PIAGGIO 2005 XEVO 400ie Workshop Manual

Table of Contents

Quick Links

Download this manual

MANUALE STAZIONE DI SERVIZIO

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

XEVO 400ie

Table of Contents

Troubleshooting

Need help?

Do you have a question about the 2005 XEVO 400ie and is the answer not in the manual?

Questions and answers

Summary of Contents for PIAGGIO 2005 XEVO 400ie

Page 1 MANUALE STAZIONE DI SERVIZIO ****** - ****** XEVO 400ie...
Page 2 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."...
Page 3 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.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Vehicle Identification
XEVO 400ie Characteristics Maintenance rules • Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non- original or non-conforming spares may damage the vehicle. • Use only the special tools designed for this scooter. • Always use new gaskets, sealing rings and split pins upon reassembly.
Page 8 XEVO 400ie Characteristics Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 171 ± 6 kg Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke Bore x stroke 85.8 X 69 mm Cubic capacity 399 cm³ Compression ratio 10.6 ± 0.5 : 1 Timing system Four valves, single overhead camshaft, chain-driven.
Page 9 XEVO 400ie Characteristics Transmission TRANSMISSION Specification Desc./Quantity TRANSMISSION Automatic expandable pulley variator with torque server, V- belt, automatic clutch. Capacities CAPACITY Specification Desc./Quantity Engine oil 1.7 l Transmission oil 250 cm³ Cooling system fluid ~ 1.8 l Fuel tank (reserve) approx.
Page 10: Assembly Clearances
IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE COR- RECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES REC- OMMENDED BY PIAGGIO. Overhaul data Assembly clearances Cylinder - piston assy.
Page 11 XEVO 400ie Characteristics 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.
Page 12 XEVO 400ie Characteristics Intermediate ring Standard coupling clear- ance:0.02÷0.07 mm Maximum clearances allowed after use: 0.10 Oil scraper ring Standard coupling clearance: 0.01÷0.06 mm Maximum clearances allowed after use: 0.10 Replace the piston if clearances exceed the max- imum limits specified in the table. Crankcase - crankshaft - connecting rod Diameter of crankshaft bearings.
Page 13 XEVO 400ie Characteristics Characteristic crankshaft / crankcase axial clearance: 0.1 ÷ 0.405 mm AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission-side 1±0.025 D = 0.20 - 0.50 shoulder Half-shaft, transmission 20.9 -0.05 D = 0.20 - 0.50 side Connecting rod 22 -0.10 -0.15...
Page 14 XEVO 400ie Characteristics 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 ÷...
Page 15 XEVO 400ie Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 4-stroke engines (throttle control) AGIP FILTER OIL Oil for air filter sponge...
Page 16 INDEX OF TOPICS MAIN AINTENANCE...
Page 17: Maintenance Chart
XEVO 400ie Maintenance Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequen- tially.
Page 18 XEVO 400ie Maintenance 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...
Page 19: Spark Plug
XEVO 400ie Maintenance 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»...
Page 20 XEVO 400ie Maintenance 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;...
Page 21 XEVO 400ie Maintenance 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...
Page 22: Engine Oil
XEVO 400ie Maintenance - Wash the sponge with water and mild soap. - Dry it with a clean cloth and short blasts of com- pressed air. - Soak it in a mixture of 50% petrol and 50% speci- fied oil. - Gently squeeze the filtering element with your hands but do not wring it;...
Page 23 XEVO 400ie Maintenance 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 ».
Page 24 XEVO 400ie Maintenance 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.
Page 25: Engine Oil Filter
XEVO 400ie Maintenance 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.
Page 26: Checking The Ignition Timing
XEVO 400ie Maintenance 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 fly- wheel 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.
Page 27 XEVO 400ie Maintenance Cooling system Adding engine coolant. Check coolant level when the engine is cold as in- dicated in the scheduled maintenance table, fol- lowing 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.
Page 28 XEVO 400ie Maintenance 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 han- dlebars perfectly horizontal; - Check the fluid level through the sight glass «C».
Page 29: Headlight Adjustment
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.
Page 30 XEVO 400ie Maintenance 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 ±...
Page 31 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 32 XEVO 400ie Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION Possible Cause Operation Wrong valve adjustment Adjust the valve clearance properly Overheated valves...
Page 33 XEVO 400ie Troubleshooting Possible Cause Operation Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift of the disc with a dial gauge and with wheel mounted on the scooter. Brakes overheating BRAKES OVERHEATING Possible Cause Operation Defective plunger sliding...
Page 34 XEVO 400ie Troubleshooting Suspension oil leakage IL 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. TROUBL - 34...
Page 35 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 36 XEVO 400ie Electrical system 1. Magneto flywheel 2. Engine stop switch 3. Diode 4. Side stand button 5. Key switch 6. Electric fan 7. Engine stop remote control switch 8. Voltage regulator 9. Main fuses 10.12V-180W Plug socket 11. Auxiliary fuses 12.
Page 37 XEVO 400ie Electrical system 20. Starter button 21. Saddle opening actuator 22.Saddle opening control unit 23. Wiring for anti-theft device 24. «HAZARD» button 25. Turn indicator switch 26. Light switch 27. Turn indicator control device 28. Light switch remote control 29.
Page 38 XEVO 400ie Electrical system 53. Injection ECU 54. Intake air temperature sensor 55. Fuel pump 56. Diagnosis connector Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black, Ro = Pink, Rs = Red, Ve = Green, Vi = Purple Components arrangement 6 - Electric fan: placed at the front of the vehicle,...
Page 39 XEVO 400ie Electrical system 7 / 14 / 28 / 39 / 43 / 57 / 27 - Remote control switches: engine stop / immobilizer / light switch / headlight / injection load / electric fan / turn indi- cator control device: remove the instrument panel bottom section to reach them.
Page 40 XEVO 400ie Electrical system 22 - Saddle opening control unit: remove the left side panel to reach it. 41 - Horn: remove the wheel housing lower clamp to reach it. 44 - Ambient temperature sensor: remove the front headlight assembly to reach it. 45 / 60 - Fuel injector / Engine temperature sensor: remove the inspection door in the helmet compart- ment to reach them.
Page 41 XEVO 400ie Electrical system 46 / 55 - Fuel level transmitter / Fuel pump: remove the central chassis cover to reach them. 47 - Oil pressure sensor. 49 - Wheel turning sensor: the sensor is placed on the engine crankcase, near the left shock absorber lower attachment.
Page 42 XEVO 400ie Electrical system 51 / 52: Immobilizer aerial / Decoder: remove the legshield and the shield back plate to reach them. 53 - Injection ECU: remove the front shield to reach it. 54 - Intake air temperature sensor: remove the left side fairing and the air filter manifold to reach it.
Page 43 XEVO 400ie Electrical system 62 - Lambda probe: The lambda probe is fitted on the exhaust manifold. Conceptual diagrams Ignition 2. Engine stop switch 3. Diode 4. Side stand button 5. Key switch 7. Engine stop remote control switch 9. Main fuses 11.
Page 44 XEVO 400ie Electrical system 15. 12V-12Ah Battery 43. Injection load remote control 50. HV coil 51. Immobilizer aerial 52.Decoder 53. Injection ECU Battery recharge and starting 1. Magneto flywheel 2. Engine stop switch 3. Diode 4. Side stand button 5. Key switch 7.
Page 45 XEVO 400ie Electrical system 14.Immobilizer remote control switch 15. 12V-12Ah Battery 16. Starter motor 17. Start-up remote control switch 20. Starter button 32. Rear light A. Stop light bulbs Level indicators and enable signals section 2. Engine stop switch 3. Diode 4.
Page 46 XEVO 400ie Electrical system 45. Fuel injector 46. Fuel level transmitter 47. Oil pressure sensor 48. Instrument panel 49.Wheel turning sensor 51. Immobilizer aerial 52.Decoder 53. Injection ECU 54.Intake air temperature sensor 58. Engine rpm sensor 60. Engine temperature sensor 61.
Page 47 XEVO 400ie Electrical system 6. Electric fan 7. Engine stop remote control switch 9. Main fuses 10. 12V-180W Plug socket 11. Auxiliary fuses 15.12V-12Ah Battery 18. Boot actuator 19. Boot opening switch 21. Saddle opening actuator 22.Saddle opening control unit 23.
Page 48 XEVO 400ie Electrical system Lights and turn indicators 5. Key switch 9. Main fuses 11. Auxiliary fuses 15.12V-12Ah Battery 24. «HAZARD» button 25. Turn indicator switch 26. Light switch 27. Turn signal command device 28. Light switch remote control 30. License plate bulb 31.
Page 49 XEVO 400ie Electrical system B. High-beam light bulb C. Low-beam light bulb 36. Front right turn indicator 39. Headlight remote control 48. Instrument panel Checks and inspections Immobiliser The electronic ignition system is controlled by the control unit and the immobilizer decoder. The immo- bilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit.
Page 50 XEVO 400ie Electrical system • Battery voltage between terminals 26-23 and terminals 26-chassis ground (continuous pow- er supply). If there is no voltage, check: 1. that fuses No. 11 and No. 2 and their wirings are in good conditions. 2. that the engine stop remote control switch is in good conditions. •...
Page 51 XEVO 400ie Electrical system MASTER key: BROWN KEY SERVICE key. BLACK KEY Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
Page 52 XEVO 400ie Electrical system 5. Decoder programmed - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be trans- mitted are: •...
Page 53 XEVO 400ie Electrical system Diagnostic code - 3 flashes The 3-flash code indicates a system where the de- coder does not recognise the key. Turn the switch to ON using several keys: If the error code is re- peated even with the Master key, replace the de- coder.
Page 54 XEVO 400ie Electrical system 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator. Recharge system voltage check Maximum current output check. - With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V. - Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.
Page 55 XEVO 400ie Electrical system Turn signals system check The circuit of the turn indicators is controlled by the electronic control unit. If it does not work, it is necessary to: 1. Check that the fuse No. 8 is in good condition 2.
Page 56 ING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE). BESIDES, IF AFTER REPLACING A FUSE, THE NEW FUSE ALSO BLOWS, THE SCOOTER NEEDS TO BE TAKEN TO AN AUTHORISED PIAGGIO/GILERA SERVICE CENTRE TO IDENTIFY THE CAUSE OF THE FAULT AND AVOID FUR- ELE SYS - 56...
Page 57 XEVO 400ie Electrical system THER DAMAGE TO THE ELECTRIC SYSTEM COMPO- NENTS OR THE VEHICLE ITSELF. CAUTION MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS- TEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE OPERATING ERRORS AND RISK OF FIRE.
Page 58 XEVO 400ie Electrical system Specification Desc./Quantity Protected circuits: horn, instrument panel lightning, tail lights, license plate light, light switch. Location:battery compartment, on vehicle RHS. Fuse No. 11 Capacity: 7.5 A Protected circuits: injection load remote control, injec- tion ECU, electrical fan remote control, decoder. Location:battery compartment, on vehicle RHS.
Page 59 XEVO 400ie Electrical system These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and, afterwards, every six months.
Page 60 XEVO 400ie Electrical system Dry-charge battery - Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corresponding to 30 Bé at a minimum tem- perature of 15°C until the upper level is reached.
Page 61: Battery Installation
XEVO 400ie Electrical system The battery runs down completely in the course of three months. When refitting the battery onto the scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must be attached to the positive, + terminal.
Page 62 XEVO 400ie Electrical system IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYS- TEM, NEVER DISCONNECT THE WIRING WHILE THE EN- GINE IS RUNNING. DO NOT TIP THE SCOOTER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKS OF BATTERY ELECTROLYTE. Connectors Layout of the system-side connectors and the con- nectors on the electronic control unit.
Page 63 XEVO 400ie Electrical system Specification Desc./Quantity Injector control Stepper motor Stepper motor Injection telltale light Decoder (serial) Battery powered Intake air temperature sensor Injection load remote control HV coil Stepper motor Stepper motor Sensor ground Ground lead Stepper motor Stepper motor Continuous power supply Seat opening receiver SADDLE OPENING RECEIVER CONTROL UNIT...
Page 64 XEVO 400ie Electrical system IMMOBILIZER DECODER Specification Desc./Quantity Immobilizer LED control (negative) Base power supply (positive) Ground lead electronic control unit (serial) Continuous power supply (positive) Dashboard CONNECTOR A Specification Desc./Quantity Live supply Instrument panel lighting Battery-powered Ground lead General live power supply CONNECTOR B Specification Desc./Quantity...
Page 65: Battery Replacement
XEVO 400ie Electrical system Specification Desc./Quantity Ground lead Remote seat opening The vehicle is equipped with a remote control to open the saddle. This remote control is supplied together with the keys and at the manufacturing stage, it has been programmed to work together with the ECU that control the opening device.
Page 66 XEVO 400ie Electrical system Zeroing - To access the saddle opening control/reception unit, remove the left side fairing. - A white cable, that comes from pin 3 of the control unit, goes out from the wiring. - Earth the cable at least 10 seconds in order to delete all the remote controls stored in the control unit.
Page 67 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 68 XEVO 400ie Engine from vehicle Exhaust assy. Removal - Remove the right-hand side fairing - Undo the two exhaust manifold fixings on the head. - Remove the Lambda probe from its support and disconnect it. Remove the screw indicated in the photograph. - Loosen the screw shown in the figure so as to loosen the muffler strap and remove the whole muffler.
Page 69 XEVO 400ie Engine from vehicle N.B. DUE TO MUFFLER DIMENSIONS IT IS NOT POSSIBLE TO ACTUATE ON THE SCREW PERPENDICULARLY TO RE- MOVE IT; USE A COMMERCIALLY AVAILABLE «BON- DUS» MALE HEXAGONAL WRENCH. Remove the lambda probe from the manifold. Removal of the engine from the vehicle CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.
Page 70 XEVO 400ie Engine from vehicle - Remove the electrical connections to the sensors and devices. - Remove the throttle control cable from the throttle body by undoing the nut "C". - Remove the positive and negative wiring from the starter motor. - Disconnect the connectors from the flywheel wir- ing harness.
Page 71 XEVO 400ie Engine from vehicle Check that there is a small clearance when the valve is in abutment against the set screw. -Check the engine oil level and if necessary top it up with the recommended type. - Top-up the cooling circuit. - Check the functioning of the accelerator and the electrical devices.
Page 72 INDEX OF TOPICS NGINE...
Page 73: Automatic Transmission
XEVO 400ie Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap. - Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush.
Page 74 XEVO 400ie Engine - Remove the six M6 screws. - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely, otherwise replace it. Air duct - Remove the transmission cover. - Unscrew the two screws shown in the figure to remove the air conveyor.
Page 75 XEVO 400ie Engine Air duct filter - Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the fig- ure to remove the conveyor filter. Removing the driven pulley shaft bearing - Remove the transmission cover. - Remove the Seeger ring. - Place transmission cover on a wood surface and use the special tool so that it is adequately sup- ported.
Page 76 XEVO 400ie Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little grease to prevent it from coming out.
Page 77: Removing The Driven Pulley
XEVO 400ie Engine Anti-vibration roller screw 16.7 ÷ 19.6 Removing the driven pulley - Remove the clutch bell. - Remove the fixed driving half-pulley. - Remove the driven pulley assembly with the belt. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.
Page 78: Removing The Clutch
XEVO 400ie Engine Removing the clutch - To remove the clutch with the driven pulley it is necessary to use the special tool; - Arrange the tool with the mean pins screwed in position "E" on the inside; - Fit the adapter ring to the clutch assembly as shown in the photograph.
Page 79 XEVO 400ie Engine - Do not open the masses using tools to prevent a variation in the return spring load. Pin retaining collar - Extract the collar using 2 screwdrivers. - Remove the 4 guide pins. - Extract the moving driven half-pulley. Removing the driven half-pulley bearing - Check that the bushing is free from wear and damage;...
Page 80 XEVO 400ie Engine - Using the special tool inserted through the roller bearing, pull out the ball bearing. N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAM- AGING THE THREADING. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide N.B.
Page 81 XEVO 400ie Engine Inspecting the driven sliding half-pulley - Check that the belt contact surface is free from wear. - Remove the 2 inside sealing rings and the 2 out- side O-rings. - Measure the movable half-pulley bushing inside diameter. Characteristic Maximum admissible diameter: 50.05 mm...
Page 82: Refitting The Driven Pulley
XEVO 400ie Engine Refitting the driven pulley - Insert the new oil guards - Insert the new O-rings N.B. O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RA- DIUS, AT THE BASE OF THE HALF-PULLEY. - Install the half-pulley on the bushing being careful not to damage the top sealing ring during the in- troduction.
Page 83 XEVO 400ie Engine Refitting the clutch - Prepare the special tool as for removal; - Preassemble the driven pulley unit with the drive belt according to its direction of rotation; - Insert the driven pulley unit, the spring with sheath and clutch into the tool. Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch...
Page 84: Removing The Driving Pulley
XEVO 400ie Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width: 27 mm Standard width: 28.2 mm Removing the driving pulley - Using a 27 mm wrench, turn the central pulley nut to horizontally align the central inside holes and install the special tool.
Page 85 XEVO 400ie Engine - Move the belt downwards. - Suitable support the roller contrast and extract the movable driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out. Inspecting the rollers case - Check that the inside bushings shown in the figure exhibit no signs of abnormal wear and measure the inside diameter.
Page 86 XEVO 400ie Engine - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt contact surfaces on both pulley halves. Refitting the driving pulley Installing the roller container - Install the spacer with the internal chamfer facing towards the inside.
Page 87 XEVO 400ie Engine - Insert the half-pulley on the crankshaft. - Insert the spacer bushing. Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley.
Page 88 XEVO 400ie Engine - Insert the nut in the original position (nut side in contact with the belleville washer). - Turn the central pulley nut to horizontally align the holes and install the special tool. N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY IN- SERTED INTO THE PULLEY AND IN THE ENGINE CRANK- CASE.
Page 89 XEVO 400ie Engine - Insert the transmission cover with the bearing and install the relevant retainers. - Lock the four M8 retainers. Locking torques (N*m) M8 retainers for transmission cover 23 ÷ 26 - Lock the 7 M6 retainers. Locking torques (N*m) M6 retainer 11 ÷...
Page 90 XEVO 400ie Engine - Install the outside plastic transmission cover. - Tighten the 4 fastening screws to the prescribed torque. Locking torques (N*m) External transmission cover screws 7 ÷ 9 End gear Removing the hub cover - Drain the rear hub oil through the oil drainage cap located under the engine.
Page 91 XEVO 400ie Engine Removing the hub bearings - Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts. Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings 001467Y034 Pliers to extract ø...
Page 92 XEVO 400ie Engine - Support the hub cover using the stud bolt set. - Pull out the bearing using the special tool. Specific tooling 020476Y Stud bolt set 020376Y Adaptor handle 020477Y 37 mm adaptor 020483Y 30-mm guide - Remove the oil guard using a screwdriver. Removing the driven pulley shaft bearing - If you have to remove the driven pulley shaft, the relevant bearing and the oil guard, remove the...
Page 93 XEVO 400ie Engine Inspecting the hub shaft - Check that the 3 shafts exhibit no wear or defor- mation on the grooved surfaces, at the bearings and at the oil guards. - In case of faults, replace the damaged parts. Characteristic Connection diameter for countershaft: A = diameter 20 - 0.01 -0.02 mm...
Page 94 XEVO 400ie Engine - Check the capacity of the bearings. In case of faults, replace the hub cover. Refitting the driven pulley shaft bearing - Heat the crankcase using the heat gun. Specific tooling 020151Y Air heater - Insert the driven pulley shaft bearing until it abuts against the bottom of the seat using the special tool.
Page 95 XEVO 400ie Engine - Heat the gear shaft bearing seat on the crank- case. - Insert the gear shaft bearing in the upper crank- case seat using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE).
Page 96 XEVO 400ie Engine - Insert the intermediate shaft bearing on the cover using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020363Y 20-mm guide - Heat the gear shaft bearing seat from the cover outside.
Page 97 XEVO 400ie Engine Refitting the hub bearings - Place the 3 shafts as shown in the figure. Refitting the ub cover - Check the proper position of the centring dowels. - Install a new gasket. - Fit the gearbox cover, making sure the breather pipe is in the correct position.
Page 98 XEVO 400ie Engine Flywheel cover - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover. N.B. THE BANDS MUST BE REPLACED. TO REMOVE THEM, OPEN WITH A SCREWDRIVER OR CUT THEM.
Page 99 XEVO 400ie Engine - Loosen the 14 fastening screws. - Remove the flywheel cover with the relevant gas- ket and the cooling system sleeve support. N.B. THE SCREWS ARE OF 4 DIFFERENT LENGTHS. NOTE THE RELEVANT POSITIONS. CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR.
Page 100: Removing The Stator
XEVO 400ie Engine Removing the stator - Remove the two retaining screws and the cable guide bracket. - 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.
Page 101 XEVO 400ie Engine - Unscrew the fastening screw and remove the gas outlet union with the relevant O-ring. - Check that the mounting surface of the crankcase is not worn or deformed. - Check that the by-pass valve seat and the torque limiter bearing are free from wear.
Page 102 XEVO 400ie Engine - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Electric characteristic Resistance: 0.2 - 1 Ω - Check the ground insulation of each phase.
Page 103 XEVO 400ie Engine - Install the wiring guide bracket tightening the 2 screws to the prescribed torque. Locking torques (N*m) Stator cable harness guide bracket screws 3 - 4 Refitting the flywheel cover components - Before reassembling, check that all components are perfectly clean.
Page 104 XEVO 400ie Engine - Temporarily install the distribution timing check hole cover and the engine oil filling cap/bar. - Insert the blow-by recovery duct using a new O- ring. - Tighten the screws to the prescribed torque. Locking torques (N*m) Blow-by recovery duct fixing screws 3 - 4 - Insert the spring and the by-pass piston on the...
Page 105 XEVO 400ie Engine Refitting the flywheel cover - Install a new oil filter, lubricate the gasket, screw on and finally tighten to the prescribed torque. Locking torques (N*m) Engine oil filter 12 - 16 - Install the supply hose to the cylinder and con- nect the return hose to the pump cover using 3 new clamps.
Page 106 XEVO 400ie Engine - Install a new gasket on the engine crankcase. - Check the presence of the three centring dowels. - Turn the crankshaft in order to align the counter- shaft movement sensor with a reference point on the crankcase (see figure). - Repeat the alignment for the water pump crank- shaft using the same reference point on the en- gine.
Page 107 XEVO 400ie Engine N.B. - THE INTERMEDIATE BOLTS FOR THE REMAINING MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT FOR THE MANIFOLD SUPPORT (SHOWN IN THE FIGURE) ARE SLIGHTLY LONGER. Locking torques (N*m) Flywheel cover screws 11 - 13 Flywheel and starting Removing the starter motor N.B.
Page 108 XEVO 400ie Engine - Align the holes obtained on the flywheel with the crankcase housing to allow the introduction of the special tool. - Tighten the bushing of the flywheel lock tool on the removing 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 with the flywheel.
Page 109 XEVO 400ie Engine - Remove the washer. - Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer. CAUTION THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS STRONGLY LOCKED; THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE, WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS.
Page 110 XEVO 400ie Engine - To remove the start-up rim from the freewheel it is necessary to turn it clockwise and pull it out. - Remove the freewheel from the flywheel by loos- ening the 6 fastening screws. SINCE 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.
Page 111 XEVO 400ie Engine Inspecting the flywheel components - Check the integrity of the magnets. - Check that the magnet support cage is free from deformation or cracks. - Check that the flywheel splines exhibit no loos- ening. Starter gear rim - Check that there is no wear or abnormal impres- sions on the "rollers"...
Page 112 XEVO 400ie Engine Intermediate gear - Check that the toothing is not worn. - Check the diameter of the two bearings. Characteristic Gear bearing diameter: 12 - 0 0.011 mm Also check the shaft diameter on the flywheel cov- er and on the engine crankcase. Characteristic Bearing diameter on the flywheel cover 12 + 0.034 -0.016 mm...
Page 113 XEVO 400ie Engine Medium Loctite 243 threadlock - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel Seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
Page 114 XEVO 400ie Engine - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel 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 torque limiter gear with the start-up rim.
Page 115 XEVO 400ie Engine - Tighten thoroughly the guide bushing of the fly- wheel lock tool and loosen by 1/4 turn. N.B. FAILURE TO OBSERVE THIS PRECAUTION CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL. Specific tooling 020472Y Flywheel lock wrench - Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool.
Page 116 XEVO 400ie Engine - Install the chain guide retain plate tightening the 3 screws to the prescribed torque. N.B. BEFORE TIGHTENING THE SCREWS, MOVE THE START- UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC- TION.
Page 117 XEVO 400ie Engine Removing the rocker-arms cover - Loosen the 6 special screws with stop and the relevant rubber gaskets. - Remove the tappet cover with relevant gasket. Removing the timing system drive - Turn the engine to close the intake valves. - Remove the central screw and the valve lifting device mass stop bell using the special tool.
Page 118 XEVO 400ie Engine - Align the reference marks on the timing chain rim with those on the head. - Loosen the central 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.
Page 119: Removing The Cylinder Head
XEVO 400ie Engine Removing the cam shaft - Unscrew the 3 fastening screws and remove camshaft retaining bracket. N.B. REMOVING THE FASTENING SCREWS MAY BE DIFFI- CULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEX- AGON. IF NECESSARY, SEPARATE THE THREADS IN ADVANCE.
Page 120 XEVO 400ie Engine - Remove the coolant temperature sensor. N.B. THE SENSOR CONTROLS BOTH INJECTION AND THE AN- ALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS COMPONENT, SEE THE INJECTION CHAPTER. - Remove the 2 fastening nuts on the head, on the exhaust and on the intake side.
Page 121: Removing The Valves
XEVO 400ie Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 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).
Page 122 XEVO 400ie Engine Removing the cylinder - piston assy. - Remove the timing chain. - Loosen the fastening screw and remove the spacer and the tightening sliding block. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Page 123: Inspecting The Small End
XEVO 400ie Engine Inspecting the small end - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANK- SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Page 124 XEVO 400ie Engine THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS. Characteristic Standard clearance: 0.001 ÷ 0.010 mm - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis. - Take the measurement in the position shown in the figure.
Page 125 XEVO 400ie Engine - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D). N.B. REFER TO THE «SPECIFICATIONS» SECTION FOR THE SIZES OF THE CYLINDER AND THE CYLINDER-PISTON COUPLING CLEARANCES.
Page 126: Removing The Piston
XEVO 400ie Engine Maximum clearances allowed after use: 0.10 Replace the piston if clearances exceed the max- imum limits specified in the table. Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust.
Page 127 XEVO 400ie Engine - Install the pin lock using the key shown in the figure. Specific tooling 020470Y Pin retainers installation tool N.B. THE TOOL FOR INSTALLING THE SNAP RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING. Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket.
Page 128 XEVO 400ie Engine IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION. Characteristic Recess / Projection measured 1 - 0.185 - - 0.10 Gasket thickness 1 0.4 ±...
Page 129: Inspecting The Cylinder Head
XEVO 400ie Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork and the ring clamp, fit the cylinder as shown in the figure. N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW THE LUBRICATION DUCT AND LUBRICATE THE CYLIN- DER LINER.
Page 130 XEVO 400ie Engine N.B. IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT. Chain tensioner: - Remove the centre screw with the washer and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring.
Page 131 XEVO 400ie Engine Inspecting the valve housings - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V". Characteristic Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm - If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°...
Page 132 XEVO 400ie Engine - Check the deviation of the valve stem by resting it on a «V» shaped abutment and measuring the extent of the deformation with a dial gauge. Characteristic Limit values admitted: 0.1 mm - Check the concentricity of the valve head by ar- ranging a dial gauge at right angle relative to the valve head and rotate it on a "V"...
Page 133 XEVO 400ie Engine STANDARD VALVE LENGTH Specification Desc./Quantity Inlet: 95.0 ± 0.3 mm Outlet: 94.2 ± 0.3 mm - Check that there are no signs of wear on the surface of contact with the articulated register terminal. - If no anomalies are found during the above checks, you can use the same valves.
Page 134 XEVO 400ie Engine - Measure the unloaded spring length. Characteristic Standard length: 44.4 mm Admissible limit after use: 42.4 mm Refitting the valves - Place the valve spring support washers on the head. - Alternately insert the 4 oil guards using the spe- cial tool.
Page 135 XEVO 400ie Engine MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Bearing A Ø: 41.910 mm Bearing B diameter: 19.940 mm -Using a gauge, measure the cam height. STANDARD HEIGHT Specification Desc./Quantity intake 33.774 mm discharge 33.273 ADMISSIBLE LIMITS Specification Desc./Quantity intake 33.526 mm discharge 33.026 mm Standard axial clearance:...
Page 136 XEVO 400ie Engine - Check that the automatic valve lifting device cam, the travel end roller and the rubber abutment on the containment bell are free from wear. - Check that the valve lifting spring has not yielded. - Replace any defective or worn components. - Check that the rocking lever pins exhibit no scores or wear.
Page 137 XEVO 400ie Engine - The head gasket is made of steel and has a standard thickness. - Check that the head lubrication channel is per- fectly clean. Clean with compressed air jets, if required. - Insert the head. - Lubricate the stud bolts and the 4 fixing stud bolts.
Page 138 XEVO 400ie Engine - Tighten the 3 side screws to the prescribed tor- que. Locking torques (N*m) Head fixing screws 10 - 12 - Install the coolant temperature sensor with the washer and tighten to the prescribed torque. CAUTION FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN DAMAGE THE SENSOR.
Page 139 XEVO 400ie Engine - Clean the camshaft by blowing with little com- pressed air jets, especially the retaining plate housing. - Lubricate the 2 shafts. - Insert the camshaft into the head with the cams opposite the rocking levers. - Remove any LOCTITE residues from the screws fixing the camshaft retaining bracket using a brush.
Page 140 XEVO 400ie Engine - Insert the belt on the camshaft control timing rim. - Insert the timing rim on the camshaft checking that the references are aligned. N.B. DURING THE STROKE CHECK, KEEP THE BELT TEN- SIONED BY PRESSING ON THE TIGHTENER COMPART- MENT SIDE.
Page 141 XEVO 400ie Engine - Install the return spring and load it by about 3/4 turn. - Turn the engine to move the references to the top as shown in the figure (intake end). - Insert the valve lifting device mass stop bell. - Tighten the retaining screw to the prescribed torque, using the recommended product.
Page 142 XEVO 400ie Engine - Place the tightener cursor in the rest position, keeping the retain tab pressed. - Install a new tightener on the cylinder using a new gasket. - Tighten the two fastening screws to the prescri- bed torque. Locking torques (N*m) Tightener fastening screws: 11 ÷...
Page 143 XEVO 400ie Engine Refitting the timing chain The ignition advance is determined electronically on the basis 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 diagnostic tester.
Page 144 XEVO 400ie Engine - Repeat for the reference between driving pulley and transmission housing. - 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 four-stroke engine position (1 spark, 2 revs).
Page 145 XEVO 400ie Engine - Tighten the two screws indicated in the figure with «1» and «2» to limit the reciprocal sliding of the cover surface with the head surface. - Tighten the remaining 4 screws in a crossed se- quence (3, 4, 5, 6). N.B.
Page 146 XEVO 400ie Engine - Remove the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover" chapter. - Remove the flywheel with the starting system following the instruction given in "Flywheel and Starting system". - Remove the thermal group (cylinder, head, piston) as described in the «Thermal group and timing system chapter».
Page 147 XEVO 400ie Engine - Remove the 14 crankcase coupling screws. N.B. THE FASTENING SCREWS ARE OF 3 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION. - Split the crankcases while keeping the crankshaft inserted on the flywheel side half-crankcase. - Remove the coupling gasket. N.B.
Page 148 XEVO 400ie Engine Removing the oil pump and countershaft con- trol gear. - To remove the control gear, loosen the 4 fasten- ing screws. Remove the gear only if actually required. CAUTION THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR THREADING IS LOCKED BY LOCTITE.
Page 149 XEVO 400ie Engine Replacing the countershaft bearings - Check that the bearings are free from irregular noise or clearance. If it does, replace it. Flywheel-side half-crankcase - Remove the inside Seeger ring. - Upturn the half-crankcase. - Remove the bearing from the flywheel side half- crankcase using the special tool and a mallet.
Page 150 XEVO 400ie Engine - Insert a new bearing on the special tool after greasing the guide seat. - Install the new bearing on the half-crankcase us- ing the special tool. N.B. IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE.
Page 151 XEVO 400ie Engine 020439Y 17-mm guide Inspecting the crankshaft components - Check the axial clearance on the connecting rod. Characteristic Standard clearance: 0.20 ÷ 0.40 mm - Check the connecting rod diametrical clearance. Characteristic Standard clearance: 0.046 ÷ 0.076 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the...
Page 152 XEVO 400ie Engine IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FITTING POSITION. Specific tooling 020074Y Support base for checking crankshaft alignment - If the crankshaft - crankcase axial clearance is higher than the standard value and the crankshaft exhibits no irregularity, the problem is caused by wear or by a wrong machining on the engine crankcase. - Check the diameters of both bearings of the crankshaft in accordance with the axes and surfa- ces shown in the figure.
Page 153 XEVO 400ie Engine N.B. MAIN BEARINGS CANNOT BE MODIFIED. The connecting rod cannot be replaced. To check the connecting rod small end diameter, see chapter "Thermal group and timing system". - When cleaning the crankshaft, be careful to prevent any impurity from entering into the shaft lubrication hole.
Page 154 XEVO 400ie Engine - For the flywheel side half-crankcase, special at- tention should be given to the lubrication channels for the main bearings and to the compartment and the channels for the oil pump, as well as to the duct for the by-pass located on the flywheel cover.
Page 155 XEVO 400ie Engine - Check the inside diameter of the main bushings in the three directions indicated in the diagram. - Repeat the measurements for the other bushing half. see diagram. N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALF- SHELL COUPLING SURFACE SINCE THE ENDS ARE RE- LIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
Page 156 XEVO 400ie Engine X = Crankshaft category Y = Crankcase half-shell category A = Red B = Blue C = Yellow D = Green In case of breakdown, crankcases are together with bushings and are classified according to the centre to centre distance of the countershaft.
Page 157 XEVO 400ie Engine THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN CHAPTER "AUTOMATIC TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS DESCRIBED IN CHAPTER "FINAL REDUCTION". Countershaft - Using a micrometer, measure the 2 bearings of the countershaft as shown in the figure. Characteristic Standard diameter: 17 - 0.01 - 0.02 mm...
Page 158 XEVO 400ie Engine TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN IN- SIDE HEXAGON SOCKET WRENCH. Locking torques (N*m) Gear mounting on crankshaft screws 10 -12 - Lubricate the main bearing on the flywheel side half-crankcase.
Page 159 XEVO 400ie Engine Refitting the crankcase halves - Remove the oil guard from the transmission side half-crankcase using a screwdriver. - Install a new oil guard after lubricating it, using the special tool, arranging it at a 0.5 mm recess from the crankcase plane.
Page 160 XEVO 400ie Engine - Check that the crankshaft rotates freely. N.B. REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE BETTER SEALING PERFORMANCE. Locking torques (N*m) Engine-crankcase coupling screws 11 ÷ 13 - Install the thermal group (cylinder, head, piston) as described in section «Thermal group and timing system».
Page 161 XEVO 400ie Engine OIL FILTER Specification Desc./Quantity Type Paper with pressure relief and anti-drain back by-pass valves OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH Specification Desc./Quantity Calibration 0.3 - 0.6 bar HEAD LUBRICATION CONTROL JET Specification Desc./Quantity Diameter 1 ± 0.05 mm * * Tightening torque 5÷7 N·m PISTON COOLING NOZZLE Specification...
Page 162 XEVO 400ie Engine Specification Desc./Quantity Oil filter cartridge To the oil sump By-pass valve Oil pump Mesh pre-filter Crankshaft Connecting rod General characteristics The lubrication system is divided into two sections: - High pressure - Low pressure The high pressure section includes all components located on the engine crankcase whereas the low pressure section only refers to the thermal group.
Page 163 XEVO 400ie Engine A one-way valve and a decantation chamber are used so that gases from the crankcase do not carry any oil. The one-way valve is a metal reed valve; the decantation chamber has a drainage hole. A failure in these components implies oil getting into the line supplying air to the engine.
Page 164 XEVO 400ie Engine STANDARD VALUES Specification Desc./Quantity 20°C Temperature 1400 rpm approx. 4.5 bar N.B. RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE DIAGNOSTIC TESTER Specific tooling 020680Y Diagnosis Tool YES go to 6 NO go to 12 6 - Let the engine warm up and repeat the check with hot oil.
Page 165: Oil Pressure Check
XEVO 400ie Engine - Check the oil pump as described in the following pages. - Check that the cooling nozzle and the timing system feeding jet are properly installed. - Visually inspect the crankshaft couplings and their size ("Crankcase and crankshaft" chapter). N.B.
Page 166 XEVO 400ie Engine Oil pump Removal - Remove the closing plate of the oil pump housing by loosening 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.
Page 167 XEVO 400ie Engine - Remove the inside rotor retaining snap ring turn- ing it to move the opening at the shaft face. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and free from wear.
Page 168 XEVO 400ie Engine - Check the distance between external rotor and pump body; see figure. Characteristic Admissible limit clearance: 0.25 mm - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit values admitted: 0.1 mm Refitting...
Page 169 XEVO 400ie Engine - Insert the 2 retaining screws through the slots on the gear and tighten to the prescribed torque. N.B. THE ASSEMBLY POSITION OF THE PUMP IS FIXED BY INSTALLATION OF THE SCREWS. Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body.
Page 170 INDEX OF TOPICS INJEC NJECTION...
Page 171 XEVO 400ie Injection EMS injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. Injection and ignition are timed on the 4-stroke cycle using a tonne wheel pivoted on the camshaft control and a reluctance variation sensor.
Page 172 XEVO 400ie Injection - Fuel pump - HV coil - Injector The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel. Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles of use (cold start, running at regular engine...
Page 173 XEVO 400ie Injection Precautions 1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults. 2. The fuel supply system is pressurised at 300 kPa (3 BAR). Before disconnecting the quick coupler of a pipe in the fuel supply system, check that there are no naked flames.
Page 174 XEVO 400ie Injection Terminals setup Layout of the system-side connectors and the con- nectors on the electronic control unit. Specification Desc./Quantity Throttle potentiometer power supply +5 V Lambda sensor Rpm indicator Engine temperature Electric fan remote control Stepper motor Stepper motor Engine rpm sensor Lambda sensor EMS diagnostic connector...
Page 175 XEVO 400ie Injection Specification Desc./Quantity Base power supply (positive) Ground lead electronic control unit (serial) Continuous power supply (positive) 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.
Page 176 XEVO 400ie Injection 17. Start-up remote control switch 20. Starter button 32. Rear light A. Stop light bulbs 43. Injection load remote control 45. Fuel injector 48. Instrument panel 50. HV coil 51. Immobilizer aerial 52. Decoder 53. Injection ECU 54.
Page 177 XEVO 400ie Injection Starting difficulties ENGINE START-UP PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Injection load relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Atmospheric pressure Start-up speed Starter motor and remote control Battery Ground connections End of compression pressure...
Page 178 XEVO 400ie Injection Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH Possible Cause Operation Presence of faults detected by the self diagnosis Injection load relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Atmospheric pressure Ignition efficiency...
Page 179 XEVO 400ie Injection Possible Cause Operation Air temperature Coolant temperature Atmospheric pressure Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing Intake sleeve Filter box Ignition system Spark plug wear check Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator...
Page 180 XEVO 400ie Injection Possible Cause Operation Fuel supply Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness Decoder master-box circuit This section describes the operations to be carried out to check the power supply circuit. Constant supply circuit check The decoder basic power supply is necessary for the deterrent flashing management.
Page 181 XEVO 400ie Injection 8 - Fix any wiring short circuits and replace the fuse. YES go to 1 NO go to 9 9 - Check any short circuit on decoder or control unit and replace, if necessary. YES go to 1 10 - Place the special tool between control unit and power supply system.
Page 182 XEVO 400ie Injection Specific tooling 020680Y Diagnosis Tool 1 - Check whether the immobilizer system LED in- dicates switching to "ON" YES go to 2 NO go to 4 2 - Raise the side stand. Set the emergency switch to "OFF". Turn the key switch to "ON". Set the emergency switch to "RUN".
Page 183 XEVO 400ie Injection 9 - Control unit with proper continuous power sup- ply. 10 - If only one component is not powered check the relevant connector. If the problem involves both the decoder and ECU check the continuity of the decoder ECU power supply line. Pin 26 control unit - Pin 30 engine stop remote control switch = continuity Pin 8 decoder - Pin 30 engine stop remote control...
Page 184 XEVO 400ie Injection Diagnostic circuit 1 = CONNECTOR FOR DIAGNOSTIC TESTER 2 = INJECTION ECU Connect the diagnostic tester. Specific tooling 020680Y Diagnosis Tool If the diagnostic tester displays «No reply from the control unit», disconnect the continuous power supply for 10 seconds and switch to «ON» again; if the message is still displayed, proceed as fol- lows: 1 - Check the diagnostic tester connections.
Page 185 XEVO 400ie Injection 6 - The circuit is in good working order. Check the 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.
Page 186 XEVO 400ie Injection 15. 12V-12Ah Battery 48. Instrument panel 51. Immobilizer aerial 52. Decoder 53. Injection ECU EFERENCE VALUES Specification Desc./Quantity TERMINAL: 15 - 23 CONDITIONS: DURING THE CHECK - Switch set to "ON" - Side stand raised - Switch to "RUN" STANDARD VALUES : O V TERMINAL: 15 - 23 CONDITIONS: AFTER THE CHECK...
Page 187 XEVO 400ie Injection 5 - Check the control unit connector. Check the control unit. 6 - Check the continuity between pin 15 of the control unit and pin 16 of connector B of the in- strument panel. The injection ECU manages the negative of the light. The light must go off after the initial check. The light goes on again when the ECU self-diagnosis detects a fault.
Page 188 XEVO 400ie Injection The tester pages display the list of errors detecta- ble by the auto-diagnosis. Errors detected by the auto-diagnosis are marked by one or two reference dots. They are arranged on two lines: Line A = current failures (present) Line M = stored failures Errors detectable by the auto-diagnosis may refer to the following system circuits or sectors of the control unit:...
Page 189 XEVO 400ie Injection Fuel supply system Fuel is fed to the injector by a pump, a filter and a pressure regulator integrated with the fuel level in- dicator inside the tank. The pump unit is connected to the injector by: 2 semi-flexible pipes 4 quick unions 1 T union with O-ring and retain bracket for the injector...
Page 190 XEVO 400ie Injection 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 brake 13.
Page 191 XEVO 400ie Injection 43. Injection load remote control 45. Fuel injector 48. Instrument panel 50. HV coil 51. Immobilizer aerial 52. Decoder 53. Injection ECU 54. Intake air temperature sensor 55. Fuel pump 56. Diagnosis connector 57. Electric fan remote control 58.
Page 192 XEVO 400ie Injection Refitting the injector Carefully check to make sure the components are clean. - Fit new O-rings and grease them. - Apply the recommended product to the set screws and tighten to the prescribed torque. Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques (N*m) injector fixing screw...
Page 193 XEVO 400ie Injection - Make sure the seal rims on the coupling surfaces between the manifold-throttle body and manifold- head are in good condition. CAUTION IF AIR GETS IN IT CAN JEOPARDISE THE OPERATION OF THE INJECTION SYSTEM, ESPECIALLY WHEN THE EN- GINE IS IDLING.
Page 194 XEVO 400ie Injection Refitting the butterfly valve - Carry out the removal operations but in reverse order, tighten the 3 fixing screws to the prescribed torque. Locking torques (N*m) Throttle body fixing screws 11 ÷ 13 Pump supply circuit The control unit starts the pump in the following conditions: - by setting the switch to «ON»...
Page 195 XEVO 400ie Injection Characteristic Engine idle speed 1500 ± 50 rpm Circuit leak test Before performing the checks concerning the sys- tem pressure, it is necessary to carefully clean all feeding system components. To perform the inspections it is necessary to use the special tooling kit for fuel pressure check.
Page 196 XEVO 400ie Injection The system pressure check must be carried out, for practical reasons, by connecting on the pump side. Connect the manometer to the outlet duct (RHS) and the extension tube to the inlet duct (LHS). CAUTION BEFORE REASSEMBLING CHECK THE TOOL DUCTS ARE CLEAN.
Page 197 XEVO 400ie Injection 4 - The pressure regulator is efficient. 5 - Pressure too high Check that the return duct is not clogged or squashed YES go to 6 NO go to 7 6 - Replace the pressure regulator. 7 - Pressure regulation too low Start the pump rotation again.
Page 198 XEVO 400ie Injection 2 - Let bleed for a few seconds. Make sure that there are no leaks. Using pliers with flat and long tips, temporarily clamp the return duct by the extension of the spe- cial tool with pump power supply voltage higher than 12 V, check the system maximum pressure.
Page 199 XEVO 400ie Injection 10 - There occur trend variations YES go to 11 NO go to 13 11 - Repeat the test clamping the pipe of the spe- cial tool in the portion between the branch and the injector. Check whether the pressure decreases with the same trend as the system when free.
Page 200 XEVO 400ie Injection 17 - Introduce the return pipe into a graduated container. Using the diagnostic tester, start the fuel pump for 10 seconds. Make sure that the power supply voltage is more than 12V. Measure the amount of fuel delivered. Pump free flow rate = 300 - 320 cc.
Page 201 XEVO 400ie Injection Pump consumption check The pump power consumption may vary according - Power supply voltage - Pump running-in - Regulation pressure - Delivery filter cleaning To check current consumption, proceed as follows - disconnect the injection load remote control con- nector.
Page 202 XEVO 400ie Injection Pump bracket overhaul To remove the pump support from the tank, pro- ceed as follows: - Disconnect the electric connector. - Start the engine and wait for the spontaneous stop. - Clean the tank and the pump support (wash and blow with compressed air, if necessary).
Page 203 XEVO 400ie Injection Pass the wires through the hole found between fil- ter and pressure regulator. - Disconnect and extract the wires - Using a screwdriver on the retain tab as shown in the figure, extract the level indicator from the support - Level indicator check The check may also be carried out before removing it from the support.
Page 204 XEVO 400ie Injection - Lubricate the O-rings and repeat the operations in the reverse order for 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 the sup- port.
Page 205 XEVO 400ie Injection - Remove the filter coupling pipe - Remove the pump with annular support and pre- filter. - If the pump requires replacement, remove the pre-filter and the annular support. - For reassembly, perform the removal operations but in the reverse order using a new clamp for the delivery pipe and a new pump mounting washer.
Page 206 XEVO 400ie Injection Pump bracket installation - Before reassembling, carefully check that the tank is clean. In case of dirt or water, remove the tank. - Install the sealing gasket on the pump support. - Introduce the pump into the tank being careful not to deform the level indicator arm.
Page 207 XEVO 400ie Injection Inspecting the injector circuit 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 brake 13.
Page 208 XEVO 400ie Injection 43. Injection load remote control 45. Fuel injector 48. Instrument panel 50. HV coil 51. Immobilizer aerial 52. Decoder 53. Injection ECU 54. Intake air temperature sensor 55. Fuel pump 56. Diagnosis connector 57. Electric fan remote control 58.
Page 209 XEVO 400ie Injection 8 - The injector control circuit is efficient. Repeat the acoustic check and perform the injector hy- draulic check for safety reasons. 9 - Select the menu on the "ERRORS" function. Check whether the injector failure message only is displayed.
Page 210 XEVO 400ie Injection 16 - The injector electric circuit is steady Repeat the checks. If the fault persists, check the control unit connector. If necessary, replace the electronic control unit. 17 - Repeat the test using the resistance multime- ter. Check the resistance between pin 13 and pin 87 (black/green cable) of the injection load remote control.
Page 211 XEVO 400ie Injection Inspecting the injector hydraulics To check the injector it is advisable to remove the intake manifold along with throttle body and injec- tor. The injector should be removed from the manifold only if necessary. For these operations, see the "thermal group and timing system"...
Page 212: Troubleshooting
XEVO 400ie Injection 3 - Perform the injector sealing test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector. Slight oozing is normal. Value limit = 1 drop per minute YES go to 5 NO go to 6 4 - Higher quantities are not expected.
Page 213: System Components
XEVO 400ie Injection Specification Desc./Quantity - Dirty by-pass circuit - Faulty Stepper motor Other - Wrong distribution timing - Wrong idle speed carburetion - Wrong reset of the throttle valve position sensor 2 - Failures to the EMS system may depend on loosened connectors. Make sure that all connections are properly implemented.
Page 214 XEVO 400ie Injection Virgin circuit When control unit (ECU) and decoder are not pro- grammed, the following conditions occur: - Key switch set to "OFF". Deterrent flashing inac- tive. - Key switch set to "ON". Ignition and injection dis- abled and LED on with solid light. When the key switch is set to "ON", the LED switches on as shown in the figure.
Page 215 XEVO 400ie Injection This allows the driver clear operation without having to do anything other than just turning the key. The Immobiliser system consists of the following components: - electronic control unit - decoder - immobilizer aerial - master key with integrated transponder (brown key) - service key with incorporated transponder (black key) - HV coil - diagnosis LED...
Page 216 XEVO 400ie Injection In any case it is advisable to use resistive spark plugs. LED signals When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised when the decoder has been correctly programmed. The procedure for programming a new decoder requires the recognition of the "master"...
Page 217 XEVO 400ie Injection Checking master-box data Connect the diagnostic tester. Set to «ON» and select the immobilizer function. Scroll the pages the find the data. Specific tooling 020680Y Diagnosis Tool The information will be as follows: - Unprogrammed control unit «OFF» - Start-up disabled «OFF»...
Page 218 XEVO 400ie Injection THE CODE CARD CAN ONLY BE USED WHEN THE ORIG- INAL MASTER KEY IS AVAILABLE. Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
Page 219 XEVO 400ie Injection • 2-flash code • 3-flash code Code 1 A one-flash code indicates a system where the se- rial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessa- Code 2 A 2-flash code indicates a system where the de- coder does not recognise the transponder signal.
Page 220 XEVO 400ie Injection Tachometer Electric characteristic TERMINAL: 7 - 12 CONDITIONS : Start-up speed STANDARD: approx. 0.8 - 4.5 V CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Engine rpm sensor The sensor allows the rotations and the angular position of the crankshaft to be recognised by reference to the TDC.
Page 221 XEVO 400ie Injection The fault continues to be signalled, but the circuit is only checked when turning to "ON". Therefore faults which occur or disappear after turning to "ON" are not acknowledged. During and after the start phase, the self-diagnosis checks the alternating current produced by the sensor (synchronisation of the signal panel).
Page 222 XEVO 400ie Injection THE FAULT HAS BEEN RECORDED IN CUR- RENT STATUS: The control circuit gave a negative result when switching to "ON". AHEAD go to 8 3 Select the "PARAMETERS" function on the menu. Check the number of «lost synchronisations»: 1 TOOTH and >...
Page 223 XEVO 400ie Injection RESISTANCE OF THE RPM TIMING SENSOR: ( 25°C) Specification Desc./Quantity 860 Ω ± 130 Ω Model with 1 clamp: 680 Ω ± 100 Ω Model with 2 clamps: YES go to 11 NO go to 12 11 - Check the earth isolation between a pole and the shielding. (see the «Electrical system»...
Page 224 XEVO 400ie Injection 15 - Check the connectors carefully. Disconnect and check the continuity between connector and pin 7-12 Electric characteristic Connector - 7 = Continuity Connector - 12 = Continuity Fix the connectors or replace the cable harness. Electric characteristic Resistance 16 Repair or replace the injection wiring (short circuit) 17 - Check the earth insulation again.
Page 225 XEVO 400ie Injection HT coil This section describes the ignition system operation. Circuit diagram Electric characteristic TERMINALS: 20 - 23 CONDITIONS : During the pump timing with engine off. STANDARD: Battery voltage KEY: 2. Engine stop switch 3. Diode 4. Side stand button 5.
Page 226 XEVO 400ie Injection 15. 12V-12Ah Battery 16. Starter motor 17. Start-up remote control switch 20. Starter button 32. Rear light A. Stop light bulbs 43. Injection load remote control 45. Fuel injector 48. Instrument panel 50. HV coil 51. Immobilizer aerial 52.
Page 227 XEVO 400ie Injection The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during compression. To check the ignition circuit, proceed as follows: 1 - Connect the diagnostic tester. Select the menu on the "ACTIVE DIAGNOSIS" function. Start the HV coil check with switch set to «ON», switch to «RUN»...
Page 228 XEVO 400ie Injection Carefully check the connectors to the control unit and to the coil. Replace the control unit, if necessary. 8 - Disconnect the connector to the HV coil primary. Repeat the voltage check between the black-green wire and earth. Electric characteristic Black-green-23 = battery voltage...
Page 229 XEVO 400ie Injection YES go to 12 NO go to 13 12 - Check the earth insulation of the negative line. Electric characteristic 20-23 = Ω infinite (>1MΩ) YES go to 15 NO go to 14 13 - Repair or replace the faulty system. Repeat the check with the menu on «ACTIVE DIAGNOSIS». 14 - Repeat the earth insulation check in the two sections.
Page 230 XEVO 400ie Injection YES go to 16 NO go to 19 16 - Check the earth insulation of the primary circuit Measure between one of the primary terminals and earth. Electric characteristic Primary-earth = Ω infinite (>1MΩ) YES go to 17 NO go to 1 9 17 - Check the secondary resistance.
Page 231 XEVO 400ie Injection Inspecting the spark plug shielded cap Measure the shielded cap resistance. Electric characteristic Resistance: 5 KΩ If different values are measured (<1; >20KΩ), replace the shielded cap. N.B. A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM. FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS»...
Page 232 XEVO 400ie Injection - Remove the TDC reference inspection cap be- tween flywheel and crankcase cover. See the "fly- wheel cover" chapter - By the driving pulley, turn the engine to find the alignment of the references to identify the TDC. - Repeat for the reference between driving pulley and engine crankcase.
Page 233 XEVO 400ie Injection Coolant temperature sensor Electric characteristic TERMINALS: 4 - 22 CONDITIONS : coolant temperature STANDARD: With connected sensor: 20° = 2500 ± 100 Ω 80° = 308 ± 6 Ω KEY: 2. Engine stop switch 3. Diode 4. Side stand button 5.
Page 234 XEVO 400ie Injection 15. 12V-12Ah Battery 16. Starter motor 17. Start-up remote control switch 20. Starter button 32. Rear light A. Stop light bulbs 43. Injection load remote control 45. Fuel injector 48. Instrument panel 50. HV coil 51. Immobilizer aerial 52.
Page 235 XEVO 400ie Injection Specific tooling 020680Y Diagnosis Tool 2 - The EMS system has received no indications of temperatures out of the range of possible temper- atures. If you suspect a wrong temperature indication, proceed to perform the following check. N.B.
Page 236 XEVO 400ie Injection 10 - Connect the sensor connector and repeat the resistive check at terminals 4 and 22; Electric characteristic 4-22 = Resistance 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.
Page 237 XEVO 400ie Injection YES go to 15 NO go to 14 14 - Repair or replace the wiring. Check the air temperature lines and the throttle valve position. YES go to 15 15 - Connect the special tool to the control unit. Set the switch to "ON"...
Page 238 XEVO 400ie Injection Measured value = 0 Ω Repeat the sensor and circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector. Check the control unit power supply. Replace the control unit, if necessary. 20 - Repair or replace the cable harness.
Page 239 XEVO 400ie Injection 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 brake 13. Stop button on rear brake 14.Immobiliser remote control switch 15.
Page 240 XEVO 400ie Injection 48. Instrument panel 50. HV coil 51. Immobilizer aerial 52. Decoder 53. Injection ECU 54. Intake air temperature sensor 55. Fuel pump 56. Diagnosis connector 57. Electric fan remote control 58. Engine rpm sensor 59. Stepper motor 60.
Page 241 XEVO 400ie Injection YES go to 3 NO go to 2 Specific tooling 020680Y Diagnosis Tool 2 - The EMS system has received no indications of temperatures out of the range of possible values. If you suspect a wrong temperature indication, proceed to perform the following check. 3 - Before checking the sensor and the relevant circuit, wait until the engine has cooled down and the scooter has set to the working area temperature.
Page 242 XEVO 400ie Injection YES go to 10 NO go to 9 9 - Replace the sensor. 10 - Connect the sensor connector and repeat the resistive check at terminals 18 and 22. Electric characteristic 18-22 = Resistance 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.
Page 243 XEVO 400ie Injection 12 - Repair or replace the cable harness. YES go to 10 13 - Check that the sensor circuit is earth insulated. Electric characteristic 18-23 = infinite (>1MΩ) 22-23 = infinite (>1MΩ) YES go to 15 NO go to 14 14 - Repair or replace the wiring.
Page 244 XEVO 400ie Injection 020481Y Control unit interface wiring 16 - Measure voltage at terminals 18 and 22. Electric characteristic 18-22 = V as in the table. TEMPERATURE VOLTAGE Specification Desc./Quantity -10° C +10° C +20° C +30° C +80° C YES go to 21 NO go to 17 Electric characteristic Power supply voltage value =...
Page 245 XEVO 400ie Injection WITH MILD WEATHER, 30° C CAN BE EASILY REACHED AFTER A FEW MINUTES OF STOP WITH IDLE ENGINE. Pressure sensor This sensor does not have a system since it is di- rectly installed into the control unit. The sensor allows the control unit to optimise the engine performance based on altimetric varia- tions.
Page 246 XEVO 400ie Injection Throttle valve opening sensor Throttle position sensor (t.p.s.) Electric characteristic TERMINALS: 1 - 22 CONDITIONS: Switch set to "ON" STANDARD: 5 V TERMINALS: 11 - 22 CONDITIONS: Opening the throttle gradually STANDARD: Volt= Progressive increase CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit...
Page 247 XEVO 400ie Injection Select the tester menu on the «ERRORS» func- tion. Check whether the control unit has detected any failures relating to the throttle valve position signal. YES go to 6 NO go to 2 Specific tooling 020680Y Diagnosis Tool 2 - Select the diagnostic tester menu on the "PA- RAMETERS"...
Page 248 XEVO 400ie Injection YES go to 8 NO go to 7 7 - Repair or replace the injection wiring. YES go to 6 8 - Check the earth insulation of the three circuit lines. Electric characteristic 22-23 = Ω infinite (>1M) 1-23 = Ω...
Page 249 XEVO 400ie Injection 9 - Repair or replace the injection wiring YES go to 8 10 - Connect the special tool to the control unit. Set the switch to "ON" with switch to "RUN" and side stand raised. Measure voltage between terminals 1 and 22 of the special tool. Specific tooling 020481Y Control unit interface wiring Electric characteristic...
Page 250 XEVO 400ie Injection YES go to 13 NO go to 14 13 - Measure voltage between terminals 11 and 22. Gradually open the throttle valve and check that the voltage value increases progressively. N.B. BY WAY OF AN INDICATION, VOLTAGE MAY VARY FROM APPROX. 700MV AT MINIMUM, AND ABOVE 4V AT MAXIMUM.
Page 251 XEVO 400ie Injection The throttle body after the pre-calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself. The valve position sensor can also assume various fitting positions. For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another.
Page 252 XEVO 400ie Injection Select the "PARAMETERS" function and check that the TPS reset "YES" is displayed. Reset should be performed in the following cases: - on first fitting. - in case of replacement of the throttle body - if the injection control unit is replaced. N.B.
Page 253 XEVO 400ie Injection procedure and adjust the air feeding with cold en- gine. When the engine reaches the working tem- perature, the Stepper partly closes again. To prevent wear of the adjustment piston, opera- tion at full speed is obtained with a minimum open- ing of 43 - 45 "steps".
Page 254 XEVO 400ie Injection YES go to 3 NO go to 4 3 - Start the engine and let it warm up. With a coolant temperature of more than 70°C, the control unit must control the Stepper with about 45 «steps». YES go to 5 NO go to 4 4 - Check the coolant temperature sensor signal.
Page 255 XEVO 400ie Injection Resistance = approx. 51 Ω YES go to 11 NO go to 10 9 - Test successful. No variations of revolutions. Remove the throttle body. Check the auxiliary air circuit cleaning. Switch from "ON" to "OFF" and again to "ON" and check wheth- er the piston valve moves.
Page 256 XEVO 400ie Injection YES go to 12 NO go to 13 12 - Check the earth insulation of the 4 Stepper lines. Electric characteristic 14-23 = >1 MΩ (infinite) 6-23 = >1 MΩ (infinite) 21-23 = >1 MΩ (infinite) 24-23 = >1 MΩ...
Page 257 XEVO 400ie Injection YES go to 16 NO go to 15 15 - Check cable harness and connectors more carefully. 16 - Connect the control unit connector. Set the switch to «ON» with switch to «RUN» and side stand raised. Repeat the «ON» «OFF» «ON» switching.
Page 258 XEVO 400ie Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Connect the multimeter probes between pin 2 (-) and pin 8 (+) With the engine running at idle speed, check that the voltage oscillates between 0V and 1V...
Page 259 XEVO 400ie Injection 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 brake 13. Stop button on rear brake 14.Immobiliser remote control switch 15.
Page 260 XEVO 400ie Injection 48. Instrument panel 50. HV coil 51. Immobilizer aerial 52. Decoder 53. Injection ECU 54. Intake air temperature sensor 55. Fuel pump 56. Diagnosis connector 57. Electric fan remote control 58. Engine rpm sensor 59. Stepper motor 60.
Page 261 XEVO 400ie Injection 2 - Select the menu on the "ACTIVE DIAGNOSIS" function. Activate the electric fan diagnostic func- tion. Check acoustically for rotation of the electric fan. Wait for the exit from the diagnostic tester. YES go to 3 NO go to 4 3 - Test successful.
Page 262 XEVO 400ie Injection 12 - Repair or replace the wiring. 13 - Leaving the remote control switch disconnec- ted, check for continuity between pin 85 of the remote control switch connector and pin 5 of the ECU. 85 (green/white) - 5 = 0Ω (continuity) YES go to 14 NO go to 15 14 - Check the earth insulation.
Page 263 INDEX OF TOPICS SUSP USPENSIONS...
Page 264: Removing The Front Wheel
XEVO 400ie Suspensions Front Removing the front wheel - Remove the fixing nut from the wheel axle on the left side of the vehicle. - Loosen the two screws fixing the wheel axle clamp and remove the clamp. Front wheel hub overhaul Check that the wheel bearings do not show signs of wear.
Page 265 XEVO 400ie Suspensions - Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle, 24 mm adaptor and 15 mm guide) from the brake disc side to permit the removal of the opposite side bearing and the spacer bushing.
Page 266 XEVO 400ie Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 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 spacer with the part fitted with the Seeger ring facing the bearing on the brake disc side.
Page 267 XEVO 400ie Suspensions - Heat the bearing seat on the side the brake disc with the heat gun. 2 - Insert the two bearings one at a time using the punch consisting of adaptor handle, 32x35 mm adaptor and 15 mm guide, and take it to the stop. Specific tooling 020376Y Adaptor handle 020357Y 32x35-mm Adaptor...
Page 268: Front Fork
XEVO 400ie Suspensions - Tighten the two safety screw on the leg to the prescribed torque. Locking torques (N*m) Front wheel axle nut Safety screw on fork 45 - 50 6 ÷ 7 Front fork Removal - Remove the front wheel. - Remove the front mudguard - Remove the front brake calliper - Remove the front and rear handlebar covers.
Page 269 XEVO 400ie Suspensions Overhaul Servicing fork stems - Using an inside 17 mm hexagonal spanner, loos- en the top stem closing cap. - Loosen the stem support clamp and remove fork leg and stem. - Remove the spring. - Drain the oil. - Remove the screw with copper washer shown in the figure.
Page 270 XEVO 400ie Suspensions - Remove the oil guard safety lock using a screw- driver. - Repeatedly actuate the stem to remove it from the fork leg. - Extract the oil guard "D", the abutment washer "C" and the top bushing "B". - Widen and remove the bottom bushing "A".
Page 271 XEVO 400ie Suspensions In case of replacement, proceed as follows: - Using a bearing removal punch, inserted from the bottom, remove the top seat on the steering head. Then, remove the bottom seat of the tapered bear- ing inserting the punch from the top of the head- stock.
Page 272 XEVO 400ie Suspensions - Insert the stem into the casing being careful not to let the guiding bushing come out of the stem. - Move the oil guard in abutment using a tube. TUBE SIZE Specification Desc./Quantity Inside: 44 mm Outside: 51 mm Height:...
Page 273 XEVO 400ie Suspensions - Insert the spring with the thickest turns at the bottom. - Insert the stem into the fork clamp. - Tighten the clamp to screw the top stem closing cap. - Check that the sealing ring on the cap is in good working order, then tighten the cap on the stem to the prescribed torque.
Page 274 XEVO 400ie Suspensions Locking torques (N*m) Holding torque of lower ring nut 20 ÷ 25 - Tighten to the prescribed torque. Locking torques (N*m) Steering lower ring nut 10 - 13 ** - Install the space washer. - Using the special tool, tighten the second locking ring nut on the steering tube to the prescribed torque. Locking torques (N*m) Upper steering ring nut 36 - 39 - Install the handlebars on the steering tube, pay-...
Page 275 XEVO 400ie Suspensions In case of replacement, proceed as follows: - Support the fork in a vice. - Insert the contrast plate 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.
Page 276 XEVO 400ie Suspensions Refitting Reassembly of tapered bearing in steering tube - Insert the a new plate and a new dust guard in the steering tube - Insert the a new tapered bearing in the steering tube - Using the special tool and a mallet to move the dust guard and the bearing in abutment.
Page 277: Removing The Rear Wheel
XEVO 400ie Suspensions Removing the rear wheel Remove the full muffler assembly. - Remove the screw fixing the right-hand shock absorber to 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 to the...
Page 278 XEVO 400ie Suspensions Refitting the rear wheel To fit, follow the removal steps but in the reverse sequence, being careful to fit the spacers on the wheel axle as shown in the picture. Locking torques (N*m) Muffler arm clamping screws Rear wheel 27 ÷...
Page 279: Shock Absorbers
XEVO 400ie Suspensions - Remove the central and the right spacer. - To refit, follow the removal operations but in re- verse order, being careful to observe the original torque and to lubricate the sliding area «A» of the right spacer on the engine bearing. Locking torques (N*m) Engine - chassis fixing pin 100 - 120...
Page 280 XEVO 400ie Suspensions Centre-stand - Use a jack to support the vehicle properly. - Remove the two stand 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. Locking torques (N*m) Centre stand bolt 31 ÷...
Page 281: Side Stand
XEVO 400ie Suspensions Side 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 SUSP - 281...
Page 282 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 283: Rear Brake Calliper
XEVO 400ie Braking system Rear brake calliper Removal - Rest the scooter on its centre stand and ade- quately support the rear part of the scooter. - Remove the wheel. - Unscrew the air filter to the crankcase retainers. - Unscrew the left shock absorber lower retainer. - Release the screws from the safety washers and unscrew the crankcase fixing screws indicated.
Page 284 XEVO 400ie Braking system Refitting - Fit the fixed plate being careful to grease the guide «A» and to insert washer «B» correctly as indicated in the photo. - Hold the pads in the correct position and insert the calliper in the brake disc. - Fix the calliper to the support by means of the two screws to the prescribed torque.
Page 285 XEVO 400ie Braking system Refitting - To reassemble the brake disc on the hub, carry out the removal operations in the reverse order ar- ranging the brake disc on the hub on the side opposed the wheel keying - Follow the direction of rotation shown by the ar- row and tighten to the prescribed torque.
Page 286: Front Brake Disc
XEVO 400ie Braking system - Repeat the measurement at no fewer than six points on the disc. - Check that the measurements do not deviate over 0.1 mm - Remove the front calliper. - Place the magnetic base with the dial gauge on the brake calliper support bracket as shown in the photograph.
Page 287 XEVO 400ie Braking system For fitting, position the disc correctly using the ar- row stamped on it as reference. - Do up the screws to the prescribed torque and apply the recommended product N.B. THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE.
Page 288: Front Brake Pads
XEVO 400ie Braking system Specific tooling 020335Y Magnetic support for dial gauge Front brake pads Removal Proceed as follows: - Remove the front brake calliper. - Loosen the two pins shown in the figure that lock the two pads. - Remove the pads, being careful with the pad spring clamp.
Page 289 XEVO 400ie Braking system - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B. IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT- TING, GENTLY EXPAND THE PADS.
Page 290 XEVO 400ie Braking system See also Front brake calliper Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B.
Page 291 XEVO 400ie Braking system 020329Y Mity-Vac vacuum-operated pump Locking torques (N*m) System bleed calliper fitting: 12 ÷ 16 Nm Front - Remove the rubber hood from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered.
Page 292 XEVO 400ie Braking system - Use the appropriate spyglass on the pump to check the level of the brake fluid, as shown in the photograph - If the level is below the minimum, fill up by acting on the two screws shown in the figure. - Remove the gasket and fill with recommended brake fluid until the spyglass is completely cov- ered.
Page 293 XEVO 400ie Braking system Removal - Remove the front handlebar cover. - Drain off the braking system corresponding to the circuit being tested. - Remove the two fixing screws from the brake pump to the handlebar indicated in the photo- graph.
Page 294 XEVO 400ie Braking system Removal - Remove the front handlebar cover. - Drain off the braking system corresponding to the circuit being tested. - Remove the two fixing screws from the brake pump to the handlebar indicated in the photo- graph.
Page 295 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 296 XEVO 400ie Cooling system Circuit diagram The cooling system is a forced circulation type system, with continuous venting and air pressurisation. Circulation takes places by a centrifugal pump driven by the countershaft. The pump delivers the coolant to the thermal group. The two-way thermostat support is connected in output to the head.
Page 297 XEVO 400ie Cooling system For the system venting during the circuit filling step, there is a special union at the top of the head (see filling rules). To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection system.
Page 298 XEVO 400ie Cooling system - Select the menu on the "ACTIVE DIAGNOSIS" function and start the electric fan operation simu- lation (see "Injection" chapter). - If the electric fan is certainly efficient, check the ventilation start and stop temperatures. - Select the «PARAMETERS» function in this menu to display the coolant temperature.
Page 299: Coolant Replacement
XEVO 400ie Cooling system DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OB- SERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE SEALING GASKETS. Coolant replacement System filling instructions - Prepare the mixture of 50% water and 50% cool- ant.
Page 300 XEVO 400ie Cooling system • Place the vehicle on its centre stand and on flat ground. • Remove the bodywork components as described in the "Bodywork" Chapter. • Remove the muffler to access the flywheel cover as described in the "Removing the Engine from the Vehicle"...
Page 301 XEVO 400ie Cooling system Flywheel cover Thermostat Check Before proceeding to disassemble, carry out a few checks: - Connect the diagnostic tester and select the «PA- RAMETERS» function (see Injection chapter). - Start the cold engine and let it warm up. - Manually check the moment when there is a sud- den increase in temperature at the output of the radiator cold box.
Page 302 XEVO 400ie Cooling system - Let water and thermostat cool down. - Progressively heat the water keeping the thermostat immersed by the wire. - Check the opening temperature when the thermostat is released from the wire. Opening starts temperature approx. 82° C Specific tooling 020331Y Digital multimeter 020151Y Air heater...
Page 303 XEVO 400ie Cooling system 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) COOL SYS - 303...
Page 304 INDEX OF TOPICS CHAS HASSIS...
Page 305 XEVO 400ie Chassis This section is devoted to the operations that can be carried out on the vehicle bodywork. CAUTION WE STRONGLY RECOMMEND NOT TO CLEAN THE PAINTED PLASTIC PARTS WITH SOLVENTS CONTAINING PETROL OR PETROL BY-PRODUCTS. Seat • Raise the saddle •...
Page 306: Instrument Panel
XEVO 400ie Chassis Rear handlebar cover • - Remove the front handlebar cover • Undo the 3 screws fixing the rear han- dlebar cover and remove the cover once the connectors of the controls have been disconnected. See also Front handlebar cover Instrument panel •...
Page 307 XEVO 400ie Chassis • Undo the screw «B», then remove the cover «C» on both sides of the handle- bar. • Undo the two fixing screws at the bot- tom part. • Take out the cover by pulling it up- wards.
Page 308 XEVO 400ie Chassis For the front turn indicators: • Undo the screw «C» and remove the plastic cover. • Undo the screw «D» and remove the turn indicator once the connector has been removed. See also Legshield Flyscreen Frame central cover •...
Page 309 XEVO 400ie Chassis Handles and top side fairings Seat Knee-guard Legshield • Remove the front headlight. • Remove the three upper retainers. • Remove the mats on the footrest. • Remove the ten fixing screws «A» (five per side) on the shield back plate. •...
Page 310 XEVO 400ie Chassis Knee-guard • - Remove the front shield. • Remove the expansion tank from the shield back plate by undoing the two screws «A» and fix it to the small front frame in such a way that it does not turn over.
Page 311 XEVO 400ie Chassis Front wheel housing • - Remove the front shield. • Remove the front fork. • Undo the central screw fixing the wheel house to the frame. • Disconnect the brake pipe to the pump and slide it off. See also Legshield Taillight assy.
Page 312: License Plate Light
XEVO 400ie Chassis - From both sides, undo the screw indicated to re- move the turn indicators. License plate light - Remove the license plate support. - Undo the two screws indicated to get access to the license plate light. Footrest •...
Page 313 XEVO 400ie Chassis See also Central cover Side fairings - Remove the passenger grab 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.
Page 314 XEVO 400ie Chassis - Remove the five screws «D», then slide off the fairing by pulling it backwards to free 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.
Page 315 XEVO 400ie Chassis - Disconnect the license plate light connector and remove the license plate support. See also Helmet bay Air filter - 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.
Page 316 XEVO 400ie Chassis Helmet bay - Remove the side fairings; - Remove the frame central cover; - Remove the saddle opening receiver from its support by undoing the 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.
Page 317 XEVO 400ie Chassis - Undo the 4 screws (2 per side) on the sides of the helmet compartment. - Raise the helmet compartment as much as pos- sible; - Disconnect the electrical connection of the two light buttons; - Remove the glove box flap hook; - Remove the saddle hook;...
Page 318: Front Mudguard
XEVO 400ie Chassis See also Footrest Front mudguard • Remove the four fixing screws «A» (two per side) on the mudguard internal side. CHAS - 318...
Page 319 XEVO 400ie Chassis Top-case Rear - Open the case; - Undo the four screws «A» to remove the case cover; - Undo the eight screws «B» to remove the plastic cover; In order to remove the case support: - Remove the side fairings; - Remove the frame upper pipe;...
Page 320 XEVO 400ie Chassis Handles and top side fairings • Remove the passenger grab handle by undoing the two upper screws «A» and the two lower screws «B» 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.
Page 321 XEVO 400ie Chassis mirrors Analogue instrument panel support • Remove the windshield; • - Remove the front shield. • Undo the two front screws. • Undo the two screws «A» at the side of the handlebar cover and the two screws «B»...
Page 322 INDEX OF TOPICS PRE DE DELIVERY...
Page 323 XEVO 400ie Pre-delivery Carry out the listed tests before delivering the vehicle. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks SAFETY LOCKS Name Torque in Nm...
Page 324 XEVO 400ie Pre-delivery - Saddle electric opening button CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. CAUTION WHEN INSTALLING THE BATTERY, CONNECT THE POSITIVE CABLE BEFORE CONNECTING THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
Page 325 XEVO 400ie Pre-delivery - Restarting when warmed up - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks - Operation of the radiator electric fan Functional inspection Operating test: - Hydraulic brake system - Lever travel - Clutch - Check for correct operation - Engine - Check for correct general operation and make sure there is no unusual noise...
Page 326 INDEX OF TOPICS TIME...
Page 327 XEVO 400ie Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replacement TIME - 327...
Page 328 XEVO 400ie Time Crankcase CRANKCASE Code Action Duration 001100 Oil seal, clutch side - Replacement 001133 Engine crankcase - Replacement 001153 Crankcase half gasket - Replace- ment TIME - 328...
Page 329 XEVO 400ie Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001098 Countershaft - Replacement TIME - 329...
Page 330 XEVO 400ie Time Cylinder assy. CYLINDER ASSEMBLY Code Action Duration 001002 Cylinder / Piston - Replacement 001154 Pistonsrings-pin assembly - Service 001129 Chain tensioner - Service and Re- placement TIME - 330...
Page 331 XEVO 400ie Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001049 Valves - Adjustments 001056 Head gasket - Replacement 001126 Head - Replacement 832541 Water temperature sensor - Re- placement 005116 Rpm timing sensor - Replacement 007012 Coolant bleed valve - Replacement 001057...
Page 332 XEVO 400ie Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Valve rocking levers - Replacement TIME - 332...
Page 333: Cylinder Head Cover
XEVO 400ie Time Cylinder head cover EAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement TIME - 333...
Page 334 XEVO 400ie Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump - Replacement 001123 Oil filter -Replacement 001124 By-pass valve - Replacement 001150 Flywheel cover gasket - change 001160 Minimum oil pressure sensor - Re- placement 001102 Net oil filter - change / Cleaning...
Page 335: Driven Pulley
XEVO 400ie Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement TIME - 335...
Page 336 XEVO 400ie Time Oil pump OIL PUMP Code Action Duration 001042 Oil pump - overhaul 001051 Belt/ Timing chain - Replacement 001112 Oil pump - change 001125 Chain guide pads - Replacement TIME - 336...
Page 337 XEVO 400ie Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001010 Geared reduction unit - Service 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replacement TIME - 337...
Page 338 XEVO 400ie Time Driving pulley PULLEY REAR VIEW Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001006 Driving pulley - Service 001141 Belt anti-flapping roller - Replace- ment 001066 rear-view pulley - Replacement 001177 Variator rollers / shoes - Replace- ment TIME - 338...
Page 339 XEVO 400ie Time Transmission cover TRANSMISSION COVER Code Action Duration 001065 Internal transmission cover - Re- placement 001096 External transmission cover - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement 001170 Air manifold - replacement TIME - 339...
Page 340: Flywheel Magneto
XEVO 400ie Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001173 Rotor - Replacement 001067 Stator - Replacement 001058 Flywheel - Replacement 001104 Start-up freewheel - Replacement TIME - 340...
Page 341 XEVO 400ie Time Butterfly valve THROTTLE BODY Code Action Duration 001013 Intake manifold - Replacement 001047 Injector - Replacement 001166 Throttle body - Replacement 001171 Throttle body - Service/cleaning TIME - 341...
Page 342 XEVO 400ie Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 004169 Muffler guard - Replacement 005138 Lambda probe - Replacement TIME - 342...
Page 343 XEVO 400ie Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Cleaner / Throttle body union - Re- placement 001027 Body / air cleaner union - Replace- ment TIME - 343...
Page 344 XEVO 400ie Time Frame CHASSIS Code Action Duration 004001 Frame - Replacement 004146 Front frame - Replacement 004147 footboard support bracket one side - Replacement 004148 Footrest support bracket, both sides - Replacement 004116 Rear frame - Replacement TIME - 344...
Page 345 XEVO 400ie Time Centre-stand SIDE/CENTRAL STAND Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Side stand switch - Replacement TIME - 345...
Page 346 XEVO 400ie Time Legshield spoiler RONT SHIELD Code Action Duration 004020 Headlight frame - Replacement 004064 Legshield - Replacement TIME - 346...
Page 347 XEVO 400ie Time Rear cover SHIELD BACK PLATE Code Action Duration 004065 Shield back plate - Replacement 004156 Glove box flap and/or support - Re- placement 004145 Glove box - Replacement 007024 Expansion tank cap - Replacement TIME - 347...
Page 348 XEVO 400ie Time Central cover CENTRAL COVER Code Action Duration 004135 Fuel tank lid - Replacement 004011 Frame central cover - Replacement 004075 Front mat - Replacement 004059 Spark plug inspection flap - Replace- ment 004015 Footrest - Replacement TIME - 348...
Page 349 XEVO 400ie Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - change 004167 Grille / radiator cover - Replacement TIME - 349...
Page 350 XEVO 400ie Time Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - change TIME - 350...
Page 351 XEVO 400ie Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar covers - Replace- ment 004099 Odometer housing - Replacement 004026 Handlebar cover - Replacement 003043 Steering tube dust guard - Replace- ment TIME - 351...
Page 352 XEVO 400ie Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002063 Complete throttle transmission - Re- placement 003061 Accelerator transmission - Adjust- ment 003059 Counterweight - Replacement 004162 Mirror support and/or brake pump fit- ting U-bolt - Replacement 002024 Front brake pump - Replacement 002067...
Page 353 XEVO 400ie Time Swing-arm SWINGING ARM Code Action Duration 003081 Swinging arm support flange - Re- placement 004058 Silent block - Replacement 001072 Engine/frame swinging arm attach- ment - Replacement TIME - 353...
Page 354 XEVO 400ie Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004068 Passenger handgrip - Replacement TIME - 354...
Page 355: Turn Signal Lights
XEVO 400ie Time Locks LOCKS + LOCK TRANSMISSIONS Code Action Duration 004010 Anti-theft lock - Replacement 005146 Electric saddle opening activator - Replacement 005133 Electric glove box activator - Re- placement 004054 Saddle lock catch - Replacement 004173 Trunk opening splitter - Replacement 004158 Saddle opening splitter - Replace- ment...
Page 356 XEVO 400ie Time REAR LIGHTS Code Action Duration 005005 Taillight - change 005048 number plate holder - Replacement 005031 number plate light bulb - Replace- ment 005032 number plate light glass - Replace- ment 005022 Rear turning indicators - Replace- ment 005066 Rear light bulbs - Replacement...
Page 357 XEVO 400ie Time TURN INDICATOR LIGHTS Code Action Duration 005002 Front light - replacement 005008 Headlight bulbs - Replacement 005044 Front lights cable unit- Replacement 005012 Front turning indicators - Replace- ment 005067 Front turning indicator bulb - replace- ment 005091 Turn indicator glass - Replacement TIME - 357...
Page 358 XEVO 400ie Time Front wheel FRONT WHEEL Code Action Duration 002041 Front brake disc - Replacement 003037 Front wheel rim - Replacement 003038 Front wheel axle - Replacement 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement 003063 Tyre pressure - Check 004123 Front wheel - Replacement...
Page 359 XEVO 400ie Time Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001071 Rear wheel rim - Replacement 002070 Rear brake disc - Replacement 003063 Tyre pressure - Check 004126 Rear wheel tyre - Replacement 002028 Rear wheel hub - Replacement TIME - 359...
Page 360 XEVO 400ie Time Electric start START-UP Code Action Duration 001017 Start-up pinion - Replacement 001020 Starter motor - Replacement 001151 Starter driven gearing - Replacement TIME - 360...
Page 361: Fuel Pump
XEVO 400ie Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Pump/ injector pipe - Replacement 004138 Fuel reverse pipe - Replacement TIME - 361...
Page 362: Voltage Regulator
XEVO 400ie Time Electric devices VOLTAGE REGULATOR Code Action Duration 001023 Injection ECU - Replacement 005009 Voltage regulator - Replacement 001094 Spark plug cap - Replacement 001069 HV coil - Replacement 001093 Spark plug - Replacement 005099 Electric saddle opening device - Re- placement TIME - 362...
Page 363 XEVO 400ie Time WIRE UNIT Code Action Duration 005030 Rear headlight cable unit- Replace- ment 005044 Front lights cable unit - replace 005001 Electrical system - Replacement 005114 Electrical system - Service 002051 Odometer transmission assembly - Replacement TIME - 363...
Page 364 XEVO 400ie Time BATTERY-REMOTE CONTROL SWITCHES -HORN Code Action Duration 005007 Battery - change 005096 Remote control for injection compo- nents - Replacement 005117 Electric fan remote control - Replace- ment 005118 Arrows remote control - Replace- ment 005011 Start-up remote control switch - Re- placement 005088 Emergency stop remote control - Re-...
Page 365 XEVO 400ie Time Electronic controls LECTRIC CONTROLS Code Action Duration 005006 Light or turning indicator switch - Re- placement 005039 Lights switch - Replacement 005040 Horn button - Replacement 005132 Trunk opening button - Replacement 005041 Starter button - Replacement 005077 Emergency stop switch - Replace- ment...
Page 366 XEVO 400ie Time Transmissions RANSMISSIONS Code Action Duration 002082 Fuel tank door opening drive - Re- placement 002092 Transmission splitter/ hook transmis- sion - Replacement 002093 Top box opening transmission - Re- placement 002094 Trunk splitter/ hook transmission - Replacement TIME - 366...
Page 367 XEVO 400ie Time Helmet bay ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 005033 Glove-box light switch - Replace- ment 005026 Helmet compartment light - Replace- ment 005027 Helmet compartment bulb support - Replacement TIME - 367...
Page 368 XEVO 400ie Time Rear side fairings EAR COVERS Code Action Duration 005048 number plate holder - Replacement 005033 Glove-box light switch - Replace- ment 004081 Top box lid - Replacement 004174 Trunk levers - Replacement 004080 Trunk flap support - Replacement 004082 Top box gasket - Replacement 004036...
Page 369: Front Suspension
XEVO 400ie Time Front suspension RONT SUSPENSION Code Action Duration 003051 Complete fork - Replacement 003010 Front suspension - Service 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003002 Steering fifth wheels - Replacement TIME - 369...
Page 370: Rear Suspension
XEVO 400ie Time Rear suspension REAR SUSPENSION Code Action Duration 003085 Suspension strut - Replacement 003007 Rear shock absorber - Replacement 003077 muffler/rear shock absorber support arm - Service TIME - 370...
Page 371 XEVO 400ie Time Cooling system OOLING SYSTEM Code Action Duration 007002 Water radiator - replacement 007016 Fan with support - Replacement 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007019 Connection water pump pipe / return pipe - Replacement 007013 Radiator expansion tank connection pipe - change...
Page 372: Brake System
XEVO 400ie Time Braking system BRAKE SYSTEM Code Action Duration 002047 Front brake fluid and air bleeding system - Replacement 002020 Rear brake disc piping - Replace- ment 002081 Rear brake disc piping - Replace- ment 002080 Rear brake oil bleed system - Change 002039 Front brake calliper - Replacement...
Page 373 XEVO 400ie Time Windscreen WINDSHIELD Code Action Duration 004101 Windshield - Replacement 004066 Driving mirror - Replacement TIME - 373...
Page 374 XEVO 400ie Time Stickers TRANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 374...
Page 375 Air filter: 21, 315 Battery: 44, 53, 58, 60, 61, 65 Brake: 283, 284, 286, 288–293 Brake fluid: 291 Coolant: 233, 299 Engine oil: 22 Fuel: 189, 197, 201, 317, 350, 361 Fuses: 56 Headlight: 29, 307 Hub oil: 20 Identification: 7 Immobilizer: Instrument panel: 306, 310, 321...
Page 376 Tank: 317, 350 Technical Data: Transmission: 9, 32, 73, 88, 339 Turn indicators: 48 Tyres: 9...

PIAGGIO 2005 XEVO 400ie Workshop Manual

Quick Links

Troubleshooting

Need help?

Questions and answers

Related Manuals for PIAGGIO 2005 XEVO 400ie

Summary of Contents for PIAGGIO 2005 XEVO 400ie

Table of Contents