Page 1 SERVICE STATION MANUAL 633929(IT)-633930(EN)-633931(FR)-633932 (ES)-633937(ES)-633938(PT)-633941(NL)-633942 (EL) MP3 125...
Page 2 Not all versions shown in this publication are available in all Countries. The availability of individual versions should be confirmed with 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 125 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 CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE 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 MP3 125 Characteristics Vehicle identification Chassis prefix (FULL OPTIONAL): ZAPM47301 Chassis prefix (BASE): ZAPM300 Engine prefix: M473M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Dry weight (FULL OPTIONAL) 210 ± 5 kg Dry weight (BASE) 199 ± 5 kg Wheelbase 1490 mm Height...
Page 10: Electrical System
MP3 125 Characteristics Engine DATA Specification Desc./Quantity Type single-cylinder, four-stroke Timing system single overhead camshaft chain driven on the left- hand side, three-arm rocking levers set up with threaded set screw Bore x stroke 57 x 48.6 mm Cubic capacity 124 cm³...
Page 11: Wheels And Tyres
MP3 125 Characteristics Specification Desc./Quantity Battery 12V-12Ah Generator Three-phase alternating current 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.
Page 12: Tightening Torques
MP3 125 Characteristics Tightening Torques STEERING Name Torque in Nm Steering lower ring nut (central headstock) 22 ÷ 27 loosen by 90° Steering upper ring nut (central headstock) 27 ÷ 33 Handlebar fixing screw 50 ÷ 55 Fixing screws for handlebar control assembly U- 7 ÷...
Page 13 MP3 125 Characteristics Name Torque in Nm Shock absorber-crankcase attachment bracket 20 ÷ 25 Rear wheel axle 104 ÷ 126 Muffler arm clamping screws 27 ÷ 30 FRONT BRAKE Name Torque in Nm Oil bleed screw 8÷12 Disc tightening screw (°) 5 - 6 Brake fluid pump - hose fitting 16 ÷...
Page 14: Assembly Clearances
MP3 125 Characteristics Name Torque in Nm Timing chain tensioner central screw 5 - 6 Timing chain tensioner support screw 11 ÷ 13 Starter ground support screw 11 ÷ 15 Timing chain tensioner slider screw 10 ÷ 14 Inlet manifold screws 11 ÷...
Page 15 MP3 125 Characteristics Cylinder - piston assy. ENGINE COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059 Piston 57.011 ÷ 57.018 56.959 ÷...
Page 16 MP3 125 Characteristics Crankcase - crankshaft - connecting rod RANKSHAFT Titolo Durata/Valore Testo Breve (< 4000 Indirizzo Immagine car.) Crankshaft Crankshaft to crankcase axial clearance Crankshaft to crankcase axial clearance CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05 D = 0.20 - 0.50 mission side...
Page 17 MP3 125 Characteristics Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.
Page 18 MP3 125 Characteristics Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.
Page 19 MP3 125 Characteristics Product Description Specifications 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 Mineral oil with specific additives for increased adhesiveness AGIP GP 330 Calcium complex soap-based Grease (brake control levers, grease with NLGI 2;...
Page 20 MP3 125 Characteristics CHAR - 14...
Page 21 INDEX OF TOPICS TOOL OOLING...
Page 22 MP3 125 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 020055Y...
Page 23 MP3 125 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 24 MP3 125 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 25 MP3 125 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 26 MP3 125 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 27 MP3 125 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 28 MP3 125 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 29 MP3 125 Tooling Stores code Description 020489Y Hub cover support stud bolt set 020428Y Piston position check support 020621Y HV cable extraction adaptor 001467Y035 Belle for OD 47-mm bearings 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15-mm bear- ings TOOL - 9...
Page 30 MP3 125 Tooling Stores code Description 020627Y Flywheel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020480Y Petrol pressure check set 020244Y 15 mm diameter punch TOOL - 10...
Page 31 MP3 125 Tooling Stores code Description 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent bloc 001467Y017 Driver for OD 36 mm bearings 020234y extractor 020441Y 26 x 28 mm adaptor 020362Y 12 mm guide 020358Y 37x40-mm adaptor TOOL - 11...
Page 32 MP3 125 Tooling Stores code Description 001467Y002 Driver for OD 73 mm bearing 020641Y EFI Technology software up- grade 020469Y Reprogramming kit for scooter diagnosis tester 020639Y Tilt locking control unit software 020481Y Control unit interface wiring TOOL - 12...
Page 33 MP3 125 Tooling Stores code Description 020481Y004 Parking control unit interface wir- 020460Y Scooter diagnosis and tester TOOL - 13...
Page 34 MP3 125 Tooling TOOL - 14...
Page 35 INDEX OF TOPICS MAIN AINTENANCE...
Page 36: Maintenance Chart
MP3 125 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 37 MP3 125 Maintenance 6.000 FTER 130' Action Hub oil level - check Spark plug/ electrode gap - check Air filter - clean Sliding blocks / variable speed rollers - check Driving belt - check Coolant level - check Brake pads - check condition and wear Brake fluid level - check Tilt locking gripper control cable - adjustment Electrical system and battery - check...
Page 38 MP3 125 Maintenance Action Sliding blocks / variable speed rollers - check Driving belt - check Coolant level - check Radiator - external cleaning/ check Brake pads - check condition and wear Brake fluid level - check Tilt locking gripper control cable - adjustment Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test...
Page 39 MP3 125 Maintenance Action Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test Engine oil - change Oil filter -Replacement 36.000 FTER 260' Action Engine oil - replacement Hub oil level - check Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change...
Page 40: Checking The Spark Advance
MP3 125 Maintenance Action Brake pads - check condition and wear Brake fluid hoses - replacement Brake fluid level - check Tilt locking gripper control cable - adjustment Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test...
Page 41 MP3 125 Maintenance - 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 42: Spark Plug
MP3 125 Maintenance Spark plug To service the spark plug the engine must be cold, proceed as follows: - Undo the knob located inside the rear case and remove the saddle. - Remove the spark plug cap. - Use the supplied spanner (with retaining rubber ring) to remove the spark plug.
Page 43 MP3 125 Maintenance Spark plug NGK CR 8EB Locking torques (N*m) Spark plug 12 ÷ 14 Hub oil Make sure that there is oil in the rear hub (amount of oil contained ~ 150 cm³). To check the rear hub oil level, proceed as follows: 1) Park the scooter on level ground and place it on the centre stand.
Page 44: Air Filter
MP3 125 Maintenance UPON REPLACING HUB OIL, AVOID THE OIL COMING INTO CONTACT WITH THE REAR BRAKE DISC. Recommended products AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Check - Rest the vehicle on its centre stand on an even surface. - Unscrew the oil dipstick, dry it with a clean cloth and reinsert it, screwing it in thoroughly.- Take out the dipstick and check that the oil level reaches the 2nd notch from the bottom.- Screw the dipstick back into place completely.
Page 45: Engine Oil
The engine oil and cartridge filter, "C", must be re- placed after the first km, and every 6.000 km there- after, by an Authorised Piaggio Service Cen- tre. The engine should be emptied by draining the oil from the drainage cap "B" of the gauze filter on the flywheel side.
Page 46 MALFUNCTIONING. CAUTION USED OILS CONTAIN SUBSTANCES HARM- FUL TO THE ENVIRONMENT. FOR OIL RE- PLACEMENT, CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE, AS THEY ARE EQUIPPED TO DISPOSE OF SPENT OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY. CAUTION USING OILS OTHER THAN THOSE RECOM- MENDED CAN SHORTEN THE LIFE OF THE ENGINE.
Page 47: Checking The Valve Clearance
MP3 125 Maintenance Checking the ignition timing -Remove the 4 fixing screws and move away from the engine the flywheel cover fitted with a water pump and cooling manifolds. -Rotate the flywheel until the reference matches the crankcase operation end as shown in the figure (TDC).
Page 48: Headlight Adjustment
MP3 125 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 49 MP3 125 Maintenance Align the drive with the reference on the crankcase cover. Place the flywheel in the TDC position and align the references as shown in the figure. Check the correct fitting of the 2 reference dowels and fit the engine cover. Be careful to properly fit the flywheel connector to the relative supplements.
Page 50 MP3 125 Maintenance MAIN - 16...
Page 51 MP3 125 Maintenance Undo the 3 fixing screws "A", remove the secon- dary air filter cover and then take out the filtering element "B". - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of com- pressed air.
Page 52 MP3 125 Maintenance MAIN - 18...
Page 53 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 54 MP3 125 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 Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve Remove, wash with solvent and dry with com- damaged pressed air or replace...
Page 55 MP3 125 Troubleshooting Possible Cause Operation Rpm too low at start-up or engine and start-up Check the starter motor, the system and the torque system damaged limiter Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clear- ance Engine flooded Try starting-up with the throttle fully open.
Page 56 MP3 125 Troubleshooting Possible Cause Operation Oil level too low Restore the level using the recommended oil type (Selenia HI Scooter 4 Tech) Engine tends to cut-off at full throttle ENGINE STOP FULL THROTTLE Possible Cause Operation Faulty fuel supply Check or replace the pump and the vacuum valve, check the vacuum intake and the pipe sealing Incorrect float level...
Page 57 MP3 125 Troubleshooting High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Float level Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted.
Page 58 MP3 125 Troubleshooting Insufficient braking NSUFFICIENT BRAKING 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 59: Rear Wheel
MP3 125 Troubleshooting Possible Cause Operation control the lights are not steadily on, replace the control unit; otherwise, check the cable harness and the switch. Steering and suspensions Rear wheel REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause Operation Idling rpms too high Adjust the engine idle speed and the CO%, if nec- essary.
Page 60 MP3 125 Troubleshooting TROUBL - 8...
Page 61 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 62 MP3 125 Electrical system 1. Electronic ignition device 2. Immobilizer aerial 3. Throttle body position 4. Magneto flywheel Pick-up 5. CDI temperature sensor 6. Diagnostics socket 7. Engine stop switch 8. Voltage regulator 9. Main fuses 10. Battery 11. Starter motor 12.
Page 63 MP3 125 Electrical system 20. Turn signal switch 21. Saddle opening receiver 1. Aerial 2. Actuator 1 3. Reset 4. +Battery 6. Key 7. Ground 11. Channel 1/3 selection 12. Alarm code out 22. Saddle opening actuator 23. Reset 24. Hazard button 25.
Page 64 MP3 125 Electrical system C. High-beam bulb 34. Front right turn indicator 35. Horn button 36. Remote control headlight 37. Light switch 38. Helmet compartment light switch 39. Helmet compartment light switch 40. Instrument panel coolant temperature sensor 41. Mode button 42.
Page 65 MP3 125 Electrical system 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 Conceptual diagrams Ignition 1. Electronic ignition device 2. Immobilizer aerial 9. Main fuses 10.
Page 66 MP3 125 Electrical system Battery recharge and starting 1. Electronic ignition device 4. Magneto flywheel Pick-up 7. Engine stop switch 8. Voltage regulator 9. Main fuses 10. Battery 11. Starter motor 12. Start up remote control switch 13. Starter button 14.
Page 67 MP3 125 Electrical system 31. Rear right turn indicator A. Tail light bulb B. Stop light bulb C. Right turn indicator bulbs 60. Starter Level indicators and enable signals section 1. Electronic ignition device 2. Immobilizer aerial 3. Throttle body position 5.
Page 68 MP3 125 Electrical system 49. Right wheel revolution sensor 50. Left wheel revolution sensor 51. Potentiometer 52. Rider presence sensor 53. Oil pressure sensor 54. External temperature sensor 56. Instrument panel 57. Fuel level transmitter Devices and accessories 1. Electronic ignition device 6.
Page 69 MP3 125 Electrical system 21. Saddle opening receiver 1. Aerial 2. Actuator 1 3. Reset 4. +Battery 6. Key 7. Ground 11. Channel 1/3 selection 12. Alarm code out 22. Saddle opening actuator 23. Reset 25. Wiring for Tom-Tom 27. Wiring for antitheft device 28.
Page 70 MP3 125 Electrical system Lights and turn indicators 7. Engine stop switch 9. Main fuses 10. Battery 14. Secondary fuses 18. Key switch 20. Turn signal switch 24. Hazard button 26. Hazard and turn signal control device 1. Hazard button 2.
Page 71 MP3 125 Electrical system A. Left turn indicator bulbs B. Stop light bulb C. Tail light bulb 30. Licence plate lamp 31. Rear right turn indicator A. Tail light bulb B. Stop light bulb C. Right turn indicator bulbs 32. Front left turn indicator 33.
Page 72 MP3 125 Electrical system When the key switch is turned to "ON", this blinking function is deactivated. A flash then confirms the system has switched to "ON". The duration of the flash depends on the electronic control unit program (see figure). If the led turns off and remains so when switching to "ON", it is necessary to check if there is battery voltage in the electric control unit.
Page 73 MP3 125 Electrical system Virgin circuit If the ignition system has not been programmed, the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evi- dent loss of power may be felt. Program the system with the MASTER (Brown) and SERVICE (Black) keys as follows: - Insert the MASTER key, turn it to "ON"...
Page 74 MP3 125 Electrical system 2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial. Ignition disabled-Vehicle immobilised 3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans- ponder code. Ignition disabled-Vehicle immobilised Diagnostic code - 2 flashes Diagnosis code: 2-flashes When the 2-flash code is detected, carry out the following checks: - Check if the failure continues after changing key (MASTER key included).
Page 75 MP3 125 Electrical system To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient. No spark plug Once the lack of power to the spark plug has been detected and the led indicates it can be ignited, follow this procedure: - Pick-Up check.
Page 76 MP3 125 Electrical system Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor. Electric characteristic High voltage coil secondary resistance value High voltage coil secondary resistance value: ~ 3000 ±...
Page 77 MP3 125 Electrical system High voltage coil voltage value: > 100 Volt Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse.
Page 78 MP3 125 Electrical system - With a tester, check the circuit between connec- tions 5-3 and 5-1 is not interrupted. - Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Ω Minimum oil pressure switch check - With a tester, check the circuit between connec- tions 4 and ground (with engine off) is not inter-...
Page 79 MP3 125 Electrical system Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive terminal, measure the bat- tery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V.
Page 80 MP3 125 Electrical system positive probe to terminal No. 8 (Orange), and the negative one to terminal No. 10 (Brown) (see fig- ure). Replace the control unit if there is no voltage; oth- erwise, check the wiring connections between the starter and the control unit.
Page 81 MP3 125 Electrical system Fuses The electrical system has eleven fuses divided into 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 82 MP3 125 Electrical system Specification Desc./Quantity from the battery: parking control ECU Location:battery compartment Fuse No. 6 Capacity: 4A Protected circuits:start-up, stop lights. Location:footrest Fuse No. 7 Capacity: 4A Protected circuits:panel lighting, tail lights, license plate light Location:footrest Fuse No. 8 Capacity: 7.5 A Protected circuits:lights switch, horn, wiring for Tom-Tom...
Page 83 MP3 125 Electrical system Q = Front suspension locking system failure warn- ing light (if available) R = Warning light for parking brake engaged C = High-beam warning light Pushing the «CLOCK» button for less than 1 second displays the following sequence: •...
Page 84 MP3 125 Electrical system 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 nominal capacity of the battery - Charge time: 5 h CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Page 85 MP3 125 Electrical system - Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge. Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw.
Page 86 MP3 125 Electrical system 12-WAY INSTRUMENT CONNECTOR Specification Desc./Quantity Lighting Battery positive Earth Live positive lead Remote seat opening 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 87 MP3 125 Electrical system 2. Turn the key to «ON», press the button on the remote control, release the button, turn the key back to «OFF» from the «ON» position, all within 4 seconds. 3 Wait 1 to 8 seconds. 4.
Page 88 MP3 125 Electrical system ELE SYS - 28...
Page 89 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 90 MP3 125 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 91 MP3 125 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 92 MP3 125 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 93 MP3 125 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. - Use a jack to support the vehicle properly.
Page 94 MP3 125 Engine from vehicle PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY. ENG VE - 6...
Page 95 INDEX OF TOPICS NGINE...
Page 96: Automatic Transmission
MP3 125 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 97 MP3 125 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 020376Y Adaptor handle...
Page 98: Inspecting The Clutch Drum
MP3 125 Engine Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.
Page 99: Removing The Clutch
MP3 125 Engine - Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic support for dial gauge Characteristic...
Page 100 MP3 125 Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EX- HIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN- OTHER.
Page 101 MP3 125 Engine Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - Replace with a new one if there are. - Remove the retaining ring using two flat blade screwdrivers. - Support the pulley bushing adequately from the threaded side using a wooden surface.
Page 102 MP3 125 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. Characteristic Movable driven half-pulley max. diameter Max. diameter admitted: Ø 41.08 mm Movable driven half-pulley standard diameter Standard diameter: Ø...
Page 103: Refitting The Driven Pulley
MP3 125 Engine Refitting the driven half-pulley bearing - Support the pulley bushing adequately from the threaded side using a wooden surface. - Fit a new roller sleeve as in the figure. - For the fitting of the new ball bearing, follow the example in the figure using a modular punch.
Page 104 MP3 125 Engine - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings (A) shown in the figure. - Fit the half-pulley over the bushing using the ap- propriate tool - Check that the pins are not worn and proceed to refitting them in their slots.
Page 105 MP3 125 Engine Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 106 mm Acceptable limit after use: 101 mm Refitting the clutch - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis.
Page 106 MP3 125 Engine - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the appropri- ate tool. - Preload the clutch contrast spring with a traction/ rotation combined action until it reaches the pul- leys maximum opening and place the belt on the minimum rolling diameter.
Page 107: Removing The Driving Pulley
MP3 125 Engine Drive-belt • Check that the driving belt is not dam- aged. • Check the width of the belt is adequate. Characteristic Driving belt - standard width: 22.5 ± 0.2 mm Driving belt - minimum width: 21.5 mm During the wear checks foreseen in the scheduled maintenance services at 6,000 km;...
Page 108 MP3 125 Engine Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure the pulley sliding bushing outside di- ameter shown in the figure. - Check that the rollers are not damaged or worn.
Page 109 MP3 125 Engine Refitting the driving pulley - Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation. - Check that the roller contact plate does not have flaws and is not damaged on the grooved edge.
Page 110 MP3 125 Engine - Correctly refit the previously removed Bendix back to its position. - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread Loctite 243 Quick Set threadlock on the thread and tighten the nut to the prescribed torque. - Avoid the half-pulley rotation with the appropriate stop key tool..
Page 111 MP3 125 Engine End gear 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 112 MP3 125 Engine Removing the wheel axle bearings Hold up the hub cover and take out the bearing. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide With the appropriate tools, remove the oil seal as shown in the figure.
Page 113 MP3 125 Engine Removing the driven pulley shaft bearing When removing the driven pulley shaft, the corre- sponding bearing and oil seal, remove the trans- mission cover and the clutch group as explained 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 114 MP3 125 Engine Refitting the wheel axle bearing Support the hub cover on a wooden surface. - Heat the cover crankcase with special heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure. Specific tooling 020150Y Air heater support 020151Y Air heater...
Page 115 MP3 125 Engine Refitting the hub cover bearings In order to fitting of the hub box bearings, the en- gine 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 116 MP3 125 Engine Refitting the ub cover - Fit a new gasket together with the centring dowels. - Seal the gasket of the breather pipe using black silicone sealant. - Fit the gearbox cover, making sure the breather pipe is in the correct position. - Place the 3 shortest screws, identifiable by their different colour, as shown in the figure.
Page 117: Removing The Stator
MP3 125 Engine Flywheel cover Removing the hub cover - Remove the two clamps, the two couplings and empty the cooling system. - Remove the 4 retainers and the flywheel cover Removing the stator - Remove the electric terminal of the minimum oil pressure switch.
Page 118 MP3 125 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. - Place the cable harness as shown in the figure. - Stator screws and Pick-Up N.B.
Page 119 MP3 125 Engine Removing the flywheel magneto - Lock the rotation of the Flywheel with the calliper spanner tool. - Remove the nut. - Take out the flywheel. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS N.B.
Page 120 MP3 125 Engine Locking torques (N*m) Flywheel nut 54 ÷ 60 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. Locking torques (N*m) Starter motor screws 11 ÷...
Page 121 MP3 125 Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: 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 122 MP3 125 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 123 MP3 125 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 124: Removing The Cylinder Head
MP3 125 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket.
Page 125 MP3 125 Engine CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. ENG - 31...
Page 126: Inspecting The Small End
MP3 125 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 SHOWS SIGNS OF WEAR OR OVERHEATING.
Page 127 MP3 125 Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. - Calculate the coupling clearance between pin and connecting rod end. - Measure the capacity diameter on the piston. - Calculate the piston pin coupling clearance. - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis.
Page 128 MP3 125 Engine Characteristic Pin diameter Standard diameter: 56.997 ÷ 57.025 piston diameter 56.945 ÷ 56.973 mm Pin diameter: Standard clearance 0.015 ÷ 0.029 mm Pin diameter Standard diameter 14.996 - 15.000 mm Wrist pin seat on the piston: Standard diameter 15.001 ÷...
Page 129: Inspecting The Piston
MP3 125 Engine Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
Page 130 MP3 125 Engine N.B. THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY. Specific tooling 020430Y Pin lock fitting tool Choosing the gasket - Provisionally fit the piston into the cylinder, with- out any base gasket. - Assemble a dial gauge on the specific tool Support to check piston position 020428Y - Set the dial gauge to zero placing the tool on a contrasting surface.
Page 131 MP3 125 Engine - By means of the table shown in the specifications chapter identify the cylinder base gasket thickness to be used for refitting. The proper identification of the cylinder base gasket thickness allows main- taining the correct compression ratio. - Remove the specific tool and the cylinder.
Page 132: Inspecting The Cylinder Head
MP3 125 Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure. N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
Page 133 MP3 125 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 134 MP3 125 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 135 MP3 125 Engine CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFUL- LY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
Page 136 MP3 125 Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. 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.
Page 137 MP3 125 Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new...
Page 138 MP3 125 Engine Cam shaft check: Maximum admissible axial clearance 0.42 mm Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm Cam shaft check: Standard height Outlet: 29.209 mm Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Minimum admissible diame- Bearing B diameter: 19.950 mm Cam shaft check: Minimum admissible diame- Bearing A Ø: 36.94 mm...
Page 139 MP3 125 Engine Fit the pins and rocking levers. - Lubricate the two rocking levers through the holes at the top. - 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 140 MP3 125 Engine Assemble the limiting bell using the counterweight fixing screw as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Limiting bell screw 11 ÷ 15 Nm Set the tensioner cursor to the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the pre- scribed torque.
Page 141 MP3 125 Engine Name Torque in Nm Counterweight screw 7 ÷ 8.5 Plate screws 4 ÷ 6 Nm Slider screw 10 ÷ 14 Nm - 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.
Page 142 MP3 125 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 143 MP3 125 Engine - Remove the two retainers indicated in the figure and the starter motor. Before opening the engine crankcase, it is advis- able to check axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge.
Page 144 MP3 125 Engine Fitting clearance Connecting rod axial clearance 0.20 - 0.50 Check the radial clearance on the connecting rod. Standard clearance: 0.036 ÷ 0.054 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
Page 145 MP3 125 Engine Check the diameters of both bearings of the crank- shaft according to the axes and surfaces shown in the figure. The half-shafts are classified in two cat- egories Cat. 1 and Cat. 2 as shown the chart below.
Page 146 MP3 125 Engine To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
Page 147 MP3 125 Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take particular care when handling the oil pump com- partment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the trans- mission side (see diagram).
Page 148 MP3 125 Engine ERABLY DECREASE THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRES- SURE. N.B. THE HEAD LUBRICATION CHANNEL IS PRO- VIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP.
Page 149 MP3 125 Engine - There is only one type of main bushing housing hole in the crankcase The standard bushing diameter after driving is var- iable on the basis of a coupling selection. - The bushing housings in the crankcase are avail- able in two categories, Cat.
Page 150 MP3 125 Engine Crankcase Engine half Bushing halves shaft Cat. 1 Cat. 1 Cat. 2 Cat. 2 Cat. 1 Cat. 2 Cat. 2 Cat. 1 N.B. TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.
Page 151 MP3 125 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 152 MP3 125 Engine ENG - 58...
Page 153: Oil Pressure Check
MP3 125 Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electrical con- nexion of the minimum oil pressure switch and then remove the switch. - With engine idling at 1650 rpm check that the oil pressure is between 0.5 ÷ 1.2 atm. - With engine at 6000 rpm check that the oil pressure is between 3.2 ÷...
Page 154 MP3 125 Engine Refitting - Fit the internal bulkhead by locking the two screws to the prescribed torque. - Fit the oil filter fitting and tighten it to the specified torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, to- gether with the locating dowels.
Page 155: Oil Pump
MP3 125 Engine Oil pump - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
Page 156 MP3 125 Engine - Remove the screw, the by-pass piston, the gas- ket and centring dowels shown in the figure. 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 defective parts.
Page 157 MP3 125 Engine - Refit the drive pulley assembly, the drive belt, the sprocket wheel and the transmission cover, as de- scribed in the "Transmissions" chapter. - When testing the lubrication system, refer to chapter "Crankcase and Crankshaft", regard- ing lubrication of the crankshaft and connect- ing rod Locking torques (N*m) Oil sump screws 10 ÷...
Page 158 MP3 125 Engine Inspecting the cut-off - Remove the SAS valve - Connect the MITYVAC pump in depression mode (VACUUM) to the depression valve socket CUT - - Apply a vacuum value higher than 0.5 BAR - Check that this value is kept at all times - If a worn seal is detected, replace it.
Page 159: Fuel Supply
MP3 125 Engine 020329Y MityVac vacuum-operated pump Fuel supply Removing the carburettor - To detach the carburettor from the engine, it is necessary to move the air filter and remove the throttle control transmission, the automatic starter connection, the clamps anchoring the carburettor to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, the heater, the intake fitting and the TPS cable.
Page 160 MP3 125 Engine - Remove the 2 screws and the starter support with the gasket. - Remove the 4 fixing screws shown in the figure and the vacuum chamber cover. WARNING DURING THE REMOVAL OF THE CARBURET- TOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
Page 161 MP3 125 Engine Remove the tapered pin from the vacuum-operat- ed valve - Remove the 4 screws indicated in the figure. - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B.
Page 162 MP3 125 Engine Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side. - Remove the float and the plunger. - Remove the maximum nozzle -Remove the maximum nozzle. ENG - 68...
Page 163 MP3 125 Engine -Remove diffuser. - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT. -Remove the minimum nozzle.
Page 164 MP3 125 Engine - Remove the minimum flow set screw and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EM- BEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR PRO- GRESSIONS AND INLET NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL SHAFT.
Page 165 MP3 125 Engine - For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by flow screw, progression holes near the throttle valve. - For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations.
Page 166 MP3 125 Engine - Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the noz- zle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser. - Assemble the diffuser making sure the sprayer is being adequately inserted and lock it.
Page 167 MP3 125 Engine - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air. - Reassemble the acceleration pump valves fol- lowing this order: INTAKE VALVE (A) •...
Page 168 MP3 125 Engine - Adjust the carburettor by turning the screw twice from the close position. Level check - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
Page 169 MP3 125 Engine - Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover. - Tighten the screws. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws.
Page 170 MP3 125 Engine With a 12V battery power the automatic starter and check that the piston protrudes as much as possi- ble. - The correct warm up time depends on the ambi- ent temperature. - If protrusion, resistance or timing values are dif- ferent from the ones prescribed, replace the start- - Assemble the starter to the carburettor being careful to position the O-Ring correctly, insert the...
Page 171 MP3 125 Engine Adjusting the idle - The engine does not require frequent idle speed adjustments, but it is essential to strictly follow cer- tain rules when adjusting the idle speed. - Before adjusting the carburettor make sure to re- spect the lubrication requirements, valve clear- ance, and complying timing, spark plug should be in optimum conditions, air filter clean and sealed,...
Page 172 MP3 125 Engine ENG - 78...
Page 173 INDEX OF TOPICS SUSP USPENSIONS...
Page 174: Removing The Front Wheel
MP3 125 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 175 MP3 125 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 - Refit the ball bearing locking seeger ring...
Page 176 MP3 125 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. •...
Page 177 MP3 125 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 178 MP3 125 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 179 MP3 125 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 180 MP3 125 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 181 MP3 125 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 182 MP3 125 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 183 MP3 125 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 184 MP3 125 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 185 MP3 125 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 186 MP3 125 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 187 MP3 125 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 188 MP3 125 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 189 MP3 125 Suspensions CIDENTALLY SWALLOWED, DRINK LARGE 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 190 MP3 125 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 191 MP3 125 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 192 MP3 125 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 193 MP3 125 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 194 MP3 125 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 195 MP3 125 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. Locking torques (N*m) Electric motor coupling screws 11 ÷...
Page 196 MP3 125 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 197 MP3 125 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 198 MP3 125 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 199 MP3 125 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 200 MP3 125 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 201 MP3 125 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 202 MP3 125 Suspensions 1: PRESSURE SWITCH 2: HORN REMOTE CONTROL 3: FUSE No. 11, 7.5A 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 203 MP3 125 Suspensions Check the continuity of the yellow - red cable be- tween the pressure switch connector and the fuse- box and between the remote control base and the fuse-box. With a multimeter, also check the pressure switch operation as well as the continuity at rest as this is normally closed switch.
Page 204 MP3 125 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 13.FUSE No.
Page 205 MP3 125 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 - 33...
Page 206 MP3 125 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 POTENTIOMETER 1: POTENTIOMETER SUSP - 34...
Page 207 MP3 125 Suspensions 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). Check that the voltage in the activated lock- ing condition is 4V and 1V in the locking rest condition.
Page 208 MP3 125 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 209 MP3 125 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. EARTH 2.
Page 210 MP3 125 Suspensions 1: TILT LOCKING CALLIPER SENSOR The tilt locking calliper sensor is a normally opened switch. Check its correct operation with a multi- meter. SUSP - 38...
Page 211 MP3 125 Suspensions 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. Check the continuity of the connector black cable and an earth point on the chassis Also check that the flexible transmission control lever activates the limit stop switch properly.
Page 212 MP3 125 Suspensions 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° With interface wiring disconnected from the control unit, check the continuity between pin 23 and the brown cable of the LEFT wheel revolution sensor...
Page 213 MP3 125 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 - 41...
Page 214 MP3 125 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 - 42...
Page 215: Wheel Alignment
MP3 125 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. Wheel alignment Tool fitting Metodo di utilizzo dell'attrezzatura •...
Page 216 MP3 125 Suspensions con le necessarie riparazioni e succes- sive regolazioni. Characteristic Front tyre pressure (rider) Front tyre pressure (rider): 1.6 bar Rear tyre pressure (rider) Rear tyre pressure (rider): 2 bar • Get the vehicle off the stand, back on the ground.
Page 217 MP3 125 Suspensions • Fit the bracket locking the parallelo- gram in the holes of the previously re- moved screws; use the screws sup- plied with the tool and be careful to correctly centre the spacer in the bear- ing. •...
Page 218 MP3 125 Suspensions • Place the frame so that the sliders come into contact with the rim maxi- mum diameter but without interfering with the tyre. If required, reposition the frame by operating the 3 adjustable support feet. • Fit the frame locking bracket •...
Page 219: Removing The Rear Wheel
MP3 125 Suspensions • Check that the pointers of both tyres are correctly aligned, as shown in the photograph. Maximum misalignment allowed: 4 notches 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...
Page 220 MP3 125 Suspensions - Remove the cotter pin, the cap, the wheel axle fixing nut and the outer one of the two spacers. - 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.
Page 221 MP3 125 Suspensions Removal - Place the scooter on its centre stand; - Remove the swinging arm/engine fitting shown in the photo - Move the engine back - 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...
Page 222 MP3 125 Suspensions - Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause exces- sive clearance on the rear suspension. Overhaul - Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side.
Page 223 MP3 125 Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo. - Using a suitable pin remove the roller casings as shown in the photographs - Using an appropriate tool plant new roller cas- ings, being careful to position the bearings with the...
Page 224 MP3 125 Suspensions Length of the swinging arm tube on the frame side: 283 ± 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in the position shown in the photograph - Adjust the bolt as shown in the photograph - Position the frame side swinging arm with the...
Page 225 MP3 125 Suspensions - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the tool is centred properly on the support - Install a new silent bloc, making sure it aligns properly with the reference tooth.
Page 226: Shock Absorbers
MP3 125 Suspensions -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque. Locking torques (N*m) Engine-swinging arm bolt 55 ÷ 61 Frame-swinging arm bolt 55 ÷ 61 Swinging arm buffer nut 64 - 72 Engine arm bolt - frame arm 33 ÷ 41 Shock absorbers Removal Proceed as follows:...
Page 227 MP3 125 Suspensions 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. - Remove the centre stand.
Page 228 MP3 125 Suspensions SUSP - 56...
Page 229 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 230: Rear Brake Calliper
MP3 125 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 231 MP3 125 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 232: Brake Pipes
MP3 125 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 233 MP3 125 Braking system Unscrew the braking splitter screw. Disconnect the brake pipes removing the two met- allic straps indicated in the figure. Remove the brake oil tube fitting from the rigid pipe inside the front suspension arm and loosen the hydraulic joint fixing nut of the suspension locking to release the brake pipes.
Page 234: Parking Brake
MP3 125 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 235 MP3 125 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 236 MP3 125 Braking system BRAK SYS - 8...
Page 237 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 238 MP3 125 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 - Loosen the screw by two turns until the commu-...
Page 239 INDEX OF TOPICS CHAS HASSIS...
Page 240 MP3 125 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 241 MP3 125 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 242 MP3 125 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. See also...
Page 243 MP3 125 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. - Remove the spoiler.
Page 244 MP3 125 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 245 MP3 125 Chassis - Remove the key switch plastic ring and the two plastic covers near the footrest. - 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.
Page 246 MP3 125 Chassis Taillight assy. Open the rear case cover, remove the two screws «D», and then, the other four fixing screws «D» to pull out the headlight assembly from its fitting. Follow this procedure to remove the bulbs: Remove the snap-on bulbs «B». Remove the bulbs «A»...
Page 247 MP3 125 Chassis Frame central cover 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 248 MP3 125 Chassis License plate holder Remove the two lateral screws and the two screws inside the rear case. Operate a slight upwards thrust on the case to re- lease license plate support from the chassis. Helmet bay Remove the chassis central cover. Remove the four external screws and the two screws inside the rear case to remove the frame.
Page 249 MP3 125 Chassis Remove the upper frame, unscrewing the ten up- per screws, the two saddle closing screws and the case light wiring. Remove the rear case internal screws indicated in the photograph, to detach the supporting plates of the voltage regulator on one side and the saddle opening switch on the other.
Page 250: Fuel Tank
MP3 125 Chassis Remove the five screws indicated in the figure. See also Headlight assy. Fuel tank Remove the chassis central cover. Remove the footrest. Remove the three tank retainers. CHAS - 12...
Page 251 MP3 125 Chassis Remove the two lower bracket retainers indicated in the figure. Disconnect the electric wiring and the fuel pipes. See also Footrest Remove the chassis central cover. Remove the footrest. Remove the three tank retainers. CHAS - 13...
Page 252 MP3 125 Chassis Remove the two lower bracket retainers indicated in the figure. Disconnect the electric wiring and the fuel pipes. See also Footrest Top-case Rear Remove the four fixing screws of the cover and release it from the two leverages. Handles and top side fairings Remove the six screws indicated in the figure.
Page 253 MP3 125 Chassis 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. Remove the two screws fixing the radiator lower protection to the shield back plate.
Page 254 MP3 125 Chassis CHAS - 16...
Page 255 INDEX OF TOPICS PRE DE DELIVERY...
Page 256 MP3 125 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. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches...
Page 257 MP3 125 Pre-delivery • Lower ring nut for central steering tube • Upper ring nut for central steering tubes • Constant-velocity universal joints Electrical system • Battery • Main switch • Lights: high beams, low beams, side/taillights (front and rear) and relevant warning lights - Regulating the headlights according to the regulations currently in force •...
Page 258 MP3 125 Pre-delivery - Hydraulic brake system liquid level. - Tilt locking system fluid level - Rear hub oil level - Engine coolant level - Engine oil level Road test Test ride - Cold start - Instrument operations - Response to the gas command - Stability on acceleration and braking - Rear and front brake efficiency - Parking brake efficiency...
Page 259 MP3 125 Pre-delivery PRE DE - 5...
Page 260 MP3 125 Pre-delivery PRE DE - 6...
Page 261 INDEX OF TOPICS TIME...
Page 262 MP3 125 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 chassis - Re- moval and refit. 001127 Engine - Complete service 003064...
Page 263 MP3 125 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 264 MP3 125 Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 4...
Page 265 MP3 125 Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder / Piston - Replace- ment 001154 Pin-ring-piston assembly - Service 001176 Rings / Pin - Replacement TIME - 5...
Page 266 MP3 125 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 267 MP3 125 Time Rocker arms support assy. ROCKING LEVERS SUPPORTING UNIT Code Action Duration 001148 Valve rocking levers - Re- placement 001126 Head - Replacement 001044 Camshaft - Replacement TIME - 7...
Page 268: Cylinder Head Cover
MP3 125 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 269: Oil Filter
MP3 125 Time Oil filter IL FILTER Code Action Duration 001161 Secondary air filter - Replace- ment 001162 Secondary air filter box - Re- placement 001174 SAS valve - Replacement 001160 Oil pressure sensor - Re- placement 001123 Oil filter - Replacement 001102 Mesh oil filter - Replacement / Cleaning...
Page 270 MP3 125 Time Driven pulley DRIVEN PULLEY Code Action Duration 001012 Driven pulley - Service 001022 Clutch - Replacement 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement TIME - 10...
Page 271 MP3 125 Time Oil pump OIL PUMP Code Action Duration 001129 Chain tightener - Service and replacement 001125 Chain guide pads - Replace- ment 001122 Oil pump chain - Replace- ment 001172 Chain cover flap - Replace- ment 001130 Oil sump - Replacement 001042 Oil pump - Service 001112...
Page 272 MP3 125 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 breather pipe - Replacement 004125 Rear wheel axle - Replace- ment 001179 Hub drive shaft -replacement 001156...
Page 273 MP3 125 Time Driving pulley DRIVING PULLEY Code Action Duration 001177 Variator rollers / shoes - Re- placement 001066 Driving pulley - Removal and Refitting 001006 Driving pulley - Service 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement TIME - 13...
Page 274: Transmission Cover
MP3 125 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 deflector - Replacement 001132 Transmission air inlet pipe - Replacement TIME - 14...
Page 275: Water Pump
MP3 125 Time Water pump ATER PUMP Code Action Duration 007009 Head-pump by-pass rubber coupling - Replacement TIME - 15...
Page 276: Starter Motor
MP3 125 Time Starter motor ELECTRICAL START UP Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Replacement 001017 Start-up pinion - Replace- ment TIME - 16...
Page 277: Flywheel Magneto
MP3 125 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refit- ting 001058 Complete flywheel - Replace- ment 001173 Rotor - Replacement 001087 Flywheel cover - Replace- ment TIME - 17...
Page 278 MP3 125 Time Carburettor ARBURETTOR Code Action Duration 001063 Carburettor - Replacement 003058 Carburettor - Adjustment 001013 Intake manifold - Replace- ment TIME - 18...
Page 279 MP3 125 Time ARBURETTOR EXPLODED VIEW Code Action Duration 001008 Carburettor - Inspection Exhaust pipe MUFFLER Code Action Duration 001095 Muffler guard - Replacement 001009 Muffler - Replacement 001092 Exhaust manifold - Replace- ment TIME - 19...
Page 280: Air Cleaner
MP3 125 Time Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Replacement 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement TIME - 20...
Page 281 MP3 125 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 - 21...
Page 282 MP3 125 Time Centre-stand STAND Code Action Duration 001053 Stand bolt - Replacement 004179 Stand buffer - Replacement 004004 Stand - Replacement TIME - 22...
Page 283 MP3 125 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 284 MP3 125 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 - 24...
Page 285 MP3 125 Time Rear cover REAR SHIELD Code Action Duration 004065 Front shield, rear part - Re- moval and refitting TIME - 25...
Page 286 MP3 125 Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replacement 004135 Fuel tank lid - Replacement 004011 Central chassis cover - Re- placement 004012 Rear fairings - Removal and refitting 004015 Footrest - Removal and Re- fitting 004075 Front mat - Replacement...
Page 287 MP3 125 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 - 27...
Page 288 MP3 125 Time Fuel tank UEL TANK Code Action Duration 004137 Injector pump pipe - Replace- ment 005010 Tank float - Replacement 004168 Fuel tank cap - Replacement 004005 Fuel tank - Replacement TIME - 28...
Page 289 MP3 125 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 - 29...
Page 290: Handlebar Covers
MP3 125 Time Handlebar covers HANDLEBAR COVERS Code Action Duration 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE- MENT 004019 Rear handlebar cover - Re- placement 004026 Handlebar cover - Replace- ment 004018 Front handlebar cover - Re- placement TIME - 30...
Page 291 MP3 125 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 002059 Right-hand knob - Replace- ment 002060 Complete throttle control - Replacement 002063 Throttle control transmission - Replacement 003001 Handlebar - Replacement 002071 Left knob - Replacement 003059 Counterweight - Replace- ment 002037 Brake lever - Replacement...
Page 292 MP3 125 Time Code Action Duration 002047 Front brake fluid and air bleeding system - Replace- ment 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-...
Page 293 MP3 125 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 33...
Page 294: Instrument Panel
MP3 125 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 - 34...
Page 295: Turn Signal Lights
MP3 125 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 296 MP3 125 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 Licence plate light glass - Re- placement 005131 Licence plate light support - Replacement 005066 Rear light bulbs - Replace-...
Page 297 MP3 125 Time RONT TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005067 Front turn indicator bulb - Re- placement 005012 Front turn indicators - Re- placement 005002 Front light - replacement 005008 Headlight bulbs - Replace- ment TIME - 37...
Page 298: Front Wheel
MP3 125 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 - 38...
Page 299 MP3 125 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 - 39...
Page 300 MP3 125 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 - 40...
Page 301 MP3 125 Time ABLE HARNESS Code Action Duration 005001 Electrical system - Replace- ment 005114 Electrical system - Service TIME - 41...
Page 302 MP3 125 Time Electronic controls ANDLEBAR CONTROLS Code Action Duration 005017 Stop switch - Replacement 005077 Emergency stop switch - Re- placement 005041 Starter button - Replacement 004010 Antitheft lock - Replacement 005040 Horn button - Replacement 005006 Light or turn indicator switch - Replacement 005039 Headlight switch - Replace-...
Page 303 MP3 125 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 - 43...
Page 304 MP3 125 Time Helmet bay ELMET COMPARTMENT Code Action Duration 005046 Battery cover - change 005026 Helmet compartment light - Replacement 005027 Helmet compartment bulb support - Replacement 004016 Helmet compartment - Re- placement TIME - 44...
Page 305 MP3 125 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 - 45...
Page 306: Front Suspension
MP3 125 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 307: Cooling System
MP3 125 Time Cooling system OOLING SYSTEM Code Action Duration 007013 Expansion tank - radiator connection pipe - Replace- ment 001052 Coolant and air bleed - Re- placement 007001 Expansion tank - Replace- ment 007024 Expansion tank cap - Re- placement 007003 Coolant delivery and return...
Page 308: Braking System
MP3 125 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 309 MP3 125 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- ment...
Page 310 MP3 125 Time WINDSHIELD Code Action Duration 004101 Windshield - Replacement Secondary air box ECONDARY AIR HOUSING Code Action Duration 001163 SAS valve / Head connection - Replacement TIME - 50...
Page 311 MP3 125 Time Stickers RANSFERS Code Action Duration 004066 Rear-view mirror - Replace- ment 004159 Plates / Stickers - Replace- ment TIME - 51...
Page 312 MP3 125 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 313 MP3 125 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 314 MP3 125 Time Code Action Duration 003089 Geared motor potentiometer - replacement TIME - 54...

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PIAGGIO 633929(IT) Service Station Manual

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