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Table Of Contents - PIAGGIO MP3 400 i.e. Service Manual

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User manual (100 pages)

Table Of Contents

Table of Contents

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Table of Contents

Index Of Topics5

Characteristics7

Maintenance Rules8

Vehicle Identification9

Dimensions And Mass9

Weights And Dimensions9

Wheels And Tyres12

Tightening Torques12

Table Of Contents13

Transmission Cover15

Height At Which The Diameter Should Be Measured16

Cylinder- Piston16

Coupling Categories16

Rings/Housing Coupling Clearances17

Crankcase - Crankshaft - Connecting Rod17

Crankcase / Countershaft Coupling17

Diameter Of Crankshaft Bearings18

Crankshaft Alignment19

Max. Admissible Displacement19

Axial Clearance Between Crankshaft And Connecting Rod19

Slot Packing System20

Base Gasket Thickness20

Recommended Products Table20

Maintenance Chart36

Every 2 Years36

After 1,000 Km36

After 10,000 Km; 50,000 Km; 70,000 Km37

After 15,000 Km; 45,000 Km; 75,000 Km37

Checking The Spark Advance38

Engine Oil Filter45

Oil Pressure Warning Light45

Checking The Ignition Timing46

Cooling System46

Adding Engine Coolant46

Braking System47

Headlight Adjustment48

Troubleshooting49

Excessive Oil Consumption/Exhaust Smoke50

Excessive Consumption50

Poor Lubrication Pressure50

Irregular Clutch Performance Or Slippage50

Insufficient Braking51

Inefficient Braking System51

Brakes Overheating51

Heavy Steering51

Noisy Suspension52

Suspension Oil Leakage52

Electrical System53

Components Arrangement57

Battery Recharge And Starting64

Level Indicators And Enable Signals Section65

Devices And Accessories66

Lights And Turn Indicators68

Checks And Inspections69

With The Key Switch Set To Off70

With The Key Switch In The Off Position70

Virgin Circuit72

Diagnostic Codes73

Diagnostic Code - 1 Flash74

Diagnostic Code - 2 Flashes74

Diagnostic Code - 3 Flashes75

Battery Recharge Circuit75

Stator Winding Check-Up75

Recharge System Voltage Check76

Voltage Regulator/Rectifier76

Sealed Battery80

Injection Electronic Control Unit81

Pick-Up Connector81

Voltage Regulator Connector82

Saddle Opening Receiver Connector82

Turn Indicator Control Device Connector82

Hv Coil Connector83

Anti-Theft Device Pre-Installation Connector83

Fuel Pump Connector83

Instrument Panel Connector "A"83

Instrument Panel Connector "B"84

Parking Control Ecu Connector84

Remote Seat Opening85

Engine From Vehicle87

Exhaust Assy. Removal88

Removal Of The Engine From The Vehicle88

Automatic Transmission94

Air Duct Filter96

Removing The Driven Pulley Shaft Bearing96

Refitting The Driven Pulley Shaft Bearing97

Baffle Roller97

Plastic Roller97

Removing The Driven Pulley98

Inspecting The Clutch Drum98

Anti-Vibration Roller Screw 16.7 -98

Removing The Clutch99

Inspecting The Clutch99

Pin Retaining Collar100

Removing The Driven Half-Pulley Bearing100

Inspecting The Driven Fixed Half-Pulley101

Inspecting The Driven Sliding Half-Pulley102

Refitting The Driven Half-Pulley Bearing102

Refitting The Driven Pulley103

Inspecting The Clutch Spring103

Refitting The Clutch104

Clutch Ring Nut104

Removing The Driving Pulley105

Inspecting The Rollers Case106

Refitting The Driving Pulley107

Installing The Fixed Driving Half-Pulley108

Refitting The Transmission Cover109

Drive Pulley Nut109

M8 Retainers For Transmission Cover110

Removing The Hub Cover111

Removing The Wheel Axle112

Removing The Hub Bearings112

Removing The Wheel Axle Bearings113

Inspecting The Hub Shaft114

Inspecting The Hub Cover115

Refitting The Hub Cover Bearings117

Refitting The Hub Bearings118

Refitting The Ub Cover118

Flywheel Cover119

Removing The Flywheel Cover Components120

Removing The Stator121

Inspecting The Cover Components121

Refitting The Stator124

Refitting The Flywheel Cover Components124

Refitting The Flywheel Cover126

Starter Motor130

Start-Up Remote Control Switch130

Starter Transmission130

Removing The Starter Motor131

Removing The Flywheel Magneto131

Inspecting The Flywheel Components135

Starter Gear Rim135

Intermediate Gear136

Refitting The Free Wheel136

Loctite 243 Medium-Strength Threadlock137

Refitting The Intermediate Gear137

Refitting The Flywheel Magneto138

Refitting The Starter Motor140

Cylinder Assy. And Timing System140

Removing The Intake Manifold141

Removing The Rocker-Arms Cover141

Removing The Timing System Drive141

Removing The Cam Shaft143

Removing The Cylinder Head144

Removing The Valves145

Removing The Cylinder - Piston Assy.146

Inspecting The Small End147

Inspecting The Wrist Pin147

Inspecting The Piston148

Inspecting The Piston Rings149

Removing The Piston150

Choosing The Gasket151

Refitting The Piston Rings153

Refitting The Cylinder153

Inspecting The Cylinder Head153

Inspecting The Timing System Components154

Inspecting The Valve Sealings154

Inspecting The Valve Housings155

Inspecting The Valves155

Standard Diameter155

Minimum Admissible Diameter156

Inspecting The Valve Stem Guide Clearance156

Standard Valve Length157

Inspecting The Springs And Half-Cones158

Refitting The Valves158

Inspecting The Cam Shaft159

Standard Height159

Admissible Limits159

Refitting The Head And Timing System Components161

Exhaust / Intake Head Fixing Nuts:162

Coolant Temperature Sensor:163

Camshaft Retaining Bracket Screws:164

Valve Lifter Mass Stop Bell Fixing Screws:166

Prescribed Clearance167

Refitting The Timing Chain167

020460Y Scooter Diagnosis And Tester168

020330Y Stroboscopic Light For Timing Control168

Refitting The Rocker-Arms Cover169

Tappet Cover Fixing Screws:169

Refitting The Intake Manifold170

Crankcase - Crankshaft170

Splitting The Crankcase Halves171

Removing The Crankshaft172

Removing The Countershaft173

Replacing The Countershaft Bearings173

Inspecting The Crankshaft Components176

Inspecting The Crankshaft Alignment177

Max Admissible Displacement:177

Inspecting The Crankcase Halves178

Inspecting The Crankshaft Plain Bearings179

Check The Bench Bush180

Coupling Chart180

Countershaft182

Refitting The Crankshaft182

Refitting The Crankcase Halves184

Sump Capacity185

Recommended Engine Oil185

Conceptual Diagrams187

General Characteristics187

Diagnosis Guide188

Standard Values189

Oil Pressure Check190

Screws Fixing Oil Pump To The Crankcase195

Lambda Probe Strength199

Pressure Regulator199

Troubleshooting Hints201

Terminals Setup202

Terminal Layout202

Ems Circuit Diagram203

Troubleshooting Procedure204

Engine Does Not Start204

Engine Does Not Start If Only Pulled204

Starting Difficulties205

Engine Start-Up Problems205

Engine Stops At Idle205

Engine Does Not Hold Idling/ Idling Is Unstable/ Idling Too Low205

Engine Does Not Rev Down206

Engine Does Not Return To The Idling Speed/Idling Speed Too High206

Exhaust Backfires In Deceleration206

Exhaust Backfires When Decelerating206

Engine Revs Irregularly207

Engine Irregular Progress With Valve Slightly Open207

Poor Performance At Full Throttle207

Engine Knocking208

Presence Of Knocking (Head Knocking)208

Fuel Supply System208

Removing The Butterfly Valve209

Pump Supply Circuit211

Injection Loads212

Electrical Data212

Circuit Leak Test215

Fuel Filter Check216

Inspecting The Injector Circuit218

Spark Advance236

Coolant Temperature Sensor238

Temperature Sensor238

Zeroing The Throttle239

Resetting The Throttle Valve Position Signal (Tps Reset)239

Lambda Probe242

Removing The Front Wheel248

Front Wheel Hub Overhaul248

The Tilt Mechanism250

Hydraulic System Layout251

Steering Tubes251

Side Headstock Lower Ring Nut257

Screws Fixing The Half-Arm Coupling Flange261

Geared Motor And Suspension Locking System262

Fixing Screws For Tilt Locking Disc Section262

Clamp Fixing Pump Bolt To Anti-Tilting Device264

Before Removing The Geared Motor272

Geared Motor276

Tilt Locking-Unlocking Switch277

Potentiometer279

Rider Presence Sensor280

Tilt Locking Calliper Sensor282

Tone Wheel Sensor283

Wheel Alignment287

Removing The Rear Wheel291

Rear Wheel Axle293

Swinging Arm Fitting299

Shock Absorbers299

Centre-Stand300

Shock Absorber Lower Clamp300

Rear Brake Calliper302

Front Brake Calliper304

Brake Fluid Pipe-Calliper Fitting304

Rear Brake Disc305

Disc Inspection307

Front Brake Disc307

Front Brake Pads309

Rear Brake Pads310

Oil Bleed Screw311

Front Brake Pipes Removal312

Parking Brake313

Remove The Rear Wheel313

Circuit Diagram316

Electric Ventilation317

Electric Fan Check317

System Sealing Check318

Coolant Replacement319

System Top-Up Rules319

Removing The Water Pump Cover320

Rear Handlebar Cover324

Instrument Panel325

Front Handlebar Cover325

Headlight Assy326

Remove The Radiator Cover326

Frame Central Cover327

Taillight Assy.330

Side Fairings332

License Plate Holder332

Handles And Top Side Fairings336

Radiator Cover337

Pre-Delivery339

Aesthetic Inspection340

Tightening Torques Inspection340

Cylinder Assy.349

Cylinder Head Assy.350

Rocker Arms Support Assy.351

Cylinder Head Cover352

Driven Pulley354

Final Gear Assy.356

Driving Pulley357

Flywheel Magneto359

Butterfly Valve360

Throttle Body360

Exhaust Pipe361

Legshield Spoiler364

Central Cover367

Rear Shock-Absorber370

Handlebar Covers371

Handlebar Components372

Turn Signal Lights376

Electric Devices381

Electronic Controls383

Transmissions384

Rear Side Fairings386

Front Suspension387

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Table of Contents

Troubleshooting