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PIAGGIO 633929(IT) Service Station Manual Download Page 64

C. High-beam bulb

34.

 Front right turn indicator

35.

 Horn button

36

. Remote control headlight

37.

 Light switch

38.

 Helmet compartment light switch

39.

 Helmet compartment light switch

40.

 Instrument panel coolant temperature sensor

41.

 Mode button

42.

 Locking/unlocking switch

43.

 Horn remote control

44.

 Pressure sensor

45

. Horn

46.

 Geared motor

47.

 Brake calliper sensor

48.

 Parking electronic control unit

49.

 Right wheel revolution sensor

50.

 Left wheel revolution sensor

51.

 Potentiometer

52.

 Rider presence sensor

53.

 Oil pressure sensor

54.

 External temperature sensor

55.

 Parking brake button

56.

 Instrument panel

57.

 Fuel level transmitter

58.

 Electric pump control device (for scooters with electric pump only)

1. +Key

3. Pump ground connection

4. +Pump

5. Ground

6. Engine revs

59.

 Fuel pump (for scooters with electric pump only)

60.

 Starter

61

. Spark plug

62.

 HV coil

KEY

Electrical system

MP3 125

ELE SYS - 4

Summary of Contents for 633929(IT)

Page 1: ...SERVICE STATION MANUAL 633929 IT 633930 EN 633931 FR 633932 ES 633937 ES 633938 PT 633941 NL 633942 EL MP3 125...

Page 2: ...components parts or accessory supplies which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication ar...

Page 3: ...o read the sections of this manual relating to special tools along with the special tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers...

Page 4: ......

Page 5: ...CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS...

Page 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR...

Page 8: ...compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules U...

Page 9: ...ZAPM300 Engine prefix M473M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Dry weight FULL OPTIONAL 210 5 kg Dry weight BASE 199 5 kg Wheelbase 1490 mm Height 1245 mm Width ha...

Page 10: ...discharge 0 15 mm Engine idle speed 1 650 100 rpm Max speed 100 km h Transmission TRANSMISSION Specification Desc Quantity Transmission With automatic expandable pulley variator with tor que server V...

Page 11: ...ebar right hand lever Rear brake 240 mm disc brake with hydraulic control acti vated by the handlebar left side lever Wheels and tyres WHEELS AND TYRES Specification Desc Quantity Front wheel Alloy ri...

Page 12: ...Screws fixing the half arm coupling flange 20 25 Fixing screws for tilt locking disc section 20 25 Side headstock upper ring nut 20 24 Side headstock lower ring nut 12 15 Screw fixing sliding stem to...

Page 13: ...hreadlock Apply LOCTITE 243 medium strength threadlock MUFFLER Name Torque in Nm Muffler heat guard fixing screw 4 5 Screw for fixing muffler to the support arm 20 25 Lambda probe clamp on exhaust man...

Page 14: ...pulley nut 75 83 Clutch unit nut on driven pulley 55 60 Belt support roller screw 11 13 ENGINE FLYWHEEL Name Torque in Nm Pick Up clamping screws 3 4 Stator assembly screws 3 4 Flywheel cover fixing s...

Page 15: ...1 57 218 57 159 57 166 0 045 0 059 Piston 1st Over size D 1 57 218 57 225 57 166 57 173 0 045 0 059 Cylinder 2nd Over size A2 57 397 57 404 57 345 57 352 0 045 0 059 Cylinder 2nd Over size B 2 57 404...

Page 16: ...axial clearance CRANKSHAFT CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half shaft trans mission side 16 6 0 0 05 A D 0 20 0 50 Flywheel side half shaft 16 6 0 0 05 B D 0 20...

Page 17: ...NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH THE PISTON AT TOP DEAD CE...

Page 18: ...CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND ON A RECTIFIED PLANE MODELS WITH METALLIC HEAD GA...

Page 19: ...dditives for increased adhesiveness AGIP GP 330 Calcium complex soap based grease with NLGI 2 ISO L XBCIB2 Grease brake control levers throttle grip AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACE...

Page 20: ...Characteristics MP3 125 CHAR 14...

Page 21: ...INDEX OF TOPICS TOOLING TOOL...

Page 22: ...ts 001467Y014 Pliers to extract 15 mm bear ings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels f...

Page 23: ...20074Y Support base for checking crank shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitti...

Page 24: ...ription 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light for timing con trol 020331Y Digital multimeter 020332Y Digital rev counter Tooling...

Page 25: ...cription 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47 mm adaptor 020360Y Adaptor 52 x 55 mm MP3 125...

Page 26: ...ode Description 020363Y 20 mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Tooling MP3 12...

Page 27: ...res code Description 020393Y Piston fitting band 020412Y 15 mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork MP3 125 Tooling TOO...

Page 28: ...ion 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting removing the driv en pulley clutch 020456Y 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide To...

Page 29: ...r support stud bolt set 020428Y Piston position check support 020621Y HV cable extraction adaptor 001467Y035 Belle for OD 47 mm bearings 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract...

Page 30: ...7Y Flywheel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops 200 250 020622Y Transmission side oil guard punch 020480Y Petrol pressure check set 020244Y 15 mm diameter...

Page 31: ...ion 020115Y 18 punch 020271Y Tool for removing fitting silent bloc 001467Y017 Driver for OD 36 mm bearings 020234y extractor 020441Y 26 x 28 mm adaptor 020362Y 12 mm guide 020358Y 37x40 mm adaptor MP3...

Page 32: ...02 Driver for OD 73 mm bearing 020641Y EFI Technology software up grade 020469Y Reprogramming kit for scooter diagnosis tester 020639Y Tilt locking control unit software 020481Y Control unit interface...

Page 33: ...Stores code Description 020481Y004 Parking control unit interface wir ing 020460Y Scooter diagnosis and tester MP3 125 Tooling TOOL 13...

Page 34: ...Tooling MP3 125 TOOL 14...

Page 35: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 36: ...ayed Maintenance chart EVERY 2 YEARS 75 Action Coolant change Brake fluid change secondary air filter cleaning EVERY 3 000 KM 10 Action Engine oil level check top up AFTER 1 000 KM 90 Action Engine oi...

Page 37: ...g electrode gap check replacement Air filter clean Engine oil change Idle speed adjustment Sliding block variable speed rollers change Throttle lever adjustment Coolant level check Steering adjustment...

Page 38: ...ge Throttle lever adjustment Coolant level check Steering adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid level check Tilt locking gripper control cable adjust...

Page 39: ...and wear Brake fluid hoses replacement Brake fluid level check Tilt locking gripper control cable adjustment Transmission elements lubrication Safety locks check Suspensions check Electrical system a...

Page 40: ...arance due to wear If there are wear marks in the chamber causing inadequate tightness or a free valve slide even if it is new replace the carburettor It is advisable to replace the gaskets at every r...

Page 41: ...iper on the spark gap cable respecting the proper polarity the arrow on the calliper must be pointing at the spark plug Connect the diagnostic tester Start the engine Select the parameter function in...

Page 42: ...ith a thickness gauge and if necessary adjust the gap by carefully bend ing the outer electrode forward or away Make sure the sealing washer is in good condi tion Fit the spark plug screw it manually...

Page 43: ...stick back in checking that it is locked in place N B THE REFERENCE MARKS ON THE HUB OIL LEVEL DIPSTICK EXCEPT FOR THE ONE IN DICATING THE MAX LEVEL REFER TO OTH ER MODELS BY THE MANUFACTURER AND HAVE...

Page 44: ...w the dipstick back into place completely Recommended products AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Locking torques N m Hub oil drainag...

Page 45: ...ainage cap B of the gauze filter on the flywheel side In order to facilitate the oil drain age loosen the cap dipstick Since a certain quan tity of oil remains in the circuit still the top up should b...

Page 46: ...ne oil SAE 5W 40 API SL ACEA A3 JASO MA Syn thetic oil Check Every time the scooter is used a visual check should be made on the level of the engine oil when the engine is cold The oil level should be...

Page 47: ...ywheel cover To use this reference mark remove the spark plug and turn the engine in the opposite direction to the normal direction using a calliper spanner applied to the camshaft command pulley casi...

Page 48: ...he centre of the vehicle headlight 4 Otherwise adjust the headlight with the screws A indicated in the figure N B THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM...

Page 49: ...heel connector to the relative supplements Secure the rotor cover by using a new gasket with the 4 screws Connect the flywheel connector and the valve con trol vacuum operated pipe Fit the coupling to...

Page 50: ...Maintenance MP3 125 MAIN 16...

Page 51: ...s clamps and remove the primary filtering element Wash with water and neutral soap Dry with a clean cloth and short blasts of com pressed air Check that the filter casing is clean paying special atten...

Page 52: ...Maintenance MP3 125 MAIN 18...

Page 53: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 54: ...l level exceeds maximum Check for causes and fill to reach the correct level Lack of compression parts cylinder and valves worn Replace the worn parts Transmission belt worn Replace Inefficient automa...

Page 55: ...ith com pressed air or replace Flat battery Check the charge of the battery if there are any sulphur marks replace and use the new battery following the instructions shown in the chapter Intake coupli...

Page 56: ...the following parts work properly valve diaphragm spring and that the air calibra tion elements are clean check if the sponge filter is clean too Incorrect idle adjustment Adjust using the rpm indica...

Page 57: ...t squeezing allow to drip dry and then reassemble SAS malfunctions ANOMALIES IN THE SECONDARY AIR DEVICE Possible Cause Operation Secondary air device cut off valve not working Replace the secondary a...

Page 58: ...el mounted on the vehicle to measure the axial shift of the disc Defective piston sliding Check calliper and replace any damaged part Electrical system Battery BATTERY Possible Cause Operation Battery...

Page 59: ...or if the balls are squashed replace them Steering hardening Check the tightening of the top and bottom ring nuts If irregularities continue in turning the steer ing even after making the above adjust...

Page 60: ...Troubleshooting MP3 125 TROUBL 8...

Page 61: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 62: ...sor 6 Diagnostics socket 7 Engine stop switch 8 Voltage regulator 9 Main fuses 10 Battery 11 Starter motor 12 Start up remote control switch 13 Starter button 14 Secondary fuses 15 Stop button on rear...

Page 63: ...switch 3 Right switch 4 Left turn indicator 5 Right turn indicator 6 Ground 7 Key 8 Battery 27 Wiring for antitheft device 28 Helmet compartment internal light 29 Rear left turn indicator A Left turn...

Page 64: ...e calliper sensor 48 Parking electronic control unit 49 Right wheel revolution sensor 50 Left wheel revolution sensor 51 Potentiometer 52 Rider presence sensor 53 Oil pressure sensor 54 External tempe...

Page 65: ...low Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Conceptual diagrams Ignition KEY 1 Electronic ignition device 2 Immobilizer aerial 9 Main fuses 10 Battery 18 Key switch 61 Spark plug 6...

Page 66: ...egulator 9 Main fuses 10 Battery 11 Starter motor 12 Start up remote control switch 13 Starter button 14 Secondary fuses 15 Stop button on rear brake 16 Stop button on front brake 18 Key switch 29 Rea...

Page 67: ...section KEY 1 Electronic ignition device 2 Immobilizer aerial 3 Throttle body position 5 CDI Temperature sensor 7 Engine stop switch 9 Main fuses 10 Battery 14 Secondary fuses 18 Key switch 40 Instru...

Page 68: ...re sensor 54 External temperature sensor 56 Instrument panel 57 Fuel level transmitter Devices and accessories KEY 1 Electronic ignition device 6 Diagnostics socket 7 Engine stop switch 9 Main fuses 1...

Page 69: ...elmet compartment light switch 39 Helmet compartment light switch 41 Mode button 42 Locking unlocking switch 43 Horn remote control 44 Pressure sensor 45 Horn 46 Geared motor 48 Parking electronic con...

Page 70: ...dary fuses 18 Key switch 20 Turn signal switch 24 Hazard button 26 Hazard and turn signal control device 1 Hazard button 2 Left switch 3 Right switch 4 Left turn indicator 5 Right turn indicator 6 Gro...

Page 71: ...ections This section is devoted to the checks on the electrical system components Immobiliser The electric ignition system is fed with direct cur rent and is protected by an anti theft immobilizer int...

Page 72: ...o this disconnect the control unit connector and check if there is battery voltage between the terminal No 6 Red Green and the ground connection there is battery voltage between the terminal No 6 Red...

Page 73: ...will be necessary to repeat the procedure from the start Once the control unit has been programmed the control unit is inseparably matched with the MAS TER key transponder This matching allows progra...

Page 74: ...eplace the aerial If no failures are found in the aerial replace the control unit CAUTION BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED THIS IS NECESSARY T...

Page 75: ...le har ness and the connections In case conforming values are measured and the wiring and connections check is OK try replacing the control unit without programming and make sure the failure has been...

Page 76: ...9 see figure Use the start up system to run the engine and measure the voltage produced by the Pick Up Replace Pick Up if non conforming values are measured Electric characteristic Pick Up voltage va...

Page 77: ...rge power and at low revs a good compromise is achieved between generated power and idle stability Stator check Disconnect the connector from the voltage regulator and check there is continuity betwee...

Page 78: ...en connection 2 and ground In case of values different from the ones stated replace the defective parts N B VALUES ARE STATED AT AMBIENT TEMPER ATURE A CHECK WITH THE STATOR AT OP ERATING TEMPERATURE...

Page 79: ...supply keep the connector connec ted to the system and check that the two terminals receive battery voltage when the engine is on see figure If voltage is detected replace the automatic starter as it...

Page 80: ...ty 1 3 Helmet compartment light bulb Type CYLINDRIC Power 12V 5W Quantity 1 4 Rear turn indicator bulb Type ALL GLASS Power 12V 5W Quantity 2 RHS 2 LHS 5 Rear tail light bulb Type ALL GLASS Power 12V...

Page 81: ...antity 1 Fuse No 1 Capacity 10A Protected circuits from the battery headlight remote control Location battery compartment 2 Fuse No 2 Capacity 7 5 A Protected circuits from the battery saddle opening...

Page 82: ...h instrument panel horn remote control Location footrest 10 Fuse No 10 Capacity 7 5 A Protected circuits headlight remote control Location footrest 11 Fuse No 11 Capacity 3A Protected circuits electri...

Page 83: ...s for a period longer than 8 seconds ends the process automatically and the display shows the modified time Sealed battery If the vehicle is provided with a sealed battery the only maintenance require...

Page 84: ...HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CON TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF Dry charge battery COMMISSIONING A NEW DRY CHARGED BATTERY Remove the battery air pipe stop cap...

Page 85: ...l cap tightly and install it on the vehicle If the voltage indicated is low charge the battery another 4 6 hours in the way described above Note With the battery charger drw 020334Y it is possible to...

Page 86: ...pho tograph Remove the metal terminal and connect it to a good earth point or to terminal 7 black for at least 10 seconds In this operation all the remote controls stored in the control unit will be...

Page 87: ...ED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMING THE REMOTE CONTROLLED KEYS WARNING AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FAR AWAY FROM THE SCOO...

Page 88: ...Electrical system MP3 125 ELE SYS 28...

Page 89: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 90: ...head To undo the nuts fixing the muffler flange to the head properly you must use a jointed wrench that enables you to get at the right nut as well ac cording to the direction of travel that is diffi...

Page 91: ...fler assembly CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the rear wheel Remove the pipe feeding coolant into the pump as shown in the photograph and then empty the syste...

Page 92: ...ps Remove the coolant temperature sensor con nector indicated in the photo Remove the throttle cable from the throttle body by undoing the nut shown in the photo Remove the positive and negative wirin...

Page 93: ...do ing the nut and the head of the pin as shown in the photograph The engine is now free When refitting the engine onto the scooter carry out the removal operations but in reverse order and respect th...

Page 94: ...PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY Engine from vehicle MP3 125 ENG VE 6...

Page 95: ...INDEX OF TOPICS ENGINE ENG...

Page 96: ...h bell lock wrench shown in the figure remove the driven pulley shaft locking nut and washer Specific tooling 020423Y driven pulley lock wrench Remove the cap dipstick from the engine oil filling hole...

Page 97: ...r handle 020375Y Adaptor 28 x 30 mm 020412Y 15 mm guide Refitting the driven pulley shaft bearing Slightly heat the crankcase from the inside so as not to damage the painted surface Insert the bearing...

Page 98: ...amaged Measure the clutch bell inside diameter Characteristic Max value clutch bell Max value 134 5 mm Clutch bell standard value Standard value 134 134 2 mm Checking the bell working surface eccentri...

Page 99: ...position F from the tool internal side Insert the adapter ring 8 in the pins Assemble the driven pulley unit on the tool intro ducing the rivets heads in the adapter ring Make sure that the clutch is...

Page 100: ...IONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pin retaining collar Simultane...

Page 101: ...ley properly using the bell as shown in the figure Specific tooling 001467Y035 Belle for OD 47 mm bearings Remove the roller bearing using the modular punch Specific tooling 020376Y Adaptor handle 020...

Page 102: ...ure the movable half pulley bushing inside diameter Check that the faying surface with the belt is not abnormally worn Check the riveted joints are functional Check the evenness of the belt faying sur...

Page 103: ...ing follow the example in the figure using a modular punch Fit the clip N B FIT THE BALL BEARING WITH THE SHIELD VISIBLE Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020424Y Driv...

Page 104: ...ease through one of the holes in the bushing until it comes out through the hole on the opposite side This operation is necessary to avoid the presence of grease beyond the O rings N B THE TORQUE SERV...

Page 105: ...ss axis can be seen in full Insert the clutch on the adapter ring Lubricate the end of the spring that abuts against the servo system closing collar Insert the spring with relevant plastic holder in c...

Page 106: ...y belt assembly from the tool N B FOR DESIGN REASONS THE NUT IS SLIGHT LY ASYMMETRIC THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH N B DURING THE SPRING PRELOADING PHASE BE CAREFUL...

Page 107: ...ttom of the toothing does not show signs of incisions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does change the belt Removing the driving pulley With...

Page 108: ...es Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt Check that the O ring is not pushed out of shape CAUTION DO...

Page 109: ...r housings with the larger support surface touching the pulley according to the direction of rotation Check that the roller contact plate does not have flaws and is not damaged on the grooved edge Mou...

Page 110: ...T A WRONG TIGHTENING OF THE DRIVING HALF PULLEY Specific tooling 020368Y driving pulley lock wrench Locking torques N m Drive pulley nut 75 83 Refitting the transmission cover Check the presence of th...

Page 111: ...the wheel axis complete with gear Remove the intermediate gear Removing the hub bearings Check the state of the bearings being examined wear clearance and noisiness If faults are de tected do the foll...

Page 112: ...cover and take out the bearing Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide With the appropriate tools remove the oil seal as shown in the figure Specific tooling...

Page 113: ...ansmission side Remove the seeger ring shown in the figure With the sectional punch remove the driven pulley shaft bearing Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20...

Page 114: ...tooling 020150Y Air heater support 020151Y Air heater 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020483Y 30 mm guide Assemble the seeger ring Fit the oil guard with seal lip towards the inside...

Page 115: ...OLT SET Refit the driven pulley shaft bearing with a mod ular punch as shown in the figure N B IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNE...

Page 116: ...king sure the breather pipe is in the correct position Place the 3 shortest screws identifiable by their different colour as shown in the figure Fasten the breather pipe support bracket with the lower...

Page 117: ...e the 4 retainers and the flywheel cover Removing the stator Remove the electric terminal of the minimum oil pressure switch Remove the two Pick Up screws and the one for the wiring harness bracket as...

Page 118: ...e flywheel cover Place the flywheel with the top dead centre mark aligned with the crankcase Place the flywheel cover by aligning the reference marks of the drive and the crankcase cover Reassemble th...

Page 119: ...the internal plastic parts of the flywheel and the Pick Up control plate Refitting the flywheel magneto Fit the flywheel being careful to insert the key properly Lock the flywheel nut to the prescrib...

Page 120: ...ing the two screws to the prescribed torque Locking torques N m Starter motor screws 11 13 Cylinder assy and timing system Removing the intake manifold Remove the flywheel cover completely as de scrib...

Page 121: ...with spring and by pass piston oil pump pulley cover O ring on the crankshaft and the sprocket wheel separa tion washer Remove the tappet cover Remove the central screw fastener and the au tomatic val...

Page 122: ...its washer Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The chain tensioning pad must be removed from the tr...

Page 123: ...the cam shaft Remove the pins and the rocker arms from the flywheel side holes N B IN CASE OF NEED THE HEAD MAY BE RE MOVED WITH THE CAMSHAFT PINS ROCK ING LEVERS AND FIXING BRACKET THE HEAD CAN ALSO...

Page 124: ...ves Using the appropriate tool fitted with an adapter remove the cotter pins plates springs and valves Remove the oil guards with the appropriate tool Remove the lower spring supports CAUTION REPLACE...

Page 125: ...CAUTION TO AVOID DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL MP3 125 Engine ENG 31...

Page 126: ...micrometer N B REPLACE THE CRANKSHAFT IF THE DIAME TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR SHOWS SIGNS OF WEAR OR OVERHEATING Characteristic Rod small end check up Maximum diameter 1...

Page 127: ...ent 0 05 mm Pistons and cylinders are classified into catego ries based on their diameter The coupling is car ried out in pairs A A B B C C D D The cylinder rectifying operation should be car ried out...

Page 128: ...56 945 56 973 mm Pin diameter Standard clearance 0 015 0 029 mm Pin diameter Standard diameter 14 996 15 000 mm Wrist pin seat on the piston Standard diameter 15 001 15 006 mm Diameter of the wrist pi...

Page 129: ...ton Removing the piston Install piston and wrist pin onto the connecting rod aligning the piston arrow the arrow facing towards the exhaust Fit the pin stop ring onto the appropriate tool With opening...

Page 130: ...ic tool Support to check piston position 020428Y Set the dial gauge to zero placing the tool on a contrasting surface Keeping the zero position as semble the tool on the cylinder and lock it with 2 su...

Page 131: ...osite side from the ring gap and the word TOP towards the crown of the piston The chamfered side of the oil scraper ring should always be facing the piston crown Fit the middle piston ring with the id...

Page 132: ...Piston fitting band 020287Y Clamp to assemble piston on cylinder Inspecting the cylinder head Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted Maximum...

Page 133: ...emove 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 If examples of wear are found replace the whole...

Page 134: ...guide Accepted limit 5 022 Valve seat wear Exhaust guide Standard diameter 5 000 5 012 mm Inspecting the valves Measure the diameter of the valve stems in the three positions indicated in the diagram...

Page 135: ...d length Outlet 94 4 mm Valve check standard length Inlet 94 6 mm Valve check Maximum admissible clearance Outlet 0 072 mm Valve check Maximum admissible clearance Inlet 0 062 mm Valve check standard...

Page 136: ...valve seals Fit the valves the springs and the caps Using the appropriate tool with adapter compress the springs and insert the cotters in their seats N B DO NOT CHANGE THE VALVE FITTING POSI TION FIT...

Page 137: ...tic valve lifter cam or the end of stroke roller or the rubber buffer on the automatic valve lifter retaining cover Check that the valve lifting spring has not yielded Replace any defective or worn co...

Page 138: ...am shaft check Standard diameter Bearing B diameter 19 959 19 98 mm Cam shaft check Standard diameter Bearing A 36 95 36 975 mm Refitting the head and timing system components Assemble the lower timin...

Page 139: ...lding this position insert the chain on the cam shaft control pulley Insert the pulley on the cam shaft while keeping the reference 4V in correspondence with the ref erence mark on the head Assemble t...

Page 140: ...plug Electrode distance 0 8 mm Locking torques N m Spark plug 12 14 Refit the cylinder head cover tightening the 5 screws to the prescribed torque Make sure the gasket is positioned properly Remove th...

Page 141: ...ighten up the nuts to a pre torque of 7 1 N m Rotate by a 180 angle 2 rotations of 90 each To carry out the operations described above fol low the tightening sequence in the figure Fit the two screws...

Page 142: ...g the crankcase halves First remove the following units transmission cover driving pulley driven pulley and belt rear hub cover gears bearings and oil seals as described in the transmission chapter Re...

Page 143: ...in one of the two halves of the crankcase Remove the crankshaft CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPA RATING IT IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT A...

Page 144: ...E WIDTH OF THE CRANKSHAFT MAKE SURE THAT THE MEAS UREMENTS ARE NOT MODIFIED BY THE RAD IUSES OF FITTINGS WITH THE CRANKSHAFT BEARINGS The crankshaft can be reused when the width is within the standard...

Page 145: ...29 010 Standard diameter Category 1 28 994 29 000 STANDARD DIAMETER Specification Desc Quantity Standard diameter Category 2 29 004 29 010 Standard diameter Category 1 28 994 29 000 Inspecting the cra...

Page 146: ...d and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to prevent damaging the connecting rod bushings do not attempt cleaning the...

Page 147: ...e duct at the fly wheel side oil seal Inspect the coupling surfaces on the crankcase halves for scratches or deformation taking partic ular care with the cylinder crankcase surfaces and the crankcase...

Page 148: ...e main bushings are comprised of two half bearings one with holes and channels for lubrica tion whereas the other is solid The solid half bearing is intended to stand the thrusts caused by combustion...

Page 149: ...FICATION A RED B BLUE C YELLOW Type A RED Type B BLUE Type C YEL LOW Crankshaft half bearing 1 970 1 973 1 9703 1 976 1 976 1 979 Bush ing cat egory Crank case halves category Internal bush ing diamet...

Page 150: ...ION N B CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS BLUE Characteristic Standard driving depth 1 35 1 6 Diameter of cran...

Page 151: ...n the threaded seat on the carter thoroughly Refit a new stud bolt and apply the special product on the threading crankcase side Tighten up to the depth of the driving indicated Recommended products L...

Page 152: ...Engine MP3 125 ENG 58...

Page 153: ...ls once the measurement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the fan cover If the oil pressure is outside the specified limits in the foll...

Page 154: ...screws and tighten them to the pre scribed torque Lubricate the flywheel oil seal Using the appropriate tool assemble the oil seal Fit a new O ring on the pre filter and lubricate it Insert the filter...

Page 155: ...chain Fit the central screw and the belleville washer Tighten to the prescribed torque Fit the oil pump cover by tightening the two screws to the prescribed torque N B FIT THE BELLEVILLE WASHER SO TH...

Page 156: ...lace defective parts Characteristic By pass check up Standard length 54 2 mm Refitting the oil sump Refit the by pass valve plunger in its housing Insert the pressure regulating spring Fit a new sump...

Page 157: ...Connect the MITYVAC vacuum pump to the rub ber coupling as shown in the photograph Set the pump to the low pressure position VAC UUM Operate the pump slowly Check that the one way valve allows the ai...

Page 158: ...gher than 0 5 BAR is created Release the hose and check how the vacuum re acts Under normal functioning the vacuum undergoes a slight fall and then readjusts There follows a slow and continuous loss o...

Page 159: ...e throttle control transmission the automatic starter connection the clamps anchoring the carburettor to the filter housing and to the inlet manifold the air delivery pipe to the diaphragm the heater...

Page 160: ...Remove the 4 fixing screws shown in the figure and the vacuum chamber cover WARNING DURING THE REMOVAL OF THE CARBURET TOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Remove the vac...

Page 161: ...hamber with the accelerating pump its control and gasket Remove the oil pump seal Remove the intake and outlet valves of the intake pump from the tank N B CAUTION THE ACCELERATION PUMP VALVES ARE MADE...

Page 162: ...port the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger Remove the maximum nozzle Remove the maximum nozzle Engine M...

Page 163: ...rayer N B WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT Remove the minimum...

Page 164: ...R GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNECTION SCREWS THE FIXING SCREWS ARE CAULKED AFTER ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT Refitting the carburettor Before re...

Page 165: ...TS IN INADEQUATE SPRAY ING Check that there are 5 closing ball joints for the operating pipes on the carburettor body Check that the coupling surfaces the tank and the diaphragm are not dented Check t...

Page 166: ...ssemble the maximum nozzle Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock ab sorber pin and the return clamp Replace the rod if worn out Check that the flo...

Page 167: ...screw tightness introducing a small amount of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Check that the control roller is fre...

Page 168: ...alve and needle Check that the tapered pin of the vacuum valve does not show wear Check that the depression valve does not show threads on the external surfaces Check that the vacuum intake hole is no...

Page 169: ...ton is not de formed or rusty Check that the piston slides freely from the seat to the support Check that the piston sealing gasket is not de formed The starter must be more or less functional de pend...

Page 170: ...the O Ring correctly insert the plate with the machined side contacting the starter tighten the fixing screws Position the starter as shown in the figure Assemble the protection casing N B TO CARRY O...

Page 171: ...s air filter clean and sealed and the exhaust system tight Warm up the engine until the electrical fan is ac tivated at least once Using the rpm indicator 020332y adjust the idle set screw until reach...

Page 172: ...Engine MP3 125 ENG 78...

Page 173: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 174: ...dicated in the pho tograph Locking torques N m Wheel fixing screw 20 25 Front wheel hub overhaul Remove the ball bearing seeger ring indicated in the photograph Extract the ball bearing using the spec...

Page 175: ...stops with the shielded side facing out Refit the ball bearing locking seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42x47 mm adaptor 020412Y 15 mm guide Use the speci...

Page 176: ...and remove the throt tle Loosen the clamp fixing the handlebar to the steering tube and pulling up wards remove the handlebar then re move the lower plastic cover N B IF THE HANDLEBAR IS BEING REMOVED...

Page 177: ...Then the pipes branch out to reach the upper joints on the side steering tubes Through the rigid flexible pipes inside the side steering tubes the oil reaches the stem sliding locking device placed pa...

Page 178: ...king device making sure again that the liquid drained is collected Remove the upper fittings on the parallelogram of the brake hydraulic pipes and the suspension lock indicated in the photograph Remov...

Page 179: ...of the calliper from the steering tube as shown in the photograph and then remove the rigid part Remove the tone wheel wiring by disconnecting the connector on the fuel tank after removing the chassis...

Page 180: ...g bar by undoing the nut indicated in the photograph Use a specific tool to remove the upper tightening ring nut of the steering tube Specific tooling 020055Y Wrench for steering tube ring nut Remove...

Page 181: ...ring nut and the protection cap indicated in the photograph Now it is possible to remove the steering tube Check that the roller tapered bearing does not show signs of abnormal wear If it is replace...

Page 182: ...PENSION IS FITTED Remove the lower retainer of the sliding stem shown in the photograph Remove the sliding stem locking device retainers indicated in the photograph Check that the sliding stem locking...

Page 183: ...12 15 Screw fixing sliding stem to shock absorber 45 50 Clamp for sliding stem locking device 6 5 10 5 Fixing nuts for constant velocity universal joints 18 20 Parallelogram device Remove the steerin...

Page 184: ...dicated in the photograph Remove the retainers indicated in photograph of the half arms joint flange To facilitate the operations indicated below re move the suspension locking electronic control unit...

Page 185: ...ndicated For easy refitting operations remember to take note of the positions of the components Separate the half arms by hitting slightly with a wooden mallet where possible alternatively to the left...

Page 186: ...Carry out a visual check of the upper and lower bearings on the headstocks and their seats Re place them in case of signs of abnormal wear Suspensions MP3 125 SUSP 14...

Page 187: ...llow the operations for removal but in reverse order lubricating the locking pins on the parallelogram half arms and observing the pre scribed torques PARALLELOGRAM DEVICE Name Torque in Nm Arm coupli...

Page 188: ...pension lock ing mechanical calliper Remove the electrical connection of the geared motor position potentiometer Remove the electrical connection of the geared motor electric motor Disconnect the hydr...

Page 189: ...L ADVICE IMMEDI ATELY IF BRAKE LIQUID GETS ACCIDEN TALLY IN CONTACT WITH YOUR EYES RINSE WITH ABUNDANT FRESH WATER AND SEEK MEDICAL ADVICE IMMEDIATELY KEEP BRAKE FLUID OUT OF THE REACH OF CHIL DREN Re...

Page 190: ...figure if neces sary lock the lever with a vice making sure not to spoil the surface In case of difficulties when removing the lever use the specific tool Remove the tongue and then the moulded wash e...

Page 191: ...the two crankcases Remove the retaining seeger ring of the bearing of the flexible transmission lever control shaft bear ing Remove the bearing with the specific tool Specific tooling 020376Y Adaptor...

Page 192: ...daptor handle 020362Y 12 mm guide 020357Y 32 x 35 mm adaptor Hold the crankcase in a perfectly horizontal posi tion heat it with a heat gun at a temperature of about 120 C use the specific tool to fit...

Page 193: ...to fit the bearing of the spring toothed sector unit Hit slightly with a mallet if necessary Specific tooling 020360Y Adaptor 52 x 55 mm 020151Y Air heater 020376Y Adaptor handle Hold the crankcase in...

Page 194: ...the reference indicated on the second slot of the toothed sector Grease the pinion and the toothed sector with spe cific grease Refit the toothed sector spacer Recommended products MONTBLANC MOLYBDENU...

Page 195: ...ue Refit the flexible transmission control lever as shown in the figure Refit the potentiometer not forcing in the D type connector ensures a sole position with the con nector directed to the opposite...

Page 196: ...ing tighten the two bracket screws and the flexible transmission lever nut to the prescribed torque Locking torques N m Bracket tightening screws 8 12 Unscrew the Allen screw and remove the switch Whe...

Page 197: ...e the pads with the spring When refitting tighten the two screws to the pre scribed torque and use Threadlock When refitting adjust the cable properly so that the switch is pushed when the system is u...

Page 198: ...Select the SYSTEM RESET option from the main menu Turn the key switch to ON Select the LOWER STOP SEARCH option from the SYSTEM RESET menu WAIT PROCEDURE IN PROGRESS Suspensions MP3 125 SUSP 26...

Page 199: ...isplays the option REL ATIVE POTENTIOMETER ANGLE This function is active coming from the LOWER STOP SEARCH procedure NOTE a slight oscillation of the angle value be tween 0 00 and 0 50 is considered n...

Page 200: ...cap align the pump control and lock the screw to the prescribed torque Locking torques N m Clamp fixing pump bolt to anti tilting device 11 13 Select the SYSTEM RESET option from the MAIN menu Suspen...

Page 201: ...ESS OK TO CON TINUE Press OK The hand held computer displays the words POS SIBLE LIMIT STOP VALUES PRESS A KEY AND SHIFT OFF AND ON If this is not successful the tilt locking mechanism remains locked...

Page 202: ...inter face wiring disconnected from the control unit check the continuity of the blue black cable be tween pressure sensor connector and the horn remote control base as indicated in the photo graph Ch...

Page 203: ...or and the fuse box and between the remote control base and the fuse box With a multimeter also check the pressure switch operation as well as the continuity at rest as this is normally closed switch...

Page 204: ...T SPEED SENSOR 7 RIGHT SPEED SENSOR 8 DIAGNOSTIC TESTER SERIAL LINE 9 ENGINE CONTROL UNIT 10 DIRECT BATTERY 11 LIVE BATTERY 12 LOW BEAM LIGHT 13 FUSE No 3 20A 14 LOW BEAM LIGHT REMOTE CONTROL 15 PRESS...

Page 205: ...OR With the interface wiring disconnected from the control unit check the continuity between pin 28 and the yellow cable between pin 38 and the blue cable on the geared motor connector MP3 125 Suspens...

Page 206: ...ing disconnected from the control unit check the continuity of the geared mo tor winding placing the multimeter probes on pins 28 and 38 as indicated in the figure POTENTIOMETER 1 POTENTIOMETER Suspen...

Page 207: ...ctivated lock ing condition is 4V and 1V in the locking rest condition With the interface wiring disconnected from the control unit check the continuity between pin 17 and the yellow cable of the pote...

Page 208: ...the control unit check the continuity of the electrical lines be tween the interface wiring and the tilt locking un locking switch Pin 26 and green grey cable Pin 35 and violet black cable Pin 33 and...

Page 209: ...nnector and an earth point on the chassis With a multimeter check the operation of the tilt locking unlocking switch referring to the diagram indicated in the figure 1 EARTH 2 LOCK 3 REST 4 UNLOCK TIL...

Page 210: ...1 TILT LOCKING CALLIPER SENSOR The tilt locking calliper sensor is a normally opened switch Check its correct operation with a multi meter Suspensions MP3 125 SUSP 38...

Page 211: ...ilt locking gripper sensor con nector on the system side Check the continuity of the connector black cable and an earth point on the chassis Also check that the flexible transmission control lever act...

Page 212: ...bles of the LEFT wheel revolution sensor and brown cable of the RIGHT sensor between pin 24 and the red cable of the RIGHT wheel revolution sensor In case of failures check the continuity between pin...

Page 213: ...With a thickness gauge check that the air gap be tween the screw head and the sensor is between 0 35 and 1 mm RIDER PRESENCE SENSOR MP3 125 Suspensions SUSP 41...

Page 214: ...rom the control unit and connected to the system check the fol lowing conditions pin 17 36 resistance 15 18 kOhm when the rider is not seated on the saddle pin 17 36 resistance of about 3 kOhm when th...

Page 215: ...ia corretta Posizionare il veicolo su un pavimento piano privo di asperit e irregolarit Posizionare il veicolo sul cavalletto centrale Assicurarsi che il sistema di staziona mento sia sbloccato Sollev...

Page 216: ...6 bar Rear tyre pressure rider Rear tyre pressure rider 2 bar Get the vehicle off the stand back on the ground Remove the right lower coupling plate of the half arm by undoing the screws indicated in...

Page 217: ...correctly centre the spacer in the bear ing Remove the nut fixing the steering con trol arm and keep the original washer in position Fit the steering guiding bracket in a straight riding position fix...

Page 218: ...t interfering with the tyre If required reposition the frame by operating the 3 adjustable support feet Fit the frame locking bracket Make sure the frame is adequately centred by checking with a gauge...

Page 219: ...photograph Maximum misalignment allowed 4 notches Rear Removing the rear wheel Remove the full muffler assembly Remove the screw fixing the right hand shock absorber to the bracket Remove the two scr...

Page 220: ...f necessary 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 photograph Locking torques N m Muffl...

Page 221: ...engine back remove the spring anchoring the swinging arm to the frame as shown in the photo Remove the two screws fixing the buffer support bracket to the frame Undo the nut on the LHS shown in the fi...

Page 222: ...ms using a feeler gauge Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm To check the clearance on the frame side arm mount the retainer using the pin fixing the swingin...

Page 223: ...position the bearings with the O rings facing outwards Specific tooling 020244Y 15 mm diameter punch 020115Y 18 punch Characteristic Length of the swinging arm tube on the engine side L 175 3 0 3 0 Le...

Page 224: ...ith the most protruding part pointing towards the silent block side as shown in the photograph Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm Soap bas...

Page 225: ...upport Install a new silent bloc making sure it aligns properly with the reference tooth Fit the silent blocs making sure the chamfered part of the silent bloc matches the chamfered part of the bracke...

Page 226: ...little with a jack so as to free the two shock absorbers remove the muffler undo the shock absorber spring assembly clamp ing screw from the support fixed to the engine on the one side and from that f...

Page 227: ...the two return springs from the centre stand Undo the nut shown in the figure Remove the bolt from the right side Remove the centre stand FITTING On refitting tighten the nut to the specified torque L...

Page 228: ...Suspensions MP3 125 SUSP 56...

Page 229: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 230: ...ORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMP TIED THE SYSTEM OF THE CIRCUIT BEING EXAMINED Removal Place a container under the calliper unscrew the tube calliper joint and empty the...

Page 231: ...ter that remove the hub with the help of a rubber mallet slightly hitting on the brake disc side turning the wheel hub at the same time Loosen the 6 screws indicated in the figure and remove the brake...

Page 232: ...ewdriver pay ing attention not to spoil the calliper surface treat ment Use a corresponding measuring punch to extract the pad pin if necessary move the brake pipes manually to release the pin Then re...

Page 233: ...uspension arm and loosen the hydraulic joint fixing nut of the suspension locking to release the brake pipes Front brake pipes removal Remove front Shield Remove front wheel and mudguard Disconnect th...

Page 234: ...and remove the calliper To check calliper components refer to the chapter on the tilt locking calliper When refitting secure to the specified torque Locking torques N m Screw tightening calliper to th...

Page 235: ...e electric connection from the engaged parking brake warning light switch Remove the parking brake cable from the lever by operating the set screw indicated in the photo graph MP3 125 Braking system B...

Page 236: ...Braking system MP3 125 BRAK SYS 8...

Page 237: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 238: ...ed valve and the other in the expansion tank Loosen the screw by two turns until the commu nication hole is revealed with the head as shown in the photo Wait until only coolant comes out of the rubber...

Page 239: ...INDEX OF TOPICS CHASSIS CHAS...

Page 240: ...the vehicle s bodywork Seat Lift the saddle and disconnect the rider presence sensor Remove the three fixing screws Front handlebar cover Remove the upper cap by operating on the Allen screw indicated...

Page 241: ...er access the two screws fixing the rear part to the handlebar as indicated in the photograph Headlight assy Remove the radiator cover Remove the two wheelhouses with the turn indi cator Unscrew the...

Page 242: ...y Remove the four screws A and disconnect the wiring See also Radiator cover Frame central cover Remove the three screws on the right and the left side Open the refuelling compartment and remove the t...

Page 243: ...two front screws and the two screws under the wheelhouse Remove the four screws on the shield back plate See also spoiler Headlight assy Knee guard Remove the front shield Remove the spoiler Remove th...

Page 244: ...the frame from the instrument panel and manually re lease the unions with the shield back plate Unhook the instrument panel wiring Remove the six screws and the cable guide strap in the front part of...

Page 245: ...footrest Remove the five screws on the shield back plate rear part Remove the two shield back plate front screws see figure Remove the two shield back plate lower screws Remove the external temperatu...

Page 246: ...from its fitting Follow this procedure to remove the bulbs Remove the snap on bulbs B Remove the bulbs A on the bayonet by turning them 30 clockwise Footrest Remove the central cover Remove the four s...

Page 247: ...r the rear cover Remove the screw on the fairing front part pull the fairing to release the hooks Follow the same procedure for both fairings Remove the five screws on the right side and the five on t...

Page 248: ...ide the rear case Operate a slight upwards thrust on the case to re lease license plate support from the chassis Helmet bay Remove the chassis central cover Remove the four external screws and the two...

Page 249: ...porting plates of the voltage regulator on one side and the saddle opening switch on the other Remove the six upper screws Release the case latch Remove the case light front and rear switch con nectio...

Page 250: ...Remove the five screws indicated in the figure See also Headlight assy Fuel tank Remove the chassis central cover Remove the footrest Remove the three tank retainers Chassis MP3 125 CHAS 12...

Page 251: ...bracket retainers indicated in the figure Disconnect the electric wiring and the fuel pipes See also Footrest Remove the chassis central cover Remove the footrest Remove the three tank retainers MP3...

Page 252: ...Disconnect the electric wiring and the fuel pipes See also Footrest Top case Rear Remove the four fixing screws of the cover and release it from the two leverages Handles and top side fairings Remove...

Page 253: ...rs with the bushing Remove the two rear retainers and then the two wheelhouse front retainers Remove the two screws fixing the radiator lower protection to the shield back plate After that press up an...

Page 254: ...Chassis MP3 125 CHAS 16...

Page 255: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 256: ...ening torques inspection Lock check Safety locks clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing Front shock absorber upper fixing Front shock absorber l...

Page 257: ...S FIRST USED SHORTENS THE LIFE OF THE BATTERY CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE LEAD WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIO...

Page 258: ...Hot engine restart Minimum seal turning the handlebar Uniform steering rotation Possible losses electric radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE...

Page 259: ...MP3 125 Pre delivery PRE DE 5...

Page 260: ...Pre delivery MP3 125 PRE DE 6...

Page 261: ...INDEX OF TOPICS TIME TIME...

Page 262: ...rry out repairs For each operation the description code and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine from chassis Re moval and refit 2 001127 Engine Complete ser...

Page 263: ...ion 1 001133 Engine crankcase Replace ment 2 001099 Oil seal flywheel side Re placement 3 001100 Oil seal clutch side Re placement 4 001124 Lubrication by pass Re placement 5 001153 Crankcase halves g...

Page 264: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement Time MP3 125 TIME 4...

Page 265: ...Cylinder assy CYLINDER GROUP Code Action Duration 1 001002 Cylinder Piston Replace ment 2 001154 Pin ring piston assembly Service 3 001176 Rings Pin Replacement MP3 125 Time TIME 5...

Page 266: ...e Action Duration 1 001057 Thermostat Replacement 2 007012 Coolant bleed valve Re placement 3 001083 Thermistor Replacement 4 001056 Head gasket Replacement 5 001045 Valves Replacement 6 001049 Valves...

Page 267: ...Rocker arms support assy ROCKING LEVERS SUPPORTING UNIT Code Action Duration 1 001148 Valve rocking levers Re placement 2 001126 Head Replacement 3 001044 Camshaft Replacement MP3 125 Time TIME 7...

Page 268: ...ode Action Duration 1 001089 Head cover Replacement 2 001093 Spark plug Replacement 3 001088 Head cover gasket Replace ment 4 001074 Oil vapour recovery pipe Re placement 5 001159 Oil vapour recovery...

Page 269: ...Replace ment 2 001162 Secondary air filter box Re placement 3 001174 SAS valve Replacement 4 001160 Oil pressure sensor Re placement 5 001123 Oil filter Replacement 6 001102 Mesh oil filter Replacemen...

Page 270: ...Driven pulley DRIVEN PULLEY Code Action Duration 1 001012 Driven pulley Service 2 001022 Clutch Replacement 3 001110 Driven pulley Replacement 4 001155 Clutch bell Replacement Time MP3 125 TIME 10...

Page 271: ...ce and replacement 2 001125 Chain guide pads Replace ment 3 001122 Oil pump chain Replace ment 4 001172 Chain cover flap Replace ment 5 001130 Oil sump Replacement 6 001042 Oil pump Service 7 001112 O...

Page 272: ...002031 Rear wheel hub bearings Replacement 2 003065 Gear box oil Replacement 3 004180 Reduction gear breather pipe Replacement 4 004125 Rear wheel axle Replace ment 5 001179 Hub drive shaft replacemen...

Page 273: ...Action Duration 1 001177 Variator rollers shoes Re placement 2 001066 Driving pulley Removal and Refitting 3 001006 Driving pulley Service 4 001086 Driving half pulley Replace ment 5 001011 Driving be...

Page 274: ...tion 1 001135 Transmission cover bearing Replacement 2 001096 Transmission crankcase cov er Replacement 3 001131 Transmission air intake Re placement 4 001170 Air deflector Replacement 5 001132 Transm...

Page 275: ...Water pump WATER PUMP Code Action Duration 1 007009 Head pump by pass rubber coupling Replacement MP3 125 Time TIME 15...

Page 276: ...Starter motor ELECTRICAL START UP Code Action Duration 1 001020 Starter motor Replacement 2 005045 Starter motor cable harness Replacement 3 001017 Start up pinion Replace ment Time MP3 125 TIME 16...

Page 277: ...magneto MAGNETO FLYWHEEL Code Action Duration 1 001067 Stator Removal and Refit ting 2 001058 Complete flywheel Replace ment 3 001173 Rotor Replacement 4 001087 Flywheel cover Replace ment MP3 125 Tim...

Page 278: ...Carburettor CARBURETTOR Code Action Duration 1 001063 Carburettor Replacement 2 003058 Carburettor Adjustment 3 001013 Intake manifold Replace ment Time MP3 125 TIME 18...

Page 279: ...IEW Code Action Duration 1 001008 Carburettor Inspection Exhaust pipe MUFFLER Code Action Duration 1 001095 Muffler guard Replacement 2 001009 Muffler Replacement 3 001092 Exhaust manifold Replace men...

Page 280: ...Air cleaner AIR CLEANER Code Action Duration 1 004122 Air cleaner carburettor fitting Replacement 2 001014 Air filter Replacement cleaning 3 001015 Air filter box Replacement Time MP3 125 TIME 20...

Page 281: ...e Action Duration 1 004146 Front frame Replacement 2 004116 Rear frame Replacement 3 004001 Frame replace 4 004147 footboard support bracket one side Replacement 5 004143 Footrest support replace MP3...

Page 282: ...Centre stand STAND Code Action Duration 1 001053 Stand bolt Replacement 2 004179 Stand buffer Replacement 3 004004 Stand Replacement Time MP3 125 TIME 22...

Page 283: ...20 Headlight frame Replace ment 2 004064 Front shield Replacement 3 004055 Turn indicator frame Re placement 4 004149 Shield central cover Re placement 5 004022 Shield lower section Re placement 6 004...

Page 284: ...S Code Action Duration 1 004036 Lower chassis cover Re placement 2 004129 Rear fairing Replacement 3 004085 Fairing 1 Replacement 4 004068 Passenger handgrip Re placement 5 004037 Side aprons Replacem...

Page 285: ...Rear cover REAR SHIELD Code Action Duration 1 004065 Front shield rear part Re moval and refitting MP3 125 Time TIME 25...

Page 286: ...Spark plug inspection flap Replacement 2 004135 Fuel tank lid Replacement 3 004011 Central chassis cover Re placement 4 004012 Rear fairings Removal and refitting 5 004015 Footrest Removal and Re fit...

Page 287: ...ion Duration 1 007015 Radiator air intake Replace ment 2 004009 Rear mudguard Replace ment 3 004181 Lower cover Replacement 4 004184 Front mudguard support re placement 5 004002 Front mudguard Replace...

Page 288: ...Fuel tank FUEL TANK Code Action Duration 1 004137 Injector pump pipe Replace ment 2 005010 Tank float Replacement 3 004168 Fuel tank cap Replacement 4 004005 Fuel tank Replacement Time MP3 125 TIME 28...

Page 289: ...OCK ABSORBERS Code Action Duration 1 003007 Rear shock absorber Re moval and Refitting 2 003035 Shock absorber support and brake calliper Replacement 3 003077 muffler rear shock absorber support arm S...

Page 290: ...COVERS Code Action Duration 1 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE MENT 2 004019 Rear handlebar cover Re placement 3 004026 Handlebar cover Replace ment 4 004018 Front handlebar cover Re plac...

Page 291: ...ent 4 003001 Handlebar Replacement 5 002071 Left knob Replacement 6 003059 Counterweight Replace ment 7 002037 Brake lever Replacement 8 002048 Rear brake calliper Re placement 9 002067 Rear brake pum...

Page 292: ...ystem Replace ment Swing arm SWINGING ARM Code Action Duration 1 004058 Silent block Replacement 2 003081 Swinging arm support flange replace 3 001072 Swinging arm Engine chas sis connection Replaceme...

Page 293: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement MP3 125 Time TIME 33...

Page 294: ...nel INSTRUMENT PANEL Code Action Duration 1 004021 Shield upper section Re placement 2 005014 Odometer Replacement 3 004099 Odometer housing Replace ment 4 004035 Instrument panel Replace ment Time MP...

Page 295: ...ase closure hook Re placement 2 005099 Electric saddle opening acti vator Replacement 3 004054 Saddle lock catch Replace ment 4 004001 Chassis Replacement 5 005072 Immobilizer aerial Replace ment Turn...

Page 296: ...Rear turn indicators Re placement 3 005031 Licence plate light bulb Re placement 4 005032 Licence plate light glass Re placement 5 005131 Licence plate light support Replacement 6 005066 Rear light b...

Page 297: ...INDICATOR LIGHTS Code Action Duration 1 005067 Front turn indicator bulb Re placement 2 005012 Front turn indicators Re placement 3 005002 Front light replacement 4 005008 Headlight bulbs Replace ment...

Page 298: ...ration 1 003047 Front tyre Replacement 2 003033 Front wheel hub Replace ment 3 003037 Front wheel rim Replace ment 4 005089 Tone wheel Replacement 5 002041 Front brake disc Replace ment 6 004123 Front...

Page 299: ...l REAR WHEEL Code Action Duration 1 002070 Rear brake disc Replace ment 2 001016 Rear wheel Replacement 3 001071 Front wheel rim Removal and refitting 4 004126 Rear wheel tyre Replace ment MP3 125 Tim...

Page 300: ...Code Action Duration 1 005075 Stop remote control Re placement 2 005035 Headlight remote control Replacement 3 005011 Start up remote control switch Replacement 4 005007 Battery Replacement 5 005003 H...

Page 301: ...CABLE HARNESS Code Action Duration 1 005001 Electrical system Replace ment 2 005114 Electrical system Service MP3 125 Time TIME 41...

Page 302: ...tch Replacement 2 005077 Emergency stop switch Re placement 3 005041 Starter button Replacement 4 004010 Antitheft lock Replacement 5 005040 Horn button Replacement 6 005006 Light or turn indicator sw...

Page 303: ...4 Tilt locking calliper control ca ble replacement 2 002082 Fuel tank cap opening drive Replacement 3 002083 Saddle opening transmission Replacement 4 002093 Trunk opening transmission Replacement 5 0...

Page 304: ...PARTMENT Code Action Duration 1 005046 Battery cover change 2 005026 Helmet compartment light Replacement 3 005027 Helmet compartment bulb support Replacement 4 004016 Helmet compartment Re placement...

Page 305: ...AR COVERS Code Action Duration 1 004081 Glove box door Replace ment 2 004174 Trunk leverage 3 004141 Cat s eye Replacement 4 005048 Licence plate holder Re placement 5 004082 Trunk gasket Replacement...

Page 306: ...03010 Front suspension Service 2 003111 Side steering tube replace ment 3 003038 Front wheel axle Removal and Refit 4 003040 Front wheel bearings Re placement 5 003107 Sliding stems replacement 6 0031...

Page 307: ...on pipe Replace ment 2 001052 Coolant and air bleed Re placement 3 007001 Expansion tank Replace ment 4 007024 Expansion tank cap Re placement 5 007003 Coolant delivery and return pipe Replacement 6 0...

Page 308: ...g calliper pads re placement 4 003108 Parking brake flexible trans mission replacement 5 003109 Parking brake mechanical calliper replacement 6 002002 Shoes Rear brake pads Replacement 7 002020 Rear b...

Page 309: ...ement 13 002021 Front brake piping Replace ment 14 002007 Front brake pads Replace ment 15 002039 Front brake calliper Re placement 16 003104 Suspension system locking calliper replacement 17 003119 H...

Page 310: ...WINDSHIELD Code Action Duration 1 004101 Windshield Replacement Secondary air box SECONDARY AIR HOUSING Code Action Duration 1 001163 SAS valve Head connection Replacement Time MP3 125 TIME 50...

Page 311: ...Stickers TRANSFERS Code Action Duration 1 004066 Rear view mirror Replace ment 2 004159 Plates Stickers Replace ment MP3 125 Time TIME 51...

Page 312: ...ment 2 003112 Central steering tube re placement 3 003002 Steering fifth wheel Re placement 4 003115 Parallelogram arms re placement 5 003114 Parallelogram bearings re placement 6 003116 Steering rod...

Page 313: ...locking calliper support bracket replacement 4 001069 HV coil replace 5 001094 Spark plug cap Replace ment 6 003120 Tilt locking control unit re placement 7 003093 Geared motor crankcase re placement...

Page 314: ...Code Action Duration 11 003089 Geared motor potentiometer replacement Time MP3 125 TIME 54...

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