PIAGGIO 2005 XEVO 400ie Workshop Manual Download Page 1

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MANUALE STAZIONE DI SERVIZIO

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XEVO 400ie

Summary of Contents for 2005 XEVO 400ie

Page 1: ...MANUALE STAZIONE DI SERVIZIO XEVO 400ie...

Page 2: ...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 a...

Page 3: ...able 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 Re...

Page 4: ......

Page 5: ...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 CH...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR...

Page 7: ...eassembly 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 meas ures Me...

Page 8: ...m 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 G...

Page 9: ...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 Fr...

Page 10: ...SABLE TO USE TYRE TYPES REC OMMENDED BY PIAGGIO Overhaul data Assembly clearances Cylinder piston assy HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED Specification Desc Quantity A 43 2 mm B 43 mm CYL...

Page 11: ...nder 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 hou...

Page 12: ...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 4...

Page 13: ...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...

Page 14: ...s found at the cylinder mouth flywheel side Slot packing system Shimming system for keeping the compression ra tio DISTANCE A IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CY...

Page 15: ...cium complex soap based grease with NLGI 2 ISO L XBCIB2 Grease brake control levers throttle grip AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP BRAKE 4 Brake fluid...

Page 16: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 17: ...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...

Page 18: ...ttle 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 Slidin...

Page 19: ...al tightening of the spark plug Place cap A fully over the spark plug Refit the port making sure the rear hook is inser ted WARNING THE SPARK PLUG MUST BE REMOVED WHEN THE EN GINE IS COLD REPLACE THE...

Page 20: ...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 Unsc...

Page 21: ...ilter 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 MA...

Page 22: ...FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased ad hesiveness Engine oil In 4T engines the engine oil is used to lubricate the distribution elements the bench b...

Page 23: ...rtridge 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...

Page 24: ...ilter 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 Unsc...

Page 25: ...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...

Page 26: ...ference mark remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a cal liper spanner applied to the camshaft command pulley casing Checking the...

Page 27: ...is near or below the MIN level edge The liquid level must always be be tween the MIN and MAX level The coolant consists of an ethylene glycol and corrosion inhibitor based 50 de ionised water antifree...

Page 28: ...rvoir cover top up with the rec ommended fluid without exceeding the MAX mark This procedure applies to the rear brake pump top up operation follow the same procedure for the front brake pump Under st...

Page 29: ...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 ignitio...

Page 30: ...ome 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 Characterist...

Page 31: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 32: ...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 cartri...

Page 33: ...he 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...

Page 34: ...akage 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...

Page 35: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 36: ...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 1...

Page 37: ...ght 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 Helme...

Page 38: ...e 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 pla...

Page 39: ...ve 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...

Page 40: ...emove 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 i...

Page 41: ...assis 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 chassi...

Page 42: ...ch 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 inspectio...

Page 43: ...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 XEVO...

Page 44: ...n 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 Auxilia...

Page 45: ...ear 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...

Page 46: ...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 accesso...

Page 47: ...ator 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 In...

Page 48: ...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 tur...

Page 49: ...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...

Page 50: ...s the recognition of the master key as the first key to be pro grammed this is particularly important as it is the only key that allows the decoder to be reset and reprogrammed for programming the ser...

Page 51: ...o memory the vehicle can be started but with a limitation im posed on the number of revs 2 New decoder transponder missing or illegi ble The LED is permanently ON in this condition no operations are p...

Page 52: ...Check the Immobilizer aerial wiring and change it if necessa ry Diagnostic code 2 flashes A 2 flash code indicates a system where the de coder does not recognise the transponder signal This might depe...

Page 53: ...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...

Page 54: ...orrectly 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...

Page 55: ...ghts 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...

Page 56: ...trol 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 protec tive fuses for the various circu...

Page 57: ...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 Capaci...

Page 58: ...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 sys tem failure warning light M Low fuel...

Page 59: ...e 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 especial...

Page 60: ...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 el...

Page 61: ...rresponding 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...

Page 62: ...e connectors and the con nectors 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 Electri...

Page 63: ...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 Act...

Page 64: ...ve 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...

Page 65: ...n 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...

Page 66: ...m 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 t...

Page 67: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 68: ...t 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...

Page 69: ...UT 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 pum...

Page 70: ...ehicle 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...

Page 71: ...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 electri...

Page 72: ...INDEX OF TOPICS ENGINE ENG...

Page 73: ...ven 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 USI...

Page 74: ...rwise 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 transmis...

Page 75: ...face and use the special tool so that it is adequately sup ported 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 WOO...

Page 76: ...fic 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 retai...

Page 77: ...ng 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 ECCENT...

Page 78: ...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 UNI...

Page 79: ...ar 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 oth...

Page 80: ...Y 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 hand...

Page 81: ...roller bearing using the special tool N B PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUT WARDS Properly support the half pulley to prevent damaging the threading If you are...

Page 82: ...n re assemble 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 bushi...

Page 83: ...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 prescr...

Page 84: ...ol 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 inse...

Page 85: ...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 pul...

Page 86: ...ng 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 s...

Page 87: ...e 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...

Page 88: ...ic 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 i...

Page 89: ...e 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 C...

Page 90: ...al 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...

Page 91: ...he 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 47 mm Support...

Page 92: ...pulley shaft the relevant bearing and the oil guard remove the transmission cover and the clutch unit as descri bed in the Automatic transmission chapter Extract the driven pulley shaft from its bear...

Page 93: ...eristic 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 s...

Page 94: ...e 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 inte...

Page 95: ...tor 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 oi...

Page 96: ...over 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 rin...

Page 97: ...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 presc...

Page 98: ...mp 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 drain...

Page 99: ...NT 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 fl...

Page 100: ...racket Unscrew the 3 fastening screws and remove sta tor and its wiring Inspecting the cover components Loosen the two retaining screws and remove the reed valve support with bulkhead Remove the blow...

Page 101: ...valve seat and the torque limiter bearing are free from wear Characteristic By pass housing hole diameter 13 9 mm Connection diameter for start up gear shaft 12 mm Connection diameter for pump shaft...

Page 102: ...of the cable harness that contains two types of cable Rigid cables close to the stator and flexible cables close to the connector Check that the winding is positioned so as not to interfere with the...

Page 103: ...ness guide bracket screws 3 4 Refitting the flywheel cover components Before reassembling check that all components are perfectly clean For the cover carefully check all lubrication chan nels in parti...

Page 104: ...HE BY PASS VALVE Reinstall the blow by reed valve using a new sealing gasket Reinstall the support with head and tighten the screws to the prescribed torque Locking torques N m Supporting screws with...

Page 105: ...KING CARE TO TIGHTEN THE CLAMPS SUF FICIENTLY Install the pre filter again and insert the engine oil drain plug tightening to the prescribed torque Refill the engine with the prescribed type of oil Re...

Page 106: ...ARATION IS USEFUL PARTICULARLY IN THE EVENT OF REPAIRS WITH THE WATER PUMP COVER IN STALLED Install the flywheel cover on the engine paying attention to avoid interference between the stator and rotor...

Page 107: ...ng the starter motor N B THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED Loosen the two fastening screws Extract the complete starter motor Removing the flywheel magneto N B IF YO...

Page 108: ...tool threading Insert the special tool as shown in the figure making sure that the pins are perfectly inserted in to the previously aligned holes and that it is per fectly abutted and almost flush wi...

Page 109: ...LY LOCKED THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS Insert the special removing tool Using a 27 mm wrench and a 19 mm bushing release the f...

Page 110: ...THE FREEWHEEL MUST BE REMOVED IT IS AD VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT The freewheel is coupled to the flywheel with high preci...

Page 111: ...cteristic Hub outside diameter Diameter 45 665 0 008 0 005 mm Check the inside diameter of the bushing of the starter gearing Check that the toothing is not worn Characteristic Inside diameter of the...

Page 112: ...oved profiles this assembly allows transmitting torque lower than 10 kg In case of incorrect start up manoeuvres the lim iter prevents any kicks with consequent reversal of direction of the crankshaft...

Page 113: ...h wheel Seeger ring visible Lock the six clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Refitt...

Page 114: ...el turning it clockwise and inserting at the same time Refitting the flywheel magneto Insert the key on the crankshaft Install the flywheel checking the proper insertion of the key and engaging the to...

Page 115: ...020472Y Flywheel lock wrench Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool Insert the special tool checking that the pins are perfectly introduc...

Page 116: ...king torques N m Chain guide sliding block retain plate fasten ing screws 3 4 Refitting the starter motor Check that the O ring is in good working order and lubricate it Insert the starter motor Tight...

Page 117: ...ne to close the intake valves Remove the central screw and the valve lifting device mass stop bell using the special tool Specific tooling 020565Y Flywheel lock calliper spanner Remove the return spri...

Page 118: ...ntral screw on the tensioner first Unscrew the 2 fastening screws and remove the tensioner with relevant gasket Remove the inside hexagon screw and the coun terweight as shown in the figure Remove the...

Page 119: ...S MAY BE DIFFI CULT BE CAREFUL NOT TO DAMAGE THE INSIDE HEX AGON IF NECESSARY SEPARATE THE THREADS IN ADVANCE Remove the cam shaft Remove pins and rocking levers by the transmis sion side holes Removi...

Page 120: ...n the spark plug side with the thermostat support N B THE HEAD MAY BE REMOVED WITH THE CAMSHAFT ROCKING LEVER PINS AND FITTING BRACKET IF NECESSARY Loosen the 4 head cylinder fastening nuts in 2 or 3...

Page 121: ...ol 020382Y012 bush valve removing tool CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD FLY WHEEL SIDE AND TRANSMISSION SIDE Remove the oil guards using the special tool...

Page 122: ...CYLINDER CAUTION TO PREVENT DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER Remove the 2 piston pin locking rings by the spe cific housings Extract the pin and remove the piston N B USE PA...

Page 123: ...racteristic Standard diameter 22 0 025 0 015 mm Inspecting the wrist pin Check the pin outside diameter using a micrometer Characteristic Standard diameter 22 0 0 004 mm Calculate the coupling clearan...

Page 124: ...CIFICATIONS SECTION FOR THE SIZES OF THE PISTON AND THE CYLINDER PISTON COU PLING CLEARANCES Characteristic A 10 mm Piston diameter 85 8 mm nominal value Using a bore meter measure the cylinder inner...

Page 125: ...he opening see figure of the sealing rings using a feeler gauge If higher values than those prescribed are meas ured replace the linings Check the size of the sealing ring opening Compression ring 0 1...

Page 126: ...ving the piston Install piston and wrist pin onto the connecting rod aligning the piston arrow the arrow facing to wards the exhaust Insert the locking ring into the special tool with the opening in t...

Page 127: ...Using an abutment plane reset the dial gauge with a preload of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Install the tool on the cylinder without changi...

Page 128: ...ion and with the writing top facing the piston top The chamfered side of the oil scraper ring should always be facing the piston crown Fit the second lining with the identification letter or the writi...

Page 129: ...s not worn or distorted Characteristic Maximum allowable run out 0 1 mm In case of irregularities replace the head Check the sealing surfaces for the intake and ex haust manifold Check that the camsha...

Page 130: ...ecting the valve sealings Visually inspect the valve sealing surface CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES RIGHT LEFT If the sealing surface of the valve is found to be interrupte...

Page 131: ...escribed limits true the seats with a 45 mill and then grind In case of excessive wear or damage replace the head Inspecting the valves Measure the diameter of the valve stems in the three positions i...

Page 132: ...relative to the valve head and rotate it on a V shaped abutment Characteristic Admissible limit 0 03 mm Inspecting the valve stem guide clearance After measuring the valve guide diameter and the valve...

Page 133: ...in a horizontal position This will prevent the lapping compound residues from penetrating between the valve stem and the guide see figure CAUTION TO AVOID SCORING THE FAYING SURFACE DO NOT KEEP ROTATI...

Page 134: ...riate tool with adapter compress the springs and insert the cotters in their seats Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush valve removing tool N B DO...

Page 135: ...33 273 ADMISSIBLE LIMITS Specification Desc Quantity intake 33 526 mm discharge 33 026 mm Standard axial clearance 0 0 22 mm Maximum admissible axial clearance 0 3 mm If any of the above dimensions ar...

Page 136: ...ter of each rocking lev er Characteristic Standard diameter 13 0 026 0 015 mm Check that the cam contact sliding block and the articulated register plate is free from wear In case of wear replace the...

Page 137: ...hten the 4 fixing stud bolts crosswise to the prescribed torque as shown in the figure Locking torques N m Head fixing stud bolts Apply a preliminary torque of 7 Nm in a crossed sequence Tighten by 90...

Page 138: ...scribed torque Locking torques N m Spark plug 12 14 Insert the timing control belt on the crankshaft according to the initial direction of rotation Install the tensioner shoe with its spacer tight eni...

Page 139: ...te 243 Medium strength threadlock Medium Loctite 243 threadlock Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque being careful n...

Page 140: ...magnet support collimate with that on the flywheel cover Install the counterweight mass Centre using the bell fastening screw Lock the mass fixing screws to the prescribed torque using the recommended...

Page 141: ...ning screw to the prescribed torque using the recommended product N B THE BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD Recommended products Loctite 243 Medium strength threadl...

Page 142: ...the central screw to the prescribed tor que Locking torques N m Tightener screw 5 6 Place the engine with the valve clearance adjustment timing references aligned with the head Check the clearance bet...

Page 143: ...ance determined by the injection system matches the value actually activated on the engine by means of the stroboscopic light Specific tooling 020680Y Diagnosis Tool 020330Y Stroboscopic light to chec...

Page 144: ...pic light control in the tradi tional four stroke engine position 1 spark 2 revs Check that the real values of rpm and ignition advance match those measured using the diag nostic tester Specific tooli...

Page 145: ...ission cover as described in the Automatic transmission chapter Install the cooling system sleeves using new bands as described in the Flywheel cover chap ter Refitting the intake manifold Install the...

Page 146: ...ose use a plate e g the special tool and a support with special tool comparator Specific tooling 020262Y Crankcase splitting plate 020335Y Magnetic support for dial gauge Characteristic Standard clear...

Page 147: ...the crankshaft check the timing with the countershaft To carry out this check turn the crankshaft to align the two holes obtained on the crankshaft with the hole on the countershaft control gear This...

Page 148: ...S LOCKED BY LOCTITE BE CAREFUL NOT TO DAMAGE THE CONTROL HEXAGON TO OBTAIN BET TER RESULTS IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH Removing the countershaft Place the special tool as s...

Page 149: ...tool and a mallet Specific tooling 020376Y Adaptor handle 020358Y 37x40 mm Adaptor 020439Y 17 mm guide Remove the bearing from the transmission side half crankcase using the special tool Specific tool...

Page 150: ...39Y 17 mm guide Fit the Seeger ring Before installing the new bearing on the trans mission side crankcase heat the seat using the special tool Specific tooling 020151Y Air heater Insert a new bearing...

Page 151: ...he crank shaft between these surfaces as shown in the diagram N B BE CAREFUL NOT TO LET THE MEASUREMENT BE AF FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS Characteristic Standard dimensions 63 6 63 4...

Page 152: ...classified into two categories Cat 1 and Cat 2 Refer to the chart below STANDARD DIAMETER Specification Desc Quantity Cat 1 40 010 40 016 Cat 2 40 016 40 022 Inspecting the crankshaft alignment Instal...

Page 153: ...rankshaft see sec tion Thermal group and timing system See also Cylinder assy and timing system Inspecting the crankcase halves Before proceeding to check the crankcase halves thoroughly clean all sur...

Page 154: ...the connecting rod and main bearing lubrication pressure Check the main bearing seats that limit axial clearance in the crankshaft exhibit no wear For the dimensional check refer to the instructions a...

Page 155: ...ng maximum clearance admitted 0 08 mm The standard bushing diameter after driving is variable on the basis of a coupling selection The crankcase bushing seats are classified into 3 categories while th...

Page 156: ...ntershaft with centre to centre distance A Complete FC3 type crankcase equipped with bushings for housing a category 1 crankshaft and a countershaft with centre to centre distance B Complete FC4 type...

Page 157: ...TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NEC ESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL Before installing the gear on the crankshaft care fully clean the two matching surfaces...

Page 158: ...Specific tooling 020471Y Pin for countershaft timing Insert the crankshaft on the pin and into the bush ing Before inserting thoroughly make the oil pump gear align with the control gear Insert thorou...

Page 159: ...e Insert the gasket on the flywheel side half crank case Lubricate the main bearing on the transmission side half crankcase Couple the 2 half crankcases being careful not to damage the bushing on the...

Page 160: ...de transmission cover as described in the Automatic transmission chapter See also Flywheel cover Cylinder assy and timing system Lubrication TECHNICAL SPECIFICATIONS SUMP CAPACITY Specification Desc Q...

Page 161: ...ion Desc Quantity Diameter 1 0 05 mm Tightening torque 5 7 N m PISTON COOLING NOZZLE Specification Desc Quantity Diameter 0 8 0 05 mm CRANKCASE VENTILATION CHECK Specification Desc Quantity Device met...

Page 162: ...a pressure drop above 1 0 2 bar These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged The filtered oil is used to lubricate the water pump shaft and...

Page 163: ...e applies to the piston or the pin but in this case the cooling nozzle is particularly important Diagnosis guide 1 Minimum oil pressure warning light on with hot engine AHEAD go to 2 2 Remove the mini...

Page 164: ...ed number of kilometres covered 11 Check and restore the electrical system 12 If pressure lower than 4 bar is measured AHEAD go to 9 13 Remove the flywheel cover and check the by pass and the cover se...

Page 165: ...Specific tooling 020193Y Oil pressure check gauge 020434Y Oil pressure check fitting AHEAD go to 3 3 Check the system pressure with cold engine and medium high speed Standard pressure 6 bar YES go to...

Page 166: ...oosening the 2 retaining screws with their washers Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper Remove the gasket R...

Page 167: ...free from wear Reassemble the rotors in the pump body keep ing the two reference marks visible Insert the shaft with the gear and install the lock ring then turn it with the opening opposed to the sh...

Page 168: ...in the correct position N B THE TOOTH OF THE GASKET MUST BE IN ITS SEAT Lubricate the internal rotors Check there are no signs of scoring or wear on the oil pump cover If non conforming values or sign...

Page 169: ...crankcase 5 6 Insert the countershaft with gearing into the fly wheel side half crankcase Install the special tool in the position shown in the figure Specific tooling 020479Y Countershaft lock wrenc...

Page 170: ...INDEX OF TOPICS INJECTION INJEC...

Page 171: ...constant based on the ambient pressure The fuel supply circuit consists of Fuel pump Fuel filter Injector Pressure regulator The pump the filter and the regulator are placed inside the fuel tank on a...

Page 172: ...he diagnostic tester is also required to adjust the idle mixture Specific tooling 020680Y Diagnosis Tool The EMS injection ignition system has a control function over the rpm indicator and the radiato...

Page 173: ...fuel 7 When washing the vehicle be careful with the electric components and wiring 8 When an ignition fault is detected start the checks from the battery and the injection system con nections 9 Before...

Page 174: ...iagnostic connector 10 EMS diagnostic connector 11 Throttle potentiometer signal 12 Engine rpm sensor 13 Injector control 14 Stepper motor Stepper motor 15 Injection telltale light 16 Decoder serial 1...

Page 175: ...tive EMS circuit diagram KEY 2 Engine stop switch 3 Diode 4 Side stand button 5 Key switch 6 Electric fan 7 Engine stop remote control switch 9 Main fuses 11 Auxiliary fuses 12 Stop button on front br...

Page 176: ...o apply when troubleshooting Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient repair according to...

Page 177: ...nd actual opening Cleaning of the auxiliary air pipe and throttle valve air filter ef ficiency Engine stops at idle ENGINE DOES NOT IDLE IDLING IS UNSTABLE IDLING TOO LOW Possible Cause Operation Pres...

Page 178: ...KFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Injection load relay HV coil Injector revolution timing sensor Air temperature Coolant temperature A...

Page 179: ...temperature Atmospheric pressure Spark plug power supply Spark plug Shielded cap HV cable HV coil Intake system Air filter Filter box sealing Intake sleeve sealing Parameter reliability Throttle valve...

Page 180: ...es the information NO REPLY FROM THE CONTROL UNIT To carry out the check proceed as follows Specific tooling 020680Y Diagnosis Tool 1 Check whether the immobiliser system LED in dicates that the switc...

Page 181: ...ial tool to check the control unit power supply Pin 17 battery positive Pin 23 battery negative YES go to 12 NO go to 13 12 Control unit with proper base power supply 13 If the battery negative is not...

Page 182: ...and injection system YES go to 7 Specific tooling 020481Y Control unit interface wiring 6 Fix any short circuits and replace the fuse Check decoder and control unit if necessary YES go to 1 7 Disconne...

Page 183: ...tinuity of the key switch set to ON Pin 1 2 continuity YES go to 14 14 Check the engine stop remote control switch connector and the switch efficiency 85 86 approx 70W YES go to 15 N B CHECK THE COIL...

Page 184: ...ions YES go to 2 NO go to 3 2 Check the control unit base and continuous power supplies YES go to 4 3 Restore 4 Place the special tool between control unit and system Keep the control unit disconnecte...

Page 185: ...control unit 7 Fix the interruption or short circuit Injection warning light circuit KEY 2 Engine stop switch 3 Diode 4 Side stand button 5 Key switch 7 Engine stop remote control switch 9 Main fuses...

Page 186: ...This step is normally interrupted by the injection control unit control The timing lasts 5 seconds The diagnostic tester is not programmed to check this circuit Proceed as follows Specific tooling 020...

Page 187: ...s provided with an auto diagnosis function When a failure is detected the control unit turns on the injection telltale light only when it is current enables the engine management check according to th...

Page 188: ...nd relevant circuit HV coil and relevant circuit Stepper and relevant circuit Pump relay circuit Electric fan relay circuit RAM memory ROM memory EEPROM Microprocessor Signals panel stroke revolution...

Page 189: ...tor N B BEFORE WORKING ON THE FUEL SUPPLY SYSTEM CAREFULLY CLEAN THE PARTS TO PREVENT DAMAGING THE FAST RELEASE COUPLING SEAL OR TO PREVENT DIRT GETTING INTO THE DUCTS CAUTION THE SYSTEM IS UNDER PRES...

Page 190: ...top remote control switch 9 Main fuses 11 Auxiliary fuses 12 Stop button on front brake 13 Stop button on rear brake 14 Immobiliser remote control switch 15 12V 12Ah Battery 16 Starter motor 17 Start...

Page 191: ...motor 60 Engine temperature sensor 61 Throttle valve potentiometer 62 Lambda probe Removing the injector N B ONLY REMOVE THE INJECTOR FROM THE MANIFOLD IN THE EVENT OF A PROVEN DEFECT OPERATING TEST O...

Page 192: ...fly valve N B THE THROTTLE BODY IS A PART WHICH INCLUDES VARIOUS COMPONENTS AND IS USUAL LY SUPPLIED COMPLETE TO TEST THESE COMPONENTS SEE THE INJECTION CHAPTER Remove the 3 retaining screws indicated...

Page 193: ...n be easily removed Once clean the throttle body has and air flow equivalent to the original one The throttle valve gets dirty at variable periods according to the type of use given to the scooter amb...

Page 194: ...hat in the tank During use the pump operation will be subject to the engine speed Circuit check The injection system control unit is programmed to guarantee optimum carburetion during riding Idle mixt...

Page 195: ...SE TERMINAL PREVENT ANY POSSIBLE SPRAYING INTO THE EYES The special tool is equipped with fast release fit tings similar to those provided for the circuit In order to disconnect the female terminals i...

Page 196: ...tooling 020680Y Diagnosis Tool Select the menu on the ACTIVE DIAGNOSIS function Select the PUMP DIAGNOSIS function YES go to 2 2 Enable the function with continuous power sup ply on and engine off The...

Page 197: ...low this operation fuel pressure over 300 kPa 3 BAR YES go to 8 NO go to 9 8 Replace the pressure regulator 9 Replace the fuel pump Fuel pump and filter check This procedure is useful during maintenan...

Page 198: ...R YES go to 5 NO go to 6 Specific tooling 020680Y Diagnosis Tool 4 If pressure is lower carefully check the voltage with pump under stress If voltage is higher than 12 V replace the pump 5 The system...

Page 199: ...ations Repeat the test clamping the pipe of the special tool in the portion between the branch and the pump Check whether pressure decreases much more slowly YES go to 14 NO go to 15 Specific tooling...

Page 200: ...is dirty Replace the pump support Pump electrics check This section describes the operations to be carried out to perform electric checks on the pump Resistor check Disconnect the connector from the...

Page 201: ...E approx 12 V PUMP RUN IN SYSTEM PRESSURE 300 kPa 3 BAR FUEL FILTER CLEAN Electric characteristic Current consumption approx 3 5 4 2 A A dirty filter causes an increase of input If the pressure relief...

Page 202: ...eturn pipes by the fast release fittings CAUTION PREVENT ANY FUEL SPRAYING Loosen the pump support mounting ring nut RH threading Remove the pump support and the sealing gas ket N B UPON EXTRACTING IT...

Page 203: ...wo level indicator wires Moving the float arm check that the resistance is subject to gradual variations according to the arm motion LIMIT VALUES Specification Desc Quantity 1 Empty tank position 95 1...

Page 204: ...reassembly 3 Fuel pump Note the position of the power supply wires on the support pos 1 positive red pos 4 negative black Disconnect the power supply cables Cut the delivery pipe fastening clamp on th...

Page 205: ...g a new clamp for the delivery pipe and a new pump mounting washer N B TO CLEAN THE PRE FILTER USE PETROL AND COMPRESSED AIR Orientate the pump properly 4 Fuel filter The fuel filter is supplied alrea...

Page 206: ...le N B AN INCORRECT ORIENTATION MAY IMPAIR THE LEVEL INDICATOR PERFORMANCE Screw the mounting ring nut and tighten thoroughly Locking torques N m Electric pump locking ring nut 20 Connect the feeding...

Page 207: ...Engine stop remote control switch 9 Main fuses 11 Auxiliary fuses 12 Stop button on front brake 13 Stop button on rear brake 14 Immobiliser remote control switch 15 12V 12Ah Battery 16 Starter motor 1...

Page 208: ...ntrols the fuel pump continuously and at the same time starts the injector opening The injector openings are re peated for a few seconds YES go to 3 3 Acoustically check the injector openings and wait...

Page 209: ...the power supply circuit with the fuse No 4 and the remote control switch Common feeding to the fuel pump 13 Check the injection load relay control circuit 14 Install the special tool between the inje...

Page 210: ...jector YES go to 19 NO go to 18 18 No continuity Disconnect the connector and repeat the resistive check directly at the injector terminals Resistance 14 5 2 YES go to 21 NO go to 22 19 Check the eart...

Page 211: ...l 020480Y Petrol pressure check set 2 Prepare a graduated container with minimum capacity of 100 cm3 and a resolution of 10 20 cm3 Connect the injector to the wire supplied with the injection tester T...

Page 212: ...d impinges both in take valves N B AN INJECTOR WITH LOW FLOW RATE AFFECTS THE MAXIMUM PERFORMANCE AN INJECTOR WITH POOR SEAL AFFECTS IDLING AND THE START UP FEATURES AFTER A SHORT STOP WITH HOT ENGINE...

Page 213: ...t check the whole system carefully If the fault is fixed by replacing the EMS control unit install the original control unit again and check whether the fault occurs again 4 For troubleshooting use a...

Page 214: ...cting the terminals to the battery poles or the specific connector to the socket inside the gloves compartment Set the switch to ON and select the diagnostic tester menu to the immobiliser function Sc...

Page 215: ...t 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 groun...

Page 216: ...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 progr...

Page 217: ...t When the decoder is replaced it is necessary to program the system again Programming is indispensable for the engine start up see System programming 3 Control unit replacement Programming is indispe...

Page 218: ...s 2 New decoder transponder missing or illegi ble The LED is permanently ON in this condition no operations are possible including starting of the vehicle 3 Decoder programmed service key inserted nor...

Page 219: ...al 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 Oth erwise replace the faulty key and...

Page 220: ...utions of the crankshaft The sensor is of the reluctance variation type and is therefore comparable to an alternate current gen erator that powers the control unit The signal frequency is interrupted...

Page 221: ...ring the period the cycle is reconstructed If the rpm timing signal is completely missing due to mechanical faults or lack of magnetic activity it will be impossible to start the engine or it will sto...

Page 222: ...ngine revs indication YES go to 6 NO go to 7 6 The signal panel is in conformance 7 CHECK THE AIR GAP AND MAGNETIC AC TIVITY OF THE SENSOR See engine mechanics 8 Check the sensor and related connectio...

Page 223: ...eristic S infinite M YES go to 13 NO go to 12 12 Replace the revolution sensor 13 Reconnect the rpm timing sensor connector Repeat the resistance check through the injection wiring pin 7 pin 12 Electr...

Page 224: ...ltage between pins 7 and 12 with engine at start up speed Electric characteristic 7 12 approx 0 8 4 5 V eff Revolution speed approx 300 400 rpm YES go to 20 NO go to 21 20 The sensor circuit is in con...

Page 225: ...the pump timing with engine off STANDARD Battery voltage KEY 2 Engine stop switch 3 Diode 4 Side stand button 5 Key switch 6 Electric fan 7 Engine stop remote control switch 9 Main fuses 11 Auxiliary...

Page 226: ...temperature sensor 61 Throttle valve potentiometer 62 Lambda probe The ignition system is integrated with the injection and it is a high efficiency inductive type ignition The control unit manages two...

Page 227: ...the ERRORS function Check the presence of current or stored errors re lating to the HV coil YES go to 6 NO go to 5 4 Test failed YES go to 6 5 The coil control circuit is efficient Check the HV coil...

Page 228: ...NO go to 9 9 Check the black green wire continuity Repair or replace the cable harness N B A FAILURE OF THE REMOTE CONTROL SWITCH WOULD CAUSE THE PUMP ROTATION FAIL URE 10 The positive power supply i...

Page 229: ...n the two sections Repair or replace the cable harness Repeat the check with the menu on ACTIVE DIAGNOSIS HV coil control simulation Delete the errors stored in memory 15 Check the continuity of the H...

Page 230: ...acteristic Primary earth infinite 1M YES go to 17 NO go to 1 9 17 Check the secondary resistance Measure the resistance between one of the primary terminals and the spark plug cable output Electric ch...

Page 231: ...of parameters known by the control unit For this reason it is not possible to interpret the reference values based on the engine rpm The ignition advance value is detectable at any time using the dia...

Page 232: ...e Refit the inspection cap on the flywheel side Connect the diagnostic tester Start the engine Select the parameters function in this menu Select the stroboscopic light control in the tradi tional fou...

Page 233: ...onnected sensor 20 2500 100 80 308 6 KEY 2 Engine stop switch 3 Diode 4 Side stand button 5 Key switch 6 Electric fan 7 Engine stop remote control switch 9 Main fuses 11 Auxiliary fuses 12 Stop button...

Page 234: ...f the circuit voltage Such voltage is combined with a temperature value By this value the control unit can manage the engine operation optimising it for all temperatures A failure of this circuit caus...

Page 235: ...e menu on the param eters function Do not start the engine YES go to 5 5 Check the following values coolant temperature intake air temperature ambient temperature The three indications are equal or th...

Page 236: ...are detected check the connectors If infinite resistance is detected 1M check the continuity of the two lines with disconnected con nectors Electric characteristic Blue white 4 0 continuity Light blue...

Page 237: ...th switch to RUN and side stand raised YES go to 16 Specific tooling 020481Y Control unit interface wiring 16 Measure voltage at terminals 4 and 22 TEMPERATURE VOLTAGE Specification Desc Quantity 1 X...

Page 238: ...to 22 NO go to 23 22 The temperature signal is conforming 23 Replace the temperature sensor N B FOR A MORE ACCURATE CHECK OF THE SENSOR RE MOVE IT FROM THE ENGINE AND CHECK ITS RESIST ANCE AT CONTROL...

Page 239: ...fuses 11 Auxiliary fuses 12 Stop button on front brake 13 Stop button on rear brake 14 Immobiliser remote control switch 15 12V 12Ah Battery 16 Starter motor 17 Start up remote control switch 20 Start...

Page 240: ...NTC sensor and has the same functional layout as the coolant temperature sensor This signal is used to optimise the engine perform ance Anyway this data is less important than the coolant temperature...

Page 241: ...ng values coolant temperature intake air temperature ambient temperature indicated by the digital instrument The three indications are equal or they are slightly different e g 1 C YES go to 6 NO go to...

Page 242: ...equal to the value directly detected at the sensor YES go to 13 NO go to 11 11 If slightly higher values are detected check the connectors If infinite resistance is detected 1M check the continuity of...

Page 243: ...18 23 infinite 1M 22 23 infinite 1M YES go to 15 NO go to 14 14 Repair or replace the wiring Check the valve position and the fluid temp lines YES go to 13 15 Connect the special tool to the control...

Page 244: ...y voltage value 5 0 2 V Repeat the wiring and sensor continuity checks YES go to 18 18 Electric characteristic Measured value 0 Repeat the sensor circuit earth insulation check YES go to 19 NO go to 2...

Page 245: ...he diagnostic tester Select the function ERRORS in the menu Check whether there are any indications regarding the pressure sensor YES go to 2 NO go to 3 Specific tooling 020680Y Diagnosis Tool 2 Repla...

Page 246: ...The control unit converts this volt age at an angular position of the valve The engine rpm and the throttle valve position are the two basic signals for the engine management A failure of this circuit...

Page 247: ...ix or replace if required YES go to 2 4 Gradually open the throttle valve check that the mV value increases progressively and proportionally with the opening variation YES go to 5 NO go to 6 5 The thr...

Page 248: ...or replace the injection wiring YES go to 6 8 Check the earth insulation of the three circuit lines Electric characteristic 22 23 infinite 1M 1 23 infinite 1M 11 23 infinite 1M YES go to 10 NO go to 9...

Page 249: ...cial tool Specific tooling 020481Y Control unit interface wiring Electric characteristic 1 22 5 0 2 V YES go to 12 NO go to 11 11 Check the control unit connector Replace the control unit if necessary...

Page 250: ...ndicated by the diagnostic tester set to PARAMETERS YES go to 16 NO go to 17 16 The throttle valve position sensor and relevant circuit are conforming 17 Replace the control unit Zeroing the throttle...

Page 251: ...h the control unit following the procedure known as TPS resetting With this operation we inform the control unit as the starting point of the mV value corresponding to the pre calibrated position The...

Page 252: ...OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE CALIBRATION Step motor CIRCUIT LAYOUT Specification Desc Quantity 1 Electronic control unit 2 Stepper motor Stepper motor The throttle body is pr...

Page 253: ...in the revolutions and the subsequent closing of the Stepper to stabilise the speed In case of irregular speed before carrying out electric checks inspect the throttle valve and the auxiliary air circ...

Page 254: ...r the Stepper controls some rev olution variations and wait for the diagnostic tester response N B THE ECU ENABLES THE DIAGNOSIS ONLY WHEN THE IDLE SPEED IS WITHIN THE SPECIFI CATIONS YES go to 6 NO g...

Page 255: ...ove replace the throttle body 10 Replace the throttle body 11 Connect the special tool For these checks do not connect the special tool to the control unit Check the continuity of the 4 power supply l...

Page 256: ...3 1 M infinite 6 23 1 M infinite 21 23 1 M infinite 24 23 1 M infinite YES go to 14 NO go to 13 13 Repair or replace the wiring YES go to 11 14 Connect the Stepper connector Repeat the continuity chec...

Page 257: ...command lines Set up for direct voltage measurements N B PULSES ARE USED TO CHANGE THE STEPPER POSITION Electric characteristic 14 24 V pulses for a few seconds 6 21 V pulses for a few seconds After r...

Page 258: ...check that the voltage oscillates between 0V and 1V With the throttle valve completely open the volt age is approx 1V During the closing phase the voltage is approx 0V If the voltage remains constant...

Page 259: ...fuses 11 Auxiliary fuses 12 Stop button on front brake 13 Stop button on rear brake 14 Immobiliser remote control switch 15 12V 12Ah Battery 16 Starter motor 17 Start up remote control switch 20 Start...

Page 260: ...rols the electric fan in relation to the measured engine temperature If prolonged running of the electric fan is noticed check the following carefully before starting to check the electrical system Co...

Page 261: ...the connections to the electric fan the function of the contacts of the remote control switch the pos itive lines the negative line and the motor of the electric fan 8 Disconnect the remote control u...

Page 262: ...nite YES go to 16 NO go to 15 15 Repair or replace the cable harness 16 Connect the remote control switch and check for battery voltage between terminals 5 and 23 with the key switch in position ON 5...

Page 263: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 264: ...ng the wheel axle clamp and remove the clamp Front wheel hub overhaul Check that the wheel bearings do not show signs of wear If you have to replace the wheel bearings proceed as follows Remove the tw...

Page 265: ...the brake disc side to permit the removal of the opposite side bearing and the spacer bushing Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020412Y 15 mm guide Heat the bearing seat o...

Page 266: ...020376Y Adaptor handle 020359Y 42x47 mm Adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube Refit the cap and tighten the five fixing screws Turn over the wheel and insert the internal spa...

Page 267: ...tooling 020376Y Adaptor handle 020357Y 32x35 mm Adaptor 020412Y 15 mm guide Refitting the front wheel Grease the wheel axle then install it from the tone wheel side and install the tone wheel proper l...

Page 268: ...ve the front and rear handlebar covers Remove the pin mounting the handlebar to the steering tube Remove the handlebar and rest it on the shield back plate Using the special tool loosen and remove the...

Page 269: ...move the spring Drain the oil Remove the screw with copper washer shown in the figure To prevent the pumping member rota tion insert an inside 22 mm hexagon spanner into the stem Remove the pumping me...

Page 270: ...nit Check that the oil holes on the pumping are free from clogging Check that the sealing snap ring is not damaged Check the spring length Check the length A of the spring Characteristic Standard spri...

Page 271: ...the top of the head stock Specific tooling 020004Y Punch for removing fifth wheels from headstock Refitting Refitting stems on fork legs Preassemble the stem as indicated Install the bushing from the...

Page 272: ...stem into the fork leg being careful not to let the guiding bushing come out of the stem Insert and screw the pumping member screw with a new copper washer and tighten to the prescribed torque CAUTION...

Page 273: ...sing the specified product Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings temperature...

Page 274: ...ont and rear handlebar covers as described in the section Scooter body Install the front mudguard Install the front wheel Install the front brake callipers Tighten the retaining screws of the brake ca...

Page 275: ...e in the upper end of the steering tube Insert the special tool as shown in the figure Insert the retaining band of the two half rings Using a 19 mm hexagonal spanner extract the roller bearing Specif...

Page 276: ...teering tapered bearing seats Using the special tool reassemble the tapered bearing housings on the head as described below Place a new top housing on the head and a new bearing seat on the bottom sid...

Page 277: ...o the bracket Remove the cotter pin the cap the wheel axle fixing nut and the outer one of the two spacers Remove the two screws fixing the bracket to the engine Remove the two screws fixing the stand...

Page 278: ...ng screw 33 41 Nm Rear brake calliper fixing screws 25 30 Nm Swing arm The scooter features a rigid engine chassis retain er called Direct link The system comprises the following components A Left spa...

Page 279: ...e scooter 17 mm flanged head pin 22 mm head pin and washer Shock absorbers Removal Proceed as follows place the vehicle on its centre stand lift the engine a little with a jack so as to free the two s...

Page 280: ...return springs Working from both sides unscrew the two bolts connecting it to the supporting plate To refit follow the removal steps but in reverse order be careful to tighten to the prescribed torque...

Page 281: ...ide stand Unhook the springs Loosen the nut Pull out the screw Fitting Carry out the previous operations but in reverse order Locking torques N m Side stand clamp 15 20 XEVO 400ie Suspensions SUSP 281...

Page 282: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 283: ...RTING BRACKET FIRST LOOSEN THE OIL HOSE FITTING AF TER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING INSPECTED Refitting To fit the calliper follow the above operations but in reverse order Locking t...

Page 284: ...the prescribed torque Lock the pipe joint to the calliper to the prescribed torque Purge the system Locking torques N m Front brake calliper mounting on fork 20 25 Pipe brake calliper coupling 20 25...

Page 285: ...REASE MAY IMPAIR THE BRAKE PERFORMANCE Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings...

Page 286: ...O GET A DISTORTED READING CAUSE THE DRIVEN PULLEY SHAFT TO TURN IN ORDER TO ROTATE THE DISC Specific tooling 020335Y Magnetic support for dial gauge Characteristic Max deviation allowed 0 1 mm If you...

Page 287: ...tant it must be perfectly clean with no sign of rust oil or grease or any other dirt and must show no signs of deep scoring Characteristic New rear disc thickness 4 0 mm Disc thickness at wear limit f...

Page 288: ...iction material of the pads Replace the pads if the thickness is below the minimum value The replacement must be made with greater re sidual thickness if the pad has not worn evenly A 0 5 mm thickness...

Page 289: ...27 Pad fixing pin 19 6 24 5 Rear brake pads Removal Proceed as follows Remove the rear brake calliper Loosen the two pins shown in the figure that lock the two pads Remove the pads being careful with...

Page 290: ...ever load the system and bring it up to the required pressure Keeping the left hand brake lever pulled loosen the bleed screw to permit the air in the system to escape Then tighten the bleed screw Rep...

Page 291: ...the reservoir If necessary bleeding can be done using a special vacuum pump N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAG...

Page 292: ...G AIR IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE BRAKING WILL BE INEFFICIENT THEREFORE ALWAYS USE FLUID FROM SEALED CONTAINERS UNDER NOR MAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD...

Page 293: ...the figure Remove the stop light switch connector BRAKE PUMP TECHNICAL DATA Specification Desc Quantity Pump right piston diameter 12 Pump left piston diameter 15 Refitting To refit carry out the remo...

Page 294: ...indicated in the figure Remove the stop light switch connector BRAKE PUMP TECHNICAL DATA Specification Desc Quantity Pump right piston diameter 12 Pump left piston diameter 15 Refitting To refit carry...

Page 295: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 296: ...diator cold box is connected to the lower side of the expansion tank in the fluid When the engine is cold the thermostat output to the radiator is closed even though there is still a little flow for d...

Page 297: ...Starts opening 82 2 C ELECTRIC VENTILATION Specification Desc Quantity Type With piston Electric ventilation starts at 107 C Electric ventilation stops at 103 C WATER PUMP Specification Desc Quantity...

Page 298: ...07 C CAN ONLY BE MANAGED BY A SYSTEM SUP PLIED WITH A 50 MIXTURE AND PRESSURISED AT 0 9 BAR AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOIL ING TEMPERATURE BEFORE THE ELEC...

Page 299: ...ted Close the bleed screw Stop the engine Restore the level into the expansion tank and tighten the cap Start the engine and let it warm up to reach the electric ventilation temperature Stop the engin...

Page 300: ...the Engine Chapter Once the fault has been fixed and all components have been replaced fill and purge the system again N B FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM SEE THE COOLANT CHANGE SECT...

Page 301: ...ster Thermostat opening starts approx 80 C If opening occurs at different temperatures check the thermostat Remove the thermostat as described in the fly wheel cover paragraph Visually check that the...

Page 302: ...ther mostat Repeat the filling and bleeding procedure diagnosis Excessive system pressure 1 Check the expansion tank cap efficiency N B THE CAP IS EQUIPPED WITH A PRESSURE RELIEF VALVE CALIBRATED AT 0...

Page 303: ...3 Fix any damaged seals Oil in the fluid 1 Presence of oil in the coolant YES go to 2 2 Check the head gasket seal see Thermal group and timing system chapter XEVO 400ie Cooling system COOL SYS 303...

Page 304: ...INDEX OF TOPICS CHASSIS CHAS...

Page 305: ...plate to the central cover and remove the saddle Side fairings The scooter has two self sticking mouldings placed on the side fairings To replace them remove the relevant part clean the surface accura...

Page 306: ...ols have been disconnected See also Front handlebar cover Instrument panel Remove the instrument panel support and tip it Undo the six fixing screws A to re move the instrument panel See also Analogue...

Page 307: ...o fixing screws at the bot tom part Take out the cover by pulling it up wards Headlight assy Remove the upper cover of the head light Undo the two upper fixing screws A the lower screw B and remove th...

Page 308: ...turn indicator once the connector has been removed See also Legshield Flyscreen Frame central cover Remove the saddle Remove the shield back plate Remove the side panels Undo the two rear clamping sc...

Page 309: ...retainers Remove the mats on the footrest Remove the ten fixing screws A five per side on the shield back plate Remove the front mudguard Remove the six screws B four per side fixing the shield with...

Page 310: ...nd the plug socket Undo the screw fixing the caps of the two lower screws and remove them Remove the three fixing screws to the frame Remove the instrument panel support Remove the shield back plate b...

Page 311: ...house to the frame Disconnect the brake pipe to the pump and slide it off See also Legshield Taillight assy From inside the rear case undo two screws D fixing the rear light Disconnect the connector a...

Page 312: ...frame central cover Undo the four screws fixing the foot rest two of which are underneath the mat and remove the footrest Undo the two screws A on the inter nal side of the footrest Undo the four fixi...

Page 313: ...rab handle Remove the two upper screws A fixing the side fairings Remove the rear light unit then undo the two fairing fixing screws B underneath From both sides remove the turn indicators Undo screw...

Page 314: ...e the teeth hooking it to the central cover See also Taillight assy Handles and top side fairings License plate light License plate holder Remove the two side screws fixing the licence plate support R...

Page 315: ...er Remove the left fairing Undo the two screws fixing the housing to the engine crankcase Loosen the screw tightening the sleeve on the carburettor and slide off the sleeve Push the housing upwards to...

Page 316: ...he two screws A on the left fairing Undo the four screws fixing the frame upper pipe and remove it once the boot light connector has been removed Open the glove box flap Undo the 2 screws two on the b...

Page 317: ...connect the spark plug HV wire Pull the right and left fuse box out downwards freeing the tooth with a screwdriver from above Slide off the battery positive and negative leads and the diagnostics sock...

Page 318: ...See also Footrest Front mudguard Remove the four fixing screws A two per side on the mudguard internal side Chassis XEVO 400ie CHAS 318...

Page 319: ...ort Remove the side fairings Remove the frame upper pipe Undo the ten screws C five per side fixing the helmet compartment First slide off the rubber rim and then remove the upper cover Undo the four...

Page 320: ...in the helmet compartment Flyscreen Remove the rear view mirrors Undo the four fixing screws A and the screw B then take out the cover Remove the four screws C fixing the windshield Remove the windsh...

Page 321: ...front screws Undo the two screws A at the side of the handlebar cover and the two screws B on the upper part of the shield back plate Detach the cover from the front frame Remove the two instrument p...

Page 322: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 323: ...screw handlebar to steering tube 45 50 Upper steering ring nut 36 39 Steering lower ring nut 10 13 tighten and loosen by 90 Cover retaining screws Electrical system Electrical System Main switch Head...

Page 324: ...QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLA...

Page 325: ...correct operation Engine Check for correct general operation and make sure there is no unusual noise Other Check documents Check the frame and engine numbers Check tool kit License plate fitting Check...

Page 326: ...INDEX OF TOPICS TIME TIME...

Page 327: ...oted to the time necessary to carry out repairs For each operation the description code and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine to chassis Replacement XEVO...

Page 328: ...Crankcase CRANKCASE Code Action Duration 1 001100 Oil seal clutch side Replacement 2 001133 Engine crankcase Replacement 3 001153 Crankcase half gasket Replace ment Time XEVO 400ie TIME 328...

Page 329: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001098 Countershaft Replacement XEVO 400ie Time TIME 329...

Page 330: ...nder assy CYLINDER ASSEMBLY Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pistonsrings pin assembly Service 3 001129 Chain tensioner Service and Re placement Time XEVO 400ie TIME...

Page 331: ...ent 2 001049 Valves Adjustments 3 001056 Head gasket Replacement 4 001126 Head Replacement 5 832541 Water temperature sensor Re placement 6 005116 Rpm timing sensor Replacement 7 007012 Coolant bleed...

Page 332: ...Rocker arms support assy ROCKING LEVER SUPPORT UNIT Code Action Duration 1 001044 Camshaft Replacement 2 001148 Valve rocking levers Replacement Time XEVO 400ie TIME 332...

Page 333: ...Cylinder head cover HEAD COVER Code Action Duration 1 001089 Head cover Replacement 2 001093 Spark plug Replacement 3 001088 Head cover gasket Replacement XEVO 400ie Time TIME 333...

Page 334: ...ent 2 001113 Water pump Replacement 3 001123 Oil filter Replacement 4 001124 By pass valve Replacement 5 001150 Flywheel cover gasket change 6 001160 Minimum oil pressure sensor Re placement 7 001102...

Page 335: ...n pulley DRIVEN PULLEY Code Action Duration 1 001022 Clutch Replacement 2 001012 Driven pulley Overhaul 3 001110 Driven pulley Replacement 4 001155 Clutch bell housing Replacement XEVO 400ie Time TIME...

Page 336: ...Oil pump OIL PUMP Code Action Duration 1 001042 Oil pump overhaul 2 001051 Belt Timing chain Replacement 3 001112 Oil pump change 4 001125 Chain guide pads Replacement Time XEVO 400ie TIME 336...

Page 337: ...UCTION GEAR ASSEMBLY Code Action Duration 1 001010 Geared reduction unit Service 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replacement...

Page 338: ...086 Driving half pulley Replacement 2 001011 Driving belt Replacement 3 001006 Driving pulley Service 4 001141 Belt anti flapping roller Replace ment 5 001066 rear view pulley Replacement 6 001177 Var...

Page 339: ...on 1 001065 Internal transmission cover Re placement 2 001096 External transmission cover Re placement 3 001131 Transmission air intake Replace ment 4 001135 Transmission cover bearing Re placement 5...

Page 340: ...ywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001173 Rotor Replacement 2 001067 Stator Replacement 3 001058 Flywheel Replacement 4 001104 Start up freewheel Replacement Time XEVO 400ie TIME 3...

Page 341: ...valve THROTTLE BODY Code Action Duration 1 001013 Intake manifold Replacement 2 001047 Injector Replacement 3 001166 Throttle body Replacement 4 001171 Throttle body Service cleaning XEVO 400ie Time...

Page 342: ...R Code Action Duration 1 001009 Muffler Replacement 2 001092 Exhaust manifold Replacement 3 001095 Muffler guard Replacement 4 004169 Muffler guard Replacement 5 005138 Lambda probe Replacement Time X...

Page 343: ...ER Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Cleaner Throttle body union Re placement 4 001027 Body air cleaner union Replace ment XEVO...

Page 344: ...on 1 004001 Frame Replacement 2 004146 Front frame Replacement 3 004147 footboard support bracket one side Replacement 4 004148 Footrest support bracket both sides Replacement 5 004116 Rear frame Repl...

Page 345: ...Centre stand SIDE CENTRAL STAND Code Action Duration 1 004004 Stand Replacement 2 004102 Side stand Replacement 3 005079 Side stand switch Replacement XEVO 400ie Time TIME 345...

Page 346: ...Legshield spoiler FRONT SHIELD Code Action Duration 1 004020 Headlight frame Replacement 2 004064 Legshield Replacement Time XEVO 400ie TIME 346...

Page 347: ...BACK PLATE Code Action Duration 1 004065 Shield back plate Replacement 2 004156 Glove box flap and or support Re placement 3 004145 Glove box Replacement 4 007024 Expansion tank cap Replacement XEVO 4...

Page 348: ...de Action Duration 1 004135 Fuel tank lid Replacement 2 004011 Frame central cover Replacement 3 004075 Front mat Replacement 4 004059 Spark plug inspection flap Replace ment 5 004015 Footrest Replace...

Page 349: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard change 2 004167 Grille radiator cover Replacement XEVO 400ie Time TIME 349...

Page 350: ...Fuel tank FUEL TANK Code Action Duration 1 004005 Fuel tank Replacement 2 005010 Tank float Replacement 3 004109 Fuel tank breather change Time XEVO 400ie TIME 350...

Page 351: ...Duration 1 004018 Front handlebar covers Replace ment 2 004019 Rear handlebar covers Replace ment 3 004099 Odometer housing Replacement 4 004026 Handlebar cover Replacement 5 003043 Steering tube dus...

Page 352: ...ission Adjust ment 4 003059 Counterweight Replacement 5 004162 Mirror support and or brake pump fit ting U bolt Replacement 6 002024 Front brake pump Replacement 7 002067 Rear brake pump Replacement 8...

Page 353: ...arm SWINGING ARM Code Action Duration 1 003081 Swinging arm support flange Re placement 2 004058 Silent block Replacement 3 001072 Engine frame swinging arm attach ment Replacement XEVO 400ie Time TIM...

Page 354: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004068 Passenger handgrip Replacement Time XEVO 400ie TIME 354...

Page 355: ...Replacement 3 005133 Electric glove box activator Re placement 4 004054 Saddle lock catch Replacement 5 004173 Trunk opening splitter Replacement 6 004158 Saddle opening splitter Replace ment 7 00417...

Page 356: ...31 number plate light bulb Replace ment 4 005032 number plate light glass Replace ment 5 005022 Rear turning indicators Replace ment 6 005066 Rear light bulbs Replacement 7 005068 Rear turning indicat...

Page 357: ...ht replacement 2 005008 Headlight bulbs Replacement 3 005044 Front lights cable unit Replacement 4 005012 Front turning indicators Replace ment 5 005067 Front turning indicator bulb replace ment 6 005...

Page 358: ...brake disc Replacement 2 003037 Front wheel rim Replacement 3 003038 Front wheel axle Replacement 4 003040 Front wheel bearings Replacement 5 003047 Front tyre Replacement 6 003063 Tyre pressure Chec...

Page 359: ...ation 1 001016 Rear wheel Replacement 2 001071 Rear wheel rim Replacement 3 002070 Rear brake disc Replacement 4 003063 Tyre pressure Check 5 004126 Rear wheel tyre Replacement 6 002028 Rear wheel hub...

Page 360: ...Electric start START UP Code Action Duration 1 001017 Start up pinion Replacement 2 001020 Starter motor Replacement 3 001151 Starter driven gearing Replacement Time XEVO 400ie TIME 360...

Page 361: ...Fuel pump FUEL PUMP Code Action Duration 1 004073 Fuel pump Replacement 2 004137 Pump injector pipe Replacement 3 004138 Fuel reverse pipe Replacement XEVO 400ie Time TIME 361...

Page 362: ...ion 1 001023 Injection ECU Replacement 2 005009 Voltage regulator Replacement 3 001094 Spark plug cap Replacement 4 001069 HV coil Replacement 5 001093 Spark plug Replacement 6 005099 Electric saddle...

Page 363: ...5030 Rear headlight cable unit Replace ment 2 005044 Front lights cable unit replace 3 005001 Electrical system Replacement 4 005114 Electrical system Service 5 002051 Odometer transmission assembly R...

Page 364: ...118 Arrows remote control Replace ment 5 005011 Start up remote control switch Re placement 6 005088 Emergency stop remote control Re placement 7 005035 Headlight remote control Replace ment 8 005087...

Page 365: ...ent 4 005132 Trunk opening button Replacement 5 005041 Starter button Replacement 6 005077 Emergency stop switch Replace ment 7 005016 Key switch Replacement 8 004142 electric socket Replacement 9 005...

Page 366: ...on 1 002082 Fuel tank door opening drive Re placement 2 002092 Transmission splitter hook transmis sion Replacement 3 002093 Top box opening transmission Re placement 4 002094 Trunk splitter hook tran...

Page 367: ...Code Action Duration 1 004016 Helmet compartment Replacement 2 005033 Glove box light switch Replace ment 3 005026 Helmet compartment light Replace ment 4 005027 Helmet compartment bulb support Replac...

Page 368: ...late holder Replacement 2 005033 Glove box light switch Replace ment 3 004081 Top box lid Replacement 4 004174 Trunk levers Replacement 5 004080 Trunk flap support Replacement 6 004082 Top box gasket...

Page 369: ...Duration 1 003051 Complete fork Replacement 2 003010 Front suspension Service 3 003076 Fork sheath Replacement 4 003079 Fork stem Replacement 5 003048 Fork oil seal Replacement 6 003002 Steering fift...

Page 370: ...spension REAR SUSPENSION Code Action Duration 1 003085 Suspension strut Replacement 2 003007 Rear shock absorber Replacement 3 003077 muffler rear shock absorber support arm Service Time XEVO 400ie TI...

Page 371: ...eplacement 3 007001 Expansion tank Replacement 4 007024 Expansion tank cap Replacement 5 007019 Connection water pump pipe return pipe Replacement 6 007013 Radiator expansion tank connection pipe chan...

Page 372: ...r brake disc piping Replace ment 4 002080 Rear brake oil bleed system Change 5 002039 Front brake calliper Replacement 6 002007 Front brake pads Replacement 7 003070 Front brake pads Wear check 8 0020...

Page 373: ...Windscreen WINDSHIELD Code Action Duration 1 004101 Windshield Replacement 2 004066 Driving mirror Replacement XEVO 400ie Time TIME 373...

Page 374: ...Stickers TRANSFERS Code Action Duration 1 004159 Plates Stickers Replacement Time XEVO 400ie TIME 374...

Page 375: ...oolant 233 299 E Engine oil 22 F Fuel 189 197 201 317 350 361 Fuses 56 H Headlight 29 307 Hub oil 20 I Identification 7 Immobilizer Instrument panel 306 310 321 L Light switch M Maintenance 7 17 Mirro...

Page 376: ...T Tank 317 350 Technical Data Transmission 9 32 73 88 339 Turn indicators 48 Tyres 9...

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PIAGGIO 2005 XEVO 400ie, Workshop Manual

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