PIAGGIO MP3 400 i.e. Service Manual
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PIAGGIO MP3 400 i.e. Service Manual

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Table Of Contents
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Table of Contents

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

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  • Page 1 SERVICE STATION MANUAL 664502(IT)-664503(EN)-664504(FR)-664505 (DE)-664506(ES)-664507(PT)-664508(NL)-664509 (EL) MP3 400 i.e.
  • Page 2 Not all versions shown in this publication are available in all Countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 SERVICE STATION MANUAL MP3 400 i.e. This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera 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 TIME...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    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 9 MP3 400 i.e. Characteristics Vehicle identification Chassis prefix (A) ZAPM59101 Engine prefix (B): M474M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 253 ± 5 kg Maximum weight allowed 445 kg Maximum height 1.225 mm Width 745 mm Wheelbase 1.550 mm Length...
  • Page 10 MP3 400 i.e. Characteristics Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke Cubic capacity 399 cm³ Bore x stroke 85.8 X 69 mm Compression ratio 10.6 ± 0.5 : 1 Engine idle speed 1,500 ± 100 rpm Timing system Four valves, single overhead camshaft, chain driv- Valve clearance Inlet: 0.15 mm Outlet: 0.15 mm...
  • Page 11 MP3 400 i.e. Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission Automatic expandable pulley variator with torque server, V belt, automatic clutch. Final reduction Gear reduction unit in oil bath. Capacities CAPACITY Specification Desc./Quantity Engine oil 1.7 l Transmission oil 250 cm³ Cooling system fluid ~ 1.8 l Fuel tank (reserve)

  • Page 12: Wheels And Tyres

    MP3 400 i.e. Characteristics Brakes BRAKES Specification Desc./Quantity Front brake Ø 240 mm double disk with hydraulic control acti- vated by the handlebar right-hand lever. Rear brake disc brake, diameter 240 mm, with hydraulic servo operated from the handlebar with the left-hand lev- Wheels and tyres WHEELS AND TYRES Specification...

  • Page 13: Table Of Contents

    MP3 400 i.e. Characteristics Name Torque in Nm Screws fixing arms to side headstocks 45 ÷ 50 Screws fixing arms to central headstock 45 ÷ 50 Screws fixing the half-arm coupling flange 20 ÷ 25 Fixing screws for tilt locking disc section 20 ÷...

  • Page 14: Table Of Contents

    MP3 400 i.e. Characteristics REAR BRAKE Product Description Specifications (°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium- strength threadlock MUFFLER Name Torque in Nm Muffler heat guard fixing screw 4 ÷ 5 Screw for fixing muffler to the support arm 20 ÷...

  • Page 15: Transmission Cover

    MP3 400 i.e. Characteristics Name Torque in Nm Outside transmission cover screws 7 ÷ 9 Flywheel cover screws 11 - 13 FLYWHEEL COVER Name Torque in Nm Chain guide sliding block retain plate fastening 3 ÷ 4 screws Flywheel fixing nut 115 - 125 Stator retainers 8 - 10...
  • Page 16 MP3 400 i.e. Characteristics HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED Specification Desc./Quantity 43.2 mm 43 mm CYLINDER- PISTON Specification Desc./Quantity Cylinder diameter C 85.8 - +0.018 -0.01 mm Piston Ø P 85.768 ± 0.014 mm CYLINDER - PISTON COUPLING CATEGORIES Name Initials...
  • Page 17 MP3 400 i.e. Characteristics Check the size of the sealing ring opening: Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Rings/housing coupling clearances: Carefully clean the sealing ring housings.
  • Page 18 MP3 400 i.e. Characteristics TYPE B Specification Desc./Quantity Centre to centre distance of the gears without 76.907 ÷ 76.837 clearance Centre to centre distance on the crankcase 76.992 ÷ 76.962 The gears with centre to centre distance without clearance between 76.867 and 76.907 are considered universal and can be fitted to either crankcase type.
  • Page 19 MP3 400 i.e. Characteristics Crankshaft alignment Specific tooling 020335Y Magnetic support for dial gauge MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission-side 1±0.025 D = 0.20 - 0.50 shoulder...
  • Page 20 MP3 400 i.e. Characteristics Slot packing system Shimming system for keeping the compression ra- DISTANCE «A» IS A PROTRUSION OR RE- CESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE. DISTANCE «A» HELPS DETERMINE THE THICKNESS OF GASKET «B» THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN OR- DER TO RESTORE COMPRESSION RATIO.
  • Page 21 MP3 400 i.e. Characteristics Product Description Specifications SPECIAL AGIP PERMANENT coolant Monoethylene glycol-based anti- fluid freeze fluid, CUNA NC 956-16 CHAR - 15...
  • Page 22 MP3 400 i.e. Characteristics CHAR - 16...
  • Page 23 INDEX OF TOPICS TOOL OOLING...
  • Page 24 MP3 400 i.e. Tooling SPECIFIC TOOLS CORRECT Stores code Description 001330Y Tool for fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Pliers to extract 17 mm ø bear- ings 001467Y014 Pliers to extract ø...
  • Page 25 MP3 400 i.e. Tooling Stores code Description 001467Y031 Bell 001467Y034 Extraction pliers for ø 15 mm bearings 001467Y035 Belle for OD 47-mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut...
  • Page 26 MP3 400 i.e. Tooling Stores code Description 020151Y Air heater 020193Y Oil pressure gauge 020201Y Spacer bushing driving tube 020262Y Crankcase splitting strip 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol TOOL - 4...
  • Page 27 MP3 400 i.e. Tooling Stores code Description 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020358Y 37x40-mm adaptor 020359Y 42x47-mm adaptor TOOL - 5...
  • Page 28 MP3 400 i.e. Tooling Stores code Description 020360Y Adaptor 52 x 55 mm 020364Y 25-mm guide 020376Y Adaptor handle 020382Y012 bush (valve removing tool) 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor TOOL - 6...
  • Page 29 MP3 400 i.e. Tooling Stores code Description 020434Y Oil pressure control fitting 020439Y 17 mm guide 020444Y Tool for fitting/ removing the driv- en pulley clutch 020456Y Ø 24 mm adaptor 020458Y Puller for lower bearing on steer- ing tube TOOL - 7...
  • Page 30 MP3 400 i.e. Tooling Stores code Description 020459Y Punch for fitting bearing on steer- ing tube 020460Y Scooter diagnosis and tester 020467Y Flywheel extractor 020468Y Piston fitting ring 020469Y Reprogramming kit for scooter diagnosis tester TOOL - 8...
  • Page 31 MP3 400 i.e. Tooling Stores code Description 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set TOOL - 9...
  • Page 32 MP3 400 i.e. Tooling Stores code Description 020478Y Punch for driven pulley roller cas- 020479Y Countershaft lock wrench 020480Y Petrol pressure check set 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide TOOL - 10...
  • Page 33 MP3 400 i.e. Tooling Stores code Description 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter 020565Y Flywheel lock calliper spanner Marelli MIU diagnosis software Marelli MIU diagnosis software 020640y software euro3 TOOL - 11...
  • Page 34 MP3 400 i.e. Tooling TOOL - 12...
  • Page 35 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 36: Maintenance Chart

    MP3 400 i.e. Maintenance Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequen- tially.
  • Page 37 MP3 400 i.e. Maintenance AFTER 10,000 KM; 50,000 KM; 70,000 KM Action Safety locks - check Driving belt - replacement Throttle lever - adjustment Air filter - clean Engine oil - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement Brake pads - check condition and wear...

  • Page 38: Checking The Spark Advance

    MP3 400 i.e. Maintenance 30,000 KM Action Safety locks - check Driving Belt - replacement Throttle lever - adjustment Air filter - clean Engine oil - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement Hub oil - check Brake pads - check condition and wear...
  • Page 39 MP3 400 i.e. Maintenance - Bring the reference mark onto the transmission side between the fan and the transmission cover as shown in the photograph. - Refit the spark plug. - Refit the plastic cap on the flywheel cover. - Adjust the spark gap to the contact position (no reference mark visible) and install it on engine be- tween the spark plug and spark plug cap - Connect the induction calliper on the spark gap...

  • Page 40: Spark Plug

    MP3 400 i.e. Maintenance Spark plug Remove the port on the left-hand side panel of the vehicle by undoing the fixing screw and using a small screwdriver in the rear recess shown in the figure, then do the following : - Disconnect the HV wire cap «A»...
  • Page 41 MP3 400 i.e. Maintenance Hub oil Check -Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tightening it completely; Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end;...

  • Page 42: Air Filter

    MP3 400 i.e. Maintenance Air filter Proceed as follows: 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 compressed air. - Soak it in a mixture of 50% petrol and 50% specified oil.
  • Page 43 MP3 400 i.e. Maintenance Replacement Replace oil and 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». Once all the oil has drained through the drainage opening, unscrew and remove the oil cartridge fil- ter «C ».
  • Page 44 MP3 400 i.e. Maintenance a few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

  • Page 45: Engine Oil Filter

    MP3 400 i.e. Maintenance Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoring the level from the MIN to the MAX marks requires approx.

  • Page 46: Checking The Ignition Timing

    MP3 400 i.e. Maintenance Checking the ignition timing -Remove the plastic cap on the flywheel cover -Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the fly- wheel cover as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure.
  • Page 47 MP3 400 i.e. Maintenance Recommended products AGIP PERMANENT SPEZIAL Coolant Monoethylene glycol based antifreeze solution, CUNA NC 956-16 Braking system Level check The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal;...

  • Page 48: Headlight Adjustment

    MP3 400 i.e. Maintenance CLOTHES. IF THIS HAPPENS ACCIDENTALLY, WASH WITH WATER. Recommended products AGIP BRAKE FLUID DOT4 Brake fluid FMVSS DOT4 Synthetic fluid Headlight adjustment Proceed as follows: - Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pres- sure, onto a flat surface 10 m away from a half-lit white screen;...
  • Page 49 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 50 MP3 400 i.e. Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION Possible Cause Operation Wrong valve adjustment Adjust the valve clearance properly...
  • Page 51 MP3 400 i.e. Troubleshooting Insufficient braking INEFFICIENT BRAKING SYSTEM Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and replace brake fluid if necessary.

  • Page 52: Noisy Suspension

    MP3 400 i.e. Troubleshooting Possible Cause Operation if they are recessed or if the balls are squashed, replace them. Noisy suspension NOISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy, check: the efficien- cy of the front shock absorbers;...
  • Page 53 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 54 MP3 400 i.e. Electrical system 1. Injection ECU 2. Immobilizer aerial 3. Lambda probe 4. Magneto flywheel 5. Voltage regulator 6. Engine stop switch 7. Radiator electric fan 8. Electrical fan remote control 9. Main fuses 10. 12V socket 11. Key switch contacts 12.
  • Page 55 MP3 400 i.e. Electrical system 20. Saddle opening actuator 21. Saddle opening receiver 22. Starter button 23. Stop button on rear brake 24. Stop button on front brake 25. Turn indicator switch 26. Hazard button 27. Hazard and turn indicator control device 28.
  • Page 56 MP3 400 i.e. Electrical system 49. Parking electronic control unit 50. Brake calliper sensor 51. Geared motor 52. Fuel level transmitter 53. «MODE» button 54. Rider presence sensor 55. Locking/unlocking switch 56. Injection load remote control 57. Fuel pump 58. Fuel injector 59.
  • Page 57 MP3 400 i.e. Electrical system Components arrangement ELE SYS - 5...
  • Page 58 MP3 400 i.e. Electrical system 1 - Relays for lights / horn / injection load / electric fan: remove the front shield to reach it. 2 - Auxiliary fuses: remove the footrest flap to reach these fuses. ELE SYS - 6...
  • Page 59 MP3 400 i.e. Electrical system 3 / 4 / 19 - Electronic control unit for injection (MIU) / Start-up relay / Start-up enabling switch relay: remove the lid of the helmet compartment to reach these relays. 5 / 6 / 10 - Fuel pump / Fuel level sensor / coil: remove the chassis central cover to reach these components.
  • Page 60 MP3 400 i.e. Electrical system 7 - Voltage regulator: remove the right side panel to reach it. 8 - Immobilizer: remove the shield back plate. 9 / 18 - Saddle opening receiver/ Turn indicator control device: remove the left fairing to reach them;...
  • Page 61 MP3 400 i.e. Electrical system 11 / 12 - Diagnostics socket/ main fuses: these components are found in the helmet compartment. 13 - Lambda probe: The lambda probe is mounted on the exhaust manifold. 14 - Engine oil pressure sensor: remove the ex- haust end to reach it.
  • Page 62 MP3 400 i.e. Electrical system 16 - Rider presence sensor: open the saddle and remove the cover to reach the rider presence sen- sor. 17 - Coolant temperature sensor: remove the lid of the helmet compartment and disconnect the con- nector to reach it.
  • Page 63 MP3 400 i.e. Electrical system Ignition 1. Injection ECU 2. Immobilizer aerial 9. Main fuses 11. Key switch contacts 12. Secondary fuses 15. Battery 56. Injection load remote control 62. HV coil ELE SYS - 11...
  • Page 64 MP3 400 i.e. Electrical system Battery recharge and starting 1. Injection ECU 4. Magneto flywheel 5. Voltage regulator 6. Engine stop switch 9. Main fuses 11. Key switch contacts 12. Secondary fuses 14. Fuse 15. Battery 16. Starter motor 17. Start-up remote control switch 18.
  • Page 65 MP3 400 i.e. Electrical system 36. Rear right light B. Stop light bulb Level indicators and enable signals section 1. Injection ECU 2. Immobilizer aerial 3. Lambda probe 9. Main fuses 11. Key switch contacts 12. Secondary fuses 15. Battery 44.
  • Page 66 MP3 400 i.e. Electrical system 56. Injection load remote control 58. Fuel injector 59. Potentiometer 60. Right wheel revolution sensor 61. Left wheel revolution sensor 64. Revolution sensor Devices and accessories 1. Injection ECU 7. Radiator electric fan 8. Electrical fan remote control 9.
  • Page 67 MP3 400 i.e. Electrical system 21. Saddle opening receiver 28. Wiring for antitheft device 29. Helmet compartment light switch 30. Helmet compartment light switch 33. Helmet compartment internal light 40. Pressure sensor 41. Horn remote control 42. Horn 43. Horn button 45.
  • Page 68 MP3 400 i.e. Electrical system Lights and turn indicators 9. Main fuses 11. Key switch contacts 12. Secondary fuses 13. Key switch contacts 15. Battery 25. Turn indicator switch 26. Hazard button 27. Hazard and turn indicator control device 31. Light switch 32.
  • Page 69 MP3 400 i.e. Electrical system 37. Front left turn indicator light 38. Headlight A. Tail light bulbs B. Low beam bulb C. High beam bulb 39. Front right turn indicator light 48. Instrument panel 49. Parking electronic control unit Checks and inspections This section is devoted to the checks on the electrical system components.
  • Page 70 MP3 400 i.e. Electrical system ignition switch is turned to the "ON" position, the deterring blinker function is deactivated. Subse- quently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition- key switch and/or the instrument panel is not initi- ated, check if:...
  • Page 71 MP3 400 i.e. Electrical system • There is continuity between terminals 12-18 with the emergency cut-off switch in the RUN position. If there is no continuity check the contacts of the switch. If no faults are found, replace the electronic control unit.
  • Page 72 MP3 400 i.e. Electrical system With MIU connector disconnected check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring . Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly.
  • Page 73 MP3 400 i.e. Electrical system Characteristic MASTER key: RED KEY SERVICE key. BLACK KEY Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
  • Page 74 MP3 400 i.e. Electrical system LED remains permanently OFF. The engine can be started. 5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on permanently. The engine cannot be started. The codes that can be transmitted are: •...
  • Page 75 MP3 400 i.e. Electrical system Diagnostic code - 3 flashes The three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit.
  • Page 76 MP3 400 i.e. Electrical system 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator. Recharge system voltage check Look for any leakage 1) Access the battery by removing its cover under the saddle. 2) Check that the battery does not show signs of losing fluid before checking the output voltage.
  • Page 77 MP3 400 i.e. Electrical system Fuses The electrical system has twelve fuses divided into two fuse boxes to protect the different installation circuits. One of them is inside the battery compart- ment «A» and the other is at the internal side of the right footrest «B».To have access, loosen the screw «C»...
  • Page 78 MP3 400 i.e. Electrical system FUSE TABLE Specification Desc./Quantity Fuse No. 1 Capacity: 7.5 A Protected circuits:Injection ECU battery power Fuse No. 2 Capacity: 15 A Protected circuits:Battery-powered injec- tion loads, electrical fan Fuse No. 3 Capacity: 15 A Protected circuits:Battery power for saddle opening receiver, case lighting, headlight re- lay, turn indicator control device Fuse No.
  • Page 79 MP3 400 i.e. Electrical system Dashboard A = Led immobilizer / anti-theft device B= Speedometer with twin scale (km/h and mph) C = CLOCK switch D = Digital display E = Front suspension locking system warning light (if available) F = SET switch G = Rpm indicator H = Fuel gauge I = Warning light for helmet compartment courtesy...
  • Page 80 MP3 400 i.e. Electrical system C = High-beam warning light A = Total odometer gauge B = «BELT» maintenance icon C = «SERVICE» maintenance icon D = Engine coolant temperature indicator E = Trip odometer gauge (A-B) and ambient temperature (selected with the MODE button) F = TIME-DATE indicator G = Low fuel warning light H = Trip odometer gauge (B)
  • Page 81 MP3 400 i.e. Electrical system Connectors INJECTION ELECTRONIC CONTROL UNIT 1. Injection telltale light (Brown-Black) 2. Rpm indicator on instrument panel (Yellow) 3. CAN "L" Line (White-Blue) 4. Lambda probe (-) (White-Green) 5. Live supply (Red-White) 6. Battery powered (Orange-Black) 7.
  • Page 82 MP3 400 i.e. Electrical system VOLTAGE REGULATOR CONNECTOR 1. +Battery (Red-Black) 2. Ground (Black) 3. +Battery (Red-Black) 4. Ground (Black) SADDLE OPENING RECEIVER CONNECTOR 1. Aerial (Purple) 2. Saddle opening actuator (Yellow-Grey) 3. Reset (Blue-Black) 4. Battery powered (Blue) 5. Not connected 6.
  • Page 83 MP3 400 i.e. Electrical system HV COIL CONNECTOR 1. Injection load remote control (Black-Green) 2. Injection electronic control unit (Pink-Black) ANTI-THEFT DEVICE PRE-INSTALLATION CONNECTOR 1. LHS Turn indicators (Pink) 2. RHS Turn indicators (White-Blue) 3. Ground (Black) 4. Battery powered (Blue) 5.
  • Page 84 MP3 400 i.e. Electrical system 11. Ground (Black) 12. Live supply (Yellow-Red) INSTRUMENT PANEL CONNECTOR "B" 1. Scooter speed signal (Sky blue) 2. Fuel level signal (White-Green) 3. Water temperature sensor (Sky blue-Black) 4. Water temperature sensor ground lead (Brown- White) 5.
  • Page 85 MP3 400 i.e. Electrical system 7A. Potentiometer ground lead, rpm sensor, rider presence sensor (Yellow) 8. Ground (Black) 1B. Live supply (Yellow-Red) 2B. CAN "H" Line (Pink-White) 3B. Left wheel turning sensor (Green) 4B. Right wheel turning sensor (Red) 5B. Potentiometer signal (Green-Blue) 6B.
  • Page 86 MP3 400 i.e. Electrical system Programming Follow these steps to program the remote controls: 1. Insert the remote control key to be programmed in the steering lock key block. 2. Turn the key to «ON», press the button on the remote control, release the button, turn the key back to «OFF»...
  • Page 87 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 88 MP3 400 i.e. Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the side fairings. - Remove the central frame cover. - Remove the exhaust end. - Disconnect the lambda probe connector.
  • Page 89 MP3 400 i.e. Engine from vehicle CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD. - Remove the rear wheel. - Remove the bracket supporting the rear brake callipers and the callipers as well. - After removing the air filter from the crankcase, undo the screws fixing the bracket that secures the rear brake pipes.
  • Page 90 MP3 400 i.e. Engine from vehicle - Remove the spark plug caps. - Remove the coolant temperature sensor con- nector indicated in the photo. - Remove the throttle cables from the throttle body by undoing the nuts indicated in the photograph. - Remove the negative terminal cable from the starter motor.
  • Page 91 MP3 400 i.e. Engine from vehicle Remove the lower screw of the left-hand shock absorber. - Remove the engine-swinging arm fixing pin by undoing the nut and operating on the head of the pin as shown in the photograph. - The engine is now free. When refitting the engine onto the scooter, carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter.
  • Page 92 MP3 400 i.e. Engine from vehicle ENG VE - 6...
  • Page 93 INDEX OF TOPICS NGINE...
  • Page 94 MP3 400 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Loosen the 4 fastening screws - Extract the outside plastic transmission cover. - Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap.
  • Page 95 MP3 400 i.e. 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. - Unscrew the two screws shown in the figure to remove the air conveyor.
  • Page 96 MP3 400 i.e. 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. - Remove the seeger ring.
  • Page 97 MP3 400 i.e. Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COV- ER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little grease to prevent it from coming out.

  • Page 98: Anti-Vibration Roller Screw 16.7 -

    MP3 400 i.e. Engine Anti-vibration roller screw 16.7 - 19.6 Removing the driven pulley - Remove the clutch bell. - Remove the fixed 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. - Measure the clutch bell inside diameter.

  • Page 99: Removing The Clutch

    MP3 400 i.e. 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; - Fit the adapter ring to the clutch assembly as shown in the photograph.
  • Page 100 MP3 400 i.e. 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. - Extract the moving driven half-pulley. Removing the driven half-pulley bearing - Check that the bushing is free from wear and damage;...
  • Page 101 MP3 400 i.e. Engine - Using the special tool inserted through the roller bearing, pull out the ball bearing. N.B. PROPERLY SUPPORT THE PULLEY TO PRE- VENT DAMAGING THE THREADING. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide N.B.
  • Page 102 MP3 400 i.e. 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 103: Refitting The Driven Pulley

    MP3 400 i.e. 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. - Install the half-pulley on the bushing being careful not to damage the top sealing ring during the in- troduction.

  • Page 104: Clutch Ring Nut

    MP3 400 i.e. 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 105: Removing The Driving Pulley

    MP3 400 i.e. Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width: 27 mm Standard width: 28.2 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 106 MP3 400 i.e. Engine - Move the belt downwards. - Suitable support the roller contrast and extract the mobile driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out. Inspecting the rollers case - Check that the inside bushings shown in the figure are not worn and measure the inside diameter.
  • Page 107 MP3 400 i.e. Engine - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt contact surfaces on both pulley halves. Refitting the driving pulley Installing the roller container - Install the spacer with the internal chamfer facing towards the inside.
  • Page 108 MP3 400 i.e. 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 moving driving pulley.

  • Page 109: Drive Pulley Nut

    MP3 400 i.e. 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. N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY INSERTED INTO THE PULLEY AND IN THE ENGINE CRANKCASE.

  • Page 110: M8 Retainers For Transmission Cover

    MP3 400 i.e. 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. Locking torques (N*m) M6 retainer 11 ÷...
  • Page 111 MP3 400 i.e. Engine - Install the driving pulley shaft cover, positioning the tooth gap on the lower part with the reference mark on the transmission crankcase. N.B. ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE. - Install the outside plastic transmission cover. - Tighten the 4 fastening screws to the prescribed torque.
  • Page 112 MP3 400 i.e. Engine Removing the wheel axle - Remove the countershaft. - Remove the wheel axis complete with gear. 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 113 MP3 400 i.e. Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Support the hub cover using the column kit. - Pull out the bearing using the special tool. Specific tooling 020476Y Stud bolt set 020376Y Adaptor handle 020477Y Adaptor 37 mm...
  • Page 114 MP3 400 i.e. Engine - Pull out the driven pulley shaft bearing from the engine crankcase using the special tool. Specific tooling 020376Y Adaptor handle 020358Y 37x40-mm adaptor 020364Y 25-mm guide Inspecting the hub shaft - Check that the 3 shafts exhibit no wear or defor- mation on the grooved surfaces, at the bearings and at the oil guards.
  • Page 115 MP3 400 i.e. Engine B = diameter 30 - 0.010 -0.023 mm C = diameter 15 - 0.01 -0.02 mm Connection diameter for shaft driven pulley: D = diameter 17 - 0.01 -0.02 mm E = diameter 20 - 0.01 -0.02 mm F = diameter 25 - 0.01 -0.02 mm Inspecting the hub cover - Check that the mounting surface is not damaged or deformed.
  • Page 116 MP3 400 i.e. 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 APPLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020363Y 20 mm guide - Heat the gear shaft bearing seat on the crank-...
  • Page 117 MP3 400 i.e. Engine Refitting the hub cover bearings - Heat the bearing seats on the cover using the heat gun. - Support the hub cover using the column kit. Specific tooling 020151Y Air heater 020476Y Stud bolt set - Insert the intermediate shaft bearing on the cover using the special tool.
  • Page 118 MP3 400 i.e. Engine - Support the hub cover using the column kit. - Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover. - Place the oil guard flush with the crankcase. Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020476Y Stud bolt set...
  • Page 119 MP3 400 i.e. 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 120 MP3 400 i.e. 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. N.B. THE SCREWS ARE OF 4 DIFFERENT LENGTHS.

  • Page 121: Removing The Stator

    MP3 400 i.e. 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 122 MP3 400 i.e. 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. - Check that the by-pass valve seat, the torque limiter and the water pump shaft are free from wear.
  • Page 123 MP3 400 i.e. Engine - Check the condition of the stator and of the re- spective cable harness. - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPER- ATURE. A CHECK WITH THE STATOR AT OP- ERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.
  • Page 124 MP3 400 i.e. 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 GAS- KET INTO THE SPECIAL SEAT ON THE CRANKCASE.
  • Page 125 MP3 400 i.e. 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. Locking torques (N*m) Blow-by recovery duct fixing screws 3 - 4 - Insert the spring and the by-pass piston on the...
  • Page 126 MP3 400 i.e. 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 127 MP3 400 i.e. 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. - Install a new gasket on the engine crankcase.
  • Page 128 MP3 400 i.e. 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 EN- GINE OIL FILLER PLUG.
  • Page 129 MP3 400 i.e. 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. 4 - Connect the diagnostic tester (see chapter "Injection system").
  • Page 130 MP3 400 i.e. 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 Low electrical absorption Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing them.
  • Page 131 MP3 400 i.e. Engine The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations. The freewheel is used for a sufficiently silent starting. 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.
  • Page 132 MP3 400 i.e. 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. - Insert the special tool as shown in the figure, making sure that the pins are perfectly inserted in- to the previously aligned holes and that it is per- fectly abutted and almost flush with the flywheel.
  • Page 133 MP3 400 i.e. 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 FLY- WHEEL IS STRONGLY LOCKED; THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE, WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS.
  • Page 134 MP3 400 i.e. 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. SINCE THE FREEWHEEL MUST BE REMOVED, IT IS ADVISABLE TO LOOSEN THE 6 FASTEN- ING SCREWS IN ADVANCE WITH THE FLY- WHEEL STILL INSTALLED ON THE CRANK-...
  • Page 135 MP3 400 i.e. 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. Starter gear rim - Check that there is no wear or abnormal impres- sions on the "rollers"...
  • Page 136 MP3 400 i.e. 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 137 MP3 400 i.e. Engine Loctite 243 medium-strength 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. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
  • Page 138 MP3 400 i.e. 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. - Install the flywheel checking the proper insertion of the key and engaging the torque limiter gear with the start-up rim.
  • Page 139 MP3 400 i.e. Engine - Tighten thoroughly the guide bushing of the fly- wheel lock tool and loosen by 1/4 turn. N.B. FAILURE TO OBSERVE THIS RULE CAUSES THE LOCKING OF THE GUIDE ON THE FLY- WHEEL. Specific tooling 020472Y Flywheel lock wrench - Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool.
  • Page 140 MP3 400 i.e. 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 DIRECTION. Locking torques (N*m) Chain guide sliding block retain plate fasten- ing screws 3 ÷...
  • Page 141 MP3 400 i.e. 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. - Remove the tappet cover with relevant gasket. Removing the timing system drive - Turn the engine to close the intake valves.
  • Page 142 MP3 400 i.e. 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. N.B.
  • Page 143 MP3 400 i.e. 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 144: Removing The Cylinder Head

    MP3 400 i.e. Engine - Remove pins and rocking levers by the transmis- sion side holes. Removing the cylinder head - Remove the spark plug. - Remove the cooling system outlet sleeve with thermostat. - Remove the coolant temperature sensor. N.B.

  • Page 145: Removing The Valves

    MP3 400 i.e. 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 146 MP3 400 i.e. 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 FACILITATE THE SPRING SUPPORT RE- MOVAL. Removing the cylinder - piston assy. - Remove the timing chain.

  • Page 147: Inspecting The Small End

    MP3 400 i.e. 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 CYL- INDER HOUSING MOUTH ON THE CRANK- CASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE.

  • Page 148: Inspecting The Piston

    MP3 400 i.e. Engine - Calculate the coupling clearance between pin and connecting rod end. Characteristic Standard clearance: 0.015 ÷ 0.029 mm Inspecting the piston - Measure the capacity diameter on the piston. Characteristic Standard diameter: 22 + 0.006 + 0.001 mm - Calculate the piston pin coupling clearance.
  • Page 149 MP3 400 i.e. 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: 85.8 mm nominal value - Check that coating is free from flakes. - Check that the head matching surface exhibits no deformations or wear.

  • Page 150: Removing The Piston

    MP3 400 i.e. 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 Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Oil scraper ring: 0.25 ÷...
  • Page 151 MP3 400 i.e. 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 punch - Install the pin lock using the key shown in the figure.
  • Page 152 MP3 400 i.e. Engine - Using an abutment plane, reset the comparator with a preload of a few millimetres. - Finally fix the comparator. - Check the perfect sliding of the feeler pin. - Install the tool on the cylinder without changing the comparator position.

  • Page 153: Inspecting The Cylinder Head

    MP3 400 i.e. 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 top. The chamfered side of the oil scraper ring should always be facing the piston crown.
  • Page 154 MP3 400 i.e. Engine Characteristic Maximum allowable run-out: 0.1 mm - In case of irregularities, replace the head. - Check the sealing surfaces for the intake and ex- haust manifold. - Check that the camshaft and the rocker pin ca- pacities exhibit no wear.
  • Page 155 MP3 400 i.e. 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. - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves.
  • Page 156 MP3 400 i.e. Engine MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Inlet: 4.96 mm Outlet: 4.945 mm - Calculate the clearance between valve and valve guide. - Check the deviation of the valve stem by resting it on a "V" shaped abutment and measuring the extent of the deformation with a comparator.
  • Page 157 MP3 400 i.e. Engine INLET Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm OUTLET Specification Desc./Quantity Standard clearance: 0.025 ÷ 0.052 mm Admissible limit: 0.09 mm STANDARD VALVE LENGTH Specification Desc./Quantity Inlet: 95.0 ± 0.3 mm Outlet: 94.2 ±...
  • Page 158 MP3 400 i.e. Engine TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED. CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
  • Page 159 MP3 400 i.e. Engine - Fit the valves, the springs and the spring retaining washers. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush (valve removing tool) N.B.
  • Page 160 MP3 400 i.e. Engine Specification Desc./Quantity discharge 33.026 mm Standard axial clearance: 0 - 0.22 mm Maximum admissible axial clearance: 0.3 mm - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
  • Page 161 MP3 400 i.e. Engine - Measure the inside diameter of each rocking lev- Characteristic Standard diameter: 13 + 0.026 +0.015 mm - Check that the cam contact sliding block and the articulated register plate is free from wear. - In case of wear, replace the component. Refitting the head and timing system components - Insert the chain guide sliding block.

  • Page 162: Exhaust / Intake Head Fixing Nuts:

    MP3 400 i.e. Engine - Check that the head lubrication channel is per- fectly clean. Clean with compressed air jets, if required. - Insert the head. - Lubricate the stud bolts and the 4 fixing stud bolts. - Tighten the 4 fixing stud bolts crosswise to the prescribed torque as shown in the figure. Locking torques (N*m) Head fixing stud bolts: *** *** Apply a preliminary torque of 7 Nm in a crossed...

  • Page 163: Coolant Temperature Sensor:

    MP3 400 i.e. Engine - Install the coolant temperature sensor with the washer and tighten to the prescribed torque. CAUTION FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN DAMAGE THE SENSOR. Locking torques (N*m) coolant temperature sensor: 10 - 12 - Install the spark plug and tighten to the prescribed torque. Locking torques (N*m) Spark plug 12 ÷...

  • Page 164: Camshaft Retaining Bracket Screws:

    MP3 400 i.e. Engine - Remove any LOCTITE residues from the screws fixing the camshaft retaining bracket using a brush. - Apply the recommended product to the fixing screws and tighten to the prescribed torque. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock - Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque, being careful not to damage the inside hexagon.
  • Page 165 MP3 400 i.e. Engine - Keeping the belt slightly pulled, turn the crank- shaft using the driving pulley to make the reference on the magnet support collimate with that on the flywheel cover. - Install the counterweight mass. - Centre using the bell fastening screw. - Lock the mass fixing screws to the prescribed torque, using the recommended product.

  • Page 166: Valve Lifter Mass Stop Bell Fixing Screws:

    MP3 400 i.e. Engine - Turn the engine to move the references to the top as shown in the figure (intake end). - Insert the valve lifting device mass stop bell. - Tighten the retaining screw to the prescribed torque, using the recommended product. N.B.
  • Page 167 MP3 400 i.e. Engine - Install a new tightener on the cylinder using a new gasket. - Tighten the two fastening screws to the prescri- bed torque. Locking torques (N*m) Tightener fastening screws: 11 ÷ 13 - Insert the spring with the central screw and the washer.
  • Page 168 MP3 400 i.e. Engine 020460Y Scooter diagnosis and tester 020330Y Stroboscopic light for timing control Proceed as follows: - Remove the outside transmission cover as de- scribed in the automatic transmission chapter. - Remove the TDC reference inspection cap be- tween flywheel and crankcase cover.

  • Page 169: Tappet Cover Fixing Screws:

    MP3 400 i.e. Engine - Replace the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the menu on the "parameter" function. - Select the stroboscopic light command in the tra- ditional four-stroke engine position (1 spark 2 revs).
  • Page 170 MP3 400 i.e. Engine - Install the transmission cover and the relevant net filter and the outside transmission cover as descri- bed in the "Automatic transmission" chapter. - Install the cooling system sleeves using new bands, as described in the "Flywheel cover" chap- ter.
  • Page 171 MP3 400 i.e. Engine Specific tooling 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Standard clearance: 0.10 - 0.50 mm Admissible increase limit after use: 0.60 mm - Upper clearances are an indication of wear on the surfaces of the crankshaft casing support. - To carry out an accurate measurement, measure the clearance in both directions between crankcase and crankshaft.
  • Page 172 MP3 400 i.e. Engine - Split the crankcases while keeping the crankshaft inserted on the flywheel side half-crankcase. - Remove the coupling gasket. N.B. THE BUSHING SUPPORT CAN BE LEFT IN THE FLYWHEEL SIDE HALF-CRANKCASE. Removing the crankshaft - Before removing the crankshaft, check the timing with the countershaft.
  • Page 173 MP3 400 i.e. Engine Removing the countershaft - Place the special tool as shown in the figure. Specific tooling 020479Y Countershaft lock wrench - Remove the fastening nut with relevant washer. - Remove the special tool and extract the counter- shaft with the control gear.
  • Page 174 MP3 400 i.e. Engine - Upturn the half-crankcase. - Remove the bearing from the flywheel side half- crankcase using the special tool and a mallet. Specific tooling 020376Y Adaptor handle 020358Y 37x40-mm adaptor 020439Y 17 mm guide - Remove the bearing from the transmission side half-crankcase using the special tool.
  • Page 175 MP3 400 i.e. Engine - Fit the seeger ring. - Before installing the new bearing on the trans- mission side crankcase, heat the seat using the special tool. Specific tooling 020151Y Air heater - Insert a new bearing on the special tool after greasing the guide seat.
  • Page 176 MP3 400 i.e. Engine Inspecting the crankshaft components - Check the axial clearance on the connecting rod. Characteristic Standard clearance: 0.20 ÷ 0.40 mm - Check the connecting rod diametrical clearance. Characteristic Standard clearance: 0.046 ÷ 0.076 mm -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.
  • Page 177 MP3 400 i.e. Engine Specific tooling 020074Y Support base for checking crankshaft alignment - If the crankshaft - crankcase axial clearance is higher than the standard value and the crankshaft exhibits no irregularity, the problem is caused by wear or by a wrong machining on the engine crankcase. - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfa- ces shown in the figure.
  • Page 178 MP3 400 i.e. Engine N.B. MAIN BEARINGS CANNOT BE MODIFIED. The connecting rod cannot be replaced. To check the connecting rod small end diameter, see chapter "Thermal unit and timing system". - When cleaning the crankshaft, be careful to prevent any impurity from entering into the shaft lubrication hole.
  • Page 179 MP3 400 i.e. Engine - For the flywheel side half-crankcase, special at- tention should be given to the lubrication channels for the main bearings and to the compartment and the channels for the oil pump, as well as to the duct for the by-pass located on the flywheel cover.
  • Page 180 MP3 400 i.e. Engine - The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface. N.B. TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION, DRIVING IS FORCED ON CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.
  • Page 181 MP3 400 i.e. Engine X = Crankshaft category Y = Crankcase half-shell category A = Red B = Blue C = Yellow D = Green In case of breakdown, crankcases are together with bushings and are classified according to the centre to centre distance of the countershaft.
  • Page 182 MP3 400 i.e. Engine THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN CHAPTER "AUTOMATIC TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS DESCRIBED IN CHAPTER "FINAL REDUCTION". Countershaft - Using a micrometer, measure the 2 bearings of the countershaft as shown in the figure.
  • Page 183 MP3 400 i.e. Engine TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN IN- SIDE HEXAGON SOCKET WRENCH. Locking torques (N*m) Gear mounting on crankshaft screws 10 -12 - Lubricate the main bearing on the flywheel side half-crankcase.
  • Page 184 MP3 400 i.e. Engine Refitting the crankcase halves - Remove the oil guard from the transmission side half-crankcase using a screwdriver. - Install a new oil guard after lubricating it, using the special tool, arranging it at a 0.5 mm recess from the crankcase plane.
  • Page 185 MP3 400 i.e. Engine - Insert the 14 fastening screws by arranging the single shorter screw "A" and the single longer screw "B" as shown in the figure. - Tighten the screws thoroughly and tighten to the prescribed torque. - Check that the crankshaft rotates freely. N.B.
  • Page 186 MP3 400 i.e. Engine Specification Desc./Quantity Plunger diameter 13.9 - 0.039 -0.057 mm Spring free length 62.5 mm Calibration pressure 4 bar PRE-FILTER Specification Desc./Quantity Type mesh, plastic OIL FILTER Specification Desc./Quantity Type Paper with pressure relief and anti-drain back by- pass valves OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH Specification...
  • Page 187 MP3 400 i.e. 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 Connecting rod General characteristics Lubrication circuit is split into two sections: - High pressure - Low pressure...
  • Page 188 MP3 400 i.e. 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 189 MP3 400 i.e. Engine YES - go to 3 NO go to 11 3 Check the actual oil pressure. AHEAD - go to 4 4 - Remove the switch and fit the special tool with the relevant gasket. Specific tooling 020193Y Oil pressure gauge 020434Y Oil pressure control fitting - Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied...

  • Page 190: Oil Pressure Check

    MP3 400 i.e. Engine approx. 1.5 bar YES go to 7 NO go to 8 7 - Replace the oil minimum pressure switch. 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 191 MP3 400 i.e. Engine 2 - Install the special tool. Specific tooling 020193Y Oil pressure gauge 020434Y Oil pressure control fitting AHEAD go to 3 3 - Check the system pressure with cold engine and medium - high speed. Standard pressure < 6 bar YES go to 4 NO go to 5 4 - Replace the damaged components.
  • Page 192 MP3 400 i.e. 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. - Remove the inside rotor retaining snap ring turn- ing it to move the opening at the shaft face.
  • Page 193 MP3 400 i.e. 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. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible - Insert the shaft with the gear and install the lock ring;...
  • Page 194 MP3 400 i.e. Engine - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit values admitted: 0.1 mm Refitting - Make sure the gasket is in the correct position. N.B. THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.

  • Page 195: Screws Fixing Oil Pump To The Crankcase

    MP3 400 i.e. 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 the crankcase 5 - 6 - Insert the countershaft with gearing into the fly- wheel-side half-crankcase.
  • Page 196 MP3 400 i.e. Engine ENG - 104...
  • Page 197 INDEX OF TOPICS INJEC NJECTION...
  • Page 198 MP3 400 i.e. Injection KEY: 1. Battery 2.Throttle body and injection electronic control unit (MIU) 3. Instrument panel 4. Injection load remote control 5. Coolant temperature sensor 6. Fuel pump 7. HV coil 8. Lambda probe 9. Revolution sensor 10. Fuel injector 11.
  • Page 199 MP3 400 i.e. Injection - Lambda probe strength The system implements an idle feeding correction with cold engine through 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 200 MP3 400 i.e. Injection The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel. Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles of use (cold start, running at regular engine temperature, stop).
  • Page 201 MP3 400 i.e. Injection 5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to respect this norm will damage the fuel pump. 6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the level.
  • Page 202 MP3 400 i.e. Injection b. Dirty by-pass circuit c. Faulty Stepper motor F: Other a. Incorrect distribution timing b. Wrong idle mixture c.Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors. Make sure that all connections have been correctly made.
  • Page 203 MP3 400 i.e. Injection Specification Desc./Quantity Water temperature sensor Can «H» Line + Lambda probe Engine stop switch R.P.M. sensor (+) Fuel injector R.P.M. sensor (-) Diagnostics socket output Immobilizer LED Ground lead Connected to the engine stop switch and the water temperature sensor.
  • Page 204 MP3 400 i.e. Injection Specification Desc./Quantity Fuse 20 A Fuse 7.5 A Key switch contacts Engine stop switch Fuse 7.5 A Fuse Fuse 10 A Starter button Injection load remote control Start-up remote control relay Electric fan starter Starter motor Electric fan Fuel pump HV coil...
  • Page 205 MP3 400 i.e. Injection Starting difficulties ENGINE START-UP PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Start-up speed Starter motor and remote control Battery Ground connections End of compression pressure End of compression pressure...
  • Page 206 MP3 400 i.e. Injection Possible Cause Operation Fuel filter Injector capacity Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor...
  • Page 207 MP3 400 i.e. Injection Possible Cause Operation Muffler welding Engine revs irregularly ENGINE IRREGULAR PROGRESS WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system seal Intake sleeve Filter box Ignition system Spark plug wear check...
  • Page 208 MP3 400 i.e. Injection Engine knocking PRESENCE OF KNOCKING (HEAD KNOCKING) Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature indicator...
  • Page 209 MP3 400 i.e. 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 - 13...
  • Page 210 MP3 400 i.e. 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 MIU connector INJEC - 14...
  • Page 211 MP3 400 i.e. Injection Remove the gas command fitting as indicated in the photograph Pump supply circuit INJEC - 15...
  • Page 212 MP3 400 i.e. Injection INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan starter When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine starts up, in the presence of phase rpm signal the pump is continuously supplied.
  • Page 213 MP3 400 i.e. Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between 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 214 MP3 400 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 2 15 A) and the remote control base. N.B.
  • Page 215 MP3 400 i.e. Injection After switching to «ON», check that there is battery voltage, for about 2 seconds, between the Black- Green cable of the pump connector and the ground lead with the pump connector disconnec- ted. Otherwise, check the continuity of the Black- Green cable between the pump connector and the remote control base.
  • Page 216 MP3 400 i.e. Injection Check during regular operation by placing the ap- propriate tool between the pump and the injector. With battery voltage > 12 V check that the fuel pressure is 3 BAR and that the input current is ~2.8 With the battery voltage >...
  • Page 217 MP3 400 i.e. Injection Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 21...
  • Page 218 MP3 400 i.e. Injection Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 22...
  • Page 219 MP3 400 i.e. Injection Specification Desc./Quantity Electric fan starter When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts up, in the presence of phase rpm signal the pump is continuously supplied. ELECTRICAL DATA •...
  • Page 220 MP3 400 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the pin 20...
  • Page 221 MP3 400 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 2 15 A) and the remote control base. N.B.
  • Page 222 MP3 400 i.e. Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to "ON" and check if there is voltage, with injector disconnected and control unit connected, between the Black-Green cable of the injector con- nector and the ground lead...
  • Page 223 MP3 400 i.e. Injection Install the appropriate tool for the fuel pressure check and position the manifold over a container graduated by at least 100 cc. Connect the injector with the cable making up part of the supply for the injection tester.
  • Page 224 MP3 400 i.e. Injection - immobilizer aerial - Master key with incorporated transponder (red key) - service key with incorporated transponder (black key) - HV coil - Diagnosis LED The diagnosis LED also works as a blinking light to deter theft. This function is activated every time the ignition switch is turned to the "OFF"...
  • Page 225 MP3 400 i.e. Injection With the key switch in the OFF position: • there is battery voltage between termi- nals 5-26 and terminal 5-frame earth (fixed power supply). If there is no volt- age, check the key switch contacts, that fuse no. 10 and its cable are work- ing order.
  • Page 226 MP3 400 i.e. Injection With the ignition key switch at ON check there is battery voltage between the Red-White and Black cables With MIU connector disconnected check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring . Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter...
  • Page 227 MP3 400 i.e. Injection The maximum time to change keys is 10 seconds. A maximum of 7 service keys can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, the master key transponder is strictly matched with the control unit.
  • Page 228 MP3 400 i.e. Injection 3. Programmed control unit - the service key in (normal condition of use): a single 0.7 second flash is displayed, after which the LED remains off permanently. The engine can be started. 4. Programmed control unit - Master key in: a 0.7 sec.
  • Page 229 MP3 400 i.e. Injection Code 2 Two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary.
  • Page 230 MP3 400 i.e. Injection With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20° Disconnect the fuel pipe connector.
  • Page 231 MP3 400 i.e. Injection HT coil INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 35...
  • Page 232 MP3 400 i.e. Injection Specification Desc./Quantity Electric fan starter The ignition system combined with the injection is the high-efficiency induction type. The control unit controls two important parameters: - Ignition advance This is optimised from moment to moment in accordance with the engine revs, engine load, temperature and environmental pressure.
  • Page 233 MP3 400 i.e. Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between 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 234 MP3 400 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 2 15 A) and the remote control base. N.B.
  • Page 235 MP3 400 i.e. Injection Check there is voltage between pins 22 and 26 of the interface wiring for around two seconds when switching to «ON». Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected.
  • Page 236 MP3 400 i.e. Injection If different values are measured (<1; >20KΩ), replace the shielded cap. N.B. A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM. FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTE- NANCE» CHAPTERS. Spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit.
  • Page 237 MP3 400 i.e. Injection - By the driving pulley, turn the engine to find the alignment of the references to identify the TDC. - Repeat for the reference between driving pulley and engine crankcase. - Replace the inspection cap on the flywheel side. - Connect the diagnostic tester.
  • Page 238 MP3 400 i.e. Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor Engine stop switch Electronic control unit With the control unit side connector disconnected and the coolant temperature sensor connector connected, check that the resistance values be- tween pin 9 and ground correspond to the engine temperature.
  • Page 239 MP3 400 i.e. Injection With the control unit side connector disconnected and the coolant temperature connector discon- nected, check the continuity between pin 9 of the interface wiring harness and the light blue/green cable of the connector. Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Zeroing the throttle Resetting the throttle valve position signal (TPS reset)
  • Page 240 MP3 400 i.e. Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw. Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
  • Page 241 MP3 400 i.e. Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
  • Page 242 MP3 400 i.e. Injection Lambda probe INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 46...
  • Page 243 MP3 400 i.e. Injection Specification Desc./Quantity Electric fan starter The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type, i.e.
  • Page 244 MP3 400 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the pin 20...
  • Page 245 MP3 400 i.e. Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Place the tips of the multimeter between pins 4 (-) and 11 (+) With the engine running at idle speed, check that the voltage oscillates between 0V and 1V...
  • Page 246 MP3 400 i.e. Injection INJEC - 50...
  • Page 247 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 248: Removing The Front Wheel

    MP3 400 i.e. Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pho- tograph. Locking torques (N*m) Wheel fixing screw 20 ÷ 25 Front wheel hub overhaul - Remove the ball bearing seeger ring indicated in the photograph...
  • Page 249 MP3 400 i.e. Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide - Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the bearing until it stops, with the shielded side facing...
  • Page 250 MP3 400 i.e. Suspensions Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 Handlebar Removal - Remove the 2 handlebar covers working as ex- plained in the Bodywork Chapter. - Remove the handlebar wiring retaining straps and disconnect the electric connectors from the brake levers.
  • Page 251 MP3 400 i.e. Suspensions Hydraulic system layout When tilting is locked, the geared motor activates the hydraulic pump indicated in the photograph and pressurises the circuit. The pressurised oil reaches the distribution frame «T» and the pressure sensor «A». Then, the pipes branch out to reach the upper joints on the side steering tubes.
  • Page 252 MP3 400 i.e. Suspensions Disconnect the tone wheel connector indicated in the photograph. 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 photograph.
  • Page 253 MP3 400 i.e. Suspensions Remove the suspension tilt locking device pipes from the headstock. Remove first the flexible part of the calliper from the steering tube as shown in the photograph, and then remove the rigid part. Remove the tone wheel wiring by disconnecting the connector on the fuel tank after removing the chassis central cover.
  • Page 254 MP3 400 i.e. Suspensions Remove the constant-velocity universal joint from the steering bar by undoing the nut indicated in the photograph. Use a specific tool to remove the upper tightening ring nut of the steering tube. Specific tooling 020055Y Wrench for steering tube ring nut Remove the hydraulic pipe support bracket.
  • Page 255 MP3 400 i.e. Suspensions Remove the steering tube lower ring nut and the protection cap indicated in the photograph. Now, it is possible to remove the steering tube. Check that the roller tapered bearing does not show signs of abnormal wear. If it is, replace it. SUSP - 9...
  • Page 256 MP3 400 i.e. 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 photograph. Remove the sliding stem locking device retainers indicated in the photograph. Check that the sliding stem locking device does not show signs of abnormal wear.

  • Page 257: Side Headstock Lower Ring Nut

    MP3 400 i.e. Suspensions For refitting, follow the operations for removal but in reverse order, observing the prescribed torques and greasing the bearings and their seats. STEERING TUBES Name Torque in Nm Side headstock upper ring nut 20 - 24 Side headstock lower ring nut 12 ÷...
  • Page 258 MP3 400 i.e. Suspensions Remove the 4 screws fixing the tilt brake disc sec- tor indicated in the photograph. Remove the retainers indicated in photograph of the half-arms joint flange. To facilitate the operations indicated below, re- move the suspension locking electronic control unit indicated in the photograph.
  • Page 259 MP3 400 i.e. Suspensions 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 alternatively to the left and right side of the parallelogram.
  • Page 260 MP3 400 i.e. 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 - 14...

  • Page 261: Screws Fixing The Half-Arm Coupling Flange

    MP3 400 i.e. Suspensions 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 in reverse order, lubricating the locking pins on the parallelogram half-arms and observing the pre- scribed torques.

  • Page 262: Fixing Screws For Tilt Locking Disc Section

    MP3 400 i.e. Suspensions Name Torque in Nm Fixing screws for tilt locking disc section 20 ÷ 25 Geared motor and Suspension locking system Select the SYSTEM RESET option from the main menu Turn the key switch to ON Select the LOWER STOP SEARCH option from the SYSTEM RESET menu WAIT PROCEDURE IN PROGRESS...
  • Page 263 MP3 400 i.e. Suspensions The hand-held computer indicates the outcome of the stop search operation: POSSIBLE LIMIT STOP VALUES. TO EXIT, PRESS A KEY AND TURN OFF AND ON. SE- LECT PARAMETERS TO ADJUST AT 12°. Check the geared motor if the hand-held computer does not indicate this.

  • Page 264: Clamp Fixing Pump Bolt To Anti-Tilting Device

    MP3 400 i.e. Suspensions Remove the protection cap, align the pump control and lock the screw to the prescribed torque Locking torques (N*m) Clamp fixing pump bolt to anti-tilting device 11 ÷ 13 Select the SYSTEM RESET option from the MAIN menu SUSP - 18...
  • Page 265 MP3 400 i.e. Suspensions Select the POTENTIOMETER RESET option from the SYSTEM RESET menu and press OK. WAIT..PROCEDURE IN PROGRESS The hand-held computer displays the words: CHECK THAT THE CONTROL IS SET AT 12° FROM THE LOWER STOP. PRESS OK TO CON- TINUE Press OK The hand-held computer displays the words: POS-...
  • Page 266 MP3 400 i.e. Suspensions When refitting, tighten the two bracket screws and the flexible transmission lever nut to the prescribed torque. Locking torques (N*m) Bracket tightening screws 8 ÷ 12 Unscrew the Allen screw and remove the switch. When refitting, place the switch with the button ori- ented to the stop indicated on the calliper lever;...
  • Page 267 MP3 400 i.e. Suspensions Unscrew the two pad pin screws, remove the pads with the spring. When refitting, tighten the two screws to the pre- scribed torque and use Threadlock. When refitting, adjust the cable properly so that the switch is pushed when the system is unlocked. Refit the spring/toothed sector unit, hold the crank- case in a perfectly horizontal and stable position, place the spring/toothed sector unit keeping it per-...
  • Page 268 MP3 400 i.e. Suspensions Fit the pinion and align the reference on the pinion teeth with the reference indicated on the second slot of the toothed sector. Grease the pinion and the toothed sector with spe- cific grease. Refit the toothed sector spacer. Recommended products MONTBLANC MOLYBDENUM GREASE MON- TBLANC MOLYBDENUM GREASE...
  • Page 269 MP3 400 i.e. Suspensions Place the moulded washer of the flexible trans- mission control lever shaft and the tongue. Refit the flexible transmission control lever as shown in the figure. Refit the potentiometer (not forcing in the D-type connector ensures a sole position) with the con- nector directed to the opposite side of the hydraulic pump.
  • Page 270 MP3 400 i.e. Suspensions Extract the electric motor bearing with the specific tool. Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20 mm guide Hold the crankcase in a perfectly horizontal posi- tion, heat it with a heat gun at a temperature of about 120 °C, use the specific tool to fit the bearing of the flexible transmission lever control shaft.
  • Page 271 MP3 400 i.e. Suspensions 020376Y Adaptor handle Remove the spring/toothed sector unit from its fit- ting, slightly hit with a mallet if necessary to release the unit. 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 272 MP3 400 i.e. Suspensions Hold the crankcase in a perfectly horizontal posi- tion, heat it with a specific heat gun at a tempera- ture of about 120 °C, use the specific tool to fit the bearing of the electric motor. Hit slightly with a mallet if necessary.
  • Page 273 MP3 400 i.e. Suspensions Disconnect the hydraulic pipes between the pump and the sliding stem locking clamps. Empty the system and use a container to collect the brake fluid. CAUTION ELIMINATE ANY REMAINING BRAKE FLUID SPILLS. WARNING: BRAKE FLUID IS HIGHLY POISON- OUS.
  • Page 274 MP3 400 i.e. Suspensions Unscrew the two potentiometer screws. When 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 275 MP3 400 i.e. Suspensions Remove the three fixing screws of the electric mo- tor. It is important to mark the direction of the electric motor position in order to refit it correctly. 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...
  • Page 276 MP3 400 i.e. Suspensions 2. Brake calliper sensor 3. Tilt unlocking-locking control switch 4. Potentiometer 5. Rider presence sensor 6.Left speed sensor 7.Right speed sensor 8. Diagnostic tester serial line 9. Engine electronic control unit 10. Direct +Battery 11. Live +Battery 12.
  • Page 277 MP3 400 i.e. Suspensions 1: GEARED MOTOR With the interface wiring disconnected from the control unit, check the continuity between pin 28 and the white-red cable, between pin 38 and the blue cable on the geared motor connector With the interface wiring disconnected from the control unit, check the continuity of the geared mo- tor winding placing the multimeter probes on pins 28 and 38 as indicated in the figure.
  • Page 278 MP3 400 i.e. Suspensions 0: REST POSITION 1: LOCKING POSITION 2: UNLOCKING POSITION 3: TILT LOCKING-UNLOCKING SWITCH With interface wiring disconnected from the control unit, check the continuity of the electrical lines be- tween the interface wiring and the tilt locking-un- locking switch: Pin 26 and green - grey cable Pin 35 and violet - black cable...
  • Page 279 MP3 400 i.e. Suspensions Check the continuity between the black cable on the connector and an earth point on the chassis. With a multimeter, check the operation of the tilt locking-unlocking switch referring to the diagram indicated in the figure. 1.
  • Page 280 MP3 400 i.e. Suspensions With 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. Check that the voltage in the activated locking condition is 4V and 1V in the locking to rest condition.
  • Page 281 MP3 400 i.e. Suspensions 1: RIDER PRESENCE SENSOR With interface wiring disconnected from the control unit and connected to the system, check the fol- lowing conditions: pin 17 - 36: resistance 15 ÷ 18 kOhm when the rider is not seated on the saddle. pin 17 - 36: resistance of about 3 kOhm when the rider is seated on the saddle Check the continuity between the interface wiring...
  • Page 282 MP3 400 i.e. Suspensions 1: TILT LOCKING CALLIPER SENSOR The tilt locking calliper sensor is a normally opened switch. Check its correct operation with a multi- meter. With interface wiring disconnected from the control unit, check the continuity between pin 34 and the brown cable of the tilt locking gripper sensor con- nector on the system side.
  • Page 283 MP3 400 i.e. Suspensions Also check that the flexible transmission control lever activates the limit stop switch properly. TONE WHEEL SENSOR 1: Right tone wheel 2: Left tone wheel SUSP - 37...
  • Page 284 MP3 400 i.e. Suspensions With interface wiring disconnected from the park- ing 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 a temperature of approximately 20° With interface wiring disconnected from the control unit, check the continuity between pin 23 and the red cable of the LEFT wheel turning sensor con-...
  • Page 285 MP3 400 i.e. 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 286 MP3 400 i.e. Suspensions 1: PRESSURE SWITCH 2: HORN REMOTE CONTROL 3: FUSE No. 11, 7.5A Check 7.5 A fuse No. 11 for efficiency. With inter- face wiring disconnected from the control unit, check the continuity of the blue - black cable be- tween pressure sensor connector and the horn remote control base as indicated in the photo- graph.

  • Page 287: Wheel Alignment

    MP3 400 i.e. 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). With a multimeter, also check the pressure switch operation as well as the continuity at rest as this is normally closed switch.
  • Page 288 MP3 400 i.e. Suspensions • Check that the wheel rims rotate even- ly and whether there is abnormal clear- ance in bearings and suspensions. • Make sure that the steering control shows no signs of abnormal clearance in joints and bearings. Otherwise, cor- rect this and then adjust them.
  • Page 289 MP3 400 i.e. Suspensions • 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 290 MP3 400 i.e. Suspensions • Place the frame so that the sliders come into contact with the rim maxi- mum diameter but without interfering with the tyre. If required, reposition the frame by operating the 3 adjustable support feet. • Fit the frame locking bracket •...

  • Page 291: Removing The Rear Wheel

    MP3 400 i.e. Suspensions • Check that the pointers of both tyres are correctly aligned, as shown in the photograph. Maximum misalignment allowed: 4 notches Rear Removing the rear wheel Before removing the rear wheel, support the vehi- cle properly and operate the parking brake so as to facilitate removing the wheel fixing screws.
  • Page 292 MP3 400 i.e. Suspensions - Undo the two screws fixing the clamp to the cen- tre stand. - Remove the cotter pin and collect the cap. - Unscrew the wheel fixing nut and collect the spacer. - Unscrew the clamp. - Collect the conical spacer.

  • Page 293: Rear Wheel Axle

    MP3 400 i.e. Suspensions Refitting the rear wheel To fit, follow the removal steps but in the reverse sequence, being careful to fit the spacers on the wheel axle as shown in the photograph. Locking torques (N*m) Muffler arm clamping screws 27 ÷ 30 Rear wheel axle nut 104 ÷...
  • Page 294 MP3 400 i.e. Suspensions - Remove the silent-blocks. - Remove the retainer fixing the swinging arm to the frame: undo the screw. - Remove the pin. - Unscrew the nut of the set screw bushing. SUSP - 48...
  • Page 295 MP3 400 i.e. Suspensions - From the inside loosen the set screw bushing until the swinging arm is free. - Remove the swinging arm. - 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 296 MP3 400 i.e. Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo. - 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.
  • Page 297 MP3 400 i.e. Suspensions L182.5 ± 0.3 mm Length of the swinging arm tube on the frame side: L 222.5 ± 0.2 mm - 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- truding part facing the transmission side...
  • Page 298 MP3 400 i.e. Suspensions Refitting For correct installation of the swinging arm on the scooter, proceed as follows: 1. Position the silent block supporting clamp with part 3 inserted, and slightly tighten part 1 2. Position the swinging arm, inserting part 2 3.

  • Page 299: Shock Absorbers

    MP3 400 i.e. 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 Swinging arm, engine side / Swinging arm, frame 32.5 ÷ 40 side, bolt Shock absorbers Removal...

  • Page 300: Shock Absorber Lower Clamp

    MP3 400 i.e. Suspensions Locking torques (N*m) Shock absorber lower clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41 Centre-stand - Use a jack to support the vehicle properly. - Remove the two stand return springs. - Working from both sides, undo the two bolts con- necting it to the supporting plate.
  • Page 301 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 302: Rear Brake Calliper

    MP3 400 i.e. Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the rear wheel. - Undo the screws connecting the air filter to the crankcase so that the wrenches can be inserted. - Undo the two fixing screws and remove the cal- liper.
  • Page 303 MP3 400 i.e. Braking system Refitting 1) insert the pistons (6) and the sealing rings (7) in the body; 2) place the guide rubbers (8) and refit the fixed plate (4); 3) assemble the reaction plate (3) tightening the screws (2), insert the brake pad check spring (9) and then the pads, fixing them with the corre- sponding screws (1);...

  • Page 304: Brake Fluid Pipe-Calliper Fitting

    MP3 400 i.e. Braking system Brake fluid pipe-calliper fitting 20 ÷ 25 Pad fas- tening pin 20 ÷ 25 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 305 MP3 400 i.e. Braking system - Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully - Fit the O-rings and new dust guards - Refit the pistons in their seats being careful to lubricate with brake fluid - Re-couple the half callipers and lock the two screws at the specified torque...
  • Page 306 MP3 400 i.e. Braking system Removal - Remove the rear wheel. - Loosen the nuts fixing the safety washers. - Undo the two screws fixing the plate supporting the calliper to the frame. - Remove the calliper supporting clamp. - Remove the brake disc Refitting - To fit the rear brake disc, follow the removal steps but in reverse order;...

  • Page 307: Front Brake Disc

    MP3 400 i.e. Braking system Disc Inspection Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring. Characteristic New rear disc thickness 5 mm Disc thickness at wear limit (rear) 3.5 mm...
  • Page 308 MP3 400 i.e. Braking system - Unscrew the fixing nut. - Remove the wheel hub. - Unscrew the six bolts securing the disc to the wheel hub. - Remove the disc. 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.

  • Page 309: Front Brake Pads

    MP3 400 i.e. Braking system Characteristic Thickness of a new front disc 4.0 mm Disc thickness at wear limit (front) 3.5 mm - Remove the wheel and check using the appro- priate tools that the axial run-out of the brake surface is within the prescribed limits.
  • Page 310 MP3 400 i.e. Braking system - Remove the pads. Characteristic Minimum value 1.5 mm Refitting - Follow the removal steps but in reverse order; check that the Benzing snap ring of the pads is in good conditions. Rear brake pads Removal Proceed as follows: - Remove the rear brake calliper...

  • Page 311: Oil Bleed Screw

    MP3 400 i.e. Braking system Rear - combined Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir. - Through the bleed screw on the brake calliper, bleed the system using a hose of adequate diam- eter.

  • Page 312: Brake Pipes

    MP3 400 i.e. Braking system Front - The operations described refer to only one cal- liper but are valid and must be observed for both. - Remove the rubber hood from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered.

  • Page 313: Parking Brake

    MP3 400 i.e. Braking system Front brake pipes removal Remove front Shield. Remove front wheel and mudguard. Disconnect the brake pipes from the calliper and drain the brake fluid. Then, remove the plastic and metallic straps. Unscrew the brake pump pipes as indicated in the figure.
  • Page 314 MP3 400 i.e. Braking system Remove the two fixing screws of the mechanic calliper and remove the calliper. To check calliper components, refer to the chapter on the tilt locking calliper. When refitting, secure to the specified torque. Locking torques (N*m) Screw tightening calliper to the support 20 ÷...
  • Page 315 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 316: Circuit Diagram

    MP3 400 i.e. Cooling system Circuit diagram The cooling system is of the forced circulation type, with continuous venting and air pressurisation. Circulation takes places by a centrifugal pump driven by the countershaft. The pump delivers the coolant to the thermal unit. The two-way thermostat support is connected in output to the head.
  • Page 317 MP3 400 i.e. Cooling system For the system venting during the circuit filling step, there is a special union at the top of the head (see filling rules). To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection system.
  • Page 318 MP3 400 i.e. Cooling system - Select the menu on the "ACTIVE DIAGNOSIS" function and start the electric fan operation simu- lation (see "Injection" chapter). - If the electric fan is certainly efficient, check the ventilation start and end temperature. - Select the "PARAMETERS"...

  • Page 319: Coolant Replacement

    MP3 400 i.e. Cooling system DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OB- SERVE THIS REGULATION CAN CAUSE IRREVERSIBLE DEFORMATION TO THE SEALING GASKETS. Coolant replacement System top-up rules - Prepare the mixture of 50% water and coolant. - Fill the system to reach a level ranging between the MIX and MAX levels indicated in the expansion tank filler.
  • Page 320 MP3 400 i.e. Cooling system • Place the vehicle on its centre stand and on flat ground. • Remove the bodywork components as described in the "Bodywork" Chapter. • Remove the muffler to access the flywheel cover as described in the "Removing the Engine from the Scooter"...
  • Page 321 MP3 400 i.e. Cooling system Flywheel cover COOL SYS - 7...
  • Page 322 MP3 400 i.e. Cooling system COOL SYS - 8...
  • Page 323 INDEX OF TOPICS CHAS HASSIS...
  • Page 324 MP3 400 i.e. Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Raise the saddle. - Undo the screw shown in the figure, remove the cover and disconnect the rider presence sensor connector.
  • Page 325 MP3 400 i.e. Chassis Instrument panel - Remove the front handlebar cover. - Remove the front shield. - Remove the shield back plate upper side. - Unscrew the six fixing screws and remove the instrument panel. Front handlebar cover - Remove the upper cap by operating on the Allen screw indicated in the figure.
  • Page 326 (inwards) to release it from the shield supports. To remove the shield central finishing, remove the PIAGGIO clip-on badge paying attention not to spoil the paint, unscrew the screw underneath and remove the finish carefully. CHAS - 4...
  • Page 327 MP3 400 i.e. Chassis Remove the four screws «A» and disconnect the wiring. See also Radiator cover Frame central cover Remove the three screws on the right and the left side. Open the refuelling compartment and remove the tank cap so as to remove the central cover. Disconnect the cable, refuelling compartment opening.
  • Page 328 MP3 400 i.e. Chassis Legshield Remove the front headlight assembly. Remove the spoiler. Remove the two front screws and the two screws under the wheelhouse. Remove the four screws on the shield back plate. See also Headlight assy. spoiler Knee-guard - Remove the front shield.
  • Page 329 MP3 400 i.e. Chassis - Remove the expansion tank fixing screw and the frame from the instrument panel and manually re- lease the unions with the shield back plate. - Unhook the instrument panel wiring. - Remove the six screws and the cable guide strap in the front part of the shield back plate.
  • Page 330 MP3 400 i.e. Chassis - Remove the five screws on the shield back plate rear part. - Remove the two shield back plate front screws, see figure. - Remove the two shield back plate lower screws. - Remove the external temperature sensor con- nection.
  • Page 331 MP3 400 i.e. Chassis Footrest Remove the central cover. Remove the four screws and extract the half-foot- rest. Follow the same procedure for both half-footrests. Release the fuse-box See also Frame central cover CHAS - 9...
  • Page 332 MP3 400 i.e. Chassis Side fairings Remove the rear screw under the rear cover. Remove the screw on the fairing front part, pull the fairing to release the hooks. Follow the same procedure for both fairings. Remove the five screws on the right side and the five on the left side, indicated in the figure.
  • Page 333 MP3 400 i.e. Chassis Helmet bay Remove the chassis central cover. Remove the four external screws and the two screws inside the rear case to remove the frame. Remove the upper frame, unscrewing the ten up- per screws, the two saddle closing screws and the case light wiring.
  • Page 334 MP3 400 i.e. Chassis Remove the rear case internal screws indicated in the photograph, to detach the supporting plates of the voltage regulator on one side and the saddle opening switch on the other. Remove the six upper screws. Release the case latch. Remove the case light front and rear switch con- nections, the HV coil, the battery leads and the fuse-box.
  • Page 335 MP3 400 i.e. Chassis Headlight assy. Fuel tank Remove the chassis central cover. Remove the footrest. Remove the three tank retainers. Remove the two lower bracket retainers indicated in the figure. Disconnect the electric wiring and the fuel pipes. See also Footrest CHAS - 13...
  • Page 336 MP3 400 i.e. Chassis Top-case Rear Remove the four fixing screws of the cover and release it from the two leverages. Handles and top side fairings - Operating from the rear case remove the two screws indicated in the photograph. - Remove the ceiling fitting indicated in the photo- graph and remove the internal screw indicated in the photograph.
  • Page 337 MP3 400 i.e. Chassis Remove the six screws indicated in the figure. Radiator cover Remove the two front screws indicated in the pho- tograph Remove the two lower retainers with the bushing Remove the two rear retainers and then, the two wheelhouse front retainers.
  • Page 338 MP3 400 i.e. Chassis Remove the two screws fixing the radiator lower protection to the shield back plate. After that, press up and pull the protection front part so as to release it from the radiator frame. CHAS - 16...
  • Page 339 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 340 MP3 400 i.e. Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Position the plastic cover supplied with the cou- pling on the steering tube as shown in the figure. If a customer wishes to have mudflaps installed, proceed as follows: •...
  • Page 341 MP3 400 i.e. Pre-delivery • Front shock absorber upper fixing • Front shock absorber lower fixing • Sliding stems fixing • Break callipers fixing • Front wheels fixing screws • Front wheels axle nut • Rear wheel axle nut • Chassis - engine swinging arm fixing •...
  • Page 342 MP3 400 i.e. Pre-delivery IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS;...
  • Page 343 MP3 400 i.e. Pre-delivery CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspection Functional check up: • Hydraulic braking system: lever travel • Clutch: proper functioning check •...
  • Page 344 MP3 400 i.e. Pre-delivery PRE DE - 6...
  • Page 345 INDEX OF TOPICS TIME...
  • Page 346 MP3 400 i.e. Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replace- ment TIME - 2...
  • Page 347 MP3 400 i.e. Time Crankcase CRANKCASE Code Action Duration 001100 Oil seal, clutch side - Re- placement 001133 Engine crankcase- Replace- ment 001153 Crankcase half gasket - Re- placement TIME - 3...
  • Page 348 MP3 400 i.e. Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001098 Countershaft - Replacement TIME - 4...
  • Page 349 MP3 400 i.e. Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder piston - Replace- ment 001154 Pin ring piston unit - Service 001129 Chain tensioner - Service and Replacement TIME - 5...
  • Page 350 MP3 400 i.e. Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001049 Valves - Adjustments 001056 Head gasket - Replacement 001126 Head - Replacement 001083 Thermistor - Replacement 007012 Coolant bleed valve - Re- placement TIME - 6...
  • Page 351 MP3 400 i.e. Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Re- placement 001169 Decompressor - Replace- ment TIME - 7...
  • Page 352 MP3 400 i.e. Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replace- ment TIME - 8...
  • Page 353 MP3 400 i.e. Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - replace 001113 Water pump - Replacement 001123 Oil filter -Replacement 001124 By-pass valve - Replacement 001057 Thermostat - Replacement 001062 Water pump command shaft - Replacement 001150 Flywheel cover gasket - Re-...

  • Page 354: Driven Pulley

    MP3 400 i.e. Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Re- placement TIME - 10...
  • Page 355 MP3 400 i.e. Time Oil pump OIL PUMP Code Action Duration 001042 Oil pump - overhaul 001051 Belt/ Timing chain - Replace- ment 001112 Oil pump - change 001125 Chain guide pads - change 001071 Start-up pinion - Replace- ment 001020 Starter motor - Replacement 001102...
  • Page 356 MP3 400 i.e. Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001010 Geared reduction unit - Serv- 001156 Gear reduction unit cover - Replacement 003065 Gear box oil - Replacement 004125 Rear gear shaft - Replace- ment 002031 Rear wheel hub bearings - Replacement...
  • Page 357 MP3 400 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001006 driving pulley - Service 001141 Belt anti-flapping roller - Re- placement 001066 driving pulley - Replacement 001177 Variator rollers / shoes - Re- placement TIME - 13...
  • Page 358 MP3 400 i.e. Time Transmission cover TRANSMISSION COVER Code Action Duration 001065 Internal transmission cover - Replacement 001096 External transmission cover - Replacement 001131 Transmission air intake - Re- placement 001135 Transmission cover bearing - Replacement 001170 Air manifold - replacement TIME - 14...

  • Page 359: Flywheel Magneto

    MP3 400 i.e. Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001173 Rotor - Replacement 001067 Stator - Removal and Refit- ting 001058 Complete flywheel - Replace- ment 001104 Start-up freewheel - Replace- ment 001151 Start-up driven gearing - Re- placement TIME - 15...
  • Page 360 MP3 400 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001013 Intake manifold - change 001047 Injector - Replacement 001023 Control unit - Replacement TIME - 16...
  • Page 361 MP3 400 i.e. Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replace- ment 001095 Muffler guard - Replacement 004169 Muffler guard - Replacement 005138 Lambda probe - Replace- ment TIME - 17...

  • Page 362: Air Cleaner

    MP3 400 i.e. Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor fitting - Replacement TIME - 18...
  • Page 363 MP3 400 i.e. Time Frame HASSIS Code Action Duration 004146 Front frame - Replacement 004116 Rear frame - Replacement 004001 Frame - replace 004147 footboard support bracket one side - Replacement 004143 Footrest support - replace TIME - 19...
  • Page 364 MP3 400 i.e. Time Centre-stand STAND Code Action Duration 004004 Stand - Replacement 004179 Stand buffer - Replacement Legshield spoiler TIME - 20...
  • Page 365 MP3 400 i.e. Time RONT SHIELD Code Action Duration 004020 Headlight frame - Replace- ment 004064 Front shield - Replacement 004055 Turn indicator frame - Re- placement 004149 Shield central cover - Re- placement 004022 Shield lower section - Re- placement 004167 Grill / radiator cover - Re-...
  • Page 366 MP3 400 i.e. Time Code Action Duration 004068 Passenger handgrip - Re- placement 004037 Side aprons-Replacement Rear cover REAR SHIELD Code Action Duration 004065 Front shield, rear part - Re- moval and refitting TIME - 22...
  • Page 367 MP3 400 i.e. Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replacement 004135 Fuel tank port - Replacement 004011 Central chassis cover - Re- placement 004012 Rear fairings - Removal and refitting 004015 Footrest - Removal and Re- fitting 004075 Front mat - Replacement...
  • Page 368 MP3 400 i.e. Time Mudguard MUDGUARDS Code Action Duration 007015 Radiator air intake - Replace- ment 004009 Rear mudguard - Replace- ment 004181 Lower cover - Replacement 004184 Front mudguard support - re- placement 004002 Front mudguard - Replace- ment TIME - 24...
  • Page 369 MP3 400 i.e. Time Fuel tank UEL TANK Code Action Duration 004137 Injector pump pipe - Replace- ment 005010 Tank float - Replacement 004109 Fuel tank breather - Replace- ment 004168 Fuel tank cap - Replacement 004138 Fuel reverse pipe - Replace- ment 004005 Fuel tank - Replacement...
  • Page 370 MP3 400 i.e. Time Rear shock-absorber EAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Re- moval and Refitting 003035 Shock absorber support and brake calliper - Replacement 003077 muffler/rear shock absorber support arm - Service TIME - 26...

  • Page 371: Handlebar Covers

    MP3 400 i.e. Time Handlebar covers HANDLEBAR COVERS Code Action Duration 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE- MENT 004019 Rear handlebar covers - Re- placement 004026 Handlebar cover - Replace- ment 004018 Front handlebar covers - Re- placement TIME - 27...
  • Page 372 MP3 400 i.e. Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 002059 Right-hand knob - change 002060 Complete throttle control - Replacement 002063 Complete throttle control - Replacement 003001 Handlebar - Replacement 002071 Left knob - Replacement 003059 Counterweight - Replace- ment 002037 Brake lever - Replacement...
  • Page 373 MP3 400 i.e. Time Swing-arm SWINGING ARM Code Action Duration 004058 Silent block - Replacement 003081 Swinging arm support flange - replace 001072 Swinging arm - Engine-chas- sis connection - Replacement 003080 Swinging arm on frame - Re- placement TIME - 29...
  • Page 374 MP3 400 i.e. Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 30...
  • Page 375 MP3 400 i.e. Time Instrument panel NSTRUMENT PANEL Code Action Duration 004021 Shield upper section - Re- placement 005014 Odometer - Replacement 004099 Odometer housing - Replace- ment 004035 Instrument panel - Replace- ment TIME - 31...

  • Page 376: Turn Signal Lights

    MP3 400 i.e. Time Locks OCKS Code Action Duration 004172 Rear case closure hook - Re- placement 005099 Electric saddle opening acti- vator - Replacement 004054 Saddle lock catch - Replace- ment 004001 Chassis - Replacement 005072 Immobilizer aerial - Replace- ment Turn signal lights Rear lights...
  • Page 377 MP3 400 i.e. Time EAR TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005005 Taillight - Replacement 005022 Rear turn indicators - Re- placement 005031 Licence plate light bulb - Re- placement 005032 Transparent licence plate cover - replace 005131 Licence plate light support - Replacement 005066 Rear light bulbs - Replace-...
  • Page 378 MP3 400 i.e. Time RONT TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005067 Front direction indicator bulb - Replacement 005012 Front direction indicators - Replacement 005002 Front light - Replacement 005008 Light bulbs - Replacement TIME - 34...

  • Page 379: Front Wheel

    MP3 400 i.e. Time Front wheel RONT WHEELS Code Action Duration 003047 Front tyre - Replacement 003033 Front wheel hub- Replace- ment 003037 Front wheel rim- Replace- ment 005089 Tone wheel - Replacement 002041 Front brake disc - Replace- ment 004123 Front wheel - Replacement TIME - 35...

  • Page 380: Rear Wheel

    MP3 400 i.e. Time Rear wheel EAR WHEEL Code Action Duration 002070 Rear brake disc - Replace- ment 001016 Rear wheel - Replacement 001071 Front wheel rim - Removal and refitting 004126 Rear wheel tyre - Replace- ment TIME - 36...
  • Page 381 MP3 400 i.e. Time Electric devices LECTRICAL DEVICES Code Action Duration 005075 Stop remote control - Re- placement 005035 Headlight remote control - Replacement 005011 Start-up remote control switch - Replacement 005007 Battery - Replacement 005003 Horn - Replacement TIME - 37...
  • Page 382 MP3 400 i.e. Time ABLE HARNESS Code Action Duration 005001 Electrical system - Replace- ment 005114 Electrical system - Service TIME - 38...
  • Page 383 MP3 400 i.e. Time Electronic controls ANDLEBAR CONTROLS Code Action Duration 005017 Stop switch - Replacement 005077 Emergency stop switch - Re- placement 005041 Starter button - Replacement 004010 Anti-theft lock - Replacement 005040 Horn button - Replacement 005006 Light switch or turn indicators - Replacement 005039 Headlight switch - replace...
  • Page 384 MP3 400 i.e. Time Transmissions OCKS TRANSMISSIONS Code Action Duration 003094 Tilt locking calliper control ca- ble - replacement 002082 Fuel tank cap opening drive - Replacement 002083 Saddle opening transmission - Replacement 002093 Trunk opening transmission - Replacement 003061 Accelerator transmission - Adjustment TIME - 40...
  • Page 385 MP3 400 i.e. Time Helmet bay HELMET COMPARTMENT Code Action Duration 005046 Battery cover - change 005026 Helmet compartment bulb - Replacement 005027 Helmet compartment bulb support - Replacement 004016 Helmet compartment - Re- placement 004142 Plug socket - Replacement TIME - 41...
  • Page 386 MP3 400 i.e. Time Rear side fairings EAR COVERS Code Action Duration 004081 Glove box door - Replace- ment 004174 Trunk leverage 004141 Cat's eye - Replacement 005048 Licence plate holder - Re- placement 004082 Trunk gasket - Replacement TIME - 42...

  • Page 387: Front Suspension

    MP3 400 i.e. Time Front suspension FRONT SUSPENSION Code Action Duration 003010 Front suspension - Service 003111 Side steering tube - replace- ment 003038 Front wheel axle - Removal and Refit. 003040 Front wheel bearings - Re- placement 003107 Sliding stems - replacement 003113 Front shock absorber - re- placement...
  • Page 388 MP3 400 i.e. Time Cooling system OOLING SYSTEM Code Action Duration 007013 Radiator expansion tank con- nection pipe - Replacement 001052 Coolant and air bleed - Re- placement 007001 Expansion tank - Replace- ment 007024 Expansion tank cap - Re- placement 007003 Coolant delivery and return...
  • Page 389 MP3 400 i.e. Time Braking system RAKE SYSTEM Code Action Duration 002025 Brake piping - Replacement 003096 Tilt locking calliper- replace- ment 003100 Tilt locking calliper pads - re- placement 003108 Parking brake flexible trans- mission - replacement 003109 Parking brake mechanical calliper - replacement 002002 Shoes - Rear brake pads -...
  • Page 390 MP3 400 i.e. Time Code Action Duration 003103 Splitter for suspension lock- ing system hoses- replace- ment 003102 Hoses for the splitter-calliper suspension locking system - replacement 003088 Tilt locking hydraulic pump - replacement 002021 Front brake piping - Replace- ment 002007 Front brake pads - Replace-...
  • Page 391 MP3 400 i.e. Time WINDSHIELD Code Action Duration 004101 Windshield - Replacement Stickers RANSFERS Code Action Duration 004066 Driving mirror - Replacement 004159 Plates / Stickers - Replace- ment TIME - 47...
  • Page 392 MP3 400 i.e. Time The tilt mechanism ILT MECHANISM Code Action Duration 003073 Steering clearance - Adjust- ment 003112 Central steering tube - re- placement 003002 Steering fifth wheel - Re- placement 003115 Parallelogram arms - re- placement 003114 Parallelogram bearings - re- placement 003116 Steering rod - replacement...
  • Page 393 MP3 400 i.e. Time Geared motor EARED MOTOR Code Action Duration 003101 Tilt locking calliper control lever - replacement 005009 Voltage regulator - replace 003095 Tilt locking calliper support bracket - replacement 001069 HV coil - replace 001094 Spark plug cap - Replace- ment 003120 Tilt locking control unit - re-...
  • Page 394 MP3 400 i.e. Time Code Action Duration 003089 Geared motor potentiometer - replacement 003097 Tilt locking calliper micro- switch - replacement TIME - 50...

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