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.
"© 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
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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 |
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MAINTENANCE |
MAIN |
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TROUBLESHOOTING |
TROUBL |
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ELECTRICAL SYSTEM |
ELE SYS |
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ENGINE FROM VEHICLE |
ENG VE |
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ENGINE |
ENG |
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INJECTION |
INJEC |
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SUSPENSIONS |
SUSP |
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BRAKING SYSTEM |
BRAK SYS |
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COOLING SYSTEM |
COOL SYS |
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CHASSIS |
CHAS |
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PRE-DELIVERY |
PRE DE |
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TIME |
TIME |
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INDEX OF TOPICS
CHARACTERISTICS |
CHAR |
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XEVO 400ie |
Characteristics |
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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
CHAR - 7
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Characteristics |
XEVO 400ie |
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Dimensions and mass
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WEIGHTS AND DIMENSIONS |
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Specification |
Desc./Quantity |
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Kerb weight |
171 ± 6 kg |
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Engine |
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ENGINE |
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Specification |
Desc./Quantity |
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Type |
Single-cylinder, 4-stroke |
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Bore x stroke |
85.8 X 69 mm |
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Cubic capacity |
399 cm³ |
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Compression ratio |
10.6 ± 0.5 : 1 |
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Timing system |
Four valves, single overhead camshaft, chain-driven. |
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Valve clearance |
Inlet: 0.15 mm |
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Outlet: 0.15 mm |
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Engine idle speed |
1,500 ± 100 rpm |
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Start-up |
Electric |
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LUBRICATION |
Engine lubrication with trochoidal pump (inside the crankcase), |
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oil filter and pressure adjustment by-pass. |
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FINAL REDUCTION GEAR |
Gear reduction unit in oil bath. |
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Muffler |
Absorption-type exhaust muffler with catalytic converter and |
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lambda probe. |
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Fuel supply |
Electronic injection with Ø 38-mm throttle body and electric fuel |
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pump. |
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MAX Power |
24 kW at 7,250 rpm |
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MAX torque |
38 Nm at 5,250 rpm |
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Cooling |
Forced coolant circulation system. |
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CHAR - 8
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XEVO 400ie |
Characteristics |
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Transmission
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TRANSMISSION |
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Specification |
Desc./Quantity |
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TRANSMISSION |
Automatic expandable pulley variator with torque server, V- |
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belt, automatic clutch. |
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Capacities |
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CAPACITY |
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Specification |
Desc./Quantity |
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Engine oil |
1.7 l |
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Transmission oil |
250 cm³ |
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Cooling system fluid |
~ 1.8 l |
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Fuel tank (reserve) |
approx. 12 l (approx. 2 l) |
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Electrical system |
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ELECTRICAL SYSTEM |
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Specification |
Desc./Quantity |
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Ignition |
Electronic, inductive, high efficiency ignition, integrated with the |
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injection system, with variable advance and separate HV coil. |
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Ignition advance |
Three-dimensional map managed by control unit |
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Spark plug |
CHAMPION RG 6 YC |
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Alternative spark plug |
NGK CR7EKB |
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Battery |
12V-12Ah |
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Frame and suspensions |
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CHASSIS AND SUSPENSIONS |
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Specification |
Desc./Quantity |
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Frame |
Tubular and steel sheets. |
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Front suspension |
Hydraulic telescopic fork with Ø 35-mm stem |
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Rear suspension |
Two double-acting shock absorbers, adjustable to four posi- |
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tions at preloading. |
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Brakes |
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BRAKES |
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Specification |
Desc./Quantity |
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Front brake |
Ø 240-mm double disc brake with hydraulic control operated |
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by the handlebar right-hand lever. |
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Rear brake |
Ø 240-mm disc brake with hydraulic control operated by the |
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handlebar left-side lever. |
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Wheels and tyres |
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WHEELS AND TYRES |
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Specification |
Desc./Quantity |
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Wheel rim type |
Light alloy rims. |
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Front tyre |
Tubeless 120/70 - 14'' 55P |
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CHAR - 9
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Characteristics |
XEVO 400ie |
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Specification |
Desc./Quantity |
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Rear tyre |
Tubeless 140/70 - 14'' 68S |
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Front tyre pressure (with passenger) |
2.3 bar (-) |
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Rear tyre pressure (with passenger) |
2.6 bar (-) |
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N.B. |
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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 |
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CYLINDERPISTON |
Specification |
Desc./Quantity |
Cylinder diameter C |
85.8 - +0.018 -0.01 mm |
Piston Ø P |
85.768 ± 0.014 mm |
CYLINDER - PISTON |
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COUPLING CATEGORIES
Name |
Initials |
Cylinder |
Piston |
Play on fitting |
CylinderPiston |
A |
85.790÷85.797 |
85.754÷85.761 |
0.029÷0.043 |
CylinderPiston |
B |
85.797÷85.804 |
85.761 ÷ 85.768 |
0.029÷0.043 |
CylinderPiston |
C |
85.804÷85.811 |
85.768÷85.775 |
0.029÷0.043 |
CylinderPiston |
D |
85.811÷85.818 |
85.775÷85.782 |
0.029÷0.043 |
CATEGORIES OF COUPLING
N.B.
CHAR - 10
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XEVO 400ie |
Characteristics |
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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
CHAR - 11
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Characteristics |
XEVO 400ie |
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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.
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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
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Specification |
Desc./Quantity |
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A = |
0.15 mm |
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B = |
0.010 mm |
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C = |
0.010 mm |
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D = |
0.10 mm |
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CHAR - 12
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XEVO 400ie |
Characteristics |
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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 |
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1±0.025 |
A |
D = 0.20 - 0.50 |
shoulder |
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Half-shaft, transmission |
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20.9 -0.05 |
B |
D = 0.20 - 0.50 |
side |
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Connecting rod |
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22 -0.10 -0.15 |
C |
D = 0.20 - 0.50 |
Flywheel-side shoulder |
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1.8±0.025 |
F |
D = 0.20 - 0.50 |
Flywheel-side half-shaft |
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19.6 -0.05 |
E |
D = 0.20 - 0.50 |
Complete crankshaft |
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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).
CHAR - 13
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Characteristics |
XEVO 400ie |
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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 RE-
CESSED INTO THE CYLINDER TOP PLANE, THE SMALL-
ER THE GASKET THICKNESS.
Characteristic
Compression ratio
10.6 ± 0.5 : 1
BASE GASKET THICKNESS
Name |
Measure A |
Thickness |
«A» MEASURE TAKEN |
- 0.185 - - 0.10 |
0.4 ± 0.05 |
«A» MEASURE TAKEN |
- 0.10 - + 0.10 |
0.6 ± 0.05 |
«A» MEASURE TAKEN |
+ 0.10 ÷ + 0.185 |
0.8 ± 0.05 |
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE.
N.B.
DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»
CHAR - 14
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XEVO 400ie |
Characteristics |
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Products
RECOMMENDED PRODUCTS TABLE
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Product |
Description |
Specifications |
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AGIP ROTRA 80W-90 |
Rear hub oil |
SAE 80W/90 Oil that exceeds the re- |
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quirements of API GL3 specifications |
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AGIP CITY HI TEC 4T |
Oil to lubricate flexible transmissions |
Oil for 4-stroke engines |
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(throttle control) |
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AGIP FILTER OIL |
Oil for air filter sponge |
Mineral oil with specific additives for in- |
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creased adhesiveness |
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AGIP GP 330 |
Calcium complex soap-based grease |
Grease (brake control levers, throttle |
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with NLGI 2; ISO-L-XBCIB2 |
grip) |
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AGIP CITY HI TEC 4T |
Engine oil |
SAE 5W-40, API SL, ACEA A3, JASO MA |
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Synthetic oil |
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AGIP BRAKE 4 |
Brake fluid |
FMVSS DOT 4 Synthetic fluid |
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SPECIAL AGIP PERMANENT fluid |
coolant |
Monoethylene glycol-based antifreeze |
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fluid, CUNA NC 956-16 |
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AGIP FORK 7.5 W |
Fork oil |
Grade 7.5 W |
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AGIP GREASE PV2 |
Grease for the steering bearings, pin |
White anhydrous-calcium based grease |
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seats and swinging arm |
to protect roller bearings; temperature |
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range between -20 C and +120 C; NLGI |
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2; ISO-L-XBCIB2. |
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CHAR - 15
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INDEX OF TOPICS
MAINTENANCE |
MAIN |
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XEVO 400ie |
Maintenance |
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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
MAIN - 17
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Maintenance |
XEVO 400ie |
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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
MAIN - 18
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XEVO 400ie
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 supplied;
-Upon refitting, place the spark plug at the required 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 inserted.
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
Maintenance
MAIN - 19
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Maintenance |
XEVO 400ie |
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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
MAIN - 20
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XEVO 400ie |
Maintenance |
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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».
MAIN - 21
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Maintenance |
XEVO 400ie |
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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 NEC-
ESSARY 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".
MAIN - 22
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XEVO 400ie
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
Maintenance
MAIN - 23
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Maintenance |
XEVO 400ie |
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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.
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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.
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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
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XEVO 400ie
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
Maintenance
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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 CIR-
CUIT 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
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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 borderline 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 MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY 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.
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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
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