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PIAGGIO MP3 400 i.e. Service Manual Download Page 372

Handlebar components

H

ANDLEBAR

 

COMPONENTS

Code

Action

Duration

1

002059

Right-hand knob - change

2

002060

Complete throttle control -

Replacement

3

002063

Complete throttle control -

Replacement

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 pump - Replace-

ment

10

002080

Rear brake oil bleeding sys-

tem - Replacement

11

004162

Mirror support and/or brake

pump fitting U-bolt - Replace-

ment

12

002024

Front brake pump - replace

13

002047

Front brake fluid and air

bleeding system - Replace-

ment

Time

MP3 400 i.e.

TIME - 28

Summary of Contents for MP3 400 i.e.

Page 1: ...SERVICE STATION MANUAL 664502 IT 664503 EN 664504 FR 664505 DE 664506 ES 664507 PT 664508 NL 664509 EL MP3 400 i e...

Page 2: ...y changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publicat...

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

Page 4: ......

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

Page 6: ......

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

Page 8: ...ompressed 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 Use...

Page 9: ...prefix B M474M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Kerb weight 253 5 kg Maximum weight allowed 445 kg Maximum height 1 225 mm Width 745 mm Wheelbase 1 550 mm Length...

Page 10: ...Inlet 0 15 mm Outlet 0 15 mm MAX power 24 kW at 7 250 rpm MAX torque 38 Nm at 5 250 rpm Lubrication Engine lubrication with trochoidal pump inside the crankcase oil filter and pressure adjustment by p...

Page 11: ...able ad vance and separate HV coil Ignition advance Three dimensional map managed by control unit Spark plug CHAMPION RG 6 YC Alternative spark plug NGK CR7EKB Battery 12 V 14 Ah SEALED BATTERY Genera...

Page 12: ...2 4 bar 2 6 bar Tightening Torques STEERING Name Torque in Nm Steering lower ring nut central headstock 22 27 loosen by 90 Steering upper ring nut central headstock 27 33 Handlebar fixing screw 50 55...

Page 13: ...7 11 Joint to anti tilting device pump 20 25 Lower fitting for shock absorber sliding locking clamp pipes 20 25 Upper fitting for shock absorber sliding locking clamp pipes 20 25 REAR SUSPENSION Name...

Page 14: ...12 Lambda probe on exhaust manifold 10 12 injector fixing screw 3 4 Counterweight screw 7 8 5 Tensioner sliding block fixing screw 10 14 Rpm timing sensor fixing screw 3 4 Valve lifter mass stop bell...

Page 15: ...pporting screws with bulkhead 0 3 0 4 Minimum oil pressure sensor 12 14 Water pump impeller 4 5 CRANKCASE AND CRANKSHAFT Name Torque in Nm Countershaft fixing nut 25 29 Engine oil filter 12 16 Engine...

Page 16: ...Piston B 85 797 85 804 85 761 85 768 0 029 0 043 Cylinder Piston C 85 804 85 811 85 768 85 775 0 029 0 043 Cylinder Piston D 85 811 85 818 85 775 85 782 0 029 0 043 CATEGORIES OF COUPLING N B THE PIS...

Page 17: ...Replace the piston if clearances exceed the max imum limits specified in the table Crankcase crankshaft connecting rod Crankcase countershaft coupling Besides considering it should match the crankshaf...

Page 18: ...fitted to either crankcase type Either the pair of gears or the crankcase is identified with the letter referring to the type on the crank case this mark is found at the cylinder mouth flywheel side C...

Page 19: ...CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission side shoulder 1 0 025 A D 0 20 0 50 Half shaft trans mission side 20 0 05 B D 0 20 0 50 Connecting rod 22 0 10...

Page 20: ...E TAKEN 0 10 0 10 0 6 0 05 A MEASURE TAKEN 0 10 0 185 0 8 0 05 N B VALUES INDICATED WITH REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE N B DISTANCE A MUST BE MEASURED WITHOUT ANY G...

Page 21: ...Product Description Specifications SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol based anti freeze fluid CUNA NC 956 16 MP3 400 i e Characteristics CHAR 15...

Page 22: ...Characteristics MP3 400 i e CHAR 16...

Page 23: ...INDEX OF TOPICS TOOLING TOOL...

Page 24: ...fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Pliers to extract 17 mm bear ings 001467Y01...

Page 25: ...ings 001467Y035 Belle for OD 47 mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrenc...

Page 26: ...3Y Oil pressure gauge 020201Y Spacer bushing driving tube 020262Y Crankcase splitting strip 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum operated pump 020330Y Stroboscopic ligh...

Page 27: ...1Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020358Y 37x40 mm adaptor 020359Y 42x47 mm adapt...

Page 28: ...Y Adaptor 52 x 55 mm 020364Y 25 mm guide 020376Y Adaptor handle 020382Y012 bush valve removing tool 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extract...

Page 29: ...ion 020434Y Oil pressure control fitting 020439Y 17 mm guide 020444Y Tool for fitting removing the driv en pulley clutch 020456Y 24 mm adaptor 020458Y Puller for lower bearing on steer ing tube MP3 40...

Page 30: ...20459Y Punch for fitting bearing on steer ing tube 020460Y Scooter diagnosis and tester 020467Y Flywheel extractor 020468Y Piston fitting ring 020469Y Reprogramming kit for scooter diagnosis tester To...

Page 31: ...20470Y Pin retainers installation tool 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set M...

Page 32: ...020478Y Punch for driven pulley roller cas ing 020479Y Countershaft lock wrench 020480Y Petrol pressure check set 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide Tool...

Page 33: ...2Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter 020565Y Flywheel lock calliper spanner Marelli MIU diagnosis software Marelli MIU diagnosis software 020640y software euro...

Page 34: ...Tooling MP3 400 i e TOOL 12...

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

Page 36: ...the icon is no longer dis played Maintenance chart EVERY 2 YEARS 60 Action Coolant change Brake fluid change AFTER 1 000 KM 60 Action Safety locks check Throttle lever adjustment Engine oil change El...

Page 37: ...stment AFTER 15 000 KM 45 000 KM 75 000 KM 45 Action Engine oil level check top up Brake pads check condition and wear Centre stand lubrication AFTER 20 000 KM 40 000 KM 60 000 KM AND 80 000 KM Action...

Page 38: ...ing the spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to declare the reference values based on...

Page 39: ...w on the calliper must be pointing at the spark plug Connect the diagnostic tester Start the engine Select the menu on the parameter function Select the stroboscopic light command in the tra ditional...

Page 40: ...p A fully over the spark plug Refit the port making sure the rear hook is inser ted WARNING THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD REPLACE THE SPARK PLUG AS INDICATED IN THE SCHEDULED...

Page 41: ...ark it needs to be filled up with the right amount of hub oil Screw up the oil dipstick again and make sure it is locked properly into place Replacement Remove the oil cap A Unscrew the oil drainage c...

Page 42: ...O AVOID DAMAGING THE ENGINE Recommended products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness Engine oil In 4T engines the engine oil is use...

Page 43: ...ridge fil ter C Make sure the pre filter and discharge tap O rings are in good condition Lubricate them and refit the mesh filter and oil drainage plug screwing them up to the specified torque Refit t...

Page 44: ...filter 12 16 Engine oil drainage plug 24 30 Check This operation must be carried out with the engine cold and following the procedure below Place the vehicle on its centre stand and on flat ground Uns...

Page 45: ...e plug screwing them up to the specified torque Refit the new cartridge filter being careful to lubricate the O ring before the fitting Change the engine oil Recommended products AGIP CITY HI TEC 4T E...

Page 46: ...ion using a cal liper spanner applied to the camshaft command pulley casing Cooling system Adding engine coolant Check coolant level when the engine is cold as in dicated in the scheduled maintenance...

Page 47: ...d lift the plastic cover A in order to access the brake fluid reservoir Loosen the two fixing screws and remove the reservoir cover top up with the rec ommended fluid without exceeding the MAX mark Th...

Page 48: ...pendicular to the screen Remove the headlight assembly central cover Turn on the headlight and check that the border of the projected light beam on the screen is not higher than 9 10 or lower than 7 1...

Page 49: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 50: ...r restore the cou pling seal Worn valve oil guard Replace the valve oil guard Worn valve guides Check and replace the head unit if required Insufficient lubrication pressure POOR LUBRICATION PRESSURE...

Page 51: ...part Brake disc slack or distorted Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Clogged compensation holes on the p...

Page 52: ...the ball bearings and relevant lock nuts the limit switch rubber buffers and the movement bushings In conclusion check the tightening torque of the wheel hub the brake calliper the shock absorber disk...

Page 53: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 54: ...ch 7 Radiator electric fan 8 Electrical fan remote control 9 Main fuses 10 12V socket 11 Key switch contacts 12 Secondary fuses 13 Key switch contacts 14 Fuse 15 Battery 16 Starter motor 17 Start up r...

Page 55: ...internal light 34 Rear left light A Rear left turn indicator bulbs B Stop light bulb C Tail light bulb 35 License plate lamp 36 Rear right light A Tail light bulb B Stop light bulb C Rear right turn i...

Page 56: ...g switch 56 Injection load remote control 57 Fuel pump 58 Fuel injector 59 Potentiometer 60 Right wheel revolution sensor 61 Left wheel revolution sensor 62 HV coil 63 Diagnostics socket 64 Revolution...

Page 57: ...Components arrangement MP3 400 i e Electrical system ELE SYS 5...

Page 58: ...1 Relays for lights horn injection load electric fan remove the front shield to reach it 2 Auxiliary fuses remove the footrest flap to reach these fuses Electrical system MP3 400 i e ELE SYS 6...

Page 59: ...Start up relay Start up enabling switch relay remove the lid of the helmet compartment to reach these relays 5 6 10 Fuel pump Fuel level sensor coil remove the chassis central cover to reach these co...

Page 60: ...remove the right side panel to reach it 8 Immobilizer remove the shield back plate 9 18 Saddle opening receiver Turn indicator control device remove the left fairing to reach them Electrical system MP...

Page 61: ...helmet compartment 13 Lambda probe The lambda probe is mounted on the exhaust manifold 14 Engine oil pressure sensor remove the ex haust end to reach it 15 Centralina comando stazionamento per ac ced...

Page 62: ...r 17 Coolant temperature sensor remove the lid of the helmet compartment and disconnect the con nector to reach it 20 Horn remove the shield back plate lower side to reach it 15 Parking control unit r...

Page 63: ...Ignition KEY 1 Injection ECU 2 Immobilizer aerial 9 Main fuses 11 Key switch contacts 12 Secondary fuses 15 Battery 56 Injection load remote control 62 HV coil MP3 400 i e Electrical system ELE SYS 11...

Page 64: ...ain fuses 11 Key switch contacts 12 Secondary fuses 14 Fuse 15 Battery 16 Starter motor 17 Start up remote control switch 18 Start up enabling remote control 22 Starter button 23 Stop button on rear b...

Page 65: ...a probe 9 Main fuses 11 Key switch contacts 12 Secondary fuses 15 Battery 44 Oil pressure sensor 46 Coolant temperature sensor 47 External temperature sensor 48 Instrument panel 49 Parking electronic...

Page 66: ...tion sensor 64 Revolution sensor Devices and accessories KEY 1 Injection ECU 7 Radiator electric fan 8 Electrical fan remote control 9 Main fuses 10 12V socket 11 Key switch contacts 12 Secondary fuse...

Page 67: ...nternal light 40 Pressure sensor 41 Horn remote control 42 Horn 43 Horn button 45 Parking brake button 48 Instrument panel 49 Parking electronic control unit 51 Geared motor 53 MODE button 54 Rider pr...

Page 68: ...indicator switch 26 Hazard button 27 Hazard and turn indicator control device 31 Light switch 32 Headlight remote control 34 Rear left light A Rear left turn indicator bulbs C Tail light bulb 35 Lice...

Page 69: ...he control unit The code is integrated in a transponder in the key block This allows the driver clear operation without having to do anything other than just turn ing the key The Immobiliser system co...

Page 70: ...nit as specified below Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit Check the following conditions With the key switch set to OFF if...

Page 71: ...no faults are found replace the electronic control unit After removing the shield back plate remove the electrical connection from the aerial as shown in the photograph Remove the protective base from...

Page 72: ...sition for two seconds lower and upper limits 1 to 3 seconds Insert the service key and turn it to ON for 2 seconds If you have copies of the key repeat the operation with each key Insert the MASTER k...

Page 73: ...anently The keys can be stored to memory the vehicle can be star ted but with a limitation imposed on the number of revs 2 Previously unused control unit transpond er absent or cannot be used The LED...

Page 74: ...t or is not detected Check the Immobiliser aerial wiring and change it if nec essary Diagnostic code 2 flashes Two flash code shows a system where the control unit does not show the transponder signal...

Page 75: ...n its turn is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse The three phase generator provides good recharge power and at low revs a good c...

Page 76: ...SURE THAT THE BATTERY IS IN GOOD WORK ING ORDER 1 Place the vehicle on its centre stand 2 With the battery correctly connected to the circuit place the tester terminals between the battery terminals...

Page 77: ...internal side of the right footrest B To have access loosen the screw C and remove the plastic cover The chart shows the position and characteristics of the fuses in the vehicle CAUTION BEFORE REPLACI...

Page 78: ...ity 15 A Protected circuits L V socket 7 Fuse No 7 Capacity 7 5 A Protected circuits Battery powered instru ment panel 8 Fuse No 8 Capacity 10A Protected circuits Live stop start up and start up enabl...

Page 79: ...Fuel gauge I Warning light for helmet compartment courtesy light on L Engine control telltale light and injection sys tem failure warning light M Low fuel warning light N Engine stop warning light D T...

Page 80: ...it is therefore necessary to check the battery charge and recharge it if required before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN CIRCUIT ST...

Page 81: ...Black 12 Engine stop switch Green Black 13 Engine revolution sensor positive Red 14 Fuel injector Red Yellow 15 Engine revolution sensor negative Brown 16 Diagnosis Purple White 17 Immobilizer LED Re...

Page 82: ...7 Ground 8 Not connected 9 Not connected 10 Boot actuator Yellow 11 Channels 1 3 selector Green Blue 12 Alarm code Orange Black TURN INDICATOR CONTROL DEVICE CON NECTOR 1 Hazard switch Brown 2 LHS Swi...

Page 83: ...compartment lighting Blue Black 7 Channels 1 3 selector Green Blue 8 Alarm code Orange Black FUEL PUMP CONNECTOR 1 Injection load remote control Black Green 2 Not connected 3 Not connected 4 Ground Bl...

Page 84: ...Blue 13 Ambient temperature sensor ground lead White Yellow 14 Engine disabled warning light Orange Blue 15 Immobilizer warning light Red Green 16 Engine check warning light Brown Black 17 Parking bra...

Page 85: ...cking switch Yellow Blue 4C Calliper sensor Brown 5C Locking unlocking switch Purple Black 6C Rider presence sensor Purple 7C Scooter speed signal Sky blue 8C Geared motor Blue Remote seat opening Zer...

Page 86: ...CEDURE AGAIN FAILURE TO CARRY OUT THESE OPERATIONS WITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMING THE REMOTE CONTROLLED KEYS WARNING AVOID PRESSING...

Page 87: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 88: ...pass through the swinging arm CAUTION SHOULD IT BE NECESSARY TO REMOVE ON LY THE MUFFLER TIP ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP To fit follow the removal steps but in reverse ord...

Page 89: ...at secures the rear brake pipes Remove the pipe feeding coolant into the pump as shown in the photograph and then empty the system Remove the engine coolant outlet pipe as indi cated Disconnect the fu...

Page 90: ...cated in the photograph Remove the negative terminal cable from the starter motor Remove the positive terminal cable from the starter motor as shown in the photograph Remove the engine ground lead Dis...

Page 91: ...er carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter Check the engine oil level and if necessary top it up with the recommend...

Page 92: ...Engine from vehicle MP3 400 i e ENG VE 6...

Page 93: ...INDEX OF TOPICS ENGINE ENG...

Page 94: ...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 bus...

Page 95: ...rwise replace it Air duct Remove the transmission cover Unscrew the two screws shown in the figure to remove the air conveyor Locking torques N m Air conveyor screws 11 12 Remove the external transmis...

Page 96: ...face and use the special tool so that it is adequately sup ported Pull out the bearing using the special tool N B BELL MUST BE PLACED INTO THE TRANS MISSION COVER CLOSE TO THE BEARING SEAT AND THE WOO...

Page 97: ...ific tooling 020376Y Adaptor handle 020358Y 37x40 mm adaptor 020439Y 17 mm guide Baffle roller Plastic roller Check that the roller does not show signs of wear and that it turns freely Loosen the reta...

Page 98: ...ng half pulley Remove the driven pulley assembly with the belt Inspecting the clutch drum Check that the clutch bell is not worn or damaged Measure the clutch bell inside diameter N B CHECK THE ECCENT...

Page 99: ...TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD CAUSE AN IRREVERSIBLE TOOL DEFORMATION USING THE SPECIAL 55 MM WRENCH REMOVE THE FASTENING RING NUT LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLE...

Page 100: ...ar Extract the collar using 2 screwdrivers Remove the 4 guide pins Extract the moving driven half pulley Removing the driven half pulley bearing Check that the bushing is free from wear and damage oth...

Page 101: ...UNIT BY THE BELL Specific tooling 001467Y002 Driver for OD 73 mm bearing Remove the roller bearing using the special tool supporting the fixed half pulley with the bell Specific tooling 020376Y Adapto...

Page 102: ...r bearing using the special tool N B PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUT WARDS Properly support the half pulley to prevent damaging the threading If you are worki...

Page 103: ...e driven pulley unit with about 10 gr of grease this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole This operatio...

Page 104: ...clutch on the driven pulley bushing N B BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END Tighten the ring nut by hand and complete the tightening using the special wrench to the prescri...

Page 105: ...l Specific tooling 020474Y Driving pulley lock wrench First fit the 2 retainer clamps of the special tool onto the pulley so that the splines are completely engaged Then insert the tool so as to inser...

Page 106: ...are not worn and measure the inside diameter CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHINGS Characteristic Maximum admissible diameter 30 12 mm Standard diameter 30 021 mm Measure the pulley sliding...

Page 107: ...ng the driving pulley Installing the roller container Install the spacer with the internal chamfer facing towards the inside Position the rollers on the half pulley as shown in the figure The closed s...

Page 108: ...e fixed driving half pulley Insert the spacer Install the fixed driving half pulley and check that it is in contact with the spacer and with the guide bushing of the moving driving pulley Remove the f...

Page 109: ...c tooling 020474Y Driving pulley lock wrench Install the lock ring from the rear so that the splines are completely engaged Finally install the tool by siding the nuts by hand and ensuring the tool is...

Page 110: ...y shaft N B INSERT THE SMALLER WASHER FIRST THEN THE LARGER ONE Insert the flanged nut Prepare the torque wrench for LHS locking using a machine hexagon wrench Tighten the driven pulley shaft fastenin...

Page 111: ...ARE COMPLETELY FREE Install the outside plastic transmission cover Tighten the 4 fastening screws to the prescribed torque Locking torques N m Outside transmission cover screws 7 9 End gear Removing t...

Page 112: ...extract 15 mm bearings 001467Y034 Extraction pliers for 15 mm bear ings 001467Y031 Bell Use the special extractor to disassemble the bearing on the engine chassis of the countershaft Specific tooling...

Page 113: ...Y 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 transmis...

Page 114: ...tor 020364Y 25 mm guide 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 dam...

Page 115: ...aring 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 shaf...

Page 116: ...ft 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 APPLIES TO BEARINGS WITH PLASTIC CAG...

Page 117: ...ial tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS APPLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide Heat the gear shaf...

Page 118: ...per position of the centring dowels Install a new gasket Fit the gearbox cover making sure the breather pipe is in the correct position Position the 7 set screws tighten them to the prescribed torque...

Page 119: ...e feed hoses and disconnect the return hose from the pump cover N B THE BANDS MUST BE REPLACED TO RE MOVE THEM OPEN WITH A SCREWDRIVER OR CUT THEM BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS Removing...

Page 120: ...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 CAUTION BE CAREFUL TO PREVENT SLIPPAG...

Page 121: ...g 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 screw...

Page 122: ...crankcase is not worn or deformed Check that the by pass valve seat the torque limiter and the water pump shaft are free from wear Characteristic By pass housing hole diameter 13 9 mm Connection diam...

Page 123: ...IN VALUES HIGHER THAN THOSE STATED Electric characteristic Resistance 0 2 1 Check the ground insulation of each phase If a fault is found carry out a thorough check of the cable harness that contains...

Page 124: ...N m Stator retainers 8 10 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 co...

Page 125: ...ws 3 4 Insert the spring and the by pass piston on the flywheel cover N B LUBRICATE THE BY PASS VALVE Reinstall the blow by reed valve using a new sealing gasket Reinstall the support with head and ti...

Page 126: ...r and con nect the return hose to the pump cover using 3 new clamps N B TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS PAYING ATTENTION NOT TO CON STRICT THE HOSES BUT ALSO TAKING CARE TO TIGHTEN THE CLA...

Page 127: ...er 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 N B T...

Page 128: ...3 Flywheel and starting 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 MU...

Page 129: ...t cannot move long enough to measure the rpm and starter absorption N B THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER THE RPM READING IS NOT THE REAL ONE BUT IS VALID FOR DIAGNOSTIC PURPOSES...

Page 130: ...te control switch 13 Test the battery again and if necessary replace the starter motor N B IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE NOISE CHECK THE FREEWHEEL OF THE TOR...

Page 131: ...ore before insisting on the starter system check the consensus of the immobilizer As for checking the consensus circuit see the Electrical system chapter while for checking the engine shaft control tr...

Page 132: ...tool threading Insert the special tool as shown in the figure making sure that the pins are perfectly inserted in to the previously aligned holes and that it is per fectly abutted and almost flush wi...

Page 133: ...GLY LOCKED THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS Insert the special removing tool Using a 27 mm wrench and a 19 mm bushing release the...

Page 134: ...THE FREEWHEEL MUST BE REMOVED IT IS ADVISABLE TO LOOSEN THE 6 FASTEN ING SCREWS IN ADVANCE WITH THE FLY WHEEL STILL INSTALLED ON THE CRANK SHAFT The freewheel is coupled to the flywheel with high prec...

Page 135: ...haracteristic Hub outside diameter Diameter 45 665 0 008 0 005 mm Check the inside diameter of the bushing of the starter gearing Check that the toothing is not worn Characteristic Inside diameter of...

Page 136: ...ed profiles this assembly allows transmitting torque lower than 10 kgm In case of incorrect start up manoeuvres the lim iter prevents any kicks with consequent reversal of direction of the crankshaft...

Page 137: ...with wheel seeger ring visible Lock the six clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Re...

Page 138: ...el turning it clockwise and inserting at the same time Refitting the flywheel magneto Insert the key on the crankshaft Install the flywheel checking the proper insertion of the key and engaging the to...

Page 139: ...0472Y Flywheel lock wrench Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool Insert the special tool checking that the pins are perfectly introduced...

Page 140: ...Chain guide sliding block retain plate fasten ing screws 3 4 Refitting the starter motor Check that the O ring is in good working order and lubricate it Insert the starter motor Tighten the 2 fasteni...

Page 141: ...intake manifold unit 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...

Page 142: ...e valve lifting mass with relevant travel end washer N B BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING TO FALL INTO THE ENGINE THROUGH THE CHAIN COMPARTMENT Align the reference marks on the timing cha...

Page 143: ...amshaft Remove the timing belt rim Removing the cam shaft Unscrew the 3 fastening screws and remove camshaft retaining bracket N B REMOVING THE FASTENING SCREWS MAY BE DIFFICULT BE CAREFUL NOT TO DAM...

Page 144: ...the cooling system outlet sleeve with thermostat Remove the coolant temperature sensor N B THE SENSOR CONTROLS BOTH INJECTION AND THE ANALOGUE INSTRUMENT ON THE PANEL TO CHECK THIS COMPONENT SEE THE I...

Page 145: ...chain guide sliding block N B DO NOT REMOVE THE DOWELS IF THEY ARE FORCED INTO THEIR SEAT CAUTION WHEN YOU HAVE TO REMOVE THE HEAD PREPARE A SUITABLE CONTAINER SINCE THE THERMAL UNIT CONTAINS COOLANT...

Page 146: ...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 OR DER TO ENSURE THAT THE INITIAL DIREC TION OF ROTATION IS MAIN...

Page 147: ...G THE POSI TION IN CASE OF REUSE N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Inspecting the small end Using a bore gauge measure the connecting rod small end diameter N B IF THE CONN...

Page 148: ...USINGS 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...

Page 149: ...meter 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 Inspecting the piston rings...

Page 150: ...n in the drawing and check the coupling clearances Top ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Intermediate ring Standard coupling clear ance 0 02 0...

Page 151: ...ecific tooling 020470Y Pin retainers installation tool N B THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUSING Choosing the gasket Provis...

Page 152: ...er base gasket to be used for reassembly by the table below Cor rectly identify the cylinder base gasket thickness to keep the correct compression ratio Remove the special tool and the cylinder N B IF...

Page 153: ...ON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS SECTION THIS IS TO ACHIEVE A BETTER BEDDING Misalign the lining openings at 120 as shown in the figure Lubricate the components with engine o...

Page 154: ...m shaft timing gear and crankshaft pinion exhibit no wear In case of wear of the sliding blocks replace them In case of wear of the chain or rim replace the en tire unit N B IF THE CHAIN HAS DAMAGED T...

Page 155: ...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 th...

Page 156: ...he deformation with a comparator Characteristic Limit values admitted 0 1 mm Check the concentricity of the valve head by ar ranging a comparator at right angle relative to the valve head and rotate i...

Page 157: ...gns of wear on the surface of contact with the articulated register terminal If the checks above give no failures you can use the same valves To obtain better sealing perform ance grind the valve seat...

Page 158: ...ck that the upper and lower supporting spring washers the cotters and the oil seal show exhibit no signs of abnormal wear Replace a component when worn Measure the unloaded spring length Characteristi...

Page 159: ...RNS WITH GREATER PITCH Inspecting the cam shaft Check that the camshaft ends exhibit no scores or irregular wear Using a micrometer measure the camshaft capacity STANDARD DIAMETER Specification Desc Q...

Page 160: ...s with new ones Check that the retaining plate seat shown in the figure exhibits no wear Check that the automatic valve lifting device cam the travel end roller and the rubber abutment on the containm...

Page 161: ...mponent Refitting the head and timing system components Insert the chain guide sliding block Insert the two centring dowels between head and cylinder Install the head gasket N B THE FIGURE SHOWS THE I...

Page 162: ...figure Locking torques N m Head fixing stud bolts Apply a preliminary torque of 7 Nm in a crossed sequence Tighten by 90 in a crossed sequence Tighten again by 90 in a crossed sequence Tighten the fas...

Page 163: ...l the tensioner shoe with its spacer tight ening the bolt to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength...

Page 164: ...ge the inside hexagon Locking torques N m Camshaft retaining bracket screws 4 6 Install the intermediate gear with torque limiter the flywheel and its cover as described in Chapter Flywheel and start...

Page 165: ...screws to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking torques N m Counterweight screw...

Page 166: ...E BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Check that the decompression...

Page 167: ...esc Quantity Inlet 0 15 mm engine cold drainage 0 15 mm engine cold In case different values are found adjust by loos ening the lock nut and use a screwdriver for the set screw as shown in the figure...

Page 168: ...ibed in the automatic transmission chapter 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 t...

Page 169: ...ific tooling 020460Y Scooter diagnosis and tester If the values do not match check distribution timing revolution timing sensor Injection control unit Refitting the rocker arms cover Check that the ga...

Page 170: ...let manifold screws 11 13 Crankcase crankshaft Remove the outside and inside transmission cover and the complete driving pulley as described in Automatic transmission Remove the flywheel cover with th...

Page 171: ...wear on the surfaces of the crankshaft casing support To carry out an accurate measurement measure the clearance in both directions between crankcase and crankshaft Splitting the crankcase halves Rem...

Page 172: ...ankshaft Remove the crankshaft with the shim adjustment washer on the flywheel side CAUTION WHILE OPENING THE CRANKCASE AND RE MOVING THE CRANKSHAFT CHECK THAT THE SHAFT THREADED ENDS DO NOT INTER FER...

Page 173: ...ve the fastening nut with relevant washer Remove the special tool and extract the counter shaft with the control gear Replacing the countershaft bearings Check that the bearings are free from irregula...

Page 174: ...7Y007 Driver for OD 54 mm bearing Before installing a new bearing heat the flywheel side half crankcase using the special tool Place the half crankcase on a wooden base Specific tooling 020151Y Air he...

Page 175: ...eater Insert a new bearing on the special tool after greasing the guide seat Install the new bearing on the engine crankcase using the special tool N B IF A BEARING WITH PLASTIC CAGE IS USED KEEP THE...

Page 176: ...shown in the diagram N B BE CAREFUL NOT TO LET THE MEASURE MENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS Characteristic Standard dimensions 63 6 63 45 mm CAUTION THE CRANKSHAFT CAN BE REUSED...

Page 177: ...wo categories Cat 1 and Cat 2 STANDARD DIAMETER Specification Desc Quantity Cat 1 40 010 40 016 Cat 2 40 016 40 022 Inspecting the crankshaft alignment Install the crankshaft on the support and measur...

Page 178: ...t see sec tion Thermal unit and timing system See also Cylinder assy and timing system Inspecting the crankcase halves Before proceeding to check the crankcase halves thoroughly clean the all surfaces...

Page 179: ...er surfaces Any defects in the crankcase gasket or matching surfaces see Flywheel cover coupling can cause pressurised oil leaks thereby affecting the connecting rod and main bearing lubrication press...

Page 180: ...heck that the clearance between the engine crankcase bushing and the crankshaft is within the predetermined limits Characteristic Crankshaft bushing maximum clearance admitted 0 08 mm The standard bus...

Page 181: ...ntershaft with centre to centre distance A Complete FC3 type crankcase equipped with bushings for housing a category 1 crankshaft and a countershaft with centre to centre distance B Complete FC4 type...

Page 182: ...REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NEC ESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL Before installing the gear on the crankshaft care fully clean the two matching surfaces rem...

Page 183: ...Specific tooling 020471Y Pin for countershaft timing Insert the crankshaft on the pin and into the bush ing Before inserting thoroughly make the oil pump gear align with the control gear Insert thorou...

Page 184: ...HE LUBRICATION OIL CIRCULA TION Specific tooling 020360Y Adaptor 52 x 55 mm 020376Y Adaptor handle Insert the gasket on the flywheel side half crank case Lubricate the main bearing on the transmission...

Page 185: ...cooling system sleeves as described in the Flywheel cover chapter Install the complete driving pulley the transmission cover and the relevant mesh filter and the outside transmission cover as describ...

Page 186: ...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 Diame...

Page 187: ...istics Lubrication circuit is split into two sections High pressure Low pressure The high pressure section includes all components located on the engine crankcase while the low pressure section only r...

Page 188: ...shaft is partly compensated by the oil supplied to the small end bearings The camshaft supplies the lubricant to the rocking levers via the bores provided these are installed in a position to ensure t...

Page 189: ...tact with the crankcase bottom and pull back a few millimetres Specific tooling 020331Y Digital multimeter AHEAD go to 5 5 Measure the pressure with cold and idling engine STANDARD VALUES Specificatio...

Page 190: ...of rotation with the connecting rod in quadrature YES go to 16 NO go to 17 15 Replace the faulty components Flywheel cover chapter 16 Overhaul the engine Crankcase and crankshaft chapter 17 Open the...

Page 191: ...GHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE 1 If oil consumption is above 250 g 1000 km on a run in engine proceed as follows AHEAD go to 2 2 Check the presence of oil at the scavenge duc...

Page 192: ...ng the 2 retaining screws through the eyes machined in the gearing proper Remove the gasket Remove the two screws and the oil pump cover Remove the inside rotor retaining snap ring turn ing it to move...

Page 193: ...e shaft with the gear and install the lock ring then turn it with the opening opposed to the shaft face Check any irregular clearance between shaft and pump body Using a thickness gauge check the dist...

Page 194: ...on the oil pump cover If non conforming values or signs of wear are found replace the pump Fit the pump cover in the position that permits the crankcase fixing screws to be aligned Tighten the two fas...

Page 195: ...stall the special tool in the position shown in the figure Specific tooling 020479Y Countershaft lock wrench Keep the countershaft in position and insert the washer with the nut Tighten the nut to the...

Page 196: ...Engine MP3 400 i e ENG 104...

Page 197: ...INDEX OF TOPICS INJECTION INJEC...

Page 198: ...d with an integrated injection and ignition system Injection is indirect in the manifold through an electro injector The injection and ignition are timed on the four stroke cycle by means of a tone wh...

Page 199: ...injector is connected by a pipe with fast release fittings The pressure regulator is located at the beginning of the circuit The fuel pump is controlled by the MIU control unit this ensures the scoot...

Page 200: ...trol unit is connected to a diagnostic LED on the instrument panel that also carries out the deterrent flashing functions The MIU control unit power supply is furthermore controlled by the emergency s...

Page 201: ...the MIU system connectors if required Before reconnecting check that the connectors are dry 12 When carrying out electric inspections do not force the tester probes into the connectors Do not take mea...

Page 202: ...ck the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit install the original control unit again and check if the fault occurs again 4 When troubleshooting...

Page 203: ...Immobilizer LED 18 Ground lead Connected to the engine stop switch and the water temperature sensor 19 20 Injection load remote control 21 22 HV coil 23 24 Start up enabling 25 26 Ground lead EMS circ...

Page 204: ...Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient repair according to the indi cations of the self...

Page 205: ...era ture steps and actual opening Cleaning of the auxiliary air pipe and throttle valve air filter efficiency Engine stops at idle ENGINE DOES NOT HOLD IDLING IDLING IS UNSTABLE IDLING TOO LOW Possibl...

Page 206: ...leeve Filter box Fuel feed low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presen...

Page 207: ...HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER ENGINE IRREGULAR PROGRESS ON PICKUP...

Page 208: ...leeve Filter box TPS reset successful TPS reset successful Fuel supply Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinde...

Page 209: ...Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure Remove the fast release fitting from the injector support MP3 400 i e Injection INJEC 13...

Page 210: ...move the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the MIU connector Injection MP3 400 i e INJEC...

Page 211: ...Remove the gas command fitting as indicated in the photograph Pump supply circuit MP3 400 i e Injection INJEC 15...

Page 212: ...n switched to ON the fuel pump starts to rotate for 2 seconds and then stops When the engine starts up in the presence of phase rpm signal the pump is continuously supplied ELECTRICAL DATA Pump windin...

Page 213: ...trol energising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and the Black Purple cable of the remote control base If there is not check the...

Page 214: ...rol base and earth If there is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS...

Page 215: ...l pump by measuring the continuity between the pump connector black cable system side and the earth If when switching to ON the pump continues to turn after 2 seconds of activation check with the cont...

Page 216: ...h a flow rate of approximately 1 L Rotate the pump using the active diagnoses of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilise at...

Page 217: ...the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph Remove the filter from the pump support MP3 400 i e Injection IN...

Page 218: ...ECTION LOADS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 15A 3 Fuse 20A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda se...

Page 219: ...hm Input current during regular functioning 2 8 A Check that the injection load 15A fuse No 2 works properly Check that the live control unit power supply 7 5A fuse No 10 works properly Check the effi...

Page 220: ...Violet cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 o...

Page 221: ...rol base and earth If there is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS...

Page 222: ...Black Green cable of the injector con nector and the ground lead With injector disconnected and the injector load remote control disconnected check the continuity of the Black Green cable between the...

Page 223: ...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 Immobiliser circ...

Page 224: ...sh confirms the switching to the ON status The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition key switch a...

Page 225: ...work ing order There is continuity between terminals 12 18 with the emergency cut off switch in the RUN position If there is no continuity check the contacts of the switch If no faults are found repl...

Page 226: ...orage pro cedure for a previously not programmed control unit provides for the recognition of the master as the first key to be stored to memory this becomes particularly important because it is the o...

Page 227: ...stive spark plugs Characteristic MASTER key RED 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 diag...

Page 228: ...F The engine can be started 5 Programmed control unit fault detected a light code is displayed according to the fault detected after which the LED remains on permanently The engine cannot be started T...

Page 229: ...rial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Code 3 The three flash code...

Page 230: ...e between pins 13 and 15 is around 2 8 V With the interface cable harness disconnected from the control unit check continuity between pin 13 and the red cable of the rpm sensor connector and between p...

Page 231: ...Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 15A 3 Fuse 20A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor MP3 400...

Page 232: ...e the ignition advance is optimised to stabilise the speed at 1500 100 rpms Magnetisation time The coil magnetisation time is controlled by the control unit The power of the ignition is increased duri...

Page 233: ...rol energising coil after switching to ON make sure there is battery voltage for two seconds between the Red White cable and Black Violet cable of the remote control base If there is not check the con...

Page 234: ...rol base and earth If there is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS...

Page 235: ...il between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con trol disconnected Primary resistance...

Page 236: ...gine rpm The ignition timing value is detectable any time using the diagnostic tester It is possible to check whether the ignition advance determined by the system does in fact correspond with the val...

Page 237: ...ct the diagnostic tester Start the engine Select the menu on the parameter function Select the stroboscopic light command in the tra ditional four stroke engine position 1 spark 2 revs Check that the...

Page 238: ...disconnected and the coolant temperature sensor connector connected check that the resistance values be tween pin 9 and ground correspond to the engine temperature 20 2500 100 80 308 6 With the contro...

Page 239: ...tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition advance The throttle body after the pre...

Page 240: ...c tester on TPS RESET Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw Guaranteeing that this position will be kept...

Page 241: ...injection control unit is replaced N B THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW...

Page 242: ...DS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 15A 3 Fuse 20A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Injec...

Page 243: ...east 350 C at 600 C and it has a reaction time of just 50 milliseconds The signal generated passes from a high value to a low value with a mixture with lambda 1 Specific tooling 020481Y Control unit i...

Page 244: ...Violet cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 o...

Page 245: ...the multimeter between pins 4 and 11 With the engine running at idle speed check that the voltage oscillates between 0V and 1V With the throttle valve completely open the volt age is approx 1V During...

Page 246: ...Injection MP3 400 i e INJEC 50...

Page 247: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 248: ...cated 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 specif...

Page 249: ...ops 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 specifi...

Page 250: ...ip and remove the throttle Loosen the clamp fixing the handlebar to the steering tube and remove the handlebar by pulling it upwards then remove the lower plastic cover N B IF THE HANDLEBAR IS BEING R...

Page 251: ...en 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 para...

Page 252: ...ng 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 Remove...

Page 253: ...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 c...

Page 254: ...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 th...

Page 255: ...ing 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 it...

Page 256: ...NSION 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 d...

Page 257: ...2 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 steering...

Page 258: ...cated 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 i...

Page 259: ...icated 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 a...

Page 260: ...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 400 i e SUSP 14...

Page 261: ...ow 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 coupling...

Page 262: ...section 20 25 Geared motor and Suspension locking system 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...

Page 263: ...plays 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 nor...

Page 264: ...ap 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 Suspensi...

Page 265: ...FF AND ON If this is not successful the tilt locking mechanism remains locked for safety Adjust the flexible transmission so that a small clearance is left to guarantee switch activation on the tilt l...

Page 266: ...ews 8 12 Unscrew the Allen screw and remove the switch When refitting place the switch with the button ori ented to the stop indicated on the calliper lever observing the reference indicated on the sw...

Page 267: ...itch is pushed when the system is unlocked Refit the spring toothed sector unit hold the crank case in a perfectly horizontal and stable position place the spring toothed sector unit keeping it per fe...

Page 268: ...halves with slight hits of a mallet to get them into contact Place the flexible transmission supporting bracket refit the four screws screw them to the prescribed torque Locking torques N m Geared mo...

Page 269: ...ody and tighten the screws to the prescribed torque Fit but not tighten the pump stem coupling screw and refit the plastic protection cap The synchronisation procedure should be com plete when the ins...

Page 270: ...ever control shaft Hit slightly with a mallet if necessary Refit the bearing check seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020362Y 12 mm guide 020357Y 32 x 35 mm adaptor...

Page 271: ...002 Driver for OD 73 mm bearing Extract the bearing of the electric motor with the specific tool Hold the crankcase in a perfectly horizontal posi tion heat it with a heat gun at a temperature of abou...

Page 272: ...m guide 020151Y Air heater 020376Y Adaptor handle 020477Y Adaptor 37 mm Before removing the geared motor Disable the suspension lock Remove the front shield With the set nut indicated in the photograp...

Page 273: ...D OCULAR TIS SUE IF YOU ACCIDENTALLY SPILL BRAKE FLUID ON YOURSELF TAKE OFF YOUR CLOTHES WASH WITH HOT WATER AND SOAP AND SEEK MEDICAL ADVICE IMMEDI ATELY IF BRAKE LIQUID GETS ACCIDEN TALLY IN CONTACT...

Page 274: ...directed to the opposite side of the pump Remove the nut indicated in the figure if neces sary lock the lever with a vice making sure not to spoil the surface In case of difficulties when removing th...

Page 275: ...four screws indicated in the figure remove the flexible transmission supporting brack et separate the two crankcase halves if neces sary use a rubber mallet to hit the flexible transmission lever in...

Page 276: ...7 Right speed sensor 8 Diagnostic tester serial line 9 Engine electronic control unit 10 Direct Battery 11 Live Battery 12 To light switch 13 20A Fuse No 4 14 Light remote control 15 Pressure switch...

Page 277: ...e red cable between pin 38 and the blue cable on the geared motor connector With the interface wiring disconnected from the control unit check the continuity of the geared mo tor winding placing the m...

Page 278: ...e 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 ye...

Page 279: ...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 KEY 1 GROUND 2 LOCKING 3 REST 4 UNLOCKING...

Page 280: ...ated locking condition is 4V and 1V in the locking to rest condition With the interface wiring disconnected from the control unit check the continuity between pin 17 and the yellow cable of the potent...

Page 281: ...er is not seated on the saddle pin 17 36 resistance of about 3 kOhm when the rider is seated on the saddle Check the continuity between the interface wiring pin 17 and the yellow cable of the rider pr...

Page 282: ...ion with a multi meter With interface wiring disconnected from the control unit check the continuity between pin 34 and the brown cable of the tilt locking gripper sensor con nector on the system side...

Page 283: ...Also check that the flexible transmission control lever activates the limit stop switch properly TONE WHEEL SENSOR 1 Right tone wheel 2 Left tone wheel MP3 400 i e Suspensions SUSP 37...

Page 284: ...m at a temperature of approximately 20 With interface wiring disconnected from the control unit check the continuity between pin 23 and the red cable of the LEFT wheel turning sensor con nector the co...

Page 285: ...between pin 24 and the red cable on the connector With interface wiring disconnected from the control unit and the connectors disconnected from wheel turning sensors check that pin 23 17 and 24 17 ar...

Page 286: ...ter 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 Chec...

Page 287: ...o check the pressure switch operation as well as the continuity at rest as this is normally closed switch Wheel alignment Tool fitting How to use the tools Check that tyre pressure is correct Park the...

Page 288: ...cor rect this and then adjust them Characteristic Front tyre pressure with passenger 1 6 bar 1 8 bar Rear tyre pressure with passenger 2 4 bar 2 6 bar Get the vehicle off the stand back on the ground...

Page 289: ...rrectly 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 on...

Page 290: ...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 t...

Page 291: ...ving the rear wheel Before removing the rear wheel support the vehi cle properly and operate the parking brake so as to facilitate removing the wheel fixing screws Remove the exhaust silencer Undo the...

Page 292: ...he cen tre stand Remove the cotter pin and collect the cap Unscrew the wheel fixing nut and collect the spacer Unscrew the clamp Collect the conical spacer Undo the five wheel fixing screws and remove...

Page 293: ...Muffler arm clamping screws 27 30 Rear wheel axle nut 104 126 Shock absorber crankcase attachment bracket 20 25 Lower shock absorber clamping screw 33 41 Nm Rear brake calliper fixing screws 25 30 Nm...

Page 294: ...Remove the silent blocks Remove the retainer fixing the swinging arm to the frame undo the screw Remove the pin Unscrew the nut of the set screw bushing Suspensions MP3 400 i e SUSP 48...

Page 295: ...nt of the joint connecting the swinging arm on the engine side to the swinging arm on the frame side To check the clearance on the frame side arm mount the retainer using the pin fixing the swinging a...

Page 296: ...ove the internal spacer Using a suitable pin remove the roller casings as shown in the photographs Using an appropriate tool plant new roller cas ings being careful to position the bearings with the O...

Page 297: ...he swinging arm frame side with the pro truding part facing the transmission side Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm Soap based lithium an...

Page 298: ...htly tighten part 1 2 Position the swinging arm inserting part 2 3 Tighten part 3 to the prescribed torque 4 Screw on and tighten part 4 to the prescribed torque 5 Screw on and tighten part 5 to the p...

Page 299: ...a jack so as to free the two shock absorbers remove the exhaust silencer undo the shock absorber spring assembly clamp ing screw from the support fixed to the engine on the one side and from that fix...

Page 300: ...t the vehicle properly Remove the two stand return springs Working from both sides undo the two bolts con necting it to the supporting plate To refit follow the removal steps but in reverse order be c...

Page 301: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 302: ...e two male hexagonal screws 1 and take out the two pads 10 2 remove the two male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal el...

Page 303: ...the action and reaction prin ciple to obtain the thrust for both pads The body and the reaction plate body work inte grally and can move axially with respect of the fixed plate that is integral to the...

Page 304: ...both Remove the wheel Undo the two fixing screws to the plate and re move the calliper Overhaul Remove the rear brake calliper Suitably hold the brake calliper in a clamp Remove the two calliper coupl...

Page 305: ...ake fluid Re couple the half callipers and lock the two screws at the specified torque Locking torques N m Calliper coupling screw 22 27 Refitting To fit the front brake callipers follow the removal s...

Page 306: ...ing clamp Remove the brake disc Refitting To fit the rear brake disc follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque using threadlock Recommende...

Page 307: ...the appro priate tools that the axial run out of the brake surface is within the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DI...

Page 308: ...l to tighten the screws to the prescribed torque using threadlock Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking torques N m Front disc scre...

Page 309: ...n the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axial run out 0 1 mm Front bra...

Page 310: ...g the brake pads Remove the pads paying attention to the pad re taining spring Check the thickness of the pads If the thickness is less than the minimum value replace the pads with new pads Characteri...

Page 311: ...ing up the brake system tank to prevent air being drawn into the system until no more air escapes at the bleed fitting The operation is finished when only brake fluid comes out of the bleed screw Clos...

Page 312: ...SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT CO...

Page 313: ...pipes from the calliper and drain the brake fluid Then remove the plastic and metallic straps Unscrew the brake pump pipes as indicated in the figure Parking brake Remove the rear wheel Loosen the tra...

Page 314: ...shield back plate remove the engaging cable for the safety mechanism remov ing it from its fitting Remove the 4 screws shown in the figure When refitting pay attention to insert the metallic cable peg...

Page 315: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 316: ...diator cold box is connected to the lower side of the expansion tank in the fluid When the engine is cold the thermostat output to the radiator is closed even though there is still a little flow for d...

Page 317: ...Starts opening 82 2 C ELECTRIC VENTILATION Specification Desc Quantity Type With piston Electric ventilation start 107 C Electric ventilation end 103 C WATER PUMP Specification Desc Quantity Type Cent...

Page 318: ...C CAN ONLY BE MANAGED BY A SYSTEM SUP PLIED WITH A 50 MIXTURE AND PRESSURISED AT 0 9 BAR AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOIL ING TEMPERATURE BEFORE THE ELECTR...

Page 319: ...ted Close the bleed screw Stop the engine Restore the level into the expansion tank and tighten the cap Start the engine and let it warm up to reach the electric ventilation temperature Stop the engin...

Page 320: ...bed in the Engine Chapter Once the fault has been fixed and all components have been replaced fill and purge the system again N B FOR CHANGING THE COOLANT AND BLEED ING THE SYSTEM SEE THE COOLANT CHAN...

Page 321: ...Flywheel cover MP3 400 i e Cooling system COOL SYS 7...

Page 322: ...Cooling system MP3 400 i e COOL SYS 8...

Page 323: ...INDEX OF TOPICS CHASSIS CHAS...

Page 324: ...own in the figure remove the cover and disconnect the rider presence sensor connector Remove the three fixing screws shown in the fig ure Rear handlebar cover After removing the front part of the hand...

Page 325: ...te upper side Unscrew the six fixing screws and remove the instrument panel Front handlebar cover Remove the upper cap by operating on the Allen screw indicated in the figure Remove the two brake pump...

Page 326: ...ses with the turn indi cator Unscrew the two screws fixing the wheelhouse to the shield Disconnect the cable guide after that turn the wheelhouse anticlockwise inwards to release it from the shield su...

Page 327: ...l cover Remove the three screws on the right and the left side Open the refuelling compartment and remove the tank cap so as to remove the central cover Disconnect the cable refuelling compartment ope...

Page 328: ...o front screws and the two screws under the wheelhouse Remove the four screws on the shield back plate See also Headlight assy spoiler Knee guard Remove the front shield Remove the spoiler Remove the...

Page 329: ...nually 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 the shield back plate Remove the key switc...

Page 330: ...rnal temperature sensor con nection See also spoiler Legshield Taillight assy Open the rear case cover remove the two screws D and then the other four fixing screws D to pull out the headlight assembl...

Page 331: ...t Remove the central cover Remove the four screws and extract the half foot rest Follow the same procedure for both half footrests Release the fuse box See also Frame central cover MP3 400 i e Chassis...

Page 332: ...the same procedure for both fairings Remove the five screws on the right side and the five on the left side indicated in the figure License plate holder Remove the two lateral screws and the two screw...

Page 333: ...cover Remove the four external screws and the two screws inside the rear case to remove the frame Remove the upper frame unscrewing the ten up per screws the two saddle closing screws and the case lig...

Page 334: ...he other Remove the six upper screws Release the case latch Remove the case light front and rear switch con nections the HV coil the battery leads and the fuse box See also Frame central cover spoiler...

Page 335: ...e chassis central cover Remove the footrest Remove the three tank retainers Remove the two lower bracket retainers indicated in the figure Disconnect the electric wiring and the fuel pipes See also Fo...

Page 336: ...verages Handles and top side fairings Operating from the rear case remove the two screws indicated in the photograph Remove the ceiling fitting indicated in the photo graph and remove the internal scr...

Page 337: ...the figure Radiator cover Remove the two front screws indicated in the pho tograph Remove the two lower retainers with the bushing Remove the two rear retainers and then the two wheelhouse front reta...

Page 338: ...e the two screws fixing the radiator lower protection to the shield back plate After that press up and pull the protection front part so as to release it from the radiator frame Chassis MP3 400 i e CH...

Page 339: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 340: ...s shown in the figure making the 4 securing holes coincide Fit the 4 washers on the mudguard out er side and always on the same side insert the 4 screws and tighten to the prescribed torque Locking to...

Page 341: ...currently in force Front and rear stop light buttons and bulb Turn indicators and their warning lights Instrument lighting instruments fuel and temperature indicator Instrument panel lights Horn elec...

Page 342: ...THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Level check Hydraulic brake system liquid level Tilt locking system fluid...

Page 343: ...ction Functional check up Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check frame and engine number...

Page 344: ...Pre delivery MP3 400 i e PRE DE 6...

Page 345: ...INDEX OF TOPICS TIME TIME...

Page 346: ...oted to the time necessary to carry out repairs For each operation the description code and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine to chassis Replace ment Time...

Page 347: ...Crankcase CRANKCASE Code Action Duration 1 001100 Oil seal clutch side Re placement 2 001133 Engine crankcase Replace ment 3 001153 Crankcase half gasket Re placement MP3 400 i e Time TIME 3...

Page 348: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001098 Countershaft Replacement Time MP3 400 i e TIME 4...

Page 349: ...Cylinder assy CYLINDER GROUP Code Action Duration 1 001002 Cylinder piston Replace ment 2 001154 Pin ring piston unit Service 3 001129 Chain tensioner Service and Replacement MP3 400 i e Time TIME 5...

Page 350: ...de Action Duration 1 001045 Valves Replacement 2 001049 Valves Adjustments 3 001056 Head gasket Replacement 4 001126 Head Replacement 5 001083 Thermistor Replacement 6 007012 Coolant bleed valve Re pl...

Page 351: ...cker arms support assy ROCKING LEVER SUPPORT UNIT Code Action Duration 1 001044 Camshaft Replacement 2 001148 Rocking lever valve Re placement 3 001169 Decompressor Replace ment MP3 400 i e Time TIME...

Page 352: ...Cylinder head cover HEAD COVER Code Action Duration 1 001089 Head cover Replacement 2 001093 Spark plug Replacement 3 001088 Head cover gasket Replace ment Time MP3 400 i e TIME 8...

Page 353: ...nt 4 001124 By pass valve Replacement 5 001057 Thermostat Replacement 6 001062 Water pump command shaft Replacement 7 001150 Flywheel cover gasket Re placement 8 001160 Minimum oil pressure sensor Rep...

Page 354: ...n pulley DRIVEN PULLEY Code Action Duration 1 001022 Clutch Replacement 2 001012 Driven pulley Overhaul 3 001110 Driven pulley Replacement 4 001155 Clutch bell housing Re placement Time MP3 400 i e TI...

Page 355: ...n Replace ment 3 001112 Oil pump change 4 001125 Chain guide pads change 5 001071 Start up pinion Replace ment 6 001020 Starter motor Replacement 7 001102 Net oil filter Replacement Cleaning 8 003064...

Page 356: ...de Action Duration 1 001010 Geared reduction unit Serv ice 2 001156 Gear reduction unit cover Replacement 3 003065 Gear box oil Replacement 4 004125 Rear gear shaft Replace ment 5 002031 Rear wheel hu...

Page 357: ...086 Driving half pulley Replace ment 2 001011 Driving belt Replacement 3 001006 driving pulley Service 4 001141 Belt anti flapping roller Re placement 5 001066 driving pulley Replacement 6 001177 Vari...

Page 358: ...ion 1 001065 Internal transmission cover Replacement 2 001096 External transmission cover Replacement 3 001131 Transmission air intake Re placement 4 001135 Transmission cover bearing Replacement 5 00...

Page 359: ...de Action Duration 1 001173 Rotor Replacement 2 001067 Stator Removal and Refit ting 3 001058 Complete flywheel Replace ment 4 001104 Start up freewheel Replace ment 5 001151 Start up driven gearing R...

Page 360: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001013 Intake manifold change 2 001047 Injector Replacement 3 001023 Control unit Replacement Time MP3 400 i e TIME 16...

Page 361: ...Code Action Duration 1 001009 Muffler Replacement 2 001092 Exhaust manifold Replace ment 3 001095 Muffler guard Replacement 4 004169 Muffler guard Replacement 5 005138 Lambda probe Replace ment MP3 4...

Page 362: ...Air cleaner AIR CLEANER Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Air cleaner carburettor fitting Replacement Time MP3 400 i e TIME 18...

Page 363: ...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 40...

Page 364: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004179 Stand buffer Replacement Legshield spoiler Time MP3 400 i e TIME 20...

Page 365: ...r frame Re placement 4 004149 Shield central cover Re placement 5 004022 Shield lower section Re placement 6 004167 Grill radiator cover Re placement Side fairings SIDE COVERS Code Action Duration 1 0...

Page 366: ...on Duration 4 004068 Passenger handgrip Re placement 5 004037 Side aprons Replacement Rear cover REAR SHIELD Code Action Duration 1 004065 Front shield rear part Re moval and refitting Time MP3 400 i...

Page 367: ...park plug inspection flap Replacement 2 004135 Fuel tank port Replacement 3 004011 Central chassis cover Re placement 4 004012 Rear fairings Removal and refitting 5 004015 Footrest Removal and Re fitt...

Page 368: ...n 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 m...

Page 369: ...pump pipe Replace ment 2 005010 Tank float Replacement 3 004109 Fuel tank breather Replace ment 4 004168 Fuel tank cap Replacement 5 004138 Fuel reverse pipe Replace ment 6 004005 Fuel tank Replaceme...

Page 370: ...K 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 Ser...

Page 371: ...ERS Code Action Duration 1 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE MENT 2 004019 Rear handlebar covers Re placement 3 004026 Handlebar cover Replace ment 4 004018 Front handlebar covers Re place...

Page 372: ...071 Left knob Replacement 6 003059 Counterweight Replace ment 7 002037 Brake lever Replacement 8 002048 Rear brake calliper Re placement 9 002067 Rear brake pump Replace ment 10 002080 Rear brake oil...

Page 373: ...e Action Duration 1 004058 Silent block Replacement 2 003081 Swinging arm support flange replace 3 001072 Swinging arm Engine chas sis connection Replacement 4 003080 Swinging arm on frame Re placemen...

Page 374: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement Time MP3 400 i e TIME 30...

Page 375: ...l 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 MP3 400 i...

Page 376: ...e 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 s...

Page 377: ...ar turn indicators Re placement 3 005031 Licence plate light bulb Re placement 4 005032 Transparent licence plate cover replace 5 005131 Licence plate light support Replacement 6 005066 Rear light bul...

Page 378: ...ICATOR LIGHTS Code Action Duration 1 005067 Front direction indicator bulb Replacement 2 005012 Front direction indicators Replacement 3 005002 Front light Replacement 4 005008 Light bulbs Replacement...

Page 379: ...tion 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 w...

Page 380: ...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 Time MP3 400...

Page 381: ...de 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 Hor...

Page 382: ...CABLE HARNESS Code Action Duration 1 005001 Electrical system Replace ment 2 005114 Electrical system Service Time MP3 400 i e TIME 38...

Page 383: ...3 005041 Starter button Replacement 4 004010 Anti theft lock Replacement 5 005040 Horn button Replacement 6 005006 Light switch or turn indicators Replacement 7 005039 Headlight switch replace 8 0051...

Page 384: ...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 5 003...

Page 385: ...on Duration 1 005046 Battery cover change 2 005026 Helmet compartment bulb Replacement 3 005027 Helmet compartment bulb support Replacement 4 004016 Helmet compartment Re placement 5 004142 Plug socke...

Page 386: ...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 Ti...

Page 387: ...010 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 003113...

Page 388: ...n pipe Replacement 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 6 007...

Page 389: ...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 bra...

Page 390: ...ront brake pads Replace ment 15 002039 Front brake calliper Re placement 16 003104 Suspension system locking calliper replacement 17 003119 Hoses for the pump splitter suspension locking system replac...

Page 391: ...INDSHIELD Code Action Duration 1 004101 Windshield Replacement Stickers TRANSFERS Code Action Duration 1 004066 Driving mirror Replacement 2 004159 Plates Stickers Replace ment MP3 400 i e Time TIME 4...

Page 392: ...ent 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 r...

Page 393: ...ocking 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 8...

Page 394: ...Code Action Duration 11 003089 Geared motor potentiometer replacement 12 003097 Tilt locking calliper micro switch replacement Time MP3 400 i e TIME 50...

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