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2005 XEVO 400ie
PIAGGIO 2005 XEVO 400ie Manuals
Manuals and User Guides for PIAGGIO 2005 XEVO 400ie. We have
1
PIAGGIO 2005 XEVO 400ie manual available for free PDF download: Workshop Manual
PIAGGIO 2005 XEVO 400ie Workshop Manual (377 pages)
Brand:
PIAGGIO
| Category:
Scooter
| Size: 11 MB
Table of Contents
Index of Topics
5
Characteristics
7
Maintenance Rules
7
Vehicle Identification
7
Dimensions and Mass
8
Weights and Dimensions
8
Transmission Data
9
Capacities
9
Electrical System Data
9
Frame and Suspensions/Brakes/Wheels and Tyres Data
9
Assembly Clearances
10
Cylinder - Piston Assy.
10
Piston Rings
11
Rings/Housing Coupling Clearances
11
Crankcase - Crankshaft - Connecting Rod
12
Crankcase / Countershaft Coupling
13
Slot Packing System
14
Recommended Products
15
Maintenance
16
Maintenance Chart
17
Every 2 Years
17
Spark Plug
19
Hub Oil Check
20
Hub Oil Replacement
20
Air Filter
21
Engine Oil
22
Engine Oil Replacement
23
Engine Oil Check
24
Engine Oil Filter
25
Oil Pressure Warning Light
25
Checking the Ignition Timing
26
Checking the Valve Clearance
26
Cooling System
27
Adding Engine Coolant
27
Brake Fluid Level Check
28
Brake Fluid Top-Up
28
Headlight Adjustment
29
Checking the End Compression Pressure
29
Index of Topics
31
Troubleshooting
32
Excessive Oil Consumption/Exhaust Smoke
32
Insufficient Lubrication Pressure
32
Clutch Grabbing or Performing Inadequately
32
Brakes Overheating
33
Excessive Steering Play
33
Noisy Suspension
33
Heavy Steering
33
Suspension Oil Leakage
34
Electrical System
36
Electrical System Components Arrangement
38
Ignition Conceptual Diagram
43
Battery Recharge and Starting Conceptual Diagram
44
Level Indicators and Enable Signals Section Conceptual Diagram
45
Devices and Accessories Conceptual Diagram
46
Lights and Turn Indicators Conceptual Diagram
48
Immobiliser Inspection
49
Checks and Inspections
49
Virgin Circuit Inspection
50
Diagnostic Codes
51
Diagnostic Code - 1 Flash
52
Diagnostic Code - 2 Flashes
52
Battery Recharge Circuit
53
Stator Check
53
Diagnostic Code - 3 Flashes
53
Recharge System Voltage Check
54
Voltage Regulator/Rectifier
54
Turn Signals System Check
55
Lights List
55
Fuses
56
Dashboard
58
Sealed Battery
58
Dry-Charge Battery
60
Battery Installation
61
Connectors
62
Ecu
62
Seat Opening Receiver
63
Immobiliser Decoder
63
Remote Seat Opening
65
Battery Replacement
65
Zeroing
66
Programming
66
Index of Topics
67
Engine from Vehicle
68
Exhaust Assy. Removal
68
Removal of the Engine from the Vehicle
69
Installing the Engine on the Scooter
70
Engine
73
Automatic Transmission
73
Transmission Cover
73
Air Duct
74
Air Duct Filter
75
Removing the Driven Pulley Shaft Bearing
75
Refitting the Driven Pulley Shaft Bearing
76
Baffle Roller
76
Plastic Roller
76
Inspecting the Clutch Drum
77
Removing the Driven Pulley
77
Removing the Clutch
78
Inspecting the Clutch
78
Pin Retaining Collar
79
Removing the Driven Half-Pulley Bearing
79
Inspecting the Driven Fixed Half-Pulley
80
Inspecting the Driven Sliding Half-Pulley
81
Refitting the Driven Half-Pulley Bearing
81
Refitting the Driven Pulley
82
Inspecting the Clutch Spring
82
Refitting the Clutch
83
Drive-Belt
84
Removing the Driving Pulley
84
Inspecting the Rollers Case
85
Refitting the Driving Pulley
86
Refitting the Transmission Cover
88
End Gear
90
Removing the Hub Cover
90
Removing the Wheel Axle
90
Removing the Hub Bearings
91
Removing the Wheel Axle Bearings
91
Inspecting the Hub Shaft
93
Refitting the Hub Cover Bearings
95
Refitting the Hub Bearings
97
Refitting the Hub Cover
97
Flywheel Cover
98
Removing the Flywheel Cover Components
99
Removing the Stator
100
Inspecting the Cover Components
100
Refitting the Stator
102
Refitting the Flywheel Cover Components
103
Refitting the Flywheel Cover
105
Flywheel and Starting
107
Removing the Starter Motor
107
Removing the Flywheel Magneto
107
Inspecting the Flywheel Components
111
Starter Gear Rim
111
Intermediate Gear
112
Refitting the Free Wheel
112
Refitting the Intermediate Gear
113
Refitting the Flywheel Magneto
114
Refitting the Starter Motor
116
Cylinder Assy. and Timing System
116
Removing the Intake Manifold
116
Removing the Rocker-Arms Cover
117
Removing the Timing System Drive
117
Removing the Cam Shaft
119
Removing the Cylinder Head
119
Removing the Valves
121
Removing the Cylinder - Piston Assy.
122
Inspecting the Small End
123
Inspecting the Wrist Pin
123
Inspecting the Piston
123
Inspecting the Piston Rings
125
Removing the Piston
126
Choosing the Gasket
127
Refitting the Piston Rings
128
Refitting the Cylinder
129
Inspecting the Cylinder Head
129
Inspecting the Timing System Components
129
Inspecting the Valve Sealings
130
Inspecting the Valve Housings
131
Inspecting the Valves
131
Inspecting the Valve Stem Guide Clearance
132
Inspecting the Springs and Half-Cones
133
Refitting the Valves
134
Inspecting the Cam Shaft
134
Refitting the Head and Timing System Components
136
Refitting the Timing Chain
143
Refitting the Rocker-Arms Cover
144
Refitting the Intake Manifold
145
Crankcase - Crankshaft
145
Splitting the Crankcase Halves
146
Removing the Crankshaft
147
Removing the Countershaft
148
Replacing the Countershaft Bearings
149
Inspecting the Crankshaft Components
151
Inspecting the Crankshaft Alignment
152
Inspecting the Crankcase Halves
153
Inspecting the Crankshaft Plain Bearings
154
Coupling Chart
155
Countershaft
157
Refitting the Crankshaft
157
Refitting the Crankcase Halves
159
Lubrication
160
Technical Specifications
160
Recommended Engine Oil
160
Oil Pump
160
Conceptual Diagrams
161
Lubrication System General Characteristics
162
Diagnosis Guide (Lubrication)
163
Standard Values
164
Oil Pressure Check
165
Oil Pump Removal
166
Oil Pump Refitting
168
Index of Topics
170
EMS Injection System
171
Injection - Precautions
173
Terminals Setup
174
EMS Circuit Diagram
175
Injection System Troubleshooting
176
Engine Does Not Start
176
Troubleshooting Procedure
176
Starting Difficulties
177
Engine Stops at Idle
177
Engine Does Not Rev down
178
Exhaust Backfires in Deceleration
178
Engine Revs Irregularly
178
Poor Performance at Full Throttle
179
Engine Knocking
179
Decoder Master-Box Circuit - Constant Supply Circuit Check
180
Key-Switch Power Supply Circuit Check
181
Diagnostic Circuit
184
Injection Warning Light Circuit
185
Self-Diagnosis System
187
Fuel Supply System
189
Circuit Diagram (Injection)
190
Removing the Injector
191
Refitting the Injector
192
Removing the Butterfly Valve
192
Refitting the Butterfly Valve
194
Pump Supply Circuit
194
Circuit Check
194
Circuit Leak Test
195
Pressure Regulator Check
196
Fuel Pump and Filter Check
197
Pump Electrics Check
200
Resistor Check
200
Pump Consumption Check
201
Fuel Filter Check
201
Pump Bracket Overhaul
202
Limit Values
203
Pump Bracket Installation
206
Inspecting the Injector Circuit
207
Inspecting the Injector Hydraulics
211
EMS System Troubleshooting
212
Immobiliser Circuit
213
System Components
213
Virgin Circuit
214
Setting the Circuit
214
LED Signals
216
Checking Master-Box Data
217
Resetting the Circuit
217
Diagnostic Codes (Injection)
218
Tachometer
220
Circuit Layout
220
HT Coil
225
Ignition System Circuit Diagram
225
Inspecting the Spark Plug Shielded Cap
231
Spark Advance
231
Coolant Temperature Sensor
233
Intake Air Temperature Sensor
238
Temperature Resistance
241
Pressure Sensor
245
Throttle Valve Opening Sensor
246
Zeroing the Throttle
250
Step Motor
252
Lambda Probe
257
Signal Control
257
Electric Fan System
258
Index of Topics
263
Suspensions
264
Removing the Front Wheel
264
Front Wheel Hub Overhaul
264
Refitting the Front Wheel
267
Front Fork Removal
268
Front Fork Overhaul
269
Front Fork Refitting
271
Steering Bearing Removal
274
Steering Bearing Refitting
276
Removing the Rear Wheel
277
Refitting the Rear Wheel
278
Swing-Arm
278
Shock Absorbers Removal
279
Centre-Stand
280
Side Stand
281
Index of Topics
282
Braking System
282
Braking System
283
Rear Brake Caliper Removal
283
Rear Brake Caliper Refitting
283
Front Brake Calliper Removal
283
Front Brake Calliper Refitting
284
Rear Brake Disc Removal
284
Rear Brake Disc Refitting
285
Rear Brake Disc Inspection
285
Front Brake Disc Removal and Refitting
286
Front Brake Disc Inspection
287
Front Brake Pads Removal and Refitting
288
Rear Brake Pads Removal
289
Rear Brake Pads Refitting
290
Fill - Rear, Combined
290
Fill - Front
291
Brake Fluid Level Check
291
Front Brake Pump Removal and Refitting
293
Front Brake Pump (Combined) Removal and Refitting
294
Index of Topics
295
Cooling System
295
Cooling System Circuit Diagram
296
Electric Fan Check
297
Cooling System Sealing Check
298
Water Pump
299
Coolant Replacement
299
Thermostat Check
301
Cooling System Diagnosis
302
Excessive System Pressure (Cooling System)
302
Cooling Fluid Consumption
302
Oil in the Cooling Fluid
303
Chassis
305
Seat
305
Side Fairings
305
Driving Mirrors
305
Rear Handlebar Cover
306
Instrument Panel
306
Front Handlebar Cover
306
Headlight Assy.
307
Frame Central Cover
308
Legshield
309
Knee-Guard
310
Front Wheel Housing
311
Taillight Assy.
311
License Plate Light
312
Footrest
312
License Plate Holder
314
Air Filter
315
Helmet Bay
316
Fuel Tank
317
Front Mudguard
318
Top-Case
319
Handles and Top Side Fairings
320
Flyscreen
320
Analogue Instrument Panel Support
321
Pre-Delivery
323
Aesthetic Inspection
323
Tightening Torques Inspection
323
Electrical System Checks
323
Safety Locks
323
Levels Check
324
Road Test
324
Static Test
324
Functional Inspection
325
Time
327
Engine View
327
Crankcase View
328
Crankshaft View
329
Cylinder Assy. View
330
Cylinder Assembly
330
Cylinder Head Assy. View
331
Rocker Arms Support Assy. View
332
Cylinder Head Cover View
333
Flywheel Cover View
334
Driven Pulley View
335
Oil Pump View
336
Final Gear Assy. View
337
Driving Pulley View
338
Transmission Cover View
339
Flywheel Magneto View
340
Butterfly Valve View
341
Throttle Body
341
Exhaust Pipe View
342
Air Cleaner View
343
Frame View
344
Centre-Stand View
345
Legshield Spoiler View
346
Rear Cover View
347
Central Cover View
348
Mudguard View
349
Fuel Tank View
350
Handlebar Covers View
351
Handlebar Components View
352
Swing-Arm View
353
Swinging Arm
353
Seat View
354
Locks View
355
Turn Signal Lights
355
Turn Signal Lights View
356
Rear Lights
356
Turn Indicator Lights View
357
Front Wheel View
358
Rear Wheel View
359
Electric Start View
360
Fuel Pump View
361
Electric Devices View
362
Voltage Regulator View
362
Wire Unit View
363
Battery - Remote Control Switches - Horn View
364
Electronic Controls View
365
Transmissions View
366
Helmet Bay View
367
Rear Side Fairings
368
Front Suspension View
369
Rear Suspension View
370
Cooling System View
371
Braking System View
372
Brake System
372
Windscreen View
373
Stickers View
374
Index
375
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