Piaggio MP3 250 Service Manual

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SERVICE STATION MANUAL

633823

MP3 250 i.e.

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SERVICE STATION

MP3 250 i.e.

MANUAL

The descriptions and illustrations given in this publication are not binding. While the basic specifications 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 accessories, 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 single versions

should be checked at 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 250 i.e.

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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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

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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Characteristics MP3 250 i.e.

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.

CHAR - 2

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MP3 250 i.e. Characteristics

Vehicle identification

Chassis prefix (FULL OPTIONAL): M47201 Chassis prefix (BASE): M47200 Engine prefix: M472M

Dimensions and mass

Specification Desc./Quantity

Kerb weight 224 ± 5 Kg

Wheelbase 1490 mm

Height 1245 mm

Width (handlebar) 745 mm

Overall length 2130 mm

Track 420 mm

WEIGHTS AND DIMENSIONS

Engine

DATA

Specification Desc./Quantity

Type single-cylinder, four-stroke and four liquid-cooled

valves

CHAR - 3

Page 10

Characteristics MP3 250 i.e.

Specification Desc./Quantity

Timing system single overhead camshaft chain driven on the left-

hand side, three-arm rocking levers set up with

threaded set screw

Bore 72 mm

Stroke 60 mm

Cubic capacity 249.29 mm

Compression ratio 10.5 ÷ 11.5

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) chain-driv-

en and double filter: mesh and paper

Fuel supply by electronic injection with electric fuel pump

valve clearance intake: 0.10 mm - discharge: 0.15 mm

Engine idle speed approx. 1600 ÷ 1800 rpm

Max. speed 125 km/h

Transmission

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque

Capacities

Specification Desc./Quantity

Engine oil approx. 1300 cc (recommended oil Selenia HI

Rear hub 250 cc ( recommended oil TUTELA MATRIX)

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

Fuel reserve approx. 2.5 litres (indicative value)

Cooling circuit Capacity: ~ 2.0 l

Electrical system

Specification Desc./Quantity

Ignition/advance Electronic, with inductive discharge and variable

Spark plug CHAMPION RG 4 PHP

Generator alternating current

TRANSMISSION

server, V belt, automatic clutch, gear reduction unit

and transmission housing with forced air circula-

tion cooling

CAPACITY

Scooter 4 Tech)

ELECTRICAL COMPONENTS

advance with three-dimensional mapping

Battery 12V-12Ah

CHAR - 4

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MP3 250 i.e. Characteristics

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"x3,00

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

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

CHAR - 5

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Characteristics MP3 250 i.e.

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

Upper fitting for shock absorber sliding locking

clamp pipes

20 ÷ 25 20 ÷ 25

REAR SUSPENSION

Name Torque in Nm

Upper shock absorber clamp 33 ÷ 41

Shock absorber lower clamp 33 ÷ 41

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

CHAR - 6

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MP3 250 i.e. Characteristics

Name Torque in Nm

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 7 ÷ 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

CYLINDER HEAD

Name Torque in Nm

Spark plug 12 ÷ 14

Head cover screws 6 ÷ 7

Nuts fixing head to cylinder 7±1 + 10±1 + 270°

Head fixing side screws 11 ÷ 12 Nm

Starter ground screw 7 ÷ 8.5

Tappet set screw lock nut 6 ÷ 8

Inlet manifold screws 11 ÷ 13

Timing chain tensioner slider screw 10 ÷ 14

Starter ground support screw 11 ÷ 15

Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 4 ÷ 6

CHAR - 7

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Characteristics MP3 250 i.e.

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11 ÷ 13

Clutch unit nut on driven pulley 45 ÷ 50

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screws 24 ÷ 27

FLYWHEEL

Name Torque in Nm

Flywheel cover screw 11 ÷ 13

Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength

threadlock)

Flywheel nut 94 - 102 Nm

Pick-Up clamping screws 3 ÷ 4

Screw fixing freewheel to flywheel 13 ÷ 15

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Bleed screw: 3

Overhaul data

Assembly clearances

4 ÷ 6

threadlock)

COOLING

CHAR - 8

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MP3 250 i.e. Characteristics

Cylinder - piston assy.

ENGINE COUPLING CATEGORY

Name Initials Cylinder Piston Play on fitting

Cylinder M 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder N 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064

Piston O 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 - 0.064 Piston P 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 - 0.064

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo Durata/Valore Testo Breve (< 4000

car.)

Crankshaft Crankshaft to crankcase

axial clearance

Crankshaft to crankcase axial clearance

Indirizzo Immagine

CHAR - 9

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Characteristics MP3 250 i.e.

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

Flywheel-side half-

shaft

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

16.6 +0-0.05 A D = 0.20 - 0.50

16.6 +0-0.05 B D = 0.20 - 0.50

Slot packing system

Characteristic

Compression ratio

10.5 ÷ 11.5 : 1

CHAR - 10

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MP3 250 i.e. Characteristics

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.

N.B.

MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON A GROUND PLANE

ENGINE 250 SHIMMING

Name Measure A Thickness

shimming 3.70 - 3.60 0.4 ± 0.05 shimming 3.60 - 3.40 0.6 ± 0.05 shimming 3.40 - 3.30 0.8 ± 0.05

CHAR - 11

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Characteristics MP3 250 i.e.

Products

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Rear hub oil

Capacity approximately 250 cc

Locking torques (N*m)

Hub oil drainage screw 15 ÷ 17 Nm

MAIN - 7

Page 40

Maintenance MP3 250 i.e.

Air filter

Proceed as follows: Undo the clamping screws «A» (two of which are on the knob-type head) and remove the air-box cover.

1. Wash the sponge with water and neutral soap.

2. Dry it with a clean cloth and small blasts of compressed air.

3. Impregnate the sponge with a mixture of 50% petrol and 50% specified oil.

4. Gently squeeze the filter element, let it drip and then refit it.

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CONTROLS OF THE AIR FILTER TO AVOID DAMAGING THE ENGINE.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil

In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

At 1,000 km and after every 10,000 km, the oil and the filter must be changed. The engine must be drained by running off the oil from drainage cap "B" of the flywheel side gauze pre-filter; furthermore to facilitate oil drainage, loosen the cap/ dipstick "A". Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter "C" and remove it.

MAIN - 8

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MP3 250 i.e. Maintenance

Make sure the pre-filter and discharge tap O-rings are in good condition. Lubricate them and refit the gauze filter and oil drainage tap, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from cap "A". Then start up the scooter, leave it running for a few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

N.B.

THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Check

This operation must be carried out with the engine cold and following the procedure below:

1. Place the vehicle on its centre stand and on flat ground.

2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down com- pletely.

3. Remove the cap/dipstick again and check that the level is between the min and max. marks; top up if necessary.

MAIN - 9

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Maintenance MP3 250 i.e.

The MAX level mark indicates a quantity of around 1300 cc of engine oil. 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.

Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoration of the level from MIN to MAX requires approximately 200 cc.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before the fitting. Change the engine oil.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Oil pressure warning light

The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been started.

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

MAIN - 10

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MP3 250 i.e. Maintenance

Checking the ignition timing

-Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark «T» on

the rotor matches the reference mark on the flywheel cover 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 is opposite the indicator on the head, turn the crankshaft once more. For the use of this reference mark, remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a calliper spanner applied to the camshaft command pulley casing.

Cooling system

Introduction of the engine coolant.

The fluid level must checked every 10,000 kilometres with a cold engine, in the way shown below: Place the scooter on its centre stand and on flat ground.

- Undo the screw shown in the figure and remove

the expansion tank cap on RHS.

- Top up if the fluid level is near or below the MIN

level edge. The liquid level must always be between the MIN and MAX level.

-The coolant consists of an ethylene glycol and

corrosion inhibitor based 50% demineralised water- antifreeze solution mix.

CAUTION

DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE vehicle IS IN USE.

MAIN - 11

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Maintenance MP3 250 i.e.

Braking system

Level check

The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows:

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

- Check the fluid level through the sight glass «C». A certain lowering of the level is caused by wear on the pads.

Top-up

Proceed as follows: Loosen the screw "B" and lift the plastic cover "A" in order to access the brake fluid reservoir. Loosen the two fixing screws and remove the reservoir cover; top-up with the recommended fluid without exceeding the 'MAX.' mark. This procedure applies to the rear brake pump topup operation; follow the same procedure for the front brake pump. Under normal climatic conditions, the fluid must be changed every 20,000 km or anyway every two years.

WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. COOLING SYSTEM FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION

MAKE SURE THE BRAKE FLUID DOES NOT GET INTO YOUR EYES OR ON YOUR SKIN OR CLOTHES. IF THIS HAPPENS ACCIDENTALLY, WASH WITH WATER.

MAIN - 12

Page 45

MP3 250 i.e. Maintenance

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.

MAIN - 13

Page 46

Maintenance MP3 250 i.e.

MAIN - 14

Page 47

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 48

Troubleshooting MP3 250 i.e.

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

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause Operation

Wrong valve adjustment Adjust the valve clearance properly

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

the valves

Misshapen/worn valve seats Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston

rings

Worn or broken piston rings or piston rings that

have not been fitted properly

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

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Replace the piston cylinder unit or just the piston

rings

pling seal

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

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

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

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level using the recommended oil type

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-

fully clean the By-Pass area.

components

(Selenia HI Scooter 4 Tech)

alous way

TROUBL - 2

Page 49

MP3 250 i.e. Troubleshooting

Insufficient braking

INEFFICIENT BRAKING SYSTEM

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

Brake disc slack or distorted Check the brake disc screws are locked; measure

the axial shift of the disc with a dial gauge and with

wheel mounted on the scooter.

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective sliding of pistons Check calliper and replace any damaged part.

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.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or glued rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

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.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

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:

TROUBL - 3

Page 50

Troubleshooting MP3 250 i.e.

Possible Cause Operation

if they are recessed or if the balls are squashed,

replace them.

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

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.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Seal fault or breakage Replace the shock absorber Check the condition

of wear of the steering covers and the adjust-

ments.

TROUBL - 4

Page 51

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 52

Electrical system MP3 250 i.e.

KEY

1. Immobilizer aerial

2. Injection ECU

3. Engine rev sensor

4. Magneto flywheel

5. Diagnostics socket

6. Voltage regulator

7. Key switch

8. Fuse-box

9. Fuse-box

10. Battery

11. Starter motor

12. Start up remote control switch

13. Starter button

14. Stop button on front brake

15. Stop button on rear brake

16. Helmet compartment light switch

17. Helmet compartment light switch

18. Helmet compartment light bulb

19. Saddle opener actuator

20. Saddle opening receiver

ELE SYS - 2

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MP3 250 i.e. Electrical system

21. Preparation for anti-theft device

22. Turn indicator switch

23. Hazard switch

24. Turn indicator control device

25. Left rear turn indicator bulbs

26. Rear headlight assembly A. Tail light C. Stop light

27. License plate bulb

28. Right rear turn indicator bulbs

29. Left front turn indicator bulb

30. Front headlight assembly A. Low-beam light bulb B. Tail light C. High-beam light bulb

31. Right front turn indicator bulb

32. Light switch

33. Remote control headlight

34. Horn remote control

35. Horn

36. Horn button

37. Pressure sensor

38. Locking/unlocking switch

39. Geared motor

40. Right tone wheel

41. Left tone wheel

42. Brake calliper sensor

43. Parking electronic control unit

44. Oil pressure sensor

45. Hand brake

46. Rider presence sensor

47. Potentiometer

48. Instrument panel

49. External temperature sensor

50. Fuel level transmitter

51. Electric fan

52. Remote control for electric fan

53. Injection load remote control

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54. Engine stop switch

55. Mode button

56. Engine temperature sensor

57. Fuel pump

58. Fuel injector

59. Lambda probe

60. Spark plug

61. High voltage coil Key

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

Electrical system installation

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Conceptual diagrams

Ignition

KEY

1. Immobilizer aerial

2. Injection ECU

3. Revolution sensor

7. Key switch

8. Fuse-box

9. Fuse-box

10. Battery

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MP3 250 i.e. Electrical system

53. Injection load remote control

60. Spark plug

61. High voltage coil

Battery recharge and starting

KEY

2. Injection ECU

4. Magneto flywheel

6. Voltage regulator

7. Key switch

8. Fuse-box

9. Fuse-box

10. Battery

11. Starter motor

12. Start up remote control switch

13. Starter button

14. Stop button on front brake

15. Stop button on rear brake

26. Rear headlight assembly B. Stop light

54. Engine stop switch

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Level indicators and enable signals section

KEY

1. Immobilizer aerial

2. Injection ECU

3. Revolution sensor

7. Key switch

8. Fuse-box

9. Fuse-box

10. Battery

38. Locking/unlocking switch

39. Geared motor

40. Right tone wheel

41. Left tone wheel

42. Brake calliper sensor

43. Parking electronic control unit

44. Oil pressure sensor

45. Hand brake

46. Rider presence sensor

47. Potentiometer

48. Instrument panel

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MP3 250 i.e. Electrical system

49. External temperature sensor

50. Fuel level transmitter

53. Injection load remote control

54. Engine stop switch

55. Mode button

56. Engine temperature sensor

57. Fuel pump

58. Fuel injector

59. Lambda probe

Devices and accessories

KEY

2. Injection ECU

7. Key switch

8. Fuse-box

9. Fuse-box

10. Battery

19. Saddle opening actuator

20. Saddle opening receiver

21. Wiring for antitheft device

34. Horn remote control

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35. Horn

36. Horn button

37. Pressure sensor

43. Parking electronic control unit

51. Electric fan

52. Remote control for electric fan

Lights and turn indicators

KEY

7. Key switch

8. Fuse-box

9. Fuse-box

10. Battery

21. Wiring for antitheft device

22. Turn indicator switch

23. Hazard switch

24. Turn indicator control device

25. Left rear turn indicator bulbs

26. Rear headlight assembly A. Tail light B. Stop light

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27. License plate bulb

28. Right rear turn indicator bulbs

29. Left front turn indicator bulb

30. Front headlight assembly A. Low-beam light bulb B. Tail light C. High-beam light bulb

31. Right front turn indicator bulb

32. Light switch

33. Remote control headlight

43. Parking electronic control unit

48. Instrument panel

Checks and inspections

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

Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the scooter to be operated only when it is started with coded keys recognised by the control unit. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobiliser system consists of the following components:

- Electronic control unit

- Immobilizer aerial

- Master key with incorporated transponder (red key)

- service key with incorporated transponder (black key)

- H.V. coil

- Diagnostic LED The diagnostic LED also works as a deterring blinker. This function is activated every time the

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ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to the "ON" position, the deterring blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or the instrument panel is not initiated, check:

•

there is battery voltage

•

fuses 6,7,10 are in working order

•

there is power to the control unit as specified below:

Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions:

With the key switch set to OFF:

•

if there is battery voltage between terminals 6-26 and terminal 6-chassis ground (fixed power supply). If there is no voltage check that fuse 6 and its cable are in working order.

With the key switch in the OFF position:

•

there is battery voltage between terminals 5-26 and terminal 5-frame earth

ELE SYS - 16

(fixed power supply). If there is no voltage, check the key switch contacts, that fuse no. 10 and its cable are working order.

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MP3 250 i.e. Electrical system

•

There is continuity between terminals 12-18 and 12-19 with the emergency cut-out switch in the RUN position. If there is no continuity check the contacts of the latter.

If no faults are found, replace the electronic control unit.

After removing the shield back plate, remove the electrical connection from the aerial as shown in the photograph

Remove the protective base from the connector.

With the ignition key switch at ON check there is battery voltage between the Red-White and Black cables

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With MIU connector disconnected check the continuity between the Orange-White cable and pin 7 of the interface wiring .

Specific tooling

020481Y Control unit interface wiring 020331Y Digital multimeter

Virgin circuit

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly. The data storage procedure for a previously not programmed control unit provides for the recognition of the master as the first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys. The master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits 1 to 3 seconds).

- Insert the service key and turn it to "ON" for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds. During a single data storage sequence a maximum of 7 service keys are allowed. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to keep using. If a service key should become un-coded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any case it is advisable to use resistive spark plugs.

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MP3 250 i.e. Electrical system

Characteristic

MASTER key:

RED KEY

SERVICE key.

BLACK KEY

Diagnostic codes

The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the led remains on permanently, it means the ignition is inhibited:

1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after

which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs.

2. Previously unused control unit - transponder absent or cannot be used: The LED is per-

manently ON; in this condition, no operations are possible, including starting of the vehicle.

3. Programmed control unit - the service key in (normal condition of use): a single 0.7 second

flash is displayed, after which the LED remains off permanently. The engine can be started.

4. Programmed control unit - Master key in: a

0.7 sec. flash is displayed followed by the LED remaining off for 2 sec. and then by short 0.46 sec. flashes the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been completed, the

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LED remains permanently OFF. The engine can be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on permanently. The engine cannot be started. The codes that can be transmitted are:

•

Code 1 flash

•

2 flash code

•

3 flash code

Diagnostic code - 1 flash

The one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobiliser aerial wiring and change it if necessary.

Diagnostic code - 2 flashes

Two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. If this is not the case, replace the defective key and/or reprogram the control unit. Replace the control unit if the problem continues.

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Diagnostic code - 3 flashes

The three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit. If this is not the case, perform a reprogramming.

Battery recharge circuit

The recharge system is provided with a three-phase alternator with permanent magneto flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective 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

Stator winding check-up

WARNING

THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1 Remove the right side panel.

2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the photograph.

3) Measure the resistance between each of the yellow terminals and the other two.

Electric characteristic

Resistance:

0.2 - 1 Ω

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4) Check that there is insulation between the each yellow cable and the ground.

5) If values are incorrect, replace the stator.

Recharge system voltage check

Look for any leakage

1) Access the battery by removing its cover under the saddle.

2) Check that the battery does not show signs of losing fluid before checking the output voltage.

3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery.

4) With ignition key still at OFF, the reading detected by the ammeter must be ≤ 0.5 mA.

Check the charging current

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the tester terminals between the battery terminals..

3) Turn on the engine, increase the revs and, at the same time, measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm. Maximum current output check.

- With the engine off and the panel at «ON» with the lights on, allow the battery voltage to stop at 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Start the engine and rev it up to a high engine speed while reading the value on the pincer. With an efficient battery a value must be detected: > 20A

VOLTAGE REGULATOR/RECTIFIER

Specification Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 ÷ 15V at 5000 rpm with lights off

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Fuses

The electrical system has twelve fuses divided in 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, 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 TABLE

Specification Desc./Quantity

1 Fuse No. 1 Capacity: 30A

Protected circuits:Voltage regulator

Location:battery compartment

2 Fuse No. 2 Capacity: 20A

Protected circuits:battery-powered fuse

No. 7, live fuses No. 8 - No. 9 - No.10 - No.

Location:battery compartment

3 Fuse No. 3 (if present) Capacity: 20A

Protected circuits:parking control ECU

Location:battery compartment

4 Fuse No. 4 Capacity: 15 A

Protected circuits:Battery-powered saddle

opening switch, glove-box lighting, headlight,

emergency turn indicator

Location:battery compartment

5 Fuse No. 5 Capacity: 15 A

Protected circuits:Battery-powered injec-

tion loads, electrical fan

Location:battery compartment

6 Fuse No. 6 Capacity: 3A

Protected circuits:Battery-powered injec-

tion control unit

Location:battery compartment

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Specification Desc./Quantity

7 Fuse No. 7 Capacity: 7.5 A

Protected circuits:Battery-powered instru-

ment panel

Location:footrest

8 Fuse No. 8 Capacity: 10A

Protected circuits:Live stop and start lights

Location:footrest

9 Fuse No. 9 Capacity: 7.5 A

Protected circuits:live passing and horn

Location:battery compartment

10 Fuse No. 10 Capacity: 7.5A

Protected circuits:Live injection, electrical

fan remote control antenna, injection loads

remote control

Location:footrest

11 Fuse No. 11 Capacity: 7.5A

Protected circuits:Live ECU parking lever, antitheft device, instrument panel, headlight

remote control, horn remote control

Location:footrest

12 Fuse No. 12 Capacity: 7.5A

Protected circuits:Live turn indicator, saddle opening switch, tail lights, panel lighting

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 Q = Front suspension locking system failure warning light (if available) R = Warning light for parking brake engaged C = High-beam warning light

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A = Total odometer gauge B = «BELT» maintenance icon C = «SERVICE» maintenance icon D = Engine coolant temperature indicator E = Trip odometer gauge (A-B) and ambient tem-

perature (selected with the MODE button)

F = TIME-DATE indicator G = Low fuel warning light H = Trip odometer gauge (B) I = Trip odometer gauge (A) L = Kilometre - mile indicator

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 RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check up

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

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

- Charge time: 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 battery rated capacity

- Charge time: Maximum 5 h

Connectors

1A Alimentazione potenziometro 2A Linea CAN 3A Alimentazione spie 4A Spia blocco rollio 5A Spia warning 6A Uscita teleruttore anabbaglianti 7A Massa potenziometro 8A Massa centralina 1B Alimentazione da chiave 2B Linea CAN 3B Sensore giri ruota SX 4B Sensore giri ruota DX 5B Segnale potenziometro 6B Pulsante comando bolocco - sblocco rollio 7B Teleruttore claxon (allarme) 8B Uscita (A) motore elettro-attuatore 1C Alimentazione da batteria 2C Linea "K" 3C Pulsante comando bolocco - sblocco rollio 4C Pulsante pinza rollio 5C Pulsante comando bolocco - sblocco rollio 6C Sensore presenza pilota 7C Segnale di velocita per il gruppo strumenti 8C Uscita (B) motore elettro-attuatore

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Dashboard

1/20 Sensore velocità 2/20 Segnale livello carburante 3/20 Sensore temperatura liquido di raffreddamento 4/20 Massa sensore temperatura liquido di raffreddamento 5/20 Pulsante mode remoto 6/20 Spia pressione olio 7/20 Spia lampeggiatore sinistro 8/20 Spia lampeggiatore destro 9/20 Spia luce abbagliante 10/20 Spia bauliera aperta 11/20 Sensore giri 12/20 Sensore temperatura ambiente 13/20 Massa sensore temperatura ambiente 14/20 Spia motore inibito 15/20 Spia immobilizer 16/20 Spia controllo motore 17/20 Spia freno di stazionamento 18/20 Spia blocco rollio attivato 19/20 Spia avaria sistema blocco rollio 20/20 Positivo sotto chiave dalla centralina comando di stazionamento

5/12 Illuminazione 6/12 Positivo batteria 11/12 Massa 12/12 Positivo sotto chiave

Remote seat opening

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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.

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

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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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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

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Engine from vehicle MP3 250 i.e.

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.

ENG VE - 2

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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.

ENG VE - 3

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- 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.

ENG VE - 4

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- 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

ENG VE - 5

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Engine from vehicle MP3 250 i.e.

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY.

ENG VE - 6

Page 87

INDEX OF TOPICS

ENGINE ENG

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Engine MP3 250 i.e.

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.

N.B.

WHEN YOU ARE REMOVING THE TRANSMISSION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH BELL.

Air duct

Versione 250

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

ENG - 2

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MP3 250 i.e. Engine

- To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by means of:

Specific tooling

020376Y Adaptor handle 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

Baffle roller

ENG - 3

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Engine MP3 250 i.e.

Plastic roller

- Check that the roller does not show signs of wear and that it turns freely.

- Remove the special clamping screws as indicated in the photograph

- Check the outer diameter of the roller does not have defects that could jeopardise belt functioning

- For refitting, place the roller with the belt containment edge on the engine crankcase side

- Tighten the wrench to the prescribed torque.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Removing the driven pulley

- Remove the clutch bell housing and the driven pulley assembly.

N.B.

THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.

ENG - 4

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MP3 250 i.e. Engine

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.

- 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

ENG - 5

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Engine MP3 250 i.e.

Removing the clutch

Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side.

- Introduce the adapter ring No. 11 with the chamfering facing the inside of the tool.

- Fit the driven pulley unit on the tool with the insertion of the 3 pins in the ventilation holes in the mass holder support.

- 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 No. 9 to remove the nut fixing the clutch in place.

- Dismantle the driven pulley components (Clutch and spring with its plastic holder)

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

020444Y011 adapter ring 020444Y009 46x55 Wrench 020444Y Tool for fitting/ removing the driven

pulley clutch

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

ENG - 6

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MP3 250 i.e. Engine

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.

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisiness; - Replace with a new one if there are.

- Remove the retaining ring using two flat blade screwdrivers.

- Support the pulley bushing adequately from the threaded side using a wooden surface.

- Using a hammer and pin, knock the ball bearing out as shown in the figure.

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Engine MP3 250 i.e.

- Support the pulley properly using the bell as shown in the figure.

Specific tooling

001467Y035 Belle for OD 47-mm bearings

- Remove the roller bearing using the modular punch.

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide

Inspecting the driven fixed half-pulley

Version 250

- Measure the outer diameter of the pulley bushing.

- Check the contact surface with the belt to make sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

Characteristic

Half-pulley minimum diameter

Minimum admissible diameter Ø 40.96 mm

Half-pulley standard diameter

Standard diameter: Ø 40.985 mm

Wear limit

0.3 mm

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MP3 250 i.e. Engine

Inspecting the driven sliding half-pulley

- Remove the two internal grommets and the two O-rings.

- Measure the movable half-pulley bushing inside diameter.

- Check the contact surface with the belt to make sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt faying surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Specification Desc./Quantity

Wear limit 0.3 mm

standard diameter Diameter 41.000 - 41.035 mm

maximum allowable diameter Ø 41.08 mm

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the threaded side using a wooden surface.

- Fit a new roller sleeve as in the figure.

- For the fitting of the new ball bearing, follow the example in the figure using a modular punch. Fit the retention ring

WARNING N.B.

FIT THE BALL BEARING WITH THE VISIBLE SHIELD

Specific tooling

020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020424Y Driven pulley roller casing fitting

punch

ENG - 9

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Engine MP3 250 i.e.

Refitting the driven pulley

- Insert the new oil guards and O-rings on the movable half-pulley.

- Lightly grease the O-rings «A» shown in the figure.

- Fit the half-pulley over the bushing using the specific tool.

- Check that the pins are not worn and proceed to refitting them in their slots.

- Refit the torque server closure collar.

- Using a curved-spout grease gun, lubricate the driven pulley unit with approximately 6 gr. of grease. Apply the grease through one of the holes in the bushing until it comes out through the hole on the opposite side. This operation is necessary to avoid the presence of grease beyond the Orings.

N.B.

THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED; UNDERTAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling

020263Y Sheath for driven pulley fitting

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel revolving ring

ENG - 10

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MP3 250 i.e. Engine

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Inspecting the clutch spring

- Measure the length of the spring, while it is relaxed.

Characteristic

Standard length

123 mm

acceptable limit after use:

118 mm

Refitting the clutch

- Support the driven pulley spring compressor appropriate tool with the control screw in vertical axis.

- Arrange the tool with the medium length pins screwed in position "C" on the inside.

- Introduce the adapter ring No. 11 with the chamfering facing upwards.

- Insert the clutch on the adapter ring.

- Lubricate the end of the spring that abuts against the servo-system closing collar.

- Insert the spring with its plastic holder in contact with the clutch.

- Insert the driving belt into the pulley unit according to their direction of rotation.

- Insert the pulley unit with the belt into the tool.

- Slightly preload the spring.

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

- Place the tool in the clamp with the control screw on the horizontal axis.

- Fully preload the spring.

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Engine MP3 250 i.e.

- Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench.

- Loosen the tool clamp and insert the belt according to its direction of rotation.

- Lock the driven pulley again using the specific tool.

- Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position.

- Remove the driven pulley /belt unit from the tool.

N.B.

DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING.

N.B.

FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

020444Y011 adapter ring 020444Y009 46x55 Wrench

Locking torques (N*m)

Clutch unit nut on driven pulley 45 ÷ 50

Refitting the driven pulley

- Refit the clutch bell.

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MP3 250 i.e. Engine

Drive-belt

- Check that the driving belt is not damaged.

- Check the width of the belt.

Characteristic

250 4T Transmission belt/minimum width

19.5 mm

250 4T Transmission belt/standard width

21.3 ± 0.2 mm

During the wear checks in the scheduled servicing programme, you are advised to check the rim bottom of the toothing does not show signs of incisions or cracking (see figure): The rim bottom of the tooth must not have incisions or cracking; if it does, change the belt.

Removing the driving pulley

- Turn the crankshaft until the ropes of the pulley are on a horizontal axis

- Insert the adaptor sleeve of the appropriate tool in the hole shown in the photograph

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Engine MP3 250 i.e.

- Insert the tool in the hollows and apply the retention ring

- Bring in the ring's clamping screws while keeping the tool to support the pulley

Specific tooling

020626Y Driving pulley lock wrench

- Remove the fixing nut and the washer

- Remove the stationary drive pulley half.

Inspecting the rollers case

- Check that the internal bushing shown in the figure is not abnormally worn and measure inner diameter A.

- Measure outer diameter B of the pulley sliding bushing shown in the figure.

- Check that the rollers are not damaged or worn.

- Check the guide shoes for the variator back-plate are not worn.

- Check the wear of the roller housings and of the belt contact surfaces on both pulley halves.

- Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt.

- Check that the O-ring is not pushed out of shape.

CAUTION

DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic

Movable driving half-pulley bushing: Standard Diameter

ENG - 14

Piaggio MP3 250 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual