PIAGGIO MP3 500 ie SPORT Business LT 2011 Manual

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MANUALE STAZIONE DI SERVIZIO

xxx(IT)-xxx(EN)-xxx(FR)-xxx(DE)-xxx(ES)-xxx(PT)-

xxx(NL)-xxx(EL)

MP3 500 ie SPORT Business LT (2011)

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Summary of Contents for PIAGGIO MP3 500 ie SPORT Business LT 2011

Page 1 MANUALE STAZIONE DI SERVIZIO xxx(IT)-xxx(EN)-xxx(FR)-xxx(DE)-xxx(ES)-xxx(PT)- xxx(NL)-xxx(EL) MP3 500 ie SPORT Business LT (2011)
Page 2 Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official PIAGGIO sales network. © Copyright 2013 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited.
Page 3 MP3 500 ie SPORT Business LT (2011) Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 8 MP3 500 ie SPORT Business LT (2011) Characteristics Vehicle identification The identification registration numbers consist of a prefix stamped on the chassis and engine "B" re- spectively, followed by a number. These numbers must always be indicated on spare parts requests. To read the chassis number, remove the relevant port "A"...
Page 9 MP3 500 ie SPORT Business LT (2011) Characteristics Chassis prefix (A) ZAPM643001 Engine prefix (B): M611M Dimensions and mass CHAR - 9...
Page 10 MP3 500 ie SPORT Business LT (2011) Characteristics WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 253 ± 8 kg Maximum weight allowed 445 kg Maximum height 1440 mm Width 760 mm Wheelbase 1550 mm Length 2210 mm Track 465 mm Engine ENGINE Specification...
Page 11 MP3 500 ie SPORT Business LT (2011) Characteristics Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Starter Electric starter Ignition Electronic, inductive, high efficiency ignition, integrated with the injection system, with variable advance and separate H.V. coil. Ignition advance Three-dimensional map managed by control unit Spark plug NGK CR7EKB Alternative spark plug...
Page 12 MP3 500 ie SPORT Business LT (2011) Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Wheel rim type Light alloy wheel rims. Front wheel rim 12'' x 3.00 Rear wheel rim 14'' x 4.50 Front tyre Tubeless, 120/70-12" 51S or 51P Rear tyre Tubeless, 140/70 -14"...
Page 13 MP3 500 ie SPORT Business LT (2011) Characteristics Name Torque in Nm Screw fixing sliding stem to shock absorber 45 to 50 Clamp for sliding stem locking device 6.5 - 10.5 Fixing nuts for constant-velocity universal joints 18 - 20 Potentiometer to anti-tilting device clamp 8 to 10 Electric motor to anti-tilting device clamp...
Page 14 MP3 500 ie SPORT Business LT (2011) Characteristics THERMAL GROUP AND TIMING SYSTEM Name Torque in Nm Spark plug 12 ÷ 14 Head fixing stud bolts Head fixing nuts 10 - 12 Exhaust / intake head fixing nuts 10 - 12 Head lubrication control jet 5 - 7 Coolant temperature sensor:...
Page 15 MP3 500 ie SPORT Business LT (2011) Characteristics Name Torque in Nm Water pump cover screws 3 - 4 Thermostat cover screws 3 ÷ 4 Bleed screw Overhaul data Assembly clearances Cylinder - piston assy. HEIGHT TO MEASURE THE PISTON Specification Desc./Quantity 10 mm...
Page 16 MP3 500 ie SPORT Business LT (2011) Characteristics Name Initials Cylinder Piston Play on fitting Cylinder- Piston 94.004÷94.011 93.968÷93.975 0.029÷0.043 Cylinder- Piston 94.011÷94.018 93.975÷93.982 0.029÷0.043 N.B. THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.
Page 17 MP3 500 ie SPORT Business LT (2011) Characteristics Rings/slots coupling clearances: Carefully clean the sealing rings housings. Place a feeler gauge between the ring and the housing as shown in the drawing and check the coupling clearances. Top ring Standard coupling clearance: 0.01-0.06 mm Maximum clearances allowed after use: 0.10 Intermediate ring Standard coupling clear-...
Page 18 MP3 500 ie SPORT Business LT (2011) Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission-side 1 ± 0.025 D = 0.20 ÷ 0.50 shoulder Half-shaft, transmission 20.9 - 0.05 D = 0.20 ÷...
Page 19 MP3 500 ie SPORT Business LT (2011) Characteristics CRANKSHAFT Specification Desc./Quantity Cat. 1 Standard diameter: 40.010 ÷ 40.016 Cat. 2 Standard diameter: 40.016 ÷ 40.022 Crankshaft alignment Specific tooling 020335Y Magnetic mounting for dial gauge MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm...
Page 20 MP3 500 ie SPORT Business LT (2011) Characteristics 0.1 ÷ 0.405 mm (when cold) Compression ratio 10.5: 1 Slot packing system Shimming system to control compression ratio DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE.
Page 21 INDEX OF TOPICS TOOL OOLING...
Page 22 MP3 500 ie SPORT Business LT (2011) Tooling SPECIFIC TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings 001467Y008 Pliers to extract 17 mm ø...
Page 23 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 001467Y031 Bell 001467Y034 Pliers to extract ø 15-mm bearings 001467Y035 Bearing housing, external ø 47 mm 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on steering tube 020004Y Punch for removing steering bearings from headstock...
Page 24 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge 020201Y Spacer bushing driving tube 020262Y Crankcase splitting plate 020306Y Punch for assembling valve seal rings TOOL - 24...
Page 25 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020648Y Single battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35-mm Adaptor 020358Y 37 x 40mm Adaptor TOOL - 25...
Page 26 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020359Y 42 x 47mm Adaptor 020360Y 52 x 55-mm Adaptor 020364Y 25-mm guide 020376Y Adaptor handle 020382Y012 bush (valve removing tool) 020412Y 15-mm guide 020424Y Driven pulley roller casing fitting punch TOOL - 26...
Page 27 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020439Y 17-mm guide 020444Y Tool for fitting/ removing the driven pulley clutch 020456Y Ø 24 mm adaptor TOOL - 27...
Page 28 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020458Y Puller for lower bearing on steering tube 020459Y Punch for fitting bearing on steering tube 020922Y Diagnosis Tool 020467Y Flywheel extractor 020468Y Piston assembly band 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing TOOL - 28...
Page 29 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020478Y Punch for driven pulley roller casing 020479Y Countershaft lock wrench TOOL - 29...
Page 30 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020480Y Petrol pressure check kit 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30-mm guide 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter TOOL - 30...
Page 31 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020640y software euro 3 020481Y004 Parking control unit interface wiring Marelli MIU diagnosis software Marelli MIU diagnosis software 020646Y Parallelogram and steering positioning tool 020647Y Toe-in checking tool 020647Y028...
Page 32 MP3 500 ie SPORT Business LT (2011) Tooling Stores code Description 020661Y Water pump overall seal replacement kit TOOL - 32...
Page 33 INDEX OF TOPICS MAIN AINTENANCE...
Page 34 MP3 500 ie SPORT Business LT (2011) Maintenance ADJUSTMENT PROCEDURE OF THE RING NUTS OF THE SIDE HEADSTOCKS Remove the Piaggio clip-on badge with a flat- headed screwdriver Undo the screw under the badge and remove the centre headlight cover Undo the screws "A"...
Page 35 MP3 500 ie SPORT Business LT (2011) Maintenance Undo the screws "D" and remove the front grille surround Undo the two upper fastener screws "E" for the headlight assembly Undo the two lower fastener screws "F" and re- move the headlight assembly from its seat Undo the indicated screws and remove the wind- screen Undo the indicated screws and remove the spoiler...
Page 36 MP3 500 ie SPORT Business LT (2011) Maintenance Undo the indicated screws and remove the com- plete shield Once the plastics have been remove the ring nuts of the side headstock of the front suspension can be reached Unscrew the upper ring nut Bring the upper ring nut to the end of the headstock thread of the side suspension Tighten the lower ring nut to the specified torque...
Page 37 MP3 500 ie SPORT Business LT (2011) Maintenance Tighten upper ring nut to the specified torque with the appropriate key. Carry out the assembly of the plastic covers in re- verse order to the disassembly. Specific tooling 020892y Steering side headstock ring nut key Locking torques (N*m) Side headstock upper ring nut 20 - 24...
Page 38 MP3 500 ie SPORT Business LT (2011) Maintenance Km x 1,000 Sliding shoes / CVT rollers Suspension Spark plugs Roll lock calliper control cable Valve clearance Operation time 10' 19 10' 22 10' 19 10' 22 10' 19 10' 22 10' 19 10' 22 Checking the spark advance...
Page 39 MP3 500 ie SPORT Business LT (2011) Maintenance - 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 the engine between the spark plug and spark plug cap - Connect the induction clamp on the spark gap cable respecting the proper polarity (the arrow on...
Page 40 MP3 500 ie SPORT Business LT (2011) Maintenance - Upon refitting, place the spark plugs at the re- quired angle and tighten by hand until it is finger tight; - Use the wrench only for final tightening of the spark plug; - Place cap «A»...
Page 41 MP3 500 ie SPORT Business LT (2011) Maintenance Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end; if the level is below the MAX mark, it needs to be filled up with the right amount of hub oil.
Page 42 MP3 500 ie SPORT Business LT (2011) Maintenance - Dry it with a clean cloth and short blasts of compressed air. - Soak it in a mixture of 50% petrol and 50% specified oil. - Gently squeeze the filtering element with your hands but do not wring it; allow it to drip dry and then refit.
Page 43 MP3 500 ie SPORT Business LT (2011) Maintenance Once all the oil has drained through the drainage hole, unscrew and remove the oil cartridge filter «C ». Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque.
Page 44 MP3 500 ie SPORT Business LT (2011) Maintenance Check This operation must be carried out with the engine cold and following the procedure below: - Place the vehicle on its centre stand and on flat ground. - Unscrew the cap/dipstick «A», dry it with a clean cloth and reinsert it, screwing it all the way down.
Page 45 MP3 500 ie SPORT Business LT (2011) Maintenance Oil pressure warning light The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been started. If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication sys-...
Page 46 MP3 500 ie SPORT Business LT (2011) Maintenance - Undo the screw shown in the figure and remove the expansion tank cap on RHS. - Top up if the fluid level is near or below the MIN level edge. The liquid level must always be be- tween the MIN and MAX level.
Page 47 MP3 500 ie SPORT Business LT (2011) Maintenance INTEGRAL BRAKING SYSTEM LEVEL CHECK - Rest the vehicle on its centre stand on level ground. - Remove the inspection cover and check that the brake fluid inside the reservoir is not below the recommended level.
Page 48 MP3 500 ie SPORT Business LT (2011) Maintenance INTEGRAL BRAKING SYSTEM LEVEL TOP- PING UP - Remove the inspection cover, unscrew the cap indicated and top up using the recommended product. - If there is air in the circuit, bleed the system as described in the «Braking system/filling - bleeding the rear - integral braking system»...
Page 49 MP3 500 ie SPORT Business LT (2011) Maintenance MAIN - 49...
Page 50 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 51 MP3 500 ie SPORT Business LT (2011) Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION Possible Cause Operation...
Page 52 MP3 500 ie SPORT Business LT (2011) Troubleshooting Possible Cause Operation Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift of the disc with a dial gauge and with wheel mounted on the vehicle.
Page 53 MP3 500 ie SPORT Business LT (2011) Troubleshooting Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber Check the condition of wear of the steering covers and the adjustments. TROUBL - 53...
Page 54 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 55 MP3 500 ie SPORT Business LT (2011) Electrical system 1.BATTERY 2.STARTER SOLENOID 3. STARTER MOTOR 4. FUSE 01 - 15 A 5. FUSE 02 - 20 A 6. FUSE 03 - 20 A 7.FUSE 04 - 15 A 8. FUSE 05 - 15 A 9.FUSE 06 - 7.5 A 10.IGNITION KEY CONTACTS 11.
Page 56 MP3 500 ie SPORT Business LT (2011) Electrical system 21. TURN INDICATOR CONTROL DEVICE AND HAZARD 22. TURN INDICATOR SWITCH 23. STOP BUTTONS 24. 12V - 10W RIGHT BULBS 25. LEFT BULBS 12V-10W 26. PRE-INSTALLATION FOR SADDLE OPENING RECEIVER 27. PRE-INSTALLATION FOR ANTI-THEFT DEVICE 28.LICENSE PLATE LAMP 29.FRONT DAYLIGHT RUNNING LIGHT 30.
Page 57 MP3 500 ie SPORT Business LT (2011) Electrical system 59. INJECTION LOAD RELAY 60.C.D.I. 61. ENGINE SPEED SENSOR 62.LAMBDA PROBE 63. LOCK/UNLOCK PRESSURE SENSOR 64.FUEL PUMP 65. ENGINE TEMPERATURE SENSOR 66.12V - 10W STOP LIGHT BULBS 67. ENGINE STOP 68. BOOT LIGHT SWITCH 69.SADDLE LIGHT SWITCH 70.START-UP ENABLING REMOTE CONTROL SWITCH 71.HEADLIGHT WITH 12V-55W TWIN-FILAMENT BULB...
Page 58 MP3 500 ie SPORT Business LT (2011) Electrical system GV = Yellow-Green Ar = Orange Az = Sky blue GrBl = Grey-Blue GrN = Grey-Black RBl = Red-Blue GR =Yellow-Red BlN = Blue-Black THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION. 1.
Page 59 MP3 500 ie SPORT Business LT (2011) Electrical system 9. 1 front daylight running light bulb 12 V - 5 W, 2 rear daylight running light bulbs 12 V - 5 W, 2 license plate bulbs 12 V - 5 W; 10.
Page 60 MP3 500 ie SPORT Business LT (2011) Electrical system 46. Rider presence sensor 47. Unlock switch 48. Lock switch 49. Hand brake 50. Engine speed sensor 51. H.V. coil 52. Fuel injector 53. Engine temperature sensor 54. Fuel pump 55. Diagnosis socket 56.
Page 61 MP3 500 ie SPORT Business LT (2011) Electrical system Az = Sky blue GrBl = Grey-Blue GrN = Grey-Black RBl = Red-Blue GR =Yellow-Red BlN = Blue-Black Components arrangement 1. Immobilizer Aerial Remove the shield back plate to reach it. ELE SYS - 61...
Page 62 MP3 500 ie SPORT Business LT (2011) Electrical system 2. Geared motor Remove the legshield to reach it. 3. Remote control switches Remove the legshield to reach it. 4. Auxiliary fuses Remove the flap of the right-side footrest to reach these fuses.
Page 63 MP3 500 ie SPORT Business LT (2011) Electrical system 6. Fuel level transmitter 7. HV coil Remove the central chassis cover to reach it. 8. Lambda probe The lambda probe is mounted on the exhaust manifold. 9. Oil pressure sensor Remove the exhaust end to reach it.
Page 64 MP3 500 ie SPORT Business LT (2011) Electrical system 10. Turn indicator control device Remove the left side fairing to reach it. 11. Voltage regulator Remove the right side fairing to reach it. 12. Diagnosis connector 13. Main fuses These components are found in the battery com- partment.
Page 65 MP3 500 ie SPORT Business LT (2011) Electrical system 17. Rider presence sensor Open the saddle and remove the cover to reach the rider presence sensor. 18. Parking control ECU Remove the shield back plate to reach it. Conceptual diagrams ELE SYS - 65...
Page 66 MP3 500 ie SPORT Business LT (2011) Electrical system Ignition 1.BATTERY 5. FUSE 02 - 20 A 7.FUSE 04 - 15 A 10.IGNITION KEY CONTACTS 14. FUSE 10 - 7.5 A 32. IMMOBILIZER AERIAL 35.INSTRUMENT PANEL 44. PARKING CONTROL ECU 45.
Page 67 MP3 500 ie SPORT Business LT (2011) Electrical system THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION. 1. Instrument panel 12. Auxiliary fuses 29. Main fuses 34. Battery 12 V - 14 A 35. Ignition switch contacts 37. Injection load relay 50.
Page 68 MP3 500 ie SPORT Business LT (2011) Electrical system Battery recharge and starting 1.BATTERY 2.STARTER SOLENOID 3. STARTER MOTOR 5. FUSE 02 - 20 A 10.IGNITION KEY CONTACTS 12. FUSE 08 - 10 A 17. FUSE 13 - 30 A 18.VOLTAGE REGULATOR 19.
Page 69 MP3 500 ie SPORT Business LT (2011) Electrical system THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION. 1. Instrument panel 12. Auxiliary fuses 15. Brake pedal button, 2 stop buttons; 21. Engine stop switch 27. Magneto flywheel 28. Voltage regulator 29.
Page 70 MP3 500 ie SPORT Business LT (2011) Electrical system Level indicators and enable signals section 1.BATTERY 5. FUSE 02 - 20 A 7.FUSE 04 - 15 A 10.IGNITION KEY CONTACTS 14. FUSE 10 - 7.5 A 32. IMMOBILIZER AERIAL 34. FUEL GAUGE 35.INSTRUMENT PANEL 39.OIL PRESSURE SENSOR 57.
Page 71 MP3 500 ie SPORT Business LT (2011) Electrical system 1. Instrument panel 11. Headlight relay 12. Auxiliary fuses 21. Engine stop switch 29. Main fuses 34. Battery 12 V - 14 A 35. Ignition switch contacts 38. Horn relay 39. Geared motor 40.
Page 72 MP3 500 ie SPORT Business LT (2011) Electrical system 50. Engine speed sensor 54. Fuel pump 56. Injection ECU 58. Immobilizer antenna 59. External temperature sensor 61. Fuel level transmitter 62. Oil pressure sensor Devices and accessories 1.BATTERY 4. FUSE 01 - 15 A 5.
Page 73 MP3 500 ie SPORT Business LT (2011) Electrical system 26. PRE-INSTALLATION FOR SADDLE OPENING RECEIVER 27. PRE-INSTALLATION FOR ANTI-THEFT DEVICE 33. HORN RELAY 35.INSTRUMENT PANEL 36.SWITCH FOR SADDLE OPENING 37.AMBIENT TEMPERATURE SENSOR 38.MODE BUTTON 40.CASE OPENING SWITCH 41.SADDLE OPENING ACTUATOR 42.
Page 74 MP3 500 ie SPORT Business LT (2011) Electrical system 1. Instrument panel 2. 2 bulbs for rear turn indicators 12 V - 10 W 3. 2 bulbs for front turn indicators 12 V- 10 W 6. PMP connection 8. Pre-installation for anti-theft device 10.
Page 75 MP3 500 ie SPORT Business LT (2011) Electrical system 38. Horn relay 41. Parking control ECU 55. Diagnosis socket 56. Injection ECU 57. Pre-installation heated handgrips control device and leg warmer 60. Pressure sensor 61. Fuel level transmitter 63. MODE button 64.
Page 76 MP3 500 ie SPORT Business LT (2011) Electrical system 20.HAZARD BUTTON 21. TURN INDICATOR CONTROL DEVICE AND HAZARD 22. TURN INDICATOR SWITCH 23. STOP BUTTONS 24. 12V - 10W RIGHT BULBS 25. LEFT BULBS 12V-10W 28.LICENSE PLATE LAMP 29.FRONT DAYLIGHT RUNNING LIGHT 30.
Page 77 MP3 500 ie SPORT Business LT (2011) Electrical system 1. Instrument panel 2. 2 bulbs for rear turn indicators 12 V - 10 W 3. 2 bulbs for front turn indicators 12 V- 10 W 4. Turn indicator switch 5. Turn indicator control device with Hazard 7.
Page 78 MP3 500 ie SPORT Business LT (2011) Electrical system - service key with incorporated transponder (black key) - H.V. coil - diagnosis LED The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF"...
Page 79 MP3 500 ie SPORT Business LT (2011) Electrical system With the key switch in the ON 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 ignition switch contacts and that fuses No.
Page 80 MP3 500 ie SPORT Business LT (2011) Electrical system With the ignition switch at ON check there is bat- tery 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.
Page 81 MP3 500 ie SPORT Business LT (2011) Electrical system 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 82 MP3 500 ie SPORT Business LT (2011) Electrical system 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 steadily. The engine can be started. 4.
Page 83 MP3 500 ie SPORT Business LT (2011) Electrical system Diagnostic code - 2 flashes A two-flash code shows a system where the con- trol unit does not show the transponder signal. This might depend on the inefficiency of the immobilizer antenna or the transponder.
Page 84 MP3 500 ie SPORT Business LT (2011) Electrical system This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. The three-phase alternator provides good recharge power and at low revs a good compromise is ach- ieved between generated power and idle stability.
Page 85 MP3 500 ie SPORT Business LT (2011) Electrical system 2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals.. 3) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage. Electric characteristic Voltage ranging between 14.0 and 15.0V at 5000 rpm.
Page 86 MP3 500 ie SPORT Business LT (2011) Electrical system 6. Fuse No. 8 7. Start-up enabling relay switch 8. Stop buttons 9. Starter button 10. Injection ECU WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No.
Page 87 MP3 500 ie SPORT Business LT (2011) Electrical system 1. Battery 2. Fuse No. 2 3. ignition switch contacts 4. Fuse No. 9 5. Horn button 6. Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
Page 88 MP3 500 ie SPORT Business LT (2011) Electrical system 5. Turn indicator switch 6. Hazard button 7. Turn indicator control device with Hazard 8. Rear right turn indicator bulb 9. Front right turn indicator bulb 10. Front left turn indicator bulb 11.
Page 89 MP3 500 ie SPORT Business LT (2011) Electrical system Lights list 1. Battery 2. Fuse No. 2 3. ignition switch contacts 4. Fuse No. 4 5. Fuse No. 9 6. Fuse No. 11 7. Headlight solenoid 8. Ignition switch contacts 9.
Page 90 MP3 500 ie SPORT Business LT (2011) Electrical system 2) Check fuses No. 4 and 12. 3) Check ignition switch contacts. 4) Check there is voltage between the Yellow-Black of fuse No. 12 and the ground lead. Otherwise, check the continuity of cable harnesses. 5) Check the continuity of the bulb cable harnesses using fuse No.
Page 91 MP3 500 ie SPORT Business LT (2011) Electrical system Specification Desc./Quantity Power: 12V - 5W Quantity: 1 Instrument panel bulb Type:Incandescent Power:12V - 2W Quantity:4 THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION. 1. Battery 2. Fuse No. 2 3. ignition switch contacts 4.
Page 92 MP3 500 ie SPORT Business LT (2011) Electrical system 15. Light switch WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. DAYLIGHT RUNNING LIGHT LINE CHECK 1) Check that bulbs operate properly. 2) Check fuses No. 4 and 12. 3) Check ignition switch contacts.
Page 93 MP3 500 ie SPORT Business LT (2011) Electrical system Specification Desc./Quantity License plate bulb Type: Incandescent Power:12V - 5W Quantity:2 Front turn indicator light bulb Type: Incandescent (BAU 15s) Power: 12V - 10W Quantity: 1 RHS + 1 LHS Front side light bulb Type: Incandescent (W2.1x9.5d) Power: 12V - 5W Quantity: 1...
Page 94 MP3 500 ie SPORT Business LT (2011) Electrical system The fuse No. 13 is located on the starter relay FUSE TABLE Specification Desc./Quantity Fuse No. 1 Capacity: 7.5 A Protected circuits:Injection ECU battery power Fuse No. 2 Capacity: 15A Protected circuits:Battery-powered injection loads, electric fan Fuse No.
Page 95 MP3 500 ie SPORT Business LT (2011) Electrical system Specification Desc./Quantity Protected circuits:Key powered stop, start-up and start-up enabling lights. Fuse No. 9 Capacity: 7.5 A Protected circuits:Key powered passing and horn Fuse No. 10 Capacity: 7.5A Protected circuits:Key powered injection ECU, immo- bilizer aerial, electric fan relay, injection load relay Fuse No.
Page 96 MP3 500 ie SPORT Business LT (2011) Electrical system The fuse No. 13 is located on the starter relay FUSE CHART Specification Desc./Quantity Fuse No. 1 Capacity: 15A Protected circuits:Battery-powered pre-installation heated handgrips control device and leg warmer, L.V. socket Fuse No.
Page 97 MP3 500 ie SPORT Business LT (2011) Electrical system Specification Desc./Quantity Protected circuits:Battery-powered PMP connection, instrument panel Fuse No. 8 Capacity: 10A Protected circuits:Key powered stop, start-up and start-up enabling lights. Fuse No. 9 Capacity: 7.5 A Protected circuits:Key powered passing and horn Fuse No.
Page 98 MP3 500 ie SPORT Business LT (2011) Electrical system I = Warning light for helmet compartment courtesy light on L = Engine control telltale light and injection system failure warning light M = Low fuel warning light N = Engine stop warning light O= Turn indicator warning light P = Low oil pressure warning light Q = Front suspension locking system failure warning light (if available)
Page 99 MP3 500 ie SPORT Business LT (2011) Electrical system Minimum 6 h Maximum 24 h 3) Constant current battery charge mode - Charge current equal to 1/10 of the battery rated capacity - Charge time: Maximum 5 h Battery installation VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF) WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS.
Page 100 MP3 500 ie SPORT Business LT (2011) Electrical system 3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals.
Page 101 MP3 500 ie SPORT Business LT (2011) Electrical system 12.8 - 13.15 V Bring the battery to full charge, us- ing the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and...
Page 102 MP3 500 ie SPORT Business LT (2011) Electrical system g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge pro-...
Page 103 MP3 500 ie SPORT Business LT (2011) Electrical system 15. Engine speed sensor negative (Brown) 16. Diagnosis (Purple-White) 17. Immobilizer LED (Red-Green) 18. Engine stop switch, coolant temperature sen- sor (Grey-Green) 19. Not connected 20. Injection load solenoid (Black-Purple) 21. Not connected 22.
Page 104 MP3 500 ie SPORT Business LT (2011) Electrical system 7. Not connected 8. Key powered (Yellow-Black) 9. Ground lead (Black) 10. Not connected 11. Not connected 12. Not connected H.V. COIL CONNECTOR 1. Injection load relay (Black-Green) 2. Injection ECU (Red-Black) ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1.
Page 105 MP3 500 ie SPORT Business LT (2011) Electrical system INSTRUMENT PANEL CONNECTOR "A" 1. Not connected 2. Not connected 3. Not connected 4. Not connected 5. Instrument panel lighting (Yellow-Black) 6. Battery-powered (Red-Blue) 7. Not connected 8. Not connected 9. Not connected 10.
Page 106 MP3 500 ie SPORT Business LT (2011) Electrical system 20. Key powered from the parking control ECU (Yellow-Green) PARKING CONTROL ECU CONNECTOR 1A. Potentiometer power supply (Orange-Blue) 2A. CAN "L" Line (White-Blue) 3A. Warning light power supply (Yellow-Green) 4A. Roll lock activated warning light (Pink-Black) 5A.
Page 107 MP3 500 ie SPORT Business LT (2011) Electrical system INJECTION ELECTRONIC CONTROL UNIT CONNECTOR 1. Injection telltale light LED (Brown-Black) 2. Rpm indicator on instrument panel (Yellow) 3. CAN "L" Line (Pink-White) 4. Lambda probe (-) (White-Green) 5. Key powered (Red-White) 6.
Page 108 MP3 500 ie SPORT Business LT (2011) Electrical system VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Black) 2. Ground lead (Black) 3. Battery positive (Red-Black) 4. Ground lead (Black) TURN INDICATOR CONTROL DEVICE CON- NECTOR 1. Hazard button (Brown) 2. Left Switch (White-Pink) 3.
Page 109 MP3 500 ie SPORT Business LT (2011) Electrical system ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. Left turn indicators (Pink) 2. Right turn indicators (White-Blue) 3. Ground lead (Black) 4. Battery-powered (Blue) 5. Key powered (Yellow-Red) 6. Helmet compartment lighting (Blue-Black) 7. Not connected 8.
Page 110 MP3 500 ie SPORT Business LT (2011) Electrical system INSTRUMENT PANEL CONNECTOR "B" 1. Vehicle speed signal (Sky blue) 2. Fuel level indicator (White-Green) 3. Water temperature sensor (Sky blue-Black) 4. Water temperature sensor ground lead (Brown- White) 5. «MODE» remote button (Green) 6.
Page 111 MP3 500 ie SPORT Business LT (2011) Electrical system 2B. CAN "H" line (Pink-Red) 3B. Left wheel speed sensor (Green) 4B. Right wheel speed sensor (Red) 5B. Potentiometer signal (Green-Blue) 6B. Locking/unlocking switch (Green-Grey) 7B. Horn solenoid for alarms (White) 8B.
Page 112 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 113 MP3 500 ie SPORT Business LT (2011) Engine from vehicle Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo. Exhaust assy. Removal - Remove the side fairings. - Remove the central frame cover. - Remove the exhaust end. - Disconnect the lambda probe connector.
Page 114 MP3 500 ie SPORT Business LT (2011) 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 115 MP3 500 ie SPORT Business LT (2011) Engine from vehicle - Remove the spark plug caps. - Remove the coolant temperature sensor con- nector indicated in the photograph. - 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 116 MP3 500 ie SPORT Business LT (2011) 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.
Page 117 INDEX OF TOPICS NGINE...
Page 118 MP3 500 ie SPORT Business LT (2011) 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 119 MP3 500 ie SPORT Business LT (2011) 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 120 MP3 500 ie SPORT Business LT (2011) 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 121 MP3 500 ie SPORT Business LT (2011) Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little...
Page 122 MP3 500 ie SPORT Business LT (2011) Engine Anti-vibration roller screw 16.7 ÷ 19.6 Removing the driven pulley - Remove the clutch bell. - Remove the stationary driving half-pulley. - Remove the driven pulley assembly with the belt. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.
Page 123 MP3 500 ie SPORT Business LT (2011) 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 124 MP3 500 ie SPORT Business LT (2011) 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.
Page 125 MP3 500 ie SPORT Business LT (2011) Engine - Using the special tool inserted through the roller bearing, pull out the ball bearing. N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAM- AGING THE THREADING. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide N.B.
Page 126 MP3 500 ie SPORT Business LT (2011) 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 127 MP3 500 ie SPORT Business LT (2011) 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 128 MP3 500 ie SPORT Business LT (2011) 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 129 MP3 500 ie SPORT Business LT (2011) Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width 27.5 mm Overall width 28.7 mm Removing the driving pulley - Using a 27 mm wrench, turn the central pulley nut to horizontally align the central inside holes and install the special tool.
Page 130 MP3 500 ie SPORT Business LT (2011) Engine - Move the belt downwards. - Suitable support the roller contrast and extract the movable driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out. Inspecting the rollers case - Check that the inside bushings shown in the figure exhibit no signs of abnormal wear and measure the inside diameter.
Page 131 MP3 500 ie SPORT Business LT (2011) Engine - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt faying surfaces on both pulley halves. Refitting the driving pulley Installing the roller container - Install the spacer with the internal chamfer facing towards the inside.
Page 132 MP3 500 ie SPORT Business LT (2011) Engine - Insert the half-pulley on the crankshaft. - Insert the spacer bushing. Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley.
Page 133 MP3 500 ie SPORT Business LT (2011) 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.
Page 134 MP3 500 ie SPORT Business LT (2011) 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 135 MP3 500 ie SPORT Business LT (2011) Engine - Install the outside plastic transmission cover. - Tighten the 4 fastening screws to the prescribed torque. Locking torques (N*m) External transmission cover screws 7 to 9 End gear Removing the hub cover - Drain the rear hub oil through the oil drainage cap located under the engine.
Page 136 MP3 500 ie SPORT Business LT (2011) Engine Removing the hub bearings - Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts. Specific tooling 001467Y014 Calliper to extract ø...
Page 137 MP3 500 ie SPORT Business LT (2011) Engine - Support the hub cover using the stud bolt set. - Pull out the bearing using the special tool. Specific tooling 020476Y Stud bolt set 020376Y Adaptor handle 020477Y 37 mm adaptor 020483Y 30-mm guide - Remove the oil guard using a screwdriver.
Page 138 MP3 500 ie SPORT Business LT (2011) Engine 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 seals. - In case of faults, replace the damaged parts. Characteristic Connection diameter for countershaft: A = diameter 20 - 0.01 -0.02 mm...
Page 139 MP3 500 ie SPORT Business LT (2011) Engine - Check the capacity of the bearings. In case of faults, replace the hub cover. Refitting the driven pulley shaft bearing - Heat the crankcase using the heat gun. Specific tooling 020151Y Air heater - Insert the driven pulley shaft bearing until it abuts against the bottom of the seat using the special tool.
Page 140 MP3 500 ie SPORT Business LT (2011) Engine - Heat the gear shaft bearing seat on the crank- case. - Insert the gear shaft bearing in the upper crank- case seat using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE).
Page 141 MP3 500 ie SPORT Business LT (2011) Engine - Insert the intermediate shaft bearing on the cover using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle 020360Y 52 x 55-mm Adaptor 020363Y 20-mm guide...
Page 142 MP3 500 ie SPORT Business LT (2011) Engine Refitting the hub bearings - Place the 3 shafts as shown in the figure. Refitting the ub cover - Check the proper position of the centring dowels. - Install a new gasket. - Fit the gearbox cover, making sure the breather pipe is in the correct position.
Page 143 MP3 500 ie SPORT Business LT (2011) Engine 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. N.B.
Page 144 MP3 500 ie SPORT Business LT (2011) Engine - 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. NOTE THE RELEVANT POSITIONS. CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR.
Page 145 MP3 500 ie SPORT Business LT (2011) Engine 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. Inspecting the cover components - Loosen the two retaining screws and remove the reed valve support with bulkhead.
Page 146 MP3 500 ie SPORT Business LT (2011) Engine - 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 147 MP3 500 ie SPORT Business LT (2011) Engine - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Electric characteristic Resistance: 0.2 - 1 Ω...
Page 148 MP3 500 ie SPORT Business LT (2011) Engine - Install the wiring guide bracket tightening the 2 screws to the prescribed torque. Locking torques (N*m) Stator cable harness guide bracket screws 3 - 4 Refitting the flywheel cover components - Before reassembling, check that all components are perfectly clean.
Page 149 MP3 500 ie SPORT Business LT (2011) Engine - 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...
Page 150 MP3 500 ie SPORT Business LT (2011) Engine Refitting the flywheel cover - Install a new oil filter, lubricate the gasket, screw on and finally tighten to the prescribed torque. Locking torques (N*m) Engine oil filter 12 - 16 - Install the supply hose to the cylinder and con- nect the return hose to the pump cover using 3 new clamps.
Page 151 MP3 500 ie SPORT Business LT (2011) Engine - Install a new gasket on the engine crankcase. - Check the presence of the three centring dowels. - Turn the crankshaft in order to align the counter- shaft movement sensor with a reference point on the crankcase (see figure).
Page 152 MP3 500 ie SPORT Business LT (2011) Engine N.B. - THE INTERMEDIATE BOLTS FOR THE REMAINING MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT FOR THE MANIFOLD SUPPORT (SHOWN IN THE FIGURE) ARE SLIGHTLY LONGER. Locking torques (N*m) Flywheel cover screws 11 - 13 Flywheel and starting - Remove the three bands shown in the figure for...
Page 153 MP3 500 ie SPORT Business LT (2011) Engine Start the engine (so that it cannot move) long enough to measure the rpm and starter absorption. N.B. THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER, THE RPM READING IS NOT THE REAL ONE, BUT IS VALID FOR DIAGNOSTIC PURPOSES.
Page 154 MP3 500 ie SPORT Business LT (2011) Engine 9 - High trailing speed Low electrical absorption The engine turns too freely, check the compression end pressure. If the values are not correct proceed as follows. 10 - The starter motor works properly. 11 - Check the rotation of the armature.
Page 155 MP3 500 ie SPORT Business LT (2011) Engine THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED. - Loosen the two fastening screws. - Extract the complete starter motor. Removing the flywheel magneto N.B. IF YOU MUST REMOVE THE FLYWHEEL, IT IS NECESSARY TO REMOVE THE CHAIN GUIDE SLIDING BLOCK RETAIN PLATE FIRST.
Page 156 MP3 500 ie SPORT Business LT (2011) Engine - 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. Specific tooling 020472Y Flywheel lock wrench - Loosen the magneto flywheel fastening nut.
Page 157 MP3 500 ie SPORT Business LT (2011) Engine - Insert the special removing tool. - Using a 27-mm wrench and a 19-mm bushing, release the flywheel. Specific tooling 020467Y Flywheel extractor - Remove the extractor. - Remove the nut and extract the flywheel with the start-up rim.
Page 158 MP3 500 ie SPORT Business LT (2011) Engine - The freewheel is coupled to the flywheel with high precision; if removal is difficult, use 2 screws as gripping points and as removing tools, if required. - Extract the intermediate gear provided with tor- que limiter.
Page 159 MP3 500 ie SPORT Business LT (2011) Engine - Check the inside diameter of the bushing of the starter gearing. - Check that the toothing is not worn. Characteristic Inside diameter of the bushing: Diameter 27 + 0.020 +0.041 mm N.B.
Page 160 MP3 500 ie SPORT Business LT (2011) Engine Driven plates consist of 4 Belleville springs provi- ded with grooved profiles; this assembly allows transmitting torque lower than 10 kg. In case of incorrect start-up manoeuvres, the lim- iter prevents any kicks, with consequent reversal of direction of the crankshaft which would impair the engine structure.
Page 161 MP3 500 ie SPORT Business LT (2011) Engine Refitting the intermediate gear - Lubricate the gear housing on the engine crank- case. - Insert the intermediate gear with torque limiter - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel turning it clockwise and inserting at the same time.
Page 162 MP3 500 ie SPORT Business LT (2011) Engine 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. - Insert washer and nut on the crankshaft.
Page 163 MP3 500 ie SPORT Business LT (2011) Engine - Insert the special tool checking that the pins are perfectly introduced into the seat. Specific tooling 020472Y Flywheel lock wrench - Tighten the flywheel lock nut to the prescribed torque. Locking torques (N*m) Flywheel fixing nut 115 - 125 - Install the chain guide retain plate tightening the...
Page 164 MP3 500 ie SPORT Business LT (2011) Engine Cylinder assy. and timing system - Remove the external and internal transmission cover. - Remove the flywheel cover, the flywheel and the torque limiter. Removing the intake manifold - Remove the 3 mounting screws. - Remove the intake manifold unit.
Page 165 MP3 500 ie SPORT Business LT (2011) Engine Removing the timing system drive - Turn the engine to close the intake valves. - Remove the central screw and the valve lifting device mass stop bell using the special tool. Specific tooling 020565Y Flywheel lock calliper spanner - Remove the return spring and the valve lifting mass with relevant travel end washer.
Page 166 MP3 500 ie SPORT Business LT (2011) Engine - Loosen the central screw on the tensioner first. - Unscrew the 2 fastening screws and remove the tensioner with relevant gasket. Remove the inside hexagon screw and the coun- terweight as shown in the figure. - Remove the timing belt rim from the camshaft.
Page 167 MP3 500 ie SPORT Business LT (2011) Engine - Remove the cam shaft. - Remove pins and rocking levers by the transmis- sion side holes. Removing the cylinder head - Remove the spark plugs. - Remove the cooling system outlet sleeve with thermostat.
Page 168 MP3 500 ie SPORT Business LT (2011) Engine - Remove the 2 fastening nuts on the head, on the exhaust and on the intake side. - Remove the two M6 screws into the distribution channel and the M6 screw on the spark plug side with the thermostat support.
Page 169 MP3 500 ie SPORT Business LT (2011) Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush (valve removing tool) CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD (FLY- WHEEL SIDE AND TRANSMISSION SIDE).
Page 170 MP3 500 ie SPORT Business LT (2011) Engine Removing the cylinder - piston assy. - Remove the timing chain. - Loosen the fastening screw and remove the spacer and the tightening sliding block. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Page 171 MP3 500 ie SPORT Business LT (2011) Engine Inspecting the small end - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANK- SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Page 172 MP3 500 ie SPORT Business LT (2011) Engine THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS. Characteristic Standard clearance: 0.001 - 0.010 mm - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis.
Page 173 MP3 500 ie SPORT Business LT (2011) Engine - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D). N.B. REFER TO THE «SPECIFICATIONS» SECTION FOR THE SIZES OF THE CYLINDER AND THE CYLINDER-PISTON COUPLING CLEARANCES.
Page 174 MP3 500 ie SPORT Business LT (2011) Engine Maximum clearances allowed after use: 0.10 If clearances measured exceed the maximum val- ues specified in the table, the piston should be replaced by a new one. Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust.
Page 175 MP3 500 ie SPORT Business LT (2011) Engine - Install the pin lock using the key shown in the figure. Specific tooling 020470Y Pin retainers installation tool N.B. THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.
Page 176 MP3 500 ie SPORT Business LT (2011) Engine IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION. Characteristic Recess / Projection measured 1 - 0.185 - - 0.10...
Page 177 MP3 500 ie SPORT Business LT (2011) Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork and the ring clamp, fit the cylinder as shown in the figure. N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW THE LUBRICATION DUCT AND LUBRICATE THE CYLIN- DER LINER.
Page 178 MP3 500 ie SPORT Business LT (2011) Engine N.B. IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT. Chain tensioner: - Remove the centre screw with the washer and the tensioner spring. Check that the one-way mechanism is not worn.
Page 179 MP3 500 ie SPORT Business LT (2011) Engine Inspecting the valve housings - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V". Characteristic Standard value: 1 - 1.3 mm Limit allowed: 1.6 mm...
Page 180 MP3 500 ie SPORT Business LT (2011) Engine - Check the deviation of the valve stem by resting it on a «V» shaped abutment and measuring the extent of the deformation with a dial gauge. Characteristic Limit values admitted: 0.1 mm - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the «V»...
Page 181 MP3 500 ie SPORT Business LT (2011) Engine VALVE STANDARD LENGTH Specification Desc./Quantity Intake: 95.0 ± 0.3 mm Exhaust: 94.2 ± 0.3 mm - Check that there are no signs of wear on the mating surface with the set screw articulated terminal. - If no anomalies are found during the above checks, you can use the same valves.
Page 182 MP3 500 ie SPORT Business LT (2011) Engine - Measure the unloaded spring length. Characteristic Standard length: 44.4 mm Limit allowed after use: 42.4 mm Refitting the valves - Place the valve spring support washers on the head. - Alternately insert the 4 oil guards using the spe- cial tool.
Page 183 MP3 500 ie SPORT Business LT (2011) Engine MINIMUM DIAMETER ADMITTED Specification Desc./Quantity Bearing A Ø: 41.910 mm Bearing B diameter: 19.940 mm -Using a gauge, measure the cam height. STANDARD HEIGHT Specification Desc./Quantity intake 33.774 mm discharge 33.273 ADMISSIBLE LIMITS Specification Desc./Quantity intake...
Page 184 MP3 500 ie SPORT Business LT (2011) Engine - Check that the automatic valve lifting device cam, the travel end roller and the rubber abutment on the containment bell are free from wear. - Check that the valve lifting spring has not yielded. - Replace any defective or worn components.
Page 185 MP3 500 ie SPORT Business LT (2011) Engine - The head gasket is made of steel and has a standard thickness. - 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.
Page 186 MP3 500 ie SPORT Business LT (2011) Engine - Tighten the 3 side screws to the prescribed tor- que. Locking torques (N*m) Head fixing screws 10 - 12 - 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.
Page 187 MP3 500 ie SPORT Business LT (2011) Engine - Clean the camshaft by blowing with little com- pressed air jets, especially the retaining plate housing. - Lubricate the 2 shafts. - Insert the camshaft into the head with the cams opposite the rocking levers.
Page 188 MP3 500 ie SPORT Business LT (2011) Engine - Insert the belt on the camshaft control timing rim. - Insert the timing rim on the camshaft checking that the references are aligned. N.B. DURING THE STROKE CHECK, KEEP THE BELT TEN- SIONED BY PRESSING ON THE TIGHTENER COMPART- MENT SIDE.
Page 189 MP3 500 ie SPORT Business LT (2011) Engine - Install the return spring and load it by about 3/4 turn. - 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.
Page 190 MP3 500 ie SPORT Business LT (2011) Engine - Place the tightener cursor in the rest position, keeping the retain tab pressed. - Install a new tightener on the cylinder using a new gasket. - Tighten the two fastening screws to the prescri- bed torque.
Page 191 MP3 500 ie SPORT Business LT (2011) Engine Refitting the timing chain The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to interpret the reference values based on the engine rpm. The ignition advance value is detectable at any time using the diagnostic tester.
Page 192 MP3 500 ie SPORT Business LT (2011) Engine - Repeat for the reference between driving pulley and transmission housing. - Refit the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the «parameters» function in this menu. - Select the stroboscopic light control in the tradi- tional four-stroke engine position (1 spark, 2 revs).
Page 193 MP3 500 ie SPORT Business LT (2011) Engine - Tighten the two screws indicated in the figure with «1» and «2» to limit the reciprocal sliding of the cover surface with the head surface. - Tighten the remaining 4 screws in a crossed se- quence (3, 4, 5, 6).
Page 194 MP3 500 ie SPORT Business LT (2011) Engine - Remove the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover" chapter. - Remove the flywheel with the starting system following the instruction given in "Flywheel and Starting system".
Page 195 MP3 500 ie SPORT Business LT (2011) Engine - Remove the 14 crankcase coupling screws. N.B. THE FASTENING SCREWS ARE OF 3 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION. - Split the crankcases while keeping the crankshaft inserted on the flywheel side half-crankcase. - Remove the coupling gasket.
Page 196 MP3 500 ie SPORT Business LT (2011) Engine Removing the oil pump and countershaft con- trol gear. - To remove the control gear, loosen the 4 fasten- ing screws. Remove the gear only if actually required. CAUTION THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR THREADING IS LOCKED BY LOCTITE.
Page 197 MP3 500 ie SPORT Business LT (2011) Engine Replacing the countershaft bearings - Check that the bearings are free from irregular noise or clearance. If it does, replace it. Flywheel-side half-crankcase - Remove the inside Seeger ring. - Upturn the half-crankcase. - Remove the bearing from the flywheel side half- crankcase using the special tool and a mallet.
Page 198 MP3 500 ie SPORT Business LT (2011) Engine - Insert a new bearing on the special tool after greasing the guide seat. - Install the new bearing on the half-crankcase us- ing the special tool. N.B. IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE.
Page 199 MP3 500 ie SPORT Business LT (2011) Engine 020439Y 17-mm guide 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 ÷...
Page 200 MP3 500 ie SPORT Business LT (2011) Engine IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FITTING POSITION. 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.
Page 201 MP3 500 ie SPORT Business LT (2011) 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 group and timing system". - When cleaning the crankshaft, be careful to prevent any impurity from entering into the shaft lubrication hole.
Page 202 MP3 500 ie SPORT Business LT (2011) 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 203 MP3 500 ie SPORT Business LT (2011) Engine - Check the inside diameter of the main bushings in the three directions indicated in the diagram. - Repeat the measurements for the other bushing half. see diagram. N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALF- SHELL COUPLING SURFACE SINCE THE ENDS ARE RE- LIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
Page 204 MP3 500 ie SPORT Business LT (2011) Engine X = Crankshaft category Y = Crankcase halves 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 205 MP3 500 ie SPORT Business LT (2011) 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 206 MP3 500 ie SPORT Business LT (2011) 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 207 MP3 500 ie SPORT Business LT (2011) 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 208 MP3 500 ie SPORT Business LT (2011) Engine - Check that the crankshaft rotates freely. N.B. REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE BETTER SEALING PERFORMANCE. Locking torques (N*m) Engine-crankcase coupling screws 11 - 13 - Install the thermal group (cylinder, head, piston) as described in section «Thermal group and timing system».
Page 209 MP3 500 ie SPORT Business LT (2011) Engine OIL FILTER Specification Desc./Quantity Type Paper with pressure relief and anti-drain back by-pass valves OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH Specification Desc./Quantity Calibration 0.3 - 0.6 bar HEAD LUBRICATION CONTROL JET Specification Desc./Quantity Diameter 1 ±...
Page 210 MP3 500 ie SPORT Business LT (2011) Engine Specification Desc./Quantity Oil filter cartridge To the oil sump By-pass valve Oil pump Mesh pre-filter Crankshaft Connecting rod General characteristics The lubrication system is divided into two sections: - High pressure - Low pressure The high pressure section includes all components located on the engine crankcase whereas the low pressure section only refers to the thermal group.
Page 211 MP3 500 ie SPORT Business LT (2011) Engine A one-way valve and a decantation chamber are used so that gases from the crankcase do not carry any oil. The one-way valve is a metal reed valve; the decantation chamber has a drainage hole. A failure in these components implies oil getting into the line supplying air to the engine.
Page 212 MP3 500 ie SPORT Business LT (2011) Engine STANDARD VALUES Specification Desc./Quantity 20°C Temperature 1400 rpm approx. 4.5 bar N.B. RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE DIAGNOSTIC TESTER Specific tooling 020922Y Diagnosis Tool YES go to 6 NO go to 12 6 - Let the engine warm up and repeat the check with hot oil.
Page 213 MP3 500 ie SPORT Business LT (2011) Engine - Check the oil pump as described in the following pages. - Check that the cooling nozzle and the timing system feeding jet are properly installed. - Visually inspect the crankshaft couplings and their size ("Crankcase and crankshaft" chapter). N.B.
Page 214 MP3 500 ie SPORT Business LT (2011) Engine Oil pump Removal - Remove the closing plate of the oil pump housing by loosening the 2 retaining screws with their washers. - Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper.
Page 215 MP3 500 ie SPORT Business LT (2011) Engine - Remove the inside rotor retaining snap ring turn- ing it to move the opening at the shaft face. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and free from wear.
Page 216 MP3 500 ie SPORT Business LT (2011) Engine - Check the distance between external rotor and pump body; see figure. Characteristic Admissible limit clearance: 0.25 mm - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit values admitted: 0.1 mm...
Page 217 MP3 500 ie SPORT Business LT (2011) Engine - Insert the 2 retaining screws through the slots on the gear and tighten to the prescribed torque. N.B. THE ASSEMBLY POSITION OF THE PUMP IS FIXED BY INSTALLATION OF THE SCREWS. Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body.
Page 218 MP3 500 ie SPORT Business LT (2011) Engine - Remove the six screws and the pump cover with a screwdriver. - Unscrew the water pump rotor with an 8-mm wrench. - Place two flat blade screwdrivers as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal, pressure- fitted on the rotor shaft.
Page 219 MP3 500 ie SPORT Business LT (2011) Engine - Clean all the parts thoroughly before removing them. - Place the extractor together with the pin on the fixed part of the ceramic seal. - Without modifying the extractor position, make three holes on the fixed part of the seal using the pin supplied and a hammer.
Page 220 MP3 500 ie SPORT Business LT (2011) Engine - Hold the screw in position and operate the nut until the fixed part of the sealing is completely re- moved. - Remove the extractor with the fixed part of the overall seal. Specific tooling 020661Y Water pump overall seal replacement kit - Remove the six screws and the pump cover with...
Page 221 MP3 500 ie SPORT Business LT (2011) Engine - Place two flat blade screwdrivers as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal, pressure- fitted on the rotor shaft. CAUTION USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COVER SEALING SUR- FACE.
Page 222 MP3 500 ie SPORT Business LT (2011) Engine - Fix the extractor to the fixed part of the sealing using the screws supplied with the tool. CAUTION FIX IT PROPERLY WITHOUT "TEARING" THE PLATE - Complete the tool by fitting the bracket, the screw and the nut.
Page 223 MP3 500 ie SPORT Business LT (2011) Engine Fitting OVERALL SEAL FITTING CAUTION CLEAN ALL THE COMPONENTS THOROUGHLY. CAUTION LUBRICATE THE ROTOR SHAFT WITH ENGINE OIL. - Fit the tie rod by screwing it to the rotor shaft. CAUTION TIGHTEN MANUALLY UNTIL IT STOPS. - Place the overall seal on the shaft.
Page 224 MP3 500 ie SPORT Business LT (2011) Engine - Fit the pump cover with a new gasket, lubricate the gasket previously with petroleum jelly grease. - Tighten the six cover screws to the prescribed torque. N.B. TO AVOID DEFORMATION, DO NOT LUBRICATE THE O- RING WITH PETROLEUM GREASE.
Page 225 MP3 500 ie SPORT Business LT (2011) Engine - Screw the rotor. Locking torques (N*m) Water pump rotor 4 to 5 - Fit the pump cover with a new gasket, lubricate the gasket previously with petroleum jelly grease. - Tighten the six cover screws to the prescribed torque.
Page 226 INDEX OF TOPICS INJEC NJECTION...
Page 227 MP3 500 ie SPORT Business LT (2011) Injection KEY: 1. Battery 2. Throttle body and electronic injection control unit (MIU) 3. Instrument panel 4. Injection load remote control 5. Coolant temperature sensor: 6. Fuel pump 7. HV coil 8. Lambda sensor 9.
Page 228 MP3 500 ie SPORT Business LT (2011) Injection - Lambda probe The system implements cold engine idle fuel/air mixture correction with a stepper motor on a by-pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time, thereby ensuring the idle steadiness and the proper combustion.
Page 229 MP3 500 ie SPORT Business LT (2011) 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 230 MP3 500 ie SPORT Business LT (2011) Injection 5. Before any attempt to start the vehicle, 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.
Page 231 MP3 500 ie SPORT Business LT (2011) 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 232 MP3 500 ie SPORT Business LT (2011) Injection Specification Desc./Quantity + Lambda probe engine stop switch Engine speed sensor (+) Fuel injector Engine speed sensor (-) Diagnostics socket output Immobilizer LED Ground lead Connected to the engine stop switch and the water tem- perature sensor.
Page 233 MP3 500 ie SPORT Business LT (2011) Injection 45. DIAGNOSTICS SOCKET 55. ELECTRIC FAN 56. ELECTRIC FAN RELAY 57. FUEL INJECTOR 58.HV COIL 59. INJECTION LOAD RELAY 60.C.D.I. 61. ENGINE SPEED SENSOR 62.LAMBDA PROBE 64. FUEL PUMP 65. ENGINE TEMPERATURE SENSOR 67.
Page 234 MP3 500 ie SPORT Business LT (2011) Injection 23. Electric fan relay 29. Main fuses 31. Start-up enabling relay 34. Battery 12 V - 14 A 35. Ignition switch contacts 37. Injection load relay 41. Parking control ECU 44. Oxygen sensor 50.
Page 235 MP3 500 ie SPORT Business LT (2011) Injection Possible Cause Operation Air temperature Coolant temperature Starter speed Starter motor and solenoid Battery Ground connections End of compression pressure End of compression pressure Power to spark plug Spark plug Shielded cap H.V.
Page 236 MP3 500 ie SPORT Business LT (2011) Injection Possible Cause Operation Intake system sealing (infiltrations) Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel system (low pressure) Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation...
Page 237 MP3 500 ie SPORT Business LT (2011) Injection Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM- ANCE ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature...
Page 238 MP3 500 ie SPORT Business LT (2011) 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 - 238...
Page 239 MP3 500 ie SPORT Business LT (2011) 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 ECU connector. INJEC - 239...
Page 240 MP3 500 ie SPORT Business LT (2011) Injection Remove the gas command fitting as indicated in the picture Pump supply circuit INJEC - 240...
Page 241 MP3 500 ie SPORT Business LT (2011) Injection INJECTION LOADS Specification Desc./Quantity Battery Fuse Fuse Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe Electric fan relay When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine starts, in the presence of rpm timing signal the pump is continuously supplied.
Page 242 MP3 500 ie SPORT Business LT (2011) Injection Check the power supply line of the injection load relay energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Pur- ple cable of the relay base.
Page 243 MP3 500 ie SPORT Business LT (2011) Injection Check the presence of fixed voltage between the grey/black cable of the solenoid base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the solenoid base.
Page 244 MP3 500 ie SPORT Business LT (2011) 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.
Page 245 MP3 500 ie SPORT Business LT (2011) Injection 020480Y Petrol pressure check kit Fuel filter check Disconnect the terminals from the electric pump Remove the screw shown in the picture Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture.
Page 246 MP3 500 ie SPORT Business LT (2011) Injection Remove the filter from the pump mounting Inspecting the injector circuit INJEC - 246...
Page 247 MP3 500 ie SPORT Business LT (2011) Injection INJECTION LOADS Specification Desc./Quantity Battery Fuse Fuse Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe Electric fan relay Check the efficiency of injection load 15 A fuse No. Check that the live control unit power supply 7.5A fuse No.
Page 248 MP3 500 ie SPORT Business LT (2011) Injection Check the power supply line of the injection load relay energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, be- tween the Red-White cable and Black-Purple ca- ble of the relay base.
Page 249 MP3 500 ie SPORT Business LT (2011) Injection Check the presence of fixed voltage between the grey/black cable of the solenoid base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the solenoid base.
Page 250 MP3 500 ie SPORT Business LT (2011) 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 251 MP3 500 ie SPORT Business LT (2011) 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 252 MP3 500 ie SPORT Business LT (2011) Injection - immobilizer antenna - master key with incorporated transponder (red key) - service key with incorporated transponder (black key) - H.V. coil - diagnosis LED The diagnosis LED also works as a theft-deterrent blinker.
Page 253 MP3 500 ie SPORT Business LT (2011) Injection With the key switch in the ON 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 ignition switch contacts and that fuses No.
Page 254 MP3 500 ie SPORT Business LT (2011) Injection With the ignition switch at ON check there is bat- tery 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.
Page 255 MP3 500 ie SPORT Business LT (2011) 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 256 MP3 500 ie SPORT Business LT (2011) 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 steadily. The engine can be started. 4. Programmed control unit - Master key in: a 0.7-sec flash is displayed followed by the LED re- maining off for 2 sec and then by short 0.46-sec flashes, the same number of times as there are...
Page 257 MP3 500 ie SPORT Business LT (2011) Injection Code 2 A two-flash code shows a system where the con- trol unit does not show the transponder signal. This might depend on the inefficiency of the immobilizer antenna 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 258 MP3 500 ie SPORT Business LT (2011) Injection PIN RELATIONSHIP Component Reference value Engine rpm sensor 100 ÷ 150 Ohm ~ 20°C With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20°...
Page 259 MP3 500 ie SPORT Business LT (2011) Injection HT coil INJECTION LOADS Specification Desc./Quantity Battery Fuse Fuse Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe Electric fan relay INJEC - 259...
Page 260 MP3 500 ie SPORT Business LT (2011) Injection PIN RELATIONSHIP Component Reference value +Live supply H.V. coil ~ 1 Ohm The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
Page 261 MP3 500 ie SPORT Business LT (2011) Injection Check the efficiency of the injection load relay. Check the resistance of the energising coil be- tween pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the relay.
Page 262 MP3 500 ie SPORT Business LT (2011) Injection Check the presence of fixed voltage between the grey/black cable of the solenoid base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the solenoid base.
Page 263 MP3 500 ie SPORT Business LT (2011) 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 solenoid base with the control unit disconnected and the solenoid discon- nected.
Page 264 MP3 500 ie SPORT Business LT (2011) 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»...
Page 265 MP3 500 ie SPORT Business LT (2011) 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. - Refit the inspection cap on the flywheel side. - Connect the diagnostic tester.
Page 266 MP3 500 ie SPORT Business LT (2011) Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor engine stop switch Electronic control unit PIN RELATIONSHIP Component Reference value Engine temperature sensor 2500 ± 100 Ohm at 20°C; 308 ± 6 Ohm at 80°C With the control unit side connector disconnected and the coolant temperature sensor connector...
Page 267 MP3 500 ie SPORT Business LT (2011) 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...
Page 268 MP3 500 ie SPORT Business LT (2011) Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020922Y Diagnosis Tool Make sure that the throttle valve with the control is supporting the stop screw.
Page 269 MP3 500 ie SPORT Business LT (2011) Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Page 270 MP3 500 ie SPORT Business LT (2011) Injection Lambda probe INJECTION LOADS Specification Desc./Quantity Battery Fuse Fuse Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe Electric fan relay INJEC - 270...
Page 271 MP3 500 ie SPORT Business LT (2011) Injection PIN RELATIONSHIP Component Reference value Lambda sensor ~ 0V with throttle valve closed; ~ 1V with throttle valve fully opened The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas.
Page 272 INDEX OF TOPICS SUSP USPENSIONS...
Page 273 MP3 500 ie SPORT Business LT (2011) Suspensions This section is dedicated to operations that can be carried out on the suspensions. Wheel alignment Tool fitting How to use the tools • Check that tyre pressure is correct. • Park the vehicle on level, smooth and even ground.
Page 274 MP3 500 ie SPORT Business LT (2011) Suspensions • Get the vehicle off the stand, back on the ground. • Remove the right lower coupling plate of the half-arm by undoing the screws indicated in the picture. • Remove the right upper screw and the left bottom screw of the parallelogram unit.
Page 275 MP3 500 ie SPORT Business LT (2011) 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 276 MP3 500 ie SPORT Business LT (2011) Suspensions • Fit the frame locking bracket • Make sure the frame is adequately centred by checking with a gauge that the lugs along the vertical axis show the standard protrusion. • Check that the pointers of both tyres are correctly aligned, as shown in the picture.
Page 277 MP3 500 ie SPORT Business LT (2011) Suspensions Front Removing the front wheel - Remove the 5 fixing screws indicated in the pic- ture. Locking torques (N*m) Wheel fixing screw 20 to 25 Front wheel hub overhaul - Remove the ball bearing check Seeger ring indi- cated in the picture SUSP - 277...
Page 278 MP3 500 ie SPORT Business LT (2011) Suspensions Extract the ball bearing using the specific tool Specific tooling 001467Y014 Calliper to extract ø 15-mm bear- ings 001467Y017 Bell for bearings, OD 39 mm - Remove the oil seal on the roller bearing side using a screwdriver.
Page 279 MP3 500 ie SPORT Business LT (2011) Suspensions - Use the specific tool to fit and push the roller cas- ing until it stops - Refit the oil seal on the roller bearing side - Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch...
Page 280 MP3 500 ie SPORT Business LT (2011) Suspensions The tilt mechanism Hydraulic system layout When roll is locked, the gear motor activates the hydraulic pump indicated in the picture and pres- surises the circuit. The pressurised oil reaches the distribution frame «T»...
Page 281 MP3 500 ie SPORT Business LT (2011) Suspensions Steering tubes Remove the brake calliper pipe retainers and the hydraulic pipe fitting from the brake calliper making sure there is a container to collect the brake fluid. Disconnect the tone wheel connector indicated in the picture.
Page 282 MP3 500 ie SPORT Business LT (2011) Suspensions Remove the hydraulic pipe fitting fixing nuts indi- cated in the figure from the support bracket. Remove the suspension roll lock device pipes from the headstock. Remove first the flexible part of the calliper from the steering tube as shown in the picture, and then remove the rigid part.
Page 283 MP3 500 ie SPORT Business LT (2011) Suspensions Remove the tone wheel wiring by disconnecting the connector on the fuel tank after removing the chassis central cover. After that, remove the retainers indicated in the figure. Remove the constant-velocity universal joint from the steering bar by undoing the nut indicated in the picture.
Page 284 MP3 500 ie SPORT Business LT (2011) Suspensions Remove the hydraulic pipe support bracket. Remove the steering tube lower ring nut and the protection cap indicated in the picture. Now the steering tube can be removed. SUSP - 284...
Page 285 MP3 500 ie SPORT Business LT (2011) Suspensions Check that the roller tapered bearing does not show signs of abnormal wear. If it does, replace it. THE OPERATIONS DESCRIBED BELOW CAN ALSO BE CARRIED OUT EVEN WHEN THE SUSPENSION IS FITTED Remove the lower retainer of the sliding stem shown in the picture.
Page 286 MP3 500 ie SPORT Business LT (2011) Suspensions For refitting, follow the operations for removal but in reverse order, observing the prescribed torque and greasing the bearings and their seats. STEERING TUBES Name Torque in Nm Side headstock upper ring nut 20 - 24 Side headstock lower ring nut 12 ÷...
Page 287 MP3 500 ie SPORT Business LT (2011) Suspensions Remove the hydraulic pipe retainers from the par- allelogram. Remove the 4 screws fixing the tilt brake disc sec- tor indicated in the picture. Remove the retainers indicated in picture of the half-arms joint flange.
Page 288 MP3 500 ie SPORT Business LT (2011) Suspensions To facilitate the operations indicated below, re- move the suspension locking electronic control unit indicated in the picture. 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.
Page 289 MP3 500 ie SPORT Business LT (2011) Suspensions Remove the headstocks. Carry out a visual check of the upper and lower bearings on the headstocks and their seats. Re- place them in case of signs of abnormal wear. SUSP - 289...
Page 290 MP3 500 ie SPORT Business LT (2011) 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. SUSP - 290...
Page 291 MP3 500 ie SPORT Business LT (2011) Suspensions For refitting, follow the operations for removal but in reverse order, lubricating the reference dowels on the parallelogram half-arms and observing the prescribed torque. ARALLELOGRAM DEVICE Name Torque in Nm Arm coupling screws 45 to 50 Screws fixing arms to side headstocks 45 to 50...
Page 292 MP3 500 ie SPORT Business LT (2011) Suspensions The palmtop 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 gear motor if the palmtop does not in- dicate this.
Page 293 MP3 500 ie SPORT Business LT (2011) Suspensions The palmtop displays the option: RELATIVE PO- TENTIOMETER ANGLE This function is active coming from the LOWER STOP SEARCH procedure. NOTE: a slight oscillation of the angle value be- tween 0.00° and 0.50° is considered normal Remove the protection cap of the gear motor set screw Use a plain slot screwdriver to turn the set screw...
Page 294 MP3 500 ie SPORT Business LT (2011) 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 to 13 Select the SYSTEM RESET option from the MAIN menu Select the POTENTIOMETER RESET option from the SYSTEM RESET menu and press OK.
Page 295 MP3 500 ie SPORT Business LT (2011) Suspensions Adjust the flexible transmission so that a small clearance is left to guarantee switch activation on the roll lock calliper Remove the two bracket screws after releasing the spring and freeing the flexible transmission adjust- ment.
Page 296 MP3 500 ie SPORT Business LT (2011) Suspensions Undo the Allen screw and remove the switch. Upon refitting, place the switch with the button ori- ented to the stop indicated on the calliper lever, observing the reference indicated on the switch supporting bracket.
Page 297 MP3 500 ie SPORT Business LT (2011) Suspensions Refit the spring/toothed sector unit, hold the crank- case in a perfectly horizontal and stable position, place the spring/toothed sector unit keeping it per- fectly perpendicular to the bearing already fitted on the crankcase;...
Page 298 MP3 500 ie SPORT Business LT (2011) Suspensions Lubricate the interference areas, match the crank- case halves with slight hits of a mallet to get them into contact. Place the flexible transmission supporting bracket, refit the four screws, screw them to the prescribed torque.
Page 299 MP3 500 ie SPORT Business LT (2011) Suspensions Refit the hydraulic pump on the gear motor body and tighten the screws to the prescribed torque. Fit but not tighten the pump stem coupling screw and refit the plastic protection cap. The synchronisation procedure should be com- plete when the installation is finished.
Page 300 MP3 500 ie SPORT Business LT (2011) Suspensions Hold the crankcase in a perfectly horizontal posi- tion, heat it with a specific heat gun at about 120 ° C, use the specific tool to fit the bearing of the flex- ible transmission lever control shaft.
Page 301 MP3 500 ie SPORT Business LT (2011) Suspensions Extract the bearing of the spring/toothed sector unit with the specific tool. Specific tooling 001467Y002 Driver for OD 73 mm bearing Extract the bearing of the electric motor with the specific tool. Hold the crankcase in a perfectly horizontal posi- tion, heat it with a specific heat gun at about 120 °...
Page 302 MP3 500 ie SPORT Business LT (2011) Suspensions Before removing the gear motor: Disable the suspension lock. Remove the legshield. With the set nut indicated in the picture, remove the tensioning cable of the suspension locking me- chanical calliper. Remove the electrical connection of the gear mo- tor position potentiometer.
Page 303 MP3 500 ie SPORT Business LT (2011) Suspensions TER AND SEEK MEDICAL ADVICE IMMEDIATELY. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN. Remove the 3 fixing screws indicated and remove the whole gear motor. Use a screwdriver to remove the plastic access cover to the pump joint/gear motor Undo the pump joint screw.
Page 304 MP3 500 ie SPORT Business LT (2011) Suspensions In the new solution to fix the pump to the suspen- sion lock assembly, the retainers fixing the pump body to the assembly and the clamp fixing the pump joint have been modified as shown the fig- ures below.
Page 305 MP3 500 ie SPORT Business LT (2011) Suspensions Undo the two potentiometer screws. Upon refitting, plug the potentiometer in D-type connector, afterwards place it with its electric con- nection directed to the opposite side of the pump. Remove the nut indicated in the figure, if neces- sary lock the lever with a vice making sure not to spoil the surface.
Page 306 MP3 500 ie SPORT Business LT (2011) Suspensions Remove the four screws indicated in the figure, remove the flexible transmission supporting brack- et, separate the two crankcase halves, if neces- sary, use a rubber mallet to hit the flexible transmission lever in order to separate the two crankcases.
Page 307 MP3 500 ie SPORT Business LT (2011) Suspensions 10. + Direct battery 11. + Live battery 12. To light switch 13. 20A fuse No. 3 14. Light relay 15. Pressure switch 16. Horn relay 17. Instrument panel 18. Roll lock system control unit MOTORIDUTTORE 1: GEAR MOTOR SUSP - 307...
Page 308 MP3 500 ie SPORT Business LT (2011) Suspensions 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 309 MP3 500 ie SPORT Business LT (2011) Suspensions 0: REST POSITION 1: LOCKING POSITION 2: UNLOCKING POSITION 3: ROLL LOCK-UNLOCK SWITCH With the interface wiring disconnected from the control unit, check the continuity of the electrical lines between the interface wiring and the roll lock- unlock switch: Pin 26 and green - grey cable Pin 35 and violet - black cable...
Page 310 MP3 500 ie SPORT Business LT (2011) Suspensions Check the continuity between the black cable on the connector and a ground point on the chassis. With a multimeter, check the operation of the tilt locking-unlocking switch referring to the diagram indicated in the figure.
Page 311 MP3 500 ie SPORT Business LT (2011) Suspensions With the interface wiring connected to the control unit, secure the vehicle on its centre stand and switch to "ON". Select the reading scale on 20 V. Insert the multimeter probes on pins 17 and 25. Check that the voltage in the activated locking condition is 4V and 1V in the locking rest condition.
Page 312 MP3 500 ie SPORT Business LT (2011) Suspensions 1: RIDER DETECTION SENSOR With the interface wiring disconnected from the control unit and connected to the system, check the following conditions: pin 17 - 36: resistance 15 - 18 kOhm when the rider is not seated on the saddle.
Page 313 MP3 500 ie SPORT Business LT (2011) Suspensions 1: ROLL LOCK CALLIPER SENSOR The roll lock calliper sensor is a normally opened switch. Check its correct operation with a multi- meter. With the interface wiring disconnected from the control unit, check the continuity between pin 34 and the brown cable of the roll lock gripper sensor connector on the system side.
Page 314 MP3 500 ie SPORT Business LT (2011) Suspensions Also check that the flexible transmission control lever activates the limit stop switch properly. SENSORE RUOTA FONICA 1: Right tone wheel 2: Left tone wheel SUSP - 314...
Page 315 MP3 500 ie SPORT Business LT (2011) Suspensions With the interface wiring disconnected from the parking electrical control unit and connected to the system, check that the sensor resistance between pins 23 - 17 and 24 - 17 is between 774 and 946 Ohm at approximately 20°...
Page 316 MP3 500 ie SPORT Business LT (2011) 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 317 MP3 500 ie SPORT Business LT (2011) Suspensions 1: PRESSURE SWITCH 2: HORN SOLENOID 3: FUSE No. 11, 7.5A Check that the 7.5A fuse No. 11 works properly. With interface wiring disconnected from the control unit, check the continuity of the blue - black cable between pressure sensor connector and the horn solenoid base as shown in the picture.
Page 318 MP3 500 ie SPORT Business LT (2011) 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 319 MP3 500 ie SPORT Business LT (2011) 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.
Page 320 MP3 500 ie SPORT Business LT (2011) 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 picture. Locking torques (N*m) Silencer arm clamping screws Rear 27 - 30...
Page 321 MP3 500 ie SPORT Business LT (2011) 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 - 321...
Page 322 MP3 500 ie SPORT Business LT (2011) 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.
Page 323 MP3 500 ie SPORT Business LT (2011) 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 picture. - Remove the pin connecting the engine swinging arm - frame swinging arm.
Page 324 MP3 500 ie SPORT Business LT (2011) 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-...
Page 325 MP3 500 ie SPORT Business LT (2011) Suspensions Refitting For correct installation of the swinging arm on the vehicle, proceed as follows: 1. Position the silent bloc support bracket with part 3 inserted and lightly tighten part 1 2. Position the swinging arm, inserting part 2 3.
Page 326 MP3 500 ie SPORT Business LT (2011) Suspensions SWINGING ARM FITTING Name Torque in Nm Part 1 98 ÷ 118 Part 3 5 ÷ 7 Part 4 88.5 ÷ 108 Part 5 54 ÷ 60 Bolt for swinging arm, engine side / swinging arm, frame side 32.5 ÷...
Page 327 MP3 500 ie SPORT Business LT (2011) Suspensions Lower shock absorber clamp 33 - 41 Upper shock absorber retainer 33 - 41 Centre-stand - Use a jack to support the vehicle properly. - Remove the two stand return springs. - Working from both sides, unscrew the two bolts connecting it to the supporting plate.
Page 328 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 329 MP3 500 ie SPORT Business LT (2011) Braking system This section è is dedicated to the description of the brake system components. BRAK SYS - 329...
Page 330 MP3 500 ie SPORT Business LT (2011) Braking system 1. Front brake pipes 2. Rear brake pump ø 11 mm 3. Front brake pump ø 12 mm 4. Rear brake pipes (rear brake pump - rear valve) 5. Front valve 6.
Page 331 MP3 500 ie SPORT Business LT (2011) Braking system BRAK SYS - 331...
Page 332 MP3 500 ie SPORT Business LT (2011) Braking system 1. LEFT PUMP PIPES TO REAR VALVE 2. RIGHT PUMP PIPES TO FRONT VALVE 3. FRONT VALVE PIPES TO REAR VALVE 4. FRONT BRAKE PIPES 1. FRONT PRESSURE ADJUSTMENT VALVE 2. FRONT BRAKE PIPES 3.
Page 333 MP3 500 ie SPORT Business LT (2011) Braking system 11.REAR BRAKE PIPES 12.PEDAL PUMP PIPES TO REAR VALVE 13.REAR VALVE BRAK SYS - 333...
Page 334 MP3 500 ie SPORT Business LT (2011) Braking system 1. PEDAL BRAKE PUMP 2. BRAKE FLUID RESERVOIR TO PEDAL BRAKE PUMP FITTING PIPES 3. BRAKE FLUID RESERVOIR 4. REAR VALVE 5. PEDAL PUMP - REAR VALVE PIPES 1. REAR BRAKE PIPES - REAR VALVE 2.
Page 335 MP3 500 ie SPORT Business LT (2011) Braking system 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 336 MP3 500 ie SPORT Business LT (2011) Braking system 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. Locking torques (N*m) Screw tightening calliper to support 20 to 25 Front brake calliper Removal - The operations described refer to only one cal-...
Page 337 MP3 500 ie SPORT Business LT (2011) Braking system - Remove the calliper supporting clamp. - Remove the brake disc Refitting - To fit the rear brake disc, follow the removal steps but in reverse order; be careful to tighten the screws to the prescribed torque using threadlock.
Page 338 MP3 500 ie SPORT Business LT (2011) Braking system - Remove the wheel and check using the appro- priate tools that the axial run-out of the brake surface is within the prescribed limits. - If this is not the case, replace the disc and repeat the test.
Page 339 MP3 500 ie SPORT Business LT (2011) Braking system - 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 340 MP3 500 ie SPORT Business LT (2011) Braking system - Remove the wheel and check using the appro- priate tools that the axial run-out of the brake surface is within the prescribed limits. - If this is not the case, replace the disc and repeat the test.
Page 341 MP3 500 ie SPORT Business LT (2011) 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.
Page 342 MP3 500 ie SPORT Business LT (2011) Braking system Rear - combined For the procedure in question see «Highlighted operations» section. Front For the procedure in question see «Highlighted operations» section. Brake pipes Smontaggio tubazioni freno anteriore Unscrew the braking splitter screw. Disconnect the brake pipes removing the two met- allic straps indicated in the figure.
Page 343 MP3 500 ie SPORT Business LT (2011) Braking system Parking brake Remove the rear wheel. Loosen the transmission set screw and release the cable from the calliper. Remove the two fixing screws of the mechanic calliper and remove the calliper. To check calliper components, refer to the chapter on the roll lock calliper.
Page 344 MP3 500 ie SPORT Business LT (2011) Braking system Remove the electric connection from the engaged parking brake warning light switch. Remove the parking brake cable from the lever by operating the set screw indicated in the picture. BRAK SYS - 344...
Page 345 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 346 MP3 500 ie SPORT Business LT (2011) Cooling system Circuit diagram This is a forced circulation cooling system, 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 group. The two-way thermostat support is connected in output to the head.
Page 347 MP3 500 ie SPORT Business LT (2011) 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 348 MP3 500 ie SPORT Business LT (2011) 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 stop temperatures. - Select the «PARAMETERS»...
Page 349 MP3 500 ie SPORT Business LT (2011) Cooling system DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OB- SERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE SEALING GASKETS. Coolant replacement System filling instructions - Prepare the mixture of 50% water and 50% cool- ant.
Page 350 MP3 500 ie SPORT Business LT (2011) 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 Vehicle"...
Page 351 MP3 500 ie SPORT Business LT (2011) Cooling system Flywheel cover Water pump - overhaul If noise or loss of liquid at the drain bore of the water pump is discovered, it will be necessary to overhaul the pump as described in the «Engine/ Water pump»...
Page 352 MP3 500 ie SPORT Business LT (2011) Cooling system N.B. TO AVOID DEFORMATION, DO NOT LUBRICATE THE O-RING WITH PETROLEUM GREASE. CAUTION FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O-RING. - Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque. N.B.
Page 353 INDEX OF TOPICS CHAS HASSIS...
Page 354 MP3 500 ie SPORT Business LT (2011) Chassis This section è is dedicated 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 355 MP3 500 ie SPORT Business LT (2011) Chassis Instrument panel - Remove the front handlebar cover. - Remove the legshield. - 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 356 (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 - 356...
Page 357 MP3 500 ie SPORT Business LT (2011) 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.
Page 358 MP3 500 ie SPORT Business LT (2011) Chassis Legshield Remove the headlight assembly. Remove the spoiler. Remove the two front screws and the two screws under the wheelhouse. Remove the four screws on the leg shield back plate. See also Headlight assy.
Page 359 MP3 500 ie SPORT Business LT (2011) Chassis - Remove the expansion tank fixing screw and the frame from the instrument panel and manually re- lease the unions with the leg shield back plate. - Unhook the instrument panel wiring. - Remove the six screws and the cable grommet strap in the front part of the leg shield back plate.
Page 360 MP3 500 ie SPORT Business LT (2011) Chassis - Remove the ignition switch plastic ring and the two plastic covers near the footrest. - Remove the five screws on the leg shield back plate rear part. - Remove the two leg shield back plate front screws, see figure.
Page 361 MP3 500 ie SPORT Business LT (2011) Chassis Taillight assy. Open the rear case cover, remove the two screws «D», and then, the other four fixing screws «D» to pull out the headlight assembly from its fitting. Follow this procedure to remove the bulbs: Remove the snap-on bulbs «B».
Page 362 MP3 500 ie SPORT Business LT (2011) Chassis - From the right side of the vehicle remove the re- tainer indicated above. - Undo the two screws indicated and remove the integral brake pedal. - Remove the right half-footrest. See also Frame central cover Side fairings Remove the rear screw under the rear cover.
Page 363 MP3 500 ie SPORT Business LT (2011) Chassis License plate holder Remove the two lateral screws and the two screws inside the rear case. Operate a slight upwards thrust on the case to re- lease license plate support from the chassis. Helmet bay Remove the chassis central cover.
Page 364 MP3 500 ie SPORT Business LT (2011) Chassis Remove the upper frame, unscrewing the ten up- per screws, the two saddle closing screws and the case light wiring. Remove the rear case internal screws indicated in the picture, to detach the supporting plates of the voltage regulator on one side and the saddle open- ing switch on the other.
Page 365 MP3 500 ie SPORT Business LT (2011) Chassis Remove the five screws indicated in the figure. See also Headlight assy. Fuel tank Remove the chassis central cover. Remove the footrest. Remove the three tank retainers. CHAS - 365...
Page 366 MP3 500 ie SPORT Business LT (2011) Chassis Remove the two lower bracket retainers indicated in the figure. Disconnect the electric wiring and the fuel pipes. See also Footrest Top-case Rear Remove the four fixing screws of the cover and release it from the two leverages.
Page 367 MP3 500 ie SPORT Business LT (2011) Chassis Remove the six screws indicated in the figure. Radiator cover - Remove the two front screws indicated in the pic- ture Remove the two lower retainers with the bushing CHAS - 367...
Page 368 MP3 500 ie SPORT Business LT (2011) Chassis - Remove the two rear retainers and then, the two wheelhouse front retainers. - Remove the two screws fixing the radiator lower protection to the leg shield back plate. - After that, press up and pull the protection front part so as to release it from the radiator frame.
Page 369 INDEX OF TOPICS PRE DE DELIVERY...
Page 370 MP3 500 ie SPORT Business LT (2011) Pre-delivery Carry out the listed tests before delivering the vehicle. Warning - Handle fuel with care. Fit the plastic cover supplied on the joint on the steering tube as shown in the figure. Proceed as follows if the customer requests in- stallation of splash guards on the vehicle: •...
Page 371 MP3 500 ie SPORT Business LT (2011) Pre-delivery - Shock absorbers upper fixing screw - Lower screw fixing right shock absorber to supporting plate - Lower screw fixing left shock absorber to engine - Screws fixing muffler supporting arm to engine Front brake - Screws fixing brake disc to left wheel - Screws fixing brake disc to right wheel...
Page 372 MP3 500 ie SPORT Business LT (2011) Pre-delivery IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL.
Page 373 MP3 500 ie SPORT Business LT (2011) 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 Checks: • Hydraulic braking system: lever travel • Clutch: proper functioning check •...
Page 374 Air filter: 41 Battery: 68, 83, 98, 99 Brake: 330, 335, 336, 338, 340–343 Bulbs: Checks: 77 Coolant: 266, 349 Electric: 347 Engine oil: 42 Fuel: 237, 245, 365 Fuses: 93 Headlight: 48, 356, 358, 365 Horn: 86 Hub oil: 40 Identification: 8 Instrument panel: 355 Maintenance: 7, 34, 37...
Page 375 Tank: 365 Transmission: 10, 51, 118, 133 Turn indicators: 75 Tyres: 12 Vehicle: 8, 113...

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