PIAGGIO MP3 500 i.e. SPORT Service Station Manual

Name: PIAGGIO MP3 500 i.e. SPORT
Brand: PIAGGIO
SKU: 20578990
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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.

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»

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