To bleed the brakes on a Piaggio 530 HPE:

1. Remove the inspection cover.
2. Unscrew the brake fluid container cover.
3. Use only DOT 4 synthetic brake fluid as recommended.
4. If there is air in the brake line, vent the system to remove it.

Note: The presence of air in the brake system is dangerous and must be eliminated. Avoid brake fluid contact with eyes, skin, clothing, and painted parts.

This answer is automatically generated

Daniel

January 22, 2025

jak odpowietrzyć hamulce w piaggio mp3 530

Summary of Contents for PIAGGIO MP3 530 hpe

Page 1 Machine Translated by Google SERVICE STATION MANUAL 1Q000958 MP3 530 hpe...
Page 2: Table Of Contents
Machine Translated by Google TABLE OF CONTENTS NORM GENERAL STANDARDS CON OFF CHECKS BEFORE DELIVERY TECHNICAL DATA TOOLS WORK MAINTENANCE THEY ANL ELECTRICAL SYSTEM MOT DRIVE ENGINE FROM THE VEHICLE MOTOR AGAINST BRAKE SYSTEM BRAKE COOL COOLING SYSTEM BODY IN THE WARS...
Page 3 Machine Translated by Google TABLE OF CONTENTS NORM GENERAL STANDARDS...
Page 4: General Standards
Machine Translated by Google MP3 530 hpe General standards General information This section contains general information about using the manual and the vehicle as well as important safety instructions. IMPORTANT WARNINGS AND NOTES Each symbol has a precise meaning as shown below.
Page 5 Machine Translated by Google MP3 530 hpe General standards GENERAL SAFETY INSTRUCTIONS: 1. Always wear safety glasses and appropriate clothing. 2. Always use a safety support when working under the vehicle. 3. Verify that the ignition key is always in the OFF position unless otherwise specified in the procedure ben.
Page 6 Machine Translated by Google MP3 530 hpe General standards The units of measurement used in this manual are referred to as SI UNITS (In international system of units).Example: 24.5 ÷ 34.3 Nm NORM - 9...
Page 7 Machine Translated by Google TABLE OF CONTENTS CHECKS BEFORE DELIVERY CON OFF...
Page 8: Checks Before Delivery
Machine Translated by Google MP3 530 hpe Checks before delivery The ASR system is a driver assistance system, that the driver during acceleration maneuvers vern supported, especially on surfaces with ge less traction and under conditions that cause the rear wheel to suddenly slip can.
Page 9 Machine Translated by Google MP3 530 hpe Checks before delivery • If deactivation is intentional was taken (pressure of the corresponding button «1» for longer than 1 second de), we recommend the system like this to turn it back on as quickly as possible ten.
Page 10 Machine Translated by Google MP3 530 hpe Checks before delivery DANGER AT LOW SPEED, IE BELOW 5 km/h (3 mph), THE ASR SYSTEM IS NOT EFFECTIVE. BE PARTICULARLY CAREFUL WHEN ACCELERATING FROM A STOPPING WHEN GROUND IS LOW, PARTICULARLY FOR THE FIRST METERS.
Page 11 Machine Translated by Google MP3 530 hpe Checks before delivery HOW THE ASR WARNING LAMP WORKS STATUS ASR-SYSTEM ASR WARNING LAMP ASR WARNING LAMP ASR DURING DRIVING IN OPERATION WHEN OFF WITH THE ENGINE RUNNING ENGINE OR KEY AND DRIVING (CONDITION LOWER ON«ON»...
Page 12 Machine Translated by Google MP3 530 hpe Checks before delivery • Activating the process for learning the wheel diameter or for ASR calibration is indicated by the ASR control lighting up Lamp «2» confirms with slow flashes tight. • At a constant speed of 30÷40 km/h (18.6÷24.8 mph) accelerate and...
Page 13 Machine Translated by Google MP3 530 hpe Checks before delivery - Dirt Check torques Control of torques - Safety torques - Fastening screws Safety torques: • Rear shock absorber top mount • Lower mounting rear shock absorbers • Front shock absorber top mount •...
Page 14 Machine Translated by Google MP3 530 hpe Checks before delivery • Switch off the engine using the emergency stop switch • Electric opening of the seat with remote control • Lock - Unlock Button Roll Lock System TO OBTAIN BEST PERFORMANCE, THE BATTERY MUST BE FULLY CHARGED BEFORE USE. INADEQUATE BATTERY CHARGE PRIOR TO FIRST SET AND LOW BATTERY FLUID LEVEL WILL RESULT IN PREMATURE BATTERY AGING.
Page 15 Machine Translated by Google MP3 530 hpe Checks before delivery - Excessive noise - Efficiency locking and unlocking system Roll Lock Static control Static check after the test drive: • Start with a warm engine • Idle stability (when turning the handlebars) •...
Page 16 Machine Translated by Google MP3 530 hpe Checks before delivery LICENSE PLATE HOLDER DANGER ANNOTATION ONLY THE LICENSE PLATE HOLDER IN THE THE VEHICLE IS SUPPLIED WITH ASSEMBLY AS YOU EQUIPPED WITH THE APPROVED MANDATORY REAR SPOTLIGHTS. Change unit of measurement When the SETTINGS function is called by briefly pressing the “UP”...
Page 17 Machine Translated by Google MP3 530 hpe Checks before delivery • Leave Select the desired parameter by briefly pressing press the "SET" button . CON OFF - 20...
Page 18 Machine Translated by Google TABLE OF CONTENTS TECHNICAL DATA...
Page 19: Technical Data
Brake pads do not contain asbestos, but inhaling the dust is still harmful. Maintenance instructions - Only original PIAGGIO spare parts and the lubricants recommended by the manufacturer turn around. Non-original or unsuitable spare parts can damage the vehicle. - Only use special tools designed for this vehicle.
Page 20 Machine Translated by Google MP3 530 hpe Technical data - When working on the electrical system, pay particular attention to the correct cable connections Pay attention when connecting ground and battery. Chassis and engine number The frame and engine numbers consist of a prefix and a number, each on are stamped on the frame or the engine.
Page 21 Machine Translated by Google MP3 530 hpe Technical data Vehicle data VEHICLE DATA Technical information Description/Value Frame Made of steel pipes and pressed steel sheet Front suspension Roll system with parallelogram suspension, with two die-cast aluminum arms, two side tubes and shock absorbers with hydraulic locking system Rear suspension Two gas shock absorbers with preload control.
Page 22 Machine Translated by Google MP3 530 hpe Technical data Dimensions and weight Filling quantities FILLING QUANTITIES Technical information Description/Value Engine oil 1,7 Liter Gear oil 250 cm³ ~ 1,8 l coolant Petrol tank 13,7 ± 0,5 l Torque guidelines FRONT BRAKE...
Page 23 Machine Translated by Google MP3 530 hpe Technical data Name Torque guidelines in Nm Connection pipe-hose screws 13 ÷ 18 Nm (10 ÷ 13 lb*ft) brake disc rear wheel brake (°) 5 ÷ 6,5 Nm (3.7 ÷ 4.8 lb*ft) Fastening screws for the rear brake caliper 41,5 ÷...
Page 24 Machine Translated by Google MP3 530 hpe Technical data STEERING Name Torque guidelines in Nm Lower steering tube threaded ring (middle steering tube) 10 ÷ 12 Nm (7 ÷ 9 lb*ft) Upper steering tube threaded ring (middle steering tube) 32,5 ÷ 40 Nm (24 ÷ 30 lb*ft) Handlebar mounting screw 50 ÷...
Page 25 Machine Translated by Google MP3 530 hpe Technical data FLYWHEEL COVER Name Torque guidelines in Nm 3,5 ± 0,5 Nm Chain tensioner support complete chain guide - housing Flywheel mounting nut 115 ÷ 125 Nm (85 ÷ 92 lb*ft) Fasteners stator 8 ÷...
Page 26 Machine Translated by Google MP3 530 hpe Technical data CLASSIFICATION DECOMPRESSION MASS (BOLT) - CAMSHAFT Class D (black) Ø Class E (light blue) Class F (light blue) 6.75 ± 0.004 Ø 6.60 ± 0.004 Ø 6,45 ± 0,004 Decompression mass (bolts)
Page 27 Machine Translated by Google MP3 530 hpe Technical data camshaft - Class identification: D - E - F - Stamping of the class identifier: camshaft view of the valve control gear ring ANNOTATION THE CLASSES OF TWO COMPONENTS MUST BE IDENTICAL.
Page 28 Machine Translated by Google MP3 530 hpe Technical data - Measure the bend of the valve stem. Plus that Place the valve on a V-shaped holder and the Measure the bend with a dial indicator. Technical specifications Permissible limit: 0,1 mm - The rounding of the valve head with a dial indicator measure.
Page 29 Machine Translated by Google MP3 530 hpe Technical data STANDARD LENGTH OF VALVE Technical information Description/Value 95,0 ± 0,3 mm Suction: Outlet: 94,2 ± 0,3 mm Seat - valve mating surface Technical specifications Default value: 1 ÷ 1,3 mm Permissible limit:...
Page 30 Machine Translated by Google MP3 530 hpe Technical data Height cam STANDARD HEIGHT Technical information Description/Value 31,982 mm Suction outlet 31,297 mm ALLOWABLE LIMIT Technical information Description/Value Suction 31,747 mm outlet 31,064 mm 0 ÷ 0,22 mm Standard-Axialspiel: 0,3 mm...
Page 31 Machine Translated by Google TABLE OF CONTENTS TOOLS WORK...
Page 32: Tools
Machine Translated by Google MP3 530 hpe Tools SPECIAL TOOL Stock code number Description 001330Y Tool for installing steering head bearing cups 001467Y002 Basket for bearings with outside diameter Ø 73 mm 001467Y006 Pliers for removing 20 mm bearings 001467Y007 Basket for bearings with outside diameter Ø...
Page 33 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 001467Y017 Basket for bearings with outside diameter Ø 39 mm 001467Y031 Basket 001467Y031 Pliers for removing bearings with Ø 15 001467Y035 Basket for bearings with outside diameter Ø...
Page 34 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 020055Y Key for threaded ring fork shaft 020193Y Pressure gauge for oil pressure control 020201Y Tube for inserting the spacer bushing 020262Y Plate for housing separation 020306Y Impact mandrel for installing the valve sealing...
Page 35 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 020357Y Adapter 32 x 35 mm 020358Y Adapter 37 x40 mm 020359Y Adapter 42 x 47 mm 020360Y Adapter 52 x 55 mm 020364Y Guide 25 mm 020376Y...
Page 36 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 020382Y012 Cylindrical spacer (tool for removing the valves) 020412Y Guide 15 mm 020424Y Impact mandrel for installing the roller container of the guided pulley 020431Y Oil seal valve puller...
Page 37 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 020444Y Tool for attaching and removing the clutch to the guided pulley 020456Y Adapter Ø 24 mm 020458Y Lower steering tube bearing puller 020459Y Impact mandrel for installing bearings on...
Page 38 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 020472Y Key to block the alternator 020475Y Tool for checking piston position 020476Y screw bolt 020478Y Punch mandrel for needle sleeve 020479Y Tool for blocking the countershaft 020480Y...
Page 39 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 020482Y Motor mount 020483Y Guide (30mm) 020512Y Fork for installing the piston 020527Y Motor mount stand 020604Y011 Adapter to equip 020648Y Charge individual battery 020565Y Face wrench for blocking the...
Page 40 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 020661Y Replacement kit for integral seal water pump 020674Y Clamp for installing the piston Ø 95 020892y Key threaded ring for side steering tube 020922Y Diagnose-Instrument 020924Y Bluetooth for PADS diagnostic device...
Page 41 Machine Translated by Google MP3 530 hpe Tools Stock code number Description 021021Y Fuse drive pulley 021022Y Stop guided pulley 021023Y Key to lock the ring nut 021024Y Key to lock the control socket WORK - 44...
Page 42: Maintenance
Machine Translated by Google TABLE OF CONTENTS MAINTENANCE...
Page 43 Machine Translated by Google MP3 530 hpe maintenance REAR GAS SHOCK ADJUSTMENT To adjust the preload of the rear gas shock absorbers, proceed as follows: 1. The special key for the shock absorbers Use setting, the key from below insert and with two teeth of the threaded ring connect.
Page 44 Machine Translated by Google MP3 530 hpe maintenance DANGER PERFORM THE ADJUSTMENT PROCESS WHEN THE EXHAUST IS COLD AND WEAR APPROPRIATE PROTECTIVE GLOVES AND WEAR CLOTHES. ANNOTATION WITH ITS TWO TEETH THE KEY CAN FOR THE INDIVIDUAL POSITIONS SHOWN IN BOTH DIRECTIONS CAN BE USED.
Page 45 Machine Translated by Google MP3 530 hpe maintenance To tighten the threaded rings on the side To adjust the steering tubes, proceed as follows: - The windshield and the upper sports remove disc. - Remove the front of the shield.
Page 46 ENSURE THE VEHICLE CALIBRATION IS UPDATED AFTER YOU HAVE PERFORMED THE UPDATING OF THE DIAGNOSTIC DEVICE. suggested products The Piaggio Group recommends the products of “Official partner Castrol” for the planned regular maintenance of their vehicles. Use lubricants and fluids that are the same have higher quality or higher specifications, than specified in the regulations.
Page 47 Machine Translated by Google MP3 530 hpe maintenance Product Description Declarations Gear oil 75W-140 SAE 75W-140, API GL-5 Synthetic lubricant for gears and drives. SAE J 1703; FMVSS 116; ISO 4925; ASS Brake fluid DOT 4 Synthetic brake fluid. AND NC 956 DOT4...
Page 48 Machine Translated by Google MP3 530 hpe maintenance 5. Push the plug «B» onto the ignition as far as it will go put candles; 6. Reattach the flap. Pay attention, that the rear hook is inserted correctly. DANGER THE SPARK PLUGS MUST BE REMOVED WHEN THE ENGINE IS COLD.
Page 49 Machine Translated by Google MP3 530 hpe maintenance Change - Remove the oil filler cap «A». - Unscrew the oil drain plug «B» and leave it flow the oil completely. - Screw the drain plug back on and refill the hub with the prescribed oil.
Page 50 Machine Translated by Google MP3 530 hpe maintenance - Remove the filter element. - The condition of the rubber seals on the profile Check the filter box and cover. - If they have cuts and/or tears, the Replace seals. - Insert a new filter element into its seat.
Page 51 Machine Translated by Google MP3 530 hpe maintenance Engine oil In 4-stroke engines, the engine oil becomes grease tion of the valve control, the main bearings and the Cylinder-piston unit used. Too little oil leads to inadequate lubrication and can cause serious engine damage.
Page 52 Machine Translated by Google MP3 530 hpe maintenance Once the oil has stopped flowing from the drain hole, unscrew the cartridge oil filter and re move it. Make sure the O rings are in good condition Pre-filter and drain plug ring.
Page 53 Machine Translated by Google MP3 530 hpe maintenance - Unscrew the filler cap with dipstick again and check that the oil level is between the MIN and MAX markings. If applicable refill. The oil level check is off when the engine is warm the displayed oil level is lower.
Page 54 Machine Translated by Google MP3 530 hpe maintenance Check phase setting of valve control - Remove the plastic cover from the alternator cover take. - Turn the flywheel until the mark on the rotor as shown in the figure Marking on alternator cover aligned tet ist (OT).
Page 55 Machine Translated by Google MP3 530 hpe maintenance - The fixing screws of the cover Unscrew the cooling of the drive box. - Remove the drive cooling cover. - The inspection cover on the flywheel loosen cover. - Loosen the spark plug, turn the crankshaft and the received references on the swing Align the wheel and the crankcase.
Page 56 Machine Translated by Google MP3 530 hpe maintenance - The fastening screw of the two rear ones Loosen shock absorber. - The rear brake mounting screw unscrew pipes. - Open the frame by operating the pulley of the vehicle. The engine runs one slight rotation between the rear wheel and the Swing arm through.
Page 57 Machine Translated by Google MP3 530 hpe maintenance - The alignment of the marking on the cylinder head check with the one on the distributor ring. - Use a thickness gauge to check the clearance between A Check position and valve.
Page 58 Machine Translated by Google MP3 530 hpe maintenance - The rear brake mounting screw insert and tighten. - Lower the vehicle using the lifting device ken until the lower fastening of the rear shock damper with the appropriate fasteners aligned on the engine.
Page 59: Brake System
Machine Translated by Google MP3 530 hpe maintenance Cooling system The coolant level must be checked cold engine according to the information from the Table for the maintenance program can be made as follows: - Place the vehicle on level ground Set the main stand.
Page 60 Machine Translated by Google MP3 530 hpe maintenance Level control BRAKE FILL LEVEL CHECK SYSTEM FRONT AND REAR The brake fluid reservoirs for the front and Rear brakes are on the handlebars. How proceed as follows: - The vehicle is aligned in the direction of travel Place the handlebars on the main stand.
Page 61 Machine Translated by Google MP3 530 hpe maintenance USE ONLY CLASS DOT 4 BRAKE FLUID. THE BRAKE FLUID IS HIGHLY CORROSIVE: AVOID CONTACT WITH PAINTED VEHICLE PARTS. DANGER AVOID BRAKE FLUID IN EYES, COMES INTO CONTACT WITH SKIN OR CLOTHING. IF INTENTIONAL CONTACT RINSE IMMEDIATELY WITH PLENTY OF RUNNING WATER.
Page 62 Machine Translated by Google MP3 530 hpe maintenance Adjusting the headlight Proceed as follows: - The vehicle is ready to drive, unloaded and with correct tire pressure on a flat surface in 10 m distance in front of a white one in partial shade the wall, the vehicle axle must be at right angles to the wall.
Page 63 Machine Translated by Google MP3 530 hpe maintenance A. Fuel pump B. Gas tank C. Two-way fuel vent valve dampen D.Activated carbon filter E. Vent pipe to the environment F. Unidirectional electronic force material vapor vent valve (from the engine control unit advises controlled) G.
Page 64 Machine Translated by Google MP3 530 hpe maintenance 7. Connection line from the fuel tank to the activated carbon filter disassembly of system components To access the components of the system to limit evaporative emissions Remove the helmet compartment and the side panels.
Page 65 Machine Translated by Google MP3 530 hpe maintenance Legend: 1. Connection line from the fuel tank to the activated carbon filter 2. Connection line from the solenoid valve to the activated carbon filter 3. Vent line Make sure the activated carbon filter is installed correctly is directed.
Page 66 Machine Translated by Google MP3 530 hpe maintenance When reinstalling, pay attention to the alignment of the ven tils pay attention. DANGER ENSURE THE CORRECT INSTALLATION DIRECTION OF THE COMPONENTS. IF YOU IF MOUNTED REVERSE, THIS MAY AFFECT THE OPERATION OF THE ENTIRE EVAPORATION PREVENTION SYSTEM.
Page 67 Machine Translated by Google MP3 530 hpe maintenance Even if the amount of hydrocarbons coming from the tank is quite small, the Activated carbon is regenerated by a reverse flow of ambient air sucked in by the engine to avoid saturation of the activated carbon filter.
Page 68: They Anl
Machine Translated by Google TABLE OF CONTENTS ELECTRICAL SYSTEM THEY ANL...
Page 69 Machine Translated by Google MP3 530 hpe Electrical system DANGER ANNOTATION THE GRAPHIC REPRESENTATION OF THE CABLE CONNECTORS SHOULD BE UNDERSTANDED FROM THE CABLE ENTRY SIDE, AS SHOWN IN THE EXAMPLE. Attaching the components ELE ANL - 72...
Page 70 Machine Translated by Google MP3 530 hpe Electrical system 1. Right brake lever stop switch Remove handlebar covers to access. 2. Left brake lever stop switch. Remove handlebar covers to access. ELE ANL - 73...
Page 71 Machine Translated by Google MP3 530 hpe Electrical system 3. Brake pedal stop switch. To access, remove the right footboard. 4. Preparation for heating accessories Remove handlebar covers to access. 5. Air temperature sensor. In the lower handlebar cover. 6. Keyless switch contacts To access, remove the back of the shield.
Page 72 Machine Translated by Google MP3 530 hpe Electrical system 7. PMP3 To access the component, use the above Remove the remaining part of the shield. 8. Sensor mechanical brake caliper roll Lock To get to the component, the front one Remove shield.
Page 73 Machine Translated by Google MP3 530 hpe Electrical system 11. Flasher On the left side of the vehicle for access Remove rear side panel. 12. Cable connector USB socket To get to the component, the front one Remove shield. 13. Stellmotor Roll-Lock To get to the component, the front one Remove shield.
Page 74 Machine Translated by Google MP3 530 hpe Electrical system 15. Parking brake control unit In order to access the component, the The back of the shield must be removed. 16. Parking brake switch In order to get to the component, you have to The back of the shield must be removed.
Page 75 Machine Translated by Google MP3 530 hpe Electrical system 19. Oil pressure sensor On the right side of the engine. 20. Ignition coil. Positioned on the left side of the vehicle to To access the component, remove the left side panel distant.
Page 76 Machine Translated by Google MP3 530 hpe Electrical system 23. Injection control unit 11MP Located on the right side of the vehicle. Around To be able to get to the component, you have to Helmet compartment can be removed. 24. Driver detection sensor cable connector...
Page 77 Machine Translated by Google MP3 530 hpe Electrical system 27. Reverse gear actuator assembly In order to get to the component, you have to Protective cover of the drive cover removed become. 28. Reverse gear motor The box of contacts of the positive cable of the Mo...
Page 78 Machine Translated by Google MP3 530 hpe Electrical system 31. Lambda sensor The lambda sensor is located on the exhaust manifold mer. To expose the cable connector, the right Remove rear side panel. 32. ABS sensor rear wheel The rear wheel ABS sensor is located on Engine, between the wheel and the left rear Shock absorber.
Page 79 Machine Translated by Google MP3 530 hpe Electrical system 34. Seat opening adjustment device In order to be able to access the component, the hint Remove the other side parts. 35. Injector In order to get to the component, the In Remove the inspection flap in the helmet compartment.
Page 80 Machine Translated by Google MP3 530 hpe Electrical system Legend: 1 = ASR indicator light 2 = ABS indicator light 3 = Daytime Running Lights indicator light switched on 4 = High beam indicator light switched on 5 = left indicator light...
Page 81 Machine Translated by Google MP3 530 hpe Electrical system 3) Turn the ignition key to OFF and connect the tester terminals between the negative (-) terminals. on the battery and the black cable. Only then remove the black cable from the negative pole Disconnect (-) at the battery.
Page 82 Machine Translated by Google MP3 530 hpe Electrical system Electrical information Description/Value Quantity: 1 RIGHT - 1 LEFT Taillight lamp Typ: LED Quantity: 1 Rear turn signal lamp Typ: LED Quantity: 1 RIGHT - 1 LEFT Brake light Typ: LED...
Page 83 Machine Translated by Google MP3 530 hpe Electrical system MAIN BACKUP The table shows the position and the technical information about the devices in the vehicle neral fuse listed. TABLE MAIN BACKUP Electrical information Description/Value Fuse No. 18 Power: 30A Supply: from battery Protected circuits (under ignition switch): Fuses No.
Page 84 Machine Translated by Google MP3 530 hpe Electrical system Electrical information Description/Value PMP3 (Piaggio Multimedia Platform) control unit, “Keyless” control unit, electrical storage compartment preparation. Fuse #8 Power: 30A Protected circuits: Power supply via battery; ABS control unit. The table shows the positions and the technical technical specifications of the relays are described in Fuse holder «A»...
Page 85 Machine Translated by Google MP3 530 hpe Electrical system Electrical information Description/Value Protected circuits: Power supply via ignition lock; Remote brake light relay, rear brake light, coil Remote starter relay. Fuse #6 Power: 7.5A Protected circuits: Power supply via ignition lock;...
Page 86 Machine Translated by Google MP3 530 hpe Electrical system • Parking brake control unit • Injection control unit • Horn • Ignition lock • Light switch • Ignition actuator contact • Starter remote relay contact • Flasher unit • cooling fan •...
Page 87 Machine Translated by Google MP3 530 hpe Electrical system • Handbrake switch • Brake pedal switch • Brake light switch on the right • Left brake light switch • Voltage regulator • Selector switch for drive/reverse gear operating mode •...
Page 88 Machine Translated by Google MP3 530 hpe Electrical system CABLE PLUG ADJUSTMENT DEVICE FOR TANK 1. Ground (Black) 2. Control input for tank opening via keyless (yellow Red) BATTERY-PLUS 1. Power supply (red) BATTERY-MINUS 1. Ground (Black) IGNITION COIL CABLE CONNECTOR.
Page 89 Machine Translated by Google MP3 530 hpe Electrical system MASS DUTY 1. Ground black CABLE CONNECTOR DEVELOPMENT CAN 1. Line CAN H (Orange-Grey) 2. Line CAN L (orange-light blue) ABS CONTROL UNIT CABLE CONNECTOR 1. Powered by battery (red) 2. Rear ABS sensor ground (brown-black) 3.
Page 90 Machine Translated by Google MP3 530 hpe Electrical system 22. Mass (Black) 23. Line CAN H (Rosa-Rot) 24. Not connected 25. Not connected 26. Mass (Black) CONTROL UNIT CABLE CONNECTOR FIXED PARKING BRAKE 1. Powered by battery (Blue - Red) 2.
Page 91 Machine Translated by Google MP3 530 hpe Electrical system 29. Limit switch button (brown-white) 30. Pressure sensor (white) 31. Not used 32. CAN L line (pink-white) 33. Lock/unlock suspension button (green degree) 34. Not connected 35. Right speed sensor ground (schwarz-rot) 36.
Page 92 Machine Translated by Google MP3 530 hpe Electrical system 2. Not connected 3. Not connected 4. Not connected 5. AKF valve (white-black) 6. Signal + DC M throttle body (Red-Blue) 7. Not connected 8. Not connected 9. Not connected 10. Lambda sensor heater (white-blue) 11.
Page 93 Machine Translated by Google MP3 530 hpe Electrical system 41. Not connected 42. Not connected 43. Not connected 44. Ground sensors (purple-black) 45. Ground sensors (gray-green) 46. Ground sensors (black-yellow) 47. Not connected 48. Not connected 49. Reverse motor coil signal (white-violet) 50.
Page 94 Machine Translated by Google MP3 530 hpe Electrical system 74. Not connected 75. Ground sensors (gray-brown) 76. Not connected 77. Not connected 78. ASR button (light blue-white) 79. Not connected 80. Not connected HORN CABLE CONNECTOR 1. Ground (Black) 2. Power supply (yellow-pink) IGNITION CABLE CONNECTOR 1.
Page 95 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR CONTACT ACTUATOR CAUTION FOR IGNITION 1. Signal contact actuator for ignition (purple-white) 2. Mass (Brown - Black) CABLE CONNECTOR CONTACT STARTER REMOTE RELAY 1. Powered by battery (Red) CABLE CONNECTOR THROTTLE BODY 1.
Page 96 Machine Translated by Google MP3 530 hpe Electrical system 5. Signal output switch-on control right blink ker (white-blue) 6. Powered by battery (Red-Blue) 7. Not connected 8. Power supply via ignition lock (brown Rot) 9. Ground (Black) 10. Not connected 11.
Page 97 Machine Translated by Google MP3 530 hpe Electrical system ELECTRONIC CABLE CONNECTOR DIRECTION LE 1. Power supply turn signal switch (brown-red) 2. Ground Joystick (Black-Yellow) 3. Signal for instrument unit from Joy stick button on top (pink-yellow) 4. Signal for instrument unit from Joy stick button below (pink-gray) 5.
Page 98 Machine Translated by Google MP3 530 hpe Electrical system TAIL LIGHT CONNECTOR 1. Brake light (white-black) 2. Rear parking light (light blue) 3. Right turn signal signal (white-blue) 4. Signal link Flashing (pink) 5. Ground (Black) CABLE CONNECTOR SOLENOID GROUP 1.
Page 99 Machine Translated by Google MP3 530 hpe Electrical system 21. LED immobilizer (yellow-orange) 22. Joystick button right (pink-brown) 23. Joystick left button (white-pink) 24. Mass (Black) 25. Ground sensors (black-yellow) 26. Not connected 27. DRL indicator light (yellow) 28. Parking light indicator light (light blue) 29.
Page 100 Machine Translated by Google MP3 530 hpe Electrical system 17. Switch-on control LED immobilizer (yellow orange) 18. Ground for comfort LED (gray) 19. Not connected 20. Signal right turn signal (white-blue) CABLE PLUG NUMBER PLATE LIGHTING 1. Power supply via ignition lock (light blue) 2.
Page 101 Machine Translated by Google MP3 530 hpe Electrical system FRONT LEFT BLIN CABLE CONNECTOR BECAUSE 1. Power supply (pink) 2. Ground (Black) ALARM LED CABLE CONNECTOR 1. Ground (Black) 2. Preparation for anti-theft protection (red) IGNITION COIL GROUND 1. Ground (Black) FRAME DIMENSIONS 1.
Page 102 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR ACTUATOR A. Parking brake control unit (yellow) B. Parking brake control unit (blue) PLUS STARTER MOTOR 1. Power supply (red) MINUS STARTER MOTOR 1. Ground (Black) PLUS MOTOR FOR REVERSE GEAR 1.
Page 103 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR PICK-UP 1. Injection control unit (red) 2. Injection control unit (brown) CABLE CONNECTOR FOR HELMET COMPARTMENT LIGHTING 1. Power supply (Blue-Black) 2. Ground (Black) PMP3 1. CAN H line (Rosa-Rot) 2.
Page 104 Machine Translated by Google MP3 530 hpe Electrical system 20. Not connected FUEL PUMP CABLE CONNECTOR 1. Not connected 2. Ground (Black) 3. Ground sensors (black-yellow) 4. Signal indicator light fuel indicator for In instrument unit (white-green) 5. Power supply via remote fuel relay...
Page 105 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR PREPARATION HANDLE TONGUE/LEG WARMER/SEAT HEATER 1. Power supply via ignition lock (red - green) 2. Ground (Black) 3. Powered by battery (Red-Black) 4. Preparation for heated bench (black-green) 5. CAN H line (Rosa-Rot) 6.
Page 106 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR POWER BUTTON HOT ROOT 1. Ground of control electronics PMP3 (black green) 2. Signal PMP3 control electronics (green) CABLE CONNECTOR SWITCH FOR SEAT OPENING 1. Signal seat opening for keyless (brown-yellow) 2.
Page 107 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR PARKING BRAKE BUTTON 1. Signal instrument unit (yellow-black) 2. Ground sensors (black-yellow) BRAKE LIGHT SWITCH CABLE CONNECTOR BRAKE PEDAL 2. Ground sensors (gray-brown) 3. Signal injection control unit (white-gray) 4.
Page 108 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR VOLTAGE REGULATOR 1. Battery plus (red-black) 2. Not connected 3. Ground (Black) CABLE PLUG SELECTOR SWITCH FOR BE DRIVE/REVERSE MODE 1. Injection control unit (light blue) 2. Mass (grey-green) 3.
Page 109 Machine Translated by Google MP3 530 hpe Electrical system REAR ABS SENSOR CABLE CONNECTOR 1. Minus of ABS control unit (brown-black) 2nd signal (brown-red) CABLE CONNECTOR TILT SENSOR 1. Not connected 2. Ground sensors (gray-green) 3. Supply via injection control unit (light blue green) 4.
Page 110 Machine Translated by Google MP3 530 hpe Electrical system PRESSURE SENSOR CONNECTOR 1. Parking brake control electronics (white) 2. Sensor ground (black-green) OIL PRESSURE SENSOR CABLE CONNECTOR 1. Instrument unit (Pink-Black) 2. Not connected CONNECTOR ROTATION SENSOR 1. Power supply from locking control unit...
Page 111 Machine Translated by Google MP3 530 hpe Electrical system ENGINE TEMPERATURE SENSOR CABLE CONNECTOR BEER 1. Signal (light blue-green) 2. Not connected 3. Ground reference via injection control unit (Vio lett-black) 4. Not connected T-MAP SENSOR CABLE CONNECTOR 1. Ground reference via injection control electronics (gray-green) 2.
Page 112 Machine Translated by Google MP3 530 hpe Electrical system CABLE CONNECTOR SOLENOID INTRODUCTION DIRECTION FOR IGNITION 1. Signal + solenoid actuator for ignition (green white) 2. Signal - Solenoid actuator for ignition (green-black) CABLE PLUG LAMBDA SENSOR WITH HEATER CONTRAPTION 1.
Page 113 Charges (Black-Green) ACTIVATED CHARCOAL VALVE CABLE CONNECTOR FILTERS 1. Signal for injection control unit (white-black) 2. Power supply via remote injection relay dungs (black-green) Duplication of keys/remotes Procedure for duplicating the remote control with "Piaggio KeyLess" system. ELE ANL - 116...
Page 114 Machine Translated by Google MP3 530 hpe Electrical system A= remote control B= Master key 1. Checking the initial conditions: 1.1 Battery voltage over > 12V, 1.2 The master key must be available 1.3 All remote controls to be coded must be present (including those already available before process coded), 1.4 The PADS diagnostic instrument must be connected to the vehicle's OBD connector...
Page 115 Machine Translated by Google MP3 530 hpe Electrical system 3. Start procedure in Self Diagnosis > Pro Programming the keyless remote controls through PADS: 3.1 With ignition key set to "ON", 3.2 The self-diagnosis of the keyless control unit call, 3.3 Possible errors in memory in the "MEM"...
Page 116: Mot Drive
Machine Translated by Google TABLE OF CONTENTS MOT DRIVE ENGINE FROM THE VEHICLE...
Page 117 Machine Translated by Google MP3 530 hpe Engine out of the vehicle This section describes the operations to be carried out to remove the engine from the vehicle. Removal of complete exhaust - Remove the right and left running boards.
Page 118 Machine Translated by Google MP3 530 hpe Engine out of the vehicle - Release the lambda sensor cable connector and cut him off. DANGER CLEAR THE LAMBDA SENSOR WIRING BEFORE REMOVAL OF THE EXHAUST. WILL BE THIS CABLING WITH TOO HIGH VOLTAGE CAN BE DAMAGED.
Page 119 Machine Translated by Google MP3 530 hpe Engine out of the vehicle - Remove the exhaust manifold while keeping it on top Pay attention to the lambda sensor wiring harness to pull out. INSTALLATION OF COMPLETE EXHAUST - If necessary, the lambda sensor on the exhaust install manifold.
Page 120 Machine Translated by Google MP3 530 hpe Engine out of the vehicle - The rear brake tube back in position bring and the appropriate fastening Tighten screw on frame. - Install the end piece on the exhaust manifold. DANGER ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN THE END PIECE AND THE EXHAUST MANIFOLD.
Page 121 Machine Translated by Google MP3 530 hpe Engine out of the vehicle - The metal clamp between the exhaust tailpipe and Loosen the manifold. Torque guide values (N*m) Metal clamp 13 ± 1 - Install the heat protection on the exhaust pipe end...
Page 122 Machine Translated by Google TABLE OF CONTENTS MOTOR AGAINST...
Page 123 Machine Translated by Google MP3 530 hpe Motor This section describes the work on the engine and the tools required for it. Automatic drive Gearbox cover - Unscrew the 4 fastening screws. - Remove the outer plastic drive cover. - Use a screwdriver to open the cover Remove the driven pulley axle.
Page 124 Machine Translated by Google MP3 530 hpe Motor - Remove the drive cover screws. 7 screws M6 - The screws on the right side of the lid remove. 2 screws M8x70 Remove the screws on the middle part. 2 screws M8x100 - Remove the drive cover.
Page 125 Machine Translated by Google MP3 530 hpe Motor Torque guide values (N*m) Air baffle screws 7.0 ± 1.0 Nm Removing the shaft bearing of the guided pulley - Remove the drive cover. - Remove the seeger ring. - The drive cover with a wooden plate and the Support special tools.
Page 126 Machine Translated by Google MP3 530 hpe Motor - Place the bearing on the special tool and attach with a little fat. - Insert the new bearing with the special tool build. ANNOTATION TO NOT DAMAGE THE PAINT SURFACE, PLACE THE LID ON A SUITABLE SURFACE.
Page 127 Machine Translated by Google MP3 530 hpe Motor Check clutch basket - Check that the clutch basket is not worn or otherwise damaged. - The inner diameter of the clutch basket measure. ANNOTATION THE MEASURED ECCENTRICITY MUST NOT BE MORE THAN MAXIMUM 0.2 MM.
Page 128 Machine Translated by Google MP3 530 hpe Motor - The assembly guided pulley on Attach special tool. They have to Pins inserted into the ventilation holes the. - Tighten the rear fixing screw as shown in the figure until it stops Attach the guided pulley.
Page 129 Machine Translated by Google MP3 530 hpe Motor Tenon collar ring - Remove the collar using 2 screwdrivers pull it off. - Remove the 4 guide pins. - Pull off the movable belt half pulley. Control fixed guided belt half pulley - The contact surface with the belt on ver check wear.
Page 130 Machine Translated by Google MP3 530 hpe Motor Removal of bearing guided belt half pulley - Check the bushing for signs of wear and damage. If necessary, replace the fixed guided belt half pulley. - Remove the locking ring using a suitable one Remove pliers.
Page 131 Machine Translated by Google MP3 530 hpe Motor Control movable guided belt half pulley - The contact surface with the belt on ver check wear. - Remove the 2 inner sealing rings and the 2 outer O-rings. - The inner diameter of the bushing of the movable Measure the belt half pulley.
Page 132 Machine Translated by Google MP3 530 hpe Motor - Install a new ball bearing using the specified special tool. Special tool 020376Y Handle for adapter 020477Y Adapter 37 mm 020363Y Guide 20 mm - Insert the circlip. Assembling the guided pulley - Insert the new shaft seals.
Page 133 Machine Translated by Google MP3 530 hpe Motor Check the compression spring The free length of the compression spring between the clutch and the guided pulley half mes its. Technical specifications Standard length: 146,5 mm Maximum permissible length according to use:...
Page 134 Machine Translated by Google MP3 530 hpe Motor - To facilitate installation on the engine, turn the guided movable pulley and the Insert the belt at the smallest diameter. Installation guided pulley - The assembly guided pulley together Insert the men with the belt.
Page 135 Machine Translated by Google MP3 530 hpe Motor - The 2 fastening screws can also be tightened by hand screw the main tool. - Use a 27 mm wrench to tighten the center Unscrew the drive belt pulley nut ben.
Page 136 Machine Translated by Google MP3 530 hpe Motor - The mobile drive belt half pulley with the Pull out the associated socket while doing so make sure that the rollers do not fall out. - Pull out the rear washer.
Page 137 Machine Translated by Google MP3 530 hpe Motor - The outside diameter of the pulleys Measure the liner as shown in the figure. Technical specifications Smallest permissible diameter: Ø 29,95 mm Standard diameter: Ø 29,959 mm - Check that the rollers are not damaged or worn.
Page 138 Machine Translated by Google MP3 530 hpe Motor Install drive pulley Installation of roller containers - Insert the spacer with the inner bevel in the installation direction. - Check that the running shoes fit the rollers striking plate are not worn.
Page 139 Machine Translated by Google MP3 530 hpe Motor - Place the drive belt on the guided belt mount the disc. Installation of fixed drive belt half pulley - Insert the spacer. - Insert the fixed drive belt half pulley and check that they have the spacer and the liner of the movable drive belt half disk touches.
Page 140 Machine Translated by Google MP3 530 hpe Motor - The nut in the same installation position as attach beforehand (mother side contact Tel disk). - Assemble the special tool by first attach the two retaining straps to the strap disc attaches so that the notch is complete rests.
Page 141 Machine Translated by Google MP3 530 hpe Motor DANGER WARNING THE FOUR M8 SCREWS OF THE DRIVE COVER HAVE DIFFERENT LENGTHS: THE TWO LONG SCREWS ARE MOUNTED IN THE MIDDLE PART, THE TWO SHORT SCREWS IN THE RIGHT PART. - Tighten the screws on the middle part.
Page 142 Machine Translated by Google MP3 530 hpe Motor - The washers on the shaft of the guided Put on the th belt pulley. ANNOTATION FIRST PUT ON THE WASHER WITH THE SMALLER OUTER DIAMETER AND THEN THE LARGER ONE. - Place the special tool in the designated areas Insert slots, rotate the shaft if necessary, to be able to fully introduce it.
Page 143 Machine Translated by Google MP3 530 hpe Motor - Remove the special tool. - Install the drive pulley axle lock animals. ANNOTATION CHECK THAT THE AIR INLET AND AIR OUTLETS ARE COMPLETELY CLEAR. - Put on the outer plastic drive cover.
Page 144 Machine Translated by Google MP3 530 hpe Motor Removing the rear wheel gear cover - The rear wheel gear oil through the drain screw be drained at the bottom of the engine. - The hub cover fastening screws remove. 4 long screws...
Page 145 Machine Translated by Google MP3 530 hpe Motor Removing rear wheel gearbox bearing housing - The condition of all bearings (wear, play and Check noise development). If errors are found, proceed as follows. The following tools are required to remove the wheel axle bearing from the housing of the rear wheel transmission.
Page 146 Machine Translated by Google MP3 530 hpe Motor Wheel axle bearing removal - The circlip from the outside of the lid remove. - The rear gearbox cover with the columns support sentence. - Remove the bearing using the special tool.
Page 147 Machine Translated by Google MP3 530 hpe Motor - Remove the shaft seal with a screwdriver from inside the rear wheel housing expand the drive. - Remove the circlip shown in the illustration distant. - Using the specified special tool, la ger of the shaft of the guided pulley Remove the motor housing.
Page 148 Machine Translated by Google MP3 530 hpe Motor Technical specifications Diameter of running surface of shaft guided pulley: D = Ø 15 - 0.01 -0.02 mm E = Ø 20 - 0.01 -0.02 mm F = Ø 25 - 0,01 -0,02 mm Checking the rear gearbox cover - Check that the mating surfaces are not scratched or warped.
Page 149 Machine Translated by Google MP3 530 hpe Motor - Heat the countershaft bearing seat. - The bearing of the countershaft with the specified Use the specified special tool. ANNOTATION THE BALLS MUST BE VISIBLE FROM THE REAR GEAR (THIS REQUIREMENT APPLIES TO ALL BEARINGS WITH PLASTIC CONTAINERS).
Page 150 Machine Translated by Google MP3 530 hpe Motor Installing the bearings in the rear gearbox cover - The bearing seats on the rear wheel gear cover Heat with a heat gun. - The rear gearbox cover with the columns support sentence.
Page 151 Machine Translated by Google MP3 530 hpe Motor - The rear gearbox cover with the columns support sentence. - The shaft seal of the wheel axle with the sealing lip towards the inside of the rear wheel gear Install cover.
Page 152 Machine Translated by Google MP3 530 hpe Motor - The fastening screws according to the Use the position noted when dismantling. 4 long screws 3 short screws - The screws with the specified rotation Tighten momentarily and adjust to position the retaining clamps of the ventilation line pay attention as shown in the figure.
Page 153 Machine Translated by Google MP3 530 hpe Motor Removing the alternator cover - Drain the engine oil via the oil drain plug its. - A suitable container to collect the Place the engine oil under the drain plug. - Remove the pre-filter.
Page 154 Machine Translated by Google MP3 530 hpe Motor - The alternator cover together with the associated seal and the holder for the Remove the cooling system sleeves. DANGER KEEP IT ON WHEN REMOVAL OF THE ALTERNATOR COVER MAKE SURE THAT THE STATOR AND THE ROTOR DO NOT JUMP.
Page 155 Machine Translated by Google MP3 530 hpe Motor - Unscrew the 3 fastening screws and Remove the stator completely with cables. Check the lid components - Unscrew the 2 fixing screws and the holder of the reed valve with separating plate remove.
Page 156 Machine Translated by Google MP3 530 hpe Motor - Check that the mating surfaces on the housing are not worn or deformed. - The seat of the by-pass valve, the running surface of the Torque limiter and the running surface of the Water pump shaft for signs of wear check.
Page 157 Machine Translated by Google MP3 530 hpe Motor - The current continuity between the 3 phases check. ANNOTATION THE VALUES STATED REFER TO MEASUREMENTS AT ROOM TEMPERATURE. WILL BE THE STATOR CHECKED AT OPERATING TEMPERATURE, HIGHER THAN THE STATED VALUES ARE MEASURED.
Page 158 Machine Translated by Google MP3 530 hpe Motor - Install the cable guide and secure the 2 fastening screws with the specified one Tighten torque. Torque guide values (N*m) Cable guide fixing screws Stator 3 - 4 Installing the alternator cover components - Before installation, all components must be cleaned thoroughly be cleaned.
Page 159 Machine Translated by Google MP3 530 hpe Motor - The closure on the inspection opening for the phase adjustment of the valve control and the oil in Filler plug/dipstick for the engine oil provisionally attach correctly. - The blow-by line with a new O-ring insert.
Page 160 Machine Translated by Google MP3 530 hpe Motor Installation of alternator cover - Install a new oil filter, the gasket Lubricate by hand until it stops screw and then with the provided Tighten the specified torque. Torque guide values (N*m) Engine oil filter 12 ÷...
Page 161 Machine Translated by Google MP3 530 hpe Motor - Install a new gasket on the engine housing gen. - Make sure the 3 centering pins are present are. - Turn the crankshaft until the drive the countershaft to a mark on the gear house is aligned (see illustration).
Page 162 Machine Translated by Google MP3 530 hpe Motor Torque guide values (N*m) Alternator cover screws 11 ÷ 13 Nm (8 ÷ 10 lb*ft) Alternator and starter system - To make the alternator cover easier to remove To be able to build, the three in the illustration must...
Page 163 Machine Translated by Google MP3 530 hpe Motor Only operate the starter switch (the engine cannot start) until the speed and the current consumption of the starter motor can be measured. ANNOTATION THE SPEED VALUE STATED IS THE VALUE DISPLAYED BY THE DIAGNOSTIC TEST EQUIPMENT. THE ACTUAL RPM IS NOT RECORDED, BUT THE VALUE IS VALID FOR THE CHECKS.
Page 164 Machine Translated by Google MP3 530 hpe Motor 12 - Definitely replace the starter remote relay. 13 - Check the battery again and replace the starter motor if necessary. ANNOTATION IF THE CRANKSHAFT DRIVE SPEED IS LOW AND UNUSUAL NOISE IS PRODUCED AT THE SAME TIME, THE FREEWHEEL AND TORQUE LIMITER MUST BE CHECKED (SEE CHAPTER “ALTERNATOR...
Page 165 Machine Translated by Google MP3 530 hpe Motor - Unscrew the fastening screws. 2 screws - Remove the ground cable and the cable retaining bracket, then the complete starter motor pull out gate. Removing the flywheel magneto - Align the two holes on the flywheel with the...
Page 166 Machine Translated by Google MP3 530 hpe Motor - The fastening nut of the flywheel magnet Unscrew the igniter. - The special tool, the fastening nut and remove the washer underneath with. - Put the nut back on so far that the...
Page 167 Machine Translated by Google MP3 530 hpe Motor - Unscrew the 6 fixing screws and the freewheel from the flywheel magneto Remove. IF THE FREEWHEEL IS TO BE REMOVED, THE 6 FASTENING SCREWS SHOULD ALREADY BE INCLUDED STILL ATTACHED TO THE CRANKSHAFT FLYWHEEL TO BE LOOSED.
Page 168 Machine Translated by Google MP3 530 hpe Motor Starter wreath - The «rollers» of the freewheel and the hub of the An for signs of wear and tear Check prints. - Measure the outside diameter of the hub. Technical specifications Hub outer diameter: Ø...
Page 169 Machine Translated by Google MP3 530 hpe Motor Also the diameter of the treads Alternator cover and on the engine housing measure. Technical specifications Diameter of the running surface on the alternator cover: Ø 12 + 0,034 -0,016 mm Diameter of the running surface on the engine housing with: Ø...
Page 170 Machine Translated by Google MP3 530 hpe Motor - Attach the freewheel to the flywheel magneto. Make sure that the ground side rests on the flywheel. i.e. the circlip of the Freewheel remains visible. - The 6 fastening screws crosswise Tighten to the specified torque.
Page 171 Machine Translated by Google MP3 530 hpe Motor - The inside of the liner and the hub of the Oil the starter ring. - Turn the starter ring clockwise and insert into the flywheel at the same time. Installation of flywheel magneto - Insert the key into the crankshaft.
Page 172 Machine Translated by Google MP3 530 hpe Motor - The guide bushing, which is part of the tool Blocking of the flywheel magneto is until Screw it on until it stops and then turn it around Loosen ¼ turn. ANNOTATION IF THIS INSTRUCTION IS NOT OBSERVED, THE GUIDE WILL STAY ON THE FLYWHEEL.
Page 173 Machine Translated by Google MP3 530 hpe Motor Installation of starter motor - Check the condition of the O-ring and this lubricate. - Insert the starter motor. - The fastening screws with the ground cable and mount the cable retaining bracket, as shown shown in the photo.
Page 174 Machine Translated by Google MP3 530 hpe Motor Removing the intake manifold - Unscrew the 3 fastening screws. - Completely remove the intake manifold assembly with. Removing the valve tappet cover - Unscrew the 4 flange screws to Remove valve cover.
Page 175 Machine Translated by Google MP3 530 hpe Motor Removing the valve control drive - Turn the engine until the inlet valve are closed. - The central nut and the valve holding basket lifting mass with the specified special mechanism remove stuff.
Page 176 Machine Translated by Google MP3 530 hpe Motor Remove the Allen screw and counterweight (see illustration). - Remove the valve timing chain sprocket from No remove the crankshaft. - Remove the valve timing chain sprocket. Removing the camshaft - Unscrew the 3 fastening screws and Remove the camshaft mounting bracket with.
Page 177 Machine Translated by Google MP3 530 hpe Motor - The pins and the rocker arms through the hole Remove the connectors on the gearbox side. Cylinder head removal - Remove the spark plugs. - The sleeve at the outlet of the cooling system is complete remove with thermostat.
Page 178 Machine Translated by Google MP3 530 hpe Motor - Loosen the 4 cylinder head - cylinder fastening screws in 2 - 3 passes in a criss-cross pattern. - The cylinder head, the 2 centering pins, you Remove the cable and the lower chain guide.
Page 179 Machine Translated by Google MP3 530 hpe Motor - Remove the spring supports. ANNOTATION TO EASIER REMOVAL OF THE SPRING PADS, COMPRESSED AIR CAN BE BLOWED INTO THE SEATS. Cylinder - piston removal - Remove the valve timing chain. - Unscrew the fastening screw and the Spacer and the chain tension shoe distant.
Page 180 Machine Translated by Google MP3 530 hpe Motor - The piston rings and the oil scraper from the col remove ben. DANGER WRITE DOWN THE INSTALLATION POSITION OF THE PISTON RINGS SO THAT THEY CANNOT BE MIXED UP IN ANY WAY OF INSTALLATION.
Page 181 Machine Translated by Google MP3 530 hpe Motor Check piston rings - Place the 3 piston rings one after the other in the area of the cylinder, where it still has its position original diameter. The piston rings using the piston at right angles to the cylinder Insert axle.
Page 182 Machine Translated by Google MP3 530 hpe Motor - The piston pin retaining ring as shown in Install with a mandrel shown in the illustration. Special tool 020470Y Assembly tool for piston pin retainers ANNOTATION THE TOOL FOR INSTALLING THE CIRCUIT RINGS-PISTON PIN MUST BE USED MANUALLY.
Page 183 Machine Translated by Google MP3 530 hpe Motor ANNOTATION DEVIATIONS (OVERHANGING OR SETTING BACK) ARE MEASURED CLOSE TO ONE CATEGORY LIMIT, THE MEASUREMENT MUST BE FROM THE OPPOSITE PAGE TO BE RUN AGAIN. FOR THIS PURPOSE, THE POSITION MUST BE SWAPED WHEN ASSEMBLYING THE TOOL.
Page 184 Machine Translated by Google MP3 530 hpe Motor Installation of cylinders - Install the cylinder base gasket with the previously determined thickness. - Using the fork to place the piston and the clamp, fix the cylinder as shown in the picture install.
Page 185 Machine Translated by Google MP3 530 hpe Motor Checking the valve control components - Check whether the chain tensioner pad and the chain tensioner is not excessively worn are. - The unit drive sprocket camshaft and Check crankshaft pinion for wear.
Page 186 Machine Translated by Google MP3 530 hpe Motor Check valve tightness - Carry out a visual inspection of the valve sealing surfaces. DANGER DO NOT MIX THE INSTALLATION POSITION OF THE VALVES (RIGHT - LEFT). - If the sealing surface of the valve is interrupted or irregular at one or more points, the valve must be replaced.
Page 187 Machine Translated by Google MP3 530 hpe Motor Check the fitting clearance of the valve guide Verify that the operating limits of the valve guides are within the values specified in Section "Technical data" are given. If the measured values are not correct, the be relevant part must be replaced.
Page 188 Machine Translated by Google MP3 530 hpe Motor Check springs and half cones - Check that the upper and lower spring plates, the half cones and the oil seals are not abnormal are worn out. Otherwise, this must be the case corresponding component must be changed.
Page 189 Machine Translated by Google MP3 530 hpe Motor ANNOTATION DO NOT MIX THE INSTALLATION POSITION OF THE VALVES. INSTALL THE VALVE SPRINGS SO THAT THE MARKING COLOR POINTS TOWARDS THE HALF-CONES (SPIRALS WITH LARGER SPACING). Check camshaft - Check the running surfaces of the camshaft with a microphone measure rometer.
Page 190 Machine Translated by Google MP3 530 hpe Motor Installation of cylinder head and valve control components - Insert the chain guide shoe. - The centering pins for the cylinder head and cylinder insert. - Install the cylinder head gasket. The cylinder head gasket is made of steel and has a Standard thickness.
Page 191 Machine Translated by Google MP3 530 hpe Motor - tighten 90° in a crisscross sequence. - tighten again by 90° in a crisscross sequence. - The mounting screws on the inlet side and on the outlet side with the prescribed tighten to a certain torque.
Page 192 Machine Translated by Google MP3 530 hpe Motor - Attach the valve timing chain to the crankshaft gen. The original direction of rotation of the chain must be adhered to. - Insert the chain tension shoe with spacer put the recommended product on the screw attach and the fastening screw with the Tighten to specified torque.
Page 193 Machine Translated by Google MP3 530 hpe Motor Loctite 243 Medium strength thread locking sealant. Colour blue - Insert the camshaft bracket (the beveled part must be visible) and the 3 fasteners Tighten the connection screws to the specified torque. Make sure that the Allen key screw is not damaged.
Page 194 Machine Translated by Google MP3 530 hpe Motor - Remove the counterweight. - With the basket fixing screw in the middle align. - The fastening screw with the specified tighten to the desired torque. The emp Attach foaled product. Suggested products Loctite 243 Medium strength thread locking sealant.
Page 195 Machine Translated by Google MP3 530 hpe Motor 020565Y Face wrench for blocking the alternator Recommended products Loctite 243 Medium strength thread locking sealant. Colour blue Torque guide values (N*m) Fastening screws retaining bell Ventilhebermasse 30 ÷ 35 Nm (22 ÷ 26 lb*ft) - Set the tensioner rotor to the rest position position.
Page 196 Machine Translated by Google MP3 530 hpe Motor REQUIRED PLAY: Technical information Description/Value inlet 0.15 mm (when engine is cold) outlet 0.15 mm (when engine is cold) - If different values are measured, this must be done the valve clearance can be adjusted. In addition, the con Loosen the nut and tighten the adjusting screw with a Adjust screwdriver (see illustration).
Page 197 Machine Translated by Google MP3 530 hpe Motor - The motor via the nut on the drive belt Turn the disc until the two marks ations for OT are aligned with each other. - The markings on the drive belt sheave Align the drive cover and drive cover with each other.
Page 198 Machine Translated by Google MP3 530 hpe Motor Installation of tappet cover - Check the condition of the seal. - The valve cover with the specified one Secure torque. Torque guide values (N*m) Valve cover fixing screws 7 ÷ 9 Nm (5.2 ÷ 6.6...
Page 199 Machine Translated by Google MP3 530 hpe Motor - The thermal unit (cylinder, cylinder head, piston) as in chapter «Thermal unit and valves Remove the tilt control as described. - Before separating the housing halves, the axial play of the crankshaft should be checked.
Page 200 Machine Translated by Google MP3 530 hpe Motor - Separate the housing halves. The must Crankshaft in the housing half on the light remain on the machine side. - Remove the housing gasket. ANNOTATION THE LINERS CAN REMAIN IN THE HOUSING HALF ON THE ALTERNATOR SIDE.
Page 201 Machine Translated by Google MP3 530 hpe Motor Removing the countershaft - Attach the special tool as shown in the illustration. Special tool 020479Y Tool for locking the countershaft - The nut together with the washer remove. - Remove the special tool and follow the instructions laying shaft complete with drive gear pull.
Page 202 Machine Translated by Google MP3 530 hpe Motor - Turn the housing half over. - Remove the bearing from the housing half on the alternator side using the specified special tool and remove with a rubber mallet. Special tool 020376Y Handle for adapter...
Page 203 Machine Translated by Google MP3 530 hpe Motor - Install the circlip. - Before installing a new bearing in the drive side housing half, the bearing seat must be heated using the specified special tool. Special tool 020151Y hot air gun - Grease the guide seat and install a new bearing Attach the specified special tool.
Page 204 Machine Translated by Google MP3 530 hpe Motor Crankshaft width 65,45 ÷ 65,6 mm DANGER THE CRANKSHAFT CAN BE REUSED IF THE WIDTH MATCHES STANDARD VALUES AND THE SURFACES ARE NOT SCRATCHED. Rasamento - Check the overall dimension of the crankshaft-shim- gear assembly.
Page 205 Machine Translated by Google MP3 530 hpe Motor - The condition of the crankshaft cone, the locking tongue seat, the running surface of the oil seal, the Check the grooved part and the threaded end parts. - If there are any abnormalities, the crankshaft must be replaced.
Page 206 Machine Translated by Google MP3 530 hpe Motor ANNOTATION THE NOZZLE IS SUPPLIED VIA THE CRANKSHAFT BEARINGS. A GOOD FUNCTIONING OF THIS COMPONENT IMPROVES PISTON BOTTOM COOLING. IS IF THIS NOZZLE IS CLOGGED, IT WILL CAUSE EFFECTS THAT ARE DIFFICULT TO DETECT (RISE IN TEMPERATURE ON THE PISTON).
Page 207 Machine Translated by Google MP3 530 hpe Motor Checking the crankshaft bearings - To ensure good lubrication of the crankshaft bearings To achieve this, both the lubricating pressure (4 bar) must be optimally adjusted and a sufficient oil supply must be guaranteed. In that together...
Page 208 Machine Translated by Google MP3 530 hpe Motor countershaft - Using a micrometer, check the 2 running surfaces of the front Measure layshaft (see illustration). Technical specifications Standard diameter: 17 - 0,01 - 0,02 mm - Check that the water pump driver shows no signs of wear.
Page 209 Machine Translated by Google MP3 530 hpe Motor Torque guide values (N*m) Fastening screws gear to crankshaft 10 -12 - The crankshaft bearing on the housing half Lubricate alternator side. - Grease the compensating disk. - The crankshaft and the balance disk in Insert original position.
Page 210 Machine Translated by Google MP3 530 hpe Motor Assembling the case - Put the shaft seal on the housing half Remove drive side with a screwdriver. - Lubricate and add a new shaft seal Install using the specified special tool.
Page 211 Machine Translated by Google MP3 530 hpe Motor - The 14 fastening screws according to the Use the position noted when dismantling. - Tighten the screws until they stop and then with the prescribed torque tighten. - Check whether the crankshaft rotates easily leaves.
Page 212 Machine Translated by Google MP3 530 hpe Motor BY-PASS Technical information Description/Value With piston Type Piston diameter Ø 13,9 -0,039 -0,057 mm Free spring length 62,5 mm 4 bar Calibration pressure FORFILTER Technical information Description/Value With plastic net Type OIL FILTER...
Page 213 Machine Translated by Google MP3 530 hpe Motor Schematic circuit diagram SCHEMATIC CIRCUIT DIAGRAM Technical information Description/Value camshaft Cylinder - cylinder head mating surface Cylinder - housing mating surface Impeller water pump Oil pressure sensor Oil filter cartridge To the oil pan...
Page 214 Machine Translated by Google MP3 530 hpe Motor The supply line to the pump is connected through a by-pass with a piston to regulate the pressure to 4 bar controlled. The by-pass is installed in front of the filter cartridge. Both parts are located on the Lichtma rail cover.
Page 215 Machine Translated by Google MP3 530 hpe Motor Troubleshooting 1 - The oil pressure control switches on when the engine is warm. CONTINUE - point 2 2 - Disconnect the cable connector from the oil pressure switch. Check whether the oil pressure control switches off.
Page 216 Machine Translated by Google MP3 530 hpe Motor 6 - Warm up the engine and repeat the oil pressure check when the engine is warm. DEFAULT VALUES Technical information Description/Value 80°C temperature 1400 U/Min ~ 1,5 bar YES point 7 NO point 8 7 - Replace the oil pressure switch.
Page 217 Machine Translated by Google MP3 530 hpe Motor IF THERE IS ANY DEVIATION FROM THE PRESCRIBED OIL PRESSURE IN THE OIL PAN, A VISUAL AND MEASUREMENT CHECK OF THE VALVE CONTROL COMPONENTS SHOULD BE CARRIED OUT (SEE CHAPTER THERMAL UNIT AND VALVE CONTROL).
Page 218 Machine Translated by Google MP3 530 hpe Motor expansion - The 2 fastening screws together with the Remove the associated washers and remove the partition wall to the oil pump room. - Check the oil pump mounting screws Unscrew the eyelets on the gearbox.
Page 219 Machine Translated by Google MP3 530 hpe Motor - Turn the snap ring of the inner rotor until the opening is on the joint of the oil pump shaft and can be removed. - Remove the wheels and thoroughly with Ben Clean zinc and compressed air.
Page 220 Machine Translated by Google MP3 530 hpe Motor - The distance between the outer rotor and the pump Measure the pen housing (see illustration). Technical specifications Max. allowable clearance: 0,25 mm - The axial play of the rotors with a ground a measuring stick as a reference plane as in the figure Check the information shown.
Page 221 Machine Translated by Google MP3 530 hpe Motor Torque guide values (N*m) Oil pump cover screws 0.7 ÷ 0.9 - Insert the oil pump complete with gear. - Insert the 2 screws through the slotted holes on the gear and with the prescribed rotation...
Page 222 Machine Translated by Google MP3 530 hpe Motor water pump expansion Special tool 020661Y Kit for replacing the integral seal of the water pump - Using a screwdriver, remove the six Remove screws and the pump cover. - With an 8mm wrench, the impeller of the Was Unscrew the water pump.
Page 223 Machine Translated by Google MP3 530 hpe Motor - If necessary, the position of the screw change here. - When dismantling the seal it can happen that the ceramic breaks. - Clean all parts thoroughly before pulling out. - The puller complete with pin on the static Attach part of the ceramic seal.
Page 224 Machine Translated by Google MP3 530 hpe Motor - Complete the tool by installing the bracket, screw and nut. - Hold the screw firmly and the nut as far as possible rotate until the static part of the seal is full constantly moved out.
Page 225 Machine Translated by Google MP3 530 hpe Motor DANGER SCREW IN MANUALLY UNTIL THE STOP. - Attach the integral seal to the shaft. - Attach the calibrated striking mandrel (with preload measurement). - Attach the nut to the threaded bolt.
Page 226 Machine Translated by Google MP3 530 hpe Motor Reverse gear REVERSE GEAR ADJUSTMENT ASSEMBLY To remove the group of the adjusting device Reverse gear, the screws of the protection Remove the direction of the drive cover (4 screws ben). The drive cover protection device is removed distant.
Page 227 Machine Translated by Google MP3 530 hpe Motor The screw on the wiring retaining plate unscrew and remove this. The fastenings of the assembly of the Stellvor Remove direction of reverse gear (3 screws). Disconnect the cable connector and the assembly remove.
Page 228 Machine Translated by Google MP3 530 hpe Motor Unscrew the nuts of the retaining plate, this one Remove and the positive cable of the motor for the Release reverse gear. Use a screwdriver to open the closure the axis of the guided pulley with.
Page 229 Machine Translated by Google MP3 530 hpe Motor Remove the nut. - Remove the special tool. Remove the two washers. Remove the drive cover screws (7 M6 screws). AGAINST - 232...
Page 230 Machine Translated by Google MP3 530 hpe Motor Remove the screws on the right part of the cover (2 screws M8). Remove the screws on the middle part (2 M8 screws). Remove the drive cover. The engine mounting screws for the Remove reverse gear (2 screws).
Page 231 Machine Translated by Google MP3 530 hpe Motor Remove the spacers. - A suitable container for draining the Set up gear oil. Remove the motor and the cable from the Pull out the slot in the housing. Turn the lid of the housing over to open the inside Drain the oil contained in the reverse gear system its.
Page 232 Machine Translated by Google MP3 530 hpe Motor To remove the lid, apply leverage to the projections shown in the photo. Only if high resistance is encountered, heat the area to stop the process facilitate. - The reverse gear cover lose weight.
Page 233 Machine Translated by Google MP3 530 hpe Motor Remove the second gear. Remove the shaft. Remove the drive bushing. ANNOTATION A SAFETY SYSTEM IS INSTALLED ON THE DRIVE SOCKET, WHICH WILL CAUSE IF A AT A CERTAIN SPEED, THE GUIDED BELT PULLEY MECHANICALLY PREVENTS THE RETURN GEAR INSERTION.
Page 234 Machine Translated by Google MP3 530 hpe Motor The fork group to control the ride and the Remove the selector switch by lifting it evenly distant. Remove the control bushing. The special tool on the outside of the An Put on the drive cover.
Page 235 Machine Translated by Google MP3 530 hpe Motor The tool has the dual function of holding the control socket and acting as a holder for it To serve as drive cover during removal. The other part of the special tool on one Attach vise.
Page 236 Machine Translated by Google MP3 530 hpe Motor Place the special tool on the ring nut zen and the teeth of the tool into the slots insert the ring nut. Special tool 021023Y Key to lock the ring nut Loosen the threaded ring.
Page 237 Machine Translated by Google MP3 530 hpe Motor Remove the control bushing. INSTALLING THE REVERSE GEARS AND MOTOR ANNOTATION BEFORE INSTALLING THE CONTROL BUSHING, THE FLAT LUBRICATE THE SEALING RING IN THE GEAR COVER AND THE CLUTCH SURFACE OF THE BUSHING.
Page 238 Machine Translated by Google MP3 530 hpe Motor The special tool on the outside of the An Put on the drive cover. Special tool 021024Y Key for blocking the tax bushing Pay attention to the protrusion on the tool the inner cavity is inserted, as in the photo you can see.
Page 239 Machine Translated by Google MP3 530 hpe Motor Place the special tool on the ring nut zen and the teeth of the tool into the slots insert the ring nut. Special tool 021023Y Key to lock the ring nut The ring nut with the specified size Tighten torque.
Page 240 Machine Translated by Google MP3 530 hpe Motor Mount the assembly on the control socket. ANNOTATION BEFORE INSTALLING, APPLY THE RECOMMENDED OIL BETWEEN THE TIMING BUSHING (CUTTER) AND THE GEAR SELECTOR. Suggested products Gear oil 80W-90 lubricant for gears and drives.
Page 241 Machine Translated by Google MP3 530 hpe Motor Install the second gear. Insert the spring. DANGER WARNING ANNOTATION MAKE SURE THAT THERE IS NO SECURING MEANS ON THE OUTSIDE OF THE GUIDE DRILLING OF THE CONTROLLER IS APPLIED. Clean the mating surface, the specific safety Apply solvent and remove the drive cover Attach reverse gear.
Page 242 Machine Translated by Google MP3 530 hpe Motor Screw on the inner screws of the cover (5 screws). Torque guide values (N*m) Screws of the cover of the gears of the Reverse gear 11 ÷ 13 Nm (8 ÷ 10 lb*ft) Position the motor with the cable through the slot used for this purpose.
Page 243 Machine Translated by Google MP3 530 hpe Motor Tighten the three motor mounting screws screw (2 screws). Torque guide values (N*m) Reverse motor mounting screws 11 ÷ 13 Nm (8 ÷ 10 lb*ft) Insert the drive cover. DANGER WARNING THE FOUR M8 SCREWS OF THE DRIVE COVER HAVE...
Page 244 Machine Translated by Google MP3 530 hpe Motor Screw on the screws in the right part (2 short M8 screws). Torque guide values (N*m) Fasteners M8 drive cover 23 ÷ 26 Nm (17 ÷ 19 lb*ft) Tighten the drive cover screws (7 M6 screws).
Page 245 Machine Translated by Google MP3 530 hpe Motor The nut of the shaft of the guided pulley be assembled. The mother with the prescribed dress code ment tighten. Torque guide values (N*m) Nut guided pulley 92 ÷ 100 Nm (68 ÷...
Page 246 Machine Translated by Google MP3 530 hpe Motor The positive cable of the motor for reverse gear connect, position the retaining plate and with fasten with the corresponding nuts. DANGER WARNING CHECK AND CLEAN THE CONTACTS: POOR MAINTENANCE CONDITION COULD LEAD TO FUNCTIONAL MALFUNCTIONS AND A FIRE HAZARD.
Page 247 Machine Translated by Google TABLE OF CONTENTS BRAKE BRAKE SYSTEM...
Page 248 Machine Translated by Google MP3 530 hpe Brake system Rear brake caliper expansion - In preparation, remove the exhaust end part ren. - The two fastening screws of the rear Remove brake caliper. - Remove the brake caliper from its seat on the bracket take.
Page 249 Machine Translated by Google MP3 530 hpe Brake system expansion - The specified work steps refer on one brake caliper, but apply to both. - Remove the wheel. - Unscrew the two fastening screws on the bracket and remove the brake caliper with.
Page 250 Machine Translated by Google MP3 530 hpe Brake system - Pull out the bolt and make sure that the retaining spring of the brake pads is on is maintained. - Remove the brake pads from the brake caliper with. Technical specifications...
Page 251 Machine Translated by Google MP3 530 hpe Brake system - Install the brake pad retaining spring and insert the bolt into the brake caliper. - Insert the R-split on the brake caliper bolt - Reinstall the brake caliper. Rear brake pads...
Page 252 Machine Translated by Google MP3 530 hpe Brake system Parking brake EXPANSION - In preparation, remove the exhaust end part ren. - The two right-hand fastening screws Remove fender. - Loosen the brake control cable adjusting nut sen, then the cable from the corresponding lever remove.
Page 253 Machine Translated by Google MP3 530 hpe Brake system - The cable connector from the control button Disconnect parking brake light. - The three screws securing the lever to the Unscrew the frame. - The steering brake control cable disconnect the lever.
Page 254 Machine Translated by Google MP3 530 hpe Brake system CHANGING THE BRAKE PADS - Remove the mechanical brake caliper. - Remove the two fixing pins and the Remove the brake pads from the brake caliper Make sure you have the appropriate retaining spring to withdraw.
Page 255 Machine Translated by Google TABLE OF CONTENTS COOL COOLING SYSTEM...
Page 256 Machine Translated by Google MP3 530 hpe Cooling system circuit diagram The cooling system is a pressurized water circuit with a coolant pump and constant ventilation. Cooling takes place via a centrifugal pump that is driven by the countershaft. The coolant is routed from the pump to the thermal unit.
Page 257 Machine Translated by Google MP3 530 hpe Cooling system To vent the system when filling the circuit, there is a be. on the upper part of the cylinder head A special connection is provided (see filling instructions). A cooling fan is required to ensure adequate cooling even when there is no wind provided, which is controlled via the injection system.
Page 258 Machine Translated by Google TABLE OF CONTENTS BODY IN THE WARS...
Page 259 Machine Translated by Google MP3 530 hpe body This section è is dedicated to work on the vehicle body. Bench EXPANSION - Raise the seat. - Disconnect the driver position sensor connector with. - The petrol ring from the pneumatic cylinder seat remove easily.
Page 260 Machine Translated by Google MP3 530 hpe body - Remove the seat from the vehicle. INSTALLATION - Position the seat on the vehicle. - Hold the seat and lift the rear part ben, then the two fastening screws Install hinge.
Page 261 Machine Translated by Google MP3 530 hpe body - The petrol ring on the pneumatic cylinder bolt install easily. - The driver presence cable connector connect sors. Rear handlebar fairing EXPANSION - Remove the upper handlebar cover. - The cable connector shown in the illustration separate.
Page 262 Machine Translated by Google MP3 530 hpe body - Remove the two side fastening screws distant. - Remove the handlebar cover from the vehicle nen, paying attention to the cabling Do not strain the process. INSTALLATION - Install the handlebar cover on the vehicle.
Page 263 Machine Translated by Google MP3 530 hpe body - The two side fastening screws in stall. - The cable connector shown in the illustration connect. Instrument unit EXPANSION - Remove the front of the shield. - Remove the handlebar covers.
Page 264 Machine Translated by Google MP3 530 hpe body - The cable connector shown in the illustration separate. - Disconnect the instrument cluster cable connector clamps. - Cut the plastic clamp and the Verka release the cable. - The dashboard complete with instruments unit and PMP3 control unit from the vehicle Remove.
Page 265 Machine Translated by Google MP3 530 hpe body - Adjust the dashboard to a suitable position lay the side table. - Unscrew the two fastening screws and the PMP3 control unit from the fittings remove board. - From the inside of the dashboard go and remove the two fastening screws Unscrew the frame of the instrument unit.
Page 266 Machine Translated by Google MP3 530 hpe body - The four mounting screws for the instruments Unscrew the unit. - The instrument cluster from the dashboard remove. INSTALLATION - The instrument unit in the dashboard Insert and from the inside with the four screws attach.
Page 267 Machine Translated by Google MP3 530 hpe body - The two mounting screws of the yardarm Tighten the instrument unit. - The PMP3 control unit on the mounting brackets po position, then the appropriate fasteners Tighten the connection screws. - The dashboard complete with instruments unit and PMP3 control unit on the vehicle situate.
Page 268 Machine Translated by Google MP3 530 hpe body - Connect to instrument unit cable connector the. - The cable connector shown in the illustration connect. - The cable connector of the PMP3 control electronics connect. - The six mounting screws of the Armatu Install renbretts on the back of the shield and tighten.
Page 269 Machine Translated by Google MP3 530 hpe body Front handlebar fairing EXPANSION - Remove both rear-view mirrors. - Unscrew the two fixing screws shown in the illustration. - Lift the handlebar cover up and off Remove vehicle. INSTALLATION - Place the upper handlebar cover in its seat and make sure they are properly connected to the lower steering to connect the cover.
Page 270 Machine Translated by Google MP3 530 hpe body Headlight unit HEADLIGHT EXPANSION - Remove the front of the shield from the vehicle men. - Unscrew the three fastening screws «A» ben. - Unscrew the four fastening screws "B". ben and the headlight from the front of the shield remove page.
Page 271 Machine Translated by Google MP3 530 hpe body - The turn signal upper mounting screws screw off. - Remove the indicator from the vehicle and... Disconnect cable connector. - On the opposite page the events Repeat to remove turn signal.
Page 272 Machine Translated by Google MP3 530 hpe body Medium fairing EXPANSION - Remove the side panels. - Remove the seat. - Remove the back of the shield. - Remove the two fixing screws shown in the figure on both sides.
Page 273 Machine Translated by Google MP3 530 hpe body - Disconnect the cable from the door opening control and the center cover from the vehicle remove. INSTALLATION - To reassemble, reverse the disassembly procedures and then Make sure that the door opening control cable and the presence sensor wiring are connected driver must be inserted correctly.
Page 274 Machine Translated by Google MP3 530 hpe body - The front headlight cable connector pull it off. - The two side mounting screws Remove the front spoiler. - The middle fastening screw of the front remove spoilers. - Remove the front spoiler from the vehicle.
Page 275 Machine Translated by Google MP3 530 hpe body - Unscrew the two fastening screws and remove the bracket from the vehicle. - The lower indicator mounting screws screw off. - The middle fixing screws of the Blink unscrew it first.
Page 276 Machine Translated by Google MP3 530 hpe body - Remove the indicator from the vehicle and... Disconnect cable connector. - On the opposite page the events Repeat to remove turn signal. - Remove the two middle fastening screws distant. - The side, lower, fastening screw of remove both sides.
Page 277 Machine Translated by Google MP3 530 hpe body - The front section of the shield front from Remove vehicle. - Work from the inside of the wheel arch and the three fastening screws of the side Ab Remove section of shield.
Page 278 Machine Translated by Google MP3 530 hpe body - Working from the inside of the wheel arch, install loosen the three fixing screws of the side section of the shield. - Repeat the operations for the section on the op side place.
Page 279 Machine Translated by Google MP3 530 hpe body - Install the central fixing screws. - Connect the connector and install the indicator direction on the vehicle. - Install the upper fixing screw of the indicator direction indicator. - Install the intermediate fixing screw of the index direction indicator.
Page 280 Machine Translated by Google MP3 530 hpe body - Install the two lower fixing screws. - Repeat the operations relating to the opposite side giving the installation of the direction indicator. - Install the front spoiler fixing bracket ale and tighten the relative fixing screws.
Page 281 Machine Translated by Google MP3 530 hpe body - Install the spoiler side fixing screws front. - Connect the front headlight connector. - Install the front shield mask in the relevant office. - Install the two fixing screws of the mask front.
Page 282 Machine Translated by Google MP3 530 hpe body Shield back EXPANSION - Remove the front of the shield. - Remove the handlebar covers. - Remove the two cushions from the back of the shield away and pull outwards. - The two panel mounting screws Unscrew “A”...
Page 283 Machine Translated by Google MP3 530 hpe body - The six mounting screws of the Armatu Remove the protective boards on the back of the shield. - Then the dashboard of the instruments Remove the device from the vehicle. ANNOTATION The procedure for removing the instrument cluster is described in the relevant section of the manual.
Page 284 Machine Translated by Google MP3 530 hpe body - The two lower fastening screws Remove back of shield. - From the inside of the front wheel arch ar work, on both sides those in the picture Remove specified screw. - The middle fixing screw of the shield Remove back.
Page 285 Machine Translated by Google MP3 530 hpe body - Disconnect the transmission cable from the seat opening adjusting device. - The wiring from the cable passage on the Separate the inside of the back of the shield. - Remove the back of the shield from the vehicle with.
Page 286 Machine Translated by Google MP3 530 hpe body - Attach the wiring to the corresponding cable gland on the inside of the back of the sign. - The transmission cable to the adjusting device Connect seat opening. - The cable connector of the seat opening adjusting device connection.
Page 287 Machine Translated by Google MP3 530 hpe body - From the inside of the front wheel arch ar work, on both sides those in the picture Install specified screw. - The two lower fastening screws Install shield back. - On the vehicle, the side cover of the step Install boards.
Page 288 Machine Translated by Google MP3 530 hpe body - The fastening shown in the picture install screw. - Install the inspection hatch on the running board. - The installation work of the running board cover repeat on the opposite side.
Page 289 Machine Translated by Google MP3 530 hpe body - Connect the cable connectors of the cabling and Install panel "A" on the back of the shield. - Tighten the two fixing screws and repeat the work for the panel on the opposite side.
Page 290 Machine Translated by Google MP3 530 hpe body - Remove the wheel arch from the vehicle. INSTALLATION - Install the wheel arch on the vehicle and make sure that it is correctly connected to the borders fits the plastics. - The two upper fastening screws of the Install the wheel housing on both sides.
Page 291 Machine Translated by Google MP3 530 hpe body Rear light unit - Remove both side parts. - Disconnect the cable connector and unplug the Remove the headlight unit from the retaining bracket. - Remove the two fixing screws. - Remove the taillight unit from the vehicle...
Page 292 Machine Translated by Google MP3 530 hpe body - The four fasteners shown in the picture install screws. - Install the top mounting screw. - Install the lower mounting screw. - Install the rubber footboard on the running board, Make sure the “centering pins” are correctly in place Use sitting.
Page 293 Machine Translated by Google MP3 530 hpe body - The fastening caps of the rubber cover to install. - Proceed on the right side of the footboard: the pedal on Attach the brake lever and then the corresponding one Tighten the end fastening screws. After Complete the installation the rubber clamps like attach it to the brake lever.
Page 294 Machine Translated by Google MP3 530 hpe body - Operating on the right platform: lift the ceiling rubber screw, unscrew the two fixing screws of the brake pedal and remove the pedal from the vehicle colo. - Remove the cover fixing caps eraser.
Page 295 Machine Translated by Google MP3 530 hpe body - Remove the upper fixing screw. - Remove the four fixing screws indicated in figure. - Remove the footrest from the vehicle. Helmet compartment - Remove the seat. - Disconnect and remove the battery.
Page 296 Machine Translated by Google MP3 530 hpe body - Open the two safety tabs and the Pull the relay base out of the seat. - The two securing screws Unscrew the retainer and remove the fuse Remove holder from its seat.
Page 297 Machine Translated by Google MP3 530 hpe body - The rear brake mounting screw Unscrew the oil container. - Place the rear wheel brake oil container in the corresponding Attach the end opening in the helmet compartment. - Remove the two fastening screws and attach the ignition coil to the frame tube.
Page 298 Machine Translated by Google MP3 530 hpe body - The two cables from the seat lock switch remove. - The two side fastening screws Unscrew the helmet compartment. -The process on the opposite side repeat. - Remove the front fixing screw.
Page 299 Machine Translated by Google MP3 530 hpe body - Lift the rear part of the helmet compartment to act on the seat lock cables can. - The cable lock with a screwdriver remove. - Push the cable jacket outwards to seal it...
Page 300 Machine Translated by Google Dashboard: 82 Battery: Recommended products: 49 Chassis and engine number: 23 Vehicle: 18, 120 Gear oil: 51 The control: 11 Lamps: 84 Air filter: 52 Unit of measurement: Engine oil: 54 Headlight unit: 273 Fuses: 85 Bench: 262 Technical information: 216 Maintenance: 46...

PIAGGIO MP3 530 hpe Service Station Manual

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