Piaggio MP3 250 Service Manual

Name: Piaggio MP3 250
Brand: Piaggio
SKU: 5898480
Rating: 4.5 (17 reviews)

4.5 (17)

SERVICE STATION MANUAL

633823

MP3 250 i.e.

SERVICE STATION

MANUAL

MP3 250 i.e.

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)

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.

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

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 well-

ventilated, 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 250 i.e.

CHAR - 2

Vehicle identification

Chassis prefix (FULL OPTIONAL): M47201

Chassis prefix (BASE): M47200

Engine prefix: M472M

Dimensions and mass

WEIGHTS AND DIMENSIONS

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

Engine

DATA

Specification Desc./Quantity

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

valves

MP3 250 i.e. Characteristics

CHAR - 3

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

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque

server, V belt, automatic clutch, gear reduction unit

and transmission housing with forced air circula-

tion cooling

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil approx. 1300 cc (recommended oil Selenia HI

Scooter 4 Tech)

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

ELECTRICAL COMPONENTS

Specification Desc./Quantity

Ignition/advance Electronic, with inductive discharge and variable

advance with three-dimensional mapping

Spark plug CHAMPION RG 4 PHP

Battery 12V-12Ah

Generator alternating current

Characteristics MP3 250 i.e.

CHAR - 4

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. REGU-

LATE 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

MP3 250 i.e. Characteristics

CHAR - 5

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

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

Characteristics MP3 250 i.e.

CHAR - 6

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

MP3 250 i.e. Characteristics

CHAR - 7

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

4 ÷ 6

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

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

threadlock)

COOLING

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Bleed screw: 3

Overhaul data

Assembly clearances

Characteristics MP3 250 i.e.

CHAR - 8

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.)

Indirizzo Immagine

Crankshaft Crankshaft to crankcase

axial clearance

Crankshaft to crankcase axial clearance

MP3 250 i.e. Characteristics

CHAR - 9

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

10.5 ÷ 11.5 : 1

Characteristics MP3 250 i.e.

CHAR - 10

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 CRANK-

CASE 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

MP3 250 i.e. Characteristics

CHAR - 11

Products