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PIAGGIO MP3 500 i.e. SPORT Service Station Manual

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SERVICE STATION MANUAL
1Q000267 EN
MP3 500 i.e. SPORT Business_LT_ ABS-
ASR_EU_USA (2015)

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Table of Contents

   Summary of Contents for PIAGGIO MP3 500 i.e. SPORT

  • Page 1 SERVICE STATION MANUAL 1Q000267 EN MP3 500 i.e. SPORT Business_LT_ ABS- ASR_EU_USA (2015)
  • Page 2 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 2015 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited.
  • Page 3 Business_LT_ ABS- ASR_EU_USA (2015) This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
  • Page 7 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.
  • Page 8 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Characteristics (2015) Vehicle identification The identification registration numbers consist of a prefix stamped on the chassis and engine "B" respectively, followed by a number. These num- bers must always be indicated on spare parts re- quests.
  • Page 9 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Length 2205 mm (86.8 in) Width 775 mm (30.5 in) Maximum height 1460 mm (57.5 in) Wheelbase 1540 mm (60.6 in) Track 465 mm (18.3 in)
  • Page 10 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Characteristics (2015) Specification Desc./Quantity Cooling Forced coolant circulation system. Electric Electric starter Ignition Highly efficient electronic inductive ignition, integrated with the injection system, with variable advance, separate HV coil and double spark plug. Ignition advance...
  • Page 11 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics Specification Desc./Quantity Rear suspension travel 110 mm Brakes BRAKES Specification Desc./Quantity Front brake Double disc Ø 258 with hydraulic control activated by handlebar right lever; Braking assisted by ABS system (where available).
  • Page 12 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Characteristics (2015) Name Torque in Nm Side headstock upper ring nut 20 - 24 Nm (15 - 18 lb*ft) Side headstock lower ring nut 12 - 15 Nm (9 - 11 lb*ft) Screw fixing sliding stem to shock absorber...
  • Page 13 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics HEAD-ENGINE BLOCK-PISTON ASSEMBLY Name Torque in Nm Spark plug 12 - 14 Nm (9 - 10 lb*ft) Head fixing stud bolts 7 Nm + 90° + 90° (5.2 lb*ft + 90° + 90°)
  • Page 14 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Characteristics (2015) Name Torque in Nm Bleed screw 3 Nm (2.2 lb*ft) Overhaul data Assembly clearances Cylinder - piston assy. HEIGHT TO MEASURE THE PISTON Specification Desc./Quantity 10 mm 43 mm CYLINDER - PISTON Specification Desc./Quantity...
  • Page 15 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics N.B. THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS. Piston rings * Fit piston rings «2»...
  • Page 16 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Characteristics (2015) Middle ring: Standard coupling clearance: 0.02÷0.07 mm Maximum clearances allowed after use: 0.10 Oil scraper ring: Standard coupling clear- ance: 0.01÷0.06 mm Maximum clearances allowed after use: 0.10 If clearances measured exceed the maximum val- ues specified in the table, the piston should be replaced by a new one.
  • Page 17 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics Name Description Dimensions Initials Quantity Flywheel-side shoulder 1.8 ± 0.025 D = 0.20 ÷ 0.50 Flywheel side half-shaft 19.6 + 0.05 D = 0.20 ÷ 0.50 Complete crankshaft 65.5 +0.1 -0.05 D = 0.20 ÷ 0.50 Diameter of crankshaft bearings.
  • Page 18 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Characteristics (2015) Characteristic Crankshaft-crankcase axial clearance (H) 0.1 ÷ 0.405 mm (when cold) Compression ratio 10.5: 1 Slot packing system Shimming system to control compression ratio MEASUREMENT «A» IS A PROTRUSION OR RECESS VAL- UE OF THE PISTON CROWN COMPARED WITH THE CYL- INDER PLANE.
  • Page 19 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics 10.5: 1 BASE GASKET THICKNESS Name Measure A Thickness MEASURE TAKEN «A» - 0.185 ÷ - 0.10 0.4 ± 0.05 MEASURE TAKEN «A» - 0.10 ÷ + 0.10 0.6 ± 0.05 MEASURE TAKEN «A»...
  • Page 20 INDEX OF TOPICS TOOL OOLING...
  • Page 21 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling SPECIFIC TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Bell for OD 54-mm bearings 001467Y008...
  • Page 22 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 001467Y031 Bell 001467Y034 Calliper to extract 15-mm diameter bear- ings 001467Y035 Bell for 47-mm outside diameter bearings 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on...
  • Page 23 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020193Y Gauge for oil pressure check 020201Y Spacer bushing driving tube 020262Y Crankcase splitting strip...
  • Page 24 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020329Y Vacuum pump Mity-Vac 020330Y Stroboscopic light for timing checking 020331Y Digital multimeter 020648Y Single battery charger 020335Y Dial gauge magnetic support 020357Y 32 x 35 mm adaptor 020358Y...
  • Page 25 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020359Y 42 x 47-mm adaptor 020360Y 52 x 55-mm adaptor 020364Y 25-mm Guide 020376Y Adapter handle 020382Y012 bush (valve removing tool) 020412Y 15 mm guide 020424Y Punch for fitting driven pulley roller casing...
  • Page 26 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020431Y Valve oil seal extractor 020434Y Fitting for oil pressure check 020439Y 17 mm guide 020444Y Tool for fitting/removing the clutch on the driven pulley 020456Y Ø24 mm adaptor...
  • Page 27 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020458Y Puller for lower bearing on steering tube 020459Y Punch for fitting bearing on steering tube 020922Y Diagnosis Tool 020467Y Flywheel extractor 020468Y Piston fitting ring 020470Y Pin snap ring fitting tool...
  • Page 28 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020478Y Punch for roller casing TOOL - 28...
  • Page 29 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020479Y Countershaft lock wrench 020480Y Fuel pressure check set 020482Y Engine support 020483Y 30 mm guide 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter TOOL - 29...
  • Page 30 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020481Y004 Parking control unit interface wiring 020646Y Parallelogram and steering positioning tool 020647Y Toe-in checking tool 020647Y028 MP3 LT Toe-in tool (tricycle) 020661Y Water pump overall seal replacement kit...
  • Page 31 INDEX OF TOPICS MAIN AINTENANCE...
  • Page 32 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.
  • Page 33 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance - Remove the two screws located inside the glove- box on the dashboard. - Remove the four screws indicated and recover the related spacers. - Undo the two screws indicated, then remove the spoiler.
  • Page 34 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) - Remove the Piaggio clip-on badge, fixed to the joint, by acting on the indicated slot. - Remove the indicated screw and remove the ra- diator grille frame. - Unscrew the four indicated screws and remove the radiator grille.
  • Page 35 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance - Unscrew the four indicated screws and remove the front radiator cover. - Remove the two lower fastening screws. - Disconnect the connector and remove the head- light. - Undo the four indicated screws on the leg shield back plate.
  • Page 36 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) - Working on both sides of the vehicle, unscrew the two indicated screws and remove the spoiler sup- port plastic. - Remove the two indicated screws from both sides of the vehicle, located inside the wheel housing.
  • Page 37 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance 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 Tighten upper ring nut to the specified torque with the appropriate key.
  • Page 38 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) Km x 1,000 Sliding shoes / CVT rollers Suspension Spark plugs Roll lock calliper control cable Valve clearance Operation time 10' 19 10' 22 10' 19 10' 22 10' 19 10' 22...
  • Page 39 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance Proceed as follows: - Remove the spark plugs. - Remove the transmission crankcase. - Rotate the driving pulley fan until the reference marks between the flywheel and flywheel cover meet as shown in the photograph.
  • Page 40 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) Specific tooling 020922Y Diagnosis Tool 020330Y Stroboscopic light for timing checking 020621Y HV cable extraction adaptor Spark plug Remove the port on the left-hand side panel of the vehicle by undoing the fixing screw and using a...
  • Page 41 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance Hub oil Check - Rest the vehicle on its centre stand on level ground. - Unscrew the dipstick «A», dry it with a clean rag and then reinsert it, screwing it tightly into place.
  • Page 42 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) Air filter - Unscrew the nine fixing screws «A» and remove the air filter cover. - Wash the sponge with water and mild soap. - Dry it with a clean cloth and short blasts of com- pressed air.
  • Page 43 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance Replacement Change oil and replace filter as indicated in the scheduled maintenance table. Empty the engine by draining the oil through drainage plug «B». To facilitate oil drainage, loosen the cap/dipstick «A».
  • Page 44 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED. Recommended products eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3...
  • Page 45 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it.
  • Page 46 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) Cooling system Check coolant level when the engine is cold as in- dicated in the scheduled maintenance table, fol- lowing the steps below: Place the vehicle on its centre stand and on flat ground.
  • Page 47 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance 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 vehicle onto the centre stand, with the handlebar centred.
  • Page 48 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) MAKE SURE THE BRAKE FLUID DOES NOT GET INTO YOUR EYES OR ON YOUR SKIN OR CLOTHES. IF THIS HAPPENS ACCIDENTALLY, WASH WITH WATER. Recommended products AGIP BRAKE 4 Brake fluid. SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 -...
  • Page 49 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO- PEAN STANDARDS REGARDING MAXIMUM AND MINI- MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU- TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.
  • Page 50 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) Although the amount of hydrocarbons coming from the tank is small enough to avoid the saturation of the canister, it is necessary to regenerate the activated carbon by means of a reversed flow of ambient air sucked by the engine.
  • Page 51 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Maintenance To control the valve, it is preferable to it, alterna- tively just access the manifold side pipe. • Connect the MITY-VAC pump on the engine side duct. • Select the pump command on the "vac- uum"...
  • Page 52 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Maintenance (2015) air without movements of the gauge needle. • Switch the control of the pump to "pres- sure" and, keeping the valve in the ver- tical axis, check that it is possible to pressurise the valve up to values slightly below 1.45PSI(~0.87PSI)
  • Page 53 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 54 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Troubleshooting (2015) This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Excessive oil consumption/Exhaust smoke...
  • Page 55 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Troubleshooting Possible Cause Operation Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift of the disc with a dial gauge and with wheel mounted on the vehicle.
  • Page 56 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Troubleshooting (2015) Suspension oil leakage OIL 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. TROUBL - 56...
  • Page 57 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 58 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) CAUTION THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION EQUIPPED WITH ABS - ASR SYSTEM. 1. Instrument panel 2. Ambient temperature sensor 3. Turn indicator bulbs 4. Turn indicator switch 5. Emergency turn indicator switch 6.
  • Page 59 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 18. Saddle opening switch 19. Saddle opening actuator 20. Light switch 21. Pre-installation heated handgrips control device and leg warmer 22. engine stop switch 23. Stop light relay 24. Electric fan relay 25.
  • Page 60 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 56. Engine temperature sensor 57. Fuel pump 58. ABS control unit 59. Rear ABS sensor 60. Left front ABS sensor 61. Right front ABS sensor 62. Tip over sensor 63. Diagnostic socket 64.
  • Page 61 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 1. Instrument panel 2. Ambient temperature sensor 3. Turn indicator bulbs 4. Turn indicator switch 5. Emergency turn indicator switch 6. Turn indicators control device 7. Pre-installation for anti-theft device 8. Headlight 9.
  • Page 62 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 20. Light switch 21. Pre-installation heated handgrips control device and leg warmer 22. engine stop switch 23. Stop light relay 24. Electric fan relay 25. Electric fan 26. Plug socket 27. Helmet compartment light switch 28.
  • Page 63 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 58. - 59. - 60. - 61. - 62. Tip over sensor 63. Diagnostic socket 64. Injection ECU 65. Immobilizer aerial 66. Warning light unit 67. - 68. MODE button 69. Oil pressure sensor 70.
  • Page 64 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Components arrangement 1. BRAKE LEVER STOP BUTTONS Remove the upper handlebar cover to reach it. 2. PRE-INSTALLATION HEATED HANDGRIPS CONTROL DEVICE AND LEG WARMER Remove the upper handlebar cover to reach it.
  • Page 65 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 3. AMBIENT TEMPERATURE SENSOR Remove the upper handlebar cover to reach it. 4. IMMOBILIZER AERIAL Remove the shield back plate upper side to reach 5. IGNITION KEY CONTACTS Remove the shield back plate upper side to reach 6.
  • Page 66 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 7. PMP CONNECTION Remove the leg shield to reach it. 8. BRAKE CALLIPER SENSOR Remove the leg shield to reach it. The sensor connector is fixed to the frame under the expansion tank.
  • Page 67 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 10. RELAY UNIT Remove the leg shield to reach it. A. HORN RELAY B. INJECTION LOAD RELAY C. ELECTRIC FAN RELAY D. HEADLIGHT RELAY 11. TURN INDICATORS CONTROL DEVICE Remove the leg shield to reach it.
  • Page 68 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 15. ELECTRIC FAN Remove the radiator cover to reach it. 16. SPEED SENSOR The sensors are located in the internal section of the front wheels. To access the connectors, the central chassis cov- er must be removed.
  • Page 69 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 18. STOP PEDAL BRAKES BUTTON To reach them, remove the right footrest. 19. HORN Remove the left footrest to reach them. 20. PARKING CONTROL ECU Remove the leg shield back plate to reach it.
  • Page 70 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 21. HAND BRAKE SWITCH Remove the leg shield back plate to reach it. 22. AUXILIARY FUSES To reach them, remove the cover on the left foot- rest. 23. FUEL PUMP 24. FUEL LEVEL TRANSMITTER Remove the central chassis cover to reach it.
  • Page 71 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 26. OIL PRESSURE SENSOR The sensor is positioned on the right side of the engine, near the exhaust muffler. 27. ENGINE SPEED SENSOR To reach the sensor connector, remove the right side fairing.
  • Page 72 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 30. H.V. COIL Remove the left side fairing to reach it. 31. STARTER MOTOR Remove the helmet compartment to reach it. 32. SADDLE OPENING ACTUATOR Remove the license plate support to reach it.
  • Page 73 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 33. VOLTAGE REGULATOR Remove the license plate support to reach it. To reach the connector, remove the right side fair- ing. 34. PRE-INSTALLATION FOR ANTI-THEFT DE- VICE 35. HORN CONNECTION FOR ANTI-THEFT DE- VICE Remove the right side fairing to reach it.
  • Page 74 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 37. INJECTOR 38. ENGINE TEMPERATURE SENSOR Remove the inspection cover located in the helmet compartment to reach it. 39. START-UP RELAY 40. FUSE No. 13 41. MAIN FUSES 42. FUSE No. 14 (IF APPLICABLE) 43.
  • Page 75 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 47. ABS CONTROL UNIT (IF APPLICABLE) Remove the helmet compartment to reach it. Ground points On the vehicle there is a chassis ground point "A", remove the footrest to access it.
  • Page 76 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Electrical system installation Front side 1. Control connections on the left side of the handlebar 2. At left stop button 3. Main cable harness 4. Pre-installation heated handgrips control device and leg warmer connector 5.
  • Page 77 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 9. Warning light unit connector 10. Instrument panel connector 11. USB socket connector 12. Turn indicators control device 13. PMP connection 14. Pressure sensor 15. Stop light relay ELE SYS - 77...
  • Page 78 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 16. Relay unit connections 17. Gear motor connector 18. Rotation sensor and headlamp wiring ELE SYS - 78...
  • Page 79 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 19. Rotation sensor connector 20. Headlight connector 21. Rotation sensor 22. Front daylight running light connector 23. To electric fan 24. Pressure sensor connector ELE SYS - 79...
  • Page 80 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 25. Saddle opening switch connector 26. ASR Button connector 27. Wheel sensors wiring ELE SYS - 80...
  • Page 81 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 28. Parking control ECU connector 29. To horn 30. Speed sensors connectors 31. Secondary fuses ELE SYS - 81...
  • Page 82 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 32. Front wiring branch 33. Speed sensor 34. Front ABS sensor ELE SYS - 82...
  • Page 83 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 35. Front ABS sensors connectors Back side 1. ABS control unit connector ELE SYS - 83...
  • Page 84 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 2. Main cable harness 3. To ground point on chassis 4. Positive battery pole 5. Start-up relay connections 6. Main fuses 7. HV coil ELE SYS - 84...
  • Page 85 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 8. Left taillight, license plate lights and saddle opening switch actuator wiring 9. Left taillight connector 10. Rear left turn indicator connector ELE SYS - 85...
  • Page 86 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 11. License plate lights connector 12. Saddle opening actuator 13. Engine speed sensor connector ELE SYS - 86...
  • Page 87 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 14. Rear ABS sensor connector 15. Starter motor positive 16. Injection ECU connector 17. Engine temperature sensor 18. Injector 19. Plug socket 20. Oxygen sensor connector 21. Pre-installation for anti-theft device 22.
  • Page 88 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 24. Helmet compartment light connector 25. Rear right turn indicator connector 26. Right taillight connector 27. Voltage regulator connector ELE SYS - 88...
  • Page 89 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 28. To voltage regulator Conceptual diagrams ELE SYS - 89...
  • Page 90 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Ignition 1. Instrument panel 13. Secondary fuses 31. Main fuses 32. Battery 35. Fuse No. 13 36. ignition key contacts 40. Injection load relay 53. Engine speed sensor 54. HV coil 55.
  • Page 91 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system Battery recharge and starting 11. Starter button 13. Secondary fuses 16. Stop buttons lever and brake pedals 22. engine stop switch 23. Stop light relay 29. Magneto flywheel 30. Voltage regulator 32.
  • Page 92 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Level indicators and enable signals section 1. Instrument panel 2. Ambient temperature sensor 10. Fuel level transmitter 11. Starter button 12. Headlight relay 13. Secondary fuses 16. Stop buttons lever and brake pedals 22.
  • Page 93 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 62. Tip over sensor 64. Injection ECU 66. Warning light unit 69. Oil pressure sensor Devices and accessories CAUTION THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION EQUIPPED WITH ABS - ASR SYSTEM.
  • Page 94 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 18. Saddle opening switch 19. Saddle opening actuator 20. Light switch 21. Pre-installation heated handgrips control device and leg warmer 26. Plug socket 27. Helmet compartment light switch 28. Helmet compartment light bulb 31.
  • Page 95 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 1. Instrument panel 3. Turn indicator bulbs 6. Turn indicators control device 7. Pre-installation for anti-theft device 8. Headlight 10. Fuel level transmitter 12. Headlight relay 13. Secondary fuses 14. ignition key contacts 15.
  • Page 96 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 32. Battery 35. Fuse No. 13 36. ignition key contacts 41. Pressure sensor 42. Horn relay 43. PMP connection 44. Geared motor 45. Brake calliper sensor 46. Parking control ECU 47. Right speed sensor 48.
  • Page 97 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system Lights and turn indicators 1. Instrument panel 3. Turn indicator bulbs 4. Turn indicator switch 5. Emergency turn indicator switch 6. Turn indicators control device 8. Headlight 9. Front daylight running light bulb 12.
  • Page 98 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 46. Parking control ECU Checks and 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.
  • Page 99 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system • fuses 2, 11, 13 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 connector from the control unit.
  • Page 100 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) • There is continuity between terminals 21-23 with the emergency cut-off switch set to «RUN». If there is no con- tinuity check the contacts of the switch. After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture.
  • Page 101 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system With the ignition key switch at «ON» check if there is battery voltage between the Red-White and Black cables. Disconnect the control unit connector and check the continuity between pin 29 and the aerial Or- ange-White cable.
  • Page 102 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) MASTER key: BROWN 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.
  • Page 103 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 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: •...
  • Page 104 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Diagnostic code - 3 flashes Il codice 3 lampi contraddistingue un impianto dove la centralina non riconosce la chiave (ovvero riconoscimento del transponder, ma non inserito in programmazione, una chiave è rimasta fuori dalla programmazione).
  • Page 105 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 3) Measure the resistance between each of the yellow terminals and the other two. Electric characteristic Resistance: 0.2 - 1 Ω 4) Check that there is insulation between the each yellow cable and the ground.
  • Page 106 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) VOLTAGE REGULATOR/RECTIFIER Specification Desc./Quantity Type Non-adjustable three-phase transistor Voltage 14 to 15V at 5000 rpm with lights off Starter motor 1. Injection ECU 2. Starter button 3. Stop buttons lever and brake pedals 4.
  • Page 107 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 2) Check the contacts of the ignition switch, the stop buttons, the starter button and the engine stop switch. 3) Check the correct operation of the starter relay. 4) Check the following wiring for continuity: - Red-Black cables between fuse No.
  • Page 108 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 1) Check fuses No. 13 and 9 and the key switch contacts and the horn button. 2) Check the following wiring for continuity: - Red-Black cables between fuse No. 13 (on starter relay) and ignition switch;...
  • Page 109 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check that bulbs operate properly. 2) Check fuses No. 4 and 12. 3) Check the contacts of the ignition switch, the turn indicator switch and the hazard warning light button.
  • Page 110 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Lights list 1. Instrument panel 2. Headlight 3. Front daylight running light bulb 4. Light switch 5. Headlight relay 6. Secondary fuses (no. 9, 11, 12) 7. ignition key contacts 8. Parking control ECU 9.
  • Page 111 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 2) Check fuses No. 4 and 12. 3) Check ignition switch contacts. 4) With the ignition switch «ON», check if there is voltage between the Yellow-Black cable of fuse No. 12 and the ground lead. Otherwise, check the continuity of cable harnesses.
  • Page 112 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Specification Desc./Quantity Power:12V - 5W Quantity:2 Fuses The electrical system has thirteen fuses for pro- tection of different system circuits divided into one single fuse «13» and two fuse-boxes. The fuse «13» and the first box, «A», are placed inside the battery compartment while the second box, «B», is inside the footrest on the left side of...
  • Page 113 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system CAUTION BEFORE REPLACING THE FUSE IT IS NECESSARY TO FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. DO NOT REPLACE THE FUSE WITH ANY ALTERNATIVE FORM OF CONDUCTOR. CAUTION IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCONNECT THE WIR- ING WHILE THE ENGINE IS RUNNING.
  • Page 114 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) Specification Desc./Quantity Fuse No. 8 Capacity: 5 A Protected circuits (live): Stop lights (via relay), starter relay. Fuse No. 9 Capacity: 7.5 A Protected circuits (live): Horn, high beam flashing switch.
  • Page 115 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system F = Heated handgrip warning light (if fitted) G = High beam warning light H= Turn indicator warning light I = Hazard warning light L = Immobilizer LED M = Engine control warning light and engine failure warning light...
  • Page 116 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) A = Front suspension locking system failure warn- ing light B = Engine stop warning light C = Front suspension locking system warning light D = Warning light for parking brake engaged...
  • Page 117 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system - Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode - Charge current equal to 1/10 of the battery rated capacity...
  • Page 118 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals.
  • Page 119 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 12.8 - 13.15 V Bring the battery to full charge, us- ing the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel...
  • Page 120 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the...
  • Page 121 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system zontal and vertical ax- Characteristic Vibration 0.3 V 11.25 to 11.55 V ap- proximately For the correct operation, check the correct air gap of the tone wheels: Characteristic Air gap 0.1 to 2 mm...
  • Page 122 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) 24. Lambda probe positive (Green-Blue) 25. Not connected 26. Battery powered (Red-Green) 27. Engine stop warning light (Blue) 28. CAN H line (Pink-Red) 29. Immobilizer aerial (Orange-White) 30. Starter button (Purple) 31.
  • Page 123 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system 5C. Suspension locking/unlocking button (Purple- Black) 6C. Rider detection sensor (Purple) 7C. Vehicle speed signal (Sky blue) 8C. Geared motor (Blue) ABS CONTROL UNIT CONNECTOR (IF APPLI- CABLE) 1. Battery-powered (Red) 2.
  • Page 124 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) INSTRUMENT PANEL CONNECTOR 1. Battery-powered (Red-Blue) 2. Key powered (Yellow-Red) 3. Sensors ground lead (Black) 4. Vehicle speed signal (Sky blue) 5. Not connected 6. Ambient temperature signal (Yellow-Blue) 7. Engine temperature signal (Light blue-Black) 8.
  • Page 125 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system TURN INDICATOR CONTROL DEVICE CON- NECTOR 1. Hazard button (Brown) 2. Left switch (White-Pink) 3. Right switch (Blue-Black) 4. Left turn indicators (Pink) 5. Right turn indicators (White-Blue) 6. Battery-powered (Blue) 7.
  • Page 126 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Electrical system (2015) H.V. COIL CONNECTOR 1. Injection load relay (Black-Green) 2. Injection ECU (Pink-Black) PICK-UP CONNECTOR 1. Injection ECU (Red) 2. Injection ECU (Brown) Diagnostic instrument ENGINE TEMPERATURE SENSOR Function Serves the purpose of communicating the engine temperature to the control unit in order to optimise performance.
  • Page 127 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Electrical system Temperature Resistance 227.3 - 235.1 Ω 90° C ELECTRICAL ERRORS WARNING A FAILURE OF THIS CIRCUIT CAUSES THE SWITCHING ON OF THE INJECTION WARNING LIGHT AND THE TRIPPING OF THE SAFETIES (AMONG WHICH THE ELECTRIC FAN CONTIN- UOUS START).
  • Page 128 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 129 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine from vehicle Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo. N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS»...
  • Page 130 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Engine from vehicle (2015) - Remove the front screw fixing the exhaust end to the bracket. - Remove the exhaust en by sliding it off the mani- fold. CAUTION SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUF- FLER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.
  • Page 131 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine from vehicle - Remove the two exhaust manifold fixings at the engine head. - Remove the exhaust manifold paying attention to slide off the wiring harness of the lambda probe. 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.
  • Page 132 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Engine from vehicle (2015) - Unscrew the fixing bolt of the throttle control ca- bles cover, then remove the cover. - Loosen the throttle control set nuts. ENG VE - 132...
  • Page 133 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine from vehicle - Disconnect the throttle control cables from the throttle body. - To facilitate the operation, loose the throttle con- trol set screw on the throttle grip. - Unscrew the bolt fixing the control unit connector to the bracket, then disconnect it.
  • Page 134 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Engine from vehicle (2015) - Remove the cable ties clamp from the bracket. - Disconnect the connectors of the injector and of the engine temperature sensor. - Remove the corresponding stop and disconnect the fuel piping.
  • Page 135 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine from vehicle - Open the two cable ties clamps to release the main wiring harness. - Disconnect the rear ABS sensor connector, then remove the cable ties clamp from the bracket and release the connector.
  • Page 136 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Engine from vehicle (2015) - Disconnect the starter motor positive wire. - Disconnect the starter motor negative cable and the engine ground cable. - Cut the oil pressure sensor cable clamp, then disconnect it and release it from the cable grom- mets.
  • Page 137 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine from vehicle - Cut the three fixing clamps of the flywheel wiring harness. ENG VE - 137...
  • Page 138 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Engine from vehicle (2015) - Disconnect the voltage regulator connector. - Disconnect the engine rpm sensor connector and release it from the slide housing. - Disconnect the spark plug caps. - Remove the clamp and disconnect the filter box sleeve.
  • Page 139 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine from vehicle - Undo the two screws fixing the filter box to the crankcase. - Undo the screw fixing the filter box to the internal bracket and disconnect the oil drainage recovery pipe, then remove the filter box.
  • Page 140 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Engine from vehicle (2015) - Undo the two fixing bolts of the plate to remove - Undo the bolt fixing the brake piping support bracket to the crankcase. - Open the clamp and unscrew the fixing bolt to release the brake pipes.
  • Page 141 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine from vehicle - Unscrew the expansion tank cover, then open the clamp to release the water pump inlet pipe. - Disconnect the water pump inlet pipe, by remov- ing the clamp, then empty the cooling system.
  • Page 142 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Engine from vehicle (2015) - Remove the rear left shock absorber lower re- tainer. - Remove the swinging arm - engine fixing pin by first undoing the nut and then operating on the head of the pin.
  • Page 143 INDEX OF TOPICS NGINE...
  • Page 144 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.
  • Page 145 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the six M6 screws. - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely, otherwise replace it. Air duct - Remove the transmission cover.
  • Page 146 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Air duct filter - Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the fig- ure to remove the conveyor filter. Removing the driven pulley shaft bearing - Remove the transmission cover.
  • Page 147 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE.
  • Page 148 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Anti-vibration roller screw 16.7 ÷ 19.6 Removing the driven pulley - Remove the clutch bell. - Remove the stationary driving half-pulley. - Remove the driven pulley assembly with the belt. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.
  • Page 149 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Removing the clutch - To remove the clutch with the driven pulley it is necessary to use the special tool; - Arrange the tool with the mean pins screwed in position "E" on the inside;...
  • Page 150 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Do not open the masses using tools to prevent a variation in the return spring load. Pin retaining collar - Extract the collar using 2 screwdrivers. - Remove the 4 guide pins.
  • Page 151 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Using the special tool inserted through the roller bearing, pull out the ball bearing. N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAM- AGING THE THREADING. Specific tooling 020376Y Adapter handle 020456Y Ø24 mm adaptor 020363Y 20 mm guide N.B.
  • Page 152 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Inspecting the driven sliding half-pulley - Check that the belt contact surface is free from wear. - Remove the 2 inside sealing rings and the 2 out- side O-rings. - Measure the movable half-pulley bushing inside diameter.
  • Page 153 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Refitting the driven pulley - Insert the new oil guards - Insert the new O-rings N.B. O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RA- DIUS, AT THE BASE OF THE HALF-PULLEY.
  • Page 154 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Refitting the clutch - Prepare the special tool as for removal; - Preassemble the driven pulley unit with the drive belt according to its direction of rotation; - Insert the driven pulley unit, the spring with sheath and clutch into the tool.
  • Page 155 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width 27.5 mm Overall width 28.7 mm Removing the driving pulley - Using a 27 mm wrench, turn the central pulley nut to horizontally align the central inside holes and install the special tool.
  • Page 156 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Move the belt downwards. - Suitable support the roller contrast and extract the movable driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out.
  • Page 157 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt faying surfaces on both pulley halves. Refitting the driving pulley...
  • Page 158 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Insert the half-pulley on the crankshaft. - Insert the spacer bushing. Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley.
  • Page 159 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Insert the nut in the original position (nut side in contact with the belleville washer). - Turn the central pulley nut to horizontally align the holes and install the special tool.
  • Page 160 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Insert the transmission cover with the bearing and install the relevant retainers. - Lock the four M8 retainers. Locking torques (N*m) M8 retainers for transmission cover 23 ÷ 26 - Lock the 7 M6 retainers.
  • Page 161 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Install the outside plastic transmission cover. - Tighten the 4 fastening screws to the prescribed torque. Locking torques (N*m) External transmission cover screws 7 - 9 End gear Removing the hub cover - Drain the rear hub oil through the oil drainage cap located under the engine.
  • Page 162 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Removing the hub bearings - Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts.
  • Page 163 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Support the hub cover using the stud bolt set. - Pull out the bearing using the special tool.
  • Page 164 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Pull out the driven pulley shaft bearing from the engine crankcase using the special tool. Specific tooling 020376Y Adapter handle 020358Y 37 x 40 mm adaptor 020364Y 25-mm Guide Inspecting the hub shaft...
  • Page 165 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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...
  • Page 166 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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).
  • Page 167 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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...
  • Page 168 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 169 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Locking torques (N*m) Rear hub cover screws 24 - 27 Flywheel cover - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.
  • Page 170 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the oil filter using a filter tape or shaped cup wrench. - Loosen the 14 fastening screws. - Remove the flywheel cover with the relevant gas- ket and the cooling system sleeve support.
  • Page 171 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the by-pass and the relevant spring. - Remove the oil pump seal. Removing the stator - Remove the two retaining screws and the cable guide bracket. - Unscrew the 3 fastening screws and remove sta- tor and its wiring.
  • Page 172 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the blow-by reed valve with the relevant sealing gasket. - Unscrew the fastening screw and remove the gas outlet union with the relevant O-ring. - Check that the mounting surface of the crankcase is not worn or deformed.
  • Page 173 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Check the condition of the stator and the relevant cable harness. - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.
  • Page 174 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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 INTO THE SPECIAL SEAT ON THE CRANKCASE.
  • Page 175 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Oil vapour decantation chamber - Temporarily install the distribution timing check hole cover and the engine oil filling cap/bar. - Insert the blow-by recovery duct using a new O- ring. - Tighten the screws to the prescribed torque.
  • Page 176 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Refit the water pump cover and tighten the 6 fix- ing screws to the prescribed torque. Locking torques (N*m) Pump cover fixing screws: 3 ÷ 4 Refitting the flywheel cover - Install a new oil filter, lubricate the gasket, screw on and finally tighten to the prescribed torque.
  • Page 177 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Lubricate the intermediate gear seat with torque limiter on the flywheel cover. - Align the water pump movement sensor with a reference and install the flywheel cover as descri- bed in the Flywheel cover chapter.
  • Page 178 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Tighten the 14 retaining bolts of the cover to the prescribed torque. N.B. THE BOLTS HAVE FOUR LENGTHS: - THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE FIGURE. - THE LONGEST IS INSERTED UNDER THE ENGINE OIL FILLER PLUG.
  • Page 179 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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 replace the battery.
  • Page 180 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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 found, replace the starter motor. 8- Low trailing speed...
  • Page 181 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine The starter control (energised remote control) is slaved to enabling signals by the side stand and the emergency OFF/RUN switch, which does not allow starting given dangerous conditions. The starter control circuit is not controlled by the immobilizer system, therefore before insisting on the starter system, check the consensus of the immobilizer.
  • Page 182 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 183 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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;...
  • Page 184 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 185 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Inspecting the flywheel components - Check 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.
  • Page 186 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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.
  • Page 187 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Medium Loctite 243 threadlock - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel Seeger ring visible.
  • Page 188 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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. Refitting the flywheel magneto - Insert the key on the crankshaft.
  • Page 189 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 190 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Install the chain guide retain plate tightening the 3 screws to the prescribed 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.
  • Page 191 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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.
  • Page 192 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the central screw and the valve lifting device mass stop bell using the special tool. Specific tooling 020565Y Flywheel lock calliper spanner - Remove the return spring and the valve lifting mass with relevant travel end washer.
  • Page 193 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Remove the inside hexagon screw and the coun- terweight 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.
  • Page 194 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove pins and rocking levers by the transmis- sion side holes. Removing the cylinder head - Remove the spark plugs. - Remove the cooling system outlet sleeve with thermostat. - Remove the coolant temperature sensor.
  • Page 195 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the two M6 screws into the distribution channel and the M6 screw on the spark plug side with the thermostat support. N.B. THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKING LEVER PINS AND FITTING BRACKET IF NECESSARY.
  • Page 196 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 197 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 198 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 199 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Using a bore meter, measure the cylinder inner diameter at a given height according to the direc- tions shown in the figure. Characteristic 43 mm Standard diameter: 94 mm nominal value - Check that coating is free from flakes.
  • Page 200 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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 Scraper ring: 0.25 ÷ 0.50 mm. Max. value: 0.65 mm Scraper ring: 0.25 ÷...
  • Page 201 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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...
  • Page 202 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - With a contrasting surface, reset the dial gauge with a preloading of a few millimetres. - Finally fix the dial gauge. - Check the perfect sliding of the feeler pin. - Fit the tool on the cylinder without changing the dial gauge position.
  • Page 203 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Refitting the piston rings - Place the scraper ring spring on the piston. - Install the scraper ring keeping the opening op- posed to the spring junction and with the writing "top" facing the piston crown. The chamfered side of the oil scraper ring should always be facing the piston crown.
  • Page 204 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Maximum run-out allowed: 0.1 mm - In case of irregularities, replace the head. - Check the sealing surfaces for the inlet and ex- haust manifold. - Check that the camshaft and the rocker pin bear- ings show no signs of wear.
  • Page 205 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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. - Fit the valves into the cylinder head.
  • Page 206 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine MINIMUM DIAMETER ALLOWED Specification Desc./Quantity Inlet: 4.96 mm Outlet: 4.945 mm - Calculate the clearance between the valve and its guide. - Check the deviation of the valve stem by resting it on a «V» shaped support and measuring the ex- tent of the deformation using a dial gauge.
  • Page 207 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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 Limit allowed: 0.09 mm VALVE STANDARD LENGTH Specification Desc./Quantity Inlet: 95.0 ±...
  • Page 208 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine TO AVOID SCORING THE FAYING 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.
  • Page 209 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats. Specific tooling 020382Y Tool for removing valve cotters fitted...
  • Page 210 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 211 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 212 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine *** 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.
  • Page 213 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 214 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Install the intermediate gear with torque limiter, the flywheel and its cover, as described in Chapter "Flywheel and start-up system", and in Chapter "Flywheel cover". N.B. FOR MORE CONVENIENCE, INSTALL THE FLYWHEEL COVER WITHOUT THE COOLING SYSTEM SLEEVES.
  • Page 215 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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...
  • Page 216 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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...
  • Page 217 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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- ening the lock nut and use a screwdriver for the set screw as shown in the figure.
  • Page 218 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the TDC reference inspection cap be- tween flywheel and crankcase cover. See the fly- wheel cover chapter. - By the driving pulley, turn the engine to find the alignment of the references to identify the TDC.
  • Page 219 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - revolution timing sensor - injection control unit Refitting the rocker-arms cover - Check that the gasket is in good working order. - Tighten the two screws indicated in the figure with «1»...
  • Page 220 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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.
  • Page 221 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Splitting the crankcase halves - Remove the engine support retain screw on the flywheel side half-crankcase. - Remove the 14 crankcase coupling screws. N.B. THE FASTENING SCREWS ARE OF 3 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION.
  • Page 222 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the crankshaft with the shim adjustment washer on the flywheel side. CAUTION WHILE OPENING THE CRANKCASE AND REMOVING THE CRANKSHAFT, CHECK THAT THE SHAFT THREADED ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS.
  • Page 223 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the special tool and extract the counter- shaft with the control gear. Replacing the countershaft bearings - Check that the bearings are free from irregular noise or clearance. If it does, replace it.
  • Page 224 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Before installing a new bearing, heat the flywheel side half-crankcase using the special tool. - Place the half-crankcase on a wooden base. Specific tooling 020151Y Air heater - Insert a new bearing on the special tool after greasing the guide seat.
  • Page 225 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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 INTERNAL SIDE.
  • Page 226 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft 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.
  • Page 227 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Specific tooling 020074Y Support base for checking crankshaft alignment MAX ADMISSIBLE DISPLACEMENT: Specification Desc./Quantity = 0.15 mm = 0.01 mm = 0.01 mm = 0.10 mm - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
  • Page 228 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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.
  • Page 229 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
  • Page 230 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine CHECK THE BENCH BUSH Name Description Dimensions Initials Quantity Type A - Red 1.971 ÷ 1.974 Type B - Blue 1.974 ÷ 1.977 Type C - Yellow 1.977 ÷ 1.980 Type D - Green 1.980 ÷...
  • Page 231 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 232 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 233 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 234 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Insert 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.
  • Page 235 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 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- JASO MA, MA2 - API SL - ACEA A3 formance four-stroke engines.
  • Page 236 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Conceptual diagrams PRINCIPLE DIAGRAM Specification Desc./Quantity Camshaft Cylinder-head plane Cylinder-crankcase plane Water pump impeller Minimum oil pressure sensor Oil filter cartridge To the oil sump By-pass valve Oil pump Mesh pre-filter Crankshaft...
  • Page 237 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the pressure of the circuit.
  • Page 238 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 3 Check the actual oil pressure. AHEAD - go to 4 4 - Remove the switch and fit the special tool with the relevant gasket. Specific tooling 020193Y Gauge for oil pressure check...
  • Page 239 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 8 - If pressure lower than 1.3 ÷ 1.5 bar is measured. AHEAD go to 9 9 - Replace the oil filter and repeat the pressure check with oil at 80°C. YES go to 10 NO go to 13 10 - The failure was fixed.
  • Page 240 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine 020434Y Fitting for oil pressure check 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.
  • Page 241 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 242 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and free from wear.
  • Page 243 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit value allowed: 0.1 mm Refitting - Make sure the gasket is in the correct position.
  • Page 244 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body. Locking torques (N*m) Screws fixing oil pump to crankcase 5 - 6 - Insert the countershaft with gearing into the fly- wheel-side half-crankcase.
  • Page 245 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Remove the six screws and the pump cover with a screwdriver. - Unscrew the water pump rotor with an 8-mm wrench. - Place two flat blade screwdrivers as shown in the...
  • Page 246 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 247 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 248 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Place two flat blade screwdrivers as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal, pressure- fitted on the rotor shaft. CAUTION...
  • Page 249 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - 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.
  • Page 250 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine Fitting OVERALL SEAL FITTING CAUTION CLEAN ALL THE COMPONENTS 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.
  • Page 251 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Fit the pump cover with a new 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.
  • Page 252 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Engine - Screw the rotor. Locking torques (N*m) Water pump rotor 4 ÷ 5 - Fit the pump cover with a new gasket, lubricate the gasket previously with petroleum jelly grease. - Tighten the six cover screws to the prescribed torque.
  • Page 253 INDEX OF TOPICS INJEC NJECTION...
  • Page 254 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.
  • Page 255 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection - Coolant temperature - Intake air temperature - Lambda probe The system implements cold engine idle fuel/air mixture correction with a stepper motor on a by-pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time, thereby ensuring the idle steadiness and the proper combustion.
  • Page 256 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection The control unit is fitted with a self-diagnosis sys- tem connected to a warning light on the instrument panel. Failures are detected and restored by the diagnostic tester. In any case, when the fault is no longer present, data storage is automatically wiped clean after 16 cycles of use (cold starting, running at regular engine temperature, stop).
  • Page 257 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 8. In the event of ignition problems, begin troubleshooting from the battery and the injection system connections. 9. Before disconnecting the RIU control unit connector, perform the following steps in the order shown: - Set the switch to «OFF»...
  • Page 258 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection c. Wrong reset of the throttle valve position sensor 2. Failures in the RIU system may be caused by loose connectors. Make sure that all connections are properly implemented. Check the connectors as follows: A: check that the terminals are not bent.
  • Page 259 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 23. Ground sensors (Grey-Green) 24. Lambda probe positive (Green-Blue) 25. Not connected 26. Battery powered (Red-Green) 27. Engine stop warning light (Blue) 28. CAN H line (Pink-Red) 29. Immobilizer aerial (Orange-White) 30. Starter button (Purple) 31.
  • Page 260 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 16. Stop buttons lever and brake pedals 22. engine stop switch 23. Stop light relay 24. Electric fan relay 25. Electric fan 31. Main fuses 32. Battery 33. Start-up relay 35. Fuse No. 13 36.
  • Page 261 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 1. Instrument panel 11. Starter button 13. Secondary fuses 16. Stop buttons lever and brake pedals 22. engine stop switch 23. Stop light relay 24. Electric fan relay 25. Electric fan 31. Main fuses 32.
  • Page 262 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 55. Injector 56. Engine temperature sensor 57. Fuel pump 62. Tip over sensor 63. Diagnostic socket 64. Injection ECU 65. Immobilizer aerial 66. Warning light unit Troubleshooting procedure Engine does not start...
  • Page 263 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Possible Cause Operation Stepper throttle valve position intake air temperature (steps and actual opening) Cleaning of the auxiliary air pipe and throttle valve; air filter ef- ficiency Engine stops at idle ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW...
  • Page 264 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe...
  • Page 265 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Possible Cause Operation Lambda probe Power to spark plug Spark plug Shielded cap HV Cable HV Coil Intake system Air filter Filter box (sealing) Intake sleeve (sealing) Parameter reliability Throttle valve position signal...
  • Page 266 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. Remove the fast-release fitting from the injector support INJEC - 266...
  • Page 267 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Remove the injector connector. Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. Remove the ECU RIU connector. INJEC - 267...
  • Page 268 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Remove the gas command fitting as indicated in the picture Pump supply circuit 1. Injection ECU 2. Lambda probe INJEC - 268...
  • Page 269 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 3. Engine rpm sensor 4. Engine temperature sensor 5. Injector 6. HV coil 7. Fuel pump 8. Electric fan 9. Electric fan relay 10. Injection load relay 11. Fuse No. 10 12. Ignition switch contacts 13.
  • Page 270 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Check the efficiency of the injection load solenoid. Check the resistance of the energising coil be- tween pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
  • Page 271 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Check the presence of fixed voltage between the Red-Green cable of the solenoid base and ground. If there is none, check the continuity of the Red- Green cable between the fuse box (No. 6 10A) and the remote control base.
  • Page 272 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Circuit leak 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.
  • Page 273 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Remove the clamp fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support...
  • Page 274 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Inspecting the injector circuit 1. Injection ECU 2. Lambda probe 3. Engine rpm sensor 4. Engine temperature sensor 5. Injector 6. HV coil 7. Fuel pump 8. Electric fan 9. Electric fan relay 10.
  • Page 275 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Check the efficiency of 7.5 A fuse No. 6 injection load. Check that the live control unit power supply 7.5A fuse No. 10 works properly. Check the efficiency of the injection load solenoid.
  • Page 276 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Check the power supply line of the injection loads relay energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Pur- ple cable of the relay base.
  • Page 277 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection With the control unit and the injector disconnected, check if there is continuity in the Red-Yellow cable between pin 5 of the control unit connector and the injector connector. Switch to «ON» and check if there is voltage, with...
  • Page 278 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Install the specific tool to check the fuel pressure and position the manifold on a graduated container of at least 100 cm³. Connect the injector with the cable as part of the kit for the injection tester. Con- nect the clamps of the cable to an auxiliary battery.
  • Page 279 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection - an electronic control unit - immobilizer aerial - master key with built-in transponder - service key with built-in transponder - HV coil - diagnosis LED The diagnosis LED also works as a theft-deterrent blinker.
  • Page 280 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection With the key switch in the ON position: • if there is battery voltage between ter- minals 7-4, 15-4 and terminal 4-chas- sis ground (fixed power supply). If there is no voltage, check the ignition switch contacts and that fuses No.
  • Page 281 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 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. With the ignition key switch at «ON» check if there is battery voltage between the Red-White and Black cables.
  • Page 282 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 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.
  • Page 283 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection ted but with a limitation imposed on the number of revs. 2. Previously unused control unit - transpond- er absent or cannot be used: the LED is on permanently. In this condition no operations are possible including the start up of the vehicle.
  • Page 284 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Code 1 A one-flash code indicates a system where the se- rial line is not present or is not detected. Check the Immobilizer antenna wiring and change it if nec- essary. Code 2 A two-flash code shows a system where the con- trol unit does not show the transponder signal.
  • Page 285 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Tachometer 1. Injection ECU 2. Engine speed sensor PIN RELATIONSHIP Component Reference value Engine revolution sensor 100 ÷ 150 Ohm ~ 20°C With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 12 - 13 is between 100 and 150 Ohm at an engine temperature of approxi- mately 20°...
  • Page 286 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection HT coil 1. Injection ECU 2. Lambda probe 3. Engine rpm sensor 4. Engine temperature sensor 5. Injector 6. HV coil 7. Fuel pump 8. Electric fan 9. Electric fan relay 10. Injection load relay 11.
  • Page 287 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure. With the engine at idle, the ignition advance is optimised to stabilise the speed at 1500 ± 100 rpm.
  • Page 288 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Check the power supply line of the injection loads relay energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Pur- ple cable of the relay base.
  • Page 289 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Switch to «ON» and check if there is voltage, for about 2 seconds, between pin 8 and 7 and between pin 8 and 15 of the control unit. Check that the resistance of the primary coil be-...
  • Page 290 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 020330Y Stroboscopic light for timing checking Proceed as follows: - Remove the transmission compartment cover as described in the "automatic transmission" chapter. - Remove the TDC reference inspection cap be- tween flywheel and crankcase cover. See the "fly- wheel cover"...
  • Page 291 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection - Refit the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the «parameters» function in this menu. - Select the stroboscopic light control in the tradi- tional four-stroke engine position (1 spark, 2 revs).
  • Page 292 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection PIN RELATIONSHIP Component Reference value Engine temperature sensor 1965 to 2500 Ohm at 20°C; 561.1 to 590.5 Ohm at 60°C; 227.3 ÷ 235.1 mm at 90°C With the connector on the control unit side disconnected and the coolant temperature sensor connector connected, check that the resistance values between pins 22 and 23 correspond to the engine tem- perature, as shown in the table.
  • Page 293 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection Connect the diagnosis instrument and switch to «ON». On the instrument, select the function «TPS RE- SETTING». Make sure that the throttle valve with the control is supporting the stop screw, as shown in the picture.
  • Page 294 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Injection 2. Lambda probe 3. Engine rpm sensor 4. Engine temperature sensor 5. Injector 6. HV coil 7. Fuel pump 8. Electric fan 9. Electric fan relay 10. Injection load relay 11. Fuse No. 10 12.
  • Page 295 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 296 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.
  • Page 297 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions • 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 the picture. • Remove the right upper screw and the left bottom screw of the parallelogram unit.
  • Page 298 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) • Fit the bracket locking the parallelo- gram in the holes of the previously re- moved screws; use the screws sup- plied with the tool and be careful to correctly centre the spacer in the bear- ing.
  • Page 299 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions • Fit the frame locking bracket • Make sure the frame is adequately centred by checking with a gauge that the lugs along the vertical axis show the standard protrusion. • Check that the pointers of both tyres are correctly aligned, as shown in the picture.
  • Page 300 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Front Removing the front wheel - Remove the five screws that fix the wheel. Front wheel hub overhaul - Remove the wheel. - Remove the brake calliper. - Remove the cotter pin and the cap.
  • Page 301 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions - Unscrew the fixing nut. - Remove the wheel hub. - Remove the ball bearing check Seeger ring indi- cated in the picture Extract the ball bearing using the specific tool Specific tooling...
  • Page 302 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) - Remove the oil seal on the roller bearing side using a screwdriver - Remove the roller bearing using the specific tool Specific tooling 020376Y Adapter handle 020456Y Ø24 mm adaptor 020363Y 20 mm guide...
  • Page 303 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Refitting the front wheel Refit the hub and tighten the five screws of the wheel to the specified torque. Locking torques (N*m) Wheel fixing screw 20 - 25 Handlebar Removal - Remove the 2 handlebar covers working as ex- plained in the Bodywork Chapter.
  • Page 304 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Removal - Remove the fixing of the brake pipes from the shock absorber bracket. - Unscrew the two rear fixings of the mudguard support arm. - Unscrew the front fixing and remove the arm complete with the mudguard and the suspension block device support pipe.
  • Page 305 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions - Unscrew the upper retainer and remove the shock absorber. Refitting Follow the removal steps but in reverse order; be careful to tighten the retainers to the prescribed torques. Locking torques (N*m)
  • Page 306 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) - Unscrew the fixing bolt of the sensor to remove - Unscrew the two fixing of the shock absorber to the support. - Remove the seeger stop ring of the support. - Remove the shock absorber-brake calliper sup- port and collect the washer and the O-ring.
  • Page 307 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Lower shock absorber clamp 19 to 26 The tilt mechanism Hydraulic system layout When roll is locked, the gear motor activates the hydraulic pump indicated in the picture and pres- surises the circuit.
  • Page 308 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Steering tubes Remove the brake calliper pipe retainers and the hydraulic pipe fitting from the brake calliper making sure there is a container to collect the brake fluid. Disconnect the tone wheel connector indicated in the picture.
  • Page 309 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 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.
  • Page 310 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Remove first the flexible part of the calliper from the steering tube as shown in the picture, and then remove the rigid part. - Remove the leg shield back plate. - Disconnect the ABS sensor connector, placed under the parking brake.
  • Page 311 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 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.
  • Page 312 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Remove the steering tube lower ring nut and the protection cap indicated in the picture. Now the steering tube can be removed. Check that the roller tapered bearing does not show signs of abnormal wear. If it does, replace it.
  • Page 313 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions THE OPERATIONS DESCRIBED BELOW CAN 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.
  • Page 314 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) For refitting, follow the operations for removal but in reverse order, observing the prescribed torque and greasing the bearings and their seats. STEERING TUBES Name Torque in Nm Side headstock upper ring nut...
  • Page 315 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 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. To facilitate the operations indicated below, re- move the suspension locking electronic control unit indicated in the picture.
  • Page 316 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Remove the arm coupling 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.
  • Page 317 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 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. SUSP - 317...
  • Page 318 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Check the 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. For refitting, follow the operations for removal but...
  • Page 319 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Geared motor and Suspension locking system Before removing the gear motor: Disable the suspension lock. Remove the legshield. With the set nut indicated in the picture, remove the tensioning cable of the suspension locking me- chanical calliper.
  • Page 320 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) IF BRAKE FLUID GETS ACCIDENTALLY IN CONTACT WITH YOUR EYES, RINSE WITH ABUNDANT FRESH WA- TER AND SEEK MEDICAL ADVICE IMMEDIATELY. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN. Remove the 3 fixing screws indicated and remove the whole gear motor.
  • Page 321 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions In the new solution to fix the pump to the suspen- sion lock assembly, the retainers fixing the pump body to the assembly and the clamp fixing the pump joint have been modified as shown the fig- ures below.
  • Page 322 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Undo the two potentiometer screws. Upon refitting, plug the potentiometer in D-type connector, afterwards place it with its electric con- nection directed to the opposite side of the pump. Remove the nut indicated in the figure, if neces- sary lock the lever with a vice making sure not to spoil the surface.
  • Page 323 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Remove the four screws indicated in the figure, remove the flexible transmission supporting brack- et, separate the two crankcase halves, if neces- sary, use a rubber mallet to hit the flexible transmission lever in order to separate the two crankcases.
  • Page 324 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) 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 flex- ible transmission lever control shaft.
  • Page 325 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Extract the bearing of the spring/toothed sector unit with the specific tool. Specific tooling 001467Y002 Driver for OD 73 mm bearing Extract the bearing of the electric motor with the specific tool.
  • Page 326 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Refit the spring/toothed sector unit, hold the crank- case in a perfectly horizontal and stable position, place the spring/toothed sector unit keeping it per- fectly perpendicular to the bearing already fitted on the crankcase;...
  • Page 327 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Refit the electric motor; check the position is cor- rect by means of the reference indicated during removal. The motor should be so positioned that it does not protrude from the reduction unit mould, see figure.
  • Page 328 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Remove the two bracket screws after releasing the spring and freeing the flexible transmission adjust- ment. It is very important to remove the flexible trans- mission from its fitting only for replacement.
  • Page 329 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 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.
  • Page 330 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) - Connect the diagnostic tool. - Perform the troubleshooting of the lower stop and follow the indications given by the diagnostic tool. - The parameter adjustment of the relative angle must be performed by acting on the screw indica- ted in the picture, after having removed the lower protection cap.
  • Page 331 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions - Proceed with the reset of the potentiometer fol- lowing the indications given by the diagnostic tool. - The adjustment of the flexible transmission must be performed so that a small clearance is left to guarantee switch activation on the roll lock calliper.
  • Page 332 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) 10. + Battery 11. + Key 12. To light switch 13. 20 A Fuse No. 3 14. Light relay 15. Pressure switch 16. Horn relay 17. Instrument panel / Warning light module 18.
  • Page 333 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 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 gear motor connector With the interface wiring disconnected from the...
  • Page 334 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) 0: REST POSITION 1: LOCKING POSITION 2: UNLOCKING POSITION 3: ROLL LOCK-UNLOCK SWITCH With the interface wiring disconnected from the control unit, check the continuity of the electrical lines between the interface wiring and the roll lock-...
  • Page 335 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Check the continuity between the black cable on the connector and a ground point on the chassis. With a multimeter, check the operation of the tilt locking-unlocking switch referring to the diagram indicated in the figure.
  • Page 336 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) With the interface wiring connected to the control unit, secure the vehicle on its centre stand and switch to "ON". Select the reading scale on 20 V. Insert the multimeter probes on pins 17 and 25.
  • Page 337 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 1: RIDER DETECTION SENSOR With the interface wiring disconnected from the control unit and connected to the system, check the following conditions: pin 17 - 36: resistance 15 - 18 kOhm when the rider is not seated on the saddle.
  • Page 338 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) 1: ROLL LOCK CALLIPER SENSOR The roll lock calliper sensor is a normally opened switch. Check its correct operation with a multi- 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.
  • Page 339 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Also check that the flexible transmission control lever activates the limit stop switch properly. SENSORE RUOTA FONICA 1: Right tone wheel 2: Left tone wheel SUSP - 339...
  • Page 340 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) With the interface wiring disconnected from the parking electrical control unit and connected to the system, check that the sensor resistance between pins 23 - 17 and 24 - 17 is between 774 and 946 Ohm at approximately 20°...
  • Page 341 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions In case of failures, check the continuity between pin 23 and the connector green cable on the fuel tank after removing the chassis central cover; be- tween pin 17 and the yellow cables on both con- nectors;...
  • Page 342 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) 1: PRESSURE SWITCH 2: HORN SOLENOID 3: FUSE No. 11, 7.5A Check that the 7.5A fuse No. 11 works properly. With interface 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.
  • Page 343 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Check the continuity of the yellow-red cable be- tween the pressure switch connector and the fuse box (7.5A fuse No. 11) and between the remote control base and the fuse box (7.5A fuse No. 11).
  • Page 344 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) - Undo the two screws fixing the clamp to the cen- tre stand. - Undo the two screws fixing the clamp to the en- gine. SUSP - 344...
  • Page 345 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions - Undo the two fixing screws of the ABS sensor support and remove it. * * ONLY FOR THE VEHICLE VERSION EQUIP- PED WITH ABS - ASR SYSTEM. - Unscrew the clamp.
  • Page 346 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) - Undo the upper fixing of the right shock absorber and remove it. - Remove the wheel. - If also the plastic of the side fairings has been removed previously, to allow the removal of the wheels, just pull aside the shock absorber towards the front part of the vehicle.
  • Page 347 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions 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. - Remove the silent-blocks.
  • Page 348 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) - Remove the retainer fixing the swinging arm to the frame: undo the screw. - Remove the pin. - Unscrew the nut of the set screw bushing. - From the inside loosen the set screw bushing until the swinging arm is free.
  • Page 349 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions - Check the entire swinging arm assembly. - Check all the components- Teflon bushings, si- lent-blocks, roller bushings, spacers. - Replace the work components that cause exces- sive clearance on the rear suspension.
  • Page 350 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) - Remove the pin connecting the engine swinging arm - frame swinging arm. The operations below are described once but ap- ply to both sides of the swinging arm. - Remove the internal spacer.
  • Page 351 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assembly both arms with the appropriate bolt - Adjust the bolt as shown in the photograph - Place the swinging arm, frame side, with the pro-...
  • Page 352 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Refitting For correct installation of the swinging arm on the vehicle, proceed as follows: 1. Position the silent bloc support bracket with part 3 inserted and lightly tighten part 1 2. Position the swinging arm, inserting part 2 3.
  • Page 353 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions SWINGING ARM FITTING Name Torque in Nm Part 1 98 ÷ 118 Part 3 5 ÷ 7 Part 4 88.5 ÷ 108 Part 5 54 ÷ 60 Bolt for swinging arm, engine side / swinging arm, frame side 32.5 ÷...
  • Page 354 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Suspensions (2015) Refitting Carry out the previous operations but in reverse order. Locking torques (N*m) Lower shock absorber clamp 33 - 41 Upper shock absorber retainer 33 - 41 Centre-stand - Remove the exhaust end.
  • Page 355 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Suspensions Locking torques (N*m) Centre stand bolt 31 - 39 SUSP - 355...
  • Page 356 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 357 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.
  • Page 358 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) A = Rear brake circuit B = Front brake circuit BRAK SYS - 358...
  • Page 359 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system C = Integral brake circuit 1. Rear brake pump ø 12.7 mm 2. Front brake pipes (front brake pump - front valve) 3. Front brake pump ø 14 mm 4. Rear brake pipes (rear brake pump - rear valve) 5.
  • Page 360 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) 1. Front brake pipes 2. Rear brake pump ø 11 mm BRAK SYS - 360...
  • Page 361 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system 3. Front brake pump ø 12 mm 4. Rear brake pipes (rear brake pump - rear valve) 5. Front valve 6. Front brake left calliper ø 30 mm 7. Front valve brake pipes (front valve - rigid pipes) 8.
  • Page 362 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) CF = ABS modulator pipes - front valve CR = ABS modulator pipes - rear valve FWL = ABS modulator pipes - front left brake cal- liper FWR = ABS modulator pipes - front right brake...
  • Page 363 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system CF = ABS modulator pipes - front valve CR = ABS modulator pipes - rear valve FWL = ABS modulator pipes - front left brake cal- liper FWR = ABS modulator pipes - front right brake...
  • Page 364 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) CF = ABS modulator pipes - front valve CR = ABS modulator pipes - rear valve FWL = ABS modulator pipes - front left brake cal- liper A = Left brake pump pipes...
  • Page 365 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system RW = ABS modulator pipes - rear brake calliper CAUTION THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION NOT EQUIPPED WITH ABS - ASR SYSTEM. BRAK SYS - 365...
  • Page 366 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) 1. LEFT PUMP PIPES TO REAR VALVE 2. RIGHT PUMP PIPES TO FRONT VALVE BRAK SYS - 366...
  • Page 367 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system 1. LEFT PUMP PIPES TO REAR VALVE 2. RIGHT PUMP PIPES TO FRONT VALVE 3. FRONT VALVE PIPES TO REAR VALVE 4. FRONT BRAKE PIPES BRAK SYS - 367...
  • Page 368 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) 1. FRONT PRESSURE ADJUSTMENT 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.
  • Page 369 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system 1. PEDAL BRAKE PUMP 2. BRAKE 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.
  • Page 370 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) BRAK SYS - 370...
  • Page 371 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system CAUTION THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION EQUIPPED WITH ABS - ASR SYSTEM. Operating diagram 1. Battery 2. Fuse No. 13 3. Fuse No. 14 4. Ignition switch 5. Fuse No. 10 6.
  • Page 372 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) 7. Instrument panel 8. Rear wheel ABS sensor 9. Front left wheel ABS sensor 10. Front right wheel ABS sensor 11. ABS control unit 12. CAN L line 13. CAN H line...
  • Page 373 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system The detection of malfunctions may require more or less time depending on the type of fault. Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time.
  • Page 374 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) Error Description Troubleshooting code 5DA5 Rear wheel speed sensor - identified Faulty sensor, tone wheel defect or with wrong number of teeth or wrong speed excessive tyre size. 5DC0 Front right wheel speed sensor - Electrical fault in sensor or cable harness.
  • Page 375 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system - By unscrewing the relative nuts, remove and plug the brake oil pipes in the numbered sequence in- dicated in the picture. N.B. PAY ATTENTION TO THE LOSS OF BRAKE FLUID DURING THE REMOVAL OF THE PIPING FROM THE MODULATOR.
  • Page 376 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) - Lift the ABS modulator support to unscrew the two lower fixing screws. - Remove the ABS modulator. MODULATOR INSTALLATION To install the abs modulator, repeat the operations described in the removal in reverse order, paying close attention when inserting the piping.
  • Page 377 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system • SWITCH «1»: on / off. • WARNING LIGHT «2»: operating indi- cation warning light. Flashing mode: - Off with the vehicle in gear: the system is working, but is not active (normal condition).
  • Page 378 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) THE ASR SYSTEM IS ACTIVATED AT EVERY «ON» POSI- TIONING OF THE IGNITION SWITCH. IF DISABLED BY THE USER, THE ASR SYSTEM KEEPS THE STATE OF INACTIVITY ONLY IF THE VEHICLE IS OFF, BY USING THE ENGINE STOP SWITCH;...
  • Page 379 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system In order to maintain the effectiveness of the ASR system following the replacement of one or more tyres a calibration procedure of the system must be performed as follows on a straight flat stretch of road.
  • Page 380 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) - For an easier operation, previously remove the calliper support plate by acting on the safety locks and unscrewing the two fixing bolts as indicated in the picture. Refitting To fit the rear brake calliper, follow the removal steps but in reverse order; be careful to tighten the screws to the prescribed torque.
  • Page 381 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system Rear brake calliper fixing screws 41.5 to 51.5 Calliper support plate fixing screws xxx to xxx Front brake calliper Removal - The operations described refer to only one cal- liper but apply to both.
  • Page 382 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) - Remove the calliper supporting clamp. BRAK SYS - 382...
  • Page 383 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system - Remove the brake disc Refitting - To fit the rear brake disc, follow the removal steps but in reverse order; be careful to tighten the screws to the prescribed torque using threadlock.
  • Page 384 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) 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.
  • Page 385 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system Refitting - To fit the front brake disc, follow the removal steps but in reverse order; be careful to tighten the screws to the prescribed torque using threadlock. Recommended products Loctite 243 Medium strength threadlock...
  • Page 386 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) 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.
  • Page 387 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system Removal Proceed as follows: - Remove the rear brake calliper. - Remove the two pins holding the brake pads. - Remove the pads, paying attention to the pad re- taining spring.
  • Page 388 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) Brake pipes FRONT BRAKE CALLIPER PIPES REMOVAL - The operations described refer to only one cal- liper but apply to both. - Disconnect the brake pipes from the calliper and drain the brake fluid.
  • Page 389 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system Parking brake - Remove the rear wheel. - Loosen the transmission set screw and release the cable from the calliper. - Undo the two fixing screws of the mechanical calliper and remove it.
  • Page 390 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Braking system (2015) - After removing the leg shield back plate, remove the engaging cable for the safety mechanism re- moving it from its fitting. - During refitting pay special attention to the correct insertion of the metallic drum in its seat, as shown in the picture.
  • Page 391 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Braking system - Remove the parking brake cable from the lever by operating the set screw. BRAK SYS - 391...
  • Page 392 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 393 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Cooling system N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.
  • Page 394 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Cooling system (2015) In this case, the flow is consistent in the expansion tank as well, and this ensures a continuous automatic venting. For the system venting during the circuit filling step, there is a special union at the top of the head (see filling rules).
  • Page 395 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Cooling system - If the electric fan is certainly efficient, check the ventilation start and stop temperatures. - Select the «PARAMETERS» function in this menu to display the coolant temperature. Electric fan starts: 107°C Electric fan stops: 103°C...
  • Page 396 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Cooling system (2015) - Use a transparent hose to connect the venting union with the expansion tank filler. - Loosen the vent and start the engine. - Keep it open until the air has been fully vented.
  • Page 397 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Cooling system • Remove the water pump cover shown in the figure by loosening the 6 fasten- ing screws. • Proceed to partially drain the circuit as described in the "Engine" Chapter. •...
  • Page 398 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA Cooling system (2015) CAUTION THIS OPERATION MUST 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»...
  • Page 399 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Cooling system 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.
  • Page 400 INDEX OF TOPICS CHAS HASSIS...
  • Page 401 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.
  • Page 402 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis Rear handlebar cover - Remove the upper handlebar cover. - Remove the four indicated screws fixing the lower handlebar cover to the handlebar. - Disconnect the environment temperature sensor connector. - Remove the handlebar cover sliding it off towards the rear part of the vehicle.
  • Page 403 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis Front handlebar cover - Remove the rear-view mirrors. - Remove the central plug of the handlebar cover, fixed to the fitting. - Undo the three underlying screws. - Undo the two screws in the lower part of the han- dlebar.
  • Page 404 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the windshield. - Remove the central cover fixed to the joints on the legshield. - Remove the two indicated daylight running light fixing screws. - Remove the daylight running light by disconnect- ing the connector.
  • Page 405 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Disconnect the connector and remove the head- light. TURN INDICATORS - Remove the legshield. - Remove the fixing nut inside the shield, paying attention to collect the spacer, the washer and the support plastic of the turn indicator.
  • Page 406 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the rear retainer on both sides. - Open the fuel tank access cover and temporarily undo the plug to lift the central cover. - Disconnect the cover opening transmission and slide off the rider presence sensor wiring to re- move it.
  • Page 407 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the two indicated screws from both sides of the vehicle, located inside the wheel housing. - Detach the shield from the vehicle, complete with side bumpers and turn indicators and disconnect the connectors of the turn indicators.
  • Page 408 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Unscrew the two central screws and remove the button unit by disengaging the fittings and lifting it upwards. - Disconnect the two connectors. - Undo the two screws indicated. - Remove the leg shield back plate cover by slight- ly lifting it upwards to loosen the fittings.
  • Page 409 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the screw shown in the figure and placed inside the leg shield back plate, on both sides. - Unscrew the indicated screw, then, if present, re- move the key from the switch and the switch plate.
  • Page 410 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Temporarily undo the expansion tank plug to al- low the removal of the upper part of the leg shield back plate, complete with instrument panel and warning lights unit. For an easier operation, alter- nately turn the handlebar in the two directions.
  • Page 411 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the cable grommet clamp, and collect the washer, located in the upper part. - Remove on both sides the cover located near the footrest and unscrew the underlying screw. - Lift the front part of the footpeg cover rubbers and unscrew the underlying screws.
  • Page 412 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Unscrew the two indicated screws to remove the lower guard. - Undo the indicated screw to remove the central plastic. See also Legshield Taillight assy. - Remove the side fairings. - Remove the two screws inside the fairing for each side and then the external one to remove the light assembly.
  • Page 413 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the license plate support. - Remove the indicated clamp and collect the washer and the support plastic of the turn indica- tor. WARNING DURING REFITTING, PAY PARTICULAR ATTENTION TO THE CORRECT ALIGNMENT OF THE TURN INDICATOR WITH THE OTHER PLASTICS, REFERRING TO THE FIT- TINGS ON THEM.
  • Page 414 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the indicated screw. - Remove the upper clamp and collect the washer. - Remove the footpeg. CAUTION FOR THE LEFT FOOTPEG, SLIDE OFF THE FUSE HOLDER BOX FROM THE FITTINGS ON THE PLASTIC.
  • Page 415 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis For each of the two fairings, proceed as follows: - Undo the lower rear screw. - Undo the upper rear screw. - Undo the fixing screw at the rear mudguard/li- cense plate holder.
  • Page 416 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - The fairing is now loose, however to facilitate the removal it can be useful to unscrew the central cover screw, indicated in the figure. - Then remove the fairing, by first moving it to-...
  • Page 417 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the two screws indicated. - Remove the indicated screw on both sides to re- lease the license plate support. - Disconnect the connectors of the turn indicators. - Release the wiring of the license plate lights from the fitting inside the support, then slide it off to- gether with the saddle opening linkage.
  • Page 418 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the two indicated screws on both sides. - Remove the two rear fastening screws. - Slightly lift the helmet compartment to disconnect the light connector and the saddle release linkage.
  • Page 419 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Slide off the rider presence sensor wiring and disconnect the compartment lighting button con- nectors. - Working on the right side, slide off the rubber protection and disconnect the plug socket connec- tor.
  • Page 420 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the four screws indicated and recover the related spacers. - Undo the two screws indicated, then remove the spoiler. See also Headlight assy. Fuel tank - Remove the central chassis cover.
  • Page 421 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the two lower bracket retainers indicated in the figure. - Disconnect the electric wiring and the fuel pipes. See also Frame central cover Footrest Handles and top side fairings - Unscrew the two indicated screws and collect the washers.
  • Page 422 - Unscrew the two indicated screws and collect the relative washers. Radiator cover FRONT COVER - Remove the Piaggio clip-on badge, fixed to the joint, by acting on the indicated slot. - Remove the indicated screw and remove the ra- diator grille frame.
  • Page 423 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Unscrew the four indicated screws and remove the radiator grille. - Working on both sides of the vehicle, remove the two screws in the wheel housing. - Unscrew the four indicated screws and remove the front radiator cover.
  • Page 424 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Chassis - Remove the two lower clamps. - Remove the two upper clamps. - 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.
  • Page 425 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 426 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Pre-delivery Carry out the listed checks before delivering the motorcycle. Warning - Handle fuel with care. Fit the plastic cover supplied on the joint on the steering tube as shown in the figure.
  • Page 427 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Pre- delivery ASR warning light «2» turning on with slow flash- ing. • Accelerate to a constant speed of 30 to 40 km/h and maintain it for at least to 8 seconds. The con-...
  • Page 428 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Pre-delivery - Lower screw fixing right shock absorber to supporting plate - Lower screw fixing left shock absorber to engine - Screws fixing muffler supporting arm to engine Front brake - Screws fixing brake disc to left wheel...
  • Page 429 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Pre- delivery IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN- DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL.
  • Page 430 MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Pre-delivery CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST. Functional inspection Functional Checks: • Hydraulic braking system: lever travel • Clutch: proper functioning check • Engine: proper general functioning and no abnormal noise check •...
  • Page 431 ABS: 371 Air filter: 42 Battery: 91, 104, 116, 117 Brake: 361, 379, 381, 384–386, 388, 389 Bulbs: Checks: 98 Coolant: 291, 395 Display: Electric: 394 Engine oil: 42 Fuel: 265, 272, 420 Fuses: 112 Headlight: 48, 403, 407, 420 Horn: 107 Hub oil: 41 Identification: 8...
  • Page 432 Start-up: Suspension: 55, 56, 319 Switch: Tank: 420 Technical Data: Transmission: 10, 54, 144, 159 Turn indicators: 97 Tyres: 11 Vehicle: 8, 129, 131...

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