PIAGGIO 633823 Service Station Manual

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SERVICE STATION MANUAL

633823

MP3 250 i.e.

Table of Contents

Troubleshooting

Summary of Contents for PIAGGIO 633823

Page 1 SERVICE STATION MANUAL 633823 MP3 250 i.e.
Page 2 Not all versions shown in this publication are available in all Countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 SERVICE STATION MANUAL MP3 250 i.e. This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.
Page 5: Index Of Topics
INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8: Safety Rules
Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 9: Vehicle Identification
MP3 250 i.e. Characteristics Vehicle identification Chassis prefix (FULL OPTIONAL): M47201 Chassis prefix (BASE): M47200 Engine prefix: M472M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 224 ± 5 Kg Wheelbase 1490 mm Height 1245 mm Width (handlebar) 745 mm Overall length 2130 mm...
Page 10: Electrical Components
MP3 250 i.e. Characteristics Specification Desc./Quantity Timing system single overhead camshaft chain driven on the left- hand side, three-arm rocking levers set up with threaded set screw Bore 72 mm Stroke 60 mm Cubic capacity 249.29 mm Compression ratio 10.5 ÷ 11.5 Air filter sponge, impregnated with mixture (50% petrol and 50% oil)
Page 11: Wheels And Tyres
MP3 250 i.e. Characteristics Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Chassis Tubular and sheet steel. Rear suspension Single arm with two double-acting hydraulic shock absorbers and preloading adjustable to 4 posi- tions. Front suspension The tilt mechanism is composed of an articulated parallelogram suspension with die-cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system.
Page 12: Rear Suspension
MP3 250 i.e. Characteristics FRAME Name Torque in Nm Engine arm bolt - frame arm 33 ÷ 41 Swinging arm buffer nut 64 - 72 Engine-swinging arm bolt 55 ÷ 61 Frame-swinging arm bolt 55 ÷ 61 Centre stand bolt 31 ÷...
Page 13: Rear Brake
MP3 250 i.e. Characteristics Name Torque in Nm Screw tightening calliper to the support 20 ÷ 25 Calliper upper pipe fitting 20 ÷ 25 REAR BRAKE Name Torque in Nm Rear brake disc screws(°) 5 ÷ 6.5 Rear brake calliper-pipe fitting 20 ÷...
Page 14: Crankcase And Crankshaft
MP3 250 i.e. Characteristics RANSMISSION Name Torque in Nm Belt support roller screw 11 ÷ 13 Clutch unit nut on driven pulley 45 ÷ 50 Drive pulley nut 75 ÷ 83 Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷...
Page 15 MP3 250 i.e. Characteristics Cylinder - piston assy. ENGINE COUPLING CATEGORY Name Initials Cylinder Piston Play on fitting Cylinder 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064 Piston 72.024 ÷ 72.031 71.967 ÷...
Page 16 MP3 250 i.e. Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05 D = 0.20 - 0.50 mission side Flywheel-side half- 16.6 +0-0.05 D = 0.20 - 0.50 shaft Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05 D = 0.20 - 0.50...
Page 17 MP3 250 i.e. Characteristics Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
Page 18 MP3 250 i.e. Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifi- cations AGIP CITY HI TEC 4T Oil to lubricate flexible transmis- Oil for 4-stroke engines sions (throttle control) AGIP FILTER OIL Oil for air filter sponge...
Page 19 INDEX OF TOPICS TOOL OOLING...
Page 20 MP3 250 i.e. Tooling APPROPRIATE TOOL Stores code Description 001330Y Tool for fitting steering seats 001467Y014 Pliers to extract ø 15-mm bear- ings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels from headstock...
Page 21 MP3 250 i.e. Tooling Stores code Description 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting TOOL - 3...
Page 22 MP3 250 i.e. Tooling Stores code Description 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol 020331Y Digital multimeter 020332Y Digital rev counter TOOL - 4...
Page 23 MP3 250 i.e. Tooling Stores code Description 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm TOOL - 5...
Page 24 MP3 250 i.e. Tooling Stores code Description 020363Y 20 mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool TOOL - 6...
Page 25 MP3 250 i.e. Tooling Stores code Description 020393Y Piston fitting band 020412Y 15 mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork TOOL - 7...
Page 26 MP3 250 i.e. Tooling Stores code Description 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driv- en pulley clutch 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide TOOL - 8...
Page 27 MP3 250 i.e. Tooling Stores code Description 020489Y Hub cover support stud bolt set 020428Y Piston position check support 020460Y Scooter diagnosis and tester 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Belle for OD 47-mm bearings TOOL - 9...
Page 28 MP3 250 i.e. Tooling Stores code Description 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15-mm bear- ings 020627Y Flywheel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch TOOL - 10...
Page 29 MP3 250 i.e. Tooling Stores code Description 020480Y Petrol pressure check set 020244Y 15-mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent bloc 020469Y Reprogramming kit for scooter diagnosis tester TOOL - 11...
Page 30 MP3 250 i.e. Tooling Stores code Description 020481Y004 Parking control unit interface wir- 020639Y Tilt locking control unit software 020645Y MIU software updating with CAN lines 001467Y017 Driver for OD 36 mm bearings 020234y extractor 020441Y 26 x 28 mm adaptor TOOL - 12...
Page 31 MP3 250 i.e. Tooling Stores code Description 020362Y 12 mm guide 020358Y 37x40-mm adaptor 001467Y002 Driver for OD 73 mm bearing TOOL - 13...
Page 32 MP3 250 i.e. Tooling TOOL - 14...
Page 33: Index Of Topics
INDEX OF TOPICS MAIN AINTENANCE...
Page 34: Maintenance Chart
MP3 250 i.e. Maintenance Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequen- tially.
Page 35 MP3 250 i.e. Maintenance Action Safety locks - check Throttle lever - adjustment Air filter - clean Engine oil - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement Brake pads - check condition and wear Sliding block / variable speed rollers - change Tyre pressure and wear - check...
Page 36: Checking The Spark Advance
MP3 250 i.e. Maintenance Action Coolant level - check Brake fluid level - check Engine oil - replacement Hub oil - check Brake pads - check condition and wear Sliding block / variable speed rollers - change Tyre pressure and wear - check Vehicle and brake test - road test Suspensions - check Steering - Check...
Page 37 MP3 250 i.e. Maintenance - Remove the transmission crankcase. - Rotate the driving pulley fan until the reference marks between the flywheel and flywheel cover coincide as shown in the photograph. - Bring the reference mark onto the transmission side between the fan and the transmission cover as shown in the photograph.
Page 38: Spark Plug
MP3 250 i.e. Maintenance Spark plug Remove the port on the right-hand side panel of the vehicle by undoing the clamping screw and using a small screwdriver in the rear recess shown in the figure, then do the following : 1.
Page 39 MP3 250 i.e. Maintenance CHAMPION RG4 PHP Electrode gap 0.7 ÷ 0.8 mm Hub oil Check - Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tightening it completely;...
Page 40: Air Filter
MP3 250 i.e. Maintenance Air filter Proceed as follows: Undo the clamping screws «A» (two of which are on the knob-type head) and remove the air-box cover. 1. Wash the sponge with water and neutral soap. 2. Dry it with a clean cloth and small blasts of compressed air. 3.
Page 41 MP3 250 i.e. Maintenance Make sure the pre-filter and discharge tap O-rings are in good condition. Lubricate them and refit the gauze filter and oil drainage tap, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubri- cate the O-ring before fitting it.
Page 42: Engine Oil Filter
MP3 250 i.e. Maintenance The MAX level mark indicates a quantity of around 1300 cc of engine oil. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stop- ped, so as to get the correct level.
Page 43: Checking The Ignition Timing
MP3 250 i.e. Maintenance Checking the ignition timing -Remove the plastic cap on the flywheel cover -Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the fly- wheel cover as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure.
Page 44: Braking System
MP3 250 i.e. Maintenance Braking system Level check The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal; - Check the fluid level through the sight glass «C».
Page 45: Headlight Adjustment
MP3 250 i.e. Maintenance Headlight adjustment Proceed as follows: 1. Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pres- sure, on a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the vehicle is perpendicular to the screen;...
Page 46 MP3 250 i.e. Maintenance MAIN - 14...
Page 47: Index Of Topics
INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 48 MP3 250 i.e. Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION Possible Cause Operation Wrong valve adjustment Adjust the valve clearance properly...
Page 49: Brakes Overheating
MP3 250 i.e. Troubleshooting Insufficient braking INEFFICIENT BRAKING SYSTEM Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and replace brake fluid if necessary.
Page 50: Noisy Suspension
MP3 250 i.e. Troubleshooting Possible Cause Operation if they are recessed or if the balls are squashed, replace them. Noisy suspension NOISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy, check: the efficien- cy of the front shock absorbers;...
Page 51: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 52 MP3 250 i.e. Electrical system 1. Immobilizer aerial 2. Injection ECU 3. Engine rev sensor 4. Magneto flywheel 5. Diagnostics socket 6. Voltage regulator 7. Key switch 8. Fuse-box 9. Fuse-box 10. Battery 11. Starter motor 12. Start up remote control switch 13.
Page 53 MP3 250 i.e. Electrical system 21. Preparation for anti-theft device 22. Turn indicator switch 23. Hazard switch 24. Turn indicator control device 25. Left rear turn indicator bulbs 26. Rear headlight assembly A. Tail light C. Stop light 27. License plate bulb 28.
Page 54: Electrical System Installation
MP3 250 i.e. Electrical system 54. Engine stop switch 55. Mode button 56. Engine temperature sensor 57. Fuel pump 58. Fuel injector 59. Lambda probe 60. Spark plug 61. High voltage coil Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple Electrical system installation ELE SYS - 4...
Page 55 MP3 250 i.e. Electrical system ELE SYS - 5...
Page 56 MP3 250 i.e. Electrical system ELE SYS - 6...
Page 57 MP3 250 i.e. Electrical system ELE SYS - 7...
Page 58 MP3 250 i.e. Electrical system ELE SYS - 8...
Page 59 MP3 250 i.e. Electrical system ELE SYS - 9...
Page 60 MP3 250 i.e. Electrical system Conceptual diagrams Ignition 1. Immobilizer aerial 2. Injection ECU 3. Revolution sensor 7. Key switch 8. Fuse-box 9. Fuse-box 10. Battery ELE SYS - 10...
Page 61 MP3 250 i.e. Electrical system 53. Injection load remote control 60. Spark plug 61. High voltage coil Battery recharge and starting 2. Injection ECU 4. Magneto flywheel 6. Voltage regulator 7. Key switch 8. Fuse-box 9. Fuse-box 10. Battery 11. Starter motor 12.
Page 62 MP3 250 i.e. Electrical system Level indicators and enable signals section 1. Immobilizer aerial 2. Injection ECU 3. Revolution sensor 7. Key switch 8. Fuse-box 9. Fuse-box 10. Battery 38. Locking/unlocking switch 39. Geared motor 40. Right tone wheel 41. Left tone wheel 42.
Page 63: Devices And Accessories
MP3 250 i.e. Electrical system 49. External temperature sensor 50. Fuel level transmitter 53. Injection load remote control 54. Engine stop switch 55. Mode button 56. Engine temperature sensor 57. Fuel pump 58. Fuel injector 59. Lambda probe Devices and accessories 2.
Page 64 MP3 250 i.e. Electrical system 35. Horn 36. Horn button 37. Pressure sensor 43. Parking electronic control unit 51. Electric fan 52. Remote control for electric fan Lights and turn indicators 7. Key switch 8. Fuse-box 9. Fuse-box 10. Battery 21.
Page 65: Checks And Inspections
MP3 250 i.e. Electrical system 27. License plate bulb 28. Right rear turn indicator bulbs 29. Left front turn indicator bulb 30. Front headlight assembly A. Low-beam light bulb B. Tail light C. High-beam light bulb 31. Right front turn indicator bulb 32.
Page 66 MP3 250 i.e. Electrical system ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to the "ON"...
Page 67 MP3 250 i.e. Electrical system There is continuity between terminals 12-18 and 12-19 with the emergency cut-out switch in the RUN position. If there is no continuity check the con- tacts of the latter. If no faults are found, replace the electronic control unit.
Page 68 MP3 250 i.e. Electrical system With MIU connector disconnected check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring . Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly.
Page 69: Diagnostic Codes
MP3 250 i.e. Electrical system Characteristic MASTER key: RED KEY SERVICE key. BLACK KEY Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
Page 70 MP3 250 i.e. Electrical system LED remains permanently OFF. The engine can be started. 5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on permanently. The engine cannot be started. The codes that can be transmitted are: Code 1 flash 2 flash code...
Page 71: Stator Check
MP3 250 i.e. Electrical system Diagnostic code - 3 flashes The three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit.
Page 72: Voltage Regulator/Rectifier
MP3 250 i.e. Electrical system 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator. Recharge system voltage check Look for any leakage 1) Access the battery by removing its cover under the saddle. 2) Check that the battery does not show signs of losing fluid before checking the output voltage.
Page 73 MP3 250 i.e. Electrical system Fuses The electrical system has twelve fuses divided in two fuse boxes to protect the different installation circuits. One of them is inside the battery compart- ment and the other is at the right internal side of the footrest.
Page 74 MP3 250 i.e. Electrical system Specification Desc./Quantity Fuse No. 7 Capacity: 7.5 A Protected circuits:Battery-powered instru- ment panel Location:footrest Fuse No. 8 Capacity: 10A Protected circuits:Live stop and start lights Location:footrest Fuse No. 9 Capacity: 7.5 A Protected circuits:live passing and horn Location:battery compartment Fuse No.
Page 75 MP3 250 i.e. Electrical system A = Total odometer gauge B = «BELT» maintenance icon C = «SERVICE» maintenance icon D = Engine coolant temperature indicator E = Trip odometer gauge (A-B) and ambient tem- perature (selected with the MODE button) F = TIME-DATE indicator G = Low fuel warning light H = Trip odometer gauge (B)
Page 76 MP3 250 i.e. Electrical system -Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity - Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode - Charge current equal to 1/10 of the battery rated capacity - Charge time: Maximum 5 h Connectors 1A Alimentazione potenziometro...
Page 77 MP3 250 i.e. Electrical system Dashboard 1/20 Sensore velocità 2/20 Segnale livello carburante 3/20 Sensore temperatura liquido di raffreddamento 4/20 Massa sensore temperatura liquido di raffreddamento 5/20 Pulsante mode remoto 6/20 Spia pressione olio 7/20 Spia lampeggiatore sinistro 8/20 Spia lampeggiatore destro 9/20 Spia luce abbagliante 10/20 Spia bauliera aperta 11/20 Sensore giri...
Page 78 MP3 250 i.e. Electrical system Zeroing - Remove the left side fairing to access the saddle opening receiver control unit indicated in the pho- tograph - Remove the metal terminal and connect it to a good earth point, or to terminal 7 (black), for at least 10 seconds.
Page 79 MP3 250 i.e. Electrical system TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTE CONTROL RADIO RE- CEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLE WAS SHUT OFF. JUST TURN THE KEY TO «ON» TO REACTIVATE THE RECEIVER. ELE SYS - 29...
Page 80 MP3 250 i.e. Electrical system ELE SYS - 30...
Page 81: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 82 MP3 250 i.e. Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the Lambda probe from its support and disconnect it. - Undo the two exhaust manifold fixings on the head.
Page 83 MP3 250 i.e. Engine from vehicle CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE- PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. Removal of the engine from the vehicle - Disconnect the battery - Remove the engine cover inside the helmet com- partment - Remove the side panels Remove the full muffler assembly.
Page 84 MP3 250 i.e. Engine from vehicle - Remove the coolant outlet pipe from the motor as indicated. - Remove the spark plug caps. - Remove the coolant temperature sensor con- nector indicated in the photo. - Remove the throttle cable from the throttle body by undoing the nut shown in the photo.
Page 85 MP3 250 i.e. Engine from vehicle - Disconnect the connectors from the flywheel wir- ing as shown in the photo. - Remove the cable from the retaining clip on the flywheel cover. Remove the lower screw of the left-hand shock absorber.
Page 86 MP3 250 i.e. Engine from vehicle PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY. ENG VE - 6...
Page 87 INDEX OF TOPICS NGINE...
Page 88: Automatic Transmission
MP3 250 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
Page 89: Removing The Driven Pulley Shaft Bearing
MP3 250 i.e. Engine - To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by means of: Specific tooling...
Page 90: Removing The Driven Pulley
MP3 250 i.e. Engine Plastic roller - Check that the roller does not show signs of wear and that it turns freely. - Remove the special clamping screws as indica- ted in the photograph - Check the outer diameter of the roller does not have defects that could jeopardise belt functioning - For refitting, place the roller with the belt contain- ment edge on the engine crankcase side...
Page 91: Inspecting The Clutch Drum
MP3 250 i.e. Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic Max. value clutch bell Max. value: Ø 134.5 mm Clutch bell standard value Standard value: Ø...
Page 92: Removing The Clutch
MP3 250 i.e. Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring No. 11 with the cham- fering facing the inside of the tool. - Fit the driven pulley unit on the tool with the in- sertion of the 3 pins in the ventilation holes in the mass holder support.
Page 93 MP3 250 i.e. Engine DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD. Characteristic Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B.
Page 94 MP3 250 i.e. Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide Inspecting the driven fixed half-pulley Version 250...
Page 95 MP3 250 i.e. Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the contact surface with the belt to make sure there are no flaws. - Check the riveted joints are functional.
Page 96: Refitting The Driven Pulley
MP3 250 i.e. Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Fit the half-pulley over the bushing using the spe- cific tool.
Page 97 MP3 250 i.e. Engine Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 123 mm acceptable limit after use: 118 mm Refitting the clutch - Support the driven pulley spring compressor ap-...
Page 98 MP3 250 i.e. Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool.
Page 99: Removing The Driving Pulley
MP3 250 i.e. Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic 250 4T Transmission belt/minimum width 19.5 mm 250 4T Transmission belt/standard width 21.3 ± 0.2 mm During the wear checks in the scheduled servicing programme, you are advised to check the rim bot- tom of the toothing does not show signs of inci- sions or cracking (see figure): The rim bottom of...
Page 100 MP3 250 i.e. Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 020626Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half.
Page 101 MP3 250 i.e. Engine 26.000 - 26.021 mm Movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm Sliding bushing: Minimum admissible diame- Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
Page 102 MP3 250 i.e. Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the re- moval phase. -Tighten the nut with washer to the prescribed tor- que.
Page 103 MP3 250 i.e. Engine Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket. Removing the wheel axle - Remove the wheel axis complete with gear.
Page 104 MP3 250 i.e. Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
Page 105 MP3 250 i.e. Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil guard, remove the transmission cover as described above. - Extract the driven pulley shaft from its bearing. - Remove the oil guard using a screwdriver, work- ing from inside the bearing and being careful not to damage the housing, make it come out of the...
Page 106 MP3 250 i.e. Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure. - Fit the seeger ring.
Page 107 MP3 250 i.e. Engine Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the special heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
Page 108 MP3 250 i.e. Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Seal the gasket of the breather pipe using black silicone sealant.
Page 109: Removing The Stator
MP3 250 i.e. Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the ten fixings - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
Page 110 MP3 250 i.e. 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. Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4 Refitting the flywheel cover - Position the spline clip on the crankshaft and ori- ent the end as shown in the figure.
Page 111: Removing The Starter Motor
MP3 250 i.e. Engine Removing the starter motor - Remove the two screws indicated in the figure. - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft spline clip - Line up the two holes in the flywheel as shown in the photo - Screw in the guide bushing that is part of the...
Page 112 MP3 250 i.e. Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling 020627Y Flywheel lock wrench - Remove the plate indicated in the photo. - 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 on extraction...
Page 113 MP3 250 i.e. Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
Page 114: Removing The Intake Manifold
MP3 250 i.e. Engine - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque -Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut 94 ÷ 102 Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate - Fit the starter on the crankcase, locking the two screws to the prescribed torque.
Page 115 MP3 250 i.e. Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separa- tion washer.
Page 116 MP3 250 i.e. Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure. - Remove the camshaft control pulley with its washer.
Page 117: Removing The Cam Shaft
MP3 250 i.e. Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes. N.B.
Page 118: Removing The Valves
MP3 250 i.e. Engine MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool. - Remove the lower spring supports.
Page 119: Inspecting The Small End
MP3 250 i.e. Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAME- TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Page 120: Inspecting The Piston
MP3 250 i.e. Engine Inspecting the piston - Measure the diameter of the wrist pin seat on the piston. - Calculate the piston pin coupling clearance. - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis. - Take the measurement at 5 mm from the base in the position shown in the figure.
Page 121 MP3 250 i.e. Engine Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the head coupling surface is not worn or misshapen. - Pistons and cylinders are classified according to diameter.
Page 122: Removing The Piston
MP3 250 i.e. Engine Sealing rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpen- dicularly to the cylinder axis. - Measure the opening (see figure) of the sealing rings using a feeler gauge.
Page 123 MP3 250 i.e. Engine THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING. Specific tooling 020454Y Tool for fitting piston pin stops (200 - 250) Choosing the gasket Characteristic Compression ratio 250 version CR: 10.5 ÷...
Page 124 MP3 250 i.e. Engine THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA. ENGINE 250 SHIMMING Name Measure A Thickness shimming 3.70 - 3.60...
Page 125: Inspecting The Cylinder Head
MP3 250 i.e. Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure. N.B. BEFORE FITTING THE CYLINDER, CAREFUL- LY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
Page 126 MP3 250 i.e. Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn. - If you encounter wear, replace the parts or, if the chain, sprocket wheel and pulley are worn replace the whole assembly.
Page 127 MP3 250 i.e. Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide. - Take the measurement at three different heights in the rocker arm push direction.
Page 128 MP3 250 i.e. Engine - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the surface of contact with the articulated register terminal. - If the checks above give no failures, you can use the same valves. For best sealing results, it is advisable to grind the valves.
Page 129 MP3 250 i.e. Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. ENG - 43...
Page 130: Inspecting The Cam Shaft
MP3 250 i.e. Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head. - Using the special punch, fit the four valve seals. - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
Page 131 MP3 250 i.e. Engine - Measure the internal diameter of each rocker arm. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. Characteristic Internal rocker arm diameter: Standard diame- Diameter 12.000 - 12.011 mm Rocker arm pin diameter: Standard diameter Diameter 11.977 - 11.985 mm...
Page 132 MP3 250 i.e. Engine Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head. - Lubricate the stud bolt threading. - Tighten up the nuts to an initial pre-torque of 7±1 N·m - Tighten up the nuts to a second pre-torque of 10...
Page 133 MP3 250 i.e. Engine - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que.
Page 134 MP3 250 i.e. Engine GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE EN- GINE. Locking torques (N*m) Timing chain tensioner support screw 11 ÷ 13 Spark plug 12 ÷ 14 Starter ground screw 7 ÷ 8.5 Timing chain tensioner slider screw 10 ÷...
Page 135: Crankcase - Crankshaft
MP3 250 i.e. Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
Page 136 MP3 250 i.e. Engine - Remove the two screws and the internal cover shown in the diagram. - Remove the oil guard on the flywheel side. - Remove the oil filter fitting shown in the diagram. - Check the axial clearance on the connecting rod. - Check the radial clearance on the connecting rod.
Page 137 MP3 250 i.e. Engine 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Axial crankshaft/crankcase clearance: Stand- ard clearance 0.15 - 0.40 mm (when cold) Axial connecting rod - crankshaft clearance Standard clearance 0.20 ÷ 0.50 mm Radial connecting rod - crankshaft clearance Standard clearance 0.036 ÷...
Page 138 MP3 250 i.e. Engine crankshaft, be very careful that no impurities get in through the shaft's lubrication holes. In order to prevent damaging the connecting rod bushings, do not attempt cleaning the lubrication duct with compressed air. - Make sure that the 2 caps on the crankpin are properly fitted.
Page 139 MP3 250 i.e. 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 bearings and con- nection rod.
Page 140 MP3 250 i.e. Engine Inspecting the crankshaft plain bearings o obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure (3,2 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
Page 141 MP3 250 i.e. Engine TYPE IDENTIFICATION BLUE YELLOW Type "A" Type "B" Type "C" - RED - BLUE - YEL- Main half- 1.970 ÷ 1.9703 ÷ 1.976 ÷ bearing 1.973 1.976 1.979 Bush- Crank- Internal bush- Possible ing cat- case ing diameter fitting egory...
Page 142 MP3 250 i.e. Engine N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. N.B. CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS (BLUE) Characteristic Standard driving depth...
Page 143 MP3 250 i.e. Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.
Page 144 MP3 250 i.e. Engine By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the photograph, re- move the stud bolt from its seat. Clean the threaded seat on the carter thoroughly. Refit a new stud bolt and apply the special product on the threading crankcase side.
Page 145 MP3 250 i.e. Engine ENG - 59...
Page 146: Oil Pressure Check
MP3 250 i.e. Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
Page 147 MP3 250 i.e. Engine Removal - Remove the transmission cover and the com- plete driving pulley beforehand - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.
Page 148: Oil Pump
MP3 250 i.e. Engine - Orientate the oil guard by inserting the bracket which is part of the appropriate tool - Tighten the threaded bar onto the crankshaft as far as it will go. - Use the nut to move the base of the tool until you can see end of the oil guard driving stroke - Remove all of the tool components following the inverse procedure...
Page 149 MP3 250 i.e. Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
Page 150 MP3 250 i.e. Engine Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure. Characteristic Axial rotor clearance Limit values admitted: 0.09 mm Distance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm...
Page 151 MP3 250 i.e. Engine - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the belleville washer. Tighten to the prescribed torque. - Fit the oil pump cover by tightening the two screws to the prescribed torque.
Page 152 MP3 250 i.e. 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 153: Index Of Topics
INDEX OF TOPICS INJEC NJECTION...
Page 154 MP3 250 i.e. Injection INJEC - 2...
Page 155 MP3 250 i.e. Injection TRANSPARENCY Specification Desc./Quantity Fuel injector Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Battery 12V - 12 Ah Engine rpm sensor HV coil Lambda sensor Fuel pump Water temperature sensor Injection load remote control Instrument panel MIU injection system This vehicle is fitted with an integrated injection and ignition system.
Page 156 MP3 250 i.e. Injection - HV coil - HV cable - Shielded cap - MIU control unit - Spark plug The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only in the compression phase) at the same time. The MIU injection-ignition system controls engine functions by means of a pre-set program.
Page 157 MP3 250 i.e. Injection The MIU injection-ignition system carries out checks on the rpm counter and the electric fan for radiator cooling. The MIU control unit has a decoder for the anti- theft immobiliser. The MIU control unit is connected to a diagnostic LED on the instrument panel, that also carries out the deterrent flashing functions.
Page 158 MP3 250 i.e. Injection Check the connections as follows: A check that the terminals are not bent. B check that the connectors have been properly connected. C see whether the malfunction can be fixed by shaking the connector slightly. 3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit, install the original control unit again and check if the fault occurs again.
Page 159 MP3 250 i.e. Injection EMS circuit diagram 1. Battery 12V - 12 Ah 2. Engine rpm sensor 3. coolant temperature sensor: 4. Immobilizer aerial 5. Stop switches 6. Fuse No. 2 20A 7. Fuse No. 6 3A 8. Key switch contacts 9.
Page 160: Troubleshooting Procedure
MP3 250 i.e. Injection 11.Fuse No. 10 7.5A 12.CAN line connection with tilt locking electric control unit 13.Fuse No. 8 10A 14.Starter button 15.Injection load remote control 16.Starter remote control 17.Electric fan starter 18.Starter motor 19.Electric fan motor 20.Fuel pump 21.H.V.
Page 161: Starting Difficulties
MP3 250 i.e. Injection Starting difficulties ENGINE START-UP PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Start-up speed Starter motor and remote control Battery Ground connections End of compression pressure End of compression pressure...
Page 162 MP3 250 i.e. Injection Possible Cause Operation Fuel filter Injector capacity Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor...
Page 163 MP3 250 i.e. Injection Possible Cause Operation Muffler welding Engine revs irregularly ENGINE IRREGULAR PROGRESS WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system seal Intake sleeve Filter box Ignition system Spark plug wear check...
Page 164: Fuel Supply System
MP3 250 i.e. Injection Engine knocking PRESENCE OF KNOCKING (HEAD KNOCKING) Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature indicator...
Page 165 MP3 250 i.e. Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. Remove the snap-on fittings from the injector sup- port INJEC - 13...
Page 166 MP3 250 i.e. Injection Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. Remove the MIU connector Remove the clip fixing the throttle body to the pu- rifier bellows INJEC - 14...
Page 167 MP3 250 i.e. Injection Remove the gas command fitting as indicated in the photograph Refitting the butterfly valve To refit, perform the operations in the reverse or- der from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45°...
Page 168 MP3 250 i.e. Injection Pump supply circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil INJEC - 16...
Page 169 MP3 250 i.e. Injection Specification Desc./Quantity Fuel injector Lambda sensor Electric fan starter When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts up, in the presence of rpm timing signal the pump is continuously supplied. ELECTRICAL DATA Pump winding resistance ~ 1.5 Ohm Input current during normal functioning 1.4 ÷...
Page 170 MP3 250 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the pin 20...
Page 171 MP3 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the remote control base. N.B.
Page 172 MP3 250 i.e. Injection pump circuit 6 Check, on switching to "ON", that there is battery voltage, for about two seconds, to the Black-Green cable of the pump connector and earth with pump connector disconnected. Otherwise check the continuity of the Black-Grey cable between the pump connector and the base of the remote con- trol.
Page 173 MP3 250 i.e. Injection Circuit leak test Install the appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the delivery pipe.. Check during regular operation by placing the ap- propriate tool between the pump and the injector. With the battery voltage>...
Page 174 MP3 250 i.e. Injection Remove the screw shown in the photograph Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 22...
Page 175 MP3 250 i.e. Injection Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil INJEC - 23...
Page 176 MP3 250 i.e. Injection Specification Desc./Quantity Fuel injector Lambda sensor Electric fan starter Check the resistance at the injector ends: 14.5 ± 5% Ohm Check the efficiency of injection load 15 A fuse No. Check the efficiency of live control unit power sup- ply 7.5A fuse No.
Page 177 MP3 250 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the pin 20...
Page 178 MP3 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 4 10 A) and the remote control base. N.B.
Page 179 MP3 250 i.e. Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to "ON" and check if there is voltage, with injector disconnected and control unit connected, between the Black-Green cable of the injector con- nector and the ground lead...
Page 180 MP3 250 i.e. Injection Inspecting the injector hydraulics To carry out the injector check, remove the intake manifold by removing the three clamping screws at the head and the clip connecting the control unit to the manifold. Install the appropriate tool for checking fuel pres- sure and position the manifold over a container graduated by at least 100 cm³.
Page 181 MP3 250 i.e. Injection Components location INJEC - 29...
Page 182 MP3 250 i.e. Injection TRANSPARENCY Specification Desc./Quantity Fuel injector Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Battery 12V - 12 Ah Engine rpm sensor HV coil Lambda sensor Fuel pump Water temperature sensor Injection load remote control Instrument panel Tachometer With wiring disconnected from the control unit and...
Page 183 MP3 250 i.e. Injection Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring con- nected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2.8 V With the interface cable harness disconnected from the control unit, check continuity between pin...
Page 184 MP3 250 i.e. Injection HT coil INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil INJEC - 32...
Page 185 MP3 250 i.e. Injection Specification Desc./Quantity Fuel injector Lambda sensor Electric fan starter The ignition system is integrated with the injection and is of the inductive high efficiency type. The control unit manages two important parameters: - Ignition advance This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ±...
Page 186 MP3 250 i.e. Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected. Resistance of the primary = 0.5 ±...
Page 187 MP3 250 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the pin 20...
Page 188 MP3 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the remote control base. N.B.
Page 189: Coolant Temperature Sensor
MP3 250 i.e. Injection Coolant temperature sensor EMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor Engine stop switch With the connector on the control unit side discon- nected and the coolant temperature sensor con- nector connected, check the resistance values between pins 9 and 18 correspond to the engine temperature.
Page 190 MP3 250 i.e. Injection nected, check the insulation between the two light blue-green and grey-green cables With the connector on the control unit side discon- nected and the coolant temperature sensor con- nector disconnected, check the continuity be- tween pin 9 of the interface wiring and the blue- green cable of the connector, and between pin 18 of the interface wiring and the grey-green cable of the connector.
Page 191 MP3 250 i.e. Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw. Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
Page 192: Lambda Probe
MP3 250 i.e. Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Page 193 MP3 250 i.e. Injection With the engine running at idle speed, check that the voltage oscillates between 0V and 1V With the throttle valve completely open, the volt- age is approx. 1V. During the closing phase, the voltage is approx. If the voltage remains constant, the sensor may be damaged.
Page 194 MP3 250 i.e. Injection INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 42...
Page 195 MP3 250 i.e. Injection Specification Desc./Quantity Electric fan starter The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type, i.e.
Page 196 MP3 250 i.e. Injection With the engine cold, check the resistance of the Lambda sensor heater between pin 21 of the in- terface wiring and the black green cable of the injection load remote control base, with the control unit disconnected and the remote control discon- nected.
Page 197 MP3 250 i.e. Injection INJEC - 45...
Page 198 MP3 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 4 10 A) and the remote control base. N.B.
Page 199: Index Of Topics
INDEX OF TOPICS SUSP USPENSIONS...
Page 200: Removing The Front Wheel
MP3 250 i.e. Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pho- tograph. Locking torques (N*m) Wheel fixing screw 20 ÷ 25 Front wheel hub overhaul - Remove the ball bearing seeger ring indicated in the photograph...
Page 201 MP3 250 i.e. Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide - Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the bearing until it stops, with the shielded side facing...
Page 202 MP3 250 i.e. Suspensions Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 Handlebar Removal Remove the two handlebar covers as explained in the Bodywork Chapter. Remove the handlebar wiring fixing clips and disconnect the electric con- nectors from the brake levers. Unscrew the fittings, then remove the front and rear brake pump piping.
Page 203: Hydraulic System Layout
MP3 250 i.e. Suspensions Hydraulic system layout When tilting is locked, the geared motor activates the hydraulic pump indicated in the photograph and pressurises the circuit. The pressurised oil reaches the distribution frame "T" and the pressure sensor "A". Then, the pipes branch out to reach the upper joints on the side steering tubes.
Page 204 MP3 250 i.e. Suspensions Disconnect the tone wheel connector indicated in the photograph. Remove the hydraulic pipe fitting from the sliding locking device, making sure again that the liquid drained is collected. Remove the upper fittings, on the parallelogram, of the brake hydraulic pipes and the suspension lock indicated in the photograph.
Page 205 MP3 250 i.e. Suspensions Remove the suspension tilt locking device pipes from the headstock. Remove first the flexible part of the calliper from the steering tube as shown in the photograph, and then remove the rigid part. Remove the tone wheel wiring by disconnecting the connector on the fuel tank after removing the chassis central cover.
Page 206 MP3 250 i.e. Suspensions Remove the constant-velocity universal joint from the steering bar by undoing the nut indicated in the photograph. Use a specific tool to remove the upper tightening ring nut of the steering tube. Specific tooling 020055Y Wrench for steering tube ring nut Remove the hydraulic pipe support bracket.
Page 207 MP3 250 i.e. Suspensions Remove the steering tube lower ring nut and the protection cap indicated in the photograph. Now, it is possible to remove the steering tube. Check that the roller tapered bearing does not show signs of abnormal wear. If it is, replace it. SUSP - 9...
Page 208 MP3 250 i.e. Suspensions THE OPERATIONS DESCRIBED BELOW CAN ALSO BE CARRIED OUT EVEN WHEN THE SUSPENSION IS FITTED Remove the lower retainer of the sliding stem shown in the photograph. Remove the sliding stem locking device retainers indicated in the photograph. Check that the sliding stem locking device does not show signs of abnormal wear.
Page 209 MP3 250 i.e. Suspensions For refitting, follow the operations for removal but in reverse order, observing the prescribed torques and greasing the bearings and their seats. STEERING TUBES Name Torque in Nm Side headstock upper ring nut 20 - 24 Side headstock lower ring nut 12 ÷...
Page 210 MP3 250 i.e. Suspensions Remove the 4 screws fixing the tilt brake disc sec- tor indicated in the photograph. Remove the retainers indicated in photograph of the half-arms joint flange. To facilitate the operations indicated below, re- move the suspension locking electronic control unit indicated in the photograph.
Page 211 MP3 250 i.e. Suspensions Remove the arm coupling retainers from the par- allelogram by loosening the retainers indicated. For easy refitting operations, remember to take note of the positions of the components. Separate the half-arms by hitting slightly with a wooden mallet where possible alternatively to the left and right side of the parallelogram.
Page 212 MP3 250 i.e. Suspensions Carry out a visual check of the upper and lower bearings on the headstocks and their seats. Re- place them in case of signs of abnormal wear. SUSP - 14...
Page 213 MP3 250 i.e. Suspensions Check the ball bearings on the parallelogram arms. Replace them in case of signs of abnormal wear. Check the inside tracks of the parallelogram bear- ings on the chassis. For refitting, follow the operations for removal but in reverse order, lubricating the locking pins on the parallelogram half-arms and observing the pre- scribed torques.
Page 214 MP3 250 i.e. Suspensions Name Torque in Nm Fixing screws for tilt locking disc section 20 ÷ 25 Geared motor and Suspension locking system Before removing the geared motor: Disable the suspension lock. - Remove the front shield. With the set nut indicated in the photograph, re- move the tensioning cable of the suspension lock- ing mechanical calliper.
Page 215 MP3 250 i.e. Suspensions QUANTITIES OF MILK OR WATER AND SEEK MEDICAL ADVICE IMMEDIATELY. BRAKE FLUID DESTROYS SKIN AND OCULAR TIS- SUE. IF YOU ACCIDENTALLY SPILL BRAKE FLUID ON YOURSELF, TAKE OFF YOUR CLOTHES, WASH WITH HOT WATER AND SOAP AND SEEK MEDICAL ADVICE IMMEDI- ATELY.
Page 216 MP3 250 i.e. Suspensions Unscrew the two potentiometer screws. When refitting, plug the potentiometer in D-type connector, afterwards place it with its electric con- nection directed to the opposite side of the pump. Remove the nut indicated in the figure, if neces- sary lock the lever with a vice making sure not to spoil the surface.
Page 217 MP3 250 i.e. Suspensions Remove the four screws indicated in the figure, remove the flexible transmission supporting brack- et, separate the two crankcase halves, if neces- sary, use a rubber mallet to hit the flexible transmission lever in order to separate the two crankcases.
Page 218 MP3 250 i.e. Suspensions Hold the crankcase in a perfectly horizontal posi- tion, heat it with a heat gun at a temperature of about 120 °C, use the specific tool to fit the bearing of the flexible transmission lever control shaft. Hit slightly with a mallet if necessary.
Page 219 MP3 250 i.e. Suspensions Extract the bearing of the spring/toothed sector unit with the specific tool. Specific tooling 001467Y002 Driver for OD 73 mm bearing Extract the bearing of the electric motor with the specific tool. Hold the crankcase in a perfectly horizontal posi- tion, heat it with a heat gun at a temperature of about 120 °C, use the specific tool to fit the bearing of the spring/toothed sector unit.
Page 220 MP3 250 i.e. Suspensions Refit the spring/toothed sector unit, hold the crank- case in a perfectly horizontal and stable position, place the spring/toothed sector unit keeping it per- fectly perpendicular to the bearing already fitted on the crankcase; if necessary, slightly hit the unit shaft end with a mallet and protect the thread by screwing in a nut.
Page 221 MP3 250 i.e. Suspensions Refit the electric motor; check the position is cor- rect by means of the reference indicated during removal. The motor should be so positioned that it does not protrude from the reduction unit mould, see figure. Tighten the screws to the prescribed torque.
Page 222 MP3 250 i.e. Suspensions Remove the two bracket screws after releasing the spring and freeing the flexible transmission adjust- ment. CAUTION: A FIRST PRODUCTION BATCH WILL BE EQUIPPED WITH DOUBLE COAXIAL SPRING. It is very important to remove the flexible trans- mission from its fitting only for replacement.
Page 223 MP3 250 i.e. Suspensions Unscrew the two pad pin screws, remove the pads with the spring. When refitting, tighten the two screws to the pre- scribed torque and use Threadlock. When refitting, adjust the cable properly so that the switch is pushed when the system is unlocked. SUSP - 25...
Page 224 MP3 250 i.e. Suspensions Select the SYSTEM RESET option from the main menu Turn the key switch to ON Select the LOWER STOP SEARCH option from the SYSTEM RESET menu WAIT PROCEDURE IN PROGRESS SUSP - 26...
Page 225 MP3 250 i.e. Suspensions The hand-held computer indicates the outcome of the stop search operation: POSSIBLE LIMIT STOP VALUES. TO EXIT, PRESS A KEY AND TURN OFF AND ON. SE- LECT PARAMETERS TO ADJUST AT 12°. Check the geared motor if the hand-held computer does not indicate this.
Page 226 MP3 250 i.e. Suspensions Remove the protection cap, align the pump control and lock the screw to the prescribed torque Locking torques (N*m) Clamp fixing pump bolt to anti-tilting device 11 ÷ 13 Select the SYSTEM RESET option from the MAIN menu SUSP - 28...
Page 227 MP3 250 i.e. Suspensions Select the POTENTIOMETER RESET option from the SYSTEM RESET menu and press OK. WAIT..PROCEDURE IN PROGRESS The hand-held computer displays the words: CHECK THAT THE CONTROL IS SET AT 12° FROM THE LOWER STOP. PRESS OK TO CON- TINUE Press OK The hand-held computer displays the words: POS-...
Page 228 MP3 250 i.e. Suspensions 1. GEARED MOTOR 2. TILT LOCKING CALLIPER SWITCH 3. TILT UNLOCKING-LOCKING CONTROL SWITCH 4. POTENTIOMETER 5. RIDER PRESENCE SENSOR 6. LEFT SPEED SENSOR 7. RIGHT SPEED SENSOR 8. DIAGNOSTIC TESTER SERIAL LINE 9. ENGINE CONTROL UNIT 10.+ DIRECT BATTERY 11.+ LIVE BATTERY 12.LOW-BEAM LIGHT...
Page 229 MP3 250 i.e. Suspensions 1: Right tone wheel 2: Left tone wheel With interface wiring disconnected from the park- ing electrical control unit and connected to the system, check that the sensor resistance between pins 23 - 17 and 24 - 17 is between 774 and 946 Ohm at a temperature of approximately 20°...
Page 230 MP3 250 i.e. Suspensions In case of failures, check the continuity between pin 23 and the connector green cable on the fuel tank after removing the chassis central cover; be- tween pin 17 and the yellow cables on both con- nectors;...
Page 231 MP3 250 i.e. Suspensions With a thickness gauge, check that the air gap be- tween the screw head and the sensor is between 0.35 and 1 mm RIDER PRESENCE SENSOR SUSP - 33...
Page 232 MP3 250 i.e. Suspensions 1: RIDER PRESENCE SENSOR With interface wiring disconnected from the control unit and connected to the system, check the fol- lowing conditions: pin 17 - 36: resistance 15 ÷ 18 kOhm when the rider is not seated on the saddle. pin 17 - 36: resistance of about 3 kOhm when the rider is seated on the saddle SUSP - 34...
Page 233 MP3 250 i.e. Suspensions Check the continuity between the interface wiring pin 17 and the yellow cable of the rider presence connector. Check the continuity between the interface wiring pin 36 and violet cable of the rider presence con- nector. TILT LOCKING GRIPPER SENSOR 1: TILT LOCKING CALLIPER SENSOR SUSP - 35...
Page 234 MP3 250 i.e. Suspensions The tilt locking calliper sensor is a normally opened switch. Check its correct operation with a multi- meter. With interface wiring disconnected from the control unit, check the continuity between pin 34 and the brown cable of the tilt locking gripper sensor con- nector on the system side.
Page 235 MP3 250 i.e. Suspensions 1: POTENTIOMETER With interface wiring connected to the control unit, secure the vehicle on its centre stand and switch to "ON". Select the reading scale on 20 V. Insert the multimeter probes on pins 17 (black) and 25 (red).
Page 236 MP3 250 i.e. Suspensions With the interface wiring disconnected from the control unit, check the continuity between pin 17 and the yellow cable of the potentiometer connec- tor, between pin 25 and the green-blue cable, between pin 11 and the orange-blue cable. Also check that these lines are insulated from each oth- er and earth.
Page 237 MP3 250 i.e. Suspensions 0: REST POSITION 1: LOCKING POSITION 2: UNLOCKING POSITION 3: TILT LOCKING-UNLOCKING SWITCH With interface wiring disconnected from the control unit, check the continuity of the electrical lines be- tween the interface wiring and the tilt locking-un- locking switch: Pin 26 and green - grey cable Pin 35 and violet - black cable...
Page 238 MP3 250 i.e. Suspensions Check the continuity between the black cable on the connector and an earth point on the chassis. With a multimeter, check the operation of the tilt locking-unlocking switch referring to the diagram indicated in the figure. 1.
Page 239 MP3 250 i.e. Suspensions 1: GEARED MOTOR With the interface wiring disconnected from the control unit, check the continuity between pin 28 and the yellow cable, between pin 38 and the blue cable on the geared motor connector SUSP - 41...
Page 240 MP3 250 i.e. Suspensions With the interface wiring disconnected from the control unit, check the continuity of the geared mo- tor winding placing the multimeter probes on pins 28 and 38 as indicated in the figure PRESSURE SWITCH 1: PRESSURE SWITCH 2: HORN REMOTE CONTROL 3: FUSE No.
Page 241 MP3 250 i.e. Suspensions Check 7.5 A fuse No. 11 for efficiency. With inter- face wiring disconnected from the control unit, check the continuity of the blue - black cable be- tween pressure sensor connector and the horn remote control base as indicated in the photo- graph.
Page 242: Wheel Alignment
MP3 250 i.e. Suspensions Wheel alignment Tool fitting Metodo di utilizzo dell'attrezzatura Verificare che la pressione pneumatici sia corretta. Posizionare il veicolo su un pavimento piano privo di asperità e irregolarità . Posizionare il veicolo sul cavalletto centrale. Assicurarsi che il sistema di staziona- mento sia sbloccato.
Page 243 MP3 250 i.e. Suspensions Get the vehicle off the stand, back on the ground. Remove the right lower coupling plate of the half-arm by undoing the screws indicated in the photograph. Remove the right upper screw and the left bottom screw of the parallelogram unit .
Page 244 MP3 250 i.e. Suspensions Fit the bracket locking the parallelo- gram in the holes of the previously re- moved screws; use the screws sup- plied with the tool and be careful to correctly centre the spacer in the bear- ing. Remove the nut fixing the steering con- trol arm and keep the original washer in position.
Page 245 MP3 250 i.e. Suspensions Fit the frame locking bracket Make sure the frame is adequately centred by checking with a gauge that the lugs along the vertical axis show the standard protrusion. Check that the pointers of both tyres are correctly aligned, as shown in the photograph.
Page 246: Removing The Rear Wheel
MP3 250 i.e. Suspensions Rear Removing the rear wheel Remove the full muffler assembly. - Remove the screw fixing the right-hand shock absorber to the bracket - Remove the two screws supporting the brake calliper on the bracket - Remove the cotter pin, the cap, the wheel axle fixing nut and the outer one of the two spacers.
Page 247: Refitting The Rear Wheel
MP3 250 i.e. Suspensions - Remove the mud guard clamping screw - Remove the two screws fixing the bracket to the engine - Undo the wheel axle bracket, using the heat gun if necessary. Refitting the rear wheel To fit, follow the removal steps but in the reverse sequence, being careful to fit the spacers on the wheel axle as shown in the photograph.
Page 248 MP3 250 i.e. Suspensions - remove the spring anchoring the swinging arm to the frame as shown in the photo - Remove the two screws fixing the buffer support bracket to the frame - Undo the nut on the LHS shown in the figure and remove the corresponding bolt from the opposite side.
Page 249 MP3 250 i.e. Suspensions Refitting For correct installation of the swinging arm on the scooter, proceed as follows: 1. Position the silent block supporting clamp with part 3 inserted, and slightly tighten part 1 2. Position the swinging arm, inserting part 2 3.
Page 250: Shock Absorbers
MP3 250 i.e. Suspensions SWINGING ARM FITTING Name Torque in Nm Part 1 64 ÷ 72 Nm Part 3 5 - 7 Nm Part 4 90 ÷ 110 Nm Part 5 64 ÷ 72 Nm Engine-swinging arm bolt 64 - 72 Shock absorbers Removal Proceed as follows:...
Page 251: Centre-Stand
MP3 250 i.e. Suspensions Shock absorber lower clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41 Centre-stand REMOVAL - Use a jack to support the vehicle properly. - Remove the two return springs from the centre stand. - Undo the nut shown in the figure. - Remove the bolt from the right side.
Page 252 MP3 250 i.e. Suspensions SUSP - 54...
Page 253: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 254: Rear Brake Calliper
MP3 250 i.e. Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the muffler. - Remove the two rear brake calliper devices fas- tening them to the support as shown in the photo- graph.
Page 255 MP3 250 i.e. Braking system Removal Remove the split pin. Use new split pins when refitting. Undo the wheel hub nut. - When refitting, secure to the specified torque. Locking torques (N*m) Wheel axle nut 74 ÷ 88 Remove the seeger ring, after that, remove the hub with the help of a rubber mallet slightly hitting on the brake disc side, turning the wheel hub at the same time.
Page 256: Brake Pipes
MP3 250 i.e. Braking system Removal Rest the vehicle on its centre stand and use the corresponding jack to lift the two front wheels; un- screw the five Allen screws indicated in the figure Remove the pad upper closing cap. Remove the pad pin lock with a screwdriver, pay- ing attention not to spoil the calliper surface treat- ment.
Page 257 MP3 250 i.e. Braking system Remove front Shield. Remove front wheel and mudguard. Disconnect the brake pipes from the calliper and drain the brake fluid. Then, remove the plastic and metallic straps. Unscrew the brake pump pipes as indicated in the figure.
Page 258: Parking Brake
MP3 250 i.e. Braking system Parking brake Remove the muffler loosening the 3 screws and the strap on the drainage tube indicated in the photograph. When refitting, place the parking brake flexible transmission retaining strap correctly. Loosen the transmission set screw and release the cable from the calliper.
Page 259 MP3 250 i.e. Braking system Remove the electric connection from the engaged parking brake warning light switch. Remove the parking brake cable from the lever by operating the set screw indicated in the photo- graph. BRAK SYS - 7...
Page 260 MP3 250 i.e. Braking system BRAK SYS - 8...
Page 261 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 262 MP3 250 i.e. Cooling system System bleed - Start up the engine until the operating tempera- ture is reached. - Remove the rubber hood over the bleed valve - Obtain a rubber tube that is of the right length to connect the valve to the expansion tank - Place one end of the pipe on the bleed valve and the other in the expansion tank...
Page 263 INDEX OF TOPICS CHAS HASSIS...
Page 264 MP3 250 i.e. Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat Lift the saddle and disconnect the rider presence sensor. Remove the three fixing screws. Front handlebar cover Remove the upper cap by operating on the Allen screw indicated in the figure.
Page 265 MP3 250 i.e. Chassis Remove the two screws under the brake pump caps previously removed. Unscrew the two pairs of screws in the lower part of the half-handlebar. After removing the front part of the handlebar cov- er, access the two screws fixing the rear part to the handlebar, as indicated in the photograph.
Page 266 MP3 250 i.e. Chassis To remove the shield central finishing, remove the PIAGGIO clip-on badge paying attention not to spoil the paint, unscrew the screw underneath and remove the finish carefully. Remove the four screws "A" and disconnect the wiring.
Page 267 MP3 250 i.e. Chassis Legshield Remove the front headlight assembly. Remove the spoiler. Remove the two front screws and the two screws under the wheelhouse. Remove the four screws on the shield back plate. See also spoiler Headlight assy. Knee-guard - Remove the front shield.
Page 268 MP3 250 i.e. Chassis - Remove the expansion tank fixing screw and the frame from the instrument panel and manually re- lease the unions with the shield back plate. - Unhook the instrument panel wiring. - Remove the six screws and the cable guide strap in the front part of the shield back plate.
Page 269 MP3 250 i.e. Chassis - Remove the five screws on the shield back plate rear part. - Remove the two shield back plate front screws, see figure. - Remove the two shield back plate lower screws. - Remove the external temperature sensor con- nection.
Page 270 MP3 250 i.e. Chassis Footrest Remove the central cover. Remove the four screws and extract the half-foot- rest. Follow the same procedure for both half-footrests. Release the fuse-box See also Frame central cover CHAS - 8...
Page 271 MP3 250 i.e. Chassis Side fairings Remove the rear screw under the rear cover. Remove the screw on the fairing front part, pull the fairing to release the hooks. Follow the same procedure for both fairings. Remove the five screws on the right side and the five on the left side, indicated in the figure.
Page 272 MP3 250 i.e. Chassis Helmet bay Remove the chassis central cover. Remove the four external screws and the two screws inside the rear case to remove the frame. Remove the upper frame, unscrewing the ten up- per screws, the two saddle closing screws and the case light wiring.
Page 273 MP3 250 i.e. Chassis Remove the rear case internal screws indicated in the photograph, to detach the supporting plates of the voltage regulator on one side and the saddle opening switch on the other. Remove the six upper screws. Release the case latch. Remove the case light front and rear switch con- nections, the HV coil, the battery leads and the fuse-box.
Page 274: Fuel Tank
MP3 250 i.e. Chassis Headlight assy. Fuel tank Remove the chassis central cover. Remove the footrest. Remove the three tank retainers. Remove the two lower bracket retainers indicated in the figure. Disconnect the electric wiring and the fuel pipes. See also Footrest CHAS - 12...
Page 275 MP3 250 i.e. Chassis Top-case Rear Remove the four fixing screws of the cover and release it from the two leverages. Handles and top side fairings Operating from the rear case remove the two screws indicated in the figure. Remove the ceiling fitting indicated in the photograph and remove the inter- nal screw indicated in the photograph.
Page 276: Radiator Cover
MP3 250 i.e. Chassis Remove the six screws indicated in the figure. Radiator cover Remove the two front screws indicated in the pho- tograph Remove the two lower retainers with the bushing Remove the two rear retainers and then, the two wheelhouse front retainers.
Page 277 MP3 250 i.e. Chassis Remove the two screws fixing the radiator lower protection to the shield back plate. After that, press up and pull the protection front part so as to release it from the radiator frame. CHAS - 15...
Page 278 MP3 250 i.e. Chassis CHAS - 16...
Page 279 INDEX OF TOPICS PRE DE DELIVERY...
Page 280 MP3 250 i.e. Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Position the plastic cover supplied with the cou- pling on the steering tube as shown in the figure. If a customer wishes to have mudflaps installed, proceed as follows: Place the flap in the mudguard inner side as shown in the figure, making the...
Page 281 MP3 250 i.e. Pre-delivery Front shock absorber upper fixing Front shock absorber lower fixing Sliding stems fixing Break callipers fixing Front wheels fixing screws Front wheels axle nut Rear wheel axle nut Chassis - engine swinging arm fixing Handlebar lock nut Lower ring nut for side steering tubes Upper ring nut for side steering tubes Lower ring nut for central steering tube...
Page 282 MP3 250 i.e. Pre-delivery IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS;...
Page 283: Functional Inspection
MP3 250 i.e. Pre-delivery CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspection Functional check up: • Hydraulic braking system: lever travel • Clutch: proper functioning check •...
Page 284 MP3 250 i.e. Pre-delivery PRE DE - 6...
Page 285 INDEX OF TOPICS TIME...
Page 286 MP3 250 i.e. Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and refit. 001127 Engine - Complete service 003064...
Page 287 MP3 250 i.e. Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase- Replace- ment 001099 Oil seal, flywheel side - Re- placement 001100 Oil seal, clutch side - Re- placement 001124 Lubrication by-pass - Re- placement 001153 Crankcase halves gasket - Replacement TIME - 3...
Page 288 MP3 250 i.e. Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 4...
Page 289: Cylinder Assy
MP3 250 i.e. Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder-Piston - Replace- ment 001154 Pin ring piston unit - Service 001176 Rings / Pin - Replacement TIME - 5...
Page 290: Cylinder Head Assy
MP3 250 i.e. Time Cylinder head assy. HEAD UNIT Code Action Duration 001057 Thermostat - Replacement 007012 Coolant bleed valve - Re- placement 001083 Thermistor - Replacement 001056 Head gasket - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment TIME - 6...
Page 291 MP3 250 i.e. Time Rocker arms support assy. ROCKING LEVER UNIT Code Action Duration 001148 Rocking lever valve - Re- placement 001126 Head - Replacement 001044 Camshaft - Replacement 001169 Decompressor - Replace- ment TIME - 7...
Page 292: Cylinder Head Cover
MP3 250 i.e. Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replace- ment 001074 Oil vapour recovery pipe - Re- placement 001159 Oil vapour recovery tank - Service TIME - 8...
Page 293: Oil Filter
MP3 250 i.e. Time Oil filter OIL FILTER Code Action Duration 001150 Flywheel cover gasket - Re- placement 001160 Oil pressure sensor - Re- placement 001123 Oil filter -Replacement 001102 Net oil filter - Replacement / Cleaning 001113 Water pump / Pump rotor - Replacement TIME - 9...
Page 294: Flywheel Cover
MP3 250 i.e. Time Flywheel cover FLYWHEEL COVER Code Action Duration 007009 Head-pump by-pass rubber coupling - Replacement TIME - 10...
Page 295: Driven Pulley
MP3 250 i.e. Time Driven pulley DRIVEN PULLEY Code Action Duration 001012 Driven pulley - Service 001022 Clutch - Replacement 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement TIME - 11...
Page 296: Oil Pump
MP3 250 i.e. Time Oil pump OIL PUMP Code Action Duration 001129 Chain tightener - Overhaul and replacement 001125 Chain guide pads - Replace- ment 001122 Oil pump chain - Replace- ment 001172 Chain cover flap - change 001130 Oil sump - Replacement 001042 Oil pump - Service 001112...
Page 297 MP3 250 i.e. Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 002031 Rear wheel hub bearings - Replacement 003065 Gear box oil - Replacement 004180 Reduction gear pipe - Re- placement 004125 Rear wheel axle - Replace- ment 001179 Hub drive shaft -replacement...
Page 298: Driving Pulley
MP3 250 i.e. Time Driving pulley DRIVE PULLEY Code Action Duration 001177 Variator rollers / shoes - Re- placement 001141 Belt anti-flapping roller - Re- placement 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001066 Driving pulley - Removal and Refitting 001006 driving pulley - Service...
Page 299: Transmission Cover
MP3 250 i.e. Time Transmission cover RANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Replacement 001096 Transmission crankcase cov- er - Replacement 001131 Transmission air intake - Re- placement 001170 Air duct - Replacement 001132 Transmission air inlet pipe - Replacement TIME - 15...
Page 300: Starter Motor
MP3 250 i.e. Time Starter motor ELECTRICAL START UP Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Replacement 001151 Start-up driven gearing - Re- placement 001017 Start-up pinion - Replace- ment TIME - 16...
Page 301: Flywheel Magneto
MP3 250 i.e. Time Flywheel magneto FLYWHEEL Code Action Duration 001173 Rotor - Replacement 001058 Complete flywheel - Replace- ment 001067 Stator - Removal and Refit- ting 001087 Flywheel cover - replace TIME - 17...
Page 302: Butterfly Valve
MP3 250 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001047 Injector - Replacement 001023 Control unit - Replacement 001013 Intake manifold - change Exhaust pipe TIME - 18...
Page 303: Air Cleaner
MP3 250 i.e. Time MUFFLER Code Action Duration 001095 Muffler guard - Replacement 005138 Lambda probe - Replace- ment 001092 Exhaust manifold - Replace- ment 001009 Muffler - Replacement Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Replacement 001014 Air filter - Replacement /...
Page 304 MP3 250 i.e. Time Frame HASSIS Code Action Duration 004146 Front frame - Replacement 004116 Rear frame - Replacement 004001 Frame - replace 004147 footboard support bracket one side - Replacement 004143 Footrest support - replace TIME - 20...
Page 305 MP3 250 i.e. Time Centre-stand STAND Code Action Duration 001053 Stand bolt - Replacement 004179 Stand buffer - Replacement 004004 Stand - Replacement TIME - 21...
Page 306 MP3 250 i.e. Time Legshield spoiler RONT SHIELD Code Action Duration 004020 Headlight frame - Replace- ment 004064 Front shield - Replacement 004055 Turn indicator frame - Re- placement 004149 Shield central cover - Re- placement 004022 Shield lower section - Re- placement 004167 Grill / radiator cover - Re-...
Page 307 MP3 250 i.e. Time Side fairings SIDE COVERS Code Action Duration 004036 Lower chassis cover - Re- placement 004129 Rear fairing - Replacement 004085 Fairing (1) - Replacement 004068 Passenger handgrip - Re- placement 004037 Side aprons-Replacement TIME - 23...
Page 308: Rear Cover
MP3 250 i.e. Time Rear cover REAR SHIELD Code Action Duration 004065 Front shield, rear part - Re- moval and refitting TIME - 24...
Page 309 MP3 250 i.e. Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replacement 004135 Fuel tank port - Replacement 004011 Central chassis cover - Re- placement 004012 Rear fairings - Removal and refitting 004015 Footrest - Removal and Re- fitting 004075 Front mat - Replacement...
Page 310 MP3 250 i.e. Time Mudguard MUDGUARDS Code Action Duration 007015 Radiator air intake - Replace- ment 004009 Rear mudguard - Replace- ment 004181 Lower cover - Replacement 004184 Front mudguard support - re- placement 004002 Front mudguard - Replace- ment TIME - 26...
Page 311 MP3 250 i.e. Time Fuel tank UEL TANK Code Action Duration 004137 Injector pump pipe - Replace- ment 005010 Tank float - Replacement 004109 Fuel tank breather - Replace- ment 004168 Fuel tank cap - Replacement 004138 Fuel reverse pipe - Replace- ment 004005 Fuel tank - Replacement...
Page 312: Rear Shock Absorber
MP3 250 i.e. Time Rear shock-absorber EAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Re- moval and Refitting 003035 Shock absorber support and brake calliper - Replacement 003077 muffler/rear shock absorber support arm - Service TIME - 28...
Page 313: Handlebar Covers
MP3 250 i.e. Time Handlebar covers HANDLEBAR COVERS Code Action Duration 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE- MENT 004019 Rear handlebar covers - Re- placement 004026 Handlebar cover - Replace- ment 004018 Front handlebar covers - Re- placement TIME - 29...
Page 314: Handlebar Components
MP3 250 i.e. Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 002059 Right-hand knob - change 002060 Complete throttle control - Replacement 002063 Complete throttle control - Replacement 003001 Handlebar - Replacement 002071 Left knob - Replacement 003059 Counterweight - Replace- ment 002037 Brake lever - Replacement...
Page 315: Swinging Arm
MP3 250 i.e. Time Swing-arm SWINGING ARM Code Action Duration 004058 Silent block - Replacement 003081 Swinging arm support flange - replace 001072 Swinging arm - Engine-chas- sis connection - Replacement 003080 Swinging arm on frame - Re- placement TIME - 31...
Page 316 MP3 250 i.e. Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 32...
Page 317: Instrument Panel
MP3 250 i.e. Time Instrument panel NSTRUMENT PANEL Code Action Duration 004021 Shield upper section - Re- placement 005014 Odometer - Replacement 004099 Odometer housing - Replace- ment 004035 Instrument panel - Replace- ment TIME - 33...
Page 318: Turn Signal Lights
MP3 250 i.e. Time Locks OCKS Code Action Duration 004172 Rear case closure hook - Re- placement 005099 Electric saddle opening acti- vator - Replacement 004054 Saddle lock catch - Replace- ment 004001 Chassis - Replacement 005072 Immobilizer aerial - Replace- ment Turn signal lights Rear lights...
Page 319 MP3 250 i.e. Time EAR TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005005 Taillight - Replacement 005022 Rear turn indicators - Re- placement 005031 Licence plate light bulb - Re- placement 005032 Transparent licence plate cover - replace 005131 Licence plate light support - Replacement 005066 Rear light bulbs - Replace-...
Page 320 MP3 250 i.e. Time RONT TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005067 Front direction indicator bulb - Replacement 005012 Front direction indicators - Replacement 005002 Front light - Replacement 005008 Light bulbs - Replacement TIME - 36...
Page 321: Front Wheel
MP3 250 i.e. Time Front wheel RONT WHEELS Code Action Duration 003047 Front tyre - Replacement 003033 Front wheel hub- Replace- ment 003037 Front wheel rim- Replace- ment 005089 Tone wheel - Replacement 002041 Front brake disc - Replace- ment 004123 Front wheel - Replacement TIME - 37...
Page 322: Rear Wheel
MP3 250 i.e. Time Rear wheel EAR WHEEL Code Action Duration 002070 Rear brake disc - Replace- ment 001016 Rear wheel - Replacement 001071 Front wheel rim - Removal and refitting 004126 Rear wheel tyre - Replace- ment TIME - 38...
Page 323: Electric Devices
MP3 250 i.e. Time Electric devices LECTRICAL DEVICES Code Action Duration 005075 Stop remote control - Re- placement 005035 Headlight remote control - Replacement 005011 Start-up remote control switch - Replacement 005007 Battery - Replacement 005003 Horn - Replacement TIME - 39...
Page 324 MP3 250 i.e. Time ABLE HARNESS Code Action Duration 005001 Electrical system - Replace- ment 005114 Electrical system - Service TIME - 40...
Page 325: Electronic Controls
MP3 250 i.e. Time Electronic controls ANDLEBAR CONTROLS Code Action Duration 005017 Stop switch - Replacement 005077 Emergency stop switch - Re- placement 005041 Starter button - Replacement 004010 Anti-theft lock - Replacement 005040 Horn button - Replacement 005006 Light switch or turn indicators - Replacement 005039 Headlight switch - replace...
Page 326 MP3 250 i.e. Time Transmissions OCKS TRANSMISSIONS Code Action Duration 003094 Tilt locking calliper control ca- ble - replacement 002082 Fuel tank cap opening drive - Replacement 002083 Saddle opening transmission - Replacement 002093 Trunk opening transmission - Replacement 003061 Accelerator transmission - Adjustment TIME - 42...
Page 327 MP3 250 i.e. Time Helmet bay ELMET COMPARTMENT Code Action Duration 005046 Battery cover - change 005026 Helmet compartment bulb - Replacement 005027 Helmet compartment bulb support - Replacement 004016 Helmet compartment - Re- placement TIME - 43...
Page 328 MP3 250 i.e. Time Rear side fairings EAR COVERS Code Action Duration 004081 Glove box door - Replace- ment 004174 Trunk leverage 004141 Cat's eye - Replacement 005048 Licence plate holder - Re- placement 004082 Trunk gasket - Replacement TIME - 44...
Page 329: Front Suspension
MP3 250 i.e. Time Front suspension FRONT SUSPENSION Code Action Duration 003010 Front suspension - Service 003111 Side steering tube - replace- ment 003038 Front wheel axle - Removal and Refit. 003040 Front wheel bearings - Re- placement 003107 Sliding stems - replacement 003113 Front shock absorber - re- placement...
Page 330 MP3 250 i.e. Time Cooling system OOLING SYSTEM Code Action Duration 007013 Radiator expansion tank con- nection pipe - Replacement 001052 Coolant and air bleed - Re- placement 007001 Expansion tank - Replace- ment 007024 Expansion tank cap - Re- placement 007003 Coolant delivery and return...
Page 331 MP3 250 i.e. Time Braking system RAKE SYSTEM Code Action Duration 002025 Brake piping - Replacement 003096 Tilt locking calliper- replace- ment 003100 Tilt locking calliper pads - re- placement 003108 Parking brake flexible trans- mission - replacement 003109 Parking brake mechanical calliper - replacement 002002 Shoes - Rear brake pads -...
Page 332 MP3 250 i.e. Time Code Action Duration 003103 Splitter for suspension lock- ing system hoses- replace- ment 003102 Hoses for the splitter-calliper suspension locking system - replacement 003088 Tilt locking hydraulic pump - replacement 002021 Front brake piping - Replace- ment 002007 Front brake pads - Replace-...
Page 333 MP3 250 i.e. Time WINDSHIELD Code Action Duration 004101 Windshield - Replacement Stickers RANSFERS Code Action Duration 004066 Driving mirror - Replacement 004159 Plates / Stickers - Replace- ment TIME - 49...
Page 334 MP3 250 i.e. Time The tilt mechanism ILT MECHANISM Code Action Duration 003073 Steering clearance - Adjust- ment 003112 Central steering tube - re- placement 003002 Steering fifth wheel - Re- placement 003115 Parallelogram arms - re- placement 003114 Parallelogram bearings - re- placement 003116 Steering rod - replacement...
Page 335 MP3 250 i.e. Time Geared motor EARED MOTOR Code Action Duration 003101 Tilt locking calliper control lever - replacement 005009 Voltage regulator - replace 003095 Tilt locking calliper support bracket - replacement 001069 HV coil - replace 001094 Spark plug cap - Replace- ment 003120 Tilt locking control unit - re-...
Page 336 MP3 250 i.e. Time Code Action Duration 003089 Geared motor potentiometer - replacement TIME - 52...

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PIAGGIO 633823 Service Station Manual

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