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MANUALE STAZIONE DI SERVIZIO

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MP3 500 ie SPORT Business LT (2011)

Содержание MP3 500 ie SPORT Business LT 2011

Страница 1: ...MANUALE STAZIONE DI SERVIZIO xxx IT xxx EN xxx FR xxx DE xxx ES xxx PT xxx NL xxx EL MP3 500 ie SPORT Business LT 2011 ...

Страница 2: ...blication 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 all versions models shown in this publication are available in all countries The availability of each model should be checked at the official PIAGGIO sales network Copyright 2013 Piaggio C S p A All right...

Страница 3: ...on si dispone degli impianti e delle attrezzature necessarie ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers...

Страница 4: ......

Страница 5: ...HAR 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 CHASSIS CHAS PRE DELIVERY PRE DE ...

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

Страница 7: ...ch 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 original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets s...

Страница 8: ...S IMPOUNDING OF THE VEHICLE ETC Chassis prefix A ZAPM642001 Engine prefix B M474M THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION The identification registration numbers consist of a prefix stamped on the chassis and engine B re spectively followed by a number These numbers must always be indicated on spare parts requests To read the chassis number remove the relevant port A in the helmet c...

Страница 9: ...Chassis prefix A ZAPM643001 Engine prefix B M611M Dimensions and mass MP3 500 ie SPORT Business LT 2011 Characteristics CHAR 9 ...

Страница 10: ...sion 25 kW MAX torque 46 5 Nm at 5 250 rpm Lubrication Engine lubrication with lobe pump inside crankcase chain driven with double filter mesh and paper Lubrication pressure 3 5 to 4 bar Minimum lubrication pressure 100 C 0 8 bar Fuel system Electronic injection with electric fuel pump Cooling Forced coolant circulation system Fuel Unleaded petrol 95 RON Transmission TRANSMISSION Specification Des...

Страница 11: ...h sealed battery Alternator alternating current Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc Quantity Chassis Tubular and sheet steel Front suspension The roll system is composed of an articulated parallelogram suspension with die cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking sys tem Front suspension travel 85 mm rear suspension...

Страница 12: ...t central headstock 22 5 to 25 Handlebar fixing screw 50 55 Fixing screws for the handlebar control unit U bolts 7 10 CHASSIS Name Torque in Nm Swinging arm set screw bushing 5 7 Engine arm bolt frame arm 32 5 40 Swinging arm set screw bushing nut 54 60 Engine swinging arm bolt 98 118 Frame swinging arm bolt 54 60 Centre stand bolt 31 39 FRONT SUSPENSION Name Torque in Nm Shock absorber lower clam...

Страница 13: ... 27 30 FRONT BRAKE Name Torque in Nm Calliper coupling screw 22 27 Oil bleed screw 8 12 Brake disc screws 8 to 10 Brake fluid pump hose fitting 16 20 Brake fluid pipe calliper fitting 20 25 Screw tightening calliper to support 20 to 25 Calliper upper pipe fitting 20 to 25 REAR BRAKE Name Torque in Nm Oil bleed screw 12 16 Brake disc screws 8 to 10 Rear brake calliper pipe fitting 20 to 25 Rigid fl...

Страница 14: ...ve pulley nut 160 175 Anti vibration roller screw 16 7 19 6 M8 retainers for transmission cover 23 26 M6 retainer 11 13 Anti vibration roller retainer 17 19 Clutch ring nut 65 75 Air conveyor screws 11 12 Water pump cover screws 3 4 External transmission cover screws 7 to 9 Flywheel cover screws 11 13 FLYWHEEL COVER Name Torque in Nm Chain guide sliding block retain plate fastening screws 3 4 Flyw...

Страница 15: ...n Desc Quantity A 10 mm B 43 mm CYLINDER PISTON Specification Desc Quantity Cylinder diameter 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 93 997 93 004 93 961 93 968 0 029 0 043 MP3 500 ie SPORT Business LT 2011 Characteristics CHAR 15 ...

Страница 16: ...T BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS Piston rings Fit piston rings 2 and 3 with the mark TOP facing up Position the port of the rings as shown here Value A of seal ring inside the cylinder Check the size of the sealing ring opening Compression ring 0 15 0 35 mm Max value 0 5 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Oil scraper ring 0 25 0 50 mm Max value 0 ...

Страница 17: ...06 mm Maximum clearances allowed after use 0 10 mm Intermediate ring Standard coupling clear ance 0 02 0 07 mm Maximum clearances allowed after use 0 10 mm Oil scraper ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm If clearances measured exceed the maximum val ues specified in the table the piston should be replaced by a new one MP3 500 ie SPORT Business...

Страница 18: ...0 20 0 50 Half shaft transmission side 20 9 0 05 B D 0 20 0 50 Connecting rod 22 0 10 0 15 C D 0 20 0 50 Flywheel side shoulder 1 8 0 025 F D 0 20 0 50 Flywheel side half shaft 19 6 0 05 E D 0 20 0 50 Complete crankshaft 65 5 0 1 0 05 G D 0 20 0 50 Diameter of crankshaft bearings Measure the bearings on both axes x y Characteristics MP3 500 ie SPORT Business LT 2011 CHAR 18 ...

Страница 19: ...40 016 40 022 Crankshaft alignment Specific tooling 020335Y Magnetic mounting for dial gauge MAX ADMISSIBLE DISPLACEMENT Specification Desc Quantity A 0 15 mm B 0 010 mm C 0 010 mm D 0 10 mm Characteristic Crankshaft crankcase axial clearance H MP3 500 ie SPORT Business LT 2011 Characteristics CHAR 19 ...

Страница 20: ...N A 0 10 to 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 GASKET FITTED AT B Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP GEAR SAE 80W 90 Lubricant for gearboxes and transmis sions API GL 4 eni i Ride PG 5W 40 Synthetic based lubricant for high per formance four s...

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

Страница 22: ... seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearings 001467Y008 Pliers to extract 17 mm ø bearings 001467Y014 Calliper to extract ø 15 mm bearings Tooling MP3 500 ie SPORT Business LT 2011 TOOL 22 ...

Страница 23: ...ct ø 15 mm bearings 001467Y035 Bearing housing external ø 47 mm 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on steering tube 020004Y Punch for removing steering bearings from headstock MP3 500 ie SPORT Business LT 2011 Tooling TOOL 23 ...

Страница 24: ...e ring nut 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge 020201Y Spacer bushing driving tube 020262Y Crankcase splitting plate 020306Y Punch for assembling valve seal rings Tooling MP3 500 ie SPORT Business LT 2011 TOOL 24 ...

Страница 25: ...ated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020648Y Single battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35 mm Adaptor 020358Y 37 x 40mm Adaptor MP3 500 ie SPORT Business LT 2011 Tooling TOOL 25 ...

Страница 26: ...47mm Adaptor 020360Y 52 x 55 mm Adaptor 020364Y 25 mm guide 020376Y Adaptor handle 020382Y012 bush valve removing tool 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch Tooling MP3 500 ie SPORT Business LT 2011 TOOL 26 ...

Страница 27: ...on 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020439Y 17 mm guide 020444Y Tool for fitting removing the driven pulley clutch 020456Y Ø 24 mm adaptor MP3 500 ie SPORT Business LT 2011 Tooling TOOL 27 ...

Страница 28: ...ring tube 020459Y Punch for fitting bearing on steering tube 020922Y Diagnosis Tool 020467Y Flywheel extractor 020468Y Piston assembly band 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing Tooling MP3 500 ie SPORT Business LT 2011 TOOL 28 ...

Страница 29: ...eel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020478Y Punch for driven pulley roller casing 020479Y Countershaft lock wrench MP3 500 ie SPORT Business LT 2011 Tooling TOOL 29 ...

Страница 30: ...rol pressure check kit 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter Tooling MP3 500 ie SPORT Business LT 2011 TOOL 30 ...

Страница 31: ...o 3 020481Y004 Parking control unit interface wiring Marelli MIU diagnosis software Marelli MIU diagnosis software 020646Y Parallelogram and steering positioning tool 020647Y Toe in checking tool 020647Y028 MP3 LT Toe in tool tricycle MP3 500 ie SPORT Business LT 2011 Tooling TOOL 31 ...

Страница 32: ...Stores code Description 020661Y Water pump overall seal replacement kit Tooling MP3 500 ie SPORT Business LT 2011 TOOL 32 ...

Страница 33: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Страница 34: ...under the badge and remove the centre headlight cover Undo the screws A fastening the front grille On both sides of the vehicle undo the screw B at the bottom of the front grille surround and re trieve the shim On both sides of the vehicle undo the screws C inside the front wheel housing Maintenance MP3 500 ie SPORT Business LT 2011 MAIN 34 ...

Страница 35: ...for the headlight assembly Undo the two lower fastener screws F and re move the headlight assembly from its seat Undo the indicated screws and remove the wind screen Undo the indicated screws and remove the spoiler Undo the indicated screws MP3 500 ie SPORT Business LT 2011 Maintenance MAIN 35 ...

Страница 36: ...n can be reached Unscrew the upper ring nut Bring the upper ring nut to the end of the headstock thread of the side suspension Tighten the lower ring nut to the specified torque with the appropriate key Locking torques N m Side headstock lower ring nut 12 15 Screw the upper ring nut until it stops Maintenance MP3 500 ie SPORT Business LT 2011 MAIN 36 ...

Страница 37: ...is played Maintenance chart SCHEDULED MAINTENANCE TABLE I CHECK AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST 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 Electrical system I I I I I I I I I Coolant level I I I I I I I I ...

Страница 38: ...erpret 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 advance determined by the injection system matches the value actually activated on the engine by means of the strobo scopic light Proceed as follows Remove the spark plug Remove the transmission crankcase Rotate the drivin...

Страница 39: ...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 timing engine speed sensor injection control unit Specific tooling 020922Y Diagnosis Tool 020330Y Stroboscopic light to check timing 020621Y HV cable extraction adaptor Spark plug Remove the port on the left han...

Страница 40: ...USE OF ELECTRONIC CENTRAL UNITS AND OF NON COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE N B USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR UNSHIELDED SPARK PLUG CAPS CAN LEAD TO FAULTS IN THE VEHICLE S ELECTRICAL SYSTEM Characteristic Spark plug NGK CR7EKB Electric characteristic Electrode gap 0 7 0 8 mm Hub oil Check Place the vehi...

Страница 41: ...move the oil filler plug A Unscrew the oil drainage cap B and drain out all the oil Screw in the drainage cap again and fill the hub with the prescribed oil Recommended products AGIP GEAR SAE 80W 90 Lubricant for gear boxes and transmissions API GL 4 Characteristic Rear hub oil Capacity approximately 250 cc Air filter Proceed as follows Unscrew the nine fixing screws A and remove the air filter co...

Страница 42: ...il is used to lubricate the timing elements the bench bearings and the thermal group An insufficient quantity of oil can cause serious damage to the engine In all four stroke engines the deterioration of the oil characteristics or a certain consumption should be considered normal especially if during the run in period Consumption levels in particular can be influenced by the conditions of use e g ...

Страница 43: ... added through plug A Then start up the vehicle leave it running for a few minutes and switch it off After about five mi nutes check the level and if necessary top up but never exceeding the MAX level reference mark The cartridge filter must be replaced every time the oil is changed Use new oil of the recommended type for topping up and changing purposes N B THE ENGINE MUST BE HOT WHEN THE OIL IS ...

Страница 44: ...ld be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX level Restoring the level from the MIN to the MAX marks requires approx 400 m of oil Engine oil filter Change oil and replace filter as indicated in the scheduled maintenance table Use new oil of the rec ommended type for topping up and changing purposes Make sure the pre filter and drainage...

Страница 45: ...over as shown in the figure TDC Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure If the ref erence is opposite the indicator on the head turn the crankshaft once more For the use of this reference mark remove the spark plug and turn the engine in the direction that is the reverse of the normal directi...

Страница 46: ... TANK WHEN THE VEHICLE IS IN USE Recommended products AGIP PERMANENT SPECIAL Ethylene glycol based antifreeze fluid with organic inhibition additives Red ready to use ASTM D 3306 ASTM D 4656 ASTM D 4985 CUNA NC 956 16 Braking system Level check FRONT AND REAR BRAKING SYSTEM LEVEL CHECK The front and rear brake fluid reservoirs are both positioned on the handlebars Proceed as follows Rest the vehic...

Страница 47: ... recommended fluid without exceeding the MAX mark This procedure applies to the rear brake pump top up operation follow the same procedure for the front brake pump Under standard climatic conditions replace fluid as indicated in the scheduled maintenance table WARNING ONLY USE DOT 4 CLASSIFIED BRAKE FLUID BRAKE CIRCUIT FLUID IS VERY CORROSIVE MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE P...

Страница 48: ...adjustment Proceed as follows Position the unloaded vehicle in running order and with the tyres inflated to the prescribed pres sure onto a flat surface 10 m away from a half lit white screen make sure the scooter axis is per 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 t...

Страница 49: ...MP3 500 ie SPORT Business LT 2011 Maintenance MAIN 49 ...

Страница 50: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Страница 51: ...and replace 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 too low Restore the level adding the recommended oil type Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation ...

Страница 52: ...ng even after 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 Possible Cause Operation Torque not conforming Check the tightening of the top and bottom ring nuts If irregu larities continue in turning the steering even after making the above adjustmen...

Страница 53: ...LEAKAGE FROM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber Check the condition of wear of the steering covers and the adjustments MP3 500 ie SPORT Business LT 2011 Troubleshooting TROUBL 53 ...

Страница 54: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Страница 55: ...FUSE 04 15 A 8 FUSE 05 15 A 9 FUSE 06 7 5 A 10 IGNITION KEY CONTACTS 11 FUSE 07 7 5 A 12 FUSE 08 10 A 13 FUSE 09 7 5 A 14 FUSE 10 7 5 A 15 FUSE 11 7 5 A 16 FUSE 12 7 5 A 17 FUSE 13 30 A 18 VOLTAGE REGULATOR 19 FLYWHEEL 20 HAZARD BUTTON MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 55 ...

Страница 56: ...ELAY 34 FUEL GAUGE 35 INSTRUMENT PANEL 36 SWITCH FOR SADDLE OPENING 37 AMBIENT TEMPERATURE SENSOR 38 MODE BUTTON 39 OIL PRESSURE SENSOR 40 CASE OPENING SWITCH 41 SADDLE OPENING ACTUATOR 42 BOOT ACTUATOR 43 STARTER BUTTON 44 PARKING CONTROL ECU 45 DIAGNOSTICS SOCKET 46 LEFT SPEED SENSOR 47 RIGHT SPEED SENSOR 48 RIDER DETECTION SENSOR 49 HAND BRAKE 50 LOCK SWITCH 51 UNLOCK SWITCH 52 POTENTIOMETER 53...

Страница 57: ...EMOTE CONTROL SWITCH 71 HEADLIGHT WITH 12V 55W TWIN FILAMENT BULB 72 HEADLIGHT RELAY 73 Light switch 74 HORN 75 Horn button 76 BOOT SADDLE LIGHT BULB 77 SOCKET 12V 78 C D I GROUND NODE 79 BRAKE PEDAL BUTTON Colours of the electrical cables B White Bl Blue G Yellow Mr Brown N Black BV White Green GN Yellow Black Gr Grey Rs Pink R Red Vi Violet V Green VN Green Black BN Black White BBl White Blue MP...

Страница 58: ...3 VERSION KEY 1 Instrument panel 2 2 bulbs for rear turn indicators 12 V 10 W 3 2 bulbs for front turn indicators 12 V 10 W 4 Turn indicator switch 5 Turn indicator control device with Hazard 6 PMP connection 7 Headlight with 12V 55W twin filament bulb 8 Pre installation for anti theft device Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 58 ...

Страница 59: ...ine stop switch 22 Radiator electric fan 23 Electric fan relay 24 Socket 12 V 25 Saddle lighting button 26 Boot light switch 27 Magneto flywheel 28 Voltage regulator 29 Main fuses 30 Starter button 31 Start up enabling relay 32 Starter motor 33 Starter relay 34 Battery 12 V 14 A 35 Ignition switch contacts 36 2 12 V 21 W stop light bulbs 37 Injection load relay 38 Horn relay 39 Geared motor 40 Bra...

Страница 60: ... and leg warmer 58 Immobilizer antenna 59 External temperature sensor 60 Pressure sensor 61 Fuel level transmitter 62 Oil pressure sensor 63 MODE button 64 Horn 65 Horn button Colours of the electrical cables B White Bl Blue G Yellow Mr Brown N Black BV White Green GN Yellow Black Gr Grey Rs Pink R Red Vi Violet V Green VN Green Black BN Black White BBl White Blue GV Yellow Green Ar Orange Electri...

Страница 61: ...l Grey Blue GrN Grey Black RBl Red Blue GR Yellow Red BlN Blue Black Components arrangement 1 Immobilizer Aerial Remove the shield back plate to reach it MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 61 ...

Страница 62: ...te control switches Remove the legshield to reach it 4 Auxiliary fuses Remove the flap of the right side footrest to reach these fuses 5 Horn Remove the shield back plate lower side to reach it Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 62 ...

Страница 63: ...il Remove the central chassis cover to reach it 8 Lambda probe The lambda probe is mounted on the exhaust manifold 9 Oil pressure sensor Remove the exhaust end to reach it MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 63 ...

Страница 64: ...g to reach it 12 Diagnosis connector 13 Main fuses These components are found in the battery com partment 14 Electronic control unit 15 Start up remote control switch 16 Start up enabling remote control switch Remove the lid of the helmet compartment to reach it Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 64 ...

Страница 65: ...sor Open the saddle and remove the cover to reach the rider presence sensor 18 Parking control ECU Remove the shield back plate to reach it Conceptual diagrams MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 65 ...

Страница 66: ...E 10 7 5 A 32 IMMOBILIZER AERIAL 35 INSTRUMENT PANEL 44 PARKING CONTROL ECU 45 DIAGNOSTICS SOCKET 57 FUEL INJECTOR 58 HV COIL 59 INJECTION LOAD RELAY 60 C D I 61 ENGINE SPEED SENSOR 64 FUEL PUMP 65 ENGINE TEMPERATURE SENSOR Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 66 ...

Страница 67: ...el 12 Auxiliary fuses 29 Main fuses 34 Battery 12 V 14 A 35 Ignition switch contacts 37 Injection load relay 50 Engine speed sensor 51 H V coil 52 Fuel injector 54 Fuel pump 56 Injection ECU 58 Immobilizer antenna MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 67 ...

Страница 68: ...Y CONTACTS 12 FUSE 08 10 A 17 FUSE 13 30 A 18 VOLTAGE REGULATOR 19 FLYWHEEL 23 STOP BUTTONS 35 INSTRUMENT PANEL 43 STARTER BUTTON 60 C D I 66 12V 10W STOP LIGHT BULBS 67 ENGINE STOP 70 START UP ENABLING REMOTE CONTROL SWITCH 79 BRAKE PEDAL BUTTON Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 68 ...

Страница 69: ...p buttons 21 Engine stop switch 27 Magneto flywheel 28 Voltage regulator 29 Main fuses 30 Starter button 31 Start up enabling relay 32 Starter motor 33 Starter relay 34 Battery 12 V 14 A 35 Ignition switch contacts 36 2 12 V 21 W stop light bulbs 56 Injection ECU MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 69 ...

Страница 70: ...USE 10 7 5 A 32 IMMOBILIZER AERIAL 34 FUEL GAUGE 35 INSTRUMENT PANEL 39 OIL PRESSURE SENSOR 57 FUEL INJECTOR 59 INJECTION LOAD RELAY 60 C D I 62 LAMBDA PROBE 65 ENGINE TEMPERATURE SENSOR 67 ENGINE STOP THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 70 ...

Страница 71: ... 35 Ignition switch contacts 38 Horn relay 39 Geared motor 40 Brake calliper sensor 41 Parking control ECU 42 Right speed sensor 43 Left speed sensor 44 Oxygen sensor 45 Rotation sensor 46 Rider presence sensor 47 Unlock switch 48 Lock switch 49 Hand brake MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 71 ...

Страница 72: ...el transmitter 62 Oil pressure sensor Devices and accessories KEY 1 BATTERY 4 FUSE 01 15 A 5 FUSE 02 20 A 6 FUSE 03 20 A 7 FUSE 04 15 A 10 IGNITION KEY CONTACTS 13 FUSE 09 7 5 A 15 FUSE 11 7 5 A 16 FUSE 12 7 5 A 24 12V 10W RIGHT BULBS 25 LEFT BULBS 12V 10W Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 72 ...

Страница 73: ...CONTROL ECU 46 LEFT SPEED SENSOR 47 RIGHT SPEED SENSOR 48 RIDER DETECTION SENSOR 49 HAND BRAKE 50 LOCK SWITCH 51 UNLOCK SWITCH 52 POTENTIOMETER 53 BRAKE CALLIPER SENSOR 54 GEAR MOTOR 63 LOCK UNLOCK PRESSURE SENSOR 68 BOOT LIGHT SWITCH 69 SADDLE LIGHT SWITCH 72 HEADLIGHT RELAY 74 HORN 75 Horn button 76 BOOT SADDLE LIGHT BULB 77 SOCKET 12V 78 C D I GROUND NODE THE FOLLOWING INSTRUCTIONS REFER TO THE...

Страница 74: ...t device 10 Ignition switch contacts 12 Auxiliary fuses 14 USB socket 16 Saddle opening switch 17 Boot opening switch 18 Saddle opening actuator 19 Boot actuator 20 Light switch 24 Socket 12 V 25 Saddle lighting button 26 Boot light switch 29 Main fuses 34 Battery 12 V 14 A 35 Ignition switch contacts Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 74 ...

Страница 75: ...e and leg warmer 60 Pressure sensor 61 Fuel level transmitter 63 MODE button 64 Horn 65 Horn button Lights and turn indicators KEY 1 BATTERY 5 FUSE 02 20 A 7 FUSE 04 15 A 10 IGNITION KEY CONTACTS 12 FUSE 08 10 A 13 FUSE 09 7 5 A 15 FUSE 11 7 5 A 16 FUSE 12 7 5 A MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 75 ...

Страница 76: ...ONT DAYLIGHT RUNNING LIGHT 30 LEFT REAR TAIL LIGHT BULB 31 RIGHT REAR TAIL LIGHT BULB 35 INSTRUMENT PANEL 44 PARKING CONTROL ECU 66 12V 10W STOP LIGHT BULBS 71 HEADLIGHT WITH 12V 55W TWIN FILAMENT BULB 72 HEADLIGHT RELAY 73 Light switch 79 BRAKE PEDAL BUTTON THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 76 ...

Страница 77: ...inspections This section is dedicated to the checks on the electrical system components Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys tem The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means of the coded keys that the control unit recognises The code is integrated in a transpo...

Страница 78: ...ation of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition switch and or the instrument panel is not initiated check if there is battery voltage fuses 2 6 10 are in working order there is power to the control unit as specified below Remove the connector mounting bracket shown in the photograph and disconnect the connect...

Страница 79: ...ing order There is continuity between terminals 12 18 with the emergency stop switch in the RUN position If there is no con tinuity check the contacts of the switch If no faults are found replace the electronic control unit After removing the leg shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base from the connector MP3 500 ie SPORT...

Страница 80: ...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 only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys The master and service keys must be used to code the system as follows Insert the Master key turn it to ON and keep this...

Страница 81: ...TER key RED KEY SERVICE key BLACK KEY Diagnostic codes The Immobilizer system is tested each time the ig nition key is turned from OFF to ON During this diagnosis phase a number of control unit sta tuses can be identified and various light codes displayed Regardless of the code transmitted if at the end of the diagnosis the LED remains off permanently the ignition is enabled If however the LED rem...

Страница 82: ...he Master key When the diagnosis has been completed the LED remains permanently OFF 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 steadily The engine cannot be started The codes that can be trans mitted are 1 flash code 2 flash code 3 flash code Diagnostic code 1 flash A one flash code ind...

Страница 83: ...he switch to ON using several keys if the error code is repeated even with the Master key replace the control unit If this is not the case reprogram the decoder Remote controls check To check the operation of a solenoid 1 Check that given regular conditions there is no continuity between terminals 87 and 30 2 Apply a 12V voltage to power terminals 86 and 85 of the solenoid 3 With the solenoid fed ...

Страница 84: ...Check that there is insulation between the each yellow cable and the ground 5 If values are incorrect replace the stator Recharge system voltage check Look for any leakage 1 Access the battery by removing its cover under the saddle 2 Check that the battery does not show signs of losing fluid before checking the output voltage 3 Turn the ignition key to position OFF connect the terminals of the tes...

Страница 85: ... battery voltage to stop at 12V Connect ammeter pliers to the 2 recharge positive poles in output from the regulator Start the engine and rev it up to a high engine speed while reading the value on the pincer With an efficient battery a value must be detected 20A VOLTAGE REGULATOR RECTIFIER Specification Desc Quantity Type Non adjustable three phase transistor Voltage 14 to 15V at 5000 rpm with li...

Страница 86: ...able between ignition switch and fuse box fuse No 8 Red cable between fuse box fuse No 8 stop buttons and starter relay White Black cable between stop buttons and starter button and the Orange White cable between the starter button and the starter relay Orange Blue cable between start up enabling relay and ECU pin 24 Green Blue cable between start up enabling remote control switch and starter rela...

Страница 87: ...ollowing wiring for continuity Red Black cable between fuse box fuse No 2 and ignition switch Orange cable between ignition switch and fuse box fuse No 9 Blue cable between fuse box 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 Battery 2 Fuse No 4 3 ignition switch contacts 4 Fuse N...

Страница 88: ...the left in the Blue Black cable between turn indicator control device and the ground lead with the turn indi cator switch pressed to the right between Brown cable of the turn indicator control device and the ground lead with the Hazard button pressed 5 If there is no voltage check that there is continuity in the relevant cable harness 6 Check that the turn indicator control device is powered by m...

Страница 89: ...unning light bulbs 11 License plate bulbs 12 Front daylight running light bulb 13 Parking control ECU 14 Headlight with twin filament bulb 15 Light switch WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED DAYLIGHT RUNNING LIGHT LINE CHECK 1 Check that bulbs operate properly MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 89 ...

Страница 90: ... light switch contacts 7 Check continuity in the White Black cable between the parking control ECU pin 6A and the headlight relay the Grey Red cable between the headlight relay and the light switch the cable harnesses between the headlight and the light switch Brown and Purple cables 8 Check the bulbs ground connection LIGHT BULBS TABLE Specification Desc Quantity 1 Low beam bulb Type HALOGEN H1 P...

Страница 91: ...ON KEY 1 Battery 2 Fuse No 2 3 ignition switch contacts 4 Fuse No 4 5 Fuse No 9 6 Fuse No 11 7 Headlight solenoid 8 Ignition switch contacts 9 Fuse No 12 10 Rear daylight running light bulbs 11 License plate bulbs 12 Front daylight running light bulb 13 Parking control ECU 14 Headlight with twin filament bulb MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 91 ...

Страница 92: ...he Blue cable between the light switch and the ground lead with the ignition switch set to ON 5 Check that the relevant cable harnesses are not interrupted wherever no voltage is detected 6 Check the headlight relay and the light switch contacts 7 Check continuity in the White Black cable between the parking control ECU pin 6A and the headlight relay the Grey Red cable between the headlight relay ...

Страница 93: ...e fuses divided into two fuse boxes to protect the different installation circuits One of them is inside the battery compart ment A and the other is at the 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 specifications of the fuses in the vehicle CAUTION BEFORE REPLACING A BLOWN FUSE FIND AND SOLVE THE FAILURE TH...

Страница 94: ...y glove box lighting headlight turn indicator command device pre installation for anti theft device Live fuse No 12 saddle opening and boot 4 Fuse No 4 Capacity 20A Protected circuits battery powered ECU for parking control 5 Fuse No 5 Capacity 20A Protected circuits battery powered fuse No 7 live fuses No 8 9 10 11 6 Fuse No 6 Capacity 15A Protected circuits L V socket 7 Fuse No 7 Capacity 7 5 A ...

Страница 95: ...pening switch daylight running lights panel lighting 13 Fuse No 13 Capacity 30 A Protected circuits Recharge circuit THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION The electrical system has twelve fuses divided into two fuse boxes to protect the different installation circuits One of them is inside the battery compart ment A and the other is at the internal side of the right footrest B To ...

Страница 96: ... Capacity 20A Protected circuits Battery powered parking control ECU 4 Fuse No 4 Capacity 15A Protected circuits Battery powered carry case lighting headlights turn indicator control device pre installation for anti theft device key powered fuse No 12 saddle and carry case opening 5 Fuse No 5 Capacity 15A Protected circuits Battery powered injection loads electric fan 6 Fuse No 6 Capacity 7 5 A Pr...

Страница 97: ... ECU USB socket pre installation for anti theft device instru ment panel headlight relay horn relay 12 Fuse No 12 Capacity 7 5A Protected circuits Key powered PMP connection turn indicator control device pre installation heated hand grips control device and leg warmer daylight running light license plate light panel lighting 13 Fuse No 13 Capacity 30 A Protected circuits Recharge circuit Dashboard...

Страница 98: ...y 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 stored in open circuit Besides upon pre delivery it is therefore necessary to check the battery charge and recharge it if re quired before storing the vehicle and afterwards every six months INSTRUCTIONS FOR...

Страница 99: ...LK BATTERED 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 PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CHILDREN 1 Battery preparation Position the battery on a flat surface Remove the adhesive sheet closing cells and proceed as qu...

Страница 100: ...and proceed 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 of the battery Note To do this do not use sharp objects that could damage the closing strip use gloves to protect your hands and do not bring your face close to the battery The filling proce...

Страница 101: ...mer c connect 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 the bat tery recharge Maintenance Free as shown in fig ure f Check the ignition of the green LED indicated with a red arrow in figure MP3 500 ie SPORT Business LT 2011 Electrical system ELE...

Страница 102: ...isconnect the clamps from the battery and proceed to fitting the battery on the vehicle Connectors INJECTION ELECTRONIC CONTROL UNIT CONNECTOR 1 Injection telltale light LED Brown Black 2 Rpm indicator on instrument panel Yellow 3 CAN L Line White Blue 4 Lambda probe White Green 5 Key powered Red White 6 Battery powered Orange Black 7 Immobilizer aerial Orange White 8 Electric fan relay Blue Yello...

Страница 103: ...Orange Blue 25 Not connected 26 Ground lead Black PICK UP CONNECTOR 1 Injection ECU Red 2 Injection ECU Brown VOLTAGE REGULATOR CONNECTOR 1 Battery positive Red Black 2 Ground lead Black 3 Battery positive Red Black 4 Ground lead Black TURN INDICATOR CONTROL DEVICE CON NECTOR 1 Hazard button Brown 2 Left Switch White Pink 3 RHS Switch Blue Black 4 Left turn indicators Pink 5 Right turn indicators ...

Страница 104: ...CONNECTOR 1 Left turn indicators Pink 2 Right turn indicators White Blue 3 Ground lead Black 4 Battery powered Blue 5 Key powered Yellow Red 6 Helmet compartment lighting Blue Black 7 Channels 1 3 selector Green Blue 8 Alarm code Orange Black FUEL PUMP CONNECTOR 1 Injection load relay Black Green 2 Not connected 3 Not connected 4 Ground lead Black 5 Not connected Electrical system MP3 500 ie SPORT...

Страница 105: ...MODE remote button Green 6 Oil pressure sensor Pink White 7 Left turn indicator warning light Pink 8 Right turn indicator warning light White Blue 9 High beam warning light Purple 10 Case open warning light Blue Black 11 Engine speed sensor 12 Ambient temperature sensor Yellow Blue 13 Ambient temperature sensor ground White Yellow 14 Engine disabled warning light Orange Blue 15 Immobilizer warning...

Страница 106: ...ead Black 1B Key powered Yellow Red 2B CAN H Line Pink White 3B Left wheel speed sensor Green 4B Right wheel speed sensor Red 5B Potentiometer signal Green Blue 6B Locking unlocking switch Green Grey 7B Horn solenoid for alarms White 8B Geared motor White Red 1C Battery powered Blue Red 2C Diagnosis Purple White 3C Locking unlocking switch Yellow Blue 4C Calliper sensor Brown 5C Locking unlocking ...

Страница 107: ...be Sky blue Black 12 Engine stop switch Green Black 13 Engine speed sensor positive Red 14 Fuel injector Red Yellow 15 Engine speed sensor negative Brown 16 Diagnosis Purple White 17 Immobilizer LED Red Green 18 Engine stop switch coolant temperature sen sor Grey Green 19 Not connected 20 Injection load solenoid Black Purple 21 Not connected 22 HV coil Pink Black 23 Not connected 24 Start up enabl...

Страница 108: ... Left Switch White Pink 3 RHS Switch Blue Black 4 Left turn indicators Pink 5 Right turn indicators White Blue 6 Battery powered Blue 7 Not connected 8 Key powered Yellow Black 9 Ground lead Black 10 Not connected 11 Not connected 12 Not connected H V COIL CONNECTOR 1 Injection load relay Black Green 2 Injection ECU Red Black Electrical system MP3 500 ie SPORT Business LT 2011 ELE SYS 108 ...

Страница 109: ...PUMP CONNECTOR 1 Injection load relay Black Green 2 Not connected 3 Not connected 4 Ground lead Black 5 Not connected INSTRUMENT PANEL CONNECTOR A 1 Not connected 2 Not connected 3 Not connected 4 Not connected 5 Instrument panel lighting Yellow Black 6 Battery powered Red Blue 7 Not connected 8 Not connected 9 Not connected 10 Not connected 11 Ground lead Black 12 Key powered Yellow Red MP3 500 i...

Страница 110: ...Orange Blue 15 Immobilizer warning light Red Green 16 Engine check warning light Brown Black 17 Parking brake warning light Yellow Grey 18 Roll lock activated warning light Pink Black 19 Roll lock system failure warning light Grey Black 20 Key powered from the parking control ECU Yellow Green PARKING CONTROL ECU CONNECTOR 1A Potentiometer power supply Orange Blue 2A CAN L Line Pink White 3A Warnin...

Страница 111: ...Horn solenoid for alarms White 8B Geared motor White Red 1C Battery powered Blue Red 2C Diagnosis Purple White 3C Locking unlocking switch Yellow Blue 4C Calliper sensor Brown 5C Locking unlocking switch Purple Black 6C Rider detection sensor Purple 7C Vehicle speed signal Sky blue 8C Geared motor Blue MP3 500 ie SPORT Business LT 2011 Electrical system ELE SYS 111 ...

Страница 112: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Страница 113: ...gh the swinging arm CAUTION SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUF FLER TIP ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP To fit follow the removal steps but in reverse order be careful to tighten to 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...

Страница 114: ...e rear brake pipes Remove the pipe that feeds 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 fuel delivery pipe from the injector by removing the screw locking the retainer clamp Disconnect the injector wiring and the throttle body control unit wiring Remove the coolant outlet pipe from the engine as ind...

Страница 115: ...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 Disconnect the connectors from the flywheel wir ing as shown in the photo Remove the cable from the retaining clip on the flywheel cover MP3 500 ie SPORT Business LT 2011 Engine from vehicle ENG VE 115 ...

Страница 116: ... 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 recommended type Fill and bleed the cooling circuit Check accelerator and electric devices for correct functioning CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY Engine from...

Страница 117: ...INDEX OF TOPICS ENGINE ENG ...

Страница 118: ...driven pulley axle cover near the bottom of the cap Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush Remove the nut and the two washers N B DUE TO THE HIGH TIGHTENING TORQUE USING DIFFER ENT WRENCHES SUCH AS A CONVENTIONAL POLYG ONAL BUSH MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF En...

Страница 119: ...ce 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 transmission cover Unscrew the 4 fastening screws shown in the fig ure to remove the external air conveyor MP3 500 ie SPORT Business LT 2011 Engine ENG 119 ...

Страница 120: ...e 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 TRANSMISSION COV ER CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND NOT ONLY IN THE AREA OF MAXIMUM STURDINESS Specific tooling 001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y 28 x 30 mm a...

Страница 121: ... 020376Y Adaptor handle 020358Y 37 x 40mm 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 13 mm spanner Remove the complete roller with bearing N B IF THE ROLLER DOES NOT ROTATE FREELY REPLACE THE COMPLETE ROLLER Installation of belt anti vibration roller Install the anti flapping ...

Страница 122: ...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 ECCENTRICITY MEASURED 0 2 MM MAX Characteristic Max value 160 5 mm Standard value 160 2 mm Engine MP3 500 ie SPORT Business LT 2011 ENG 122 ...

Страница 123: ... THE REAR SCREW 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 SHEATH Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Inspecting the clutch Check the thickness of the clutch mass friction material Characteristic Minimum thick...

Страница 124: ...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 otherwise replace the fixed driven half pulley Remove the lock ring using pliers Engine MP3 500 ie SPORT Business LT 2011 ENG 124 ...

Страница 125: ... 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 Adaptor handle 020375Y 28 x 30 mm adaptor 020364Y 25 mm guide 001467Y002 Driver for OD 73 mm bearing Inspecting the driven fixed half pulley Check that the belt contact surface is free from wear Measure the outer diameter ...

Страница 126: ...ing 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 the driven pulley unit fully assembled use the special tool Specific tooling 020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing Install a new ball bearing using the s...

Страница 127: ...e the 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 operation is necessary to avoid the presence of grease beyond the O rings Recommended products AGIP GREASE SM 2 Gray black smooth textured lithium grease containing molybdenum di sulphide Inspecting the c...

Страница 128: ...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 bed torque Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Locking torques N m Clutch ring nut 65 75 To facilitate reassembly on the engine turn the moving driven pulley and insert ...

Страница 129: ... 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 insert the stud bolts on the ring into the holes obtained onto the tool itself Tighten the two tool fixing screws also manually Loosen the central nut Remove the spring washer and the flat washer Remove the fixed dr...

Страница 130: ...ormal 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 outside di ameter shown in the figure Characteristic Minimum admissible diameter Ø 29 95 mm Standard diameter Ø 29 959 mm Check that the rollers are not damaged or worn Characteristic Minimum adm...

Страница 131: ...ing 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 side must rest on the inside thrust face of the roller container Assembly the half pulley with the roller contrast plate and sliding blocks MP3 500 ie SPORT Business LT 2011 Engine ENG 131 ...

Страница 132: ...ving half pulley Insert the spacer Install the fixed driving half pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley Remove the flat washer and the spring washer as shown in the figure Engine MP3 500 ie SPORT Business LT 2011 ENG 132 ...

Страница 133: ...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 resting flatly Tighten the driving pulley fastening nut to the prescribed torque Remove the special tool Locking torques N m Drive pulley nut 160 175 Refitting the transmission cover Ensure the correct install...

Страница 134: ...r LHS locking 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 ONAL BUSH MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF Locking torques N m Driven pulley nut 92 100 Install the driving pulley shaft cover positioning the tooth gap on ...

Страница 135: ...on cover screws 7 to 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 Removing the wheel axle Remove the countershaft Remove the wheel axis complete with gear MP3 500 ie SPORT Business LT 2011 Engine ENG 135 ...

Страница 136: ...l extractor to disassemble the bearing on the engine chassis of the countershaft Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y035 Bearing housing external ø 47 mm Support the hub cover using the stud bolt set Pull out the bearing using the special tool Specific tooling 020476Y Stud bolt set 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearings R...

Страница 137: ...t the relevant bearing and the oil guard remove the transmission cover and the clutch unit as descri bed in the Automatic transmission chapter Extract the driven pulley shaft from its bearing Remove the oil guard using a screwdriver into the hub gear box Remove the Seeger ring shown in the figure Pull out the driven pulley shaft bearing from the engine crankcase using the special tool Specific too...

Страница 138: ...ection diameter for countershaft A diameter 20 0 01 0 02 mm Connection diameter for wheel shaft B diameter 30 0 010 0 023 mm C diameter 15 0 01 0 02 mm Bearing diameter for driven pulley shaft D diameter 17 0 01 0 02 mm E diameter 20 0 01 0 02 mm F diameter 25 0 01 0 02 mm Inspecting the hub cover Check that the mounting surface is not damaged or deformed Engine MP3 500 ie SPORT Business LT 2011 E...

Страница 139: ...ol N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm Adaptor 020364Y 25 mm guide Heat the intermediate gear bearing seat Insert the intermediate shaft bearing using the special tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor ha...

Страница 140: ...20359Y 42 x 47mm Adaptor 020412Y 15 mm guide Place the safety lock Seeger ring of the driven pulley shaft bearing N B PLACE IT IN THE POSITION SHOWN IN THE FIGURE Insert the pulley shaft oil guard on the transmis sion side Refitting the hub cover bearings Heat the bearing seats on the cover using the heat gun Support the hub cover using the stud bolt set Specific tooling 020151Y Air heater 020476Y...

Страница 141: ... Insert the gear shaft bearing on the cover using the special punch until abutment Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm Adaptor 020483Y 30 mm guide Replace the snap ring Support the hub cover using the stud bolt set Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover Place the oil guard flush with the crankcase Specific tooling 020376Y Adaptor...

Страница 142: ...set screws tighten them to the prescribed torque being careful of the position of the bands holding the vent tube and the position of the 3 shortest screws as indicated in the figure Refill with the prescribed oil to the Max level Recommended products AGIP GEAR SAE 80W 90 Lubricant for gearboxes and transmissions API GL 4 Characteristic Quantity approx 250 cc Locking torques N m Rear hub cover scr...

Страница 143: ...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 the engine oil by removing the drainage cap Prepare a suitable container to collect the oil Remove the pre filter Remove the oil filter using a filter tape or shaped cup wrench MP3 500 ie SPORT Business LT 2011 Engine ENG 143 ...

Страница 144: ...S CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR CAUTION BE CAREFUL TO PREVENT SLIPPAGE OF THE BY PASS VALVE AND OF THE RELEVANT SPRING Removing the flywheel cover components Loosen the six mounting screws and remove the water pump cover Remove the by pass and the relevant spring Remove the oil pump seal Engine MP3 500 ie SPORT Business LT 2011 ENG 144 ...

Страница 145: ...crew the 3 fastening screws and remove sta tor and its wiring Inspecting the cover components Loosen the two retaining screws and remove the reed valve support with bulkhead Remove the blow by reed valve with the relevant sealing gasket MP3 500 ie SPORT Business LT 2011 Engine ENG 145 ...

Страница 146: ...orque limiter and the water pump shaft are free from wear Characteristic By pass housing hole diameter 13 9 mm Connection diameter for start up gear shaft 12 mm Connection diameter for pump shaft 8 mm Check that the oil filter union and matching sur face exhibit no deformations or wear Check the condition of the stator and the relevant cable harness Engine MP3 500 ie SPORT Business LT 2011 ENG 146...

Страница 147: ...cable harness that contains two types of cable Rigid cables close to the stator and flexible cables close to the connector Check that the winding is positioned so as not to interfere with the heads of the retaining screws Refitting the stator Install the stator assembly together with the wir ing harness tightening the 3 screws to the pre scribed torque N B INSERT THE RUBBER WIRING SEALING GASKET I...

Страница 148: ... bracket screws 3 4 Refitting the flywheel cover components Before reassembling check that all components are perfectly clean For the cover carefully check all lubrication chan nels in particular The 3 by pass channels Oil pressure sensor feeding duct Oil vapour decantation chamber Engine MP3 500 ie SPORT Business LT 2011 ENG 148 ...

Страница 149: ...VALVE Reinstall the blow by reed valve using a new sealing gasket Reinstall the support with head and tighten the screws to the prescribed torque Locking torques N m Supporting screws with bulkhead 0 3 0 4 Correctly fit a new O ring do not allow it to come into contact with grease or oil FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O RING Refit the water pump cover and tighten ...

Страница 150: ...S SUF FICIENTLY Install the pre filter again and insert the engine oil drain plug tightening to the prescribed torque Refill the engine with the prescribed type of oil Recommended products eni i Ride PG 5W 40 Synthetic based lubricant for high performance four stroke engines JASO MA MA2 API SL ACEA A3 Locking torques N m Engine oil drainage plug 24 to 30 Lubricate the intermediate gear seat with t...

Страница 151: ... USEFUL PARTICULARLY IN THE EVENT OF REPAIRS WITH THE WATER PUMP COVER IN STALLED Install the flywheel cover on the engine paying attention to avoid interference between the stator and rotor WARNING FAILURE TO OBSERVE THIS PRECAUTION MAY RESULT IN DESTRUCTION OF THE CERAMIC MAGNETS Tighten the 14 retaining bolts of the cover to the prescribed torque N B THE BOLTS HAVE FOUR LENGTHS THE 3 SHORTEST A...

Страница 152: ... it carry out the follow ing tests 1 Battery Check the voltage after not running a few hours Voltage 12 5V Check the density of the electrolyte of each cell Bé 30 32 Specific weight 1 25 1 26 YES go to 2 NO go to 3 2 Make sure the negative terminals battery neg ative and starter negative are correctly connected to each other and to the frame YES go to 4 NO go to 5 3 Recharge and if necessary repla...

Страница 153: ...heck of the power consumption at idle speed Remove the starter motor see the flywheel and starter system Reconnect the earth and positive and perform the test Electric characteristic Current consumption at idle speed 40 A YES go to 10 NO go to 11 7 Low trailing speed High electrical absorption Carry out a test of the engine rotation example possible melting of the bushes and if no anomalies are fo...

Страница 154: ...h built in torque limiter The starter system has a transmission between the motor armature and engine shaft equipped with freewheel coaxial to the flywheel and torque limiter on the intermediate shaft The limiter is calibrated to 10 kgm 100 Nm this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations...

Страница 155: ...CESSARY TO REMOVE THE CHAIN GUIDE SLIDING BLOCK RETAIN PLATE FIRST Unscrew the 3 fastening screws and remove the chain guide sliding block retain plate and the start up rim Align the holes obtained on the flywheel with the crankcase housing to allow the introduction of the special tool Tighten the bushing of the flywheel lock tool on the removing tool threading MP3 500 ie SPORT Business LT 2011 En...

Страница 156: ...wrench Loosen the magneto flywheel fastening nut Remove the special tool and the fastening nut Remove the washer Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer CAUTION THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS STRONGLY LOCKED THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS Engine...

Страница 157: ...start up rim Remove the crankshaft key To remove the start up rim from the freewheel it is necessary to turn it clockwise and pull it out Remove the freewheel from the flywheel by loos ening the 6 fastening screws SINCE THE FREEWHEEL MUST BE REMOVED IT IS AD VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT MP3 500 ie SPORT Business LT 2011 Eng...

Страница 158: ...ck the integrity of the magnets Check that the magnet support cage is free from deformation or cracks Check that the flywheel splines exhibit no loos ening Starter gear rim Check that there is no wear or abnormal impres sions on the rollers of the freewheel and on the surface of the starter ring gear hub Check the hub outside diameter Characteristic Hub outside diameter Diameter 45 665 0 008 0 005...

Страница 159: ...THE SURFACE OF THE CONNECTION ON THE CRANKSHAFT IN CASE OR IRREGULARITIES REPLACE THE CRANK SHAFT Intermediate gear Check that the toothing is not worn Check the diameter of the two bearings Characteristic Gear bearing diameter 12 0 0 011 mm Also check the shaft diameter on the flywheel cov er and on the engine crankcase Characteristic Bearing diameter on the flywheel cover 12 0 034 0 016 mm Beari...

Страница 160: ...rfaces are in good condition Thoroughly clean the free wheel to remove LOCTITE residue Degrease the threading of the holes in the free wheel and the clamping screws Apply the recommended product to the end of the screws Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Fit the freewheel on the magneto flywheel making sure that the ground side is in contact w...

Страница 161: ...ne crank case Insert the intermediate gear with torque limiter Lubricate the inside bushing and the starter ring gear hub surface Install the start up rim on the flywheel turning it clockwise and inserting at the same time MP3 500 ie SPORT Business LT 2011 Engine ENG 161 ...

Страница 162: ...r and nut on the crankshaft Tighten thoroughly the guide bushing of the fly wheel lock tool and loosen by 1 4 turn N B FAILURE TO OBSERVE THIS PRECAUTION CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL Specific tooling 020472Y Flywheel lock wrench Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool Engine MP3 500 ie SPORT Business LT 2011 ENG 162 ...

Страница 163: ...escribed torque N B BEFORE TIGHTENING THE SCREWS MOVE THE START UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC TION Locking torques N m 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 fastening screws to the...

Страница 164: ...flywheel and the torque limiter Removing the intake manifold Remove the 3 mounting screws Remove the 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 Engine MP3 500 ie SPORT Business LT 2011 ENG 164 ...

Страница 165: ...l Specific tooling 020565Y Flywheel lock calliper spanner Remove the return spring and the 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 COM PARTMENT Align the reference marks on the timing chain rim with those on the head MP3 500 ie SPORT Business LT 2011 Engine ENG 165 ...

Страница 166: ...ht as shown in the figure Remove the timing belt rim from the camshaft 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 DIFFI CULT BE CAREFUL NOT TO DAMAGE THE INSIDE HEX AGON IF NECESSARY SEPARATE THE THREADS IN ADVANCE Engine MP3 500 ie SPORT Business LT 2011 ENG 166 ...

Страница 167: ...der head Remove the spark plugs Remove the cooling system outlet 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 MP3 500 ie SPORT Business LT 2011 Engine ENG 167 ...

Страница 168: ... ROCKING LEVER PINS AND FITTING BRACKET IF NECESSARY Loosen the 4 head cylinder fastening nuts in 2 or 3 times and in a crossed sequence Remove the head the 2 centring dowels the gasket and the lower 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 GROUP CONTAINS COOLANT...

Страница 169: ...012 bush valve removing tool CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD FLY WHEEL SIDE AND TRANSMISSION SIDE Remove the oil guards using the special tool Specific tooling 020431Y Valve oil seal extractor Remove the spring supports N B BLOW THE SEATS WITH COMPRESSED AIR TO FACILI TATE THE SPRING SUPPORT REMOVAL MP3 500 ie SPORT Business LT 2011 Engine ENG 169 ...

Страница 170: ...AUTION TO PREVENT DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER Remove the 2 piston pin locking rings by the spe cific housings Extract the pin and remove the piston N B USE PAPER OR A CLOTH TO CLOSE THE CYLINDER HOUSING MOUTH ON THE CRANKCASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE Remove the piston sealing rings and the oil scra per CAUTION NOTE THE ASSEMBL...

Страница 171: ...tandard diameter 22 0 025 0 015 mm Inspecting the wrist pin Check the pin outside diameter using a micrometer Characteristic Standard diameter 22 0 0 004 mm Calculate the coupling clearance between pin and connecting rod small end Characteristic Standard clearance 0 015 0 029 mm Inspecting the piston Measure the diameter of the bearings on the pis ton Characteristic Standard diameter 22 0 006 0 00...

Страница 172: ...NS SECTION FOR THE SIZES OF THE PISTON AND THE CYLINDER PISTON COU PLING CLEARANCES Characteristic A 10 mm Piston diameter 94 mm nominal value Using a bore meter measure the cylinder inner diameter at a given height according to the direc tions shown in the figure Characteristic B 43 mm Standard diameter 94 mm nominal value Check that coating is free from flakes Check that the head coupling surfac...

Страница 173: ...ng see figure of the sealing rings using a feeler gauge If higher values than those prescribed are meas ured replace the linings Check the size of the sealing ring opening Compression ring 0 15 0 35 mm Max value 0 5 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Rings slots coupling clearances Carefully clean the sealing rings housings Place a fe...

Страница 174: ...e Removing the piston Install piston and wrist pin onto the connecting rod aligning the piston arrow the arrow facing to wards the exhaust Insert the locking ring into the special tool with the opening in the position indicated on the tool S left D right Place the wrist pin stop ring into position using a punch Engine MP3 500 ie SPORT Business LT 2011 ENG 174 ...

Страница 175: ... abutment plane reset the dial gauge with a preload of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Install the tool on the cylinder without changing the dial gauge position Lock the tool using the original head fixing nuts Rotate the crankshaft up to the TDC the inver sion point of the dial gauge rotation Measure the deviation from the reset value Ident...

Страница 176: ... the writing top facing the piston crown The chamfered side of the oil scraper ring should always be facing the piston crown Fit the second lining with the identification letter or the writing top facing the piston crown In any case the step must be facing opposite the piston crown Install the first compression lining in the direction imposed by the housing It is advisable to use a fitter to facil...

Страница 177: ... distorted Characteristic Maximum allowable run out 0 1 mm In case of faults replace the head Check the sealing surfaces for the intake and ex haust manifold Check that the camshaft and the rocking lever pin capacities exhibit no wear Check that the head cover shows no signs of wear Check that the coolant seal plug exhibits no oxi dation Inspecting the timing system components Check that the guide...

Страница 178: ...valve sealings Visually inspect the valve sealing surface CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES RIGHT LEFT If the sealing surface of the valve is found to be interrupted at one or more points or is not flat re place the valve Insert the valves into the cylinder head Alternatively check the intake and exhaust valves The test is carried out by filling the manifold with petrol an...

Страница 179: ...ue the seats with a 45 mill and then grind In case of excessive wear or damage replace the head Inspecting the valves Measure the diameter of the valve stems in the three positions indicated in the diagram STANDARD DIAMETER Specification Desc Quantity Intake 4 987 4 972 mm Exhaust 4 975 to 4 960 mm MINIMUM DIAMETER ADMITTED Specification Desc Quantity Intake 4 96 mm Exhaust 4 945 mm Calculate the ...

Страница 180: ...e valve head and rotating it on the V shaped support Characteristic Limit allowed 0 03 mm Inspecting the valve stem guide clearance After measuring the valve guide diameter and the valve stem diameter check clearance between guide and stem INTAKE Specification Desc Quantity Standard clearance 0 013 0 04 mm Limit allowed 0 08 mm EXHAUST Specification Desc Quantity Standard clearance 0 025 0 052 mm ...

Страница 181: ...rizontal position This will prevent the lapping compound residues from penetrating between the valve stem and the guide see figure CAUTION TO AVOID SCORING THE MATING SURFACE DO NOT ROTATE THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE ...

Страница 182: ...te tool with adapter compress the springs and insert the cotters in their seats Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush valve removing tool N B KHÔNG ĐƯỢC THAY ĐỔI VỊ TRÍ VAN ĐÃ LẮP TẠI CHỖ KHỚP MÚT VAN CÓ MÀU QUY CHIẾU BÊN CHỐT HÃM XOAY VỚI BƯỚC LỚN HƠN Inspecting the cam shaft Check that the camshaft bearings exhibit no scores or abnormal wear U...

Страница 183: ...SSIBLE LIMITS Specification Desc Quantity intake 33 526 mm discharge 33 026 mm Standard axial clearance 0 0 22 mm Maximum admissible axial clearance 0 3 mm If any of the above dimensions are outside the specified limits or there are signs of excessive wear replace the defective components with new ones Check that the retaining plate seat shown in the figure exhibits no wear MP3 500 ie SPORT Busine...

Страница 184: ...f each rocker Characteristic Standard diameter Ø 13 0 026 0 015 mm Check that the cam contact sliding block and the articulated register cap is free from wear In case of wear replace the component 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 INSERTION PO...

Страница 185: ...fixing stud bolts crosswise to the prescribed torque as shown in the 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 fastening nuts on the exhaust and on the intake side to the prescribed torque Locking torques N m Exhaust intake head fixing nuts 10 1...

Страница 186: ...ed torque Locking torques N m Spark plug 12 14 Insert the timing control belt on the crankshaft according to the initial direction of rotation Install 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 Medium Loctite 243 threadlock Locking torques N m Tensioner pad fixing screw 1...

Страница 187: ...um strength threadlock Medium Loctite 243 threadlock Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque being careful not to damage 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 u...

Страница 188: ...rt collimate with that on the flywheel cover Install the counterweight mass Centre using the bell fastening screw Lock the mass fixing screws to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Counterweight screw 7 to 8 5 Remove the central screw Install the valve lifting mass being ca...

Страница 189: ...to the prescribed torque using the recommended product N B THE BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Check that the decompression mass is free and that it is pulled by the spring Locking torques N m Valve lifter mass stop bell fixing screws 30 35 MP3 500 ie SPORT Business LT 20...

Страница 190: ...l screw to the prescribed tor que Locking torques N m Tightener screw 5 to 6 Place the engine with the valve clearance adjustment timing references aligned with the head Check the clearance between valve and rocking lever using a thickness gauge PRESCRIBED CLEARANCE Specification Desc Quantity Inlet 0 15 mm engine cold drainage 0 15 mm engine cold In case different values are found adjust by loos ...

Страница 191: ...mined by the injection system matches the value actually activated on the engine by means of the stroboscopic light Specific tooling 020922Y Diagnosis Tool 020330Y Stroboscopic light to check timing Proceed as follows Remove the outside transmission cover as de scribed in the automatic transmission chapter Remove the TDC reference inspection cap be tween flywheel and crankcase cover See the fly wh...

Страница 192: ...ontrol in the tradi tional 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 Specific tooling 020922Y Diagnosis Tool If the values do not match check distribution timing revolution timing sensor injection control unit Refitting the rocker arms cover Check that the gasket is in good working order Engin...

Страница 193: ...as described in the Automatic transmission chapter Install the cooling system sleeves using new bands as described in the Flywheel cover chap ter Refitting the intake manifold Install the intake manifold on the engine Insert the 3 fastening screws one of which with a support band for the cooling system sleeve and tighten to the prescribed torque Locking torques N m Intake manifold screws 11 to 13 ...

Страница 194: ...late e g the special tool and a support with special tool comparator Specific tooling 020262Y Crankcase splitting plate 020335Y Magnetic mounting for dial gauge Characteristic Standard clearance 0 10 0 50 mm Admissible increase limit after use 0 60 mm Upper clearances are an indication of wear on the surfaces of the crankshaft casing support To carry out an accurate measurement measure the clearan...

Страница 195: ...haft check the timing with the countershaft To carry out this check turn the crankshaft to align the two holes obtained on the crankshaft with the hole on the countershaft control gear This is an optimal position also to remove the crankshaft Remove the crankshaft with the shim adjustment washer on the flywheel side CAUTION WHILE OPENING THE CRANKCASE AND REMOVING THE CRANKSHAFT CHECK THAT THE SHA...

Страница 196: ...Y LOCTITE BE CAREFUL NOT TO DAMAGE THE CONTROL HEXAGON TO OBTAIN BET TER RESULTS IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH Removing the countershaft Place the special tool as shown in the figure Specific tooling 020479Y Countershaft lock wrench Remove the fastening nut with relevant washer Remove the special tool and extract the counter shaft with the control gear Engine MP3 500 ie S...

Страница 197: ...allet Specific tooling 020376Y Adaptor handle 020358Y 37 x 40mm Adaptor 020439Y 17 mm guide Remove the bearing from the transmission side half crankcase using the special tool Specific tooling 001467Y008 Pliers to extract 17 mm ø bearings 001467Y007 Driver for OD 54 mm bearings Before installing a new bearing heat the flywheel side half crankcase using the special tool Place the half crankcase on ...

Страница 198: ...uide Fit the Seeger ring Before installing the new bearing on the trans mission side crankcase heat the seat using the special tool Specific tooling 020151Y Air heater 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 BALLS VISIBLE FROM THE CRANKCASE INTER...

Страница 199: ...haft between these surfaces as shown in the diagram N B BE CAREFUL NOT TO LET THE MEASUREMENT BE AF FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS Characteristic Standard dimensions 63 6 63 45 mm CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VAL UES AND THE SURFACES ARE FREE FROM SCRATCHES Shimming Check the overall height of the crankshaft shoulders gear assembly Ch...

Страница 200: ...into two categories Cat 1 and Cat 2 Refer to the chart below 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 measure the displacement at the 4 points shown in the figure Specific tooling 020074Y Support base for checking crankshaft alignment MAX ADMISSIBLE DISPLACEMENT Specification ...

Страница 201: ...see sec tion Thermal group and timing system See also Cylinder assy and timing system Inspecting the crankcase halves Before proceeding to check the crankcase halves thoroughly clean all surfaces and oil ducts For the transmission side half crankcase special attention should be given to the bushings to the cooling jet on the transmission side see figure and to the lubrication duct N B THE JET IS F...

Страница 202: ...ting rod and main bearing lubrication pressure Check the main bearing seats that limit axial clearance in the crankshaft exhibit no wear For the dimensional check refer to the instructions about checking the axial clearance and the dimensions on the crankshaft Inspecting the crankshaft plain bearings To obtain a good bushing lubrication it is neces sary to have both an optimal lubricating pressure...

Страница 203: ... clearance admitted 0 08 mm The standard bushing diameter after driving is variable on the basis of a coupling selection The crankcase bushing seats are classified into 3 categories while the crankshaft ones into 2 cate gories Bushings are subdivided into 4 categories according to their thickness see the table CHECK THE BENCH BUSH Name Description Dimensions Initials Quantity Type A Red 1 971 1 97...

Страница 204: ...th 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 crankcase equipped with bushings for housing a category 2 crankshaft and a countershaft with centre to centre distance B N B THE CRANKSHAFT CATEGORY IS STAMPED ON THE COUNTERWEIGHT SHOULDER A spare crankcase cann...

Страница 205: ...E 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 removing any residues of LOCTITE from the holes using a brush Blow with compressed air and degrease the mounting holes on both surfaces to make the new LOCTITE grip Apply the recommended product to the holes a...

Страница 206: ...oling 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 thoroughly and remove the special tool N B WHEN INSERTING THE SHAFT ON THE HALF CRANKCASE BE CAREFUL NOT TO DAMAGE THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIM ING CONTROL TOOTHED PINION ...

Страница 207: ...the gasket on the flywheel side half crank case Lubricate the main bearing on the transmission side half crankcase Couple the 2 half crankcases being careful not to damage the bushing on the transmis sion side half crankcase with the threaded tang of the crankshaft Insert the engine support retain screw on the fly wheel side half crankcase without tightening Insert the 14 fastening screws by arran...

Страница 208: ...ribed in the Automatic transmission chapter See also Cylinder assy and timing system Flywheel cover Lubrication TECHNICAL SPECIFICATIONS SUMP CAPACITY Specification Desc Quantity Overhaul 1 7 l Oil and filter replacement 1 5 l RECOMMENDED ENGINE OIL Product Description Specifications eni i Ride PG 5W 40 Synthetic based lubricant for high per formance four stroke engines JASO MA MA2 API SL ACEA A3 ...

Страница 209: ...antity Diameter 1 0 05 mm Tightening torque 5 7 N m PISTON COOLING NOZZLE Specification Desc Quantity Diameter 0 8 0 05 mm CRANKCASE VENTILATION CHECK Specification Desc Quantity Device metal reed valve and decantation chamber Conceptual diagrams PRINCIPLE DIAGRAM Specification Desc Quantity A Camshaft B Cylinder head plane C Cylinder crankcase plane D Water pump impeller E Minimum oil pressure se...

Страница 210: ...e drop above 1 0 2 bar These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged The filtered oil is used to lubricate the water pump shaft and once at the engine crankcase to lubricate the main bearings the connecting rod head and the piston cooling nozzle on the transmission side bearing The main bearing on the transmission side is fitted with an oil...

Страница 211: ...to the piston or the pin but in this case the cooling nozzle is particularly important Diagnosis guide 1 Minimum oil pressure warning light on with hot engine AHEAD go to 2 2 Remove the minimum pressure switch electric connector Check that the warning light turns off YES go to 3 NO go to 11 3 Check the actual oil pressure AHEAD go to 4 4 Remove the switch and fit the special tool with the relevant...

Страница 212: ...f kilometres covered 11 Check and restore the electrical system 12 If pressure lower than 4 bar is measured AHEAD go to 9 13 Remove the flywheel cover and check the by pass and the cover sealing gasket efficiency towards the case internal side as described in the Flywheel cover chapter YES go to 14 NO go to 15 14 Check whether there is an irregular clearance on the crankshaft axial clearance see t...

Страница 213: ...tooling 020193Y Oil pressure check gauge 020434Y Oil pressure check fitting AHEAD go to 3 3 Check the system pressure with cold engine and medium high speed Standard pressure 6 bar YES go to 4 NO go to 5 4 Replace the damaged components 5 Check the working order of the adjustment by pass see flywheel cover chapter and restore proper sliding N B STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PR...

Страница 214: ...he 2 retaining screws with their washers Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper Remove the gasket Remove the two screws and the oil pump cover Engine MP3 500 ie SPORT Business LT 2011 ENG 214 ...

Страница 215: ... wear Reassemble the rotors in the pump body keep ing the two reference marks visible Insert the 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 distance be tween the rotors in the position shown in the figure Characteristic Admissible limit clearance 0 ...

Страница 216: ...rect position N B THE TOOTH OF THE GASKET MUST BE IN ITS SEAT Lubricate the internal rotors Check there are no signs of scoring or wear 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 fastening screws to the prescri bed torque Locking torques N m Oil ...

Страница 217: ...nto the fly wheel side half crankcase Install 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 prescribed torque using the recommended product Remove the special tool Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlo...

Страница 218: ... crankcase 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 SEAT EDGE DO NOT POSE FUNCTIONAL PROBLEMS Change the position of the screwdrivers if nec essary During seal disassembly the ceramic may split Engine MP3 500 ie SPORT Business LT 2011 ENG 218 ...

Страница 219: ...rt of the 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 using the screws supplied with the tool CAUTION FIX IT PROPERLY WITHOUT TEARING THE PLATE Complete the tool by fitting the bracket the screw and the nut MP3 500 ie SPORT Business LT 2011 Engine ...

Страница 220: ...ely re moved 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 water pump rotor with an 8 mm wrench Engine MP3 500 ie SPORT Business LT 2011 ENG 220 ...

Страница 221: ...ONAL PROBLEMS 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 on the fixed part of the ceramic seal Without modifying the extractor position make three holes on the fixed part of the seal using the pin supplied and a hammer N B MAKE THE HOLES WITH A STRO...

Страница 222: ...OPERLY WITHOUT 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 the extractor with the fixed part of the overall seal Engine MP3 500 ie SPORT Business LT 2011 ENG 222 ...

Страница 223: ...verall seal 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 seat on the crank case and the movable part seat on the shaft thus obtaining the correct ceramic seal preloading Screw the rotor Locking torques N m Water pump rotor 4 to 5 MP3 500 ie SPORT Busin...

Страница 224: ... THOROUGHLY 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 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 seat on the crank case and the m...

Страница 225: ...gasket lubricate 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 N m Water pump cover screws 3 4 MP3 500 ie SPORT Business LT 2011 Engine ENG 225 ...

Страница 226: ...INDEX OF TOPICS INJECTION INJEC ...

Страница 227: ... 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 wheel keyed on to the crankshaft 24 2 teeth and pick up sensor Combustion and ignition are managed on the basis of engine revs and throttle valve opening Further corrections are made according to the followin...

Страница 228: ...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 this ensures safety of the vehicle The ignition circuit consists of HV coil HV cable Shielded cap MIU control unit Spark plug The MIU control unit manages ignition with the best advance ensuring four stroke timing ignition only in the compressio...

Страница 229: ...s 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 switch to allow further safety of the vehicle Precautions 1 Before fixing any part of the injection system check to see if there are any registered faults Do not disconnect the battery before checking for faults ...

Страница 230: ...tem connectors only if re quired 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 measurements not specifically foreseen by the manual 13 At the end of every check performed with the diagnostic tester remember to protect the system connector with its cap Failure to observe this precaution ...

Страница 231: ...m 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 Use a multimeter with an internal resistance of more than 10K Ohm V when troubleshooting Instru ments that are not suitable might damage the MIU central control unit The instruments to be preferred have a definition over 0 1V and 0 5 W and ...

Страница 232: ...Ground lead Connected to the engine stop switch and the water tem perature sensor 19 20 Injection load relay 21 22 HV coil 23 24 Start up enabling 25 26 Ground lead EMS circuit diagram KEY 1 BATTERY 5 FUSE 02 20 A 8 FUSE 05 15 A 9 FUSE 06 7 5 A 10 IGNITION KEY CONTACTS 14 FUSE 10 7 5 A 32 IMMOBILIZER AERIAL 35 INSTRUMENT PANEL Injection MP3 500 ie SPORT Business LT 2011 INJEC 232 ...

Страница 233: ... D I 61 ENGINE SPEED SENSOR 62 LAMBDA PROBE 64 FUEL PUMP 65 ENGINE TEMPERATURE SENSOR 67 ENGINE STOP THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION KEY 1 Instrument panel 8 Pre installation for anti theft device 12 Auxiliary fuses 22 Radiator electric fan MP3 500 ie SPORT Business LT 2011 Injection INJEC 233 ...

Страница 234: ...epair according to the indications of the self diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Fuel system Fuel in the tank Fuel pump activation Fuel pressure low Injector capacity low Power to spark plug Shielded spark plug cap HV coil secondary insulation Parameter reliability Coolant temperature Distribution timing injection ignit...

Страница 235: ...r Air temperature Coolant temperature Ignition efficiency Spark plug Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve F...

Страница 236: ...ifold Intake sleeve Filter box Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system sealing infiltrations Manifold head Manifold silencer silencer welding Engine revs irregularly ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper In...

Страница 237: ...lf diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake system sealing Intake sleeve Filter box TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel f...

Страница 238: ...Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure Remove the fast release fitting from the injector support Injection MP3 500 ie SPORT Business LT 2011 INJEC 238 ...

Страница 239: ...ctor 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 ECU connector MP3 500 ie SPORT Business LT 2011 Injection INJEC 239 ...

Страница 240: ...Remove the gas command fitting as indicated in the picture Pump supply circuit Injection MP3 500 ie SPORT Business LT 2011 INJEC 240 ...

Страница 241: ... the pump is continuously supplied ELECTRICAL DATA Pump winding resistance 1 8 Ohm Input current during regular functioning 2 8 A Check the efficiency of injection load 15 A fuse No 5 Check that the live control unit power supply 7 5A fuse No 10 works properly Check the efficiency of the injection load relay Check the resistance of the energising coil be tween pins 86 and 85 40 to 80 Ohm Apply a v...

Страница 242: ...ack Pur ple cable of the relay base If there is not check the continuity of the Red White cable between the fuse box and the relay base and of the Black Pur ple cable between the pin 20 of the control unit and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Injection MP3 500 ie SPORT Business LT 2011 INJEC 242 ...

Страница 243: ...se and earth If there is none check the continuity of the grey black cable between the fuse box No 5 15 A and the solenoid base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC MP3 500 ie SPORT Business LT 2011 Injection INJEC 243 ...

Страница 244: ...eak test Install the specific tool for checking the fuel pressure with the pipe fitted with the gauge Check during regular operation by placing the ap propriate tool between the pump and the injector With battery voltage 12 V check that the fuel pressure is 3 BAR and that the input current is 2 8 A With the battery voltage 12 V check the pump flow rate by disconnecting from the injector the pipe e...

Страница 245: ...he terminals from the electric pump Remove the screw shown in the picture Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture MP3 500 ie SPORT Business LT 2011 Injection INJEC 245 ...

Страница 246: ...Remove the filter from the pump mounting Inspecting the injector circuit Injection MP3 500 ie SPORT Business LT 2011 INJEC 246 ...

Страница 247: ...k the efficiency of injection load 15 A fuse No 5 Check that the live control unit power supply 7 5A fuse No 10 works properly Check the efficiency of the injection load relay 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 is continuity between pins 30 and 87 of the relay MP3 500 ie SPORT Business LT 20...

Страница 248: ...ack Purple ca ble of the relay base If there is not check the continuity of the Red White cable between the fuse box and the relay base and of the Black Pur ple cable between the pin 20 of the control unit and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Injection MP3 500 ie SPORT Business LT 2011 INJEC 248 ...

Страница 249: ...se and earth If there is none check the continuity of the grey black cable between the fuse box No 5 15 A and the solenoid base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC MP3 500 ie SPORT Business LT 2011 Injection INJEC 249 ...

Страница 250: ...Black Green cable of the injector con nector and the ground lead With injector disconnected and the injector load relay disconnected check the continuity of the Black Green cable between the injector connector and relay base Inspecting the injector hydraulics To check the injector remove the inlet manifold by removing the three fixing screws at the head and the three screws connecting the control ...

Страница 251: ...t 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 circuit The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys tem The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by...

Страница 252: ... 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 switch and or the instrument panel is not initiated check if there is battery voltage fuses 2 6 10 are in working order there is power to the control unit as specified below Remove the connector mounting bracket shown in th...

Страница 253: ... working order There is continuity between terminals 12 18 with the emergency stop switch in the RUN position If there is no con tinuity check the contacts of the switch If no faults are found replace the electronic control unit After removing the leg shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base from the connector MP3 500 ie ...

Страница 254: ...ro 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 only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys The master and service keys must be used to code the system as follows Insert the Master key ...

Страница 255: ...rk plugs Characteristic MASTER key RED KEY SERVICE key BLACK KEY Diagnostic codes The Immobilizer system is tested each time the ig nition key is turned from OFF to ON During this diagnosis phase a number of control unit sta tuses can be identified and various light codes displayed Regardless of the code transmitted if at the end of the diagnosis the LED remains off permanently the ignition is ena...

Страница 256: ...e 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 steadily The engine cannot be started The codes that can be trans mitted are 1 flash code 2 flash code 3 flash code The LED indication is divided into 3 steps 1st step A flash ON switching recognition 2nd step Series of flashes diagnosis code indication...

Страница 257: ...iring 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 A three flash code indicates a system where the control unit does not recognise the key Turn the switch to ON using several keys if the error code is repeated even with the Master key replace the control unit If this is not th...

Страница 258: ...e and check that the voltage 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 engine speed sensor connector and between pin 15 and the brown ca ble of the engine speed sensor connector With the interface cable harness disconnected from the control unit and the rpm sensor connector dis...

Страница 259: ...Desc Quantity 1 Battery 2 Fuse 15A 3 Fuse 20A 4 Ignition switch contacts 5 Fuse 7 5 A 6 Injection load relay 7 Fuel pump 8 H V coil 9 Fuel injector 10 Lambda probe 11 Electric fan relay MP3 500 ie SPORT Business LT 2011 Injection INJEC 259 ...

Страница 260: ...ngine at idle the ignition advance is optimised to stabilise the speed at 1500 100 rpm Magnetisation time The coil magnetisation time is controlled by the control unit The ignition power is increased during the engine start up 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 efficie...

Страница 261: ...rgising coil after switching to ON make sure there is battery voltage for two seconds be tween the Red White cable and Black Purple ca ble of the relay base If there is not check the continuity of the Red White cable between the fuse box and the relay base and of the Black Pur ple cable between the pin 20 of the control unit and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMP...

Страница 262: ...se and earth If there is none check the continuity of the grey black cable between the fuse box No 5 15 A and the solenoid base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Injection MP3 500 ie SPORT Business LT 2011 INJEC 262 ...

Страница 263: ...tween pin 22 of the interface wiring and the green black cable of the injection load solenoid base with the control unit disconnected and the solenoid discon nected Primary resistance 1 Ohm Inspecting the spark plug shielded cap Measure the shielded cap resistance Electric characteristic Resistance 5 KΩ MP3 500 ie SPORT Business LT 2011 Injection INJEC 263 ...

Страница 264: ... engine rpm The ignition advance value is detectable at any time using the diagnostic tester It is possible to check whether the ignition advance determined by the injection system matches the value actually activated on the engine by means of the stroboscopic light Specific tooling 020922Y Diagnosis Tool 020330Y Stroboscopic light to check timing Proceed as follows Remove the transmission compart...

Страница 265: ...stic tester Start the engine Select the parameters function in this menu Select the stroboscopic light control in the tradi tional four stroke engine position 1 spark 2 revs 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 timing revolution timing sensor injection control unit MP3 500 ie SPORT Bus...

Страница 266: ...hm at 80 C With the control unit side connector 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 Ω 80 308 6 Ω With the control unit side connector disconnected and the coolant temperature connector discon nected check the insulation between the light blue green cable and g...

Страница 267: ...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 calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor can also assume various fitting positions For...

Страница 268: ...ester on TPS RESET Specific tooling 020922Y Diagnosis Tool Make sure that the throttle valve with the control is supporting the stop screw Guaranteeing that this position will be kept send a confirmation for the TPS reset procedure Injection MP3 500 ie SPORT Business LT 2011 INJEC 268 ...

Страница 269: ...n control unit is replaced N B THE TPS RESET 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 DIFFERENTLY FROM THAT OF PRE CALIBRATION MP3 500 ie SPORT Business LT 2011 Injection INJEC 269 ...

Страница 270: ...on Desc Quantity 1 Battery 2 Fuse 15A 3 Fuse 20A 4 Ignition switch contacts 5 Fuse 7 5 A 6 Injection load relay 7 Fuel pump 8 H V coil 9 Fuel injector 10 Lambda probe 11 Electric fan relay Injection MP3 500 ie SPORT Business LT 2011 INJEC 270 ...

Страница 271: ...nds The signal generated passes from a high value to a low value with a mixture with lambda 1 Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Install the electronic control unit interface wiring Start the engine and warm up until the electric fan switches on Use an analogue multimeter with a direct voltage scale measuring down to 2 V Place the tips of the multimet...

Страница 272: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Страница 273: ...em is disengaged Lift the front wheels as shown in the photograph Check that the wheel rims rotate even ly and whether there is abnormal clear ance in bearings and suspensions Make sure that the steering control shows no signs of abnormal clearance in joints and bearings Otherwise cor rect this and then adjust them Characteristic Front tyre pressure with passenger 1 6 bar 1 8 bar Rear tyre pressur...

Страница 274: ... ground Remove 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 Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 274 ...

Страница 275: ...l washer in 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 Place the frame so that the sliders come into contact with the rim maxi mum diameter but without interfering with the tyre If required reposition the frame by operating the 3 adjustable suppo...

Страница 276: ...eck that the 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 Parallelogram and steering position ing tool 020647Y Toe in checking tool 020647Y028 MP3 LT Toe in tool tricycle Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 276 ...

Страница 277: ...he 5 fixing screws indicated in the pic ture Locking torques N m Wheel fixing screw 20 to 25 Front wheel hub overhaul Remove the ball bearing check Seeger ring indi cated in the picture MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 277 ...

Страница 278: ... the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide Heat the roller bearing seat with a heat gun Use the specific tool to introduce and push the bearing until it stops with the shielded side facing out Refit the ball bearing check Seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42 x 47mm Adaptor 020412Y 15 mm guide S...

Страница 279: ...e brake levers Unscrew the fittings then remove the front and rear brake pump piping Remove the flexible transmission 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 IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING IT IS ONLY NECESSARY TO TI...

Страница 280: ...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 inside the side steering tubes the oil reaches the stem sliding locking device placed parallel to the shock absorb er Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 280 ...

Страница 281: ...fluid Disconnect the tone wheel connector indicated in the picture Remove the hydraulic pipe fitting from the sliding locking 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 picture MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 281 ...

Страница 282: ...e from the support bracket Remove the suspension roll lock device pipes from the headstock Remove first the flexible part of the calliper from the steering tube as shown in the picture and then remove the rigid part Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 282 ...

Страница 283: ... retainers indicated in the figure Remove the constant velocity universal joint from the steering bar by undoing the 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 MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 283 ...

Страница 284: ... hydraulic pipe support bracket Remove the steering tube lower ring nut and the protection cap indicated in the picture Now the steering tube can be removed Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 284 ...

Страница 285: ...N ALSO BE CARRIED OUT EVEN WHEN THE SUSPENSION IS FITTED Remove 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 signs of abnormal wear MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 285 ...

Страница 286: ...ck lower ring nut 12 15 Screw fixing sliding stem to shock absorber 45 to 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 tubes To facilitate removal operations of the brake disc sector loosen the 3 fixing screws in the hydraulic electro actuator indicated in the picture Suspensions MP3 500 ie SPORT...

Страница 287: ...ers from the par allelogram Remove the 4 screws fixing the tilt brake disc sec tor indicated in the picture Remove the retainers indicated in picture of the half arms joint flange MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 287 ...

Страница 288: ...retainers from the par allelogram by loosening the retainers indicated 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 alternately to the left and right side of the parallelogram Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 288 ...

Страница 289: ...the headstocks 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 MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 289 ...

Страница 290: ...ball bearings on the parallelogram arms Replace them in case of signs of abnormal wear Check the inside tracks of the parallelogram bear ings on the chassis Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 290 ...

Страница 291: ...g arms to side headstocks 45 to 50 Screws fixing arms to central headstock 45 to 50 Screws fixing the half arm coupling flange 20 to 25 Screws fixing roll lock disc section 20 to 25 Geared motor and Suspension locking system Select the SYSTEM RESET option from the main menu Turn the ignition switch to ON Select the LOWER STOP SEARCH option from the SYSTEM RESET menu WAIT PROCEDURE IN PROGRESS MP3 ...

Страница 292: ...POSSIBLE LIMIT STOP VALUES TO EXIT PRESS A KEY AND TURN OFF AND ON SE LECT PARAMETERS TO ADJUST AT 12 Check the gear motor if the palmtop does not in dicate this Select the PARAMETERS option from the main menu Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 292 ...

Страница 293: ...e be tween 0 00 and 0 50 is considered normal Remove the protection cap of the gear motor set screw Use a plain slot screwdriver to turn the set screw anticlockwise until replicating the 12 condition on the palmtop RELATIVE POTENTIOMETER ANGLE 12 a slight value oscillation is considered normal Refit the protection cap MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 293 ...

Страница 294: ...OTENTIOMETER RESET option from the SYSTEM RESET menu and press OK WAIT PROCEDURE IN PROGRESS The palmtop displays the words CHECK THAT THE CONTROL IS SET AT 12 FROM THE LOW ER STOP PRESS OK TO CONTINUE Press OK The palmtop displays the words POSSIBLE LIMIT STOP VALUES PRESS A KEY AND SHIFT OFF AND ON If this is not successful the roll lock mechanism remains locked for safety Suspensions MP3 500 ie...

Страница 295: ...mission adjust ment CAUTION A FIRST PRODUCTION BATCH WILL BE EQUIPPED WITH DOUBLE COAXIAL SPRING It is very important to remove the flexible trans mission from its fitting only for replacement When refitting tighten the two bracket screws and the flexible transmission lever nut to the prescribed torque Locking torques N m Bracket tightening screws 8 to 12 MP3 500 ie SPORT Business LT 2011 Suspensi...

Страница 296: ...ng bracket After refitting check in detail that the switch is reg ularly activated by the stop on the lever Undo the two pad pin screws remove the pads with the spring 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 Suspensions MP3 500 ie SPORT Business LT 2011 SUSP ...

Страница 297: ... shaft end with a mallet and protect the thread by screwing in a nut Fit the pinion and align the reference on the pinion teeth with the reference indicated on the second slot of the toothed sector Grease the pinion and the toothed sector with spe cific grease Refit the toothed sector spacer Recommended products MONTBLANC MOLYBDENUM GREASE MON TBLANC MOLYBDENUM GREASE Grease with molybdenum disulp...

Страница 298: ... during removal The motor should be so positioned that it does not protrude from the reduction unit mould see figure Tighten the screws to the prescribed torque Locking torques N m Electric motor coupling screws 11 to 13 Place the moulded washer of the flexible trans mission control lever shaft and the tongue Refit the flexible transmission control lever as shown in the figure Refit the potentiome...

Страница 299: ... Gear motor hydraulic pump tightening screws 11 to 13 Remove 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 Adaptor handle 020441Y 26 x 28 mm adaptor 020362Y 12 mm guide Extract the electric motor bearing with the specific tool Specific tooling 020376Y Adaptor handle 020375Y 28 x 3...

Страница 300: ... 020362Y 12 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 motor Hit slightly with a mallet if necessa ry Specific tooling 020363Y 20 mm guide 020358Y 37 x 40mm Adaptor 020151Y Air heater 020376Y Adaptor handle Remove the spring toothed sector unit fr...

Страница 301: ...he bearing 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 Adaptor handle 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 motor Hit slightly with a mallet if necessa ry Specific tooling 02036...

Страница 302: ...ng clamps Empty the system and use a container to collect the brake fluid CAUTION ELIMINATE ANY REMAINING BRAKE FLUID SPILLS WARNING BRAKE FLUID IS HIGHLY POISONOUS DO NOT INGEST OR SWALLOW IF ACCIDENTALLY SWAL LOWED DRINK LARGE QUANTITIES OF MILK OR WATER AND SEEK MEDICAL ADVICE IMMEDIATELY BRAKE FLUID DESTROYS SKIN AND OCULAR TISSUE IF YOU ACCIDENTALLY SPILL BRAKE FLUID ON YOURSELF TAKE OFF YOUR...

Страница 303: ...LDREN 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 pump joint screw Undo the two gear motor pump locking screws MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 303 ...

Страница 304: ...the pump 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 locking have been carried out Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 304 ...

Страница 305: ...s sary lock the lever with a vice making sure not to spoil the surface In case of difficulties when removing the lever use the specific tool Remove the tongue and then the moulded wash er Specific tooling 020234y extractor Remove the three fixing screws of the electric mo tor It is important to mark the direction of the electric motor position in order to refit it correctly MP3 500 ie SPORT Busine...

Страница 306: ...on lever in order to separate the two crankcases Electrical devices test BASIC CIRCUIT DIAGRAM FOR ROLL LOCK ELECTRICAL SYSTEM KEY 1 Geared motor 2 Brake calliper sensor 3 Tilt unlocking locking control switch 4 Potentiometer 5 Rider presence sensor 6 Left speed sensor 7 Right speed sensor 8 Diagnostic tester series line 9 Engine control unit Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 306 ...

Страница 307: ... battery 12 To light switch 13 20A fuse No 3 14 Light relay 15 Pressure switch 16 Horn relay 17 Instrument panel 18 Roll lock system control unit MOTORIDUTTORE 1 GEAR MOTOR MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 307 ...

Страница 308: ...n 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 multimeter probes on pins 28 and 38 as indicated in the figure PULSANTE BLOCCO SBLOCCO ROLLIO Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 308 ...

Страница 309: ...l unit check 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 check that the above indicated electrical lines are insulated from the ground MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 309 ...

Страница 310: ...round 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 LOCK 3 REST 4 UNLOCK POTENZIOMETRO 1 POTENTIOMETER Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 310 ...

Страница 311: ...king condition is 4V and 1V in the locking rest condition With the interface wiring disconnected from the control unit check the continuity between pin 17 and the yellow cable of the potentiometer connec tor between pin 25 and the green blue cable between pin 11 and the orange blue cable Also check that these lines are insulated from each oth er and ground SENSORE PRESENZA PILOTA MP3 500 ie SPORT ...

Страница 312: ...t 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 presence connector Check the continuity between the interface wiring pin 36 and violet cable of the rider presence con nector SENSORE PINZA BLOCCO ROLLIO Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 312 ...

Страница 313: ...ti meter 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 of the connector black cable and a ground point on the chassis MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 313 ...

Страница 314: ... check that the flexible transmission control lever activates the limit stop switch properly SENSORE RUOTA FONICA 1 Right tone wheel 2 Left tone wheel Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 314 ...

Страница 315: ...at approximately 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 and the brown cables of the LEFT and RIGHT wheel turning sensors and between pin 24 and the red cable of the RIGHT wheel turning sensor MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 315 ...

Страница 316: ...pin 24 and 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 from each other and from ground With a feeler gauge check that the air gap be tween the screw head and the sensor is between 0 35 and 1 mm PRESSOSTATO Suspensions MP3 500 ie SPORT Business LT 2...

Страница 317: ...nterface 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 pin 27 and the solenoid base white cable MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 317 ...

Страница 318: ...ation as well as the continuity 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 wheel fixing screws Remove the exhaust silencer Undo the screw fixing the right shock absorber to the clamp Undo the two screws fixing the clamp to the en gine Suspensions M...

Страница 319: ...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 the wheel MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 319 ...

Страница 320: ...clamping screws 27 30 Rear wheel axle nut 104 126 Shock absorber crank case attachment bracket 20 to 25 Lower shock absorber clamping screw 33 41 Nm Rear brake calliper fixing screws 25 30 Nm Swing arm Removal Rest the scooter on its centre stand Remove the retainer fixing the swinging arm to the engine unscrew the nut and remove the bolt Suspensions MP3 500 ie SPORT Business LT 2011 SUSP 320 ...

Страница 321: ...move 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 MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 321 ...

Страница 322: ...the swinging arm on the engine side to the swinging arm on the frame side In order to check the clearance of the swinging arm on the 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 minimum 30 mm outside diameter and 4 mm thick at least Check there is no ...

Страница 323: ...ternal 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 rings facing outwards Specific tooling 020244Y 15 mm diameter punch Characteristic Length of the swinging arm tube on the engine side L 140 5 0 7 mm Chassis side swinging arm plastic bushing shim 3 5 0 05 mm L...

Страница 324: ...otograph Place the swinging arm frame side with 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 NATO G 460 symbol Check that the silent block is not broken Other wise replace it Unscrew the retainer to the frame in order to re move the silent block supporting clamp Suspensions MP...

Страница 325: ... 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 prescribed torque 6 Tighten part 1 to the prescribed torque Insert the swinging arm engine bolt and tighten to the prescribed torque MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 325 ...

Страница 326: ...o 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 fixed to the muffler on the other unscrew the two upper nuts one on each side fixing the shock absorber spring assembly to the frame and remove the shock absorbers Refitting Carry out the previous operations but in rev...

Страница 327: ...ly Remove the two stand return springs Working from both sides unscrew the two bolts connecting it to the supporting plate To refit follow the removal steps but in reverse order be careful to tighten to the prescribed torque Locking torques N m Centre stand bolt 31 39 MP3 500 ie SPORT Business LT 2011 Suspensions SUSP 327 ...

Страница 328: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Страница 329: ...This section è is dedicated to the description of the brake system components MP3 500 ie SPORT Business LT 2011 Braking system BRAK SYS 329 ...

Страница 330: ...es fitting wheel brake calliper 11 Front brake left calliper pipes fitting wheel brake calliper 12 Rear brake pipe on calliper 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 ø 15 87 mm 19 Rear brake calliper ø 22 mm 20 Rear valve ø 14 mm Brake system fitting...

Страница 331: ...MP3 500 ie SPORT Business LT 2011 Braking system BRAK SYS 331 ...

Страница 332: ...ENT VALVE 2 FRONT BRAKE PIPES 3 RIGHT PUMP PIPES TO FRONT VALVE 4 FRONT VALVE PIPES TO REAR VALVE 5 LEFT 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 Braking system MP3 500 ie SPORT Business LT 2011 BRAK SYS 332 ...

Страница 333: ...11 REAR BRAKE PIPES 12 PEDAL PUMP PIPES TO REAR VALVE 13 REAR VALVE MP3 500 ie SPORT Business LT 2011 Braking system BRAK SYS 333 ...

Страница 334: ... FLUID RESERVOIR 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 Braking system MP3 500 ie SPORT Business LT 2011 BRAK SYS 334 ...

Страница 335: ... Undo the two fixing screws and remove the cal liper N B IF IT IS NECESSARY TO REPLACE OR SERVICE THE BRAKE CALLIPER BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM INED MP3 500 ie SPORT Business LT 2011 Braking system BRAK SYS 335 ...

Страница 336: ...ove the wheel Undo the two fixing screws to the plate and re move 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 calliper to support 20 to 25 Rear brake disc Removal Remove the rear wheel Loosen the nuts fixing the safety washers Undo the two screws ...

Страница 337: ...ducts Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Brake disc screws 8 to 10 Disc Inspection Checking the disc is important it must be perfectly clean with no sign of rust oil or grease or any oth er 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 MP3 500 ie SPORT Business L...

Страница 338: ...epeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axial run out 0 1 mm Front brake disc Removal The operations described refer to only one disc but apply to both Remove the wheel Remove the brake calliper Remove the cotter pin and remove the cap Unscrew the fixing nut Braking system MP3 500 ie SPORT Business LT 2011 BRAK SYS 338 ...

Страница 339: ...ecommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Brake disc screws 8 to 10 Disc Inspection Checking the disc is important it must be perfectly clean with no 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 MP3 5...

Страница 340: ...e 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 brake pads Removal Remove the brake calliper Remove the Benzing snap ring of the pad pin Slide off the pin paying attention to collect the retaining spring of the pads Braking system MP3 500 ie SPORT Business LT 2011 BRAK SYS 340 ...

Страница 341: ... 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 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 Screws tightening the pa...

Страница 342: ...the figure 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 locking to release the brake pipes Smontaggio tubazioni freno anteriore Remove legshield Remove front wheel and mudguard Disconnect the brake pipes from the calliper and drain the brake fluid Then remove the plastic and metallic straps Unscrew...

Страница 343: ...er When refitting tighten to the specified torque Locking torques N m Screw tightening calliper to support 20 to 25 After removing the leg shield back plate remove the engaging cable for the safety mechanism re moving it from its fitting Remove the 4 screws shown in the figure When refitting pay attention to insert the metallic cable peg in the fitting marked A as indicated in the enlarged picture...

Страница 344: ...connection from the engaged parking brake warning light switch Remove the parking brake cable from the lever by operating the set screw indicated in the picture Braking system MP3 500 ie SPORT Business LT 2011 BRAK SYS 344 ...

Страница 345: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Страница 346: ...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 de aeration obtained by a hole into the closing plate In this case the circulation into the thermal group is active to ensure an even heating Once the working temperature has been reached the main circulation on radia...

Страница 347: ...ning 82 2 C 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 Control Coaxial at the countershaft RADIATOR Specification Desc Quantity Type Aluminium with horizontal circulation EXPANSION TANK Specification Desc Quantity Calibration Automatic bleeding in ...

Страница 348: ...LY 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 ELECTRIC FAN STARTS WORKING IN CASE OF AN INCREASE OF THE ELECTRIC FAN START TIME CHECK THE THERMOSTAT OPENING TEMPERATURE AND CHECK THAT THE COOLANT DENSITY IS CORRECT THE OP TIMUM DENSITY IS OBTAINED WITH A 50 WAT...

Страница 349: ...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 engine Restore the level with cold engine CAUTION ELECTRIC VENTILATION IS CONTROLLED BY THE TEMPERATURE MEASURED AT THE HEAD THE ELECTRIC VENTILATION START DOES NOT MEAN THAT THE VENTING HAS BEEN COM PLETED VENTING ...

Страница 350: ... 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 BLEEDING THE SYSTEM SEE THE COOLANT CHANGE SECTION Characteristic Cooling system approx 1 8 l Removing the water pump cover Check that the water pump cover is not deformed or dented Check that the sealing O ring is in good working order Otherwise replace the...

Страница 351: ...ST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the water pump cover as indicated in the figure by loosening the six fixing screws Follow the instructions provided in the Engine Water pump chapter to inspect the pump Refill and drain the system again once after hav ing repaired the damage and reinstalled all the components N B FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM SEE CHAPTER COOLING S...

Страница 352: ... VALVE CALIBRATED AT 0 9 BAR There is also a valve that must allow air inlet during the cooling step YES go to 2 NO go to 3 2 Check the head gasket seal see Thermal group and timing system chapter 3 Replace the cap Cooling fluid consumption 1 Check the system outer seals as described above YES go to 2 NO go to 3 2 Check the head gasket seal see Thermal group and timing system chapter If water leak...

Страница 353: ...INDEX OF TOPICS CHASSIS CHAS ...

Страница 354: ...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 handlebar cov er access the two screws fixing the rear part to the handlebar as indicated in the picture Chassis MP3 500 ie SPORT Business LT 2011 CHAS 354 ...

Страница 355: ...e 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 caps Remove the two screws under the brake pump caps previously removed MP3 500 ie SPORT Business LT 2011 Chassis CHAS 355 ...

Страница 356: ... turn indi cator Unscrew the two screws fixing the wheelhouse to the shield Disconnect the cable grommet after that turn the wheelhouse anticlockwise inwards to release it from the shield supports To remove the shield central finishing remove the PIAGGIO clip on badge paying attention not to spoil the paint unscrew the screw underneath and remove the finish carefully Chassis MP3 500 ie SPORT Busin...

Страница 357: ...ove 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 opening See also Seat Handles and top side fairings Knee guard MP3 500 ie SPORT Business LT 2011 Chassis CHAS 357 ...

Страница 358: ... and the two screws under the wheelhouse Remove the four screws on the leg shield back plate See also Headlight assy spoiler Knee guard Remove the legshield Remove the spoiler Remove the two central screws and the coolant cap cover screw Chassis MP3 500 ie SPORT Business LT 2011 CHAS 358 ...

Страница 359: ... instrument panel and manually re lease the unions with the leg shield back plate Unhook the instrument panel wiring Remove the six screws and the cable grommet strap in the front part of the leg shield back plate MP3 500 ie SPORT Business LT 2011 Chassis CHAS 359 ...

Страница 360: ...the five screws on the leg shield back plate rear part Remove the two leg shield back plate front screws see figure Remove the two leg shield back plate lower screws Remove the external temperature sensor con nection See also spoiler Legshield Chassis MP3 500 ie SPORT Business LT 2011 CHAS 360 ...

Страница 361: ...his procedure to remove the bulbs Remove the snap on bulbs B Remove the bulbs A on the bayonet by turning them 30 clockwise Footrest Remove the central cover Remove the four fixing screws from left half foot rest Follow the same procedure for both half footr ests Release the fuse box and remove the half foot rest MP3 500 ie SPORT Business LT 2011 Chassis CHAS 361 ...

Страница 362: ...ootrest See also Frame central cover Side fairings Remove the rear screw under the rear cover Remove the screw on the fairing front part pull the fairing to release the hooks Follow the same procedure for both fairings Remove the five screws on the right side and the five on the left side indicated in the figure Chassis MP3 500 ie SPORT Business LT 2011 CHAS 362 ...

Страница 363: ... case Operate a slight upwards thrust on the case to re lease license plate support from the chassis Helmet bay Remove the chassis central cover Remove the four external screws and the two screws inside the rear case to remove the frame MP3 500 ie SPORT Business LT 2011 Chassis CHAS 363 ...

Страница 364: ... of the voltage regulator on one side and the saddle open ing switch on the 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 Remove the shield central finish then screw the six screws indicated in the figure Chassis MP3 500 ie SPORT Business LT 2011 C...

Страница 365: ...the five screws indicated in the figure See also Headlight assy Fuel tank Remove the chassis central cover Remove the footrest Remove the three tank retainers MP3 500 ie SPORT Business LT 2011 Chassis CHAS 365 ...

Страница 366: ...xing screws of the cover and release it from the two leverages 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 screw indicated in the photograph Remove the backrest cushion Chassis MP3 500 ie SPORT Business LT 2011 CHAS 366 ...

Страница 367: ... the six screws indicated in the figure Radiator cover Remove the two front screws indicated in the pic ture Remove the two lower retainers with the bushing MP3 500 ie SPORT Business LT 2011 Chassis CHAS 367 ...

Страница 368: ...use front retainers 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 500 ie SPORT Business LT 2011 CHAS 368 ...

Страница 369: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Страница 370: ...ers and the 4 screws on the outer side of the mudguard then tighten to the specified torque Locking torques N m splash guard fastener screws 2 3 Aesthetic inspection Appearance check Paintwork Fitting of plastics Scratches Dirt Tightening torques inspection Safety locks check Visually check that there is a yellow mark on the following clamps Front suspension Front left wheel fixing screws Front ri...

Страница 371: ...Headlight adjustment according 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 Instrument panel lights Horn Electric starter Engine stopping with emergency stop switch Electric opening of saddle with solenoid Tilting system locking unlocking button CAUTION TO ENS...

Страница 372: ...N THAT RECOMMENDED 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 Roll lock system fluid level Rear hub oil level Engine coolant level Engine oil level Road test Test ride Cold start Instrument operations Response to the gas command Stability on acceleration and braking Rear and front brake effici...

Страница 373: ...ional Checks Hydraulic braking system lever 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 lock check tyre pressure check rear view mirror and any accessory fitting MP3 500 ie SPORT Business LT 2011 Pre delivery PRE DE 373 ...

Страница 374: ...ant 266 349 E Electric 347 Engine oil 42 F Fuel 237 245 365 Fuses 93 H Headlight 48 356 358 365 Horn 86 Hub oil 40 I Identification 8 Instrument panel 355 M Maintenance 7 34 37 O Oil filter 44 R Recommended products S Shock absorbers 326 Spark plug 39 263 Start up Suspension 52 53 291 Switch ...

Страница 375: ...T Tank 365 Transmission 10 51 118 133 Turn indicators 75 Tyres 12 V Vehicle 8 113 ...

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