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- Insert the new oil guards and O-rings on the mov-

able half-pulley.

- Lightly grease the O-rings (A) shown in the figure.

- Fit the half-pulley over the bushing using the ap-

propriate tool

- Check that the pins are not worn and proceed to

refitting them in their slots.

- Refit the torque server closure collar.

Using a curved-spout grease gun, lubricate the

driven pulley assembly with approximately 6 g of

grease. Apply the grease through one of the holes

in the bushing until it comes out through the hole

on the opposite side. This operation is necessary

to avoid the presence of grease beyond the O-

rings.

N.B.

THE TORQUE SERVER CAN BE GREASED
WHETHER WITH BEARINGS FITTED OR
WHEN THEY ARE BEING REPLACED; UNDER-
TAKING THE OPERATION WHEN THE BEAR-
INGS ARE BEING SERVICED MIGHT BE EAS-
IER.

Specific tooling

020263Y

 

Sheath for driven pulley fitting

Recommended products

AGIP GREASE SM 2

 

Grease for the tone wheel

revolving ring

Soap-based lithium grease containing NLGI 2 Mo-

lybdenum disulphide; ISO-L-XBCHB2, DIN

KF2K-20

Engine

MP3 125

ENG - 10

Содержание 633929(IT)

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

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

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

Страница 4: ......

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

Страница 6: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 133: ...emove the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 220: ...f necessary Refitting the rear wheel To fit follow the removal steps but in the reverse sequence being careful to fit the spacers on the wheel axle as shown in the photograph Locking torques N m Muffl...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 261: ...INDEX OF TOPICS TIME TIME...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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