Piaggio MP3 400 Service Manual

SERVICE STATION MANUAL

664502(IT)-664503(EN)-664504(FR)-664505

(DE)-664506(ES)-664507(PT)-664508(NL)-664509

(EL)

MP3 400 i.e.

SERVICE STATION

MP3 400 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)

SERVICE STATION MANUAL

MP3 400 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 concerning 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

Characteristics MP3 400 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

MP3 400 i.e. Characteristics

Vehicle identification

Chassis prefix (A)

ZAPM59101

Engine prefix (B):

M474M

Dimensions and mass

Specification Desc./Quantity

Kerb weight 253 ± 5 kg

Maximum weight allowed 445 kg

Maximum height 1.225 mm

Width 745 mm

Wheelbase 1.550 mm

Length 2.180 mm

Track 420 mm

WEIGHTS AND DIMENSIONS

CHAR - 3

Characteristics MP3 400 i.e.

Engine

ENGINE

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Cubic capacity 399 cm³

Bore x stroke 85.8 X 69 mm

Compression ratio 10.6 ± 0.5 : 1

Engine idle speed 1,500 ± 100 rpm

Timing system Four valves, single overhead camshaft, chain driv-

Valve clearance Inlet: 0.15 mm

MAX. power 24 kW at 7,250 rpm

MAX torque 38 Nm at 5.250 rpm

Lubrication Engine lubrication with trochoidal pump (inside the

crankcase), oil filter and pressure adjustment by-

Lubrication pressure 3.5 ÷ 4 bar

Minimum lubrication pressure (100° C) 0.8 bar

Fuel supply Electronic injection with Ø38-mm throttle body and

Cooling Forced coolant circulation system.

Fuel Unleaded petrol (95 RON)

en.

Outlet: 0.15 mm

pass.

electric fuel pump.

CHAR - 4

MP3 400 i.e. Characteristics

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque

server, V belt, automatic clutch.

Final reduction

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1.7 l

Transmission oil 250 cm³

Cooling system fluid ~ 1.8 l

Fuel tank (reserve) ~ 12 l (~2 l)

Gear reduction unit in oil bath.

Electrical system

Specification Desc./Quantity

Start-up Electric

Ignition Electronic, inductive, high efficiency ignition, inte-

Ignition advance Three-dimensional map managed by control unit

Spark plug CHAMPION RG 6 YC

Alternative spark plug NGK CR7EKB

Battery 12 V / 14 Ah, SEALED BATTERY

Generator In alternating current

Frame and suspensions

Specification Desc./Quantity

Chassis Tubular and sheet steel

Front suspension The tilt mechanism is composed of an articulated

Front suspension travel 85 mm

Rear suspension Two double-acting shock absorbers, adjustable to

Rear suspension travel 110 mm

ELECTRICAL SYSTEM

grated with the injection system, with variable ad-

vance and separate HV coil.

FRAME AND SUSPENSIONS

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

absorbers with hydraulic locking system.

four positions at preloading.

CHAR - 5

Characteristics MP3 400 i.e.

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 disc brake, diameter 240 mm, with hydraulic servo

operated from the handlebar with the left-hand lev-

er.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rim type Light alloy rims.

Front rim 12'' x 3.00 Rear rim 14'' x 4.50

Front tyre Tubeless 120/70-12" 51S or 51P

Rear tyre Tubeless 140/70 - 14" 68S or 68P reinf

Front tyre pressure (with passenger) 1.6 bar (1.8 bar)

Rear tyre pressure (with passenger) 2.4 bar (2.6 bar)

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

CHASSIS

Name Torque in Nm

Swinging arm set screw bushing 5 ÷ 7

Engine arm bolt - frame arm 32.5 ÷ 40

Swinging arm set screw bushing nut 54 ÷ 60

Engine-swinging arm bolt 98 ÷ 118

Frame-swinging arm bolt 54 ÷ 60

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

7 ÷ 10

CHAR - 6

MP3 400 i.e. Characteristics

Name Torque in Nm

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

Calliper coupling screw 22 ÷ 27

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

Oil bleed screw 12÷16

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

pad fastening pin screws 20 ÷ 25

CHAR - 7

Characteristics MP3 400 i.e.

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

Oil pump cover screws 0.7 ÷ 0.9

Screws fixing oil pump to the crankcase 5 - 6

THERMAL UNIT AND TIMING SYSTEM

Name Torque in Nm

Spark plug 12 ÷ 14

Head fixing stud bolts: ***

Head fixing nuts 10 - 12

Exhaust / intake head fixing nuts: 10 - 12

Head lubrication control jet 5 - 7

coolant temperature sensor: 10 - 12

Lambda probe on exhaust manifold 10 - 12

injector fixing screw 3 ÷ 4

Counterweight screw 7 ÷ 8.5

Tensioner sliding block fixing screw: 10 - 14

Rpm timing sensor fixing screw: 3 - 4

Valve lifter mass stop bell fixing screws: 30 - 35

Inlet manifold screws 11 ÷ 13

Tappet cover fixing screws: 7 - 9

Throttle body fixing screws 11 ÷ 13

Head fixing screws 10 - 12

Camshaft retaining bracket screws: 4 ÷ 6

Tightener screw: 5 - 6

Tightener fastening screws: 11 ÷ 13

*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90° in a crossed sequence. - Tighten again by 90° in a crossed sequence.

CHAR - 8

TRANSMISSION COVER

Name Torque in Nm

Driven pulley nut 92 - 100

Drive pulley nut 160 - 175

Anti-vibration roller screw 16.7 - 19.6

M8 retainers for transmission cover 23 - 26

M6 retainer 11 ÷ 13

Anti-vibration roller retainer 17 - 19

Clutch ring nut 65 - 75

Air conveyor screws 11 ÷ 12

Water pump cover screws 3 ÷ 4

MP3 400 i.e. Characteristics

Name Torque in Nm

Outside transmission cover screws 7 ÷ 9

Flywheel cover screws 11 - 13

FLYWHEEL COVER

Name Torque in Nm

Chain guide sliding block retain plate fastening

screws

Flywheel fixing nut 115 - 125

Stator retainers 8 - 10

Blow-by recovery duct fixing screws 3 - 4

Screw fixing freewheel to flywheel 13 ÷ 15

Stator cable harness guide bracket screws 3 - 4

Supporting screws with bulkhead 0.3 - 0.4

Minimum oil pressure sensor 12 ÷ 14

Water pump impeller 4 ÷ 5

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Countershaft fixing nut 25 - 29

Engine oil filter 12 - 16

Engine oil drainage plug 24 ÷ 30

Engine-crankcase coupling screws 11 ÷ 13

Oil pump screws 5 - 6

Gear mounting on crankshaft screws 10 -12

Bulkhead screws for oil pump housing cover 8 - 10

3 ÷ 4

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Bleed screw: 3

Overhaul data

Assembly clearances

Cylinder - piston assy.

COOLING

CHAR - 9

Characteristics MP3 400 i.e.

HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED

Specification Desc./Quantity

A 43.2 mm B 43 mm

CYLINDER- PISTON

Specification Desc./Quantity

Cylinder diameter C 85.8 - +0.018 -0.01 mm

Piston Ø P 85.768 ± 0.014 mm

CYLINDER - PISTON

COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting

Cylinder- Piston A 85.790÷85.797 85.754÷85.761 0.029÷0.043 Cylinder- Piston B 85.797÷85.804 85.761 ÷ 85.768 0.029÷0.043 Cylinder- Piston C 85.804÷85.811 85.768÷85.775 0.029÷0.043 Cylinder- Piston D 85.811÷85.818 85.775÷85.782 0.029÷0.043

CATEGORIES OF COUPLING

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

Piston rings

*Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the openings in the rings as shown here. ***Value «A» of sealing ring inside the cylinder.

CHAR - 10

MP3 400 i.e. Characteristics

Check the size of the sealing ring opening: Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm

Rings/housing coupling clearances:

Carefully clean the sealing ring housings. Place a thickness gauge between the ring and the housing as shown in the drawing and check the coupling clearances.

Top ring Standard coupling clearance:

0.01÷0.06 mm Maximum clearances allowed after use: 0.10 mm

Intermediate ring Standard coupling clearance:0.02÷0.07 mm Maximum clearances allowed after use: 0.10

mm Oil scraper ring Standard coupling clearance:

0.01÷0.06 mm Maximum clearances allowed after use: 0.10 mm Replace the piston if clearances exceed the maximum limits specified in the table.

Crankcase - crankshaft - connecting rod

Crankcase / countershaft coupling

Besides considering it should match the crankshaft, the crankcase is chosen according to the centre to centre distance between the seat of the crankshaft and that of the contra-rotating shaft. Both the centre to centre distance and the pair of gears driving the contra-rotating shaft are divided into two types (A and B) to be matched (A with A and B with B). This selection is useful to keep the difference between the working distance of the gears and their distance without clearance at a given value in order to avoid abnormal noise.

TYPE A

Specification Desc./Quantity

Centre to centre distance of the gears without

clearance

Centre to centre distance on the crankcase 77.022 ÷ 76.992

76.937 ÷ 76.867

CHAR - 11

Characteristics MP3 400 i.e.

TYPE B

Specification Desc./Quantity

Centre to centre distance of the gears without

clearance

Centre to centre distance on the crankcase 76.992 ÷ 76.962 The gears with centre to centre distance without clearance between 76.867 and 76.907 are considered universal and can be fitted to either crankcase type. Either the pair of gears or the crankcase is identified with the letter referring to the type (on the crankcase, this mark is found at the cylinder mouth, flywheel side).

76.907 ÷ 76.837

Characteristic

crankshaft / crankcase axial clearance:

0.1 ÷ 0.405 mm

Diameter of crankshaft bearings.

Measure the capacity on both axes x-y.

Specification Desc./Quantity

Cat. 1 Standard diameter: 40.020÷40.026 Cat. 2 Standard diameter: 40.026÷40.032

CRANKSHAFT

CHAR - 12

MP3 400 i.e. Characteristics

Crankshaft alignment

Specific tooling

020335Y Magnetic support for dial gauge

MAX. ADMISSIBLE DISPLACEMENT

Specification Desc./Quantity

A = 0.15 mm B = 0.010 mm C = 0.010 mm D = 0.10 mm

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Transmission-side

shoulder

Half-shaft, trans-

mission side

Connecting rod 22 -0.10 -0.15 C D = 0.20 - 0.50

Flywheel-side

shoulder

Flywheel side half-

shaft

Complete crank-

shaft

1±0.025 A D = 0.20 - 0.50

20-0.05 B D = 0.20 - 0.50

1.8±0.025 F D = 0.20 - 0.50

19.6 -0.05 E D = 0.20 - 0.50

65 +0.10 -0.05 G D = 0.20 - 0.50

CHAR - 13

Characteristics MP3 400 i.e.

Slot packing system

Shimming system for keeping the compression ratio

DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE. DISTANCE «A» HELPS DETERMINE THE THICKNESS OF GASKET «B» THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE COMPRESSION RATIO. BASE GASKET «B» MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND, THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER THE GASKET THICKNESS.

Characteristic

Compression ratio

10.6 ± 0.5 : 1

BASE GASKET THICKNESS

Name Measure A Thickness

«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05 «A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05 «A» MEASURE TAKEN + 0.10 ÷ + 0.185 0.8 ± 0.05

N.B.

VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE.

N.B.

DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»

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Piaggio MP3 400 Service Manual

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Frequently Asked Questions

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