PIAGGIO MP3 500 ie SPORT Business LT (2011) User Manual

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MANUALE STAZIONE DI SERVIZIO

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MP3 500 ie SPORT Business LT (2011)

MANUALE

STAZIONE DI

SERVIZIO

MP3 500 ie SPORT Business LT (2011)

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

MANUALE STAZIONE DI

SERVIZIO

MP3 500 ie SPORT Business LT

(2011)

Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid 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.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the 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 ie SPORT Business LT (2011) Characteristics

CHAR - 7

Vehicle identification

Chassis prefix (A)

ZAPM642001

Engine prefix (B):

M474M

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

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

Characteristics MP3 500 ie SPORT Business LT (2011)

CHAR - 8

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification

Desc./Quantity

Kerb weight 253 ± 8 kg

Maximum weight allowed 445 kg

Maximum height 1440 mm

Width 760 mm

Wheelbase 1550 mm

Length 2210 mm

Track 465 mm

Engine

ENGINE

Specification

Desc./Quantity

Type Single-cylinder, 4-stroke with double spark plug

Engine capacity 493 cm³

Bore x Stroke 94 x 71 mm Compression ratio 10.5: 1 Engine idle speed 1,500 ± 100 rpm

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

Valve clearance Intake: 0.15 mm

Exhaust: 0.15 mm

Max. power 29 kW at 7,500 rpm

MAX. torque 44 Nm at 5,200 rpm

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

driven, with double filter: mesh and paper.

Lubrication pressure 3.5 ÷ 4 bar

Minimum lubrication pressure (100° C) 0.8 bar

Fuel system Electronic injection with electric fuel pump.

Cooling Forced coolant circulation system.

MP3 500 ie SPORT Business LT (2011) Characteristics

CHAR - 9

Specification Desc./Quantity

Fuel Unleaded petrol (95 RON)

Transmission

TRANSMISSION

Specification Desc./Quantity

TRANSMISSION Automatic expandable pulley variator with torque server, V-

belt, automatic clutch.

Final reduction gear Gear reduction unit in oil bath.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1.7 l

Transmission oil 250 cm³

Cooling system fluid ~ 1.8 l

Fuel tank (reserve) approx. 12 l (approx. 2 l)

Electrical system

ELECTRICAL SYSTEM

Specification

Desc./Quantity

Starter Electric

Ignition Electronic, inductive, high efficiency ignition, integrated with the

injection system, with variable advance and separate HV coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EKB

Alternative spark plug -

Battery 12V/14 Ah, sealed battery

Generator 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 sys-

tem.

Front suspension travel 85 mm

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

tions at preloading.

Rear suspension travel 110 mm

Brakes

BRAKES

Specification

Desc./Quantity

Front brake Ø 240-mm double disc brake with hydraulic control operated

by the handlebar right-hand lever.

Characteristics MP3 500 ie SPORT Business LT (2011)

CHAR - 10

Specification Desc./Quantity

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

handlebar left-hand lever.

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 wheel rims.

Front rim 12'' x 3.00

Rear wheel rim 14'' x 4.50

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

Rear tyre Tubeless, 140/70 -14" 68S or 68P Front tyre pressure 1.6 bar Rear tyre pressure 2.5 bar

Tightening Torques

STEERING

Name

Torque in Nm

Steering lower ring nut (central headstock) 10 to 12 Steering upper ring nut (central headstock) 22.5 to 25

Handlebar fixing screw 50 ÷ 55

Fixing screws for the handlebar control unit U-bolts 7 to 10

CHASSIS

Name

Torque in Nm

Swinging arm set screw bushing 5 ÷ 7

Engine arm bolt - frame arm 32.5 ÷ 40

Swinging arm set screw bushing nut 54 ÷ 60

Engine-swinging arm bolt 98 ÷ 118 Frame-swinging arm bolt 54 ÷ 60

Centre stand bolt 31 - 39

FRONT SUSPENSION

Name

Torque in Nm

Shock absorber lower clamping 19 - 26

Shock absorber upper clamp 19 - 29

Front wheel fixing screws 19 ÷ 24

Steering arm bolt nut 20 to 25

Tilt gripper fixing screws 20 to 25

Front wheel axle 74 - 88

Arm coupling screws 45 to 50

Screws fixing arms to side headstocks 45 to 50

Screws fixing arms to central headstock 45 to 50

Screws fixing the half-arm coupling flange 20 to 25

Screws fixing roll lock disc section 20 to 25

Side headstock upper ring nut 20 - 24

Side headstock lower ring nut 12 ÷ 15

Screw fixing sliding stem to shock absorber 45 to 50

Clamp for sliding stem locking device 6.5 - 10.5

Fixing nuts for constant-velocity universal joints 18 - 20

Potentiometer to anti-tilting device clamp 8 to 10 Electric motor to anti-tilting device clamp 11 to 13

Clamp fixing pump bolt to anti-tilting device 11 to 13

Pump to anti-tilting device clamp 11 to 13

Pressure switch to distribution frame 18 - 20

Sensor to tilt gripper clamp 2.5 - 2.9

MP3 500 ie SPORT Business LT (2011) Characteristics

CHAR - 11

Name Torque in Nm

Pipe terminals to fifth wheel check spring 7 - 11

Joint to anti-tilting device pump 20 to 25 Lower fitting for shock absorber sliding locking clamp pipes 20 to 25 Upper fitting for shock absorber sliding locking clamp pipes 20 to 25

REAR SUSPENSION

Name Torque in Nm

Shock absorber upper clamp 33 to 41

Shock absorber lower clamping 33 to 41

Shock absorber-crankcase attachment bracket 20 to 25

Rear wheel axle 104 to 126

Silencer arm clamping screws 27 - 30

FRONT BRAKE

Name Torque in Nm

Calliper coupling screw 22 ÷ 27

Oil bleed screw 8 - 12

Brake disc screws 8 to 10

Brake fluid pump-hose fitting 16 - 20

Brake fluid pipe-calliper fitting 20 to 25

Screw tightening calliper to support 20 to 25

Calliper upper pipe fitting 20 to 25

REAR BRAKE

Name

Torque in Nm

Oil bleed screw 12÷16

Brake disc screws 8 to 10

Rear brake calliper-pipe fitting 20 to 25

Rigid / flexible pipe fitting 13 - 18

Rear brake pump-pipe fitting 16 - 20

Rear brake calliper fixing screws 20 to 25

pad fastening pin screws 20 ÷ 25

REAR BRAKE

Product

Description Specifications

(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-strength

threadlock

SILENCER

Name

Torque in Nm

Silencer heat guard fixing screw 4 to 5

Screw for fixing silencer to supporting arm 20 to 25

Lambda probe tightening on exhaust manifold 40 to 50

Exhaust manifold-silencer joint tightening 12÷13

Manifold - silencer diaphragm tightening clamp 16 to 18

LUBRICATION

Name

Torque in Nm

Oil pump cover screws 0.7 - 0.9

Screws fixing oil pump to the crankcase 5 to 6

THERMAL GROUP AND TIMING SYSTEM

Name

Torque in Nm

Spark plug 12 ÷ 14

Head fixing stud bolts ***

Head fixing nuts 10 - 12

Exhaust / intake head fixing nuts 10 - 12

Head lubrication control jet 5 - 7

Coolant temperature sensor: 10 - 12

Lambda probe on exhaust manifold 10 - 12

injector fixing screw 3 ÷ 4

Characteristics MP3 500 ie SPORT Business LT (2011)

CHAR - 12

Name Torque in Nm

Counterweight screw 7 to 8.5

Tensioner sliding block fixing screw 10 - 14

Rpm timing sensor fixing screw 3 - 4

Valve lifter mass stop bell fixing screws 30 - 35

Intake manifold screws 11 to 13 Tappet cover fixing screws 7 - 9 Throttle body fixing screws 11 ÷ 13

Head fixing screws 10 - 12

Camshaft retaining bracket screws: 4 ÷ 6

Tightener screw: 5 to 6

Tightener fastening screws: 11 to 13

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

TRANSMISSION COVER

Name Torque in Nm

Driven pulley nut 92 - 100

Drive pulley nut 160 - 175

Anti-vibration roller screw 16.7 ÷ 19.6

M8 retainers for transmission cover 23 ÷ 26

M6 retainer 11 ÷ 13

Anti-vibration roller retainer 17 - 19

Clutch ring nut 65 - 75

Air conveyor screws 11 ÷ 12

Water pump cover screws 3 ÷ 4

External transmission cover screws 7 ÷ 9

Flywheel cover screws 11 - 13

FLYWHEEL COVER

Name

Torque in Nm

Chain guide sliding block retain plate fastening screws 3 ÷ 4

Flywheel fixing nut 115 - 125

Stator retainers 8 - 10

Blow-by recovery duct fixing screws 3 - 4

Screw fixing freewheel to flywheel 13 - 15

Stator cable harness guide bracket screws 3 - 4

Supporting screws with bulkhead 0.3 - 0.4

Minimum oil pressure sensor 12 to 14

Water pump impeller 4 ÷ 5

CRANKCASE AND CRANKSHAFT

Name

Torque in Nm

Countershaft fixing nut 25 ÷ 29

Engine oil filter 12 - 16

Engine oil drainage plug 24 to 30

Engine-crankcase coupling screws 11 to 13

Oil pump screws 5 to 6

Gear mounting on crankshaft screws 10 -12

Bulkhead screws for oil pump housing cover 8 - 10

COOLING

Name

Torque in Nm

Water pump impeller 4 ÷ 5

Water pump cover screws 3 ÷ 4

Thermostat cover screws 3 to 4

Bleed screw 3

Overhaul data

MP3 500 ie SPORT Business LT (2011) Characteristics

CHAR - 13

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

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.

Characteristics MP3 500 ie SPORT Business LT (2011)

CHAR - 14

Piston rings

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

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

Rings/housing coupling clearances:

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

Top ring Standard coupling clearance:

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

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

MP3 500 ie SPORT Business LT (2011) Characteristics

CHAR - 15

Oil scraper ring Standard coupling clearance:

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

Crankcase - crankshaft - connecting rod

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

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

Characteristics MP3 500 ie SPORT Business LT (2011)

CHAR - 16

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 Magnetic mounting for dial gauge

MAX. ADMISSIBLE DISPLACEMENT

Specification

Desc./Quantity

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

MP3 500 ie SPORT Business LT (2011) 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

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

Characteristic

Compression ratio

10.5: 1

Characteristics MP3 500 ie SPORT Business LT (2011)

CHAR - 18

BASE GASKET THICKNESS

Name Measure A Thickness

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

N.B.

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

N.B.

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

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PIAGGIO MP3 500 ie SPORT Business LT (2011) User Manual

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