PIAGGIO MP3 500 i.e. SPORT Service Station Manual

SERVICE STATION MANUAL

1Q000267 EN

MP3 500 i.e. SPORT Business_LT_ ABS­ASR_EU_USA (2015)

SERVICE STATION

MANUAL

MP3 500 i.e. SPORT Business_LT_ ABS-

ASR_EU_USA (2015)

The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. 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/models shown in this publication are available in all countries. The availability of each

model should be checked at the official PIAGGIO sales network.

© Copyright 2015 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or

in part is prohibited.

Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

SERVICE STATION MANUAL

MP3 500 i.e. SPORT

Business_LT_ ABS-

ASR_EU_USA (2015)

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio 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

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 naked 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 solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.

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

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.

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

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 7

Vehicle identification

The identification registration numbers consist of
a prefix stamped on the chassis and engine "B"
respectively, followed by a number. These num­bers must always be indicated on spare parts re­quests. To read the chassis number, remove the
relevant port "A" in the helmet compartment. We
recommend checking that the chassis registration
number stamped on the vehicle corresponds with
that on the vehicle documentation.

CAUTION

PLEASE REMIND THAT ALTERING IDENTIFICATION REG­ISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL
SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).

VEHICLE IDENTIFICATION

Specification

Desc./Quantity

Frame prefix (VERSION EQUIPPED WITH ABS - ASR SYS-

TEM)

ZAPM86100

Frame prefix (VERSION NOT EQUIPPED WITH ABS - ASR

SYSTEM)

ZAPM86101

Frame prefix USA/CND ZAPM860X

Engine prefix M861M

Engine prefix USA/CND M863M

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 8

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification

Desc./Quantity

Length 2205 mm (86.8 in)

Width 775 mm (30.5 in)

Maximum height 1460 mm (57.5 in)

Wheelbase 1540 mm (60.6 in)

Track 465 mm (18.3 in)

Kerb weight 266 kg (586 lb)

Maximum weight limit 460 kg (1014 lb)

Engine

ENGINE TECHNICAL DATA

Specification

Desc./Quantity

Type Single-cylinder, 4-stroke

Engine capacity 493 cm³

Bore x Stroke 94 x 71 mm
Compression ratio 10.5 ± 0.5 : 1
Engine idle speed 1,600 ± 100 rpm

Timing system Four valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.15 mm

Outlet: 0.15 mm

MAX. power 29.5 kW at 7,250 rpm

MAX. torque 45.5 Nm at 5,250 rpm

Transmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmission

housing with forced-circulation air cooling.

Final reduction with gear reduction unit in oil bath.

Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 9

Specification Desc./Quantity

Cooling Forced coolant circulation system.
Electric Electric starter
Ignition Highly efficient electronic inductive ignition, integrated with the

injection system, with variable advance, separate HV coil and

double spark plug.

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EKB

Electrode gap 0.7 ÷ 0.9 mm

Fuel system By electronic injection with electric fuel pump.

Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter and

lambda probe.

Emissions compliance EURO 2

Transmission

TRANSMISSION

Specification Desc./Quantity

TRANSMISSION Automatic expandable pulley variator with torque server, V-

belt, automatic clutch.

Final reduction with gear reduction unit in oil bath.

Capacities

CAPACITY

Specification

Desc./Quantity

Engine oil 0.44 gal (1.7 l)

Transmission oil 15.3 in³ (250 cm³)

Cooling system fluid ~ 0.47 gal (~ 1.8 l)

Fuel tank 3.2 gal ± 0.1 (12.0 ± 0.5 l)

Electrical system

ELECTRICAL SYSTEM

Specification

Desc./Quantity

Electric Electric starter
Ignition Electronic, inductive, high efficiency, integrated with the injec-

tion system, with variable advance separate HV coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EKB

Alternative spark plug -

Battery 12V-12Ah

Alternator alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification

Desc./Quantity

Chassis Tubular and sheet steel

Front suspension The roll system is composed of an articulated parallelogram

suspension with die-cast aluminium control arms and two side
headstocks plus shock absorbers with hydraulic locking system

Front suspension travel 85 mm

Rear suspension Two double-acting shock absorbers, adjustable to four posi-

tions at preloading.

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 10

Specification Desc./Quantity

Rear suspension travel 110 mm

Brakes

BRAKES

Specification Desc./Quantity

Front brake Double disc Ø 258 with hydraulic control activated by handlebar

right lever; Braking assisted by ABS system (where available).

Rear brake Ø 240-mm disc brake with hydraulic control operated by the

handlebar left-hand lever; Braking assisted by ABS system

(where available).

Integral braking system The system operates all three discs simultaneously and is con-

trolled hydraulically via the pedal on the footrest.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rim type Light alloy.

Front wheel rims 13" x 3.00"

Rear wheel rim 14'' x 4.50

Front tyres Tubeless 110/70 - 13" 48S

Rear tyre Tubeless 140/70 - 14" 68S

Front tyres pressure 2 bar

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

Tightening Torques

STEERING

Name

Torque in Nm

Steering lower ring nut (central headstock) 10 - 12 Nm (7 - 9 lb*ft)

Steering upper ring nut (central headstock) 32.5 - 40 Nm (24 - 30 lb*ft)

Handlebar fixing screw 50 - 55 Nm (37 - 41 lb*ft)

Fixing screws for the control unit U-bolts to the handlebar 7 - 10 Nm (5.2 - 7 lb*ft)

FRAME

Name

Torque in Nm

Swinging arm adjuster bushing 5 - 7 Nm (3.7 - 5.2 lb*ft)

Engine arm bolt - frame arm 32.5 - 40 Nm (24 - 30 lb*ft)

Swinging arm adjuster bushing nut 54 - 60 Nm (40 - 44 lb*ft)

Engine-swinging arm bolt 98 - 118 Nm (72 - 87 lb*ft)

Frame-swinging arm bolt 54 - 60 Nm (40 - 44 lb*ft)

Centre stand bolt 31 - 39 Nm (23 - 29 lb*ft)

FRONT SUSPENSION

Name

Torque in Nm

Lower shock absorber clamp 19 - 26 Nm (14 - 19 lb*ft)

Upper shock absorber retainer 19 - 29 Nm (14 - 21 lb*ft)

Front wheel fixing screws 19 - 24 Nm (14 - 18 lb*ft)

Tilt gripper fixing screws 20 - 25 Nm (15 - 18 lb*ft)

Steering arm bolt nut 20 - 25 Nm (15 - 18 lb*ft)

Arm coupling screws 45 - 50 Nm (33 - 37 lb*ft)
Screws fixing arms to lateral headstocks 45 - 50 Nm (33 - 37 lb*ft)
Screws fixing arms to central headstock 45 - 50 Nm (33 - 37 lb*ft)

Screws fixing the half-arm coupling flange 20 - 25 Nm (15 - 18 lb*ft)

Screws fixing roll lock disc section 20 - 25 Nm (15 - 18 lb*ft)

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 11

Name Torque in Nm

Side headstock upper ring nut 20 - 24 Nm (15 - 18 lb*ft)
Side headstock lower ring nut 12 - 15 Nm (9 - 11 lb*ft)

Screw fixing sliding stem to shock absorber 45 - 50 Nm (33 - 37 lb*ft)

Clamp for sliding stem locking device 6.5 - 10.5 Nm (4.8 - 8 lb*ft)

Fixing nuts for constant-velocity universal joints 18 - 20 Nm (13 - 15 lb*ft)

Potentiometer to anti-tilting device clamp 8 - 10 Nm (5.9 - 7 lb*ft)
Electric motor to anti-tilting device clamp 11 - 13 Nm (8 - 10 lb*ft)

Clamp fixing pump spindle to anti-tilting device 11 - 13 Nm (8 - 10 lb*ft)

Pump to anti-tilting device clamp 11 - 13 Nm (8 - 10 lb*ft)

Pressure switch to distribution frame 18 - 20 Nm (13 - 15 lb*ft)

Sensor to tilt gripper clamp 2.5 - 2.9 Nm (1.8 - 2.1 lb*ft)

Pipe terminals to fifth wheel check spring 7 - 11 Nm (5.2 - 8 lb*ft)

Joint to anti-tilting device pump 20 - 25 Nm (15 - 18 lb*ft)

Suspension lock calliper pipe fitting on side steering pipe 25 - 28 Nm (18 - 21 lb*ft)

REAR SUSPENSION

Name Torque in Nm

Upper shock absorber retainer 33 - 41 Nm (24 - 30 lb*ft)

Lower shock absorber clamp 33 - 41 Nm (24 - 30 lb*ft)

Shock absorber-crankcase attachment bracket 20 - 27 Nm (15 - 18 lb*ft)

Rear wheel axle 104 - 126 Nm (77 - 93 lb*ft)

Silencer arm fixing screw 27 - 30 Nm (20 - 22 lb*ft)

FRONT BRAKE

Name Torque in Nm

Calliper coupling screw 22 - 27 Nm (16 - 20 lb*ft)

Oil bleed screw 8 - 12 Nm (5.9 - 9 lb*ft)

Front brake disc screws 8 - 10 Nm (5.9 - 7 lb*ft)

Front brake pump-pipe fitting 16 - 20 Nm (12 - 15 lb*ft)

Joint pipe-calliper 20 - 25 Nm (15 - 18 lb*ft)

Screw tightening calliper to support 20 - 25 Nm (15 - 18 lb*ft)

Brake calliper pipe fitting on side steering pipe 25 - 28 Nm (18 - 21 lb*ft)

REAR BRAKE

Name

Torque in Nm

Rear brake disc screws(°) 5 - 6.5 Nm (3.7 - 4.8 lb*ft)

Rear brake calliper-pipe fitting 20 - 25 Nm (15 - 18 lb*ft)

Rigid - flexible pipe fitting 13 - 18 Nm (10 - 13 lb*ft)

Rear brake pump-pipe fitting 16 - 20 Nm (12 - 15 lb*ft)

Rear brake calliper fixing screws 41.5 - 51.5 Nm (31 - 38 lb*ft)

Parking brake - Screw tightening calliper to support (°) 24 - 27 Nm (18 - 20 lb*ft)

(°) Apply LOCTITE 243 medium-strength threadlock.

ABS SYSTEM (IF FITTED)

Name

Torque in Nm

ABS sensors tightening screws 6 - 10 Nm (4.4 - 7 lb*ft)

Screw fixing ABS control unit to support 10 - 12 Nm (7 - 9 lb*ft)

Pipe fittings - ABS control unit 13 - 18 Nm (10 - 13 lb*ft)

ABS control unit supporting bracket fixing screw 8 - 10 Nm (5.9 - 7 lb*ft)

SILENCER

Name

Torque in Nm

Silencer heat guard fixing screw 4 - 5 Nm (3 - 3.7 lb*ft)

Screw for fixing silencer to supporting arm 20 - 25 Nm (15 - 18 lb*ft)

Oxygen sensor tightening on exhaust manifold 40 - 50 Nm (30 - 37 lb*ft)

Exhaust manifold-silencer joint tightening 12 - 13 Nm (9 - 10 lb*ft)

Manifold-silencer clamp tightening 16 - 18 Nm (12 - 13 lb*ft)

LUBRICATION

Name

Torque in Nm

Oil pump cover screws 0.7 - 0.9 Nm (0.52 - 0.66 lb*ft)

Screws fixing oil pump to the crankcase 5 - 6 Nm (3.7 - 4.4 lb*ft)

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 12

HEAD-ENGINE BLOCK-PISTON ASSEMBLY

Name Torque in Nm

Spark plug 12 - 14 Nm (9 - 10 lb*ft)

Head fixing stud bolts 7 Nm + 90° + 90° (5.2 lb*ft + 90° + 90°)

Head fixing nuts 10 - 12 Nm (7 - 9 lb*ft)

Exhaust / intake head fixing nuts 10 - 12 Nm (7 - 9 lb*ft)

Head lubrication control jet 5 - 7 Nm (3.7 - 5.2 lb*ft)

Coolant temperature sensor 10 - 12 Nm (7 - 9 lb*ft)

Lambda probe on exhaust manifold 10 - 12 Nm (7 - 9 lb*ft)

injector fixing screw 3 - 4 Nm (2.2 - 3 lb*ft)

Counterweight screw 7 - 8.5 Nm (5.2 - 6.3 lb*ft)

Tensioner pad fixing screw 10 - 14 Nm (7 - 10 lb*ft)

Speed/phase sensor fixing screw 3 - 4 Nm (2.2 - 3 lb*ft)

Valve lifter mass stop bell fixing screws 30 - 35 Nm (22 - 26 lb*ft)

Intake manifold screws 11 - 13 Nm (8 - 10 lb*ft)
Tappet cover fixing screws 7 - 9 Nm (5.2 - 6.6 lb*ft)
Throttle body fixing screws 11 - 13 Nm (8 - 10 lb*ft)

Head fixing screws 10 - 12 Nm (7 - 9 lb*ft)

Camshaft retaining bracket screws: 4 - 6 Nm (3 - 4.4 lb*ft)

Tightener screw: 5 - 6 Nm (3.7 - 4.4 lb*ft)

Tensioner fastening screws: 11 - 13 Nm (8 - 10 lb*ft)

TRANSMISSION COVER

Name Torque in Nm

Driven pulley nut 92 - 100 Nm (68 - 74 lb*ft)
Driving pulley nut 160 - 175 Nm (118 - 129 lb*ft)

Anti-vibration roller screw 16.7 - 19.6 Nm (12 - 14 lb*ft)

M8 retainers for transmission cover 23 - 26 Nm (17 - 19 lb*ft)

M6 retainer 11 - 13 Nm (8 - 10 lb*ft)

Anti-vibration roller retainer 17 - 19 Nm (13 - 14 lb*ft)

Clutch ring nut 65 - 75 Nm (48 - 55 lb*ft)

Air duct screws 11 - 12 Nm (8 - 9 lb*ft)

Water pump cover screws 3 - 4 Nm (2.2 - 3 lb*ft)

External transmission cover screws 7 - 9 Nm (5.2 - 6.6 lb*ft)

Flywheel cover screws 11 - 13 Nm (8 - 10 lb*ft)

FLYWHEEL COVER

Name

Torque in Nm

Chain guide sliding block fastening screws 3 - 4 Nm (2.2 - 3 lb*ft)

Flywheel fixing nut 115 - 125 Nm (85 - 92 lb*ft)

Stator clamps 8 - 10 Nm (5.9 - 7 lb*ft)
Blow-by recovery duct fixing screws 3 - 4 Nm (2.2 - 3 lb*ft)
Screws fixing freewheel to flywheel 13 - 15 Nm (10 - 11 lb*ft)

Stator wiring harness guide bracket screws 3 - 4 Nm (2.2 - 3 lb*ft)

Supporting screws with bulkhead 0.3 - 0.4 Nm (0.22 - 0.30 lb*ft)

Minimum oil pressure sensor 12 - 14 Nm (9 - 10 lb*ft)

Water pump rotor 4 - 5 Nm (3 - 3.7 lb*ft)

CRANKCASE AND CRANKSHAFT

Name

Torque in Nm

Countershaft fixing nut 25 - 29 Nm (18 - 21 lb*ft)

Engine oil filter 12 - 16 Nm (9 - 12 lb*ft)

Engine oil drainage plug 24 - 30 Nm (18 - 22 lb*ft)

Engine-crankcase coupling screws 11 - 13 Nm (8 - 10 lb*ft)

Oil pump screws 5 - 6 Nm (3.7 - 4.4 lb*ft)

Gear mounting on crankshaft screws 10 - 12 Nm (7 - 9 lb*ft)

Oil pump compartment cover bulkhead screws 8 - 10 Nm (5.9 - 7 lb*ft)

COOLING

Name

Torque in Nm

Water pump rotor 4 - 5 Nm (3 - 3.7 lb*ft)

Water pump cover screws 3 - 4 Nm (2.2 - 3 lb*ft)

Thermostat cover screws 3 - 4 Nm (2.2 - 3 lb*ft)

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 13

Name Torque in Nm

Bleed screw 3 Nm (2.2 lb*ft)

Overhaul data

Assembly clearances

Cylinder - piston assy.

HEIGHT TO MEASURE THE PISTON

Specification

Desc./Quantity

A 10 mm
B 43 mm

CYLINDER - PISTON

Specification

Desc./Quantity

Cylinder diameter C 94 +0.018-0.01mm

Piston diameter P 93.968 - ±0.014 mm

COUPLING CATEGORIES

Name

Initials Cylinder Piston Play on fitting

Cylinder- Piston A 93.990÷93.997 93.954÷93.961 0.029÷0.043
Cylinder- Piston B 93.997÷93.004 93.961÷93.968 0.029÷0.043
Cylinder- Piston C 94.004÷94.011 93.968÷93.975 0.029÷0.043
Cylinder- Piston D 94.011÷94.018 93.975÷93.982 0.029÷0.043

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 14

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 piston rings «2» and «3» with the mark «TOP» facing up.
** Position the opening in the rings as shown in this figure.
*** Value «A» of the sealing ring inside the cylinder.

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

Rings/slots coupling clearances:

Carefully clean the sealing rings housings.
Check coupling clearances by placing a thickness
gauge between the ring and the slot as shown in
the figure.

Top ring: Standard coupling clearance:

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

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 15

Middle 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
If clearances measured exceed the maximum val­ues specified in the table, the piston should be
replaced by a new one.

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name

Description Dimensions Initials Quantity

Transmission-side

shoulder

1 ± 0.025 A D = 0.20 ÷ 0.50

Half-shaft, transmission

side

20.9 - 0.05 B D = 0.20 ÷ 0.50

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

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 16

Name Description Dimensions Initials Quantity

Flywheel-side shoulder 1.8 ± 0.025 F D = 0.20 ÷ 0.50

Flywheel side half-shaft 19.6 + 0.05 E D = 0.20 ÷ 0.50

Complete crankshaft 65.5 +0.1 -0.05 G D = 0.20 ÷ 0.50

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

CRANKSHAFT

Specification Desc./Quantity

Cat. 1 Standard diameter: 40.010 ÷ 40.016
Cat. 2 Standard diameter: 40.016 ÷ 40.022

Crankshaft alignment

Specific tooling

020335Y Dial gauge magnetic support

MAXIMUM OFF-LINE ALLOWED

Specification

Desc./Quantity

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

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 17

Characteristic

Crankshaft-crankcase axial clearance (H)

0.1 ÷ 0.405 mm (when cold)

Compression ratio

10.5: 1

Slot packing system

Shimming system to control compression ratio

MEASUREMENT «A» IS A PROTRUSION OR RECESS VAL­UE OF THE PISTON CROWN COMPARED WITH THE CYL­INDER PLANE.
MEASUREMENT «A» ALLOWS TO DETERMINE THE
THICKNESS OF THE GASKET «B» THAT HAS TO BE FIT­TED INTO THE CYLINDER BASE IN ORDER TO RESTORE
THE COMPRESSION RATIO. THE MORE THE PLANE
FORMED BY THE PISTON CROWN PROTRUDES BEYOND
THE PLANE FORMED BY THE CYLINDER UPPER END,
THE THICKER THE GASKET TO BE USED AT THE CYLIN­DER BASE «B» SHOULD BE. ON THE OTHER HAND, THE
MORE THE PISTON CROWN IS RECESSED INTO THE CYL­INDER TOP PLANE, THE SMALLER THE GASKET THICK­NESS.

Characteristic

Compression ratio

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 18

10.5: 1

BASE GASKET THICKNESS

Name Measure A Thickness

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

N.B.

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

N.B.

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

Products

RECOMMENDED PRODUCTS TABLE

Product Description Specifications

AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis-

sions.

API GL-4

eni i-Ride PG 5W-40 Synthetic based lubricant for high-per-

formance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3

AGIP FILTER OIL Special product for the treatment of foam

filters.

-

AGIP GP 330 Water repellent stringy calcium spray

grease.

R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 ­I.A.T.A. 2 - I.M.D.G. class 2 UN 1950

Page 9022 EM 25-89

AGIP BRAKE 4 Brake fluid. SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO

4925 - CUNA NC 956 DOT 4 synthetic

fluid

AGIP PERMANENT SPECIAL Ethylene glycol-based antifreeze fluid

with organic inhibition additives. Red,

ready to use.

ASTM D 3306 - ASTM D 4656 - ASTM D

4985 - CUNA NC 956-16

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 19

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLS

Stores code Description

001330Y Tool for fitting steering seats

001467Y002 Driver for OD 73 mm bearing

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Bell for OD 54-mm bearings

001467Y008 Calliper to extract 17-mm diameter bear-

ings

001467Y014 Calliper to extract 15-mm diameter bear-

ings

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling

TOOL - 21

Stores code Description

001467Y031 Bell

001467Y034 Calliper to extract 15-mm diameter bear-

ings

001467Y035 Bell for 47-mm outside diameter bearings

002465Y Calliper for circlips

006029Y Punch for fitting steering bearing seat on

steering tube

020004Y Punch to remove steering bearings from

headstock

Tooling MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

TOOL - 22

Stores code Description

020055Y Wrench for steering tube ring nut

020150Y Air heater support

020151Y Air heater

020193Y Gauge for oil pressure check

020201Y Spacer bushing driving tube
020262Y Crankcase splitting strip

020306Y Punch for fitting the valve seal rings

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling

TOOL - 23

Stores code Description

020329Y Vacuum pump Mity-Vac

020330Y Stroboscopic light for timing checking

020331Y Digital multimeter

020648Y Single battery charger

020335Y Dial gauge magnetic support

020357Y 32 x 35 mm adaptor
020358Y 37 x 40 mm adaptor

Tooling MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

TOOL - 24

Stores code Description

020359Y 42 x 47-mm adaptor

020360Y 52 x 55-mm adaptor

020364Y 25-mm Guide

020376Y Adapter handle

020382Y012 bush (valve removing tool)

020412Y 15 mm guide

020424Y Punch for fitting driven pulley roller casing

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling

TOOL - 25

Stores code Description

020431Y Valve oil seal extractor

020434Y Fitting for oil pressure check

020439Y 17 mm guide

020444Y Tool for fitting/removing the clutch on the

driven pulley

020456Y Ø24 mm adaptor

Tooling MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

TOOL - 26

Stores code Description

020458Y Puller for lower bearing on steering tube

020459Y Punch for fitting bearing on steering tube

020922Y Diagnosis Tool

020467Y Flywheel extractor

020468Y Piston fitting ring

020470Y Pin snap ring fitting tool

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling

TOOL - 27

Stores code Description

020471Y Pin for countershaft timing

020472Y Flywheel lock wrench

020474Y Driving pulley lock wrench

020475Y Piston position checking tool

020476Y Stud bolt set

020478Y Punch for roller casing

Tooling MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

TOOL - 28

Stores code Description

020479Y Countershaft lock wrench

020480Y Fuel pressure check set

020482Y Engine support

020483Y 30 mm guide

020512Y Piston fitting fork

020527Y Engine support base

020604Y011 Fitting adapter

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Tooling

TOOL - 29

Stores code Description

020565Y Flywheel lock calliper spanner

020481Y004 Parking control unit interface wiring

020646Y Parallelogram and steering positioning

tool

020647Y Toe-in checking tool

020647Y028 MP3 LT Toe-in tool (tricycle)

020661Y Water pump overall seal replacement kit

Tooling MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

TOOL - 30

INDEX OF TOPICS

MAINTENANCE MAIN

N.B.

THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS
OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED
IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE «CHARACTERISTICS» CHAPTER.

SERVICE ICON RESET

When switching to «ON», immediately after the ig­nition check, if there are less than 300 km (187.5
miles) to the next scheduled service, the corre­sponding icon flashes for 5 seconds. Once the
service mileage has been reached, the icon re­mains steadily on until it is reset. The icon reset is
carried out by pressing the button «SET» for more
than 10 seconds when switching to «ON»: the icon
with the key, after the ignition check, must flash
with a frequency of 1 Hz and then turn off after 10
seconds to indicate the performed reset. If the but­ton is released before the 10 seconds, the icon is
not reset.

ADJUSTMENT PROCEDURE OF THE RING NUTS OF THE SIDE HEADSTOCKS

- Remove the windshield.

- Remove the central cover fixed to the joints on
the legshield.

- Remove the two indicated daylight running light
fixing screws.

- Remove the daylight running light by disconnect­ing the connector.

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 32

- Remove the two screws located inside the glove­box on the dashboard.

- Remove the four screws indicated and recover
the related spacers.

- Undo the two screws indicated, then remove the
spoiler.

- Remove the two headlight upper fixing screws.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 33

- Remove the Piaggio clip-on badge, fixed to the
joint, by acting on the indicated slot.

- Remove the indicated screw and remove the ra­diator grille frame.

- Unscrew the four indicated screws and remove
the radiator grille.

- Working on both sides of the vehicle, remove the
two screws in the wheel housing.

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 34

- Unscrew the four indicated screws and remove
the front radiator cover.

- Remove the two lower fastening screws.

- Disconnect the connector and remove the head­light.

- Undo the four indicated screws on the leg shield
back plate.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 35

- Working on both sides of the vehicle, unscrew the
two indicated screws and remove the spoiler sup­port plastic.

- Remove the two indicated screws from both sides
of the vehicle, located inside the wheel housing.

- Detach the shield from the vehicle, complete with
side bumpers and turn indicators and disconnect
the connectors of the turn indicators.

WARNING

DURING THE REFITTING, PAY PARTICULAR ATTENTION
TO THE CORRECT POSITION OF THE TWO SPOILER SUP­PORT PLASTICS, REFERRING TO THE INDICATIONS ON
THE PLASTIC.

Once the plastics have been remove the ring nuts
of the side headstock of the front suspension can
be reached

Unscrew the upper ring nut

Bring the upper ring nut to the end of the headstock
thread of the side suspension

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 36

Tighten the lower ring nut to the specified torque
with the appropriate key.

Locking torques (N*m)

Side headstock lower ring nut 12 - 15

Screw the upper ring nut until it stops

Tighten upper ring nut to the specified torque with
the appropriate key.
Specified torque: 20 to 24 Nm.
Carry out the assembly of the plastic covers in re­verse order to the disassembly.

Specific tooling

020892y Steering side headstock ring nut key

Locking torques (N*m)

Side headstock upper ring nut 20 to 24

Maintenance chart

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE

* Replace every 2 years

Km x 1,000

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Safety fasteners I I I I I
Throttle control A A A A A A A A A
Engine oil filter R R R R R R R R R
Electrical system I I I I I I I I I
Coolant level * I I I I I I I I I
Brake oil level* I I I I I I I I I
Engine oil R I R I R I R I R I R I R I R I R
Brake pads I I I I I I I I I I I I I I I I I
Tyre pressure and wear I I I I I I I I I
Vehicle and brake test - test drive I I I I I I I I I
Hub oil R I R I R I R I R
Centre and side steering A A A A A A A A A
Parking control unit software upgrading
(if available)

I I I I I I I I I I I I I I I I I

Centre stand L L L L L L L L L L L L L L L L
Drive belt R R R R R R R R
Air filter C I C I C I C I

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 37

Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Sliding shoes / CVT rollers R R R R R R R R
Suspension I I I I I I I I
Spark plugs R R R R R R R R
Roll lock calliper control cable A A A A A A A A
Valve clearance I I I I
Operation time 105'10' 190'10' 220'10' 190'10' 220'10' 190'10' 220'10' 190'10' 22

0'

Versions for market USA-CND

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE

* Replace every 2 years

km x 1,000 (mi x 1000) 1

(0.

6)

5

(3.

1)

10
(6.

2)

15
(9.

3)

20

(12

.4)

25
(15
.5)

30

(18

.6)

35
(21
.7)

40

(24

.9)

45

(28

.0)

50

(31

.1)

55
(34
.2)

60

(37

.3)

65
(40
.4)

70

(43

.5)

75
(46
.6)

80

(49

.7)

Safety fasteners I I I I I
Throttle control A A A A A A A A A
Engine oil filter R R R R R R R R R
Electrical system I I I I I I I I I
Coolant level * I I I I I I I I I
Brake oil level* I I I I I I I I I
Engine oil R I R I R I R I R I R I R I R I R
Brake pads I I I I I I I I I I I I I I I I I
Tyre pressure and wear I I I I I I I I I
Vehicle and brake test - test drive I I I I I I I I I
Hub oil R I R I R I R I R
Centre and side steering A A A A A A A A A
Parking control unit software upgrading
(if available)

I I I I I I I I I I I I I I I I I

Centre stand L L L L L L L L L L L L L L L L
Drive belt R R R R R R R R
Air filter C I C I C I C I
Sliding shoes / CVT rollers R R R R R R R R
Suspension I I I I I I I I
Spark plugs R R R R R R R R
Roll lock calliper control cable A A A A A A A A
Valve clearance I I I I
Operation time 105'10' 190'10' 220'10' 190'10' 220'10' 190'10' 220'10' 190'10' 22

0'

Checking the spark advance

The ignition advance is electronically determined
based on the parameters known by the control
unit. This is why it is not possible to measure the
reference values based on the engine rpm. The
ignition advance value is detectable at any time
using the diagnostic tester. It is possible to check
whether the ignition advance determined by the
injection system matches the value actually acti­vated on the engine, by means of the stroboscopic
light.

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 38

Proceed as follows:

- Remove the spark plugs.

- Remove the transmission crankcase.

- Rotate the driving pulley fan until the reference
marks between the flywheel and flywheel cover
meet as shown in the photograph.

- Bring the reference mark onto the transmission
side between the fan and the transmission cover
as shown in the photograph.

- Refit the spark plugs.

- Refit the plastic cap on the flywheel cover.

- Adjust the spark gap to the contact position (no
reference mark visible) and install it on the engine
between the spark plugs and spark plug caps.

- Connect the induction clamp to the spark gap
cable respecting the proper polarity (the arrow on
the clamp must be pointing at the spark plug).

- Connect the diagnostic tool.

- Start the engine.

- On the diagnostic tool, select the function «PA-
RAMETERS».

- Set the stroboscopic light control to the traditional
four-stroke engine position (1 spark, 2 revs).

- Check that the real values of rpm and ignition
advance match those measured using the diag­nostic tool.

If the values do not correspond, check:

- distribution timing

- rpm timing sensor

- injection control unit

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 39

Specific tooling

020922Y Diagnosis Tool
020330Y Stroboscopic light for timing checking
020621Y HV cable extraction adaptor

Spark plug

Remove the port on the left-hand side panel of the
vehicle by undoing the fixing screw and using a
small screwdriver in the rear recess shown in the
figure, then do the following:

- Disconnect the HV wire caps «A» of the spark
plugs;

- Unscrew the spark plugs using the wrench sup­plied;

- Upon refitting, place the spark plugs at the re­quired angle and tighten by hand until it is finger
tight;

- Use the wrench only for final tightening of the
spark plug;

- Place cap «A» fully over the spark plugs

- Refit the port making sure the rear hook is inser-

ted.

WARNING

THE SPARK PLUG MUST BE REMOVED WHEN THE EN­GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA­TED IN THE SCHEDULED MAINTENANCE TABLE. THE
USE OF ELECTRONIC CENTRAL UNITS AND OF NON­COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGS
OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY
DAMAGE THE ENGINE.

N.B.
USING SPARK PLUGS OTHER THAN THE INDICATED

TYPE OR SHIELDLESS SPARK PLUG CAPS CAN CAUSE
ELECTRICAL SYSTEM FAILURES.

Characteristic

Spark plug

NGK CR7EKB

Electric characteristic

Electrode gap

0.7 - 0.8 mm

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 40

Hub oil

Check

- Rest the vehicle on its centre stand on level
ground.

- Unscrew the dipstick «A», dry it with a clean rag
and then reinsert it, screwing it tightly into
place.

- Extract the dipstick checking that the oil level is
between the MAX and MIN index marks; if the lev­el is below the MIN mark, it needs to be filled up
with the right amount of hub oil.

-Screw up the oil dipstick again and make sure it
is locked properly into place.

Replacement

- Remove the oil filler plug «A».

- Unscrew the oil drainage cap «B» and drain out
all the oil.

- Screw in the drainage cap again and fill the hub
with the prescribed oil.

Recommended products

AGIP GEAR SAE 80W-90 Lubricant for gear­boxes and transmissions.

API GL-4

Characteristic

Rear hub oil

Capacity approximately 250 cc

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 41

Air filter

- Unscrew the nine fixing screws «A» and remove
the air filter cover.

- Wash the sponge with water and mild soap.

- Dry it with a clean cloth and short blasts of com­pressed air.

- Gently squeeze the filtering element with your
hands but do not wring it; allow it to drip dry and
then refit.

CAUTION

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

Recommended products

AGIP FILTER OIL Special product for the treat­ment of foam filters.

-

Engine oil

In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and
the thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all four stroke 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".

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 42

Replacement

Change oil and replace filter as indicated in the
scheduled maintenance table. Empty the engine
by draining the oil through drainage plug «B».

To facilitate oil drainage, loosen the cap/dipstick
«A».

Once all the oil has drained through the drainage
hole, unscrew the oil cartridge filter and remove it.
Make sure the pre-filter and drainage plug O-rings
are in good conditions.
Lubricate them and refit the mesh filter and the oil
drainage plug, screwing them up to the prescribed
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, engine oil must be added through plug
«A». Then start up the vehicle, leave it running for
a few minutes and switch it off: After about five mi­nutes, check the level and, if necessary, top-up but
never exceeding the MAX level reference mark.
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.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 43

THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products

eni i-Ride PG 5W-40 Synthetic based lubricant
for high-performance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3

Locking torques (N*m)

Engine oil filter 12 - 16 Engine oil drainage plug

24 to 30

Check

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

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

- Unscrew the cap/dipstick «A», dry it with a clean
cloth and reinsert it, screwing it all the way
down.

- Remove the cap/dipstick again and check that
the level is between the min and max reference
marks; top-up, if required.
If the check is carried out after the vehicle has
been used, and therefore with a hot engine, the
level will be lower; in order to carry out a correct
check, wait at least 10 minutes after the engine
has been stopped so as to get the correct level.

Engine 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.
Restoring the level from the MIN to the MAX marks
requires approx. 400 m³ of oil.

Engine oil filter

Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the rec­ommended type for topping up and changing purposes.

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 44

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended products

eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3

Oil pressure warning light

The vehicle is equipped with a telltale light on the
dashboard 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.

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.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 45

Cooling system

Check coolant level when the engine is cold as in­dicated in the scheduled maintenance table, fol­lowing the steps below:
Place the vehicle on its centre stand and on flat
ground.

- Unscrew the screw shown in the figure and re­move the expansion tank cover.

- Top up if the coolant level by undoing the plug
«A», if the coolant level is near or below the level
edge MIN. The coolant level should always be be­tween the MIN and MAX levels.

-The coolant consists of an ethylene glycol and
corrosion inhibitor based 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.

Recommended products

AGIP PERMANENT SPEZIAL Ethylene glycol­based antifreeze fluid with organic inhibition
additives. Red, ready to use.

ASTM D 3306 - ASTM D 4656 - ASTM D 4985 ­CUNA NC 956-16

Braking system

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 46

Level check

FRONT AND REAR BRAKING SYSTEM LEVEL
CHECK

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

- Rest the vehicle onto the centre stand, with the
handlebar centred.

- Check the fluid level through the sight glass. A
drop in the brake fluid level may be caused by pad
wear.

INTEGRAL BRAKING SYSTEM LEVEL CHECK

- Rest the vehicle on its centre stand on level
ground.

- Remove the inspection cover and check that the
brake fluid inside the reservoir is not below the
recommended level.

- A drop in the brake fluid level may be caused by
pad wear.

Top-up

FRONT AND REAR BRAKING SYSTEM TOP­PING UP

For both brake pumps, proceed as follows:

- Loosen the two fixing screws and remove the
reservoir cover; top-up with the recommended flu­id and without exceeding the maximum mark.
Under standard climatic conditions, replace fluid
as indicated in the scheduled maintenance table.

WARNING

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. BRAKE
CIRCUIT FLUID IS VERY CORROSIVE; MAKE SURE THAT
IT DOES NOT COME INTO CONTACT WITH THE PAINT­WORK.

CAUTION

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 47

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

Recommended products

AGIP BRAKE 4 Brake fluid.

SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 ­CUNA NC 956 DOT 4 synthetic fluid

INTEGRAL BRAKING SYSTEM LEVEL TOP­PING UP

- Remove the inspection cover, unscrew the tank
cap and top up using the recommended product.

- If there is air in the circuit, bleed the system.

CAUTION

AIR INSIDE THE INTEGRAL CIRCUIT IS SPECIALLY DAN­GEROUS: THIS SPECIFIC BRAKING SYSTEM CAN PUMP
AIR INTO THE REAR AND/OR FRONT CIRCUITS THUS
COMPROMISING THE CORRECT OPERATION OF EACH
SYSTEM WHEN USED INDIVIDUALLY.

Recommended products

AGIP BRAKE 4 Brake fluid.

SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 ­CUNA NC 956 DOT 4 synthetic fluid

Headlight adjustment

Proceed as follows:

- Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pres­sure, onto a flat surface 10 m away from a half-lit
white screen; make sure the scooter axis is per­pendicular to the screen;

- Remove the headlight assembly central cover.

- Turn on the headlight and check that the border
of the projected light beam on the screen is not
higher than 9/10 or lower than 7/10 f the height
from the ground to the centre of vehicle headlamp;

- Otherwise, adjust the headlight with the screws
« A» indicated in the figure

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 48

N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINI­MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU­TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.

Anti-evaporation system

Removing system components

To access the canister system components:

- Open the saddle.

- Undo the fixing screws of the system components
cover.

- Remove the components from their seat acting
on the rubber supports.

Refitting system components

To refit, proceed in reverse order, taking care to use new metal clamps to fix the pipes.

Canister inspection

The canister is essential to treat the hydrocarbons present in the volume of gas that escapes from the
tank when there is an increase in internal pressure (tank heating induced by the cooling radiator, by the
motor or by the external environment).
The volume of air is limited by the operation of the ventilation valve (Roll-over).

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 49

Although the amount of hydrocarbons coming from the tank is small enough to avoid the saturation of
the canister, it is necessary to regenerate the activated carbon by means of a reversed flow of ambient
air sucked by the engine.
These vacuums of pollution and carbon regeneration take place at each cycle of use of the vehicle.

To control the canister, it is necessary to proceed
with its removal while keeping the 2 pipes connec­ted.

•

Shake the Canister and make sure
there is no noise.

•

Using a compressed air gun, blow al­ternately in 3 ducts and make sure that
pressure does not build inside the can­ister.

•

Check that the air flow is kept free and
that no carbon residues escape out of
any pipe.

If you detect noise, clogging or loss of carbon, re­place the canister.

Safety valve check

The cleaning of the canister is achieved via a controlled flow of air from the vacuum socket in the intake
manifold.
To ensure that the engine works properly, it is necessary that the flow of air is not too intense, this is
achieved by means of a restricted section 0.0354in (0.9 mm) formed in the socket on the intake manifold.
The relative connecting pipe with the canister, includes the installation of the safety valve.
This is a one-way valve which ensures the passage of air in the direction of the manifold when the
control vacuum is greater than 2.9PSI (20kPa) (200mbar).
The vacuum of the engine at idle, causes a slight flow of air easily compensated by the idle speed
adjustment parameters.
When the vehicle is stopped, the safety valve will be closed due to the lack of control vacuum therefore,
any expansion of the fuel tank, will not cause pollution of the intake manifold, and then cause flooding
of the engine.

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

MAIN - 50

To control the valve, it is preferable to it, alterna­tively just access the manifold side pipe.

•

Connect the MITY-VAC pump on the
engine side duct.

•

Select the pump command on the "vac­uum" position, then slowly apply vac­uum up to the valve threshold check
opening.

If you detect different pressures, replace the valve.
Note: An opening vacuum that is too high, causes
a lack of regeneration of the activated carbon; vice
versa, an opening vacuum that is too low, increa­ses the flow of air to the engine causing the thin­ning of idle.

Characteristic

Standard opening vacuum

(2.90-3.77)PSI (20-26)kPa (200-260)mbar

Roll-over valve check

The valve must enable the following results:

•

Aeration of the tank while riding (the ambient air enters the tank in relation to the volume of
fuel used).

•

Pressurisation of the tank (while riding or during a break, you may experience increases in
the temperature inside the tank. The valve must pressurize the tank to limit the escape of
fuel vapour to the canister).

•

Prevent pollution of the canister with the liquid fuel (in case of fall of the vehicle, the valve
must block the connection with the canister).

To control the valve, it is necessary to remove it
from the vehicle.
For the check, it is planned to use a MITY-VAC
pump and a piece of tube, then proceed as follows:

•

Connect the MITY-VAC pump to the
lower joint of the safety valve (white).

•

Select the "vacuum" control position
and keeping the valve in the vertical
axis, check that it is possible to intake

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Maintenance

MAIN - 51

air without movements of the gauge
needle.

•

Switch the control of the pump to "pres­sure" and, keeping the valve in the ver­tical axis, check that it is possible to
pressurise the valve up to values
slightly below 1.45PSI(~0.87PSI)
10kPa(~6kPa) 100mbar(~60mbar).

Note: The setting pressure is easily recognisable
in that, when it is reached, the valve discharges
the air emitting a little noise.

•

Position the valve in the horizontal axis
and check that you can pressurise it to
values well above the setting pressure
(eg. 7.25PSI (50 kPa) (0.5bar) without
guaranteeing the maintenance).

If you detect abnormal behaviour, replace the
valve.
Note: Any malfunction of the valve can cause de­formation of the fuel tank or aggravate the working
conditions of the canister.

Maintenance MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

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MAIN - 52

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations 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 unit

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

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil seal Replace the valve oil seal
Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

Operation

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

By-Pass area.

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

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level adding 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 faying surface with the bell is mainly in the centre
with equivalent characteristics on the three masses. Check that
the clutch housing is not scored or worn in an anomalous way

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

Troubleshooting MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

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TROUBL - 54

Possible Cause Operation

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

vehicle.

Brakes overheating

BRAKE OVERHEAT

Possible Cause Operation

Defective plunger sliding 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 stuck 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 irregu-

larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause

Operation

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-

tened.

Noisy suspension

NOISY SUSPENSION

Possible Cause

Operation

Faults in the suspension system If the front suspension is noisy, check: the efficiency of the front

shock absorber; 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 disc in the

attachment to the hub and the steering tube.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Troubleshooting

TROUBL - 55

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of the

steering covers and the adjustments.

Troubleshooting MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

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TROUBL - 56

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

CAUTION

THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION EQUIPPED WITH ABS ­ASR SYSTEM.

KEY

1. Instrument panel

2. Ambient temperature sensor

3. Turn indicator bulbs

4. Turn indicator switch

5. Emergency turn indicator switch

6. Turn indicators control device

7. Pre-installation for anti-theft device

8. Headlight

9. Front daylight running light bulb

10. Fuel level transmitter

11. Starter button

12. Headlight relay

13. Secondary fuses

14. ignition key contacts

15. USB socket

16. Stop buttons lever and brake pedals

17. Ignition switch contacts

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18. Saddle opening switch

19. Saddle opening actuator

20. Light switch

21. Pre-installation heated handgrips control device and leg warmer

22. engine stop switch

23. Stop light relay

24. Electric fan relay

25. Electric fan

26. Plug socket

27. Helmet compartment light switch

28. Helmet compartment light bulb

29. Magneto flywheel

30. Voltage regulator

31. Main fuses

32. Battery

33. Start-up relay

34. Starter motor

35. Fuse No. 13

36. ignition key contacts

37. License plate bulbs

38. Rear headlight assembly

39. Fuse No. 14

40. Injection load relay

41. Pressure sensor

42. Horn relay

43. PMP connection

44. Geared motor

45. Brake calliper sensor

46. Parking control ECU

47. Right speed sensor

48. Left speed sensor

49. Lambda sensor

50. Rotation sensor

51. Hand brake switch

52. Suspension locking/unlocking switches

53. Engine speed sensor

54. HV coil

55. Injector

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56. Engine temperature sensor

57. Fuel pump

58. ABS control unit

59. Rear ABS sensor

60. Left front ABS sensor

61. Right front ABS sensor

62. Tip over sensor

63. Diagnostic socket

64. Injection ECU

65. Immobilizer aerial

66. Warning light unit

67. ASR Button

68. MODE button

69. Oil pressure sensor

70. Horn

71. horn button

72. Horn connection for anti-theft device

73. Rider presence sensor
Cable colour:

Az = Sky blue
Bi = White
Ar = Orange
Gi = Yellow
BL = Blue
Ma = Brown
Ne = Black
Rs = Red
Ro = Pink
Ve = Green
Vi = Violet
Gr = Grey

CAUTION

THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION NOT EQUIPPED WITH
ABS - ASR SYSTEM.

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ELE SYS - 60

KEY

1. Instrument panel

2. Ambient temperature sensor

3. Turn indicator bulbs

4. Turn indicator switch

5. Emergency turn indicator switch

6. Turn indicators control device

7. Pre-installation for anti-theft device

8. Headlight

9. Front daylight running light bulb

10. Fuel level transmitter

11. Starter button

12. Headlight relay

13. Secondary fuses

14. ignition key contacts

15. USB socket

16. Stop buttons lever and brake pedals

17. Ignition switch contacts

18. Saddle opening switch

19. Saddle opening actuator

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20. Light switch

21. Pre-installation heated handgrips control device and leg warmer

22. engine stop switch

23. Stop light relay

24. Electric fan relay

25. Electric fan

26. Plug socket

27. Helmet compartment light switch

28. Helmet compartment light bulb

29. Magneto flywheel

30. Voltage regulator

31. Main fuses

32. Battery

33. Start-up relay

34. Starter motor

35. Fuse No. 13

36. ignition key contacts

37. License plate bulbs

38. Rear headlight assembly

39. -

40. Injection load relay

41. Pressure sensor

42. Horn relay

43. PMP connection

44. Geared motor

45. Brake calliper sensor

46. Parking control ECU

47. Right speed sensor

48. Left speed sensor

49. Lambda sensor

50. Rotation sensor

51. Hand brake switch

52. Suspension locking/unlocking switches

53. Engine speed sensor

54. HV coil

55. Injector

56. Engine temperature sensor

57. Fuel pump

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58. -

59. -

60. -

61. -

62. Tip over sensor

63. Diagnostic socket

64. Injection ECU

65. Immobilizer aerial

66. Warning light unit

67. -

68. MODE button

69. Oil pressure sensor

70. Horn

71. horn button

72. Horn connection for anti-theft device

73. Rider presence sensor
Cable colour:

Az = Sky blue
Bi = White
Ar = Orange
Gi = Yellow
BL = Blue
Ma = Brown
Ne = Black
Rs = Red
Ro = Pink
Ve = Green
Vi = Violet
Gr = Grey

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Components arrangement

1. BRAKE LEVER STOP BUTTONS

Remove the upper handlebar cover to reach it.

2. PRE-INSTALLATION HEATED HANDGRIPS
CONTROL DEVICE AND LEG WARMER

Remove the upper handlebar cover to reach it.

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3. AMBIENT TEMPERATURE SENSOR

Remove the upper handlebar cover to reach it.

4. IMMOBILIZER AERIAL

Remove the shield back plate upper side to reach
it.

5. IGNITION KEY CONTACTS

Remove the shield back plate upper side to reach
it.

6. STOP LIGHTS RELAY

Remove the leg shield to reach it.

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7. PMP CONNECTION

Remove the leg shield to reach it.

8. BRAKE CALLIPER SENSOR

Remove the leg shield to reach it.
The sensor connector is fixed to the frame under
the expansion tank.

9. PRESSURE SENSOR

Remove the leg shield to reach it.

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10. RELAY UNIT

Remove the leg shield to reach it.

A. HORN RELAY
B. INJECTION LOAD RELAY
C. ELECTRIC FAN RELAY
D. HEADLIGHT RELAY

11. TURN INDICATORS CONTROL DEVICE

Remove the leg shield to reach it.

12. USB SOCKET CONNECTOR

Remove the leg shield to reach it.

13. GEAR MOTOR

14. ROTATION SENSOR

Remove the leg shield to reach it.

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15. ELECTRIC FAN

Remove the radiator cover to reach it.

16. SPEED SENSOR

The sensors are located in the internal section of
the front wheels.
To access the connectors, the central chassis cov­er must be removed.

17. FRONT ABS SENSORS (IF APPLICABLE)

The sensors are located in the internal section of
the front wheels.
Remove the leg shield back plate to reach the con­nectors.

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18. STOP PEDAL BRAKES BUTTON

To reach them, remove the right footrest.

19. HORN

Remove the left footrest to reach them.

20. PARKING CONTROL ECU

Remove the leg shield back plate to reach it.

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21. HAND BRAKE SWITCH

Remove the leg shield back plate to reach it.

22. AUXILIARY FUSES

To reach them, remove the cover on the left foot­rest.

23. FUEL PUMP

24. FUEL LEVEL TRANSMITTER

Remove the central chassis cover to reach it.

25. LAMBDA SENSOR

To reach the connector of the probe, positioned on
the exhaust manifold, remove the inspection cover
located in the helmet compartment.

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26. OIL PRESSURE SENSOR

The sensor is positioned on the right side of the
engine, near the exhaust muffler.

27. ENGINE SPEED SENSOR

To reach the sensor connector, remove the right
side fairing.

28. MAGNETO FLYWHEEL

To reach the flywheel connector, remove the right
side fairing.

29. REAR ABS SENSOR (IF APPLICABLE)

Remove the helmet compartment in order to reach
the connector.

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30. H.V. COIL

Remove the left side fairing to reach it.

31. STARTER MOTOR

Remove the helmet compartment to reach it.

32. SADDLE OPENING ACTUATOR

Remove the license plate support to reach it.

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33. VOLTAGE REGULATOR

Remove the license plate support to reach it.
To reach the connector, remove the right side fair­ing.

34. PRE-INSTALLATION FOR ANTI-THEFT DE­VICE

35. HORN CONNECTION FOR ANTI-THEFT DE­VICE

Remove the right side fairing to reach it.

36. INJECTION ECU

Remove the inspection cover located in the helmet
compartment to reach it.

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37. INJECTOR

38. ENGINE TEMPERATURE SENSOR

Remove the inspection cover located in the helmet
compartment to reach it.

39. START-UP RELAY

40. FUSE No. 13

41. MAIN FUSES

42. FUSE No. 14 (IF APPLICABLE)

43. TIP OVER SENSOR

These components are found in the helmet com­partment.

44. BATTERY

45. DIAGNOSIS SOCKET

These components are found in the helmet com­partment.

46. RIDER DETECTION SENSOR

The sensor is located under the saddle, undo the
screw and remove the cover to reach it.

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47. ABS CONTROL UNIT (IF APPLICABLE)

Remove the helmet compartment to reach it.

Ground points

On the vehicle there is a chassis ground point
"A", remove the footrest to access it.

There is another ground point "B" on the starter
motor, remove the helmet compartment to reach
it.

On the left side of the vehicle is an engine-chassis
ground cable «C» fixed, remove the footrest and
the side fairing to reach it.

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Electrical system installation

Front side

1. Control connections on the left side of the handlebar

2. At left stop button

3. Main cable harness

4. Pre-installation heated handgrips control device and leg warmer connector

5. At right stop button

6. Control connections on the right side of the handlebar

7. Immobilizer aerial

8. Ignition switch contacts

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9. Warning light unit connector

10. Instrument panel connector

11. USB socket connector

12. Turn indicators control device

13. PMP connection

14. Pressure sensor

15. Stop light relay

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16. Relay unit connections

17. Gear motor connector

18. Rotation sensor and headlamp wiring

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19. Rotation sensor connector

20. Headlight connector

21. Rotation sensor

22. Front daylight running light connector

23. To electric fan

24. Pressure sensor connector

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25. Saddle opening switch connector

26. ASR Button connector

27. Wheel sensors wiring

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28. Parking control ECU connector

29. To horn

30. Speed sensors connectors

31. Secondary fuses

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32. Front wiring branch

33. Speed sensor

34. Front ABS sensor

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35. Front ABS sensors connectors

Back side

1. ABS control unit connector

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2. Main cable harness

3. To ground point on chassis

4. Positive battery pole

5. Start-up relay connections

6. Main fuses

7. HV coil

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8. Left taillight, license plate lights and saddle opening switch actuator wiring

9. Left taillight connector

10. Rear left turn indicator connector

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11. License plate lights connector

12. Saddle opening actuator

13. Engine speed sensor connector

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14. Rear ABS sensor connector

15. Starter motor positive

16. Injection ECU connector

17. Engine temperature sensor

18. Injector

19. Plug socket

20. Oxygen sensor connector

21. Pre-installation for anti-theft device

22. Horn connection for anti-theft device

23. Magneto flywheel connector

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24. Helmet compartment light connector

25. Rear right turn indicator connector

26. Right taillight connector

27. Voltage regulator connector

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28. To voltage regulator

Conceptual diagrams

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Ignition

KEY

1. Instrument panel

13. Secondary fuses

31. Main fuses

32. Battery

35. Fuse No. 13

36. ignition key contacts

40. Injection load relay

53. Engine speed sensor

54. HV coil

55. Injector

57. Fuel pump

64. Injection ECU

65. Immobilizer aerial

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Battery recharge and starting

KEY

11. Starter button

13. Secondary fuses

16. Stop buttons lever and brake pedals

22. engine stop switch

23. Stop light relay

29. Magneto flywheel

30. Voltage regulator

32. Battery

33. Start-up relay

34. Starter motor

35. Fuse No. 13

36. ignition key contacts

38. Rear headlight assembly

64. Injection ECU

66. Warning light unit

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Level indicators and enable signals section

KEY

1. Instrument panel

2. Ambient temperature sensor

10. Fuel level transmitter

11. Starter button

12. Headlight relay

13. Secondary fuses

16. Stop buttons lever and brake pedals

22. engine stop switch

23. Stop light relay

24. Electric fan relay

31. Main fuses

32. Battery

33. Start-up relay

35. Fuse No. 13

36. ignition key contacts

40. Injection load relay

46. Parking control ECU

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62. Tip over sensor

64. Injection ECU

66. Warning light unit

69. Oil pressure sensor

Devices and accessories

CAUTION

THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION EQUIPPED WITH ABS ­ASR SYSTEM.

KEY

1. Instrument panel

3. Turn indicator bulbs

6. Turn indicators control device

7. Pre-installation for anti-theft device

8. Headlight

10. Fuel level transmitter

12. Headlight relay

13. Secondary fuses

14. ignition key contacts

15. USB socket

17. Ignition switch contacts

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18. Saddle opening switch

19. Saddle opening actuator

20. Light switch

21. Pre-installation heated handgrips control device and leg warmer

26. Plug socket

27. Helmet compartment light switch

28. Helmet compartment light bulb

31. Main fuses

32. Battery

35. Fuse No. 13

36. ignition key contacts

39. Fuse No. 14

41. Pressure sensor

42. Horn relay

43. PMP connection

44. Geared motor

45. Brake calliper sensor

46. Parking control ECU

47. Right speed sensor

48. Left speed sensor

50. Rotation sensor

51. Hand brake switch

52. Suspension locking/unlocking switches

58. ABS control unit

59. Rear ABS sensor

60. Left front ABS sensor

61. Right front ABS sensor

63. Diagnostic socket

64. Injection ECU

66. Warning light unit

68. MODE button

70. Horn

71. horn button

72. Horn connection for anti-theft device

73. Rider presence sensor

CAUTION

THE FOLLOWING INSTRUCTIONS REFER TO THE VEHICLE VERSION NOT EQUIPPED WITH
ABS - ASR SYSTEM.

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KEY

1. Instrument panel

3. Turn indicator bulbs

6. Turn indicators control device

7. Pre-installation for anti-theft device

8. Headlight

10. Fuel level transmitter

12. Headlight relay

13. Secondary fuses

14. ignition key contacts

15. USB socket

17. Ignition switch contacts

18. Saddle opening switch

19. Saddle opening actuator

20. Light switch

21. Pre-installation heated handgrips control device and leg warmer

26. Plug socket

27. Helmet compartment light switch

28. Helmet compartment light bulb

31. Main fuses

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32. Battery

35. Fuse No. 13

36. ignition key contacts

41. Pressure sensor

42. Horn relay

43. PMP connection

44. Geared motor

45. Brake calliper sensor

46. Parking control ECU

47. Right speed sensor

48. Left speed sensor

50. Rotation sensor

51. Hand brake switch

52. Suspension locking/unlocking switches

63. Diagnostic socket

64. Injection ECU

66. Warning light unit

68. MODE button

70. Horn

71. horn button

72. Horn connection for anti-theft device

73. Rider presence sensor

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Lights and turn indicators

KEY

1. Instrument panel

3. Turn indicator bulbs

4. Turn indicator switch

5. Emergency turn indicator switch

6. Turn indicators control device

8. Headlight

9. Front daylight running light bulb

12. Headlight relay

13. Secondary fuses

14. ignition key contacts

20. Light switch

31. Main fuses

32. Battery

35. Fuse No. 13

36. ignition key contacts

37. License plate bulbs

38. Rear headlight assembly

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46. Parking control ECU

Checks and inspections

This section is dedicated 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 operation of the vehicle only if it is star­ted with the keys encoded and recognized by the
control unit. The code is integrated in a transpond­er in the key body. This allows transparent opera­tion to the driver who does not have to carry out
any other operation than to normally turn the key.
The immobilizer system contains the following
components:

- an electronic control unit

- immobilizer aerial

- master key with built-in transponder

- service key with built-in transponder

- HV coil

- diagnosis LED
The diagnosis LED also works as a theft-deterrent
blinker. This function is activated every time the
ignition switch is set to «OFF» or the emergency
stop switch is set to «OFF». It remains activated
for 48 hours in order not to affect the battery
charge. When the ignition switch is turned to
«ON», the deterring blinker function is deactivated
and a flash confirms the switching to « ON». 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 switch and/
or the instrument panel is not initiated, check if:

•

there is battery voltage

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•

fuses 2, 11, 13 are in working order

•

there is power to the control unit as
specified below

Remove the connector mounting 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 7-26, 15-26 and terminal 26­chassis ground (fixed power supply). If
there is no voltage, check that fuse 6
and its cable harness are in working
order.

With the key switch in the ON position:

•

if there is battery voltage between ter­minals 7-4, 15-4 and terminal 4-chas­sis ground (fixed power supply). If
there is no voltage, check the ignition
switch contacts and that fuses No. 10,
13 and their cables are in working or­der.

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•

There is continuity between terminals
21-23 with the emergency cut-off
switch set to «RUN». If there is no con­tinuity check the contacts of the switch.

After removing the leg shield back plate, remove
the electrical connection from the aerial as shown
in the picture.

Remove the protective base from the connector.

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