PIAGGIO MP3 400 hpe E5 2021 Service Manual
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PIAGGIO MP3 400 hpe E5 2021 Service Manual

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MANUALE STAZIONE DI SERVIZIO
1Q000906
MP3 400 hpe E5

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Summary of Contents for PIAGGIO MP3 400 hpe E5 2021

  • Page 1 MANUALE STAZIONE DI SERVIZIO 1Q000906 MP3 400 hpe E5...
  • Page 2 Not all the versions shown in this publication are available in every country. Availability of the individual versions must be verified with the official PIAGGIO sales network. © Copyright 2021 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited.
  • Page 3 SERVIZIO MP3 400 hpe E5 Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio. 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

    INDEX OF TOPICS ENERAL MANDATORY REQUIREMENTS NORM PRE DE DELIVERY ECHNICAL TOOL OOLING MAIN AINTENANCE NGINE...
  • Page 6 INDEX OF TOPICS NORM ENERAL MANDATORY REQUIREMENTS...
  • Page 7 MP3 400 hpe E5 General mandatory requirements General information This section contains general information regarding the vehicle and the use of the manual, as well as important notes regarding safety. IMPORTANT WARNINGS AND NOTES Each symbol has a precise meaning, as illustrated below. •...

  • Page 8: General Safety Warnings

    MP3 400 hpe E5 General mandatory requirements GENERAL SAFETY WARNINGS : 1. Always wear protective goggles and proper clothing. 2. Always use a safety support to operate under the vehicle. 3. Check that the ignition switch is always OFF, unless the procedure indicates otherwise. 4.
  • Page 9 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 10 MP3 400 hpe E5 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 11 MP3 400 hpe E5 Pre-delivery ASR warning light «2» turning on with slow flash- ing. • Accelerate to a constant speed of 30 to 40 km/h and maintain it for at least to 8 seconds. The con- tinuity of the vehicle speed in the correct field to complete the procedure will be confirmed by a very fast flashing of the ASR warning light «2».

  • Page 12: Electrical System

    MP3 400 hpe E5 Pre-delivery • Front shock absorber lower fixing • Sliding shafts fixing • Brake calliper fixing • Front wheels fastening screws • Front wheels axle nut • Rear wheel axle nut • Engine - frame oscillating arm fastening •...
  • Page 13 MP3 400 hpe E5 Pre-delivery BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG- ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO- TECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN. CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED.

  • Page 14: Functional Inspection

    MP3 400 hpe E5 Pre-delivery Functional inspection Functional Checks: • Hydraulic braking system: lever travel • Clutch: proper functioning check • Engine: proper general functioning and no abnormal noise check • Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting, lock check, tyre pressure check, rear-view mirror and any accessory fitting Specific operations for the vehicle TOOLKIT...
  • Page 15 MP3 400 hpe E5 Pre-delivery Rest and keep it resting with a light pressure (so that it does not fall) the windshield on the top fair- ing, aligning the holes and making sure that the spacers are in place. Insert the bushing. Put in place the cover cap.
  • Page 16 MP3 400 hpe E5 Pre-delivery Repeat the operation for the other three fasten- ings. Tighten all four fastenings using an Allen wrench. LICENCE PLATE HOLDER CAUTION N.B. ONLY FIT THE LICENCE PLATE HOLDER SUPPLIED AS STANDARD WITH THE VEHICLE, SINCE IT HAS TYPE-AP- PROVED AND OBLIGATORY SIDE REFLECTORS.
  • Page 17 INDEX OF TOPICS ECHNICAL...

  • Page 18: Vehicle Identification

    MP3 400 hpe E5 Technical Data This section describes the general specifications of the vehicle. Vehicle identification The frame prefix «A» is stamped near the fuel tank. The engine prefix «B» is stamped near the rear left shock absorber lower support. VEHICLE IDENTIFICATION Specification Desc./Quantity...

  • Page 19: Engine Data

    MP3 400 hpe E5 Technical Data Specification Desc./Quantity Rear tire Tubeless 140/70 - 14" 68S Front tyre pressure 2 bar Rear tire pressure (with passenger) 2.4 (2.6) bar Kerb weight 257 kg Maximum weight limit 460 kg Battery 12V - 12Ah Engine Data ENGINE SPECIFICATIONS Specification...
  • Page 20 INDEX OF TOPICS TOOL OOLING...
  • Page 21 MP3 400 hpe E5 Tooling ATTREZZATURA SPECIFICA - SPECIAL TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y Extractor for bearings for holes 001467Y002 Driver for OD 73 mm bearing 001467Y003 001467Y004 Lug / Taper pin 001467Y005 Screw TOOL - 21...
  • Page 22 MP3 400 hpe E5 Tooling Stores code Description 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings 001467Y014 Calliper to extract ø 15-mm bearings 001467Y017 Bearing housing, external ø 36 mm 001467Y035 Bearing housing, external ø 47 mm 006029Y Punch for fitting steering bearing on the steering tube...
  • Page 23 MP3 400 hpe E5 Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020084Y punch ø 20 020115Y punch ø 18 020128Y Piston fitting ring 020151Y Air heater TOOL - 23...
  • Page 24 MP3 400 hpe E5 Tooling Stores code Description 020163Y Crankcase splitting plate 020193Y Oil pressure gauge 020234y extractor 020244Y punch ø 15 020271Y Tool for removing-fitting silent bloc 020306Y Punch valve seal rings fitting 020329Y Mity-Vac vacuum pump TOOL - 24...
  • Page 25 MP3 400 hpe E5 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35-mm Adaptor 020358Y 37 x 40 mm Adaptor TOOL - 25...
  • Page 26 MP3 400 hpe E5 Tooling Stores code Description 020359S 42 x 47 mm Adaptor 020360S 52 x 55 mm adaptor 020362Y 12 mm guide 020363Y 20-mm guide 020364Y 25-mm guide 020375Y 28 x 30 mm adaptor TOOL - 26...
  • Page 27 MP3 400 hpe E5 Tooling Stores code Description 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re- moval tool 020382Y011 adapter for valve removal tool 020382Y012 bush (valve removing tool) 020412Y 15-mm guide 020431Y Valve oil seal extractor TOOL - 27...
  • Page 28 MP3 400 hpe E5 Tooling Stores code Description 020434Y Union for oil pressure measurement 020439Y 17-mm guide 020441S 26 x 28 mm adaptor 020442Y Pulley lock wrench 020444Y009 wrench 46 x 55 020454Y Tool for fitting the pin snap rings (200 - 250) TOOL - 28...
  • Page 29 MP3 400 hpe E5 Tooling Stores code Description 020456Y Ø 24 mm adaptor 020467Y Flywheel extractor 020477Y Adapter 37 mm 020480Y Fuel pressure measurement kit 020483Y 30-mm guide 020489Y Hub cover support stud bolt kit TOOL - 29...
  • Page 30 MP3 400 hpe E5 Tooling Stores code Description 020627Y Flywheel lock tool 020648Y Single battery charger 020661Y Water pump overall seal replacement kit 020892y Steering side headstock ring nut key 020916Y Magneto flywheel blocking tool 020917Y Driven pulley stop TOOL - 30...
  • Page 31 MP3 400 hpe E5 Tooling Stores code Description 020918Y Clutch lock 020919Y Clutch discs disassembly tool 020921Y Piston position checking tool 020922Y Diagnosis Tool 020924Y Bluetooth for the PADS diagnostic tool 021017Y EOBD E5 diagnostics cable TOOL - 31...
  • Page 32 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 33: Maintenance Chart

    CEED WITH THE MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE COUPON OF 10,000 km (6,214 miles) OR 10 MONTHS. Recommended products Piaggio Group recommends the use of prod- ucts from its Castrol official partner for the scheduled maintenance of its vehicles.
  • Page 34 MP3 400 hpe E5 Maintenance TABLE OF RECOMMENDED PRODUCTS Product Description Specifications Engine oil 5W -40 Synthetic-based lubricant for four-stroke SAE 5W-40; JASO MA, MA2; API SL; engines. ACEA A3 Transmission oil 80W-90 Lubricant for gearboxes and transmis- SAE 80W-90 API GL-4 sions.
  • Page 35 INDEX OF TOPICS NGINE...
  • Page 36 MP3 400 hpe E5 Engine This section describes the operations to be carried out on the engine and the tools to be used. N.B. ENG - 36...

  • Page 37: Specifications

    MP3 400 hpe E5 Engine THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. IN THE CASE OF VALUES EXPRESSED USING IMPERIAL AND US CUSTOMARY MEASUREMENT UNITS, REFER TO THE CONVERSION TABLE IN CHAP. «SPECIFICATIONS».
  • Page 38 MP3 400 hpe E5 Engine - Undo and remove the central screw from the transmission cover. - Remove the transmission cover. Air duct - Unscrew and remove the cooling cover fastening screws. Remove the cooling cover. ENG - 38...

  • Page 39: Removing The Driven Pulley Shaft Bearing

    MP3 400 hpe E5 Engine Removing the driven pulley shaft bearing - Remove the Seeger ring. CAUTION PLACE THE COVER ON A SURFACE, REMOVING OR EX- CLUDING THE ALIGNMENT DOWELS. - Using the housing to support the cover of the transmission, interpose a few layers of heavy cloth so as not to damage the outer surface of the cover.

  • Page 40: Removing The Driven Pulley

    MP3 400 hpe E5 Engine - Insert the Seeger ring. - Insert the alignment dowels if removed during disassembly. Removing the driven pulley To remove the driven pulley, proceed as follows: - Remove the drive pulley to release the drive belt. - Remove the driven pulley together with the belt.
  • Page 41 MP3 400 hpe E5 Engine - Using the specific tool to maintain the clutch housing in position, unscrew the nut to recover the washer. Specific tooling 020917Y Driven pulley stop - Remove the housing from the shaft. - To fit, follow the removal steps but in reverse order, being careful to tighten to the specified torque. CAUTION ALWAYS USE A NEW NUT FOR RETAINING THE CLUTCH OUTPUT SHAFT, THEN PROCEED TO THE CAULKING.

  • Page 42: Removing The Clutch

    MP3 400 hpe E5 Engine Removing the clutch - To remove the clutch assembly it is necessary to remove the inlet pinion to the final reduction unit, operating as described in the section «Dismount- ing the hub cover». - Working from the automatic transmission side, remove the driven pulley.
  • Page 43 MP3 400 hpe E5 Engine Inspecting the clutch COVER REVISION - Adequately support the cover and using a screw- driver remove the seal ring. Specific tooling 001467Y007 Driver for OD 54-mm bearings - Working from the opposite side, supporting the cover, proceed to the removal of the bearing.
  • Page 44 MP3 400 hpe E5 Engine - Replace the outer O-ring and grease properly. WARNING IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE, WE RECOM- MEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH. DISASSEMBLY - Insert the clutch assembly in the special tool and tighten the three wing nuts until you hear the end...
  • Page 45 MP3 400 hpe E5 Engine - Using pliers remove the lock circlips. - Disengage the upper ring of the specific tool. - Remove the outer ring with the seat for the Bel- leville spring. - Remove the Belleville spring. - Remove the spring door upper disc. ENG - 45...
  • Page 46 MP3 400 hpe E5 Engine - Remove the discs separation spring. - Remove the semi-trimmed duct disc (trimmed on one side). - Remove a conductor disc. - Remove the discs clearance recovery spring - Remove a duct metallic disc. - Remove a conductor disc (trimmed on both sides).
  • Page 47 MP3 400 hpe E5 Engine - Remove the discs clearance recovery spring - Remove a non-trimmed duct metallic disc. - Remove a conductor disc (trimmed on both sides). - Remove the discs clearance recovery spring - Remove the semi-trimmed duct disc (trimmed on one side).
  • Page 48 MP3 400 hpe E5 Engine CAUTION THE CLEARANCE RECOVERY SPRING DISCS ARE FIT- TED INDIVIDUALLY. THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI- TIONED TOWARDS THE INSIDE OF THE HOUSING, AS SHOWN IN FIGURE. - Remove the hub. - Remove the shaft. ENG - 48...
  • Page 49 MP3 400 hpe E5 Engine - Remove the lower spring holder disc complete with the six springs. - Remove the rollers. - Check that there is no abnormal wear on the roll- ers, the support channels for rollers and those for discs.
  • Page 50 MP3 400 hpe E5 Engine CLUTCH SPRING REVISION Characteristic Clutch springs Free spring measurement 15.3 mm Clutch spring wear limit 15,0 mm CLEARANCE RECOVERY SPRING REVISION Check for any deformation or abnormal wear. Characteristic Clearance recovery spring «A» standard di- mensions 3.2±0.1 mm Clearance recovery spring wear limit...
  • Page 51 MP3 400 hpe E5 Engine DISCS WEAR LIMIT If the discs exceed the following wear limits, replace them all. Characteristic Clutch discs wear limit Conductor disc wear limit «B» = 2.6 mm Trimmed duct wear limit «C» = 1.7 mm CLUTCH DISCS REVISION: MAXIMUM DEFOR- MATION Measure the maximum deformation of the discs by...
  • Page 52 MP3 400 hpe E5 Engine REASSEMBLY - Working in reverse order to the removal, insert the components while taking care to follow the fol- lowing guidelines: - Place the rollers as shown in the photo, after ev- ery two leave a clearance so that each pair has its opposite for proper balance.
  • Page 53 MP3 400 hpe E5 Engine - Insert the semi-trimmed disc with the trimmed surface facing the lower support disc - Respect the indicated position of the discs clear- ance recovery spring. CAUTION THE CLEARANCE RECOVERY SPRING DISCS ARE FIT- TED INDIVIDUALLY. THE LAST IN THE ASSEMBLY PHASE MUST BE POSI- TIONED TOWARDS THE INSIDE OF THE HOUSING, AS SHOWN IN FIGURE.

  • Page 54: Final Check

    MP3 400 hpe E5 Engine - Insert the Belleville spring facing upwards, taking care to insert it properly into the seat in the closure ring. - Fit the specific tool to compress the clutch pack and place the retaining ring at the specified loca- tion.
  • Page 55 MP3 400 hpe E5 Engine CLUTCH OUTPUT SHAFT ROLLER CASING IN- SPECTION - Using specific tools, remove the roller casing Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings - Insert a new roller casing and set it with specific tools.
  • Page 56 MP3 400 hpe E5 Engine Pin retaining collar - Use the tool equipped with medium length pins in "C" position screwing them from the inside of the tool. - Install the driven pulley into the tool providing the support of an appendix against a pin. - Ensure the centring of the driven pulley by means of the key inserted on the nut.
  • Page 57 MP3 400 hpe E5 Engine - Remove the following components in this order: • upper cap; • spring; • lower spring support; • synthetic ring. - Using two screwdrivers lift the locking sheath of the torque server and remove it. ENG - 57...
  • Page 58 MP3 400 hpe E5 Engine - Remove the two O-rings and replace them, mak- ing sure to lubricate them during installation. - Thoroughly clean the slots and pins. - Check that the bushings on the pins and the slots of the torque server are free from wear and rotate freely.

  • Page 59: Refitting The Driven Pulley

    MP3 400 hpe E5 Engine - Insert the closure sheath of the torque server taking care to respect the positioning of the ap- pendices in their corresponding seats. Refitting the driven pulley - Insert the synthetic ring. - Insert the lower spring support. - Insert the spring, lubricating the ends.
  • Page 60 MP3 400 hpe E5 Engine - Insert the upper cap. - Insert the belt paying attention to the direction of rotation. Specific tooling 020444Y Tool for installing/removing clutch on/from driven pulley - Turn the control screw of the specific tool and spring preloading.
  • Page 61 MP3 400 hpe E5 Engine Refitting the clutch - Insert the complete clutch assembly. - Insert the clutch cover and tighten the six screws to the specified torque. WARNING IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE, WE RECOM- MEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH.

  • Page 62: Removing The Driving Pulley

    MP3 400 hpe E5 Engine - Replace according to the scheduled maintenance table. Removing the driving pulley - Using specific tools, lock the driving pulley and loosen the flanged nut. Specific tooling 020442Y Pulley lock wrench - remove the flat washer and the cup washer. - remove the stationary half-pulley and the washer.
  • Page 63 MP3 400 hpe E5 Engine Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure outer diameter B of the pulley sliding bushing shown in the figure. - Check that the rollers are not damaged or worn.
  • Page 64 MP3 400 hpe E5 Engine Refitting the driving pulley - perform the operations in reverse order of disas- sembly. CAUTION INSERT THE ROLLERS WITH THE LARGEST SUPPORT SURFACE ACCORDING TO THE DIRECTION OF ROTA- TION. - Use the specific tool to lock the pulley, tightening to the prescribed torque.
  • Page 65 MP3 400 hpe E5 Engine - Insert the transmission cover central screw and tighten it to the prescribed torque. Locking torques (N*m) Transmission cover screws 11 ÷ 13 - Insert and tighten the external fixing screws of the transmission cover to the crankcase to the pre- scribed torque.
  • Page 66 MP3 400 hpe E5 Engine End gear Removing the hub cover - Use a container large enough to recover the final reduction oil. Unscrew the indicated screw and re- cover the aluminium seal. - Unscrew the oil filler screw in order to facilitate bleeding.
  • Page 67 MP3 400 hpe E5 Engine - Using a suitable screwdriver use leverage on the upper and lower appendices to detach the sealant. - Remove the final reduction cap complete with the wheel axle, being careful not to drop the inter- mediate gear.
  • Page 68 MP3 400 hpe E5 Engine - Remove the nut and incorporated washer secur- ing the pinion. - The pinion is symmetrical: mark the outer surface to avoid reversed reassembly. - Remove the pinion and the specific tool. CAUTION CLEAN THE THREAD FROM ANY RESIDUAL THREAD- LOCK.
  • Page 69 MP3 400 hpe E5 Engine Removing the hub bearings REMOVAL Removing the clutch shaft bearing - Remove the screw and countersunk washer. - Using the specific tools remove the bearing. Specific tooling 020376Y Adaptor handle 020357Y 32 x 35-mm Adaptor 020363Y 20-mm guide Wheel axle bearing removal - Using the specific tools remove the bearing.
  • Page 70 MP3 400 hpe E5 Engine Fitting the Wheel axle bearing - Using the equipment set a new bearing. Specific tooling 020376Y Adaptor handle 020359S 42 x 47 mm Adaptor 020363Y 20-mm guide Fitting the Clutch shaft bearing - Using the equipment set a new bearing. Specific tooling 020376Y Adaptor handle 020360S 52 x 55 mm adaptor...
  • Page 71 MP3 400 hpe E5 Engine Inspecting the hub shaft - Check the three shafts and the intermediate gear for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of faults, replace the damaged parts. Characteristic Driven pulley shaft standard sizes A: 25mm -0.01 -0.02...
  • Page 72 MP3 400 hpe E5 Engine Inspecting the hub cover - Check that the fitting surface is not dented or dis- torted. - Check the bearing bearings. - In case of faults, replace the damaged compo- nents. - Check the thorough cleaning of lubrication duct. Refitting the hub cover bearings REMOVAL Wheel axle bearing removal...
  • Page 73 MP3 400 hpe E5 Engine Removing the intermediate gear bearing - Take out the bearing using the specific tool. Specific tooling 001467Y003 Nut 001467Y004 Lug / Taper pin 001467Y005 Screw 001467Y006 Pliers to extract 20 mm bearings 001467Y035 Bearing housing, external ø 47 FITTING Fitting the Intermediate gear bearing - Heat the crankcase by means of the specific tool...
  • Page 74 MP3 400 hpe E5 Engine - Fit the seeger ring. - Insert a new seal ring with the seal facing the in- side of the hub by means of the appropriate tool. - Grease the sealing lips. Specific tooling 020376Y Adaptor handle 020360S 52 x 55 mm adaptor Refitting the hub bearings Insert the gears in the cover in order to prevent...
  • Page 75 MP3 400 hpe E5 Engine Refitting the ub cover - Working in reverse order to the removal and us- ing the specific tool, insert the control pinion, use the recommended product and tighten the torque. CAUTION FOR THE INSTALLATION, ALWAYS USE NEW NUTS AL- READY PROVIDED WITH SCOTCH GRIP.

  • Page 76: Flywheel Cover

    MP3 400 hpe E5 Engine - Restore the level of oil inside reduction unit with the recommended product, acting on the filler screw until touching. - Tighten to the specified torque. Recommended products Transmission oil 80W-90 Lubricant for gear- boxes and transmissions. SAE 80W-90 API GL-4 Characteristic Final reduction unit oil...
  • Page 77 MP3 400 hpe E5 Engine - Remove the gasket. Removing the flywheel cover components - Disconnect the spark plug cap. - Undo the two fixing screws of the coil. - Loosen the two clamps and remove the coolant internal recirculation pipe. - Undo the four screws «A»...

  • Page 78: Removing The Stator

    MP3 400 hpe E5 Engine - Remove the cover and the relative gasket. - The flywheel cover can be removed without un- screwing the impeller. - Should it be necessary to remove the impeller, loosen the moulded nut. CAUTION THE THREAD IS ANTICLOCKWISE. CAUTION IF THE EFFORT REQUIRED TO UNSCREW THE IMPELLER IS HIGHER THAN THE NORMAL LOCKING TORQUE, REF-...
  • Page 79 MP3 400 hpe E5 Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. - Respect the operation of the pick-up. Characteristic Pick-up rotor measurement 0.4 to 0.75 mm Locking torques (N*m) Stator fixing screws...

  • Page 80: Removing The Starter Motor

    MP3 400 hpe E5 Engine Flywheel and starting Removing the starter motor - Undo the two fixing screws and remove the start- er motor. Removing the flywheel magneto - Undo the screw indicated and remove the plate. - Install the support plate. Specific tooling 020916Y Magneto flywheel blocking tool ENG - 80...
  • Page 81 MP3 400 hpe E5 Engine - Install the specific tool and unscrew the retainer nut of the flywheel, recovering the washer. Specific tooling 020627Y Flywheel lock tool - Act on the extractor to remove the flywheel to- gether with the starting sprocket. - Remove the flywheel nut with its washer - Do up the flywheel nut by three or four threads so that the flywheel does not fall accidentally dur-...

  • Page 82: Intermediate Gear

    MP3 400 hpe E5 Engine Intermediate gear - Remove the flywheel. - Remove the intermediate gear from its housing. - Visually inspect the surfaces, if there is no abnormal wear, grease the housing thoroughly and insert the intermediate gear. Refitting the free wheel - Make sure the freewheel contact surfaces are in good condition.
  • Page 83 MP3 400 hpe E5 Engine Refitting the intermediate gear - Lubricate the sliding surfaces and insert the in- termediate gear in its seat. Refitting the flywheel magneto - Place the tab. - Insert the magneto flywheel on the crankshaft. - Insert the washer. ENG - 83...
  • Page 84 MP3 400 hpe E5 Engine - Insert the flywheel fixing nut. - Place the support plate. Specific tooling 020916Y Magneto flywheel blocking tool - Fit the specific tool. - Tighten the flywheel fixing nut to the specified torque. Specific tooling 020627Y Flywheel lock tool Locking torques (N*m) Flywheel fixing nut...

  • Page 85: Removing The Intake Manifold

    MP3 400 hpe E5 Engine Removing the intake manifold - The intake manifold is housed in the big end, loosen the clamps to remove the sleeve. - Remove the sleeve connecting the throttle body. Removing the rocker-arms cover - Support the big end cover. - Unscrew and remove the special cover fastening screws.
  • Page 86 MP3 400 hpe E5 Engine Removing the timing system drive - Before working on the timing system it is recom- mended to place the engine at TDC in compres- sion, aligning the references as shown in the figure. - First loosen the tensioner and unscrew the fixing screws.
  • Page 87 MP3 400 hpe E5 Engine - Undo the fixing screw and remove the washer. - Remove the complete mass of the return spring. - Loosen the screw - Remove the counterweight fixing screw. ENG - 87...

  • Page 88: Removing The Cam Shaft

    MP3 400 hpe E5 Engine - Remove the counterweight. - Disengage the chain from the sprocket and re- move the camshaft control sprocket. Removing the cam shaft - Remove the big end cover. - Remove the timing system control. - Unscrew the two screws of the camshaft lock. ENG - 88...
  • Page 89 MP3 400 hpe E5 Engine - Remove the plate. - Remove the camshaft. - Remove the lock of the rockers to allow them to slide on the pins to access the calibrated pads. - Remove the calibrated pads CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS.

  • Page 90: Removing The Cylinder Head

    MP3 400 hpe E5 Engine - Remove the pins and the rockers. N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER. Removing the cylinder head - Undo the two external screws.

  • Page 91: Removing The Valves

    MP3 400 hpe E5 Engine - Remove the gasket. Removing the valves - Use the specific tool to remove the cotters, cap and spring. CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS. Specific tooling 020382Y Tool to extract valve cotters 020382Y012 bush (valve removing tool) ENG - 91...
  • Page 92 MP3 400 hpe E5 Engine - Use the specific tool to remove the valve oil seal. Specific tooling 020431Y Valve oil seal extractor - Slide off the valve and remove the lower support. ENG - 92...
  • Page 93 MP3 400 hpe E5 Engine Removing the cylinder - piston assy. - Unscrew and remove the fastening screws of the coil. - Remove the coil. - Unscrew and remove the lower cylinder fixing screw. - Remove the cylinder, paying attention to the cyl- inder - head alignment dowels.
  • Page 94 MP3 400 hpe E5 Engine - Remove the base gasket. - Remove the retainer rings and remove the piston. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. Inspecting the small end N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.

  • Page 95: Removing The Piston

    MP3 400 hpe E5 Engine Removing the piston - Insert the pin. - Insert the retainer rings. CAUTION POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING. CAUTION AT EVERY NEW MOUNTING USE RETAINER RING PINS. Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket.
  • Page 96 MP3 400 hpe E5 Engine Slot packing system Refitting the piston rings - Pistons (like cylinders) are supplied in 4 catego- ries: M,N,O,P, must be mounted so that the refer- ence arrow is pointing towards the exhaust duct. The letter is found at the centre of the piston. - Fit the sealing rings with the word TOP or the identification letter facing upwards.
  • Page 97 MP3 400 hpe E5 Engine Refitting the cylinder - Insert the cylinder base gasket. - Fit the specific tool. Specific tooling 020426Y Piston fitting fork - Place the seal rings as indicated in the figure. - Place the cylinder and the specific tool. Specific tooling 020128Y Piston fitting ring ENG - 97...

  • Page 98: Inspecting The Cylinder Head

    MP3 400 hpe E5 Engine - Check the position of the dowels and insert the gasket with the previously determined thickness. Inspecting the cylinder head N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out.

  • Page 99: Valve Clearance Check

    MP3 400 hpe E5 Engine Inspecting the valves VALVE CLEARANCE CHECK - Remove the cover. - Position the engine to the TDC in compression. - Using a feeler gauge check the valve clearance. CAUTION - USE THE FEELER GAUGE LATERALLY, IN LINE WITH THE VALVES, IN ORDER TO PREVENT ACCIDENTAL BENDING OF THE BLADE THAT MAY AFFECT THE MEAS- UREMENTS.
  • Page 100 MP3 400 hpe E5 Engine - Move the rocker and replace the interested pad, correcting the clearance in the pre-set value. N.B. INSERT THE CALIBRATED PADS WITH THE WORDS SIDE VALVE IN ORDER TO PRESERVE THE INDICATION OF THICKNESS OVER TIME. THE OUTLET ROCKER SLIDES ON THE AXIS ONLY AF- TER THE INTAKE ROCKER HAS BEEN MOVED.

  • Page 101: Inspecting The Cam Shaft

    MP3 400 hpe E5 Engine Inspecting the springs and half-cones - Check that the upper and lower supporting spring washers, the cotters and the oil seal show exhibit no signs of abnormal wear. Replace a component when worn. N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 102 MP3 400 hpe E5 Engine Refitting the head and timing system components CAUTION AT EACH REMOVAL OF THE CYLINDER HEAD IT IS NEC- ESSARY TO REPLACE THE STUD BOLTS. FOR FITTING QUOTA SEE THE SECTION "MOTOR/STUD BOLT SHAFT CRANKCASE" - Position the crankshaft to the TDC in compres- sion.
  • Page 103 MP3 400 hpe E5 Engine - Tighten up the nuts to an initial pre-torque of 9-11 ± 1 Nm. - Tighten up the nuts by rotating 270.0±5.0° with crossed sequence. - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.
  • Page 104 MP3 400 hpe E5 Engine - Working in reverse order, assemble the camshaft command components, respecting the phase po- sition. - To tighten the decompressor, bring the mass screw to a stop and, holding it tightly, tighten the central locking screw of the starter crown. - Then tighten the central screw.

  • Page 105: Crankcase - Crankshaft

    MP3 400 hpe E5 Engine - Tighten the special screws to the specified tor- que. Locking torques (N*m) Head cover screws 6 ÷ 7 Refitting the intake manifold - Connect the rubber sleeve complete with throttle body to the intake manifold. - Place the clamps and tighten them to the speci- fied torque.
  • Page 106 MP3 400 hpe E5 Engine Splitting the crankcase halves - Undo the twelve crankcase coupling screws. - Separate the crankcase halves while keeping the crankshaft in one of these two halves. - Only after the halves have been separated, can the crankshaft be checked.
  • Page 107 MP3 400 hpe E5 Engine - After removing the oil bulkhead, blow and clean thoroughly before fitting. Inspecting the crankshaft components N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. Inspecting the crankshaft alignment N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 108 MP3 400 hpe E5 Engine - Inspect the coupling surfaces on the crankcase halves for scratches or deformation, taking partic- ular care with the cylinder/crankcase surfaces and the crankcase halves surfaces. - Defects in the crankcase coupling gasket be- tween the crankcase halves or the mating surfaces shown in the diagram, could cause a drop in the oil pressure lubricating the main bushings and connecting rod.
  • Page 109 MP3 400 hpe E5 Engine AXIS CYLINDER - The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface. N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 110 MP3 400 hpe E5 Engine - Insert the by-pass valve. - Place a new crankcase gasket. - Couple the crankcases, paying particular atten- tion to avoid accidental movements during inser- tion of the crankcase half which could cause collision with the oil pump control toothing on the crankshaft and, consequently, damage the bush- ings.
  • Page 111 MP3 400 hpe E5 Engine - Complete the coupling operations with the verifi- cation of the crankshaft axial clearance. - Using specific tools to support the dial gauge, verify that the fitting clearance is within the limits. - Higher clearances are signs of wear of the crank- shaft - crankcase supporting surfaces.

  • Page 112: Oil Pressure Check

    MP3 400 hpe E5 Engine Conceptual diagrams The lobe pump «F» sucks the oil from the sump, through the mesh pre-filter «C», it pushes it into the cartridge filter «E» where there is also a safety valve «D». Through the suitable passages found in the crankcases, the oil enters the crank chamber «G» where the main bearings are lubricated and the big end (with high pressure), the piston pin and connecting rod small end via spray «H».

  • Page 113: Crankshaft Oil Seals

    MP3 400 hpe E5 Engine - Check that the oil pressure is between 3.2 and 4.2 bar with the engine running at 6000 rpm and the oil at the required temperature. - Remove the appropriate tools once the meas- urement is complete, refit the oil pressure switch and washer, tightening it to the specified torque and fit the flywheel cover.
  • Page 114 MP3 400 hpe E5 Engine - Using pliers remove the door by acting on the appendices. - Remove the spacer and the O-ring. ENG - 114...

  • Page 115: Oil Pump

    MP3 400 hpe E5 Engine Refitting - Insert the components making sure to thoroughly grease the O-ring and the oil seal. - Follow the steps in reverse order taking care to tighten to torque. WARNING IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE, WE RECOM- MEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH.
  • Page 116 MP3 400 hpe E5 Engine - Unscrew the two screws and remove the ten- sioner pad - Remove the oil pump command sprocket com- plete with chain. - Undo the fastening screws of the oil pump. - Remove the oil pump and collect the gasket. ENG - 116...
  • Page 117 MP3 400 hpe E5 Engine - Remove the oil pump command sprocket com- plete with chain. - Unscrew the two screws and remove the oil pump. Inspection - Remove the two screws and remove the oil pump cover. - Remove and wash the rotors thoroughly with pet- rol and compressed air.
  • Page 118 MP3 400 hpe E5 Engine Admissible limit clearance: 0.12 mm Refitting - - Insert the oil pump with the corresponding gas- ket in the seat. ENG - 118...
  • Page 119 MP3 400 hpe E5 Engine - Insert and tighten the oil pump fastening screws to the crankcase to the specified torque. Recommended products Loctite 243 Medium strength thread-locking sealant. Blue Locking torques (N*m) Screws fixing oil pump to the crankcase 5 ÷...

  • Page 120: Water Pump

    MP3 400 hpe E5 Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defec- tive parts.
  • Page 121 MP3 400 hpe E5 Engine - Using the special tool and appropriate supports, ensure a proper support surface. Using a hammer and a plug (of diameter less than 8 mm and being careful not to damage the shaft seat) remove the shaft and ceramic seal.
  • Page 122 MP3 400 hpe E5 Engine - Using a screwdriver, remove the seal ring from the flywheel cover. - Check that the shaft housing hole on the crank- case does not show abnormal wear. Make sure the ceramic seal seat does not show signs of scoring. Check the cleaning of the drain and lubrication holes.
  • Page 123 MP3 400 hpe E5 Engine - Grease the shaft and insert it in the seat. Insert the shim washer and manually start-up the drive. - Locking the drive in a vice, properly lock the shaft. - Check that the shaft rotates freely (considering the friction of the oil seal) and that the axial clear- ance is noticeable but not excessive.
  • Page 124 MP3 400 hpe E5 Engine - Insert the new ceramic seal using the specific tool. - Start the tool. - Insert the new ceramic seal. - Insert the housing of the tool and tighten the nut with a wrench while holding the central pin locked. Screw until the seal stops on the crankcase.
  • Page 125 MP3 400 hpe E5 Engine - Insert and screw the impeller to the specified tor- que. Locking torques (N*m) Impeller on the pump shaft 4 ÷ 6 ENG - 125...
  • Page 126 Identification: 18 Maintenance: 33 Recommended products: 33 Technical Data: 18 Transmission: 37, 64 Vehicle: 14, 18...

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