PIAGGIO XEVO User Manual

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MANUALE STAZIONE DI SERVIZIO

****** - ******

XEVO 400ie

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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

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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.

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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

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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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

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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

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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

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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

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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

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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

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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

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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

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Products

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

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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

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- 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

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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

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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

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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

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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

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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

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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

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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

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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

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

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This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given.

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valves

Misshapen/worn valve seats Replace the head unit

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

Worn or broken piston rings or piston rings that have not been

fitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

LOW LUBRICATION PRESSURE

Possible Cause

Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the

By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump components

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause

Operation

Faulty clutch Check that there is no grease on the masses. Check that the

clutch mass faying surface with the bell is mainly in the centre with equivalent characteristics on the three masses. Check that

the clutch casing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause

Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are

not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Troubleshooting XEVO 400ie

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Possible Cause Operation

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift

of the disc with a dial gauge and with wheel mounted on the

scooter.

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective plunger sliding Check calliper and replace any damaged part.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

a wheel mounted on the vehicle to measure the axial deviation

of the disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or stuck rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause

Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause

Operation

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

Noisy suspension

NOISY SUSPENSION

Possible Cause

Operation

Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front

shock absorber; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers; and the movement

bushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disc in the

attachment to the hub and the steering tube.

XEVO 400ie Troubleshooting

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Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of the

steering covers and the adjustments.

Troubleshooting XEVO 400ie

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

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KEY

1. Magneto flywheel

2. Engine stop switch

3. Diode

4. Side stand button

5. Key switch

6. Electric fan

7. Engine stop remote control switch

8. Voltage regulator

9. Main fuses

10.12V-180W Plug socket

11. Auxiliary fuses

12. Stop button on front brake

13. Stop button on rear brake

14.Immobilizer remote control switch

15. 12V-12Ah Battery

16. Starter motor

17. Start-up remote control switch

18. Boot actuator

19. Boot opening switch

Electrical system XEVO 400ie

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20. Starter button

21. Saddle opening actuator

22.Saddle opening control unit

23. Wiring for anti-theft device

24. «HAZARD» button

25. Turn indicator switch

26. Light switch

27. Turn indicator control device

28. Light switch remote control

29. Helmet compartment light bulb

30. License plate bulb

31. Rear left turn indicator

32. Rear light A. Stop light bulbs B. Tail light bulbs

33. Rear right turn indicator

34. Front left turn indicator

35. Front light A. Tail light bulbs B. High-beam light bulb C. Low-beam light bulb

36. Front right turn indicator

37. «MODE» button

38. Helmet compartment light switch

39. Headlight remote control

40. Boot light switch

41. Horn

42. Horn button

43. Injection load remote control

44.Ambient temperature sensor

45. Fuel injector

46. Fuel level transmitter

47. Oil pressure sensor

48. Instrument panel

49.Wheel turning sensor

50. HV coil

51. Immobilizer aerial

52. Decoder

XEVO 400ie Electrical system

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53. Injection ECU

54. Intake air temperature sensor

55. Fuel pump

56. Diagnosis connector Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black,

Ro = Pink, Rs = Red, Ve = Green, Vi = Purple

Components arrangement

6 - Electric fan: placed at the front of the vehicle,

remove the shield back plate to reach it and remove the radiator to extract it.

Electrical system XEVO 400ie

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7 / 14 / 28 / 39 / 43 / 57 / 27 - Remote control switches: engine stop / immobilizer / light switch / headlight / injection load / electric fan / turn indicator control device: remove the instrument panel bottom section to reach them.

8 / 17 - Voltage regulator / Start-up remote control switch: remove the right fairing to reach them

9 / 11 / 15 / 56 - Main fuses / Auxiliary fuses / 12V-12Ah Battery / Connector for diagnosis: remove the cover located in the helmet compartment to reach them.

10 - 12V-180W Plug socket

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22 - Saddle opening control unit: remove the left side panel to reach it.

41 - Horn: remove the wheel housing lower clamp to reach it.

44 - Ambient temperature sensor: remove the front headlight assembly to reach it.

45 / 60 - Fuel injector / Engine temperature sensor: remove the inspection door in the helmet compartment to reach them.

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46 / 55 - Fuel level transmitter / Fuel pump: remove the central chassis cover to reach them.

47 - Oil pressure sensor.

49 - Wheel turning sensor: the sensor is placed on

the engine crankcase, near the left shock absorber lower attachment.

50 - HV coil: remove the central chassis cover to reach it.

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51 / 52: Immobilizer aerial / Decoder: remove the legshield and the shield back plate to reach them.

53 - Injection ECU: remove the front shield to reach it.

54 - Intake air temperature sensor: remove the left side fairing and the air filter manifold to reach it.

59 - Stepper motor: remove the inspection door in the helmet compartment to reach them.

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62 - Lambda probe: The lambda probe is fitted on the exhaust manifold.

Conceptual diagrams

Ignition

KEY

2. Engine stop switch

3. Diode

4. Side stand button

5. Key switch

7. Engine stop remote control switch

9. Main fuses

11. Auxiliary fuses

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15. 12V-12Ah Battery

43. Injection load remote control

50. HV coil

51. Immobilizer aerial

52.Decoder

53. Injection ECU

Battery recharge and starting

KEY

1. Magneto flywheel

2. Engine stop switch

3. Diode

4. Side stand button

5. Key switch

7. Engine stop remote control switch

8. Voltage regulator

9. Main fuses

11. Auxiliary fuses

12. Stop button on front brake

13. Stop button on rear brake

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14.Immobilizer remote control switch

15. 12V-12Ah Battery

16. Starter motor

17. Start-up remote control switch

20. Starter button

32. Rear light A. Stop light bulbs

Level indicators and enable signals section

KEY

2. Engine stop switch

3. Diode

4. Side stand button

5. Key switch

7. Engine stop remote control switch

9. Main fuses

11. Auxiliary fuses

15. 12V-12Ah Battery

43. Injection load remote control

44.Ambient temperature sensor

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45. Fuel injector

46. Fuel level transmitter

47. Oil pressure sensor

48. Instrument panel

49.Wheel turning sensor

51. Immobilizer aerial

52.Decoder

53. Injection ECU

54.Intake air temperature sensor

58. Engine rpm sensor

60. Engine temperature sensor

61. Throttle valve potentiometer

62. Lambda probe

Devices and accessories

KEY

2. Engine stop switch

3. Diode

4. Side stand button

5. Key switch

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6. Electric fan

7. Engine stop remote control switch

9. Main fuses

10. 12V-180W Plug socket

11. Auxiliary fuses

15.12V-12Ah Battery

18. Boot actuator

19. Boot opening switch

21. Saddle opening actuator

22.Saddle opening control unit

23. Wiring for anti-theft device

29. Helmet compartment light bulb

37. «MODE» button

38. Helmet compartment light switch

40. Boot light switch

41. Horn

42. Horn button

43. Injection load remote control

48. Instrument panel

53. Injection ECU

55. Fuel pump

56. Diagnosis connector

57. Electric fan remote control

59.Stepper motor

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Lights and turn indicators

KEY

5. Key switch

9. Main fuses

11. Auxiliary fuses

15.12V-12Ah Battery

24. «HAZARD» button

25. Turn indicator switch

26. Light switch

27. Turn signal command device

28. Light switch remote control

30. License plate bulb

31. Rear left turn indicator

32. Rear light B. Tail light bulbs

33. Rear right turn indicator

34. Front left turn indicator

35. Front light A. Tail light bulbs

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B. High-beam light bulb C. Low-beam light bulb

36. Front right turn indicator

39. Headlight remote control

48. Instrument panel

Checks and inspections

Immobiliser

The electronic ignition system is controlled by the control unit and the immobilizer decoder. The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobiliser system consists of the following components:

- electronic control unit

- decoder

- immobilizer aerial

- master key with integrated transponder (brown key)

- service key with incorporated transponder (black key)

- HV coil

- diagnosis LED The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to the "ON" position, the theft-deterrent blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or the instrument panel is not initiated, check if:

•

there is battery voltage

•

efficiency of fuse No. 7

•

there is power to the control unit as specified below:

Disconnect the connector from the control unit. Check the following conditions:

With the key switch set to OFF:

•

Battery voltage between terminals 17-23 and terminals 17-chassis ground (continuous power supply). If there is no voltage, check that fuse No. 6 is in good conditions.

With the key switch in position ON and the engine stop switch in RUN:

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•

Battery voltage between terminals 26-23 and terminals 26-chassis ground (continuous power supply). If there is no voltage, check:

1. that fuses No. 11 and No. 2 and their wirings are in good conditions.

2. that the engine stop remote control switch is in good conditions.

•

Check for voltage on the white-black cable at the exit from the engine stop remote control switch. If there is no voltage, check:

1. key switch contacts

2. the condition of the engine stop switch, then the ground connection of the green/black cable of the

engine stop remote control switch with the stand lifted and the engine stop switch in the RUN position.

3. that the engine stop remote control switch diode is in good conditions. If no fault is found, replace the control unit.

N.B.

AN ACCIDENTAL LOSS OF THE SERVICE KEY PROGRAMMING CAN ARISE FROM GENERAL FAULTS OF THE IGNITION SYSTEM. IN THIS CASE, CHECK THE HV LINE SHIELDING.

In any case it is advisable to use resistive spark plugs.

Virgin circuit

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised when the decoder has been correctly programmed. The procedure for programming a new decoder requires the recognition of the "master" key as the first key to be programmed: this is particularly important as it is the only key that allows the decoder to be reset and reprogrammed for programming the service keys. The master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits 1 to 3 seconds).

- Insert the service key and turn it to «ON» for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- Insert the MASTER key again and turn it to «ON» for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to keep using. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any case it is advisable to use resistive spark plugs.

Characteristic

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MASTER key:

BROWN KEY

SERVICE key.

BLACK KEY

Diagnostic codes

The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the led remains on permanently, it means the ignition is inhibited:

1. New decoder - key inserted: a single 2 second flash is displayed, after which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs.

2. New decoder - transponder missing or illegible: The LED is permanently ON; in this condition,

no operations are possible, including starting of the vehicle.

3. Decoder programmed - service key inserted (normal operating condition): a single 0.7-sec-

ond flash is displayed, after which the LED remains off steadily. The engine can be started.

4. Decoder programmed - master key inserted: a 0.7-sec flash is displayed followed by the

LED remaining off for 2 sec. and then by short

0.46-sec flashes the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been completed, the LED remains permanently OFF. The engine can be started.

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5. Decoder programmed - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are:

•

1-flash code

•

2-flash code

•

3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessary.

Diagnostic code - 2 flashes

A 2-flash code indicates a system where the decoder does not recognise the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. Otherwise replace the faulty key and/or reprogram the decoder. If the problem persists, replace the decoder.

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Diagnostic code - 3 flashes

The 3-flash code indicates a system where the decoder does not recognise the key. Turn the switch to ON using several keys: If the error code is repeated even with the Master key, replace the decoder. If this is not the case, reprogram the decoder.

Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. This system therefore requires no connection to the key switch. The three- phase generator provides good recharge power and at low revs, a good compromise is achieved between generated power and idle stability.

Stator check

Checking the stator windings

WARNING

THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Remove the right side panel.

2) Disconnect the connectors between stator and regulator with the three yellow cables.

3) Measure the resistance between each of the yellow terminals and the other two.

Electric characteristic

Resistance:

0.2 - 1 Ω

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4) Check that there is insulation between the each yellow cable and the ground.

5) If values are incorrect, replace the stator.

Recharge system voltage check

Maximum current output check.

- With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter. With an efficient battery a value must be detected: > 20A

Charging current check

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the tester terminals between the battery terminals..

3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm.

Look for any leakage

1) Check that the battery does not show signs of leaking fluid before checking the output voltage.

2) Turn the ignition key to OFF and connect the multimeter leads between the battery negative pole (-) and the Black cable.

3) With the multimeter leads connected, disconnect the Black cable from the battery negative pole (-).

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

VOLTAGE REGULATOR/RECTIFIER

Specification

Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 ÷ 15V at 5000 rpm with lights off

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Turn signals system check

The circuit of the turn indicators is controlled by the electronic control unit. If it does not work, it is necessary to:

1. Check that the fuse No. 8 is in good condition

2. Check that the bulbs are in good condition

3. Check that the turn signal indicator switch is in good condition

4. With the key switch set to ON; check there is battery voltage on the turn indicator switch connector.

If there is no voltage, check the wiring and the correct function of the electrical control units. Replace the control unit if the problem persists.

Lights list

BULBS

Specification Desc./Quantity

1 High-beam light bulb Type: HALOGEN (H7)

Power: 12V - 55W

Quantity: 1

2 Low-beam light bulb Type: HALOGEN (H7)

Power: 12V - 55W

Quantity: 1

3 Front tail light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 2

4 Instrument panel bulb Type: ALL GLASS

Power: 12V - 2W

Quantity: 4

5 Front turn indicator light bulb Type: ALL GLASS

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

6 Helmet compartment light bulb Type: CYLINDRIC

Power: 12V - 5W

Quantity: 1

7 Rear turn indicator light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 2 RHS + 2 LHS

8 Rear tail light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 2

9 Stop light bulb Type: SPHERICAL

Power: 12V - 10W

Quantity: 2

10 License plate bulb Type: All glass

Power: 12V - 5W

Quantity: 1

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Fuses

Remote control switches - Diode unit

The electrical system is equipped with 5 remote control switches plus the diode unit placed under legshield and the start-up remote control switch under the right side fairing. To access the remote control switches under the shield it is necessary to:

•

Remove the legshield.

•

Remove the knee-guard panel.

In order to access the start-up remote control switch, remove the right side fairing. The following table shows the functions of each remote control switch:

A: Immobiliser B: Injection load C. Light switch remote control D: Electric fan remote control E: Light remote control F: Engine stop remote control switch G: Starter remote control

The electrical system is equipped with 12 protective fuses for the various circuits on the vehicle, subdivided into two fuse boxes «A» and «B» located alongside the battery. The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE). BESIDES, IF AFTER REPLACING A FUSE, THE NEW FUSE ALSO BLOWS, THE SCOOTER NEEDS TO BE TAKEN TO AN AUTHORISED PIAGGIO/GILERA SERVICE CENTRE TO IDENTIFY THE CAUSE OF THE FAULT AND AVOID FUR-

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THER DAMAGE TO THE ELECTRIC SYSTEM COMPONENTS OR THE VEHICLE ITSELF.

CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE OPERATING ERRORS AND RISK OF FIRE.

FUSES

Specification

Desc./Quantity

1 Fuse No. 1 Capacity: 30 A

Protected circuits:battery recharge.

Location:battery compartment, on vehicle LHS.

2 Fuse No. 2 Capacity:15A

Protected circuits:

Turn indicator control device, live fuses No. 8-9-10-12,

live engine stop remote control switch.

Location:Battery compartment - on LHS.

3 Fuse No. 3 Capacity: 15A

Protected circuits:

- LV socket, electric fan (via relay), wiring for anti-theft device, saddle opening control unit.

- boot opening live power supply.

Location:battery compartment - on LHS

4 Fuse No. 4 Capacity: 10 A

Protected circuits: injection load (via relay).

Location:battery compartment, on vehicle LHS.

5 Fuse No. 5 Capacity: 10A

Protected circuits: luggage light, headlight (via relay).

Location:battery compartment, on vehicle LHS.

6 Fuse No. 6 Capacity: 3A

Protected circuits: injection ECU, decoder.

Location:battery compartment, on vehicle LHS.

7 Fuse No. 7 Capacity: 7.5 A

Protected circuits:instrument panel.

Location:battery compartment, on vehicle RHS.

8 Fuse No. 8 Capacity: 7.5 A

Protected circuits: saddle opening control unit power

supply, hazard button, turn indicator switch, turn indica-

tor control device.

Location:battery compartment, on vehicle RHS.

9 Fuse No. 9 Capacity: 10 A

Protected circuits: stop lights, headlight remote con-

trol.

Location:battery compartment, on vehicle RHS.

10 Fuse No. 10 Capacity: 7.5 A

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Specification Desc./Quantity

Protected circuits: horn, instrument panel lightning, tail

lights, license plate light, light switch.

Location:battery compartment, on vehicle RHS.

11 Fuse No. 11 Capacity: 7.5 A

Protected circuits: injection load remote control, injec-

tion ECU, electrical fan remote control, decoder. Location:battery compartment, on vehicle RHS.

12 Fuse No. 12 Capacity:7.5 A

Protected circuits:wheel turning sensor, instrument

panel, wiring for anti-theft device.

Location:battery compartment, on vehicle RHS.

Dashboard

A = Immobilizer / antitheft LED B= Speedometer with twin scale (km/h and mph) C = CLOCK switch D = Digital display E = Emergency turn indicator warning light F= SET switch G = Rpm indicator H = Fuel gauge I = Warning light for helmet compartment courtesy

light on L = Engine control telltale light and injection system failure warning light

M = Low fuel warning light N = Engine stop warning light O= Turn indicator warning light P = Low oil pressure warning light Q = High-beam warning light

The clock, powered directly by the vehicle's battery, may be set by pressing the «T» button located inside the LHS glove-box on the knee-guard panel. Pressing the button for less than one second will add one minute to the displayed time; Keep the «T» button pressed to rapidly increase the time.

Sealed battery

Commissioning sealed batteries

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary.

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These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and, afterwards, every six months. INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 ÷ 14.70V

-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity

- Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

-Charge current equal to 1/10 of the nominal capacity of the battery

- Charge time: 5 h

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Cleaning the battery The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY.

If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the + positive sign.

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Dry-charge battery

- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of

1.26, corresponding to 30 Bé at a minimum temperature of 15°C until the upper level is reached.

- Allow to stand for at least 2 hours, then top up the level with sulphuric acid.

- Within 24 hours, recharge using the special battery charger (single) or (multiple) at an intensity of about 1/10 of the battery nominal capacity and until the acid gravity is about 1.27, corresponding to 31 Bé and such values become steady.

- After charging, top up the acid (adding distilled water). Close and clean carefully.

- After carrying out the operations above, install the battery on the scooter, observing the connections described in point 3) of paragraph "Battery re-

charge".

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

1 Keep the pipe in vertical position 2 Inspect visually 3 The float must be freed

Checking the electrolyte level

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.

Charging status check

After topping-up the electrolyte level, check its density using special density gauge. When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery.

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The battery runs down completely in the course of three months. When refitting the battery onto the scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must be attached to the positive, + terminal.

Battery recharge

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.

Remove the battery from the vehicle removing the negative clamp first. Normal bench charging must be performed using the special battery charger (single) or (multiple), setting the battery charge selector to the type of battery that requires recharging (i.e., at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ).

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY.

Battery installation

To access the battery, proceed as follows:

1. Place the scooter on its centre stand;

2. Open the saddle.

3. Remove the two screws A and the cover B.

4. Remove the electrical connections, disconnect

the breather pipe C and take out the battery. To refit, follow the steps but in reverse order.

CAUTION

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IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCONNECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE SCOOTER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKS OF BATTERY ELECTROLYTE.

Connectors

ECU

Layout of the system-side connectors and the connectors on the electronic control unit.

ECU

Specification

Desc./Quantity

1 Throttle potentiometer power supply +5 V 2 Lambda sensor (-) 3 Rpm indicator 4 Engine temperature (+) 5 Electric fan remote control 6 Stepper motor Stepper motor 7 Engine rpm sensor 8 Lambda sensor (+) 9 EMS diagnostic connector 10 EMS diagnostic connector 11 Throttle potentiometer signal 12 Engine rpm sensor

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Specification Desc./Quantity

13 Injector control (-) 14 Stepper motor Stepper motor 15 Injection telltale light (-) 16 Decoder (serial) 17 Battery powered (+) 18 Intake air temperature sensor (+) 19 Injection load remote control (-) 20 HV coil (-) 21 Stepper motor Stepper motor 22 Sensor ground (-) 23 Ground lead 24 Stepper motor Stepper motor 25 26 Continuous power supply (+)

Seat opening receiver

SADDLE OPENING RECEIVER CONTROL UNIT

Specification

Desc./Quantity

1 Radio aerial 2 Actuator 2 3 Reset / Input clearing 4 Battery positive 5 (Not connected) 6 Live positive lead 7 Ground lead 8 (Not connected) 9 (Not connected) 10 Actuator 1 11 Channel selection 1/3 12 Alarm code output

Immobiliser decoder

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IMMOBILIZER DECODER

Specification Desc./Quantity

1 2 Immobilizer LED control (negative) 3 Base power supply (positive) 4 Ground lead 5 6 electronic control unit (serial) 7 8 Continuous power supply (positive)

Dashboard

CONNECTOR A

Specification

Desc./Quantity

1 2 3 4 5 Live supply Instrument panel lighting 6 Battery-powered 7 8 9 10 11 Ground lead 12 General live power supply

CONNECTOR B

Specification

Desc./Quantity

1 Speed sensor 2 Fuel level indicator 3 Water temperature sensor (+) 4 Water temperature sensor (-) 5 «MODE» button 6 Oil pressure sensor 7 Left direction warning light 8 Right direction warning light 9 High-beam lamp warning light 10 Open boot warning light 11 Rpm indicator signal 12 Ambient temperature sensor (+) 13 Ambient temperature sensor (-) 14 Engine disabled warning light 15 Immobilizer LED 16 Injection check warning light 17 Ground lead 18 Hazard warning light

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Specification Desc./Quantity

19 Ground lead 20 -

Remote seat opening

The vehicle is equipped with a remote control to open the saddle. This remote control is supplied together with the keys and at the manufacturing stage, it has been programmed to work together with the ECU that control the opening device. If the remote control is lost, a new one can be requested and reprogram it by resetting the ECU memory and following the same steps as per programming the immobilizer system in the keys.

Battery replacement

The remote control for the black key is powered by inner batteries that get discharged after extended used. You may need to replace the batteries if the remote control fails or if its range of operation is reduced. To replace the batteries remove the three screws and uncouple the two half-shells.

Electric characteristic

Batteries used:

CR1616

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Zeroing

- To access the saddle opening control/reception unit, remove the left side fairing.

- A white cable, that comes from pin 3 of the control unit, goes out from the wiring.

- Earth the cable at least 10 seconds in order to delete all the remote controls stored in the control unit.

Programming

- Follow these steps to program the remote controls:

1. Insert the remote control key to be programmed in the steering lock key block.

2. Turn the key to ON, press the button on the remote control, release the button, turn the key back to OFF from the ON position, all within four seconds.

3. Wait 1 to 8 seconds

4. Repeat steps 2 and 3 for 4 times without removing the key. The control unit confirms the programming has been successful by opening the saddle.

N.B.

THE CONTROL UNIT CAN PROGRAMME UP TO 7 REMOTE CONTROLS.

Electrical system XEVO 400ie

ELE SYS - 66

Page 67

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 68

Exhaust assy. Removal

- Remove the right-hand side fairing

- Undo the two exhaust manifold fixings on the head.

- Remove the Lambda probe from its support and disconnect it.

Remove the screw indicated in the photograph.

- Loosen the screw shown in the figure so as to loosen the muffler strap and remove the whole muffler.

Engine from vehicle XEVO 400ie

ENG VE - 68

Page 69

N.B. DUE TO MUFFLER DIMENSIONS IT IS NOT POSSIBLE TO

ACTUATE ON THE SCREW PERPENDICULARLY TO REMOVE IT; USE A COMMERCIALLY AVAILABLE «BONDUS» MALE HEXAGONAL WRENCH.

Remove the lambda probe from the manifold.

Removal of the engine from the vehicle

CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Disconnect the battery.

- Remove the side fairings.

- Remove the helmet compartment. Remove the full muffler unit.

- Remove the rear wheel.

- Remove the pipe feeding coolant into the pump "A" as shown in the photograph and then empty the system.

- Remove the engine coolant outlet pipe as indicated.

- Disconnect the delivery and reverse fuel pipes "B".

- Remove the coolant outlet pipe from the motor as indicated.

- Remove the spark plug cap.

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Page 70

- Remove the electrical connections to the sensors and devices.

- Remove the throttle control cable from the throttle body by undoing the nut "C".

- Remove the positive and negative wiring from the starter motor.

- Disconnect the connectors from the flywheel wiring harness.

- Remove the lower screw of the left shock absorber "D".

- Use a jack to support the vehicle properly.

- Remove the engine-swinging arm fixing pin by undoing the nut "E" and operating on the head of the pin "F" indicated in the photograph.

- Remove the rear brake calliper and the relevant pipes from the engine crankcase.

- The engine is now free.

Installing the engine on the scooter

- Carry out the removal operations but in reverse order and respect the locking torques indicated in the «Specifications» Chapter.

CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.

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ENG VE - 70

Page 71

Check that there is a small clearance when the valve is in abutment against the set screw.

-Check the engine oil level and if necessary top it up with the recommended type.

- Top-up the cooling circuit.

- Check the functioning of the accelerator and the electrical devices.

XEVO 400ie Engine from vehicle

ENG VE - 71

Page 72

INDEX OF TOPICS

ENGINE ENG

Page 73

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap.

- Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush.

- Remove the nut and the two washers.

N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-

ENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

- Loosen the 4 fastening screws

- Extract the outside plastic transmission cover.

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Page 74

- Remove the six M6 screws.

- Remove the four M8 screws.

- Remove the transmission cover.

- Check that the bearing rotates freely, otherwise replace it.

Air duct

- Remove the transmission cover.

- Unscrew the two screws shown in the figure to remove the air conveyor.

Locking torques (N*m)

Air conveyor screws 11 ÷ 12

- Remove the external transmission cover.

- Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor.

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Page 75

Air duct filter

- Remove the external air conveyor.

- Unscrew the 2 fastening screws shown in the figure to remove the conveyor filter.

Removing the driven pulley shaft bearing

- Remove the transmission cover.

- Remove the Seeger ring.

- Place transmission cover on a wood surface and use the special tool so that it is adequately supported.

- Pull out the bearing using the special tool.

N.B. BELL MUST BE PLACED INTO THE TRANSMISSION COV-

ER, CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND. NOT ONLY IN THE AREA OF MAXIMUM STURDINESS.

Specific tooling

001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020439Y 17-mm guide

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Page 76

Refitting the driven pulley shaft bearing

- Heat the transmission cover interior using the heat gun.

N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS

WOULD DAMAGE THE OUTSIDE PAINTED SURFACE.

Specific tooling

020151Y Air heater

- Place the bearing onto the special tool with a little grease to prevent it from coming out.

- Install the new bearing using the special tool.

N.B. PROPERLY SUPPORT THE OUTSIDE COVER TO PRE-

VENT DAMAGING THE PAINTED SURFACE.

Specific tooling

020376Y Adaptor handle 020358Y 37x40-mm Adaptor 020439Y 17-mm guide

Baffle roller

Plastic roller

- Check that the roller does not show signs of wear and that it turns freely.

- Loosen the retaining bolt using a 13 mm spanner.

- Remove the complete roller with bearing.

N.B. IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE

THE COMPLETE ROLLER.

Installation of belt anti-vibration roller

- Install the anti-flapping roller with the lip facing the engine crankcase.

- Tighten the central screw to the prescribed torque.

N.B.

TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT IS OBTAINED.

Locking torques (N*m)

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Page 77

Anti-vibration roller screw 16.7 ÷ 19.6

Removing the driven pulley

- Remove the clutch bell.

- Remove the fixed driving half-pulley.

- Remove the driven pulley assembly with the belt.

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

N.B. CHECK THE ECCENTRICITY MEASURED, 0.2 MM MAX.

Characteristic

Max. value:

160.5 mm

Standard value:

160.2 mm

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Page 78

Removing the clutch

- To remove the clutch with the driven pulley it is necessary to use the special tool;

- Arrange the tool with the mean pins screwed in position "E" on the inside;

- Fit the adapter ring to the clutch assembly as shown in the photograph.

- Install the driven pulley unit onto the tool inserting the pins into the ventilation holes;

- Move the rear stop screw in abutment against the fixed driven pulley as shown in the figure.

CAUTION

THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIAL TOOL. DO NOT TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD IRRETRIEVABLY DEFORM THE TOOL. USING THE SPECIAL 55-MM WRENCH, REMOVE THE FASTENING RING NUT. LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT, CLUTCH, SPRING WITH SHEATH.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction material.

Characteristic

Minimum thickness permitted:

1 mm

- The masses must not show traces of lubricants. Otherwise, check the driven pulley unit seals.

N.B.

UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

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Page 79

- Do not open the masses using tools to prevent a variation in the return spring load.

Pin retaining collar

- Extract the collar using 2 screwdrivers.

- Remove the 4 guide pins.

- Extract the moving driven half-pulley.

Removing the driven half-pulley bearing

- Check that the bushing is free from wear and damage; otherwise replace the fixed driven halfpulley.

- Remove the lock ring using pliers.

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Page 80

- Using the special tool inserted through the roller bearing, pull out the ball bearing.

N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAM-

AGING THE THREADING.

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide

N.B.

IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS NECESSARY TO SUPPORT THE UNIT BY THE BELL

Specific tooling

001467Y002 Driver for OD 73 mm bearing

- Remove the roller bearing using the special tool, supporting the fixed half-pulley with the bell.

Specific tooling

020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020364Y 25-mm guide 001467Y002 Driver for OD 73 mm bearing

Inspecting the driven fixed half-pulley

- Check that the belt contact surface is free from wear.

- Measure the outer diameter of the pulley bushing.

Characteristic

Minimum admissible diameter

49.91 mm

Standard diameter:

50.00 -0.015 -0.035 mm

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Page 81

Inspecting the driven sliding half-pulley

- Check that the belt contact surface is free from wear.

- Remove the 2 inside sealing rings and the 2 outside O-rings.

- Measure the movable half-pulley bushing inside diameter.

Characteristic

Maximum admissible diameter:

50.05 mm

Standard diameter:

50.00 +0.035 0.00 mm

Refitting the driven half-pulley bearing

- Install a new roller bearing using the special tool.

N.B.

PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUTWARDS.

- Properly support the half-pulley to prevent damaging the threading. If you are working on the driven pulley unit fully assembled, use the special tool.

Specific tooling

020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing

- Install a new ball bearing using the special tool.

Specific tooling

020376Y Adaptor handle 020477Y 37 mm adaptor 020363Y 20-mm guide

- Insert the Seeger lock ring.

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Page 82

Refitting the driven pulley

- Insert the new oil guards

- Insert the new O-rings

N.B.

O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RADIUS, AT THE BASE OF THE HALF-PULLEY.

- Install the half-pulley on the bushing being careful not to damage the top sealing ring during the introduction.

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of grease, this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.

Inspecting the clutch spring

- Measure the length of the movable driven halfpulley spring while it is unloaded.

Characteristic

Standard length:

125.5 mm

Admissible limit after use:

120 mm

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Page 83

Refitting the clutch

- Prepare the special tool as for removal;

- Preassemble the driven pulley unit with the drive belt according to its direction of rotation;

- Insert the driven pulley unit, the spring with sheath and clutch into the tool.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

- Compress the spring and insert the clutch on the driven pulley bushing.

N.B.

BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END.

- Tighten the ring nut by hand and complete the tightening using the special wrench to the prescribed torque.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

Locking torques (N*m)

Clutch ring nut 65 - 75

- To facilitate reassembly on the engine, turn the moving driven pulley and insert the belt onto the smaller diameter.

Refitting the driven pulley

- Install the driven pulley assembly with belt.

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Page 84

Drive-belt

- Check that the driving belt is not damaged.

- Check the width of the belt.

Characteristic

Minimum width:

27 mm

Standard width:

28.2 mm

Removing the driving pulley

- Using a 27 mm wrench, turn the central pulley nut to horizontally align the central inside holes and install the special tool.

Specific tooling

020474Y Driving pulley lock wrench

- First fit the 2 retainer clamps of the special tool onto the pulley so that the splines are completely engaged.

- Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself.

- Tighten the two tool fixing screws, also manually.

- Loosen the central nut.

- Remove the spring washer and the flat washer.

- Remove the fixed driving half-pulley.

- Remove the bushing connection washer.

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Page 85

- Move the belt downwards.

- Suitable support the roller contrast and extract the movable driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out.

Inspecting the rollers case

- Check that the inside bushings shown in the figure exhibit no signs of abnormal wear and measure the inside diameter.

CAUTION

DO NOT LUBRICATE OR CLEAN THE BUSHINGS

Characteristic

Maximum admissible diameter:

30.12 mm

Standard diameter:

30.021 mm

- Measure the pulley sliding bushing outside diameter shown in the figure.

Characteristic

Minimum admissible diameter

Ø 29.95 mm

Standard diameter:

Ø 29.959 mm

- Check that the rollers are not damaged or worn.

Characteristic

Minimum admissible diameter

Ø 24.5 mm

Standard diameter:

Ø 24.9 mm

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Page 86

- Check the guide shoes for the variator back-plate are not worn.

- Check the wear of the roller housings and of the belt contact surfaces on both pulley halves.

Refitting the driving pulley

Installing the roller container

- Install the spacer with the internal chamfer facing towards the inside.

- Position the rollers on the half-pulley as shown in the figure.

- The closed side must rest on the inside thrust face of the roller container.

- Assembly the half-pulley with the roller contrast plate and sliding blocks.

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Page 87

- Insert the half-pulley on the crankshaft.

- Insert the spacer bushing.

Installing the fixed driving half-pulley

- Insert the spacer.

- Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley.

- Remove the flat washer and the spring washer as shown in the figure.

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Page 88

- Insert the nut in the original position (nut side in contact with the belleville washer).

- Turn the central pulley nut to horizontally align the holes and install the special tool.

N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY IN-

SERTED INTO THE PULLEY AND IN THE ENGINE CRANKCASE.

Specific tooling

020474Y Driving pulley lock wrench

- Install the lock ring from the rear so that the splines are completely engaged.

- Finally install the tool by siding the nuts by hand and ensuring the tool is resting flatly.

- Tighten the driving pulley fastening nut to the prescribed torque

- Remove the special tool.

Locking torques (N*m)

Drive pulley nut 160 - 175

Refitting the transmission cover

- Ensure the correct installation on the crankcase of the 2 centring dowels.

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Page 89

- Insert the transmission cover with the bearing and install the relevant retainers.

- Lock the four M8 retainers.

Locking torques (N*m)

M8 retainers for transmission cover 23 ÷ 26

- Lock the 7 M6 retainers.

Locking torques (N*m)

M6 retainer 11 ÷ 13

- Insert the washers on the driven pulley shaft.

N.B.

INSERT THE SMALLER WASHER FIRST, THEN THE LARGER ONE.

- Insert the flanged nut.

- Prepare the torque wrench for LHS locking using a machine hexagon wrench.

- Tighten the driven pulley shaft fastening nut using an offset wrench.

N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-

ENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

Locking torques (N*m)

Driven pulley nut 92 - 100

- Install the driving pulley shaft cover, positioning the tooth gap on the lower part with the reference mark on the transmission crankcase.

N.B.

ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE.

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Page 90

- Install the outside plastic transmission cover.

- Tighten the 4 fastening screws to the prescribed torque.

Locking torques (N*m)

External transmission cover screws 7 ÷ 9

End gear

Removing the hub cover

- Drain the rear hub oil through the oil drainage cap located under the engine.

-Remove the 7 fastening screws. Remove the hub cover and the relevant gasket.

Removing the wheel axle

- Remove the countershaft.

- Remove the wheel axis complete with gear.

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Page 91

Removing the hub bearings

- Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts.

Specific tooling

001467Y014 Pliers to extract ø 15-mm bearings 001467Y034 Pliers to extract ø 15-mm bearings 001467Y031 Bell

- Use the special extractor to disassemble the bearing on the engine chassis of the countershaft.

Specific tooling

001467Y006 Pliers to extract 20 mm bearings 001467Y035 Bearing housing, outside ø 47 mm

- Support the hub cover using the stud bolt set.

- Pull out the bearing using the special tool.

Specific tooling

020476Y Stud bolt set 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings

Removing the wheel axle bearings

- Take out the clip on the outside of the gearbox cover.

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Page 92

- Support the hub cover using the stud bolt set.

- Pull out the bearing using the special tool.

Specific tooling

020476Y Stud bolt set 020376Y Adaptor handle 020477Y 37 mm adaptor 020483Y 30-mm guide

- Remove the oil guard using a screwdriver.

Removing the driven pulley shaft bearing

- If you have to remove the driven pulley shaft, the relevant bearing and the oil guard, remove the transmission cover and the clutch unit as described in the « Automatic transmission» chapter.

- Extract the driven pulley shaft from its bearing.

- Remove the oil guard using a screwdriver into the hub gear box.

- Remove the Seeger ring shown in the figure.

- Pull out the driven pulley shaft bearing from the engine crankcase using the special tool.

Specific tooling

020376Y Adaptor handle 020358Y 37x40-mm Adaptor 020364Y 25-mm guide

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Inspecting the hub shaft

- Check that the 3 shafts exhibit no wear or deformation on the grooved surfaces, at the bearings and at the oil guards.

- In case of faults, replace the damaged parts.

Characteristic

Connection diameter for countershaft: A = diameter 20 - 0.01 -0.02 mm Connection diameter for wheel shaft: B = diameter 30 - 0.010 -0.023 mm C = diameter 15 - 0.01 -0.02 mm

Bearing diameter for driven pulley shaft: D = diameter 17 - 0.01 -0.02 mm E = diameter 20 - 0.01 -0.02 mm

F = diameter 25 - 0.01 -0.02 mm

Inspecting the hub cover

- Check that the mounting surface is not damaged or deformed.

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Page 94

- Check the capacity of the bearings.

In case of faults, replace the hub cover.

Refitting the driven pulley shaft bearing

- Heat the crankcase using the heat gun.

Specific tooling

020151Y Air heater

- Insert the driven pulley shaft bearing until it abuts against the bottom of the seat using the special tool.

N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-

PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling

020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020364Y 25-mm guide

- Heat the intermediate gear bearing seat.

- Insert the intermediate shaft bearing using the special tool.

N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-

PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling

020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020363Y 20-mm guide

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Page 95

- Heat the gear shaft bearing seat on the crankcase.

- Insert the gear shaft bearing in the upper crankcase seat using the special tool.

N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-

PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling

020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020412Y 15-mm guide

- Place the safety lock Seeger ring of the driven pulley shaft bearing.

N.B. PLACE IT IN THE POSITION SHOWN IN THE FIGURE.

- Insert the pulley shaft oil guard on the transmission side.

Refitting the hub cover bearings

- Heat the bearing seats on the cover using the heat gun.

- Support the hub cover using the stud bolt set.

Specific tooling

020151Y Air heater 020476Y Stud bolt set

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Page 96

- Insert the intermediate shaft bearing on the cover using the special tool.

N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-

PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling

020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020363Y 20-mm guide

- Heat the gear shaft bearing seat from the cover outside.

- Insert the gear shaft bearing on the cover using the special punch until abutment.

Specific tooling

020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020483Y 30-mm guide

- Replace the snap ring

- Support the hub cover using the stud bolt set.

- Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover.

- Place the oil guard flush with the crankcase.

Specific tooling

020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020476Y Stud bolt set

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Refitting the hub bearings

- Place the 3 shafts as shown in the figure.

Refitting the ub cover

- Check the proper position of the centring dowels.

- Install a new gasket.

- Fit the gearbox cover, making sure the breather pipe is in the correct position.

- Position the 7 set screws, tighten them to the prescribed torque, being careful of the position of the bands holding the vent tube, and the position of the 3 shortest screws as indicated in the figure.

- Refill with the prescribed oil to the Max. level.

Recommended products

AGIP ROTRA 80W-90 rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Quantity:

approx. 250 cc

Locking torques (N*m)

Rear hub cover screws 24 ÷ 27

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Page 98

Flywheel cover

- Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.

N.B. THE BANDS MUST BE REPLACED. TO REMOVE THEM,

OPEN WITH A SCREWDRIVER OR CUT THEM. BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.

Removing the hub cover

- Drain the engine oil by removing the drainage cap.

- Prepare a suitable container to collect the oil.

- Remove the pre-filter.

- Remove the oil filter using a filter tape or shaped cup wrench.

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- Loosen the 14 fastening screws.

- Remove the flywheel cover with the relevant gasket and the cooling system sleeve support.

N.B. THE SCREWS ARE OF 4 DIFFERENT LENGTHS. NOTE

THE RELEVANT POSITIONS.

CAUTION

REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR.

CAUTION

BE CAREFUL TO PREVENT SLIPPAGE OF THE BY-PASS VALVE AND OF THE RELEVANT SPRING.

Removing the flywheel cover components

- Loosen the six mounting screws and remove the water pump cover.

- Remove the by-pass and the relevant spring.

- Remove the oil pump seal.

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Removing the stator

- Remove the two retaining screws and the cable guide bracket.

- Unscrew the 3 fastening screws and remove stator and its wiring.

Inspecting the cover components

- Loosen the two retaining screws and remove the reed valve support with bulkhead.

- Remove the blow-by reed valve with the relevant sealing gasket.

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