PIAGGIO MP3 500 ie SPORT Business LT (2011) Manuals

Manuals and User Guides for PIAGGIO MP3 500 ie SPORT Business LT (2011). We have 1 PIAGGIO MP3 500 ie SPORT Business LT (2011) manual available for free PDF download: User Manual

PIAGGIO MP3 500 ie SPORT Business LT (2011) User Manual (411 pages)

Brand: PIAGGIO | Category: Scooter | Size: 23.01 MB

Index of Topics
5
Safety Rules
7
Characteristics
7
Maintenance Rules
7
Vehicle Identification
8
Dimensions and Mass
9
Engine Data
9
Capacities
10
Electrical System Data
10
Frame and Suspensions Data/Brakes Data
10
Transmission Data
10
Tightening Torques
11
Wheels and Tyres Data
11
Front Brake
12
Rear Suspension
12
Table of Contents
13
Overhaul Data
13
Assembly Clearances
14
Cylinder - Piston Assy Clearance
14
Piston Rings Clearance
15
Rings/Housing Coupling Clearances
15
Crankcase - Crankshaft - Connecting Rod Clearance
16
Oil Scraper Ring Standard Coupling Clearance
16
Slot Packing System
18
Recommended Products Table
19
Specific Tools
21
Tooling
21
Adjustment Procedure of the Ring Nuts of the Side Headstocks
33
Maintenance
33
Maintenance Chart
36
Engine Oil Filter
36
Transmission Cover
37
Checking the Spark Advance
37
Spark Plug
38
Hub Oil Check
39
Air Filter
40
Hub Oil Replacement
40
Engine Oil Replacement
41
Engine Oil Check
43
Engine Oil Filter
43
Checking the Ignition Timing
44
Cooling System
44
Oil Pressure Warning Light
44
Braking System
45
Level Check
45
Front and Rear Braking System Topping up
46
Integral Braking System Level Topping up
46
Headlight Adjustment
47
Troubleshooting
48
Engine Troubleshooting
49
Transmission and Brakes Troubleshooting
49
Steering and Suspensions Troubleshooting
50
Electrical System
53
Schematic Diagram
53
Electrical Components Arrangement
56
Immobilizer Aerial View
56
Auxiliary Fuses View
57
Geared Motor View
57
Horn View
57
Remote Control Switches View
57
Oil Pressure Sensor View
58
Fuel Level Transmitter View
58
Lambda Probe View
58
HV Coil View
58
Diagnosis Connector/Main Fuses View
59
Electronic Control Unit/Start-Up Remote Control Switch View
59
Turn Indicator Control Device View
59
Voltage Regulator View
59
Parking Control ECU View
60
Rider Presence Sensor View
60
Conceptual Diagrams
61
Ignition Diagram
61
Battery Recharge and Starting Diagram
62
Level Indicators and Enable Signals Section Diagram
63
Devices and Accessories Diagram
64
Lights and Turn Indicators Diagram
66
Electrical Components Checks and Inspections
67
Immobiliser Check
67
Virgin Circuit
70
Diagnostic Codes
71
Diagnostic Code - 1 Flash
72
Diagnostic Code - 2 Flashes
72
Battery Recharge Circuit
73
Diagnostic Code - 3 Flashes
73
Remote Controls Check
73
Stator Check
73
Recharge System Voltage Check
74
Starter Motor
75
Horn Control
76
Turn Signals System Check
77
Lights List
79
Light Bulbs Table
80
Fuses
81
Dashboard
83
Battery Installation
84
Sealed Battery
84
Battery Preparation
85
Control the Flow of Electrolyte
85
Electrolyte Preparation
85
Procedure for Filling the Battery with Acid
85
Battery Closing
86
Recharging the New Battery
86
Take out the Container
86
Connectors
88
Injection Electronic Control Unit Connector
88
Voltage Regulator Connector
89
Turn Indicator Control Device Connector
89
Pick-Up Connector
89
Anti-Theft Device Pre-Installation Connector
90
Fuel Pump Connector
90
HV Coil Connector
90
Instrument Panel Connector "A"
90
Instrument Panel Connector "B"
91
Parking Control ECU Connector
91
Engine from Vehicle
94
Exhaust Assy. Removal
94
Removal of the Engine from the Vehicle
94
Automatic Transmission
99
Transmission Cover

99
- Air Duct
  100
- Air Duct Filter
  101
- Removing the Driven Pulley Shaft Bearing
  101
- Refitting the Driven Pulley Shaft Bearing
  102
- Baffle Roller
  102
- Plastic Roller
  102
- Removing the Driven Pulley
  103
- Inspecting the Clutch Drum
  103
- Anti-Vibration Roller Screw 16.7 ÷
  103
- Removing the Clutch
  104
- Inspecting the Clutch
  104
- Pin Retaining Collar
  105
- Removing the Driven Half-Pulley Bearing
  105
- Inspecting the Driven Fixed Half-Pulley
  106
- Inspecting the Driven Sliding Half-Pulley
  107
- Refitting the Driven Half-Pulley Bearing
  107
- Refitting the Driven Pulley
  108
- Inspecting the Clutch Spring
  108
- Refitting the Clutch
  109
- Clutch Ring Nut
  109
  - Drive-Belt
    110
  - Removing the Driving Pulley
    110
  - Inspecting the Rollers Case
    111
  - Refitting the Driving Pulley
    112
  - Refitting the Transmission Cover
    114
- Drive Pulley Nut
  114
- M6 Retainer
  115
  - End Gear
    116
  - Removing the Hub Cover
    116
  - Removing the Wheel Axle
    116
- External Transmission Cover Screws
  116
  - Removing the Hub Bearings
    117
  - Removing the Wheel Axle Bearings
    117
  - Inspecting the Hub Shaft
    119
  - Inspecting the Hub Cover
    119
  - Refitting the Hub Cover Bearings
    121
  - Refitting the Hub Bearings
    123
  - Refitting the Ub Cover
    123
  - Flywheel Cover
    124
  - Removing the Flywheel Cover Components
    125
  - Removing the Stator
    126
  - Inspecting the Cover Components
    126
  - Refitting the Stator
    128
  - Refitting the Flywheel Cover Components
    129
  - Refitting the Flywheel Cover
    131
  - Flywheel and Starting
    133
- Flywheel Cover Screws
  133
  - Removing the Starter Motor
    135
  - Removing the Flywheel Magneto
    136
  - Inspecting the Flywheel Components
    139
  - Starter Gear Rim
    139
  - Intermediate Gear
    140
  - Refitting the Free Wheel
    141
- Screw Fixing Freewheel to Flywheel
  141
  - Refitting the Intermediate Gear
    142
  - Refitting the Flywheel Magneto
    143
  - Refitting the Starter Motor
    144
- Flywheel Fixing Nut
  144
  - Cylinder Assy. and Timing System
    145
  - Removing the Intake Manifold
    145
  - Removing the Rocker-Arms Cover
    145
  - Removing the Timing System Drive
    146
  - Removing the Cam Shaft
    147
  - Removing the Cylinder Head
    148
  - Removing the Valves
    150
  - Removing the Cylinder - Piston Assy
    151
  - Inspecting the Small End
    152
  - Inspecting the Wrist Pin
    152
  - Inspecting the Piston
    152
  - Inspecting the Piston Rings
    154
  - Removing the Piston
    155
  - Choosing the Gasket
    156
  - Refitting the Piston Rings
    157
  - Refitting the Cylinder
    158
  - Inspecting the Cylinder Head
    158
  - Inspecting the Timing System Components
    158
  - Inspecting the Valve Sealings
    159
  - Inspecting the Valve Housings
    160
  - Inspecting the Valves
    160
  - Inspecting the Valve Stem Guide Clearance
    161
  - Inspecting the Springs and Half-Cones
    162
  - Refitting the Valves
    163
  - Inspecting the Cam Shaft
    163
  - Refitting the Head and Timing System Components
    165
- Tensioner Sliding Block Fixing Screw
  167
- Camshaft Retaining Bracket Screws:
  168
- Counterweight Screw 7 to
  169
- Valve Lifter Mass Stop Bell Fixing Screws
  170
  - Refitting the Timing Chain
    172
  - Refitting the Rocker-Arms Cover
    173
  - Refitting the Intake Manifold
    174
  - Crankcase - Crankshaft
    174
  - Splitting the Crankcase Halves
    175
  - Removing the Crankshaft
    176
  - Removing the Countershaft
    177
  - Replacing the Countershaft Bearings
    178
  - Inspecting the Crankshaft Components
    180
  - Inspecting the Crankshaft Alignment
    181
  - Inspecting the Crankcase Halves
    182
  - Inspecting the Crankshaft Plain Bearings
    183
  - Coupling Chart
    184
  - Countershaft
    186
  - Refitting the Crankshaft
    186
- Bulkhead Screws for Oil Pump Housing Cover
  187
  - Refitting the Crankcase Halves
    188
  - Engine Lubrication
    189
  - Principal Diagram
    190
  - General Characteristics of the Lubrication System
    191
  - Diagnosis Guide
    192
  - Oil Pressure Check
    194
  - Oil Pump Removal
    195
  - Oil Pump Refitting
    197
  - Water Pump Removal
    198
  - Water Pump Fitting
    204
- Water Pump Cover Screws
  205
  - Injection
    208
  - The Fuel System Circuit Consists of
    209
  - The Ignition Circuit Consists of
    209
  - Injection System - Precautions
    210
  - Injection System - Troubleshooting Hints
    211
  - Terminals Setup
    212
  - EMS Circuit Diagram
    213
  - Troubleshooting Procedure
    214
  - Engine Does Not Start
    214
  - Starting Difficulties
    214
  - Engine Stops at Idle
    215
  - Engine Does Not Rev down
    215
  - Exhaust Backfires in Deceleration
    216
  - Engine Revs Irregularly
    216
  - Poor Performance at Full Throttle
    216
  - Engine Knocking
    217
  - Fuel Supply System
    217
  - Removing the Butterfly Valve
    218
  - Pump Supply Circuit
    220
  - Injection Loads
    221
  - Circuit Leak Test
    224
  - Fuel Filter Check
    225
  - Inspecting the Injector Circuit
    226
  - Inspecting the Injector Hydraulics
    230
  - Immobiliser Circuit
    231
  - Injecton - Diagnostic Codes
    235
  - Code 1
    236
  - Code 2
    237
  - Code 3
    237
  - Tachometer
    237
  - HT Coil
    239
  - Inspecting the Spark Plug Shielded Cap
    243
  - Spark Advance
    244
  - Coolant Temperature Sensor
    246
  - Zeroing the Throttle
    247
  - Lambda Probe
    250
  - Suspensions
    253
  - Removing the Front Wheel
    253
  - Front Wheel Hub Overhaul
    253
  - Handlebar Removal
    255
  - Handlebar Refitting
    255
  - The Tilt Mechanism
    255
  - Hydraulic System Layout
    256
  - Steering Tubes
    256
  - Parallelogram Device
    262
  - Geared Motor and Suspension Locking System
    267
  - Electrical Devices Test
    281
  - Gear Motor
    283
  - Potentiometer
    285
  - Rider Detection Sensor
    287
  - Roll Lock Caliper Sensor
    288
  - Front Wheel Alignment
    293
  - Removing the Rear Wheel
    297
  - Refitting the Rear Wheel
    299
  - Swing-Arm Removal
    299
  - Swing-Arm Overhaul
    301
  - Swing-Arm Refitting
    304
  - Shock Absorbers Removal
    305
  - Centre-Stand
    306
  - Shock Absorber Lower Clamping 33 to
    306
  - Braking System Diagram
    308
  - Brake System Fitting
    309
  - Rear Brake Calliper Removal
    314
  - Rear Brake Calliper Refitting
    315
  - Front Brake Calliper Removal
    315
  - Front Brake Calliper Refitting
    315
  - Rear Brake Disc Removal
    315
  - Screw Tightening Calliper to Support 20 to
    315
  - Rear Brake Disc Refitting
    316
  - Disc Inspection
    316
Char

316
- Front Brake Disc Removal
  317
- Front Brake Disc Refitting
  318
- Front Brake Pads Removal
  319
- Front Brake Pads Refitting
  320
- Rear Brake Pads Removal
  320
- Rear Brake Pads Refitting
  320
- Rear - Combined
  321
- Front - Combined
  323
- Brake Pipes
  324
- Parking Brake
  325
- Cooling System Circuit Diagram
  328
- Cooling System Specifications
  329
- Electric Fan Check
  329
- Cooling System Sealing Check
  330
- Coolant Replacement
  331
- Water Pump
  331
- Water Pump - Overhaul
  333
- Excessive System Pressure
  334
- Cooling Fluid Consumption
  334
- Oil in the Fluid
  334
- Chassis
  336
- Seat
  336
- Rear Handlebar Cover
  336
- Instrument Panel
  337
- Front Handlebar Cover
  337
- Headlight Assy
  338
- Frame Central Cover
  339
- Legshield
  340
- Knee-Guard
  340
- Taillight Assy
  343
- Footrest
  343
- Side Fairings
  344
- License Plate Holder
  345
- Helmet Bay
  345
- Spoiler
  346
- Fuel Tank
  347
- Top-Case
  348
- Handles and Top Side Fairings
  348
- Radiator Cover
  349
- Pre-Delivery
  352
- Aesthetic Inspection
  352
- Tightening Torques Inspection
  352
- Electrical System Inspection
  353
- Levels Check
  354
- Road Test
  354
- Static Test
  354
- Functional Inspection
  355
- Time
  357
- Engine - Time
  357
- Crankcase - Time
  358
- Crankshaft - Time
  359
- Cylinder Assy - Time
  360
- Cylinder Head Assy - Time
  361
- Rocker Arms Support Assy - Time
  362
- Cylinder Head Cover - Time
  363
- Flywheel Cover - Time
  364
- Driven Pulley - Time
  365
- Oil Pump - Time
  366
- Final Gear Assy - Time
  367
- Driving Pulley - Time
  368
- Transmission Cover - Time
  369
- Water Pump - Time
  370
- Starter Motor - Time
  371
- Flywheel Magneto - Time
  372
- Butterfly Valve - Time
  373
- Exhaust Pipe - Time
  374
- Air Cleaner - Time
  375
- Frame - Time
  376
- Centre-Stand - Time
  377
- Legshield Spoiler - Time
  378
- Side Fairings - Time
  379
- Rear Cover - Time
  380
- Central Cover - Time
  381
- Mudguard - Time
  382
- Fuel Tank - Time
  383
- Rear Shock-Absorber - Time
  384
- Handlebar Covers - Time
  385
- Handlebar Components - Time
  386
- Swing-Arm - Time
  387
- Seat - Time
  388
- Instrument Panel - Time
  389
- Locks - Time
  390
- Turn Signal Lights
  390
- Rear Turning Lights - Time
  391
- Front Turning Indicator Lights - Time
  392
- Front Wheel - Time
  393
- Rear Wheel - Time
  394
- Fuel Pump - Time
  395
- Electric Devices - Time
  396
- Electronic Controls - Time
  397
- Transmissions - Time
  398
- Helmet Bay - Time
  399
- Rear Side Fairings - Time
  400
- Front Suspension - Time
  401
- Cooling System - Time
  402
- Braking System - Time
  403
- Windscreen - Time
  405
- Stickers - Time
  406
- The Tilt Mechanism - Time
  407
- Geared Motor - Time
  408
- Index
  409

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PIAGGIO MP3 500 ie SPORT Business LT (2011) Manuals

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