The coolant consists of an ethylene glycol and
corrosion inhibitor based 50% de-ionised waterantifreeze solution mix.
CAUTION
DO NOT EXCEED THE MAX LEVEL WHEN FILLING SO
THAT COOLANT DOES NOT SPILL OVER THE EXPANSION TANK WHEN THE VEHICLE IS BEING USED.
Recommended products
SPECIAL AGIP PERMANENT fluid Coolant
Monoethylene glycol based antifreeze solution,
CUNA NC 956-16
Braking system
XEVO 400ie Maintenance
MAIN - 27
Level check
The front and rear brake fluid reservoirs are both
positioned on the handlebars. Proceed as follows:
- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;
- Check the fluid level through the sight glass
«C». A certain lowering of the level is caused by
wear on the pads.
Top-up
Proceed as follows: Loosen the screw «B» and lift
the plastic cover «A» in order to access the brake
fluid reservoir. Loosen the two fixing screws and
remove the reservoir cover; top-up with the recommended fluid without exceeding the 'MAX.'
mark.
This procedure applies to the rear brake pump topup operation; follow the same procedure for the
front brake pump.
Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance
table.
WARNING
ONLY USE DOT 4 CLASS BRAKE FLUIDS. BRAKING CIRCUIT FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE
THAT IT DOES NOT COME INTO CONTACT WITH THE
PAINTWORK.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR
EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT4 Synthetic fluid
Maintenance XEVO 400ie
MAIN - 28
Headlight adjustment
Proceed as follows:
1. Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a half-lit
white screen; ensure that the longitudinal axis of
the vehicle is perpendicular to the screen;
2. Turn on the headlight and check that the bor-
derline of the projected light beam is lower than
9/10 and higher than 7/10 of the distance from the
ground to the centre of the vehicle headlight;
3. If not, adjust the headlight by turning the central
screw «A» placed behind the Piaggio badge.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
Checking the end compression pressure
- Remove the spark plug cap when the engine is cold.
- Remove the ignition spark plug.
- Fit a compression test gauge into the spark plug seat using a 10mm spark plug union at the proper
tightening torque.
- Turn the switch to «ON», wait a few seconds and then disconnect the rpm-timing sensor connector
to disable the injector and spark plug operation.
- Let the engine run using the starter motor and with the throttle body in fully open position as long as
the pressure gauge value is steady.
- If the pressure exceeds the level specified, remove the tool and proceed with the vehicle refitting.
- If the pressure is below the level specified, check the rpm at which the test is carried out; if less than
450 rpm, check the start-up system.
XEVO 400ie Maintenance
MAIN - 29
If the compression end pressure is below the standard, remove the pressure gauge coupling and pour
some oil into the combustion chamber, turn the engine (preferably manually) to lubricate the cylinder.
Repeat the pressure test:
If the new values are still low, check valves for correct sealing.
Characteristic
Compression ratio
10.6 ± 0.5 : 1
Locking torques (N*m)
Spark plug 12 ÷ 14
Maintenance XEVO 400ie
MAIN - 30
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