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MP3 400 i.e.
PIAGGIO MP3 400 i.e. User Manual
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Final gear assy.
FINAL REDUCTION GEAR ASSEMBLY
Code
Action
Duration
1
001010
Geared reduction unit - Serv-
ice
2
001156
Gear reduction unit cover -
Replacement
3
003065
Gear box oil - Replacement
4
004125
Rear gear shaft - Replace-
ment
5
002031
Rear wheel hub bearings -
Replacement
Time
MP3 400 i.e.
TIME - 12
355
357
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
5
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PIAGGIO MP3 400 i.e. Specifications
General
Brand
PIAGGIO
Model
MP3 400 i.e.
Category
Scooter
Language
English
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