PIAGGIO MP3 400 i.e. Manuals

Manuals and User Guides for PIAGGIO MP3 400 i.e.. We have 2 PIAGGIO MP3 400 i.e. manuals available for free PDF download: Service Manual, User Manual

PIAGGIO MP3 400 i.e. Service Manual

PIAGGIO MP3 400 i.e. Service Manual (395 pages)

Brand: PIAGGIO | Category: Scooter | Size: 15.39 MB

Table of Contents

Index of Topics
5
Characteristics
7
Maintenance Rules
8
Safety Rules
8
Dimensions and Mass
9
Vehicle Identification
9
Weights and Dimensions
9
Engine
10
Tightening Torques
12
Wheels and Tyres
12
Table of Contents
13
Transmission Cover
15
Coupling Categories
16
Cylinder- Piston
16
Height at Which the Diameter Should be Measured
16
Piston Rings
16
Crankcase - Crankshaft - Connecting Rod
17
Crankcase / Countershaft Coupling
17
Rings/Housing Coupling Clearances
17
Diameter of Crankshaft Bearings
18
Axial Clearance between Crankshaft and Connecting Rod
19
Crankshaft Alignment
19
Max. Admissible Displacement
19
Base Gasket Thickness
20
Recommended Products Table
20
Slot Packing System
20
Tooling
23
Maintenance
35
After 1,000 Km
36
Every 2 Years
36
Maintenance Chart
36
After 10,000 Km; 50,000 Km; 70,000 Km
37
After 15,000 Km; 45,000 Km; 75,000 Km
37
Checking the Spark Advance
38
Transmission Cover
39
Spark Plug
40
- Hub Oil
  41
- Replacement
  41
- Air Filter
  42
- Engine Oil
  42
- Engine Oil Filter
  45
- Oil Pressure Warning Light
  45
- Oil Top up
  45
- Adding Engine Coolant
  46
- Checking the Ignition Timing
  46
- Cooling System
  46
- Braking System
  47
- Level Check
  47
- Top-Up
  47
- Headlight Adjustment
  48
- Troubleshooting
  49
- Excessive Consumption
  50
- Excessive Oil Consumption/Exhaust Smoke
  50
- Irregular Clutch Performance or Slippage
  50
- Poor Lubrication Pressure
  50
- Brakes Overheating
  51
- Heavy Steering
  51
- Inefficient Braking System
  51
- Insufficient Braking
  51
- Noisy Suspension
  52
- Suspension Oil Leakage
  52
- Electrical System
  53
- Components Arrangement
  57
- Ignition
  63
- Battery Recharge and Starting
  64
- Level Indicators and Enable Signals Section
  65
- Devices and Accessories
  66
- Lights and Turn Indicators
  68
- Checks and Inspections
  69
- Immobiliser
  69
- With the Key Switch in the off Position
  70
- With the Key Switch Set to off
  70
- Virgin Circuit
  72
- Diagnostic Codes
  73
- Diagnostic Code - 1 Flash
  74
- Diagnostic Code - 2 Flashes
  74
- Battery Recharge Circuit
  75
- Diagnostic Code - 3 Flashes
  75
- Stator Check
  75
- Stator Winding Check-Up
  75
- Recharge System Voltage Check
  76
- Voltage Regulator/Rectifier
  76
- Fuses
  77
- Fuse Table
  78
- Dashboard
  79
- Sealed Battery
  80
- Connectors
  81
- Injection Electronic Control Unit
  81
- Pick-Up Connector
  81
- Saddle Opening Receiver Connector
  82
- Turn Indicator Control Device Connector
  82
- Voltage Regulator Connector
  82
- Anti-Theft Device Pre-Installation Connector
  83
- Fuel Pump Connector
  83
- Hv Coil Connector
  83
- Instrument Panel Connector "A"
  83
- Instrument Panel Connector "B"
  84
- Parking Control Ecu Connector
  84
- Remote Seat Opening
  85
- Zeroing
  85
- Programming
  86
- Engine from Vehicle
  87
- Exhaust Assy. Removal
  88
- Removal of the Engine from the Vehicle
  88
- Automatic Transmission
  94
- Transmission Cover
  94
- Air Duct
  95
- Transmission Cover
  95
- Air Duct Filter
  96
- Removing the Driven Pulley Shaft Bearing
  96
- Transmission Cover
  96
- Baffle Roller
  97
- Plastic Roller
  97
- Refitting the Driven Pulley Shaft Bearing
  97
- Transmission Cover
  97
- Anti-Vibration Roller Screw 16.7 -
  98
- Inspecting the Clutch Drum
  98
- Removing the Driven Pulley
  98
- Inspecting the Clutch
  99
- Removing the Clutch
  99
- Pin Retaining Collar
  100
- Removing the Driven Half-Pulley Bearing
  100
- Inspecting the Driven Fixed Half-Pulley
  101
- Inspecting the Driven Sliding Half-Pulley
  102
- Refitting the Driven Half-Pulley Bearing
  102
- Inspecting the Clutch Spring
  103
- Refitting the Driven Pulley
  103
Clutch Ring Nut
104
- Refitting the Clutch
  104
- Drive-Belt
  105
- Removing the Driving Pulley
  105
- Inspecting the Rollers Case
  106
- Refitting the Driving Pulley
  107
- Installing the Fixed Driving Half-Pulley
  108
Drive Pulley Nut
109
Refitting the Transmission Cover
109
M8 Retainers for Transmission Cover
110
- End Gear
  111
- Removing the Hub Cover
  111
- Removing the Hub Bearings
  112
- Removing the Wheel Axle
  112
- Removing the Wheel Axle Bearings
  113
- Inspecting the Hub Shaft
  114
- Inspecting the Hub Cover
  115
- Refitting the Hub Cover Bearings
  117
- Refitting the Hub Bearings
  118
- Refitting the Ub Cover
  118
- Flywheel Cover
  119
- Removing the Flywheel Cover Components
  120
- Inspecting the Cover Components
  121
- Removing the Stator
  121
- Refitting the Flywheel Cover Components
  124
- Refitting the Stator
  124
- Refitting the Flywheel Cover
  126
- Battery
  130
- Start-Up Remote Control Switch
  130
- Starter Motor
  130
- Starter Transmission
  130
- Removing the Flywheel Magneto
  131
- Removing the Starter Motor
  131
- Inspecting the Flywheel Components
  135
- Starter Gear Rim
  135
- Intermediate Gear
  136
- Refitting the Free Wheel
  136
- Loctite 243 Medium-Strength Threadlock
  137
- Refitting the Intermediate Gear
  137
- Refitting the Flywheel Magneto
  138
- Cylinder Assy. and Timing System
  140
- Refitting the Starter Motor
  140
- Removing the Intake Manifold
  141
- Removing the Rocker-Arms Cover
  141
- Removing the Timing System Drive
  141
- Removing the Cam Shaft
  143
- Removing the Cylinder Head
  144
- Removing the Valves
  145
- Removing the Cylinder - Piston Assy.
  146
- Inspecting the Small End
  147
- Inspecting the Wrist Pin
  147
- Inspecting the Piston
  148
- Inspecting the Piston Rings
  149
- Removing the Piston
  150
- Choosing the Gasket
  151
- Inspecting the Cylinder Head
  153
- Refitting the Cylinder
  153
- Refitting the Piston Rings
  153
- Inspecting the Timing System Components
  154
- Inspecting the Valve Sealings
  154
- Inspecting the Valve Housings
  155
- Inspecting the Valves
  155
- Standard Diameter
  155
- Inspecting the Valve Stem Guide Clearance
  156
- Minimum Admissible Diameter
  156
- Standard Valve Length
  157
- Inspecting the Springs and Half-Cones
  158
- Refitting the Valves
  158
- Admissible Limits
  159
- Inspecting the Cam Shaft
  159
- Standard Height
  159
- Refitting the Head and Timing System Components
  161
Exhaust / Intake Head Fixing Nuts:
162
Coolant Temperature Sensor:
163
Camshaft Retaining Bracket Screws:
164
Valve Lifter Mass Stop Bell Fixing Screws:
166
- Prescribed Clearance
  167
- Refitting the Timing Chain
  167
- 020330Y Stroboscopic Light for Timing Control
  168
- 020460Y Scooter Diagnosis and Tester
  168
- Refitting the Rocker-Arms Cover
  169
- Tappet Cover Fixing Screws:
  169
  - Crankcase - Crankshaft
    170
  - Refitting the Intake Manifold
    170
  - Splitting the Crankcase Halves
    171
  - Removing the Crankshaft
    172
  - Removing the Countershaft
    173
  - Replacing the Countershaft Bearings
    173
  - Inspecting the Crankshaft Components
    176
  - Inspecting the Crankshaft Alignment
    177
  - Max Admissible Displacement:
    177
  - Inspecting the Crankcase Halves
    178
  - Inspecting the Crankshaft Plain Bearings
    179
  - Check the Bench Bush
    180
  - Coupling Chart
    180
  - Countershaft
    182
  - Refitting the Crankshaft
    182
  - Refitting the Crankcase Halves
    184
  - Lubrication
    185
  - Oil Pump
    185
  - Recommended Engine Oil
    185
  - Sump Capacity
    185
  - Conceptual Diagrams
    187
  - General Characteristics
    187
  - Diagnosis Guide
    188
  - Standard Values
    189
  - Oil Pressure Check
    190
Screws Fixing Oil Pump to the Crankcase
195
- Injection
  197
- Lambda Probe Strength
  199
- Pressure Regulator
  199
- Precautions
  200
- Troubleshooting Hints
  201
- Terminal Layout
  202
- Terminals Setup
  202
- EMS Circuit Diagram
  203
- Engine Does Not Start
  204
- Engine Does Not Start if Only Pulled
  204
- Troubleshooting Procedure
  204
- Engine Does Not Hold Idling/ Idling Is Unstable/ Idling too Low
  205
- Engine Start-Up Problems
  205
- Engine Stops at Idle
  205
- Starting Difficulties
  205
- Engine Does Not Return to the Idling Speed/Idling Speed too High
  206
- Engine Does Not Rev down
  206
- Exhaust Backfires in Deceleration
  206
- Exhaust Backfires When Decelerating
  206
- Engine Irregular Progress with Valve Slightly Open
  207
- Engine Revs Irregularly
  207
- Poor Performance at Full Throttle
  207
- Engine Knocking
  208
- Fuel Supply System
  208
- Presence of Knocking (Head Knocking)
  208
- Removing the Butterfly Valve
  209
- Pump Supply Circuit
  211
- Electrical Data
  212
- Injection Loads
  212
- Circuit Leak Test
  215
- Fuel Filter Check
  216
- Inspecting the Injector Circuit
  218
- HT Coil
  231
- Spark Advance
  236
- Coolant Temperature Sensor
  238
- Temperature Sensor
  238
- Resetting the Throttle Valve Position Signal (TPS Reset)
  239
- Zeroing the Throttle
  239
- Lambda Probe
  242
- Suspensions
  247
- Front Wheel Hub Overhaul
  248
- Removing the Front Wheel
  248
- Handlebar
  250
- The Tilt Mechanism
  250
- Hydraulic System Layout
  251
- Steering Tubes
  251
Side Headstock Lower Ring Nut
257
Screws Fixing the Half-Arm Coupling Flange
261
Fixing Screws for Tilt Locking Disc Section
262
Geared Motor and Suspension Locking System
262
Clamp Fixing Pump Bolt to Anti-Tilting Device
264
- Before Removing the Geared Motor
  272
- Geared Motor
  276
- Tilt Locking-Unlocking Switch
  277
- Potentiometer
  279
- Rider Presence Sensor
  280
- Tilt Locking Calliper Sensor
  282
- Tone Wheel Sensor
  283
- Wheel Alignment
  287
- Removing the Rear Wheel
  291
- Rear Wheel Axle
  293
  - Shock Absorbers
    299
  - Swinging Arm Fitting
    299
  - Centre-Stand
    300
- Shock Absorber Lower Clamp
  300
Rear Brake Calliper
302
Brake Fluid Pipe-Calliper Fitting
304
- Front Brake Calliper
  304
- Rear Brake Disc
  305
- Disc Inspection
  307
- Front Brake Disc
  307
- Front Brake Pads
  309
- Rear Brake Pads
  310
- Oil Bleed Screw
  311
  - Brake Pipes
    312
  - Front Brake Pipes Removal
    312
  - Parking Brake
    313
  - Remove the Rear Wheel
    313
  - Circuit Diagram
    316
  - Electric Fan Check
    317
  - Electric Ventilation
    317
  - Thermostat
    317
  - Water Pump
    317
  - System Sealing Check
    318
  - Coolant Replacement
    319
  - Pompa Acqua
    319
  - System Top-Up Rules
    319
  - Removing the Water Pump Cover
    320
  - Chassis
    323
  - Rear Handlebar Cover
    324
  - Seat
    324
  - Front Handlebar Cover
    325
  - Instrument Panel
    325
  - Headlight Assy
    326
  - Remove the Radiator Cover
    326
  - Frame Central Cover
    327
  - Knee-Guard
    328
  - Legshield
    328
  - Taillight Assy.
    330
  - Footrest
    331
  - License Plate Holder
    332
  - Side Fairings
    332
  - Helmet Bay
    333
  - Spoiler
    334
  - Fuel Tank
    335
  - Handles and Top Side Fairings
    336
  - Rear
    336
  - Top-Case
    336
  - Radiator Cover
    337
  - Pre-Delivery
    339
  - Aesthetic Inspection
    340
  - Tightening Torques Inspection
    340
  - Time
    345
  - Crankcase
    347
  - Crankshaft
    348
  - Cylinder Assy.
    349
  - Cylinder Head Assy.
    350
  - Rocker Arms Support Assy.
    351
  - Cylinder Head Cover
    352
  - Driven Pulley
    354
    
    Final Gear Assy.
    356
    
    Driving Pulley
    357
    
    Flywheel Magneto
    359
    
    Butterfly Valve
    360
    
    Throttle Body
    360
    
    Exhaust Pipe
    361
    
    Muffler
    361
    
    Air Cleaner
    362
    
    Frame
    363
    
    Legshield Spoiler
    364
    
    Rear Cover
    366
    
    Central Cover
    367
    
    Mudguard
    368
    
    Rear Shock-Absorber
    370
    
    Handlebar Covers
    371
    
    Handlebar Components
    372
    
    Swing-Arm
    373
    
    Locks
    376
    
    Turn Signal Lights
    376
    
    Front Wheel
    379
    
    Rear Wheel
    380
    
    Electric Devices
    381
    
    Electronic Controls
    383
    
    Transmissions
    384
    
    Rear Side Fairings
    386
    
    Front Suspension
    387
    
    Stickers
    391

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PIAGGIO MP3 400 i.e. User Manual

PIAGGIO MP3 400 i.e. User Manual (100 pages)

Brand: PIAGGIO | Category: Scooter | Size: 1.18 MB

Table of Contents

Table of Contents
5
Vehicle

7
- Dashboard
  9
- Analogue Instrument Panel
  11
- Clock
  12
- Digital Lcd Display
  12
  - Maintenance Icons
    13
  - MODE* Button
    13
- Key Switch
  14
  - Locking the Steering Wheel
    14
  - Releasing the Steering Wheel
    14
- Switch Direction Indicators
  15
- Horn Button
  15
- Light Switch
  16
- Emergency Flashing Light Button
  16
- Start-Up Button
  17
- Engine Stop Button
  17
- Front Suspension Unlock-Lock Switch
  18
- The Immobilizer System
  18
  - Keys
    18
  - Immobilizerdevice Enabled Indicator Led
    19
  - Operation
    19
  - Programming the Immobilizer System
    20
- Saddle Opening Remote Control
  21
  - Remote Control Programming
    22
- Accessing the Fuel Tank
  23
- The Saddle
  24
  - Opening the Saddle to Access the Helmet Compartment by Remote Control
    24
  - Opening the Saddle to Access the Helmet Compartment in an Emergency
    25
- Opening of Top Box
  26
- Identification
  26
Use

27
- Checks
  28
- Refuelling
  28
- Tyre Pressure
  30
- Shock Absorbers Adjustment
  31
- Running in
  32
- Starting up the Engine
  33
  - Precautions
    35
- Difficult Start up
  35
- Stopping the Engine
  36
- Stand
  36
- Automatic Transmission
  37
- Safe Driving
  37
- Front Suspension Locking System
  39
Maintenance

45
- Engine Oil Level
  46
  - Engine Oil Level Check
    46
  - Engine Oil Top-Up
    46
  - Warning Light (Insufficient Oil Pressure)
    46
  - Engine Oil Change
    47
- Hub Oil Level
  48
- Tyres
  50
- Spark Plug Dismantlement
  51
- Removing the Air Filter
  52
- Air Filter Cleaning
  52
- Cooling Fluid Level
  53
- Checking the Brake Oil Level
  55
  - Braking System Fluid Top up
    55
- Battery
  56
  - Use of a New Battery
    56
- Long Periods of Inactivity
  57
- Fuses
  57
- Front Light Group
  63
  - Headlight Adjustment
    63
  - Front Direction Indicators
    66
  - Rear Optical Unit
    67
  - Number Plate Light
    68
  - Helmet Compartment Lighting Bulb
    69
  - Rear-View Mirrors
    69
  - Front and Rear Disc Brake
    69
  - Puncture
    70
  - Periods of Inactivity
    71
  - Cleaning the Vehicle
    72
Technical Data

77
- Kit Equipment
  85
Spare Parts and Accessories

87
- Warnings
  88
Programmed Maintenance

91
- Scheduled Maintenance Table
  92

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