PIAGGIO 633929, 633930, 633931, 633932, 633937 Service Station Manual

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SERVICE STATION MANUAL

633929(IT)-633930(EN)-633931(FR)-633932

(ES)-633937(ES)-633938(PT)-633941(NL)-633942

(EL)

MP3 125

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SERVICE STATION

MANUAL

MP3 125

The descriptions and illustrations given in this publication are not binding. While the basic features as described and illustrated in this manual remain unchanged, PIAGGIO - GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessory supplies, which it considers necessary to improve the product or which

are required for manufacturing or construction reasons.

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.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

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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. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to special tools, along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

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Page 5

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. 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.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

Characteristics MP3 125

CHAR - 2

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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 1245 mm

Width (handlebar) 745 mm

Overall length 2130 mm

Track 420 mm

MP3 125 Characteristics

CHAR - 3

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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

Compression ratio 11.5 - 12.5 : 1

Air filter sponge, impregnated with mixture (50% petrol and

50% oil)

Starting system electric starter motor with freewheel

Lubrication with lobe pump (inside the crankcase) controlled

by a chain and double filter: mesh and paper

Fuel supply Unleaded petrol; depression carburettor, electric

pump or vacuum pump.

valve clearance intake: 0.10 mm - discharge: 0.15 mm

Engine idle speed 1,650±100 rpm

Max. speed 100 km/h

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator with tor-

que server, V belt, self-ventilating automatic cen-

trifugal dry clutch, gear reduction unit and trans-

mission housing with forced air circulation cooling.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1200 cm³

Rear hub oil Capacity ~ 150 cm³

Fuel tank capacity Tank capacity: ~12 l (approximate value)

Fuel reserve ~ 2.0 l (approximate value)

Cooling circuit Capacity: ~ 2.0 l

Electrical system

ELECTRICAL COMPONENTS

Specification Desc./Quantity

Ignition/advance Electronic, with inductive discharge and variable

advance with three-dimensional mapping Spark plug NGK CR 8EB Spark plug Champion RG 4 HC

Characteristics MP3 125

CHAR - 4

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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.

Front suspension The tilt mechanism is composed of an articulated

parallelogram suspension with die-cast aluminium control arms and two side headstocks plus shock

absorbers with hydraulic locking system.

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 240 mm double disk with hydraulic control acti-

vated by the handlebar right-hand lever.

Rear brake Ø 240 mm disc brake with hydraulic control acti-

vated by the handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheel Alloy rims: 12" x 3.00"

Rear wheel Alloy rim: 12"x 3.50"

Front tyre 120/70-12", without inner tube

Rear tyre Without inner tube: 130/70-12" 62P

TYRE PRESSURE

Specification Desc./Quantity

Front tyre pressure (rider) Front tyre pressure (rider): 1.6 bar

Front tyre pressure (rider and passenger) Front tyre pressure (rider and passenger): 1.8 bar

Rear tyre pressure (rider) Rear tyre pressure (rider): 2 bar

Rear wheel pressure (rider and passenger): Rear tyre pressure (rider and passenger): 2.4 bar

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

MP3 125 Characteristics

CHAR - 5

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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-

bolts

7 ÷ 10

FRAME

Name Torque in Nm

Engine arm bolt - frame arm 33 ÷ 41

Swinging arm buffer nut 64 - 72

Engine-swinging arm bolt 55 ÷ 61

Frame-swinging arm bolt 55 ÷ 61

Centre stand bolt 31 ÷ 39

FRONT SUSPENSION

Name Torque in Nm

Shock absorber lower clamp 19 ÷ 26

Upper shock absorber clamp 19 ÷ 29

Front wheel fixing screws 19 ÷ 24

Steering arm bolt nut 20 ÷ 25

Tilt calliper fixing screws 20 ÷ 25

Front wheel shaft 74 ÷ 88

Arm coupling screws 45 ÷ 50

Screws fixing arms to side headstocks 45 ÷ 50

Screws fixing arms to central headstock 45 ÷ 50

Screws fixing the half-arm coupling flange 20 ÷ 25

Fixing screws for tilt locking disc section 20 ÷ 25

Side headstock upper ring nut 20 - 24

Side headstock lower ring nut 12 ÷ 15

Screw fixing sliding stem to shock absorber 45 ÷ 50

Clamp for sliding stem locking device 6.5 ÷ 10.5

Fixing nuts for constant-velocity universal joints 18 ÷ 20

Potentiometer to anti-tilting device clamp 8 ÷ 10 Electric motor to anti-tilting device clamp 11 ÷ 13

Clamp fixing pump bolt to anti-tilting device 11 ÷ 13

Pump to anti-tilting device clamp 11 ÷ 13

Pressure switch to distribution frame 18 ÷ 20

Sensor to tilt gripper clamp 2.5 ÷ 2.9

Pipe terminals to fifth wheel check spring 7 ÷ 11

Joint to anti-tilting device pump 20 ÷ 25

Lower fitting for shock absorber sliding locking

clamp pipes

20 ÷ 25

Upper fitting for shock absorber sliding locking

clamp pipes

20 ÷ 25

REAR SUSPENSION

Name Torque in Nm

Upper shock absorber clamp 33 ÷ 41

Shock absorber lower clamp 33 ÷ 41

Characteristics MP3 125

CHAR - 6

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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 ÷ 20

Brake fluid pipe-calliper fitting 20 ÷ 25

Screw tightening calliper to the support 20 ÷ 25

Calliper upper pipe fitting 20 ÷ 25

REAR BRAKE

Name Torque in Nm

Rear brake disc screws(°) 5 ÷ 6.5

Rear brake calliper-pipe fitting 20 ÷ 25

Rigid / flexible pipe fitting 13 ÷ 18

Rear brake pump-pipe fitting 16 ÷ 20

Rear brake calliper fixing screws 20 ÷ 25

REAR BRAKE

Product Description Specifications

(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-

strength threadlock

MUFFLER

Name Torque in Nm

Muffler heat guard fixing screw 4 ÷ 5

Screw for fixing muffler to the support arm 20 ÷ 25

Lambda probe clamp on exhaust manifold 40 ÷ 50

Exhaust manifold-muffler joint clamp 12 ÷ 13

Manifold - muffler diaphragm tightening clamp 16 ÷ 18

LUBRICATION

Name Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 4 ÷ 6

Oil pump cover screws 0.7 ÷ 0.9

Screws fixing oil pump to the crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

ENGINE - CYLINDER HEAD

Name Torque in Nm

Manifold-silencer retaining bolt 15 ÷ 20

Nut fixing muffler to cylinder head 16 ÷ 18

Camshaft retention plate screw 4 ÷ 6

MP3 125 Characteristics

CHAR - 7

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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 ÷ 13

Tappet set screw lock nut 6 ÷ 8

Starter ground screw 7 ÷ 8.5

Head fixing side screws 11 ÷ 12

Nuts fixing head to cylinder (*) 27 ÷ 29

Tappet cover screws 6 ÷ 7

Spark plug 12 ÷ 14

ENGINE - TRANSMISSION

Name Torque in Nm

Rear hub cover screws 24 ÷ 27

Driven pulley shaft nut 54 ÷ 60

Transmission cover screws 11 ÷ 13

Drive pulley nut 75 ÷ 83

Clutch unit nut on driven pulley 55 ÷ 60

Belt support roller screw 11 ÷ 13

ENGINE - FLYWHEEL

Name Torque in Nm

Pick-Up clamping screws 3 ÷ 4

Stator assembly screws (°) 3 ÷ 4

Flywheel cover fixing screws 5 - 6

Flywheel nut (250) 94 ÷ 102

Screw fixing freewheel to flywheel 13 ÷ 15

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws

4 ÷ 6

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing system cover screws (°) 3.5 ÷ 4.5

ENGINE - COOLING

Product Description Specifications

(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-

strength threadlock

Overhaul data

Assembly clearances

Characteristics MP3 125

CHAR - 8

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Cylinder - piston assy.

ENGINE COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059 Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059

Cylinder 1st Over-

size

A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059

Cylinder 1st Over-

size

B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059

Piston 1st Over-

size

C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059

Piston 1st Over-

size

D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059

Cylinder 2nd Over-

size

A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059

Cylinder 2nd Over-

size

B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059

Piston 2nd Over-

size

C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059

Piston 2nd Over-

size

D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059

Cylinder 3rd Over-

size

A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059

Cylinder 3rd Over-

size

B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059

Piston 3rd Over-

size

C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059

Piston 3rd Over-

size

D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

MP3 125 Characteristics

CHAR - 9

Page 16

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo Durata/Valore Testo Breve (< 4000

car.)

Indirizzo Immagine

Crankshaft Crankshaft to crankcase

axial clearance

Crankshaft to crankcase axial clearance

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

16.6 +0-0.05 A D = 0.20 - 0.50

Flywheel-side half-

shaft

16.6 +0-0.05 B D = 0.20 - 0.50

Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50

Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

Slot packing system

Characteristic

Compression ratio

Cr: 11.50 ÷ 13:1

Characteristics MP3 125

CHAR - 10

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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.

N.B.

NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND ON A RECTIFIED PLANE.

MODELS WITH FIBRE HEAD GASKET (1.1)

Name Measure A Thickness

Shimming 125 - Cylinder 67 -

Head gasket 1.1 - Base gasket

0.4

2.20 ÷ 2.45 0.4 ± 0.05

Shimming 125 - Cylinder 67 -

Head gasket 1.1 - Base gasket

0.6

2.45 ÷ 2.70 0.6 ± 0.05

Characteristic

Compression ratio

Cr: 11.50 ÷ 13:1

MP3 125 Characteristics

CHAR - 11

Page 18

N.B.

MODELS WITH METALLIC HEAD GASKET (0.3)

Name Measure A Thickness

Shimming 125 - Cylinder 67.8 -

Head gasket 0.3 - Base gasket

0.4

1.40 ÷ 1.65 0.4 ± 0.05

Shimming 125 - Cylinder 67.8 -

Head gasket 0.3 - Base gasket

0.6

1.65 ÷ 1.90 0.6 ± 0.05

Products

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil

Check

Every time the scooter is used, a visual check should be made on the level of the engine oil when the engine is cold. The oil level should be somewhere between the MAX and MIN index marks on the level bar; the check must be made with the scooter upright, resting on the centre stand. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level.

Maintenance MP3 125

MAIN - 12

Page 47

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). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference mark is opposite the indicator on the head, make the crankshaft turn once more.

-The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel cover. To use this reference mark, remove the spark plug and turn the engine in the opposite direction to the normal direction using a calliper spanner applied to the camshaft command pulley casing.

N.B.

TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

Checking the valve clearance

-To check valve clearance, centre the reference marks of the timing system

- Use a thickness gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clearance values, intake and drainage respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operate on the register with a screwdriver as shown in the figure. Intake: 0.10 mm (when cold) Discharge: 0.15 mm (when cold)

MP3 125 Maintenance

MAIN - 13

Page 48

Headlight adjustment

Proceed as follows:

1. Position the unloaded vehicle, in running order

and with the tyres inflated to the prescribed pressure, 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;

2. Remove the headlight assembly central cover

3. Turn on the headlight and check that the limit of

the projected light beam is not over 9/10 or below 7/10 of the distance from the ground to the centre of the vehicle headlight;

4. Otherwise, adjust the headlight with the

screws«A» indicated in the figure

N.B.

THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.

SAS filters inspection and cleaning

Insert the filter into its housing. Fit the valve support with the 3 screws Insert the rubber spacer on the valve and proceed with the assembly on the support. Fix the support with the 2 screws. Fit the pre-filter and position it matching the 2 references shown in the figure. Fit the sealing gasket.

Maintenance MP3 125

MAIN - 14

Page 49

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. Secure the rotor cover by using a new gasket with the 4 screws. Connect the flywheel connector and the valve control vacuum-operated pipe. Fit the coupling to the valve and position it as shown in the figure. Lock the upper clamp. Fix the metal tube to the head using the gasket and the 2 screws. Lock the lower clamp connecting manifold / pipe.

Locking torques (N*m)

Stator assembly screws (°) 3 ÷ 4

MP3 125 Maintenance

MAIN - 15

Page 50

Maintenance MP3 125

MAIN - 16

Page 51

Undo the 3 fixing screws "A", remove the secondary 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 compressed air. Remove the flywheel cover by operating on its clamps and remove the primary filtering element.

- Wash with water and neutral soap.

-Dry with a clean cloth and short blasts of compressed air. Check that the filter casing is clean paying special attention to "A" and "B" passages

CAUTION

NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER

CAUTION

WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

MP3 125 Maintenance

MAIN - 17

Page 52

Maintenance MP3 125

MAIN - 18

Page 53

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 54

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

damaged

Remove, wash with solvent and dry with com-

pressed air or replace

Excess of encrustations in the combustion cham-

ber

Descale the cylinder, the piston, the head and the

valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Air filter blocked or dirty. Dismantle the sponge, wash with water and sham-

poo, then soak it in a mixture of 50% petrol and

50% of specific oil (Selenia Air Filter Oil), then

hand dry without squeezing, allow to drip dry and

then reassemble.

Automatic starter failure Check: mechanical movement, electric connec-

tion and fuel supply, replace if required.

Oil level exceeds maximum Check for causes and fill to reach the correct level

Lack of compression: parts, cylinder and valves

worn

Replace the worn parts

Transmission belt worn Replace

Inefficient automatic transmission Check the rollers and the pulley movement, re-

place the damaged parts and lubricate the driven

pulley moveable guide with Montblanc Molybde-

num Grease

Clutch slipping Check the clutch system and/or the bell and re-

place if necessary

Overheated valves Remove the head and the valves, grind or replace

the valves

Wrong valve adjustment Adjust the valve clearance properly

Valve seat distorted Replace the head assembly

Air filter dirty Dismantle the sponge, wash with water and sham-

poo, then soak it in a mixture of 50% petrol and

50% of specific oil (Selenia Air Filter Oil), then

hand dry without squeezing, allow to drip dry and

then reassemble.

Defective floating valve Check the proper sliding of the float and the func-

tioning of the valve

Starting difficulties

DIFFICULT STARTING

Possible Cause Operation

Altered fuel characteristics Drain off the fuel no longer up to standard; then,

refill

Troubleshooting MP3 125

TROUBL - 2

Page 55

Possible Cause Operation

Rpm too low at start-up or engine and start-up

system damaged

Check the starter motor, the system and the torque

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. If the

engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to

expel the fuel excess taking care to connect the

cap to the spark plug, and this in turn to the ground.

If the fuel tank is empty, refuel and start up.

Automatic starter failure Check: mechanical movement, electric connec-

tion and fuel supply, replace if required.

Air filter blocked or dirty. Dismantle the sponge, wash with water and sham-

poo, then soak it in a mixture of 50% petrol and

50% of specific oil (Selenia Air Filter Oil), then

hand dry without squeezing, allow to drip dry and

then reassemble.

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit

components

The carburettor is dirty; fuel pump or vacuum valve

damaged

Remove, wash with solvent and dry with com-

pressed air or replace

Flat battery Check the charge of the battery, if there are any

sulphur marks, replace and use the new battery

following the instructions shown in the chapter

Intake coupling cracked or clamps incorrectly

tightened

Replace the intake coupling and check the clamps

are tightened

Defective floating valve Check the proper sliding of the float and the func-

tioning of the valve

Carburettor nozzles clogged Dismantle, wash with solvent and dry with com-

pressed air

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Worn valve guides Check and replace the head unit if required

Worn valve oil guard Replace the valve oil guard

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou-

pling seal

Worn or broken piston rings or piston rings that

have not been fitted properly

Replace the piston cylinder unit or just the piston

rings

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Care-

fully clean the By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump

components

Oil filter too dirty Replace the cartridge filter

MP3 125 Troubleshooting

TROUBL - 3

Page 56

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 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.

Water in the carburettor Empty the tank through the appropriate bleed nip-

ple.

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with com-

pressed air

Engine tends to cut-off at idle

ENGINE STOP IDLING

Possible Cause Operation

Incorrect timing Time the system and check the timing system

components

Cut off device failure Check that the following parts work properly:

valve; diaphragm; spring; and that the air calibration elements are clean; check if the sponge filter

is clean too

Incorrect idle adjustment Adjust using the rpm indicator

Pressure too low at the end of compression Check the thermal group seals and replace worn

components

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit

components

The starter remains on Check: electric wiring, circuit not interrupted, me-

chanical movement and power supply; replace if

necessary

Minimum nozzle dirty Wash the nozzle with solvent and dry with com-

pressed air

Excessive exhaust noise

EXCESSIVE EXHAUST NOISE

Possible Cause Operation

Secondary air device cut-off valve not working Replace the secondary air device

Depression intake pipe of the secondary air device

disconnected or dented

Replace the pipe

Reed valve of the secondary air device does not

close correctly and wears out the rubber coupling

between the device and the head pipe

Replace the device and the coupling

Troubleshooting MP3 125

TROUBL - 4

Page 57

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.

Loose nozzles Check the maximum and minimum nozzles are

adequately fixed in their fittings

Fuel pump failure Check that there is no fuel in the low-pressure duct

Starter inefficient Check: electric wiring, circuit continuity, mechani-

cal sliding and power supply

Air filter blocked or dirty. Dismantle the sponge, wash with water and sham-

poo, then soak it in a mixture of 50% petrol and

50% of specific oil (Selenia Air Filter Oil), then

hand dry without squeezing, allow to drip dry and

then reassemble.

SAS malfunctions

ANOMALIES IN THE SECONDARY AIR DEVICE

Possible Cause Operation

Secondary air device cut-off valve not working Replace the secondary air device

Depression intake pipe of the secondary air device

disconnected or dented

Replace the pipe

Reed valve of the secondary air device does not

close correctly and wears out the rubber coupling

between the device and the head pipe

Replace the device and the coupling

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Faulty clutch Check that there is no grease on the masses.

Check that the clutch mass contact surface with

the casing is mainly in the centre with equivalent

characteristics on the three masses. Check that

the clutch casing is not scored or worn in an anom-

alous way

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Insufficient braking

INSUFFICIENT 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. Check there is no air in the circuits; if necessary, bleed the air. Check that the front brake calliper moves in axis with the disc.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump

seals, replace

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Rubber gaskets swollen or stuck Replace gaskets.

Compensation holes on the pump clogged Clean carefully and blast with compressed air

Brake disc slack or distorted Check the brake disc screws are locked; use a dial

gauge and a wheel mounted on the vehicle to

measure the axial shift of the disc.

Defective piston sliding Check calliper and replace any damaged part.

Electrical system

Battery

BATTERY

Possible Cause Operation

Battery This is the device in the system that requires the

most frequent attention and the most thorough

maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down com-

pletely in the course of 3 months. If the battery is

fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground wire is connected to the negative terminal while the

red wire is connected to the terminal marked+.

Turn signal lights malfunction

TURN INDICATOR NOT WORKING

Possible Cause Operation

Electronic ignition device failure With the key switch set to "ON" jump the contacts

1 (Blue - Black) and 5 (Red/Blue) on the control unit connector. If by operating the turn indicator

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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.

Clutch fault Check the springs / clutch masses

Controls

STEERING CONTROLS AND SUSPENSIONS

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

if they are recessed or if the balls are squashed,

replace them.

Steering hardening Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

if they are recessed or if the balls are squashed,

replace them.

Malfunctions in the suspension system If the front suspension is noisy, check: the efficien-

cy of the front shock absorbers; the condition of

the ball bearings and relevant lock-nuts, the limit

switch rubber buffers and the movement bushings.

In conclusion, check the tightening torque of the wheel hub, the brake calliper, the shock absorber disk in the attachment to the hub and the steering

tube.

Seal fault or breakage Replace the shock absorber Check the condition

of wear of the steering covers and the adjust-

ments.

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 62

KEY

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. Start up remote control switch

13. Starter button 14 Secondary fuses

15. Stop button on rear brake

16. Stop button on front brake

17. Thermoswitch

18. Key switch

19. Radiator electric fan

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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. Wiring for Tom-Tom

26. Hazard and turn indicator control device

1. Hazard button

2. Left switch

3. Right switch

4. Left turn indicator

5. Right turn indicator

6. Ground

7. Key

8. +Battery

27. Wiring for antitheft device

28. Helmet compartment internal light

29. Rear left turn indicator

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. Headlight assembly

A. Tail light bulbs B. Low-beam bulb

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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. Locking/unlocking switch

43. Horn remote control

44. Pressure sensor

45. Horn

46. Geared motor

47. Brake calliper sensor

48. Parking electronic control unit

49. Right wheel revolution sensor

50. Left wheel revolution sensor

51. Potentiometer

52. Rider presence sensor

53. Oil pressure sensor

54. External temperature sensor

55. Parking brake button

56. Instrument panel

57. Fuel level transmitter

58. Electric pump control device (for scooters with electric pump only)

1. +Key

3. Pump ground connection

4. +Pump

5. Ground

6. Engine revs

59. Fuel pump (for scooters with electric pump only)

60. Starter

61. Spark plug

62. HV coil KEY

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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

KEY

1. Electronic ignition device

2. Immobilizer aerial

9. Main fuses

10. Battery

18. Key switch

61. Spark plug

62. HV coil

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Battery recharge and starting

KEY

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. Secondary fuses

15. Stop button on rear brake

16. Stop button on front brake

18. Key switch

29. Rear left turn indicator

A. Left turn indicator bulbs B. Stop light bulb C. Tail light bulb

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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

KEY

1. Electronic ignition device

2. Immobilizer aerial

3. Throttle body position

5. CDI Temperature sensor

7. Engine stop switch

9. Main fuses

10. Battery

14. Secondary fuses

18. Key switch

40. Instrument panel cooling liquid temperature sensor

47. Brake calliper sensor

48. Parking electronic control unit

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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

KEY

1. Electronic ignition device

6. Diagnostics socket

7. Engine stop switch

9. Main fuses

10. Battery

14. Secondary fuses

17. Thermoswitch

18. Key switch

19. Radiator electric fan

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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. Helmet compartment internal light

35. Horn button

38. Helmet compartment light switch

39. Helmet compartment light switch

41. Mode button

42. Locking/unlocking switch

43. Horn remote control

44. Pressure sensor

45. Horn

46. Geared motor

48. Parking electronic control unit

55. Parking brake button

56. Instrument panel

58. Electric pump control device (for scooters with electric pump only)

1. +Key

3. Pump ground connection

4. +Pump

5. Ground

6. Engine revs

59. Fuel pump (for scooters with electric pump only)

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Lights and turn indicators

KEY

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. Left switch

3. Right switch

4. Left turn indicator

5. Right turn indicator

6. Ground

7. Key

8. +Battery

29. Rear left turn indicator

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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. Headlight assembly

A. Tail light bulbs B. Low-beam bulb C. High-beam bulb

34. Front right turn indicator

36. Remote control headlight

37. Light switch

48. Parking electronic control unit

56. Instrument panel

Checks and inspections

This section is devoted to the checks on the electrical system components.

Immobiliser

The electric ignition system is fed with direct current and is protected by an anti-theft immobilizer integrated to the control unit. The ignition system consists of:

- electronic control unit

- immobilizer aerial

- master and service keys with built-in transponder

- H.V. coil

- diagnosis led The diagnosis led also works as a blinking light to deter theft. This function is activated every time the key switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process.

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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. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located below the spark plug inspection port. If the serial led remains off, check the control unit voltage supply; in order to do this, disconnect the control unit connector and check if:

- there is battery voltage between the terminal No. 6 (Red/Green) and the ground connection.

- there is battery voltage between the terminal No. 6 (Red/Green) and the terminal No. 9 (Negative) as shown in the figure. If no voltage is detected, check the wiring to the battery positive lead and see if 15A fuse No. 4 is in good conditions.

- there is battery voltage between the terminal No. 8 (Orange) and the terminal No. 9 (Negative) with the key switch set to "ON" and the emergency switch set to "RUN". If no faults are found, replace the control unit; otherwise check the wiring and the following components:

- Engine stop remote control;

- Emergency cut-off switch;

- Key switch contacts.

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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 evident 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" and keep it in that position for 2 seconds (limit values: 1 ÷ 3 seconds).

- Alternately insert all the available black keys and turn each one of them to "ON" for 2 seconds.

- Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 (Black) service keys can be programmed at one time. Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start. Once the control unit has been programmed, the control unit is inseparably matched with the MASTER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stored one is deleted. If a service key setting is lost, it is essential to carefully check the efficiency of the high voltage system: Shielded cap resistance ~ 5000 Ω. In any case it is advisable to use resistive spark plugs.

Diagnostic codes

The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings. That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:

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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). If the failure persists with any key, disconnect the aerial connector from the control unit and check the aerial continuity with the 020331Y multimeter. If non-conforming values are measured, replace the aerial. If no failures are found in the aerial, replace the control unit.

CAUTION

BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT

Electric characteristic

immobilizer aerial

~ 7 ÷ 9 Ohm

Ignition circuit

Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control unit is connected to the Pick-Up by the chassis and the engine ground lead.

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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. Disconnect the control unit connector and check that the cable between terminal No. 11 (Green) and terminal No. 9 (Black) is not interrupted. Check the Pick-Up and its power line:

Electric characteristic

Pick-up resistance value

Pick-up resistance value: 105 ÷ 124 Ohm

If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine manual). If non-conforming values are detected, replace the Pick-Up, otherwise check the cable harness and the connections. In case conforming values are measured and the wiring and connections check is OK, try replacing the control unit (without programming) and make sure the failure has been solved by checking sparks are produced in the spark plug; only then program the control unit. If no sparks are produced with the new control unit, proceed as follows.

- HV primary coil check Disconnect the control unit connector and check that the cable between terminal No. 17 (Violet) and terminal No. 9 (Black) is not interrupted (see figure). If non-conforming values are detected, disconnect the two connectors on the HV coil and check its continuity (see figure). If the values are correct, repair the cable harness and restore the connections; otherwise, replace the HV coil.

Electric characteristic

High voltage coil primary resistance value

High voltage coil primary resistance value: 0.4 ÷

0.5 Ohm

HV coil secondary check

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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 ± 300 Ohm

- Pick-Up. Disconnect the control unit connector and connect the positive wire to connector No. 11 and the negative wire to connector No. 9 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up. Replace Pick-Up if non-conforming values are measured.

Electric characteristic

Pick-Up voltage value

Pick-Up voltage value: > 2 Volt

- H.V. coil With the control unit and HV coil connected, measure the voltage of the coil primary during the startup test with the voltage peak adaptor and connecting the positive terminal to the earth one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit.

N.B.

THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE HV COIL PRIMARY IS BLACK AND THE NEGATIVE TERMINAL ONE IS GREEN.

Electric characteristic

High voltage coil voltage value

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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. The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability.

Stator check

Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.

Electric characteristic

Ohm value:

0.7 ÷ 0.9 Ohm Also check that all yellow cables are insulated from

the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.

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- With a tester, check the circuit between connections 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 connections 4 and ground (with engine off) is not interrupted. Pick-Up check

- Check that there is a resistance of about 105 ÷ 124 Ω at 20° C between connection 2 and ground.

- In case of values different from the ones stated, replace the defective parts.

N.B.

VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.

Voltage regulator check

With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.

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Recharge system voltage check

Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine. In case the generated current value is lower than 10A, repeat the test using a new regulator and/ stator alternatively.

Choke Inspection

Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If voltage is detected, replace the automatic starter as it is surely failing. If no voltage is detected, connect the multimeter negative terminal to the earth terminal and the positive terminal to the automatic starter orange cable; with the key switch set to «ON» check whether there is battery voltage; if there is no voltage, check the wiring connections to the key switch and that the 15A fuse works properly. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed; then check there is voltage connecting the multimeter

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positive probe to terminal No. 8 (Orange), and the negative one to terminal No. 10 (Brown) (see figure). Replace the control unit if there is no voltage; otherwise, check the wiring connections between the starter and the control unit.

Lights list

LIGHT BULBS TABLE

Specification Desc./Quantity

1 Low-beam bulb Type: HALOGEN (H1)

Power: 12V - 55W

Quantity: 1

2 High-beam light bulb Type: HALOGEN (H1)

Power: 12V - 55W

Quantity: 1

3 Helmet compartment light bulb Type: CYLINDRIC

Power: 12V - 5W

Quantity: 1

4 Rear turn indicator bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 2 RHS + 2 LHS

5 Rear tail light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 1 RHS + 1 LHS

6 Stop light bulb Type: SPHERICAL

Power: 12V - 10W

Quantity: 2

7 License plate light bulb Type: ALL GLASS

Power: 12V - 5W

Quantity: 1

8 Front turn indicator bulb Type: ALL GLASS

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

9 Front tail light bulb Type: ALL GLASS

Power: 12V - 3W

Quantity: 1 RHS + 1 LHS

10 Instrument panel bulb Type: ALL GLASS

Power: 12V - 2W

Quantity: 4

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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 compartment and the other is at the right internal side of the footrest. To be able to reach them, loosen the screw "A" and remove the plastic cover. The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

BEFORE REPLACING THE BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

FUSE CHART

Specification Desc./Quantity

1 Fuse No. 1 Capacity: 10A

Protected circuits:

from the battery: headlight remote control

Location:battery compartment

2 Fuse No. 2 Capacity: 7.5 A

Protected circuits:

from the battery: saddle opening receiver,

hazard and turn indicator control device, anti-

theft device pre-installation, instrument pan-

el, helmet compartment lighting

Location:battery compartment

3 Fuse No. 3 Capacity: 15 A

Protected circuits:

live: parking control ECU, fuses 8, 9 and 10

Location:battery compartment

4 Fuse No. 4 Capacity: 15 A

Protected circuits:

from the battery: voltage regulator, electric

fan, electronic ignition device

live: engine stop switch, starter, electronic ig-

nition device, TPS, fuses 7 and 11

Location:battery compartment

5 Fuse No. 5 Capacity: 20A

Protected circuits:

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Specification Desc./Quantity

from the battery: parking control ECU

Location:battery compartment

6 Fuse No. 6 Capacity: 4A

Protected circuits:start-up, stop lights.

Location:footrest

7 Fuse No. 7 Capacity: 4A

Protected circuits:panel lighting, tail lights,

license plate light Location:footrest

8 Fuse No. 8 Capacity: 7.5 A

Protected circuits:lights switch, horn, wiring

for Tom-Tom

Location:footrest

9 Fuse No. 9 Capacity: 7.5 A

Protected circuits:saddle opening receiver, hazard and turn indicator control device, anti-

theft device pre-installation, turn indicator

switch, instrument panel, horn remote control

Location:footrest

10 Fuse No. 10 Capacity: 7.5 A

Protected circuits:headlight remote control

Location:footrest

11 Fuse No. 11 Capacity: 3A

Protected circuits:electric pump control de-

vice

Location:footrest

Dashboard

A = Led immobilizer / anti-theft device B= Speedometer with twin scale (km/h and mph) C = CLOCK switch D = Digital display E = Front suspension locking system warning light (if available) F = SET switch G = Rpm indicator H = Fuel gauge I = Warning light for helmet compartment courtesy light on L = Engine control telltale light and injection system failure warning light M = Low fuel warning light N = Engine stop warning light D= Turn indicator warning light P = Low oil pressure warning light

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Q = Front suspension locking system failure warning 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:

•

TIME

•

DATE To set the clock push and hold the «CLOCK» button longer than 3 seconds. The numbers showing the hours will begin flashing. Set the hour using the «SET» button. Push the «CLOCK» button again and the minutes numbers start flashing. Set the minutes using the «SET»button. Push the «CLOCK» button again and the day numbers start flashing. Set the day with the «SET» button. Push the «CLOCK» button again and the month numbers start flashing. Set the month with the «SET» button. Push the «CLOCK» button again and the year numbers start flashing. Set the year with the «SET» button. Press the «CLOCK » button again for 4 seconds to exit the adjustment menu. During the reset process, not pressing any buttons for a period longer than 8 seconds ends the process automatically and the display shows the modified time.

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and, afterwards, every six months. INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 ÷ 14.70V

-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity

- Charge time:

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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. CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS TO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THE COURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE, BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL MARKED WITH THE +POSITIVE SIGN

WARNING

WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Dry-charge battery

COMMISSIONING A NEW DRY-CHARGED BATTERY

- Remove the battery air pipe stop cap and each single element caps.

- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an ambient temperature not below 15°C, until it reaches the upper level indicated on the block.

- Tilt the battery slightly to remove any air bubbles formed during filling.

- Place the caps on each single element filling holes without screwing them and leave the battery to rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases.

- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).

- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water;

- Before 24 hours elapse, recharge the battery following these steps:

- Connect the battery charger terminals observing the correct polarity;

- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity;

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- 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. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge.

- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester.

- If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging.

- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle.

- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.

Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the Check function. The value indicated on the display must be higher than the value indicated on the chart;

otherwise, recharge the battery again in the same way indicated above.

Connectors

Dashboard

20-WAY INSTRUMENT CONNECTOR

Specification Desc./Quantity

1 1 Speed signal 2 2 Fuel level signal 3 3 Water temperature sensor 4 4 Water temperature sensor ground connec-

tion 5 5 Remote mode button 6 6 Oil pressure warning light 7 7 Left direction warning light 8 8 Right direction warning light 9 9 High-beam lamp warning light 10 10 Open boot warning light 11 11 Revolution sensor 12 12 Ambient temperature sensor 13 13 Ambient temperature sensor ground connec-

tion 14 14 Engine disabled warning light 15 15 Immobilizer warning light 16 16 Engine control warning light 17 17 Parking brake warning light 18 18 Tilt locking warning light 19 19 Tilt locking system failure warning light 20 20 Live positive lead of parking control unit

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12-WAY INSTRUMENT CONNECTOR

Specification Desc./Quantity

1 5 Lighting 2 6 Battery positive 3 11 Earth 4 12 Live positive lead

Remote seat opening

Zeroing

- Remove the left side fairing to access the saddle opening receiver control unit indicated in the photograph

- Remove the metal terminal and connect it to a good earth point, or to terminal 7 (black), for at least 10 seconds.

- In this operation all the remote controls stored in the control unit will be deleted.

WARNING

THE CONTROL UNIT CAN PROGRAMME UP TO 8 REMOTE CONTROLS.

Programming

Follow these steps to program the remote controls:

1. Insert the remote control key to be programmed in the steering lock key block.

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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. Repeat steps 2 and 3 for 4 times without removing the key.

The control unit confirms the programming has been successfully executed by opening the saddle.

WARNING

TO STORE THE OTHER REMOTE CONTROLS TO MEMORY, (MAXIMUM 8), YOU NEED TO REPEAT THE WHOLE PROCEDURE AGAIN. FAILURE TO CARRY OUT THESE OPERATIONS WITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMING THE REMOTE-CONTROLLED KEYS.

WARNING

AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FAR AWAY FROM THE SCOOTER. THE SYNCHRONISM BETWEEN THE REMOTE CONTROL AND THE RECEIVER CAN BE IMPAIRED. SHOULD THIS BE THE CASE, REPEAT THE PROGRAMMING PROCEDURE. DO NOT KEEP THE REMOTE CONTROL IN PLACES WITH TEMPERATURES EXCEEDING 60° C THE BATTERY WILL RUN DOWN TOO QUICKLY.

WARNING

TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTE CONTROL RADIO RECEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLE WAS SHUT OFF. JUST TURN THE KEY TO «ON» TO REACTIVATE THE RECEIVER.

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Electrical system MP3 125

ELE SYS - 28

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 90

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. To undo the nuts fixing the muffler flange to the head properly, you must use a jointed wrench that enables you to get at the right nut as well, according to the direction of travel, that is difficult to get at with a traditional straight wrench.

- Undo the three screws fixing the muffler to the support arm. Remove the full muffler unit.

Remove the lambda probe from the manifold.

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CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

Removal of the engine from the vehicle

- Disconnect the battery

- Remove the engine cover inside the helmet compartment

- Remove the side panels Remove the full muffler assembly.

CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Remove the rear wheel.

- Remove the pipe feeding coolant into the pump as shown in the photograph and then empty the system.

- Remove the engine coolant outlet pipe as indicated.

- Disconnect the fuel delivery and return pipes from the injector by removing the screw locking the retaining clip.

- Disconnect the injector wiring and the throttle body control unit wiring.

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Page 92

- Remove the coolant outlet pipe from the motor as indicated.

- Remove the spark plug caps.

- Remove the coolant temperature sensor connector indicated in the photo.

- Remove the throttle cable from the throttle body by undoing the nut shown in the photo.

- Remove the positive and negative wiring from the starter motor as shown in the photo.

Engine from vehicle MP3 125

ENG VE - 4

Page 93

- Disconnect the connectors from the flywheel wiring 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. Remove the engine-swinging arm fixing pin by undoing the nut and the head of the pin as shown in the photograph.

- The engine is now free.

When refitting the engine onto the scooter, carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter.

-Check the engine oil level and if necessary top it up with the recommended type.

- Fill and bleed the cooling circuit.

- Check the functioning of the accelerator and the electrical devices.

CAUTION

MP3 125 Engine from vehicle

ENG VE - 5

Page 94

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY.

Engine from vehicle MP3 125

ENG VE - 6

Page 95

INDEX OF TOPICS

ENGINE ENG

Page 96

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. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.

Specific tooling

020423Y driven pulley lock wrench

- Remove the cap/dipstick from the engine oil filling hole.

- Remove the ten screws.

- Remove the transmission cover. If this operation is carried out directly on the vehicle, remove the cooling air supply coupling of the transmission housing.

Air duct

- Remove the five screws on two different levels as well as the small casing.

Engine MP3 125

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Page 97

- 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 020375Y Adaptor 28 x 30 mm 020412Y 15 mm guide

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase from the inside so as not to damage the painted surface.

- Insert the bearing in its seat.

- Refit the Seeger ring.

CAUTION

USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.

N.B.

ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING.

Specific tooling

020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide

MP3 125 Engine

ENG - 3

Page 98

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.

Characteristic

Max. value clutch bell

Max. value: Ø 134.5 mm

Clutch bell standard value

Standard value: Ø 134 - 134.2 mm

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2 bearings (inner diameter 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft assembly on the support to check the crankshaft alignment.

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- 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

clutch bell inspection: Limit eccentricity.

Admissible limit eccentricity: 0.15 mm

Removing the clutch

Clutch removal (125 cm³ H2O)

Fit the driven pulley spring compressor specific tool with medium length pins screwed in position F from the tool internal side.

- Insert the adapter ring 8 in the pins.

- Assemble the driven pulley unit on the tool introducing the rivets heads in the adapter ring.

- Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to loosen/tighten the clutch nut.

- Use the special 46x55 wrench component n°9 to remove the nut fixing the clutch in place.

- Separate the driven pulley components (Clutch, fan and spring with plastic fitting).

CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE.

Specific tooling

020444Y009 46x55 Wrench 020444Y010 adapter ring

MP3 125 Engine

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Page 100

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 EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

Pin retaining collar

- Simultaneously turn and pull the collar manually to remove it.

N.B.

USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY.

N.B.

BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O-RING SEAL.

- Remove the four torque server pins and pull the pulley halves apart.

Engine MP3 125

ENG - 6

PIAGGIO 633929, 633930, 633931, 633932, 633937 Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual