PIAGGIO MP3 500 i.e. SPORT Service Station Manual Download Page 1

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SERVICE STATION MANUAL

1Q000267 EN

MP3 500 i.e. SPORT Business_LT_ ABS-
ASR_EU_USA (2015)

Summary of Contents for MP3 500 i.e. SPORT

Page 1: ...SERVICE STATION MANUAL 1Q000267 EN MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015...

Page 2: ...s publication beforehand to make any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not...

Page 3: ...erefore advisable 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 o...

Page 4: ......

Page 5: ...AR TOOLING 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...

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

Page 7: ...hat 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 original PIAGGIO spare parts...

Page 8: ...number stamped on the vehicle corresponds with that on the vehicle documentation CAUTION PLEASE REMIND THAT ALTERING IDENTIFICATION REG ISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS IMPOUNDIN...

Page 9: ...ngine idle speed 1 600 100 rpm Timing system Four valves single overhead camshaft chain driven Valve clearance Inlet 0 15 mm Outlet 0 15 mm MAX power 29 5 kW at 7 250 rpm MAX torque 45 5 Nm at 5 250 r...

Page 10: ...antity Engine oil 0 44 gal 1 7 l Transmission oil 15 3 in 250 cm Cooling system fluid 0 47 gal 1 8 l Fuel tank 3 2 gal 0 1 12 0 0 5 l Electrical system ELECTRICAL SYSTEM Specification Desc Quantity El...

Page 11: ...ring nut central headstock 32 5 40 Nm 24 30 lb ft Handlebar fixing screw 50 55 Nm 37 41 lb ft Fixing screws for the control unit U bolts to the handlebar 7 10 Nm 5 2 7 lb ft FRAME Name Torque in Nm Sw...

Page 12: ...t brake disc screws 8 10 Nm 5 9 7 lb ft Front brake pump pipe fitting 16 20 Nm 12 15 lb ft Joint pipe calliper 20 25 Nm 15 18 lb ft Screw tightening calliper to support 20 25 Nm 15 18 lb ft Brake call...

Page 13: ...13 Nm 8 10 lb ft Anti vibration roller retainer 17 19 Nm 13 14 lb ft Clutch ring nut 65 75 Nm 48 55 lb ft Air duct screws 11 12 Nm 8 9 lb ft Water pump cover screws 3 4 Nm 2 2 3 lb ft External transmi...

Page 14: ...eter C 94 0 018 0 01mm Piston diameter P 93 968 0 014 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder Piston A 93 990 93 997 93 954 93 961 0 029 0 043 Cylinder Piston B 9...

Page 15: ...nder Check the size of the sealing ring opening Compression ring 0 15 0 35 mm Max value 0 5 mm Scraper ring 0 25 0 50 mm Max value 0 65 mm Scraper ring 0 25 0 50 mm Max value 0 65 mm Rings slots coupl...

Page 16: ...maximum val ues specified in the table the piston should be replaced by a new one Crankcase crankshaft connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions...

Page 17: ...aft bearings Measure the bearings on both axes x y CRANKSHAFT Specification Desc Quantity Cat 1 Standard diameter 40 010 40 016 Cat 2 Standard diameter 40 016 40 022 Crankshaft alignment Specific tool...

Page 18: ...KNESS OF THE GASKET B THAT HAS TO BE FIT TED INTO THE CYLINDER BASE IN ORDER TO RESTORE THE COMPRESSION RATIO THE MORE THE PLANE FORMED BY THE PISTON CROWN PROTRUDES BEYOND THE PLANE FORMED BY THE CYL...

Page 19: ...i Ride PG 5W 40 Synthetic based lubricant for high per formance four stroke engines JASO MA MA2 API SL ACEA A3 AGIP FILTER OIL Special product for the treatment of foam filters AGIP GP 330 Water repel...

Page 20: ...INDEX OF TOPICS TOOLING TOOL...

Page 21: ...Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Bell for OD 54 mm bearings 001467Y008 Calliper to extract 17 mm diameter bear ings 001467Y014 Calliper to extract 15...

Page 22: ...er bear ings 001467Y035 Bell for 47 mm outside diameter bearings 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on steering tube 020004Y Punch to remove steering bearing...

Page 23: ...020150Y Air heater support 020151Y Air heater 020193Y Gauge for oil pressure check 020201Y Spacer bushing driving tube 020262Y Crankcase splitting strip 020306Y Punch for fitting the valve seal rings...

Page 24: ...30Y Stroboscopic light for timing checking 020331Y Digital multimeter 020648Y Single battery charger 020335Y Dial gauge magnetic support 020357Y 32 x 35 mm adaptor 020358Y 37 x 40 mm adaptor Tooling M...

Page 25: ...r 020360Y 52 x 55 mm adaptor 020364Y 25 mm Guide 020376Y Adapter handle 020382Y012 bush valve removing tool 020412Y 15 mm guide 020424Y Punch for fitting driven pulley roller casing MP3 500 i e SPORT...

Page 26: ...ve oil seal extractor 020434Y Fitting for oil pressure check 020439Y 17 mm guide 020444Y Tool for fitting removing the clutch on the driven pulley 020456Y 24 mm adaptor Tooling MP3 500 i e SPORT Busin...

Page 27: ...ring on steering tube 020459Y Punch for fitting bearing on steering tube 020922Y Diagnosis Tool 020467Y Flywheel extractor 020468Y Piston fitting ring 020470Y Pin snap ring fitting tool MP3 500 i e SP...

Page 28: ...ountershaft timing 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020478Y Punch for roller casing Tooling MP3 500 i e SPORT...

Page 29: ...aft lock wrench 020480Y Fuel pressure check set 020482Y Engine support 020483Y 30 mm guide 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter MP3 500 i e SPORT Business...

Page 30: ...Parking control unit interface wiring 020646Y Parallelogram and steering positioning tool 020647Y Toe in checking tool 020647Y028 MP3 LT Toe in tool tricycle 020661Y Water pump overall seal replaceme...

Page 31: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 32: ...until it is reset The icon reset is carried out by pressing the button SET for more than 10 seconds when switching to ON the icon with the key after the ignition check must flash with a frequency of...

Page 33: ...on the dashboard Remove the four screws indicated and recover the related spacers Undo the two screws indicated then remove the spoiler Remove the two headlight upper fixing screws MP3 500 i e SPORT B...

Page 34: ...t Remove the indicated screw and remove the ra diator grille frame Unscrew the four indicated screws and remove the radiator grille Working on both sides of the vehicle remove the two screws in the wh...

Page 35: ...the front radiator cover Remove the two lower fastening screws Disconnect the connector and remove the head light Undo the four indicated screws on the leg shield back plate MP3 500 i e SPORT Busines...

Page 36: ...connect the connectors of the turn indicators WARNING DURING THE REFITTING PAY PARTICULAR ATTENTION TO THE CORRECT POSITION OF THE TWO SPOILER SUP PORT PLASTICS REFERRING TO THE INDICATIONS ON THE PLA...

Page 37: ...ST L LUBRICATE Replace every 2 years Km x 1 000 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Safety fasteners I I I I I Throttle control A A A A A A A A A Engine oil filter R R R R R R R R R Elect...

Page 38: ...ressure and wear I I I I I I I I I Vehicle and brake test test drive I I I I I I I I I Hub oil R I R I R I R I R Centre and side steering A A A A A A A A A Parking control unit software upgrading if a...

Page 39: ...l it on the engine between the spark plugs and spark plug caps Connect the induction clamp to the spark gap cable respecting the proper polarity the arrow on the clamp must be pointing at the spark pl...

Page 40: ...Use the wrench only for final tightening of the spark plug Place cap A fully over the spark plugs Refit the port making sure the rear hook is inser ted WARNING THE SPARK PLUG MUST BE REMOVED WHEN THE...

Page 41: ...d up with the right amount of hub oil Screw up the oil dipstick again and make sure it is locked properly into place Replacement Remove the oil filler plug A Unscrew the oil drainage cap B and drain o...

Page 42: ...d products AGIP FILTER OIL Special product for the treat ment of foam filters Engine oil In four stroke engines the engine oil is used to lubricate the timing elements the bench bearings and the therm...

Page 43: ...them up to the prescribed torque Refit the new cartridge filter being careful to lubri cate the O ring before fitting it Change the engine oil Since a certain quantity of oil still remains in the cir...

Page 44: ...between the min and max reference marks top up if required If the check is carried out after the vehicle has been used and therefore with a hot engine the level will be lower in order to carry out a...

Page 45: ...turns on during braking at idling speed or while turning a corner it is necessary to check the oil level and the lubrication sys tem Checking the ignition timing Remove the plastic cap on the flywhee...

Page 46: ...nt level should always be be tween the MIN and MAX levels The coolant consists of an ethylene glycol and corrosion inhibitor based demineralised water an tifreeze solution mix CAUTION DO NOT EXCEED TH...

Page 47: ...luid inside the reservoir is not below the recommended level A drop in the brake fluid level may be caused by pad wear Top up FRONT AND REAR BRAKING SYSTEM TOP PING UP For both brake pumps proceed as...

Page 48: ...ON OF EACH SYSTEM WHEN USED INDIVIDUALLY Recommended products AGIP BRAKE 4 Brake fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 synthetic fluid Headlight adjustment Proceed as follows P...

Page 49: ...ents from their seat acting on the rubber supports Refitting system components To refit proceed in reverse order taking care to use new metal clamps to fix the pipes Canister inspection The canister i...

Page 50: ...The cleaning of the canister is achieved via a controlled flow of air from the vacuum socket in the intake manifold To ensure that the engine works properly it is necessary that the flow of air is not...

Page 51: ...tion of the tank while riding the ambient air enters the tank in relation to the volume of fuel used Pressurisation of the tank while riding or during a break you may experience increases in the tempe...

Page 52: ...t when it is reached the valve discharges the air emitting a little noise Position the valve in the horizontal axis and check that you can pressurise it to values well above the setting pressure eg 7...

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

Page 54: ...e if required Carefully clean the By Pass area Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level t...

Page 55: ...r making the above adjustments check the seats in which the ball bearings rotate replace them if they are recessed or if the balls are flat tened Excessive steering play EXCESSIVE STEERING CLEARANCE P...

Page 56: ...OM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber Check the condition of wear of the steering covers and the adjustments Troubleshooting MP3 500 i e SPORT Busine...

Page 57: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 58: ...indicator switch 6 Turn indicators control device 7 Pre installation for anti theft device 8 Headlight 9 Front daylight running light bulb 10 Fuel level transmitter 11 Starter button 12 Headlight rel...

Page 59: ...2 Battery 33 Start up relay 34 Starter motor 35 Fuse No 13 36 ignition key contacts 37 License plate bulbs 38 Rear headlight assembly 39 Fuse No 14 40 Injection load relay 41 Pressure sensor 42 Horn r...

Page 60: ...ASR Button 68 MODE button 69 Oil pressure sensor 70 Horn 71 horn button 72 Horn connection for anti theft device 73 Rider presence sensor Cable colour Az Sky blue Bi White Ar Orange Gi Yellow BL Blue...

Page 61: ...r anti theft device 8 Headlight 9 Front daylight running light bulb 10 Fuel level transmitter 11 Starter button 12 Headlight relay 13 Secondary fuses 14 ignition key contacts 15 USB socket 16 Stop but...

Page 62: ...tor 35 Fuse No 13 36 ignition key contacts 37 License plate bulbs 38 Rear headlight assembly 39 40 Injection load relay 41 Pressure sensor 42 Horn relay 43 PMP connection 44 Geared motor 45 Brake call...

Page 63: ...E button 69 Oil pressure sensor 70 Horn 71 horn button 72 Horn connection for anti theft device 73 Rider presence sensor Cable colour Az Sky blue Bi White Ar Orange Gi Yellow BL Blue Ma Brown Ne Black...

Page 64: ...UTTONS Remove the upper handlebar cover to reach it 2 PRE INSTALLATION HEATED HANDGRIPS CONTROL DEVICE AND LEG WARMER Remove the upper handlebar cover to reach it Electrical system MP3 500 i e SPORT B...

Page 65: ...MOBILIZER AERIAL Remove the shield back plate upper side to reach it 5 IGNITION KEY CONTACTS Remove the shield back plate upper side to reach it 6 STOP LIGHTS RELAY Remove the leg shield to reach it M...

Page 66: ...RAKE CALLIPER SENSOR Remove the leg shield to reach it The sensor connector is fixed to the frame under the expansion tank 9 PRESSURE SENSOR Remove the leg shield to reach it Electrical system MP3 500...

Page 67: ...RELAY D HEADLIGHT RELAY 11 TURN INDICATORS CONTROL DEVICE Remove the leg shield to reach it 12 USB SOCKET CONNECTOR Remove the leg shield to reach it 13 GEAR MOTOR 14 ROTATION SENSOR Remove the leg s...

Page 68: ...e front wheels To access the connectors the central chassis cov er must be removed 17 FRONT ABS SENSORS IF APPLICABLE The sensors are located in the internal section of the front wheels Remove the leg...

Page 69: ...reach them remove the right footrest 19 HORN Remove the left footrest to reach them 20 PARKING CONTROL ECU Remove the leg shield back plate to reach it MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 20...

Page 70: ...t foot rest 23 FUEL PUMP 24 FUEL LEVEL TRANSMITTER Remove the central chassis cover to reach it 25 LAMBDA SENSOR To reach the connector of the probe positioned on the exhaust manifold remove the inspe...

Page 71: ...ENSOR To reach the sensor connector remove the right side fairing 28 MAGNETO FLYWHEEL To reach the flywheel connector remove the right side fairing 29 REAR ABS SENSOR IF APPLICABLE Remove the helmet c...

Page 72: ...fairing to reach it 31 STARTER MOTOR Remove the helmet compartment to reach it 32 SADDLE OPENING ACTUATOR Remove the license plate support to reach it Electrical system MP3 500 i e SPORT Business_LT_...

Page 73: ...e fair ing 34 PRE INSTALLATION FOR ANTI THEFT DE VICE 35 HORN CONNECTION FOR ANTI THEFT DE VICE Remove the right side fairing to reach it 36 INJECTION ECU Remove the inspection cover located in the he...

Page 74: ...o 14 IF APPLICABLE 43 TIP OVER SENSOR These components are found in the helmet com partment 44 BATTERY 45 DIAGNOSIS SOCKET These components are found in the helmet com partment 46 RIDER DETECTION SENS...

Page 75: ...A remove the footrest to access it There is another ground point B on the starter motor remove the helmet compartment to reach it On the left side of the vehicle is an engine chassis ground cable C fi...

Page 76: ...button 3 Main cable harness 4 Pre installation heated handgrips control device and leg warmer connector 5 At right stop button 6 Control connections on the right side of the handlebar 7 Immobilizer a...

Page 77: ...or 10 Instrument panel connector 11 USB socket connector 12 Turn indicators control device 13 PMP connection 14 Pressure sensor 15 Stop light relay MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 E...

Page 78: ...16 Relay unit connections 17 Gear motor connector 18 Rotation sensor and headlamp wiring Electrical system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 ELE SYS 78...

Page 79: ...onnector 20 Headlight connector 21 Rotation sensor 22 Front daylight running light connector 23 To electric fan 24 Pressure sensor connector MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Electric...

Page 80: ...25 Saddle opening switch connector 26 ASR Button connector 27 Wheel sensors wiring Electrical system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 ELE SYS 80...

Page 81: ...28 Parking control ECU connector 29 To horn 30 Speed sensors connectors 31 Secondary fuses MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Electrical system ELE SYS 81...

Page 82: ...32 Front wiring branch 33 Speed sensor 34 Front ABS sensor Electrical system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 ELE SYS 82...

Page 83: ...35 Front ABS sensors connectors Back side 1 ABS control unit connector MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Electrical system ELE SYS 83...

Page 84: ...ain cable harness 3 To ground point on chassis 4 Positive battery pole 5 Start up relay connections 6 Main fuses 7 HV coil Electrical system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 ELE SYS...

Page 85: ...ight license plate lights and saddle opening switch actuator wiring 9 Left taillight connector 10 Rear left turn indicator connector MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Electrical syste...

Page 86: ...11 License plate lights connector 12 Saddle opening actuator 13 Engine speed sensor connector Electrical system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 ELE SYS 86...

Page 87: ...or 17 Engine temperature sensor 18 Injector 19 Plug socket 20 Oxygen sensor connector 21 Pre installation for anti theft device 22 Horn connection for anti theft device 23 Magneto flywheel connector M...

Page 88: ...t compartment light connector 25 Rear right turn indicator connector 26 Right taillight connector 27 Voltage regulator connector Electrical system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 EL...

Page 89: ...28 To voltage regulator Conceptual diagrams MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Electrical system ELE SYS 89...

Page 90: ...fuses 32 Battery 35 Fuse No 13 36 ignition key contacts 40 Injection load relay 53 Engine speed sensor 54 HV coil 55 Injector 57 Fuel pump 64 Injection ECU 65 Immobilizer aerial Electrical system MP3...

Page 91: ...engine stop switch 23 Stop light relay 29 Magneto flywheel 30 Voltage regulator 32 Battery 33 Start up relay 34 Starter motor 35 Fuse No 13 36 ignition key contacts 38 Rear headlight assembly 64 Inje...

Page 92: ...adlight relay 13 Secondary fuses 16 Stop buttons lever and brake pedals 22 engine stop switch 23 Stop light relay 24 Electric fan relay 31 Main fuses 32 Battery 33 Start up relay 35 Fuse No 13 36 igni...

Page 93: ...QUIPPED WITH ABS ASR SYSTEM KEY 1 Instrument panel 3 Turn indicator bulbs 6 Turn indicators control device 7 Pre installation for anti theft device 8 Headlight 10 Fuel level transmitter 12 Headlight r...

Page 94: ...nsor 46 Parking control ECU 47 Right speed sensor 48 Left speed sensor 50 Rotation sensor 51 Hand brake switch 52 Suspension locking unlocking switches 58 ABS control unit 59 Rear ABS sensor 60 Left f...

Page 95: ...ry fuses 14 ignition key contacts 15 USB socket 17 Ignition switch contacts 18 Saddle opening switch 19 Saddle opening actuator 20 Light switch 21 Pre installation heated handgrips control device and...

Page 96: ...7 Right speed sensor 48 Left speed sensor 50 Rotation sensor 51 Hand brake switch 52 Suspension locking unlocking switches 63 Diagnostic socket 64 Injection ECU 66 Warning light unit 68 MODE button 70...

Page 97: ...cators control device 8 Headlight 9 Front daylight running light bulb 12 Headlight relay 13 Secondary fuses 14 ignition key contacts 20 Light switch 31 Main fuses 32 Battery 35 Fuse No 13 36 ignition...

Page 98: ...nents an electronic control unit immobilizer aerial master key with built in transponder service key with built in transponder HV coil diagnosis LED The diagnosis LED also works as a theft deterrent b...

Page 99: ...ter minals 7 26 15 26 and terminal 26 chassis ground fixed power supply If there is no voltage check that fuse 6 and its cable harness are in working order With the key switch in the ON position if th...

Page 100: ...ere is no con tinuity check the contacts of the switch After removing the leg shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base from...

Page 101: ...ep this position for 2 seconds limit values 1 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 key ag...

Page 102: ...n 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 is on permanently In this condition no operations are p...

Page 103: ...hange it if nec essary Diagnostic code 2 flashes Il codice 2 lampi contraddistingue un impianto dove la centralina non rileva il segnale del tras ponder Ci pu dipendere dalla inefficienza dell antenna...

Page 104: ...ty between terminals 87 and 30 4 If these conditions are not met the relay is sure ly damaged and therefore it should be replaced Battery recharge circuit The charging circuit consists of three phase...

Page 105: ...ding indicated by the ammeter must be 0 5 mA Charging current check WARNING BEFORE CARRYING OUT THE CHECK MAKE SURE THAT THE BATTERY IS IN GOOD WORK ING ORDER 1 Place the vehicle on its centre stand 2...

Page 106: ...ECU 2 Starter button 3 Stop buttons lever and brake pedals 4 engine stop switch 5 Fuse No 8 6 ignition key contacts 7 Starter motor 8 Start up relay 9 Fuse No 13 10 Battery WARNING ALL CONTINUITY TEST...

Page 107: ...fuse box fuse No 8 Red cable between fuse box fuse No 8 and starter relay Purple White cable between starter relay and injection control unit pin 1 5 Check the starter motor ground connection Black ca...

Page 108: ...fuse No 9 and horn button Yellow Pink cable between horn button and the horn itself 3 Check the horn ground connection Black cable Turn signals system check KEY 1 Turn indicators control device 2 Emer...

Page 109: ...he Brown cable of the turn indicator control device and ground with pressed turn indicator button 5 If there is no voltage check that there is continuity in the relevant cable harness 6 Check that the...

Page 110: ...ng control ECU 9 Ignition switch contacts 10 Fuse No 13 11 Fuse No 4 12 Battery 13 License plate bulbs 14 Rear headlight assembly WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDIN...

Page 111: ...detected 6 Check the correct operation of the headlight relay 7 Check the light switch contacts 8 check if there is continuity in the White Black cable between parking control ECU pin 6A and headlight...

Page 112: ...B is inside the footrest on the left side of the vehicle To reach the box B remove the plastic cover after removing the screw indicated in the picture The vehicle version equipped with ABS ASR sys te...

Page 113: ...H OR DAMAGE THEM FUSE CHART Specification Desc Quantity 1 Fuse no 1 Capacity 15 A Protected circuits Plug socket pre installation heated handgrips control device and leg warmer 2 Fuse no 2 Capacity 5...

Page 114: ...ion for anti theft device instru ment panel warning lights unit 12 Fuse No 12 Capacity 7 5 A Protected circuits live PMP connection daylight run ning lights licence plate lights instrument panel light...

Page 115: ...nt panel light up The fuel reserve warning light e 3 re mains on for two seconds then it has the normal function to indicate that the fuel reaches the re serve The needles move up to full scale and ba...

Page 116: ...he only maintenance required is the check of its charge and recharging if necessary These operations should be carried out before delivering the vehicle and on a six month basis while the vehicle is s...

Page 117: ...MILK BEATEN EGG OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS W...

Page 118: ...ed immediately to the next point 6 Battery closing Insert the airtight cover strips into the filling holes Press horizontally with both hands and make sure that the strip is levelled with the top part...

Page 119: ...ect the clamps of the battery charger to the battery poles black clamp to negative pole and red clamp to positive pole d Press the red button as shown in figure e Press the MF black button to activate...

Page 120: ...tery and proceed to fitting the battery on the vehicle Phonic wheel It is a magneto resistive sensor with an integrated circuit inside It sends a current signal with two levels according to the positi...

Page 121: ...lead 1 Black 8 HV coil Pink Black 9 ABS Warning Light Light blue Red 10 Injection loads relay Black Purple 11 Injection warning light Brown Black 12 Engine speed sensor negative Brown 13 Engine speed...

Page 122: ...rning light Pink Black 5A Roll lock system failure warning light Grey Black 6A Headlight solenoid White Black 7A Potentiometer ground lead wheels and en gine speed sensor rider detection sensor Yellow...

Page 123: ...nsor ground Purple Black 7 Not connected 8 Left front ABS sensor ground Light blue Black 9 Left front ABS sensor signal Light blue Red 10 ABS warning light Orange 11 Not connected 12 Not connected 13...

Page 124: ...r warning light White Blue 13 Emergency turn indicator warning light White Black 14 Engine oil low pressure signal Pink White 15 Injection warning light Brown Black 16 ABS warning light Orange if appl...

Page 125: ...d 11 Not connected 12 Not connected ANTITHEFT DEVICE PRE INSTALLATION CONNECTOR 1 Left turn indicators Pink 2 Right turn indicators White Blue 3 Ground lead Black 4 Battery powered Blue 5 Key powered...

Page 126: ...icating the engine temperature to the control unit in order to optimise performance Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Pin out 1 Inject...

Page 127: ...PINS 22 and 23 Disconnect the sensor connector Check the continuity of the wiring harness between the sensor connector and control unit connector Control unit PIN 22 sensor PIN 1 and control unit PIN...

Page 128: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 129: ...RMS OF THE ANGLO SAXON SYSTEM SEE THE CHARACTERISTICS CHAPTER Exhaust assy Removal Remove the chassis central cover Loosen the fixing clamp between the manifold and the exhaust end Loosen the rear loc...

Page 130: ...AND TIP Release the lambda probe connector and dis connect it CAUTION FREE THE CABLES OF THE OXYGEN SENSOR BEFORE REMOVING THE SILENCER PUTTING THIS CABLE HAR NESS UNDER AN EXCESSIVE VOLTAGE MAY DAMA...

Page 131: ...o the correct locking torques once the muffler silencer has been refitted Removal of the engine from the vehicle Use a jack to support the vehicle properly Disconnect the battery Remove the helmet com...

Page 132: ...nscrew the fixing bolt of the throttle control ca bles cover then remove the cover Loosen the throttle control set nuts Engine from vehicle MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 ENG VE 13...

Page 133: ...body To facilitate the operation loose the throttle con trol set screw on the throttle grip Unscrew the bolt fixing the control unit connector to the bracket then disconnect it MP3 500 i e SPORT Busin...

Page 134: ...nectors of the injector and of the engine temperature sensor Remove the corresponding stop and disconnect the fuel piping Unscrew the bolt fixing the fuel piping to the en gine head Engine from vehicl...

Page 135: ...o release the main wiring harness Disconnect the rear ABS sensor connector then remove the cable ties clamp from the bracket and release the connector MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 201...

Page 136: ...onnect the starter motor negative cable and the engine ground cable Cut the oil pressure sensor cable clamp then disconnect it and release it from the cable grom mets Engine from vehicle MP3 500 i e S...

Page 137: ...Cut the three fixing clamps of the flywheel wiring harness MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Engine from vehicle ENG VE 137...

Page 138: ...sconnect the engine rpm sensor connector and release it from the slide housing Disconnect the spark plug caps Remove the clamp and disconnect the filter box sleeve Engine from vehicle MP3 500 i e SPOR...

Page 139: ...bracket and disconnect the oil drainage recovery pipe then remove the filter box Remove the rear wheel as described in chapter Suspensions Slightly bend the two safety stops of the brake calliper sup...

Page 140: ...e to remove it Undo the bolt fixing the brake piping support bracket to the crankcase Open the clamp and unscrew the fixing bolt to release the brake pipes Engine from vehicle MP3 500 i e SPORT Busine...

Page 141: ...et pipe Disconnect the water pump inlet pipe by remov ing the clamp then empty the cooling system Remove the clamp from the coolant outlet pipe from the engine and empty the system from resid ual flui...

Page 142: ...perations 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 recommended type Fill and bleed the...

Page 143: ...INDEX OF TOPICS ENGINE ENG...

Page 144: ...he 4 fastening screws Extract the outside plastic transmission cover Using a screwdriver remove the driven pulley axle cover near the bottom of the cap Loosen the driven pulley shaft fastening nut usi...

Page 145: ...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 transmission cover Unscrew t...

Page 146: ...cial tool so that it is adequately sup ported Pull out the bearing using the special tool N B BELL MUST BE PLACED INTO THE TRANSMISSION COV ER CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE SINCE WI...

Page 147: ...dapter handle 020358Y 37 x 40 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 retaining bolt using a 1...

Page 148: ...ove 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 ECCENTRICITY MEASURED 0...

Page 149: ...EW TOO MUCH AS THIS COULD IRRETRIEVABLY DEFORM THE TOOL USING THE SPECIAL 55 MM WRENCH REMOVE THE FASTENING RING NUT LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT CLUTCH SPRING WITH SHE...

Page 150: ...r 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 otherwise replace the f...

Page 151: ...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 Adapter handle 020375Y 28 x 30 m...

Page 152: ...g 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 working on th...

Page 153: ...ven 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 operation is...

Page 154: ...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 bed torque Specific...

Page 155: ...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 insert the stud bolts on...

Page 156: ...wear and measure the inside diameter CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHINGS Characteristic Maximum admissible diameter 30 12 mm Standard diameter 30 021 mm Measure the pulley sliding bushing o...

Page 157: ...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 side must rest on the...

Page 158: ...pulley Insert the spacer Install the fixed driving half pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley Remove the flat washer and the s...

Page 159: ...iving 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 resting flatly Tigh...

Page 160: ...ing using a machine hexagon wrench Tighten the driven pulley shaft fastening nut using an offset wrench N B DUE TO THE HIGH TIGHTENING TORQUE USING DIFFER ENT WRENCHES SUCH AS A CONVENTIONAL POLYG ONA...

Page 161: ...screws 7 9 End gear Removing the hub cover Drain the rear hub oil through the oil drainage cap located under the engine Remove the 7 fastening screws Remove the hub cover and the relevant gasket Remo...

Page 162: ...bearings 001467Y031 Bell Use the special extractor to disassemble the bearing on the engine chassis of the countershaft Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y035 Bell fo...

Page 163: ...ve 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 transmission cover and the...

Page 164: ...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 seals In case of faults replace the damaged parts Characte...

Page 165: ...case of faults replace the hub cover Refitting the driven pulley shaft bearing Heat the crankcase using the heat gun Specific tooling 020151Y Air heater Insert the driven pulley shaft bearing until it...

Page 166: ...he crank case Insert the gear shaft bearing in the upper crank case seat using the special tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling...

Page 167: ...IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adapter handle 020360Y 52 x 55 mm adaptor 020363Y 20 mm guide Heat the gear shaft bearing seat fro...

Page 168: ...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 bein...

Page 169: ...connect the return hose from the pump cover N B THE BANDS MUST BE REPLACED TO REMOVE THEM OPEN WITH A SCREWDRIVER OR CUT THEM BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS Removing the hub cover Drain t...

Page 170: ...WS 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 SLIPPAGE OF THE BY PASS VAL...

Page 171: ...the two retaining screws and the cable guide bracket Unscrew the 3 fastening screws and remove sta tor and its wiring Inspecting the cover components Loosen the two retaining screws and remove the ree...

Page 172: ...rn 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 diameter for start up ge...

Page 173: ...HOSE 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 two types of cable Rigi...

Page 174: ...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 cover components Before...

Page 175: ...g 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 tighten the screws to the...

Page 176: ...ump cover using 3 new clamps N B TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS PAYING ATTENTION NOT TO CONSTRICT THE HOSES BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUF FICIENTLY Install the pre filter...

Page 177: ...nter 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 THIS PREPARATION IS...

Page 178: ...ng Remove the three bands shown in the figure for an easier removal of the flywheel cover remove the feed hoses and disconnect the return hose from the pump cover N B THE BANDS MUST BE REPLACED TO REM...

Page 179: ...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 Specific tool...

Page 180: ...D WITH STRANGE NOISE CHECK THE FREEWHEEL OF THE TORQUE LIMITER SEE THE FLYWHEEL AND STARTER SYSTEM CHAPTER STARTER MOTOR Specification Desc Quantity Type Mitsuba sm13d Power 0 9 kW BATTERY Specificati...

Page 181: ...em chapter whereas to check the engine shaft control transmission follow what is described in the Flywheel and starter system chapter Removing the starter motor N B THIS OPERATION MAY ALSO BE CARRIED...

Page 182: ...rt the special tool as shown in the figure making sure that the pins are perfectly inserted in to the previously aligned holes and that it is per fectly abutted and almost flush with the flywheel Spec...

Page 183: ...ETACHMENT 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 flywheel Specific too...

Page 184: ...BE REMOVED IT IS AD VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT The freewheel is coupled to the flywheel with high precision if removal is d...

Page 185: ...e diameter Diameter 45 665 0 008 0 005 mm Check the inside diameter of the bushing of the starter gearing Check that the toothing is not worn Characteristic Inside diameter of the bushing Diameter 27...

Page 186: ...ssembly allows transmitting torque lower than 10 kg In case of incorrect start up manoeuvres the lim iter prevents any kicks with consequent reversal of direction of the crankshaft which would impair...

Page 187: ...sible Lock the six clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screws fixing freewheel to flywheel 13 to 15 Oil the free wheel rollers Refitting the intermedia...

Page 188: ...ise and inserting at the same time Refitting the flywheel magneto Insert the key on the crankshaft Install the flywheel checking the proper insertion of the key and engaging the torque limiter gear wi...

Page 189: ...k 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 into the seat Spe...

Page 190: ...ding 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 fastening screws to the...

Page 191: ...Removing the rocker arms cover Loosen the 6 special screws with stop and the relevant rubber gaskets Remove the tappet cover with relevant gasket Removing the timing system drive Turn the engine to c...

Page 192: ...with relevant travel end washer N B BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING TO FALL INTO THE ENGINE THROUGH THE CHAIN COM PARTMENT Align the reference marks on the timing chain rim with those on...

Page 193: ...iming belt rim Removing the cam shaft Unscrew the 3 fastening screws and remove camshaft retaining bracket N B REMOVING THE FASTENING SCREWS MAY BE DIFFI CULT BE CAREFUL NOT TO DAMAGE THE INSIDE HEX A...

Page 194: ...utlet sleeve with thermostat Remove the coolant temperature sensor N B THE SENSOR CONTROLS BOTH INJECTION AND THE AN ALOGUE INSTRUMENT ON THE PANEL TO CHECK THIS COMPONENT SEE THE INJECTION CHAPTER Re...

Page 195: ...lock 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 GROUP CONTAINS COOLANT Removing the valves...

Page 196: ...n the fastening screw and remove the spacer and the tightening sliding block N B IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Extract the...

Page 197: ...EUSE N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Inspecting the small end Measure the inside diameter of the connecting rod small end using a bore meter N B IF THE CONNECTING ROD SMA...

Page 198: ...TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS Characteristic Standard clearance 0 001 0 010 mm Measure the outside diameter of the piston per pendicular t...

Page 199: ...g 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 Alternately inse...

Page 200: ...he figure Top ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Middle ring Standard coupling clearance 0 02 0 07 mm Maximum clearances allowed after use 0 10...

Page 201: ...70Y Pin snap ring fitting tool N B THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUSING Choosing the gasket Provisionally fit the pist...

Page 202: ...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 DEVIATIONS OR RECES...

Page 203: ...PERED 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 oil The engine uses the firs...

Page 204: ...r 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 THE PINION REPLACE...

Page 205: ...carbon deposits from the valve seats Check the width of the mark on the valve seat V with Prussian blue Characteristic Standard value 1 1 3 mm Limit allowed 1 6 mm If the width of the mark on the val...

Page 206: ...using a dial gauge Characteristic Limit value allowed 0 1 mm Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the V shaped support...

Page 207: ...n the faying surface with the set screw articulated terminal If no faults are found during the above checks the same valves can be reused For better sealing results we recommend grinding the valve sea...

Page 208: ...pporting 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 Characteristic Standard length 44 4 mm Limi...

Page 209: ...for signs of abnormal wear or scores Using a micrometer measure the camshaft bearings STANDARD DIAMETER Specification Desc Quantity Bearing A 42 0 060 0 085 mm Bearing B diameter 20 0 020 0 041 mm MI...

Page 210: ...abutment on the containment bell are free from wear Check that the valve lifting spring has not yielded Replace any defective or worn components Check that the rocking lever pins exhibit no scores or...

Page 211: ...THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY THE DOWELS The head gasket is made of steel and has a standard thickness Check that the head lubrication channel is per fectly clean Clean wit...

Page 212: ...12 Tighten the 3 side screws to the prescribed tor que Locking torques N m Head fixing screws 10 12 Install the coolant temperature sensor with the washer and tighten to the prescribed torque CAUTION...

Page 213: ...ressed air jets especially the retaining plate housing Lubricate the 2 shafts Insert the camshaft into the head with the cams opposite the rocking levers Remove any LOCTITE residues from the screws fi...

Page 214: ...e timing check cap Insert the belt on the camshaft control timing rim Insert the timing rim on the camshaft checking that the references are aligned N B DURING THE STROKE CHECK KEEP THE BELT TEN SIONE...

Page 215: ...being careful to the proper positioning of the travel end ring Lubricate the mass and de compressor control pin Install the return spring and load it by about 3 4 turn Turn the engine to move the ref...

Page 216: ...cylinder using a new gasket Tighten the two fastening screws to the prescri bed torque Locking torques N m Tensioner fastening screws 11 13 Insert the spring with the central screw and the washer Tig...

Page 217: ...not possible to interpret the reference values based on the engine rpm The ignition advance value is detectable at any time using the diagnostic tester It is possible to check whether the ignition adv...

Page 218: ...inspection cap on the flywheel side Connect the diagnostic tester Start the engine Select the parameters function in this menu Select the stroboscopic light control in the tradi tional four stroke eng...

Page 219: ...Tighten the remaining 4 screws in a crossed se quence 3 4 5 6 N B CHECK THE PROPER POSITION OF THE GASKET Locking torques N m Tappet cover fixing screws 7 9 Install the transmission cover and the rele...

Page 220: ...uction given in Flywheel and Starting system Remove the thermal group cylinder head piston as described in the Thermal group and timing system chapter Before opening the crankcase check the crankshaft...

Page 221: ...e flywheel side half crankcase Remove the coupling gasket N B THE BUSHING SUPPORT CAN BE LEFT IN THE FLY WHEEL SIDE HALF CRANKCASE Removing the crankshaft Before removing the crankshaft check the timi...

Page 222: ...ve the control gear loosen the 4 fasten ing screws Remove the gear only if actually required CAUTION THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR THREADING IS LOCKED BY LOCTITE BE CAREFUL NOT TO DAMAG...

Page 223: ...urn the half crankcase Remove the bearing from the flywheel side half crankcase using the special tool and a mallet Specific tooling 020376Y Adapter handle 020358Y 37 x 40 mm adaptor 020439Y 17 mm gui...

Page 224: ...ng on the half crankcase us ing the special tool N B IF A BEARING WITH PLASTIC CAGE IS USED KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE Specific tooling 020376Y Adapter handle 020359Y 42 x...

Page 225: ...OM THE CRANKCASE INTERNAL SIDE Specific tooling 020376Y Adapter handle 020359Y 42 x 47 mm adaptor 020439Y 17 mm guide Inspecting the crankshaft components Check the axial clearance on the connecting r...

Page 226: ...W UTILISATION MAINTAIN THE FIRST FITTING POSITION Specific tooling 020074Y Support base for checking crankshaft alignment If the crankshaft crankcase axial clearance is higher than the standard value...

Page 227: ...e replaced To check the connecting rod small end diameter see chapter Thermal group and timing system When cleaning the crankshaft be careful to prevent any impurity from entering into the shaft lubri...

Page 228: ...LLY IMPORTANT THAT THE BY PASS HOUSING ON THE FLYWHEEL COVER IS FREE FROM WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON THE HEAD LUBRICATION CHANNEL IS EQUIPPED...

Page 229: ...limiting surface N B TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION DRIVING IS FORCED ON CAST IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES Check the inside diameter of the main...

Page 230: ...ory A Red B Blue C Yellow D Green In case of breakdown crankcases are together with bushings and are classified according to the centre to centre distance of the countershaft Find below the possible c...

Page 231: ...MOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI FLAPPING ROLLER FROM THE TRANSMISSION SIDE HALF CRANKCASE AS DESCRIBED IN CHAPTER AUTOMATIC TRANSMISSION AND THE HUB COVER WITH THE RELEVANT GEARS AND BEAR...

Page 232: ...the control gear on the crankshaft with the hole countersink visible Tighten the 4 fastening screws to the prescribed torque N B TO AVOID DAMAGING THE SCREW CONTROL HEXAGON IT IS PREFERABLE TO USE AN...

Page 233: ...te Tighten the 2 flanged fastening screws to the prescribed torque Locking torques N m Oil pump compartment cover bulkhead screws 8 10 Refitting the crankcase halves Remove the oil guard from the tran...

Page 234: ...B REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE TO ENSURE BETTER SEALING PERFORMANCE Locking torques N m Engine crankcase coupling screws 11 13 Install the thermal group c...

Page 235: ...ith piston Plunger diameter 13 9 0 039 0 057 mm Spring free length 62 5 mm Calibration pressure 4 bar PRE FILTER Specification Desc Quantity Type mesh plastic OIL FILTER Specification Desc Quantity Ty...

Page 236: ...n system is divided into two sections High pressure Low pressure The high pressure section includes all components located on the engine crankcase whereas the low pressure section only refers to the t...

Page 237: ...e oil supplied to the smaller diameter bearing The camshaft supplies the lubricant to the rocking levers via the holes provided these are installed in a position to ensure that the lubrication is main...

Page 238: ...res Specific tooling 020331Y Digital multimeter AHEAD go to 5 5 Measure the pressure with cold and idling engine STANDARD VALUES Specification Desc Quantity 20 C Temperature 1400 rpm approx 4 5 bar N...

Page 239: ...ents Flywheel cover chapter 16 Overhaul the engine Crankcase and crankshaft chapter 17 Open the engine crankcase and remove the oil pump as described in the Crankcase and crank shaft chapter Check the...

Page 240: ...RE 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 in the scavenge duct on the filter box YES go to 3 NO go to 4 3 Check the...

Page 241: ...crews 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 the opening at the...

Page 242: ...r 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 distance be tween the ro...

Page 243: ...r 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 fastening screws to the...

Page 244: ...Specific tooling 020479Y Countershaft lock wrench Keep the countershaft in position and insert the washer with the nut Tighten the nut to the prescribed torque using the recommended product Remove the...

Page 245: ...edge and disassemble the overall seal pressure fitted on the rotor shaft CAUTION USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COVER SEALING SUR FACE SMALL SCRATCHES ON THE SEA...

Page 246: ...seal using the pin supplied and a hammer N B MAKE THE HOLES WITH A STRONG HIT MULTIPLE LIGHT BLOWS COULD DEFORM THE PART WITHOUT PASSING THROUGH Fix the extractor to the fixed part of the sealing usi...

Page 247: ...ed Remove the extractor with the fixed part of the overall seal Specific tooling 020661Y Water pump overall seal replacement kit Remove the six screws and the pump cover with a screwdriver Unscrew the...

Page 248: ...LEMS Change the position of the screwdrivers if nec essary During seal disassembly the ceramic may split Clean all the parts thoroughly before removing them Place the extractor together with the pin o...

Page 249: ...HOUT TEARING THE PLATE Complete the tool by fitting the bracket the screw and the nut Hold the screw in position and operate the nut until the fixed part of the sealing is completely re moved Remove t...

Page 250: ...eal on the shaft Place the calibrated punch at preloading value Fit the nut to the tie rod Keep the tie rod in position and screw the nut up to the end of stroke The tool will drive the fixed part sea...

Page 251: ...LY CAUTION LUBRICATE THE ROTOR SHAFT WITH ENGINE OIL Fit the tie rod by screwing it to the rotor shaft CAUTION TIGHTEN MANUALLY UNTIL IT STOPS Place the overall seal on the shaft Place the calibrated...

Page 252: ...icate the gasket previously with petroleum jelly grease Tighten the six cover screws to the prescribed torque N B TO AVOID DEFORMATION DO NOT LUBRICATE THE O RING WITH PETROLEUM GREASE Locking torques...

Page 253: ...INDEX OF TOPICS INJECTION INJEC...

Page 254: ...ay 9 Diagnostic socket 10 Battery RIU Injection system This is an integrated ignition and injection system Injection is indirect in the manifold through an electro injector Injection and ignition are...

Page 255: ...ed 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 RIU control unit therefore the vehicle s safety is enhanced...

Page 256: ...n system check if any faults have been stored Do not dis connect the battery before checking for faults 2 The fuel supply system is pressurised at 300 kPa 3 BAR Before disconnecting the fast release f...

Page 257: ...check performed with the diagnostic tester remember to protect the system connector with its cap Failure to observe this precaution may damage the RIU control unit 14 Before reconnecting the quick co...

Page 258: ...may damage the RIU control unit The instruments to be preferred have a definition over 0 1V and 0 5W and an accuracy over 2 Terminals setup INJECTION ECU CONNECTOR 1 Start up enabling switch Purple Wh...

Page 259: ...ge White 30 Starter button Purple 31 Stop buttons White Black 32 Tip over sensor Grey Black 33 Lambda probe negative Light blue Black 34 Not connected EMS circuit diagram CAUTION THE FOLLOWING INSTRUC...

Page 260: ...ction 46 Parking control ECU 49 Lambda sensor 53 Engine speed sensor 54 HV coil 55 Injector 56 Engine temperature sensor 57 Fuel pump 58 ABS control unit 62 Tip over sensor 63 Diagnostic socket 64 Inj...

Page 261: ...Stop light relay 24 Electric fan relay 25 Electric fan 31 Main fuses 32 Battery 33 Start up relay 35 Fuse No 13 36 ignition key contacts 40 Injection load relay 43 PMP connection 46 Parking control EC...

Page 262: ...cap HV Coil secondary insulation Parameter reliability Coolant temperature Distribution timing injection ignition Intake air temperature End of compression pressure End of compression pressure Starti...

Page 263: ...pipe and Stepper Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve Filter box Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector fl...

Page 264: ...LVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing Intake sleeve Filter box Ignition system...

Page 265: ...lug Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake system sealing Intake sleeve Filter box TPS reset succes...

Page 266: ...he butterfly valve Remove the fuel piping clamping screw indicated in the figure Remove the fast release fitting from the injector support Injection MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015...

Page 267: ...ector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the ECU RIU connector MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA...

Page 268: ...Remove the gas command fitting as indicated in the picture Pump supply circuit KEY 1 Injection ECU 2 Lambda probe Injection MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 INJEC 268...

Page 269: ...rotate for 2 seconds and then stops When the engine starts in the presence of rpm timing signal the pump is continuously supplied ELECTRICAL DATA Pump winding resistance 1 5 Input current during regul...

Page 270: ...rgising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and the Black Pur ple cable of the relay base If there is not check the continuity of th...

Page 271: ...se check the continuity of the Black Green cable between the pump connector and the relay base Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump con...

Page 272: ...of the appropriate tool Prepare a graded burette with flow rate of approximately 1 L Turn the pump with active diagnosis of the PDA Using a pair of long flat needle nose pliers choke the fuel pipe mak...

Page 273: ...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 500 i e SPORT Business_LT_ ABS ASR_EU_U...

Page 274: ...5 Injector 6 HV coil 7 Fuel pump 8 Electric fan 9 Electric fan relay 10 Injection load relay 11 Fuse No 10 12 Ignition switch contacts 13 Fuse No 13 14 Battery 15 Main fuses no 5 no 6 ELECTRICAL DATA...

Page 275: ...rly Check the efficiency of the injection load solenoid Check the resistance of the energising coil be tween pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there i...

Page 276: ...cable between the pin 10 of the control unit and the relay base WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED Check the presence of fixed voltage bet...

Page 277: ...Green cable of the injector con nector and the ground lead With injector disconnected and the injector load solenoid disconnected check the continuity of the Black Green cable between the injector con...

Page 278: ...vate 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 circuit The electronic ignition system...

Page 279: ...flash depends on the programming of the electronic control unit If the LED is off re gardless of the position of the ignition switch and or the instrument panel is not initiated check if there is bat...

Page 280: ...y If there is no voltage check the ignition switch contacts and that fuses No 10 13 and their cables are in working or der There is continuity between terminals 21 23 with the emergency cut off switch...

Page 281: ...and check the continuity between pin 29 and the aerial Or ange White cable Specific tooling 020331Y Digital multimeter Virgin circuit When the ignition system is not encrypted any key will start the...

Page 282: ...ervice keys in the event of losses replacements etc Each new programming deletes the previous one to add or delete a key it is therefore necessary to repeat the procedure using all the keys that you i...

Page 283: ...short 0 46 sec flashes the same number of times as there are keys stored in the memory including the Master key When the diagnosis has been completed the LED remains permanently OFF The engine can be...

Page 284: ...everal keys if the code is repeated even with the Master key check the aerial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Repl...

Page 285: ...for it to stop Try to start the engine and check that the voltage between pins 12 and 13 is 2 8 V With the control unit disconnected check if there is continuity between pin 12 and the brown cable of...

Page 286: ...relay 10 Injection load relay 11 Fuse No 10 12 Ignition switch contacts 13 Fuse No 13 14 Battery 15 Main fuses no 5 no 6 PIN RELATIONSHIP PIN PIN Component Reference value 8 Live supply H V coil 570 5...

Page 287: ...phase The injection system recognises the 4 stroke cycle so ignition is only commanded in the compression phase Specific tooling 020331Y Digital multimeter Check the efficiency of 7 5 A fuse No 6 inje...

Page 288: ...cable between the pin 10 of the control unit and the relay base WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED Check the presence of fixed voltage bet...

Page 289: ...SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM FOR INFORMATION ON THE SPARK PLUG SEE THE SPECIFICATIONS AND MAINTE NANCE CHAPTERS Spark advance The ignition advance is determin...

Page 290: ...apter Remove the TDC reference inspection cap be tween flywheel and crankcase cover See the fly wheel cover chapter By the driving pulley turn the engine to find the alignment of the references to ide...

Page 291: ...four stroke engine position 1 spark 2 revs Check that the real values of rpm and ignition advance match those measured using the diag nostic tester If the values do not match check distribution timin...

Page 292: ...brated Pre calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre set reference conditions Pre calibration ensures optimal air flow for the...

Page 293: ...reset procedure Reset should be performed in the following cases on first fitting if the injection control unit is replaced N B THE TPS RESETTING PROCEDURE MUST NOT BE CAR RIED OUT WITH A USED THROTT...

Page 294: ...robe is positioned on the exhaust manifold before the catalytic converter in an area where the gas temperature is always high The temperature at which the sensor works is at least 350 C with a reactio...

Page 295: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 296: ...rk the vehicle on level smooth and even ground Rest the vehicle on its centre stand Make sure that the parking system is disengaged Lift the front wheels as shown in the picture Check that the wheel r...

Page 297: ...move the right lower coupling plate of the half arm by undoing the screws indicated in the picture Remove the right upper screw and the left bottom screw of the parallelogram unit MP3 500 i e SPORT Bu...

Page 298: ...n position Fit the steering guiding bracket in a straight riding position fix one end to the attachment of the half arm coupling flange and the other end to the screw fixing the steering control arm P...

Page 299: ...he pointers of both tyres are correctly aligned as shown in the picture Maximum misalignment al lowed 4 notches Use tool 020647Y028 for LT version with extended track Specific tooling 020646Y Parallel...

Page 300: ...t wheel Remove the five screws that fix the wheel Front wheel hub overhaul Remove the wheel Remove the brake calliper Remove the cotter pin and the cap Suspensions MP3 500 i e SPORT Business_LT_ ABS A...

Page 301: ...ck Seeger ring indi cated in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Calliper to extract 15 mm diame ter bearings 001467Y017 Bell for bearings OD 39 mm...

Page 302: ...he ball bearing check Seeger ring Specific tooling 020151Y Air heater 020376Y Adapter handle 020359Y 42 x 47 mm adaptor 020412Y 15 mm guide Use the specific tool to fit and push the roller cas ing unt...

Page 303: ...of the throttle grip and remove the throttle control 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 I...

Page 304: ...o rear fixings of the mudguard support arm Unscrew the front fixing and remove the arm complete with the mudguard and the suspension block device support pipe Unscrew the two fixing of the shock absor...

Page 305: ...prescribed torques Locking torques N m Upper shock absorber retainer 19 to 29 Lower shock absorber clamp 19 to 26 Shock absorber calliper bracket Removal Remove the wheel hub Unscrew the fixing bolt o...

Page 306: ...ger stop ring of the support Remove the shock absorber brake calliper sup port and collect the washer and the O ring Refitting Follow the removal steps but in reverse order be careful to tighten the r...

Page 307: ...circuit The pressurised oil reaches the distribution frame T and the pressure sensor A Then the pipes branch out to reach the upper joints on the side steering tubes Through the rigid flexible pipes i...

Page 308: ...lliper making sure there is a container to collect the brake fluid Disconnect the tone wheel connector indicated in the picture Undo the ABS sensor fixing screw and remove it ONLY FOR THE VEHICLE VERS...

Page 309: ...ittings on the parallelogram of the brake hydraulic pipes and the suspension lock indicated in the picture Remove the hydraulic pipe fitting fixing nuts indi cated in the figure from the support brack...

Page 310: ...ect the ABS sensor connector placed under the parking brake ONLY FOR THE VEHICLE VERSION EQUIP PED WITH ABS ASR SYSTEM Remove the tone wheel wiring by disconnecting the connector on the fuel tank afte...

Page 311: ...nut indicated in the picture 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 the hydraulic pipe suppo...

Page 312: ...protection cap indicated in the picture Now the steering tube can be removed Check that the roller tapered bearing does not show signs of abnormal wear If it does replace it Suspensions MP3 500 i e S...

Page 313: ...emove the lower retainer of the sliding stem shown in the picture Remove the sliding stem locking device retainers indicated in the picture Check that the sliding stem locking device does not show sig...

Page 314: ...ocking device 6 5 10 5 Fixing nuts for constant velocity universal joints 18 20 Suspension lock calliper pipe fitting on side steering pipe 25 28 Brake calliper pipe fitting on side steering pipe 25 2...

Page 315: ...cture Remove the retainers indicated in picture of the half arms joint flange To facilitate the operations indicated below re move the suspension locking electronic control unit indicated in the pictu...

Page 316: ...itting operations remember to take note of the positions of the components Separate the half arms by hitting slightly with a wooden mallet where possible alternately to the left and right side of the...

Page 317: ...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 MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Suspensions SUS...

Page 318: ...se order lubricating the reference dowels on the parallelogram half arms and observing the prescribed torque PARALLELOGRAM DEVICE Name Torque in Nm Arm coupling screws 45 50 Screws fixing arms to side...

Page 319: ...raulic pipes between the pump and the sliding stem locking clamps Empty the system and use a container to collect the brake fluid CAUTION ELIMINATE ANY REMAINING BRAKE FLUID SPILLS WARNING BRAKE FLUID...

Page 320: ...BRAKE FLUID OUT OF THE REACH OF CHILDREN Remove the 3 fixing screws indicated and remove the whole gear motor Use a screwdriver to remove the plastic access cover to the pump joint gear motor Undo the...

Page 321: ...body to the assembly and the clamp fixing the pump joint have been modified as shown the fig ures below A safety screw A on the lower part of the pump been also added to be tightened after the main lo...

Page 322: ...ck 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 er Specific tooling 0202...

Page 323: ...move the retaining Seeger ring of the bearing of the flexible transmission lever control shaft bearing Remove the bearing with the specific tool Specific tooling 020376Y Adapter handle 020441Y 26 x 28...

Page 324: ...2 mm guide 020357Y 32 x 35 mm adaptor Hold the crankcase in a perfectly horizontal posi tion heat it with a specific heat gun at about 120 C use the specific tool to fit the bearing of the electric mo...

Page 325: ...of the spring toothed sector unit Hit slightly with a mallet if necessary Specific tooling 020360Y 52 x 55 mm adaptor 020151Y Air heater 020376Y Adapter handle Hold the crankcase in a perfectly horiz...

Page 326: ...n 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 MOLYBDENUM GREASE MON TBLANC MOLYB...

Page 327: ...e 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 side of the hydraul...

Page 328: ...ssion lever nut to the prescribed torque Locking torques N m Bracket tightening screws 8 12 Undo the Allen screw and remove the switch Upon refitting place the switch with the button ori ented to the...

Page 329: ...ing Upon refitting tighten the two screws to the pre scribed torque and use threadlock Upon refitting adjust the cable properly so that the switch is pushed when the system is unlocked MP3 500 i e SPO...

Page 330: ...ve angle must be performed by acting on the screw indica ted in the picture after having removed the lower protection cap Remove the upper protection cap align the pump control and lock the screw to t...

Page 331: ...antee switch activation on the roll lock calliper Electrical devices test BASIC CIRCUIT DIAGRAM FOR ROLL LOCK ELECTRICAL SYSTEM KEY 1 Geared motor 2 Brake calliper sensor 3 Tilt unlocking locking cont...

Page 332: ...13 20 A Fuse No 3 14 Light relay 15 Pressure switch 16 Horn relay 17 Instrument panel Warning light module 18 Roll lock system control unit GEAR MOTOR 1 GEAR MOTOR Suspensions MP3 500 i e SPORT Busin...

Page 333: ...nd the blue cable on the gear motor connector With the interface wiring disconnected from the control unit check the continuity of the geared mo tor winding placing the multimeter probes on pins 28 an...

Page 334: ...eck the continuity of the electrical lines between the interface wiring and the roll lock unlock switch Pin 26 and green grey cable Pin 35 and violet black cable Pin 33 and yellow blue cable Also chec...

Page 335: ...t 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 LOCK 3 REST 4 UNLOCK POTENZIOMETRO 1 POTENTI...

Page 336: ...tion 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 potentiometer connec tor be...

Page 337: ...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 presence connector...

Page 338: ...With the interface wiring disconnected from the control unit check the continuity between pin 34 and the brown cable of the roll lock gripper sensor connector on the system side Check the continuity o...

Page 339: ...at the flexible transmission control lever activates the limit stop switch properly SENSORE RUOTA FONICA 1 Right tone wheel 2 Left tone wheel MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Suspens...

Page 340: ...mately 20 With the interface wiring disconnected from the control unit check the continuity between pin 23 and the red cable of the LEFT wheel turning sen sor connector the continuity between pin 17 a...

Page 341: ...the red cable on the connector With the interface wiring disconnected from the control unit and the connectors disconnected from wheel turning sensors check that pin 23 17 and 24 17 are insulated fro...

Page 342: ...wiring disconnected from the control unit check the continuity of the blue black cable between pressure sensor connector and the horn solenoid base as shown in the picture Check the continuity between...

Page 343: ...at rest as this is normally closed switch Rear Removing the rear wheel Before removing the rear wheel support the vehi cle properly and operate the parking brake so as to facilitate removing the whee...

Page 344: ...Undo the two screws fixing the clamp to the cen tre stand Undo the two screws fixing the clamp to the en gine Suspensions MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 SUSP 344...

Page 345: ...or support and remove it ONLY FOR THE VEHICLE VERSION EQUIP PED WITH ABS ASR SYSTEM Unscrew the clamp Collect the conical spacer Unscrew the five screws that fix the wheel MP3 500 i e SPORT Business_L...

Page 346: ...efitting the rear wheel To fit follow the removal steps but in the reverse sequence being careful to fit the spacers on the wheel axle as shown in the picture Locking torques N m Silencer arm clamping...

Page 347: ...the scooter on its centre stand Remove the retainer fixing the swinging arm to the engine unscrew the nut and remove the bolt Remove the silent blocks MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 201...

Page 348: ...e frame undo the screw Remove the pin Unscrew the nut of the set screw bushing From the inside loosen the set screw bushing until the swinging arm is free Remove the swinging arm Suspensions MP3 500 i...

Page 349: ...e frame side prepare a retainer using the fixing pin of the swinging arm on the frame and two rings from the special tool 020229Y Alternatively use two washers with 12 mm inside diameter for pins mini...

Page 350: ...new roller cas ings being careful to position the bearings with the O rings facing outwards Specific tooling 020244Y 15 mm diameter punch Characteristic Length of the swinging arm tube on the engine s...

Page 351: ...the pro truding part facing the transmission side Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 Check that the...

Page 352: ...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 prescribed torque 6 Tig...

Page 353: ...gine a little with 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...

Page 354: ...bracket to the engine Remove the centre stand complete with support bracket At the workbench release the two return springs unscrew the relative fixing bolts and separate the centre stand from the sup...

Page 355: ...Locking torques N m Centre stand bolt 31 39 MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Suspensions SUSP 355...

Page 356: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 357: ...SUREMENT EXPRESSED IN TERMS OF THE ANGLO SAXON SYSTEM SEE THE CHARACTERISTICS CHAPTER This section is dedicated to the description of the brake system components CAUTION THE FOLLOWING INSTRUCTIONS REF...

Page 358: ...A Rear brake circuit B Front brake circuit Braking system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 BRAK SYS 358...

Page 359: ...iper pipes ABS modulator wheel brake calliper 12 Rear brake pipes ABS modulator wheel brake calliper 13 Rear valve 14 Rear valve brake pipes rear valve ABS modulator 15 Brake pipes front valve rear va...

Page 360: ...1 Front brake pipes 2 Rear brake pump 11 mm Braking system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 BRAK SYS 360...

Page 361: ...alliper side 13 Integral brake pump support bracket with pedal 14 Pedal fork 15 Brake pipes pedal brake pump rear valve 16 Brake fluid reservoir 17 Brake fluid pipes fitting 18 Integral brake pump 15...

Page 362: ...t left brake cal liper FWR ABS modulator pipes front right brake calliper RW ABS modulator pipes rear brake calliper FWL ABS modulator pipes front left brake cal liper FWR ABS modulator pipes front ri...

Page 363: ...ulator pipes front left brake cal liper FWR ABS modulator pipes front right brake calliper A Left brake pump pipes C Right suspension block pipes D Integral brake pump pipes G Integral brake tank pipe...

Page 364: ...modulator pipes front valve FWL ABS modulator pipes front left brake cal liper FWR ABS modulator pipes front right brake calliper A Left brake pump pipes B Front valve pipes rear valve E Left suspensi...

Page 365: ...dulator pipes rear brake calliper CAUTION THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION NOT EQUIPPED WITH ABS ASR SYSTEM MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Braking system BRA...

Page 366: ...1 LEFT PUMP PIPES TO REAR VALVE 2 RIGHT PUMP PIPES TO FRONT VALVE Braking system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 BRAK SYS 366...

Page 367: ...1 LEFT PUMP PIPES TO REAR VALVE 2 RIGHT PUMP PIPES TO FRONT VALVE 3 FRONT VALVE PIPES TO REAR VALVE 4 FRONT BRAKE PIPES MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Braking system BRAK SYS 367...

Page 368: ...PUMP PIPES TO REAR VALVE 6 RIGHT PUMP PIPES TO FRONT VALVE 7 FRONT BRAKE PIPES 8 FRONT VALVE PIPES TO REAR VALVE 9 LEFT PUMP PIPES TO REAR VALVE 10 FRONT VALVE PIPES TO REAR VALVE 11 REAR BRAKE PIPES...

Page 369: ...ERVOIR TO PEDAL BRAKE PUMP FITTING PIPES 3 BRAKE FLUID RESERVOIR 4 REAR VALVE 5 PEDAL PUMP REAR VALVE PIPES 1 REAR BRAKE PIPES REAR VALVE 2 REAR BRAKE PIPES MP3 500 i e SPORT Business_LT_ ABS ASR_EU_U...

Page 370: ...Braking system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 BRAK SYS 370...

Page 371: ...ER TO THE VEHICLE VERSION EQUIPPED WITH ABS ASR SYSTEM Operating diagram KEY 1 Battery 2 Fuse No 13 3 Fuse No 14 4 Ignition switch 5 Fuse No 10 6 Diagnostic socket MP3 500 i e SPORT Business_LT_ ABS A...

Page 372: ...reduction is made gradually so the wheel spin is reported in the optimal values B Pressure restoration once the wheel spin returns in a stable zone the fluid pressure in the brake circuit is reset bec...

Page 373: ...wheel speed sensor the signal declines frequently Possible tone wheel fault due to deformations or dirt possible alterations on the wheel bearing surface In very rare cases abnormal tone wheel vibra...

Page 374: ...he sensor regarding the tone wheel 5DC5 Front right wheel speed sensor identified speed excessive Faulty sensor tone wheel defect or with wrong number of teeth or wrong tyre size 5DD3 Control unit fai...

Page 375: ...ATTENTION TO THE LOSS OF BRAKE FLUID DURING THE REMOVAL OF THE PIPING FROM THE MODULATOR USE A SMALL CONTAINER AND A CLOTH Remove the three fixing bolts of the ABS modu lator support Remove the latera...

Page 376: ...ASR SYSTEM The ASR system is a device to help riding that helps the rider during acceleration manoeuvres espe cially on slippery surfaces or in conditions that can cause sudden slippage of the rear wh...

Page 377: ...sible If the deactivation was NOT voluntary there is an ASR failure in this case you must contact an Authorised Service Centre for the diagnosis and the reac tivation of the system To ensure maximum s...

Page 378: ...IN CONDITIONS OF LOW GRIP ESPECIALLY IN THE FIRST METRES N B IN CASE OF ROADS FULL OF HOLES THERE MAY OCCUR BRIEF ACTIVATION OF THE ASR SYSTEM THIS OCCURS UNDER NORMAL OPERATING CONDITIONS OF THE VE H...

Page 379: ...end of the procedure will be indicated by the steady lighting ASR warning light 2 The ASR system is not active Once the procedure is complete it is necessary to switch to OFF and wait for at least 60...

Page 380: ...unscrewing the two fixing bolts as indicated in the picture Refitting To fit the rear brake calliper follow the removal steps but in reverse order be careful to tighten the screws to the prescribed to...

Page 381: ...the calliper Refitting To fit the front brake callipers follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque Locking torques N m Screw tightening cal...

Page 382: ...Remove the calliper supporting clamp Braking system MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 BRAK SYS 382...

Page 383: ...perfectly clean with no sign of rust oil or grease or any other dirt and must show no signs of deep scoring Characteristic New rear disc thickness 5 mm Disc thickness at wear limit rear 3 5 mm Remove...

Page 384: ...both Remove the wheel Remove the brake calliper Remove the cotter pin and remove the cap Unscrew the fixing nut Remove the wheel hub Unscrew the six bolts securing the disc to the wheel hub Remove th...

Page 385: ...sign of rust oil or grease or any other dirt and must show no signs of deep scoring Characteristic Thickness of a new front disc 4 0 mm Disc thickness at wear limit front 3 5 mm Remove the wheel and...

Page 386: ...to collect the retaining spring of the pads Remove the pads Characteristic Minimum value 1 5 mm Refitting Follow the removal steps but in reverse order check that the Benzing snap ring of the pads is...

Page 387: ...ads Characteristic Minimum value 1 5 mm Refitting To fit the rear brake pads follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque Locking torques N m...

Page 388: ...fluid Remove the brake oil tube fitting from the rigid pipe inside the front suspension arm and loosen the hydraulic joint fixing nut of the suspension lock ing to release the brake pipes Cut the tie...

Page 389: ...ecure to the prescribed torque Locking torques N m Parking brake Screw tightening calliper to support Apply medium LOCTITE threadlock of type 243 24 27 For an easier operation previously remove the ca...

Page 390: ...ting pay special attention to the correct insertion of the metallic drum in its seat as shown in the picture Undo the four fixing screws of the lever Cut the indicated clamp and disconnect the con nec...

Page 391: ...Remove the parking brake cable from the lever by operating the set screw MP3 500 i e SPORT Business_LT_ ABS ASR_EU_USA 2015 Braking system BRAK SYS 391...

Page 392: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 393: ...xpansion tank is connected in parallel to the radiator The radiator hot box is connected to the upper side of the expansion tank in air The radiator cold box is connected to the lower side of the expa...

Page 394: ...ELECTRIC VENTILATION Specification Desc Quantity Type With piston Electric ventilation starts at 107 C Electric ventilation stops at 103 C WATER PUMP Specification Desc Quantity Type Centrifugal Contr...

Page 395: ...CHECK THE THERMOSTAT OPENING TEMPERATURE AND CHECK THAT THE COOLANT DENSITY IS CORRECT THE OP TIMUM DENSITY IS OBTAINED WITH A 50 WATER 50 COOLING CIRCUIT FLUID MIXTURE System sealing check Check the...

Page 396: ...XPANSION TANK TEMPERATURE RISES Water pump Water pump If noise or loss of liquid at the drain hole of the water pump is discovered replace the flywheel cover and the water pump as described in the Fly...

Page 397: ...with grease or oil CAUTION FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O RING Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque Locking torques...

Page 398: ...he component Adequately fit a new O ring be careful to lubricate it with petroleum jelly grease N B TO AVOID DEFORMATION DO NOT LUBRICATE THE O RING WITH PETROLEUM GREASE CAUTION FAILURE TO OBSERVE TH...

Page 399: ...ck the head gasket seal see Thermal group and timing system chapter If water leaks are detected in the engine oil inspect the pad on the head cooling circuit 3 Fix any damaged seals Oil in the fluid 1...

Page 400: ...INDEX OF TOPICS CHASSIS CHAS...

Page 401: ...CHARACTERISTICS CHAPTER This section is dedicated to the operations that can be carried out on the vehicle s bodywork Seat Raise the saddle Undo the screw shown in the figure remove the cover and disc...

Page 402: ...ironment temperature sensor connector Remove the handlebar cover sliding it off towards the rear part of the vehicle See also Front handlebar cover Instrument panel Remove the shield back plate upper...

Page 403: ...o screws in the lower part of the han dlebar Working on both sides of the handlebar undo the indicated screw to release the control lock Unscrew the underlying screw on both sides Remove the upper han...

Page 404: ...screws Remove the daylight running light by disconnect ing the connector HEADLIGHT Remove the daylight running light Remove the spoiler Remove the two upper fixing screws of the head light Remove the...

Page 405: ...icator WARNING DURING REFITTING PAY PARTICULAR ATTENTION TO THE CORRECT ALIGNMENT OF THE TURN INDICATOR WITH THE OTHER PLASTICS REFERRING TO THE FIT TINGS ON THEM See also spoiler Radiator cover Legsh...

Page 406: ...and slide off the rider presence sensor wiring to re move it See also Seat Knee guard Side fairings Legshield Remove the headlight Undo the four indicated screws on the leg shield back plate Working...

Page 407: ...WARNING DURING THE REFITTING PAY PARTICULAR ATTENTION TO THE CORRECT POSITION OF THE TWO SPOILER SUP PORT PLASTICS REFERRING TO THE INDICATIONS ON THE PLASTIC See also Headlight assy Knee guard Remov...

Page 408: ...ngaging the fittings and lifting it upwards Disconnect the two connectors Undo the two screws indicated Remove the leg shield back plate cover by slight ly lifting it upwards to loosen the fittings Ch...

Page 409: ...figure and placed inside the leg shield back plate on both sides Unscrew the indicated screw then if present re move the key from the switch and the switch plate MP3 500 i e SPORT Business_LT_ ABS AS...

Page 410: ...ning lights unit For an easier operation alter nately turn the handlebar in the two directions Disconnect the instrument panel warning lights unit and USB socket connectors Unscrew on both sides of th...

Page 411: ...ated near the footrest and unscrew the underlying screw Lift the front part of the footpeg cover rubbers and unscrew the underlying screws Remove the central fixing Remove the leg shield back plate sl...

Page 412: ...to remove the central plastic See also Legshield Taillight assy Remove the side fairings Remove the two screws inside the fairing for each side and then the external one to remove the light assembly...

Page 413: ...GS ON THEM See also Side fairings License plate holder Footrest First remove the central chassis cover then for both sides of the footpeg proceed as follows Open the passenger footpeg and unscrew the...

Page 414: ...otpeg CAUTION FOR THE LEFT FOOTPEG SLIDE OFF THE FUSE HOLDER BOX FROM THE FITTINGS ON THE PLASTIC See also Frame central cover Side fairings Remove the handgrips Remove the two screws indicated and th...

Page 415: ...er rear screw Undo the upper rear screw Undo the fixing screw at the rear mudguard li cense plate holder Undo the lower side screw placed near the pas senger footrest Undo the upper side screw MP3 500...

Page 416: ...ease the fittings and disconnect the light assembly connector See also Handles and top side fairings License plate holder Remove the side fairings Remove the three indicated screws Remove the three lo...

Page 417: ...the saddle opening linkage See also Side fairings Helmet bay Remove the central cover Disconnect and remove the battery Release the diagnostic socket and the tip over sensor connector from the fitting...

Page 418: ...ng screws Slightly lift the helmet compartment to disconnect the light connector and the saddle release linkage Working on the left side act on the two fixing bolts of the coil support bracket to remo...

Page 419: ...sconnect the plug socket connec tor Slide off the two fuse boxes all previously dis connected wiring and the saddle lever from the helmet compartment to remove it See also Frame central cover spoiler...

Page 420: ...the spoiler See also Headlight assy Fuel tank Remove the central chassis cover Remove the footrest First remove the lower cover by removing the three indicated clamps and collecting the washers and s...

Page 421: ...the figure Disconnect the electric wiring and the fuel pipes See also Frame central cover Footrest Handles and top side fairings Unscrew the two indicated screws and collect the washers MP3 500 i e SP...

Page 422: ...tting Unscrew the two indicated screws and collect the relative washers Radiator cover FRONT COVER Remove the Piaggio clip on badge fixed to the joint by acting on the indicated slot Remove the indica...

Page 423: ...both sides of the vehicle remove the two screws in the wheel housing Unscrew the four indicated screws and remove the front radiator cover LOWER GUARD Remove the two indicated clamps and the rela tive...

Page 424: ...Remove the two screws fixing the radiator lower protection to the leg shield back plate After that press up and pull the protection front part so as to release it from the radiator frame Chassis MP3...

Page 425: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 426: ...ibration procedure of the system must be carried out according to what is indicated below riding on a straight flat stretch of road In order to maintain the effectiveness of the ASR system the procedu...

Page 427: ...of failure to complete the procedure within 5 minutes the ASR warning light 2 will stay on steady and the ASR will remain off until switching to OFF To switch again to ON it is necessary to reac tiva...

Page 428: ...rding to the regulations currently in force Front and rear stop light buttons and bulb Turn indicators and their warning lights Instrument lighting instruments fuel and temperature indicator Instrumen...

Page 429: ...AY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Level check Hydraulic brake system liquid level Roll lock system fluid level Rear hub oil level Engine coolant level Engine oil level...

Page 430: ...er travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check chassis and engine number check tools and equipment licence plate fitting loc...

Page 431: ...bs C Checks 98 Coolant 291 395 D Display E Electric 394 Engine oil 42 F Fuel 265 272 420 Fuses 112 H Headlight 48 403 407 420 Horn 107 Hub oil 41 I Identification 8 Instrument panel 402 M Maintenance...

Page 432: ...Start up Suspension 55 56 319 Switch T Tank 420 Technical Data Transmission 10 54 144 159 Turn indicators 97 Tyres 11 V Vehicle 8 129 131...

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PIAGGIO MP3 500 i.e. SPORT, Service Station Manual

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