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SERVICE STATION MANUAL

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1.
2. Check the presence of fixed voltage between the grey black cable of the remote control base and earth If there is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC INJEC 217 Injection MP3 LT 400 i e With the control unit and the injector disconnected check the continuity of the Red Yellow cable be tween pin 14 of the interface wiring and the injector connector Switch to ON and check if there is voltage with injector disconnected and control unit connected between the Black Green cable of the injector con nector and the ground lead With injector disconnected and the injector load remote control disconnected check the continuity of the Black Green cable between the injector con nector and remote control base Inspecting the injector hydraulics To check the injector remove the inlet manifold by removing the three fixing screws at the head and the three screws connecting the control unit to the manifold INJEC 218 MP3 LT 400 i e Injection Install the appropriate tool for the fuel pressure check and position the manifold over a container graduated by at least 100 cc Connect the injector with the cable making up part of the supply for the injection tester Connect
3. 020482Y Engine support 020483Y 30 mm guide 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter 020565Y Flywheel lock calliper spanner 020640y software euro 3 TOOL 30 MP3 LT 400 i e Stores code 020481 Y004 Tooling Description Parking control unit interface wiring Marelli MIU diagnosis software Marelli MIU diagnosis software 020646Y Parallelogram and steering positioning tool f v 020647Y Toe in checking tool 020647 Y028 MP3 LT Toe in tool tricycle 020661Y Water pump overall seal replacement kit TOOL 31 INDEX OF TOPICS MP3 LT 400 i e Maintenance Follow these steps to reset the service icons 1 With the key set to OFF hold down the SET button and turn the key to ON the BELT and SERVICE icons start flashing 2 Push the CLOCK button for less than 1 second and the icons are displayed sequen tially The icon selected remains ON and the other is no longer displayed 3 Press the CLOCK button again for more than 3 seconds to reset the relative mainte nance step and the icon is no longer dis played Maintenance chart CLOCK 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 Safety locks 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
4. Replace the snap ring Support the hub cover using the stud bolt set Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover Place the oil guard flush with the crankcase Specific tooling 020376Y Adaptor handle 020360Y 52x55 mm Adaptor 020476Y Stud bolt set ENG 114 MP3 LT 400 i e Engine Refitting the hub bearings Place the 3 shafts as shown in the figure Refitting the ub cover Check the proper position ofthe centring dowels Install a new gasket Fitthe gearbox cover making sure the breather Pipe is in the correct position Position the 7 set screws tighten them to the prescribed torque being careful of the position of the bands holding the vent tube and the position of the 3 shortest screws as indicated in the figure Refill with the prescribed oil to the Max level Recommended products AGIP ROTRA 80W 90 rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Characteristic Quantity approx 250 cc Locking torques N m Rear hub cover screws 24 27 ENG 115 Engine MP3 LT 400 i e Flywheel cover Remove the three bands shown in the figure for an easier removal of the flywheel cover remove the feed hoses and disconnect the return hose from the pump cover N B THE BANDS MUST BE REPLACED TO REMOVE THEM OPEN WITH A SCREWDRIVER OR CUT THEM BE CAREFUL NOT TO DAMAGE THE PLASTIC UN
5. ENG 164 MP3 LT 400 i e Engine Repeat for the reference between driving pulley and transmission housing Refit the inspection cap on the flywheel side Connect the diagnostic tester Start the engine Select the parameters function in this menu Select the stroboscopic light control in the tradi tional four stroke engine position 1 spark 2 revs Check that the real values of rpm and ignition advance match those measured using the diag nostic tester Specific tooling 020680Y Diagnosis Tool If the values do not match check distribution timing revolution timing sensor injection control unit Refitting the rocker arms cover Check that the gasket is in good working order ENG 165 Engine MP3 LT 400 i e Tighten the two screws indicated in the figure with 1 and 2 to limit the reciprocal sliding of the cover surface with the head surface Tighten the remaining 4 screws in a crossed se quence 3 4 5 6 N B CHECK THE PROPER POSITION OF THE GASKET Locking torques N m Tappet cover fixing screws 7 9 Install the transmission cover and the relevant mesh filter and the outside transmission cover as described in the Automatic transmission chapter Install the cooling system sleeves using new bands as described in the Flywheel cover chap ter Refitting the intake manifold Install the intake manifold on t
6. KEY 1 Instrument panel 2 Rear turn indicator bulbs 3 Front turn indicator bulbs 4 Turn indicator switch 5 Hazard button 6 Turn indicator control device with Hazard 7 Pre installation for anti theft device 8 Headlight with twin filament bulb 9 Tail light bulbs e License plate bulb 11 Front position light bulbs 12 Key switch contacts 13 Headlight remote control 14 Brake pedal button 15 Stop buttons 16 Boot opening switch 17 Saddle opening switch 18 Saddle opening actuator ELE SYS 50 MP3LT 400 i e 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Boot actuator Light switch Engine stop switch Radiator electric fan Electric fan remote control LV socket Helmet compartment light bulb Helmet compartment lighting buttons Magneto flywheel Voltage regulator Main fuses Starter button Start up enabling remote control switch Battery Start up remote control switch Starter motor Key switch contacts Stop bulbs Injection load remote control Pre installation for saddle opening receiver Horn remote control Geared motor Brake calliper sensor Parking control ECU Tilt locking unlocking switch Hand brake Rider presence sensor Potentiometer Lambda sensor Left speed sensor Right speed sensor Engine rpm sensor HV coil Fuel in
7. Remove the silent blocks Remove the retainer fixing the swinging arm to the frame undo the screw Remove the pin Unscrew the nut of the set screw bushing SUSP 288 MP3 LT 400 i e Suspensions From the inside loosen the set screw bushing until the swinging arm is free Remove the swinging arm Check the entire swinging arm assembly Check all the components Teflon bushings si lent blocks roller bushings spacers Replace the work components that cause exces sive clearance on the rear suspension Overhaul Properly support the swinging arm in the vice Check there is no jamming in the movement of the joint connecting the swinging arm on the engine side to the swinging arm on the frame side To check the clearance on the frame side arm mount the retainer using the pin fixing the swinging arm to the frame and two adaptor rings of the appropriate tool 020229Y Alternatively use two washers with inner diameter for 12 mm pins min outer diameter 30 mm min thickness 4 mm Check there is no sticking in the rotation Check the axial clearance of the swinging arm on the frame side Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm SUSP 289 Suspensions MP3 LT 400 i e Separate the swinging arm on the engine side from the vehicle side arm Remove the plastic bushings and the internal s
8. Check that the clutch bell is not worn or damaged Measure the clutch bell inside diameter N B CHECK THE ECCENTRICITY MEASURED 0 2 MM MAX Characteristic Max value 160 5 mm Standard value 160 2 mm ENG 95 Engine MP3 LT 400 i e Removing the clutch To remove the clutch with the driven pulley it is necessary to use the special tool Arrange the tool with the mean pins screwed in position E on the inside Fit the adapter ring to the clutch assembly as shown in the photograph Install the driven pulley unit onto the tool inserting the pins into the ventilation holes Move the rear stop screw in abutment against the fixed driven pulley as shown in the figure CAUTION THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIAL TOOL DO NOT TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD IRRETRIEVABLY DEFORM THE TOOL USING THE SPECIAL 55 MM WRENCH REMOVE THE FASTENING RING NUT LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT CLUTCH SPRING WITH SHEATH Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Inspecting the clutch Check the thickness of the clutch mass friction material Characteristic Minimum thickness permitted 1mm The masses must not show traces of lubricants Otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE
9. Proceed as follows Remove the rear brake calliper Remove the two pins holding the brake pads Remove the pads paying attention to the pad re taining spring Check the thickness of the pads If the thickness is less than the minimum value replace the pads with new pads Characteristic Minimum value 1 5 mm Refitting To fit the rear brake pads follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque Locking torques N m Screws tightening the pad fixing pin 20 25 Nm Fill Rear combined Proceed as follows Position the vehicle on a flat surface and on the stand Loosen the two screws shown in the figure and open the front brake fluid reservoir BRAK SYS 311 Braking system MP3 LT 400 i e Through the bleed screw on the brake calliper bleed the system using a hose of adequate diam eter Collect the used fluid in a container Pump on the brake lever to completely drain the system of all used fluid Tighten the bleed valve Refill the brake system tank up to the maximum level with the prescribed fluid Attach the tube of the special tool to the bleed fitting Actuate the tool at the bleed fitting at the same time constantly topping up the brake system tank to prevent air being drawn into the system until no more air escapes at the bleed fitting The operation is finished when only brake fluid comes o
10. 020359 Y 42x47 mm Adaptor 020360Y 52x55 mm Adaptor 020364Y 25 mm guide 020376Y Adaptor handle 020382Y012 bush valve removing tool 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch TOOL 25 Tooling Stores code Description MP3LT 400 i e 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020439Y 17 mm guide 020444Y Tool for fitting removing the driven pulley clutch 020456Y 24 mm adaptor TOOL 26 MP3 LT 400 i e Stores code Description Tooling 020458Y Puller for lower bearing on steering tube D 020459Y Punch for fitting bearing on steering tube 020680Y Diagnosis Tool gt gt C gt 020467Y Flywheel extractor 020468Y Piston assembly band TOOL 27 Tooling MP3LT 400 i e Stores code Description 020469Y Reprogramming kit for scooter diagnostic tester PIAGGIO 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench TOOL 28 MP3LT 400 i e Stores code Tooling Description 020475Y Piston position checking tool 020476Y Stud bolt set 020478Y Punch for driven pulley roller casing 020479Y Countershaft lock wrench 020480Y Petrol pressure check set 020481Y Control unit interface wiring TOOL 29 Tooling Stores code Description MP3LT 400 i e
11. Remove the inspection cover and check that the brake fluid inside the reservoir is not below the recommended level drop in the brake fluid level may be caused by pad wear MAIN 42 MP3 LT 400 i e Maintenance Top up FRONT AND REAR BRAKING SYSTEM TOP PING UP Proceed as follows Loosen the screw B and lift the plastic cover A in order to access the brake fluid reservoir Loosen the two fixing screws and remove the res ervoir cover top up with the recommended fluid without exceeding the MAX mark This procedure applies to the rear brake pump top up operation follow the same procedure for the front brake pump Under standard climatic conditions replace cool ant 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 PAINT WORK CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES SKIN AND CLOTHING IN CASE OF ACCIDENTAL CONTACT WASH WITH WATER Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid INTEGRAL BRAKING SYSTEM LEVEL TOP PING UP Remove the inspection cover unscrew the cap indicated and top up using the recommended product If there is air in the circuit bleed the system as described in the Braking system filling bleeding the rear integral braking system CAUTION MAIN 43 Main
12. Time COOLING SYSTEM Code Action Duration 1 007013 Radiator expansion tank connection pipe change 2 001052 Coolant and air bleed Replacement 3 007001 Expansion tank Replacement 4 007024 Expansion tank cap Replacement 5 007003 Coolant delivery and return pipe change 6 007016 Fan with support Replacement 7 007002 Water radiator replacement TIME 393 Time MP3 LT 400 i e Braking system INTEGRAL BRAKE PEDAL Code Action Duration 1 002014 Brake pedal Removal and Refitting 2 002088 Integral brake pump Replacement 3 002084 Integral brake pump pipe device Replacement 4 002089 Integral braking device Replace ment 5 002090 Integral brake fluid and system bleeding Change TIME 394 MP3 LT 400 i e BRAKING SYSTEM Time Code Action Duration 1 002025 Brake piping Replacement 2 003096 Tilt locking calliper replacement 3 003100 Tilt locking calliper pads replace ment 4 003108 Parking brake flexible transmission replacement 5 003109 Parking brake mechanical calliper replacement 6 002002 Shoes Rear brake pads Replace ment 7 002020 Rear brake pipes Removal and re fitting 8 002081 Rear brake disc piping Replace ment 9 003118 Tilt locking disc section replace ment 10 003103 Splitter for suspension locking sys tem pipes replacement 11 003102 Pipes for the splitter calliper susp
13. 3 Fix any damaged seals Cil in the fluid 1 Presence of oil in the coolant YES go to 2 2 Check the head gasket seal see Thermal group and timing system chapter COOL SYS 325 INDEX OF TOPICS Cassis CHAS MP3 LT 400 i e Chassis This section is devoted to the operations that can be carried out on the vehicle s bodywork Seat Raise the saddle Undo the screw shown in the figure remove the cover and disconnect the rider presence sensor connector Remove the three fixing screws shown in the fig ure Rear handlebar cover After removing the front part of the handlebar cov j er access the two screws fixing the rear part to the handlebar as indicated in the picture CHAS 327 Chassis MP3 LT 400 i e Instrument panel Remove the front handlebar cover Remove the legshield Remove the shield back plate upper side Unscrew the six fixing screws and remove the instrument panel Front handlebar cover Remove the upper cap by operating on the Allen screw indicated in the figure Remove the two brake pump caps Remove the two screws under the brake pump caps previously removed CHAS 328 MP3 LT 400 i e Chassis Unscrew the two pairs of screws in the lower part of the half handlebar Release the handlebar control locks Remove the front handlebar cover Headlight assy Remove the rad
14. 320 MP3 LT 400 i e Cooling system Select the menu on the ACTIVE DIAGNOSIS function and start the electric fan operation simu lation see Injection chapter If the electric fan is certainly efficient check the 1 557087 ventilation start and stop temperatures ORBICELLAZ I ONE ERE fis OT Ls Select the PARAMETERS function in this menu to display the coolant temperature Electric fan starts 107 C GIP roh Electric fan stops 103 C Mahad 2 ED as m If non conforming values are detected replace soe un s PRESS ATN mmia 77 ic 1 P gt the injection control unit see Injection Chapter rue 14 IET DS A in If the analogue instrument temperature is close to the red zone but the degrees indicated by the diagnostic tester are below the electric fan start temperature check the temperature sensor on the head and the relevant injection circuit see Injec tion chapter N B THE ELECTRIC FAN TEMPERATURE AT 107 C CAN ONLY BE MANAGED BY A SYSTEM SUP PLIED WITH A 50 MIXTURE AND PRESSURISED AT 0 9 BAR AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOIL ING TEMPERATURE BEFORE THE ELECTRIC FAN STARTS WORKING IN CASE OF AN INCREASE OF THE ELECTRIC FAN START TIME CHECK THE THERMOSTAT OPENING TEMPERATURE AND CHECK THAT THE COOLANT DENSITY IS CORRECT THE OP TIMUM DENSITY IS OBTAINED WITH A 50 WATER 50 COOLING CI
15. 48 49 50 52 53 Main fuses Battery Key switch contacts Injection load remote control Brake calliper sensor Parking control ECU Tilt locking unlocking switch Rider presence sensor Potentiometer Lambda sensor Left speed sensor Right speed sensor Engine rpm sensor Fuel injector Engine temperature sensor Electrical system ELE SYS 59 Electrical system MP3 LT 400 i e 56 Injection ECU 58 External temperature sensor 60 Fuel level transmitter 61 Oil pressure sensor 65 Key switch contacts 66 Auxiliary fuses Devices and accessories KEY 1 Instrument panel 2 Rear turn indicator bulbs 3 Front turn indicator bulbs 7 Pre installation for anti theft device 12 Key switch contacts 13 Headlight remote control 16 Boot opening switch 17 Saddle opening switch 18 Saddle opening actuator 19 Boot actuator 22 Radiator electric fan ELE SYS 60 MP3LT 400 i e 23 24 25 26 29 32 35 37 38 39 40 42 44 54 56 59 62 63 64 65 66 Electric fan remote control LV socket Helmet compartment light bulb Helmet compartment lighting buttons Main fuses Battery Key switch contacts Injection load remote control Pre installation for saddle opening receiver Horn remote control Geared motor Parking control ECU Hand brake Fuel pump Injection ECU Pressure sensor Mode button Horn Horn
16. 71 804 72 000 mm Check that shim adjustment is free from scratches N B ENG 172 MP3 LT 400 i e Engine IN CASE OF NEW UTILISATION MAINTAIN THE FIRST FITTING POSITION Specific tooling 020074Y Support base for checking crankshaft alignment If the crankshaft crankcase axial clearance is higher than the standard value and the crankshaft exhibits no irregularity the problem is caused by wear or by awrong machining on the engine crankcase Check the diameters of both bearings of the An crankshaft in accordance with the axes and surfa ces shown in the figure Half shafts are classified into two categories Cat 1 and Cat 2 Refer to the Jil STANDARD DIAMETER Specification Cat 1 Cat 2 Desc Quantity 40 010 40 016 40 016 40 022 Inspecting the crankshaft alignment Install the crankshaft on the support and measure the displacement at the 4 points shown in the figure Specific tooling 020074Y Support base for checking crankshaft alignment MAX ADMISSIBLE DISPLACEMENT Specification Desc Quantity A 0 15mm B 0 01 mm C 0 01 mm 0 10 Check that the driving shaft the tab seat the oil seal capacity the toothed gear and the threaded tangs are in good working order In case of failures replace the crankshaft ENG 173 Engine MP3 LT 400 i e N B MAIN BEARINGS CANNOT BE MODIFIED The connecting rod cannot be replaced To ch
17. CHAS PRE DE TIME INDEX OF TOPICS Characrenistcs CHAR MP3 LT 400 i e Characteristics 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 spare parts may
18. ENG 167 Engine MP3 LT 400 i e Remove the 14 crankcase coupling screws N B THE FASTENING SCREWS ARE OF 3 DIFFERENT LENGTHS NOTE THEIR CORRECT POSITION Split the crankcases while keeping the crankshaft inserted on the flywheel side half crankcase Remove the coupling gasket N B THE BUSHING SUPPORT CAN BE LEFT IN THE FLY WHEEL SIDE HALF CRANKCASE Removing the crankshaft Before removing the crankshaft check the timing with the countershaft To carry out this check turn the crankshaft to align the two holes obtained on the crankshaft with the hole on the countershaft control gear This is an optimal position also to remove the crankshaft Remove the crankshaft with the shim adjustment washer on the flywheel side CAUTION WHILE OPENING THE CRANKCASE AND REMOVING THE CRANKSHAFT CHECK THAT THE SHAFT THREADED ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BEARING ENG 168 MP3 LT 400 i e Engine Removing the oil pump and countershaft con trol gear To remove the control gear loosen the 4 fasten ing screws Remove the gear only if actually required CAUTION THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR THREADING IS LOCKED BY LOCTITE BE CAREFUL NOT TO DAMAGE THE CONTROL HEXAGON TO OBTAIN BET TER RESULTS IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH B1 Removing the
19. Remove the engine cover inside the helmet compartment Remove the side fairings Remove the footrests Remove the full muffler unit ENG VE 86 MP3 LT 400 i e Engine from vehicle CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the rear wheel Remove the bracket supporting the rear brake callipers and the callipers as well After removing the air filter from the crankcase undo the screws fixing the bracket that secures the rear brake pipes Remove the pipe that feeds coolant into the pump as shown in the photograph and then empty the system Remove the engine coolant outlet pipe as indi cated Disconnect the fuel delivery pipe from the injector by removing the screw locking the retainer clamp Disconnect the injector wiring and the throttle body control unit wiring Remove the coolant outlet pipe from the engine as indicated ENG VE 87 Engine from vehicle MP3 LT 400 i e Remove the spark plug caps Remove the coolant temperature sensor con nector indicated in the photograph Remove the throttle cables from the throttle body by undoing the nuts indicated in the photograph Remove the negative terminal cable from the starter motor Remove the positive terminal cable from the starter motor as shown in the photograph Remove the engine ground lead Disconnect the connectors from the flywheel wir ing as
20. connecting rod Measure the diameter of bushings A in the three directions shown in the figure Measure the diameter of the crankshaft bearings B Check that the diametral clearance A B is be Di ACCOPPIAMENTO tween the pre set interval Characteristic Diameter clearance 0 025 0 043 mm If value A B is above the limit check that value B is within the admissible values of the categories CRANKSHAFT Specification Desc Quantity Category 1 40 020 40 026 Category 2 40 026 40 032 If the crankshaft is within the set limits replace the crankshaft half bearings mounting the crankcase so as to suit the specified couplings The crankcase halves can be mounted with four types of crankshaft half bearings identified by letters A red B blue C yellow D green CRANKCASE Specification Desc Quantity Category 1 43 974 43 980 Category 2 43 980 43 986 Category 3 43 986 43 992 CHAR 16 MP3LT 400 i e Characteristics CRANKCASE CRANKSHAFT COUPLING CRANKSHAFT HALF BEARINGS Specification Desc Quantity Crankshaft category 1 Crankcase category 1 B B A C Crankshaft category 2 Crankcase category 1 A A Crankshaft category 1 Crankcase category 2 C C B D Crankshaft category 2 Crankcase category 2 B B A C Crankshaft category 1 Crankcase category D D Crankshaft category 2 Crankcase category 3 C C B D Character
21. 1 004172 Rear case lock catch Replacement 2 005099 Saddle opening electric actuator Replacement 3 004054 Saddle lock catch Replacement 4 005072 Immobilizer aerial Replacement 5 005133 Electric glove box activator Re Turn signal lights Rear lights placement TIME 381 Time MP3 LT 400 i e REAR TURNING INDICATOR LIGHTS Code Action Duration 1 005005 Taillight change 2 005022 Rear turning indicators Replace ment 3 005031 number plate light bulb Replace ment 4 005032 number plate light glass Replace ment 5 005131 number plate light support Replace ment 6 005066 Rear light bulbs Replacement 7 005068 Rear turning indicator bulb Re placement Front lights TIME 382 MP3 LT 400 i e FRONT TURNING INDICATOR LIGHTS Time Code Action Duration 1 005067 Front turning indicator bulb replace ment 2 005012 Front turning indicators Replace ment 3 005002 Front light replacement 4 005008 Headlight bulbs Replacement TIME 383 Time Front wheel MP3 LT 400 i e FRONT WHEELS Code Action Duration 1 003047 Front tyre Replacement 2 003033 Front wheel hub Replacement 9 003037 Front wheel rim Replacement 4 005089 Tone wheel Replacement 5 002041 Front brake disc Replacement 6 004123 Front wheel Replacement TIME 384 MP3 LT 400 i e Time Rear wheel 4 QS T 4 6 REAR WHEEL Code
22. 27 loosen by 90 Steering upper ring nut central headstock 27 33 Handlebar fixing screw 50 55 Fixing screws for the handlebar control unit U bolts 7210 CHASSIS Name Torque in Nm Swinging arm set screw bushing 5 7 Engine 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 Lower shock absorber clamp 19 26 Upper shock absorber clamp 19 29 Front wheel fixing screws 19 24 Steering arm bolt nut 20 25 Tilt gripper fixing screws 20 25 Front wheel axle 74 88 Arm coupling screws 45 50 Screws fixing arms to side headstocks 45 50 Screws fixing arms to central headstock 45 50 Screws fixing the half arm coupling flange 20 25 Screws fixing tilt locking disc section 20 25 Side headstock upper ring nut 20 24 Side headstock lower ring nut 12 15 Screw fixing sliding stem to shock absorber 45 50 Clamp for sliding stem locking device 6 5 10 5 Fixing nuts for constant velocity universal joints 18 20 Potentiometer to anti tilting device clamp 8 10 Electric motor to anti tilting device clamp 11 13 Clamp fixing pump bolt to anti tilting device 11 13 Pump to anti tilting device clamp 11 13 Pressure switch to distribution frame 18 20 Sensor to tilt gripper clamp 2 5 2 9 Pipe termin
23. 6 Check the bulbs ground connection HIGH LOW BEAM LIGHTS LINE CHECK 1 Check that bulbs operate properly 2 Check fuses No 3 5 9 and 11 3 Check key switch contacts 4 Check there is voltage in the Blue cable between the headlight remote control and the ground lead in the Yellow Red cable between the headlight remote control and the ground lead with the key switch set to ON in the Blue cable between the light switch and the ground lead with the key switch set to ON 5 Check that the relevant cable harnesses are not interrupted wherever no voltage is detected 6 Check the headlight remote control and the light switch contacts 7 Check continuity in the White Black cable between the parking control ECU pin 6A and the headlight remote control the Grey Red cable between the headlight remote control and the light switch the cable harnesses between the headlight and the light switch Brown and Purple cables 8 Check the bulbs ground connection LIGHT BULBS TABLE Specification Desc Quantity 1 Low beam bulb Type HALOGEN H1 ELE SYS 75 Electrical system MP3 LT 400 i e Specification Desc Quantity Power 12V 55W Quantity 1 2 High beam light bulb Type HALOGEN 1 Power 12V 55W Quantity 1 3 Helmet compartment light bulb Type FESTOON BULB Power 12V 5W Quantity 1 4 Rear turn indicator light bulb Type Incandescent BAU 15s Power 12V 10W Quantity 1 RHS 1 L
24. Battery Main switch Lights high beam lights low beam lights taillights front and rear and relevant warning lights Headlight adjustment according to the regulations currently in force Front and rear stop light buttons and bulb Turn indicators and their warning lights Instrument lighting instruments fuel and temperature indicator Instrument panel lights Horn Electrical start up Engine stopping with emergency stop switch Electric opening of saddle with remote control Tilting system locking unlocking button CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE ONE WARNING PRE DE 344 MP3 LT 400 i e Pre delivery BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS IT CONTAINS SUL PHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING IN CASE OF CONTACT WITH YOUR EYES OR SKIN RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION IF IT ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSU
25. Compression ratio 10 64 0 5 1 Engine idle speed 1 500 100 rpm Timing system Four valves single overhead camshaft chain driven Valve clearance Inlet 0 15 mm Outlet 0 15 mm MAX Power 24 kW at 7 250 rom MAX torque 38 Nm at 5 250 rom LUBRICATION Engine lubrication with trochoidal pump inside the crankcase oil filter and pressure adjustment by pass Lubrication pressure 3 5 4 bar Minimum lubrication pressure 100 C 0 8 bar Fuel supply Electronic injection with 38 mm throttle body and electric fuel pump Cooling Forced coolant circulation system Fuel Unleaded petrol 95 RON CHAR 9 Characteristics Transmission Specification TRANSMISSION MP3 LT 400 i e TRANSMISSION Desc Quantity 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 71 Transmission oil 250 cm Cooling system fluid 1 81 Fuel tank reserve approx 12 approx 21 Electrical system ELECTRICAL SYSTEM Specification Desc Quantity Start up 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 CHAMPION RG 6 YC Alternative spark plug
26. better sealing performance grind the valve seats Grind the valves gently with a fine grained lapping compound During the grinding keep the cylinder head with the valve axes in a horizontal position This will prevent the lapping compound residues from penetrating between the valve stem and the guide see figure CAUTION TO AVOID SCORING THE FAYING SURFACE DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES RIGHT LEFT Inspecting the springs and half cones Checkthat the upper and lower supporting spring washers the cotters and the oil seal show exhibit no signs of abnormal wear Replace a component when worn ENG 154 MP3 LT 400 i e Engine Measure the unloaded spring length Characteristic Standard length 44 4 mm Admissible limit after use 42 4 the valves Place the valve spring support washers on the head Alternately insert the 4 oil guards using the spe cial tool Lubricate the oil guards and the valve guides Specific tooling 020306Y Punch for assembling valve seal rings Fitthe valves the springs and the caps Using the appropriate tool with adapter compress the springs and insert the cotters in their seats Specific tooling 020382Y Valve co
27. bushing of the movable driving pulley Remove the flat washer and the spring washer as shown in the figure ENG 105 Engine MP3 LT 400 i e Insert the nut in the original position nut side in contact with the belleville washer Turn the central pulley nut to horizontally align the holes and install the special tool N B CHECK THAT THE STOP WRENCH TOOL IS EASILY IN SERTED INTO THE PULLEY AND IN THE ENGINE CRANK CASE Specific tooling 020474Y Driving pulley lock wrench Install the lock ring from the rear so that the splines are completely engaged Finally install the tool by siding the nuts by hand and ensuring the tool is resting flatly Tighten the driving pulley fastening nut to the prescribed torque Remove the special tool Locking torques N m Drive pulley nut 160 175 Refitting the transmission cover Ensure the correct installation on the crankcase e of the 2 centring dowels ENG 106 MP3 LT 400 i e Engine Insert the transmission cover with the bearing and install the relevant retainers Lock the four M8 retainers Locking torques N m 8 retainers for transmission cover 23 26 Lock the 7 M6 retainers Locking torques N m M6 retainer 11 13 Insert the washers on the driven pulley shaft N B INSERT THE SMALLER WASHER FIRST THEN THE LARGER ONE Insert the flanged nut Prepare the torque w
28. flywheel cover chapter and restore proper sliding N B STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY A HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE 1 If oil consumption is above 250 9 1000 km on a run in engine proceed as follows AHEAD go to 2 2 Check the presence of oil in the scavenge duct on the filter box YES go to 3 NO go to 4 3 Check the one way reed valve and the decantation chamber drainage hole YES go to 5 NO go to 4 4 Check the thermal group seals piston rings valve guides and oil guards see Thermal group and Timing system chapter 5 Restore the valve or the drainage hole efficiency ENG 186 MP3 LT 400 i e Engine Oil pump Removal Remove the closing plate of the oil pump housing by loosening the 2 retaining screws with their washers Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper Remove the gasket Remove the two screws and the oil pump cover E E 3 ENG 187 Engine MP3 LT 400 i e Remove the inside rotor retaining snap ring turn ing it to move the opening at the shaft face Remove and wash the rotors thoroughly with pet rol and compressed air Extract the shaft with its gear and check that it is in good working order and free from wear Reassemble the rotors in the pump body k
29. 243 threadlock Repeat the same procedure for the 4 fastening screws Insert the control gear on the crankshaft with the hole countersink visible Tighten the 4 fastening screws to the prescribed torque N B ENG 178 MP3 LT 400 i e Engine TO AVOID DAMAGING THE SCREW CONTROL HEXAGON IT IS PREFERABLE TO USE AN IN SIDE HEXAGON SOCKET WRENCH Locking torques N m Gear mounting on crankshaft screws 10 12 Lubricate the main bearing on the flywheel side JR CY half crankcase Lubricate the shim adjustment washer Insert the shim adjustment washer on the crank shaft in its original position Insert the special timing tool in the hole on the countershaft Specific tooling 020471Y Pin for countershaft timing Insert the crankshaft on the pin and into the bush ing Before inserting thoroughly make the oil pump gear align with the control gear Insert thoroughly and remove the special tool N B WHEN INSERTING THE SHAFT ON THE HALF CRANKCASE BE CAREFUL NOT TO DAMAGE THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIM ING CONTROL TOOTHED PINION Install the oil pump closing plate Tighten the 2 flanged fastening screws to the prescribed torque Locking torques N m Bulkhead screws for oil pump housing cover 8 10 ENG 179 Engine MP3 LT 400 i e Refitting the crankcase halves Remove the oil guard from the transmission side
30. ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR ENG 96 MP3 LT 400 i e Engine Do not open the masses using tools to prevent a variation in the return spring load Pin retaining collar Extract the collar using 2 screwdrivers Remove the 4 guide pins Extract the moving driven half pulley Removing the driven half pulley bearing Check that the bushing is free from wear and damage otherwise replace the fixed driven half pulley Remove the lock ring using pliers ENG 97 Engine MP3 LT 400 i e Using the special tool inserted through the roller bearing pull out the ball bearing N B PROPERLY SUPPORT THE PULLEY TO PREVENT DAM AGING THE THREADING Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020363Y 20 mm guide N B IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT IT IS NECESSARY TO SUPPORT THE UNIT BY THE BELL Specific tooling 001467 Y002 Driver for OD 73 mm bearing Remove the roller bearing using the special tool supporting the fixed half pulley with the bell Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020364Y 25 mm guide 001467Y002 Driver for OD 73 mm bearing Inspecting the driven fixed half pulley Check that the belt contact surface is free from wear Measure the outer diameter of the pulley bushing Characteristic Minimum admissible
31. Action Duration 1 002070 Rear brake disc Replacement 2 001016 Rear wheel Replacement 9 001071 Front wheel rim Removal and Re fitting 4 004126 Rear wheel tyre Replacement TIME 385 Time MP3 LT 400 i e Fuel pump 4 S 1 Ce d GY d 2 Pad 8 FUEL PUMP Code Action Duration 1 004073 Fuel pump Replacement 2 004137 Carburettor pump hose Replace ment TIME 386 MP3 LT 400 i e Electric devices Code 005007 DISPOSITIVI ELETTRICI Action Battery change Time Duration 005003 Horn Replacement 000319 AJOJN Remote control Replac 005011 Starter remote control switch Re placement 5 005052 Fuse 1 Replacement TIME 387 Time MP3 LT 400 i e CABLAGGIO Code Action Duration 1 005001 Electrical system Replacement Electronic controls TIME 388 MP3 LT 400 i e Time HANDLEBAR CONTROLS Code Action Duration 1 005017 Stop switch Replacement 2 005077 Emergency stop switch Replace ment 3 005041 Starter button Replacement 4 004010 Anti theft lock Replacement 5 005040 Horn button Replacement 6 005006 Light or turning indicator switch Re placement 7 005039 Lights switch Replacement 8 005143 Mode button Replacement 9 005142 Unlocking switch Replacement 10 005084 Emergency light switch Replace ment 11 888126 Helmet compartment light
32. CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT Chain tensioner Remove the centre screw with the washer and the tensioner spring Check that the one way amp mechanism is not worn Check the condition of the tensioner spring po If examples of wear are found replace the whole unit Inspecting the valve sealings Visually inspect the valve sealing surface CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES RIGHT LEFT If the sealing surface of the valve is found to be interrupted at one or more points or is not flat re place the valve Insert the valves into the cylinder head Alternatively check the intake and exhaust valves The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers ENG 151 Engine MP3 LT 400 i e Inspecting the valve housings Clean the valve seats of any carbon residues Using the Prussian blue check the width of the impression on the valve seat V Characteristic Standard value 1 1 3mm Admissible limit 1 6 mm If the impression width on the valve seat is larger than the prescribed limits true the seats with 45 mill and then grind In case of excessive wear or damage replace the head Inspecting the valves Measure the diameter of the valve stems in the three positions ind
33. FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT ENG 130 MP3 LT 400 i e Engine The freewheel is coupled to the flywheel with high precision if removal is difficult use 2 screws as gripping points and as removing tools if required Extract the intermediate gear provided with tor que limiter Inspecting the flywheel components Check the integrity of the magnets Check that the magnet support cage is free from deformation or cracks Check that the flywheel splines exhibit no loos ening Starter gear rim Check that there is no wear or abnormal impres sions on the rollers of the freewheel and on the surface of the starter ring gear hub Check the hub outside diameter Characteristic Hub outside diameter Diameter 45 665 0 008 0 005 mm ENG 131 Engine MP3 LT 400 i e Check the inside diameter of the bushing of the starter gearing Check that the toothing is not worn Characteristic Inside diameter of the bushing Diameter 27 0 020 0 041 mm N B IF THE FAULTS DISCOVERED AFFECT THE HUB REPLACE THE STARTER RING GEAR AND FREEWHEEL IF ONLY THE BUSHING IS WORN IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE START ING RING GEAR IN THAT CASE CHECK ALSO THE DIAMETER AND THE SURFACE OF THE CONNECTION ON THE CRANKSHAFT IN CASE OR IRREGULARITIES REPLACE THE CRANK SHAFT Intermediate gear Check that the toothing is not worn Check th
34. Flywheel fixing nut 115 125 Install the chain guide retain plate tightening the 3 screws to the prescribed torque N B BEFORE TIGHTENING THE SCREWS MOVE THE START UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC TION Locking torques N m Chain guide sliding block retain plate fasten ing screws 3 4 Refitting the starter motor Check that the O ring is in good working order and lubricate it Insert the starter motor Tighten the 2 fastening screws to the prescribed torque Locking torques N m Starter screws 11 13 ENG 136 MP3 LT 400 i e Engine Cylinder assy and timing system Remove the external and internal transmission cover Remove the flywheel cover the flywheel and the torque limiter Removing the intake manifold Remove the 3 mounting screws Remove the intake manifold unit Removing the rocker arms cover Loosen the 6 special screws with stop and the relevant rubber gaskets Remove the tappet cover with relevant gasket ENG 137 Engine MP3 LT 400 i e Removing the timing system drive Turn the engine to close the intake valves Remove the central screw and the valve lifting device mass stop bell using the special tool Specific tooling 020565Y Flywheel lock calliper spanner Remove the return spring and the valve lifting mass with relevant tra
35. SUSP 293 Suspensions MP3 LT 400 i e Lower shock absorber clamp 33 41 Upper shock absorber clamp 33 41 Centre stand Use a jack to support the vehicle properly Remove the two stand return springs iu ud er ur eror NR Working from both sides unscrew the two bolts connecting it to the supporting plate To refit follow the removal steps but in reverse order be careful to tighten to the prescribed torque Locking torques N m Centre stand bolt 31 39 SUSP 294 INDEX OF TOPICS Braxinc SYSTEM BRAK SYS MP3LT 400 i e Braking system This section amp is devoted to the description of the braking system components EGEND A CIRCUITO FREND ANTERIORE Lm CIRCUITO FRENO POSTERIORE m CIRCUITO FRENO A PEDALE BRAK SYS 296 MP3 LT 400 i e Braking system Front brake pipes Rear brake pump 11 mm Front brake pump 12 mm Rear brake pipes rear brake pump rear valve 1 2 3 4 5 Front valve 6 Front brake left calliper 30 mm 7 Front valve brake pipes front valve rigid pipes 8 Front right brake calliper o 30 mm 9 Brake pipes front valve rear valve 10 Front brake right calliper pipes fitting wheel brake calliper 11 Front brake left calliper pipes fitting wheel brake calliper 12 Rear brake pipe on calliper side 13 Integral brake pump support bracket with pedal 14 Pedal fork 15 Brake pipes pedal brake pump
36. Tooling 001330Y Tool for fitting steering seats oO 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings A 001467Y007 Driver for OD 54 mm bearings 001467Y008 Pliers to extract 17 mm bearings 001467Y014 Pliers to extract 15 mm bearings an nn TOOL 21 Tooling MP3LT 400 i e Stores code Description 001467Y031 Bell 001467Y034 Pliers to extract 15 mm bearings 001467Y035 Bearing housing outside 47 mm 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer ing tube 020004Y Punch for removing fifth wheels from TOOL 22 headstock MP3LT 400 i e Stores code Tooling Description 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure check gauge 5 C es e 020201Y Spacer bushing driving tube 020262Y Crankcase splitting plate 020306Y Punch for assembling valve seal rings TOOL 23 Tooling Stores code MP3 LT 400 i e Description 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020648Y Single battery charger BatteryMate 150 9 oss 020335Y Magnetic support for dial gauge 020357Y 32x35 mm Adaptor 020358Y 37x40 mm Adaptor TOOL 24 MP3LT 400 i e Stores code Description Tooling
37. back plate Unhook the instrument panel wiring Remove the six screws and the cable guide strap in the front part of the shield back plate CHAS 332 MP3 LT 400 i e Chassis Remove the key switch plastic ring and the two plastic covers near the footrest Remove the five screws on the shield back plate rear part Remove the two shield back plate front screws see figure Remove the two shield back plate lower screws Remove the external temperature sensor con nection See also spoiler Legshield CHAS 333 Chassis MP3 LT 400 i e Taillight assy Open the rear case cover remove the two screws D and then the other four fixing screws D to pull out the headlight assembly from its fitting Follow this procedure to remove the bulbs Remove the snap on bulbs B Remove the bulbs A on the bayonet by turning them 30 clockwise Footrest Remove the central cover Remove the four fixing screws from left half foot rest Follow the same procedure for both half footr ests Release the fuse box and remove the half foot rest CHAS 334 MP3 LT 400 i e Chassis From the right side of the vehicle remove the re tainer indicated above Undo the two screws indicated and remove the integral brake pedal Remove the right half footrest See also Frame central cover Side fairings Remove the rear screw und
38. countershaft Place the special tool as shown in the figure Specific tooling 020479Y Countershaft lock wrench Remove the fastening nut with relevant washer Remove the special tool and extract the counter shaft with the control gear ENG 169 Engine MP3 LT 400 i e Replacing the countershaft bearings Check that the bearings are free from irregular noise or clearance If it does replace it Flywheel side half crankcase Remove the inside Seeger ring Upturn the half crankcase Remove the bearing from the flywheel side half crankcase using the special tool and a mallet Specific tooling 020376Y Adaptor handle 020358Y 37x40 mm Adaptor 020439Y 17 mm guide Remove the bearing from the transmission side half crankcase using the special tool Specific tooling 001467Y008 Pliers to extract 17 mm bearings 001467Y007 Driver for OD 54 mm bearings Before installing a new bearing heat the flywheel side half crankcase using the special tool Place the half crankcase on a wooden base Specific tooling 020151Y Air heater ENG 170 MP3 LT 400 i e Engine Insert a new bearing on the special tool after greasing the guide seat Install the new bearing on the half crankcase us ing the special tool N B IF A BEARING WITH PLASTIC CAGE IS USED KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE Specific tooling 020376Y Adaptor handle 020359
39. crankcase is not worn or deformed Check that the by pass valve seat the torque limiter and the water pump shaft are free from wear Characteristic By pass housing hole diameter 13 9 mm Connection diameter for start up gear shaft 12mm Connection diameter for pump shaft 8mm Check that the oil filter union and matching sur face exhibit no deformations or wear Check the condition of the stator and the relevant cable harness ENG 119 Engine MP3 LT 400 i e Check the continuity between the 3 phases N B VALUES ARE STATED AT AMBIENT TEMPERATURE A CHECK WITH THE STATOR AT OPERATING TEMPERA TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED Electric characteristic Resistance 02 10 Check the ground insulation of each phase If a fault is found carry out a thorough check of the cable harness that contains two types of cable Rigid cables close to the stator and flexible cables close to the connector Check that the winding is positioned so as not to interfere with the heads of the retaining screws Refitting the stator Install the stator assembly together with the wir ing harness tightening the 3 screws to the pre scribed torque N B INSERT THE RUBBER WIRING SEALING GASKET INTO THE SPECIAL SEAT ON THE CRANKCASE Locking torques N m Stator retainers 8 10 ENG 120 MP3 LT 400 i e Engine Install the wiring guid
40. 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 electric connections have been made properly particularly the ground and battery connections CHAR 7 MP3 LT 400 i e Characteristics Vehicle identification Chassis prefix A ZAPM642001 Engine prefix B M474M Dimensions and mass WEIGHTS AND DIMENSIONS Desc Quantity Specification Kerb weight 253 8 kg Maximum weight allowed 445 kg Maximum height 1350 mm Width 760 mm Wheelbase 1550 mm Length 2210 mm Track 465 mm CHAR 8 MP3 LT 400 i e Characteristics Engine ENGINE Specification Desc Quantity Type Single cylinder 4 stroke Cubic capacity 399 cm Bore x stroke 85 8 X 69 mm
41. each oth er and earth RIDER PRESENCE SENSOR SUSP 274 MP3 LT 400 i e 5V Suspensions 1 RIDER PRESENCE SENSOR With the interface wiring disconnected from the control unit and connected to the system check the following conditions pin 17 36 resistance 15 18 kOhm when the rider is not seated on the saddle pin 17 36 resistance of about 3 KOhm when the rider is seated on the saddle Check the continuity between the interface wiring pin 17 and the yellow cable of the rider presence connector Check the continuity between the interface wiring pin 36 and violet cable of the rider presence con nector TILT LOCKING CALLIPER SENSOR SUSP 275 Suspensions MP3 LT 400 i e 12V 34 4C 1 TILT LOCKING CALLIPER SENSOR The tilt locking calliper sensor is a normally opened switch Check its correct operation with a multi meter With the interface wiring disconnected from the control unit check the continuity between pin 34 and the brown cable of the tilt locking gripper sen sor connector on the system side Check the continuity of the connector black cable and an earth point on the chassis SUSP 276 MP3 LT 400 i e Suspensions Also check that the flexible transmission control lever activates the limit stop switch properly TONE WHEEL SENSOR 1 Right tone wheel 2 Left tone wheel SUSP 277 Sus
42. flashes diagnosis code indication 3rd step Steady light on or off ON start up disabled OFF start up enabled Code 1 A one flash code indicates a system where the se rial line is not present or is not detected Check the Immobilizer aerial wiring and change it if necessa 07 05 ry 0 INJEC 224 MP3 LT 400 i e Code 2 Injection A two flash code shows a system where the con trol unit does not show the transponder signal This might depend on the inefficiency of the immobiliser aerial or the transponder Turn the switch to ON using several keys if the code is repeated even with the Master key check the aerial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Code 3 A three flash code indicates a system where the control unit does not recognise the key Turn the switch to ON using several keys if the error code is repeated even with the Master key replace the control unit If this is not the case reprogram the decoder Tachometer 0 7 0 5 0 5 0 5 4 0 2 0 5 0 5 zn INJEC 225 Injection MP3 LT 400 i e PIN RELATIONSHIP PIN PIN Component Reference value 13 15 Engine rpm sensor 100 150 Ohm 20 C With wiring disconnected from the control unit and connected to the system check that the sensor res
43. fuse box fuse No 5 and key switch Orange cable between key switch and fuse box fuse No 9 Blue cable between fuse box fuse No 9 and horn button Yellow Pink cable between horn button and the horn itself 3 Check the horn ground connection Black cable ELE SYS 72 MP3 LT 400 i e Turn signals system check Rs Bi Bl Ne KEY Battery Fuse No 3 Key switch contacts Fuse No 12 Turn indicator switch Hazard button Turn indicator control device with Hazard Rear right turn indicator bulb O ON oO a FF ON Front right turn indicator bulb 10 Front left turn indicator bulb 11 Rear left turn indicator bulb WARNING Electrical system Bi ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Check that bulbs operate properly 2 Check fuses No 3 and 12 3 Check the contacts of the key switch the turn indicator switch and the Hazard button 4 With the key switch set to ON check if there is battery voltage in the White Pink cable between turn indicator control device and the ground lead with the turn indi cator switch pressed to the left ELE SYS 73 Electrical system MP3 LT 400 i e in the Blue Black cable between turn indicator control device and the ground lead with the turn indi cator switch pressed to the right in the Brown cable between turn indicator control device and the ground lead wi
44. has not yielded Replace any defective or worn components Check that the rocking lever pins exhibit no scores or wear d Check that the cam contact sliding block and the articulated register plate is free from wear In case of wear replace the component Characteristic Standard diameter 13 0 010 0 018 mm Measure the inside diameter of each rocking lev er Characteristic Standard diameter 13 0 026 40 015 mm Refitting the head and timing system components Insert the chain guide sliding block Insert the two centring dowels between head and cylinder Install the head gasket N B THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN HEAD AND CYLINDER THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY THE DOWELS ENG 157 Engine MP3 LT 400 i e The head gasket is made of steel and has a standard thickness Check that the head lubrication channel is per fectly clean Clean with compressed air jets if required Insert the head Lubricate the stud bolts and the 4 fixing stud bolts Tighten the 4 fixing stud bolts crosswise to the prescribed torque as shown in the figure Locking torques N m Head fixing stud bolts Apply a preliminary torque of 7 Nm in a crossed sequence Tighten by 90 in a crossed sequence tighten again by 90 in a crossed sequence Tighten the fastening nuts on t
45. key service key with incorporated transponder black key HV coil diagnosis LED The diagnosis LED also works as a theft deterrent blinker This function is activated every time the ignition switch is turned to the OFF position or the emergency stop switch is turned to the OFF position It remains activated for 48 hours in order not to affect the battery charge When the ignition switch is turned to the ON position the theft de terrent blinker function is deactivated Subse quently a flash confirms the switching to the ON status 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 ELE SYS 63 Electrical system key switch and or the instrument panel is not initi ated check if there is battery voltage fuses 1 7 10 are in working order there is power to the control unit as specified below Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit Check the following conditions MP3LT 400 i e With the key switch set to OFF if there is battery voltage between ter minals 6 26 and terminal 6 chassis ground fixed power supply Ifthere is no voltage check that fuse 1 and its ca ble are in working order With the key switch in the OFF position there is battery voltage between termi nals 5 26 and terminal 5 frame earth fixed
46. least 350 C at 600 C and it has a reaction time of just 50 milliseconds The signal generated passes from a high value to a low value with a mixture with lambda 1 Specific tooling 020481 Y Control unit interface wiring 020331 Y Digital multimeter Install the electronic control unit interface wiring Start the engine and warm up until the electric fan switches on Use an analogue multimeter with a direct voltage scale measuring down to 2 V Place the tips of the multimeter between pins 4 and 11 With the engine running at idle speed check that the voltage oscillates between OV and 1V With the throttle valve completely open the volt age is approx 1V During the closing phase the voltage is approx OV If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits inside it INJEC 239 INDEX OF TOPICS MP3 LT 400 i e Suspensions This section is devoted to operations that can be carried out on the suspensions Front Removing the front wheel Remove the 5 fixing screws indicated in the pic ture Locking torques N m Wheel fixing screw 20 25 Front wheel hub overhaul Remove the ball bearing check Seeger ring indi cated in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract o 15 mm bearings 001467Y017 Bell for bearings
47. of the special tool Tighten the bushing of the flywheel lock tool on the removing tool threading ENG 128 MP3 LT 400 i e Engine Insert the special tool as shown in the figure making sure that the pins are perfectly inserted in to the previously aligned holes and that it is per fectly abutted and almost flush with the flywheel Specific tooling 020472Y Flywheel lock wrench Loosen the magneto flywheel fastening nut Remove the special tool and the fastening nut Remove the washer Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer CAUTION THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS STRONGLY LOCKED THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS ENG 129 Engine MP3 LT 400 i e Insert the special removing tool Using a 27 mm wrench and a 19 mm bushing release the flywheel Specific tooling 020467Y Flywheel extractor Remove the extractor Remove the nut and extract the flywheel with the start up rim Remove the crankshaft key To remove the start up rim from the freewheel it is necessary to turn it clockwise and pull it out Remove the freewheel from the flywheel by loos ening the 6 fastening screws SINCE THE FREEWHEEL MUST BE REMOVED IT IS AD VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE
48. pump by pass rubber coupling Replacement TIME 361 Time Starter motor MP3 LT 400 i e STARTER MOTOR Code Action Duration 1 001020 Starter motor Replacement 2 001017 Start up pinion Replacement 001151 Starter driven gearing Replacement 4 005045 Starter motor cable assembly Re TIME 362 placement MP3 LT 400 i e Flywheel magneto MAGNETO FLYWHEEL Time Code Action Duration 1 001173 Rotor Replacement 2 001067 Stator Replacement 3 001058 Flywheel Replacement 4 001104 Start up freewheel Replacement TIME 363 Time MP3 LT 400 i e Butterfly valve THROTTLE BODY Code Action Duration 1 001013 Intake manifold Replacement 2 001047 Injector Replacement 9 001023 Control unit Replacement TIME 364 MP3 LT 400 i e Exhaust pipe Time MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001092 Exhaust manifold Replacement 3 001095 Muffler guard Replacement 4 004169 Muffler guard Replacement 5 005138 Lambda probe Replacement TIME 365 Time Air cleaner MP3 LT 400 i e AIR CLEANER Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Cleaner Throttle body union Re placement 4 001027 Body air cleaner union Replace ment TIME 366 MP3 LT 400 i e Frame Time FRAME Code Action Duration
49. rear valve 16 Brake fluid reservoir 17 Brake fluid pipes fitting 18 Integral brake pump 15 87 mm 19 Rear brake calliper 22 mm 20 Rear valve 14 Brake system fitting 1 LEFT PUMP PIPES TO REAR VALVE 2 RIGHT PUMP PIPES TO FRONT VALVE BRAK SYS 297 Braking system MP3 LT 400 i e BRAK SYS 298 MP3 LT 400 i e Braking system LEFT PUMP PIPES REAR VALVE RIGHT PUMP PIPES TO FRONT VALVE FRONT VALVE PIPES TO REAR VALVE FRONT BRAKE PIPES MNO AR wm FRONT PRESSURE ADJUSTMENT VALVE FRONT BRAKE PIPES RIGHT PUMP PIPES TO FRONT VALVE FRONT VALVE PIPES TO REAR VALVE LEFT PUMP PIPES TO REAR VALVE RIGHT PUMP PIPES TO FRONT VALVE FRONT BRAKE PIPES FRONT VALVE PIPES TO REAR VALVE LEFT PUMP PIPES TO REAR VALVE 0 FRONT VALVE PIPES TO REAR VALVE BRAK SYS 299 Braking system MP3 LT 400 i e 11 REAR BRAKE PIPES 12 PEDAL PUMP PIPES TO REAR VALVE 13 REAR VALVE BRAK SYS 300 MP3 LT 400 i e Braking system 1 PEDAL BRAKE PUMP 2 BRAKE FLUID RESERVOIR TO PEDAL BRAKE PUMP FITTING PIPES 3 BRAKE FLUID RESERVOIR 4 REAR VALVE 5 PEDAL PUMP REAR VALVE PIPES 1 REAR BRAKE PIPES REAR VALVE 2 REAR BRAKE PIPES BRAK SYS 301 Braking system MP3 LT 400 i e Rear brake calliper Removal Remove the rear wheel Undo the screws connecting the air filter to the crankcase so that the wrenches can b
50. there is H m no continuity check the contacts of the d switch ER If no faults are found replace the electronic control E unit 8 After removing the shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base from the connector INJEC 221 Injection MP3 LT 400 i e With the ignition key switch at ON check there is battery voltage between the Red White and Black cables With MIU connector disconnected check the con tinuity between the Orange White cable and pin 7 of the interface wiring Specific tooling 020481Y Control unit interface wiring 020331 Y Digital multimeter Virgin circuit When the ignition system is not encrypted any key will start the engine but limited to 2000 rpm The keys can only be recognised if the control unit has been programmed properly The data storage pro cedure for a previously not programmed control unit provides for the recognition of the master as the first key to be stored to memory this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys The master and service keys must be used to code the system as follows Insert the Master key turn it to ON and keep this position for two seconds limit values 1 to 3 seconds Insert the service key and turn it to ON for 2 seconds If
51. to extract o 15 mm bearings 001467Y031 Bell Use the special extractor to disassemble the bearing on the engine chassis of the countershaft Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y035 Bearing housing outside o 47 mm Support the hub cover using the stud bolt set Pull out the bearing using the special tool Specific tooling 020476Y Stud bolt set 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearings Removing the wheel axle bearings Take out the clip on the outside of the gearbox cover ENG 109 Engine MP3 LT 400 i e Support the hub cover using the stud bolt set Pull out the bearing using the special tool Specific tooling 020476Y Stud bolt set 020376Y Adaptor handle 020477Y 37 mm adaptor 020483Y 30 mm guide Remove the oil guard using a screwdriver Removing the driven pulley shaft bearing If you have to remove the driven pulley shaft the relevant bearing and the oil guard remove the transmission cover and the clutch unit as descri bed in the Automatic transmission chapter Extract the driven pulley shaft from its bearing Remove the oil guard using a screwdriver into the hub gear box Remove the Seeger ring shown in the figure Pull out the driven pulley shaft bearing from the engine crankcase using the special tool Specific tooling 020376Y Adaptor handle 020358Y 37x4
52. to the steering tube and remove the handlebar by pulling it upwards then remove the lower plastic cover N B IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING IT IS ONLY NECESSARY TO TILT THE HANDLEBAR FORWARD ONTO THE FRONT PART OF THE VEHICLE WITHOUT REMOVING THE PARTS FITTED SO AS TO AVOID DAMAGING THE SHAFTS Refitting Carry out the above operations by working in the reverse order from that used for removal Locking torques N m Handlebar fixing screw 50 55 The tilt mechanism SUSP 243 Suspensions MP3 LT 400 i e Hydraulic system layout When tilting is locked the geared motor activates the hydraulic pump indicated in the photograph and pressurises the circuit The pressurised oil reaches the distribution frame T and the pressure sensor A Then the pipes branch out to reach the upper joints on the side steering tubes Through the rigid flexible pipes inside the side steering tubes the oil reaches the stem sliding locking device placed parallel to the shock absorb er Steering tubes Remove the brake calliper pipe retainers and the hydraulic pipe fitting from the brake calliper making sure there is a container to collect the brake fluid SUSP 244 MP3 LT 400 i e Suspensions Disconnect the tone wheel connector indicated in the picture Remove the hydraulic pipe fitting from the sliding locking device making sure again that the liquid d
53. tor que Locking torques N m Tightener screw 5 6 Place the engine with the valve clearance adjustment timing references aligned with the head Check the clearance between valve and rocking lever using a thickness gauge PRESCRIBED CLEARANCE Specification Desc Quantity Inlet 0 15 mm engine cold drainage 0 15 mm engine cold In case different values are found adjust by loos ening the lock nut and use a screwdriver for the set screw as shown in the figure ENG 163 Engine MP3 LT 400 i e Refitting the timing chain The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to interpret 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 Specific tooling 020680Y Diagnosis Tool 020330Y Stroboscopic light to check timing Proceed as follows Remove the outside transmission cover as de scribed in the automatic transmission chapter Remove the TDC reference inspection cap be tween flywheel and crankcase cover See the fly wheel cover chapter By the driving pulley turn the engine to find the alignment of the references to identify the TDC
54. 0 mm Adaptor 020364Y 25 mm guide ENG 110 MP3LT 400 i e Inspecting the hub shaft Engine Check that the 3 shafts exhibit no wear or defor mation on the grooved surfaces at the bearings and at the oil guards In case of faults replace the damaged parts Characteristic Connection diameter for countershaft A diameter 20 0 01 0 02 mm Connection diameter for wheel shaft B diameter 30 0 010 0 023 mm diameter 15 0 01 0 02 mm Bearing diameter for driven pulley shaft D diameter 17 0 01 0 02 mm E diameter 20 0 01 0 02 mm F diameter 25 0 01 0 02 mm Inspecting the hub cover Check that the mounting surface is not damaged or deformed ENG 111 Engine MP3 LT 400 i e Check the capacity of the bearings In case of faults replace the hub cover Refitting the driven pulley shaft bearing Heat the crankcase using the heat gun Specific tooling 020151Y Air heater Insert the driven pulley shaft bearing until it abuts against the bottom of the seat using the special tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020360Y 52x55 mm Adaptor 020364Y 25 mm guide Heat the intermediate gear bearing seat Insert the intermediate shaft bearing using the special tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WIT
55. 1 004146 Front frame Replacement 2 004116 Rear frame Replacement 3 004001 Frame Replacement 4 004147 footboard support bracket one side Replacement 5 004143 Footrest support Replacement TIME 367 MP3 LT 400 i e a Duration Stand Replacement Time Centre stand 1 6 em j Code 1 004004 2 004179 TIME 368 Stand buffer Replacement MP3 LT 400 i e Legshield spoiler Time LEGSHIELD Code Action Duration 1 004020 Headlight frame Replacement 2 004064 Legshield Replacement 3 004055 Turning indicator frame Replace ment 4 004149 Shield central cover Replacement 5 004022 Shield lower section Replacement 6 004167 Grille radiator cover Replacement TIME 369 Time Side fairings MP3 LT 400 i e SIDE COVERS Code Action Duration 1 004036 Lower chassis cover Replacement 2 004129 Rear fairing Replacement 3 004085 Fairing 1 Replacement 4 004068 Passenger handgrip Replacement 5 004037 Side aprons Replacement TIME 370 MP3 LT 400 i e Time Rear cover Y M M REAR SHIELD Code Action Duration 004065 Legshield rear part Removal and refitting TIME 371 Time Central cover MP3 LT 400 i e CENTRAL COVER Code Action Duration 1 004059 Spark plug inspection flap Replace ment 2 004135 Fuel tank port Replacement 9 004011 Central frame cover Replacement 4 00401
56. 2 Rear fairings Removal and refitting 5 004015 Footrest Removal and Refitting 6 004075 Front mat Replacement TIME 372 MP3 LT 400 i e Mudguard Time MUDGUARDS Code Action Duration 1 007015 Radiator air intake Replacement 2 004009 Rear mudguard Replacement 3 004181 Lower cover Replacement 4 004184 Front mudguard support replace ment 5 004002 Front mudguard change TIME 373 Time MP3 LT 400 i e Fuel tank A ty YG FUEL TANK Code Action Duration 1 005010 Tank float Replacement 2 004109 Fuel tank breather change 3 004168 Fuel tank cap Replacement 4 004005 Fuel tank Replacement TIME 374 MP3 LT 400 i e Time Rear shock absorber REAR SHOCK ABSORBERS Code Action Duration 1 003007 Rear shock absorber Removal and Refitting 2 003035 Shock absorber support and brake calliper Replacement 3 003077 muffler rear shock absorber support arm Service TIME 375 Time Handlebar covers MP3 LT 400 i e HANDLEBAR COVERS Code Action Duration 1 000307 RIGHT OR LEFT CONTROL AS SEMBLY REPLACEMENT 2 004019 Rear handlebar covers Replace ment 9 004026 Handlebar cover Replacement 4 004018 Front handlebar covers Replace ment TIME 376 MP3 LT 400 i e Handlebar components Time HANDLEBAR COMPONENTS Code Action Duration 1 002060 Complete throttle control Replace men
57. 3 Engine MP3 LT 400 i e Refitting the driven pulley shaft bearing Heat the transmission cover interior using the heat gun N B BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE Specific tooling 020151Y Air heater Place the bearing onto the special tool with a little grease to prevent it from coming out Install the new bearing using the special tool N B PROPERLY SUPPORT THE OUTSIDE COVER TO PRE VENT DAMAGING THE PAINTED SURFACE Specific tooling 020376Y Adaptor handle 020358Y 37x40 mm Adaptor 020439Y 17 mm guide Baffle roller Plastic roller Check that the roller does not show signs of wear and that it turns freely Loosen the retaining bolt using a 13 mm spanner Remove the complete roller with bearing N B IF THE ROLLER DOES NOT ROTATE FREELY REPLACE THE COMPLETE ROLLER Installation of belt anti vibration roller Install the anti flapping roller with the lip facing the engine crankcase Tighten the central screw to the prescribed torque N B TURN THE DRIVEN AND OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT IS OBTAINED Locking torques N m ENG 94 MP3LT 400 i e Anti vibration roller screw 16 7 19 6 Removing the driven pulley Engine Remove the clutch bell Remove the fixed driving half pulley Remove the driven pulley assembly with the belt Inspecting the clutch drum
58. 3 001112 Oil pump change 4 001125 Chain guide pads Replacement TIME 357 Time MP3 LT 400 i e Final gear assy FINAL REDUCTION GEAR Code Action Duration 1 001010 Geared reduction unit Service 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replacement 5 002031 Rear wheel hub bearings Replace ment 6 004180 Reduction gear pipe replace TIME 358 MP3LT 400 i e Driving pulley Time DRIVING PULLEY Code Action Duration 1 001086 Driving half pulley Replacement 2 001011 Driving belt Replacement 3 001066 Driving pulley Removal and refitting 4 001177 Variator rollers shoes Replace ment 5 001141 Belt anti flapping roller Replace ment 6 001006 Driving pulley Service TIME 359 Time Transmission cover MP3 LT 400 i e TRANSMISSION COVER Code Action Duration 1 001065 Internal transmission cover Re placement 2 001096 External transmission cover Re placement 9 001131 Transmission air intake Replace ment 4 001135 Transmission cover bearing Re placement 5 001170 Air manifold replacement TIME 360 MP3 LT 400 i e Time Water pump x gt x WATER PUMP Code Action Duration 1 007017 Water pump cover Replacement 2 161011 Water pump and or gasket Re placement 3 001182 Head intake rubber sleeve Replac 4 007009 Head
59. 8 0 029 0 043 Cylinder Piston 85 804 85 811 85 768 85 775 0 029 0 043 Cylinder Piston D 85 811 85 818 85 775 85 782 0 029 0 043 CATEGORIES OF COUPLING N B THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS CHAR 14 MP3 LT 400 i e Characteristics 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 sealing ring inside the cylinder Check the size of the sealing ring opening Compression ring 0 15 0 35 Max value 0 5 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Rings housing coupling clearances Carefully clean the sealing ring housings Place a thickness gauge between the ring and the housing as shown in the drawing and check the coupling clearances Top ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Intermediate ring Standard coupling clear ance 0 02 0 07 mm Maximum clearances allowed after use 0 10 mm CHAR 15 Characteristics MP3LT 400 i e 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 max imum limits specified in the table Crankcase crankshaft
60. 80 Throttle control Engine oil filter Electrical system and battery Coolant level Brake oil level Engine oil Brake pads Tyre pressure and wear Vehicle and brake test test ride A R R Hub oil Steering 5 59 gt 29 5 gt Parking control unit software upgrading if available 2 3 3 m 3 izgi izmi im izm imi i imi i Centre stand L Driving belt Air filter Sliding blocks variable speed rollers Suspensions Spark plugs 3J uo q r Tilt locking caliper control cable J uo x r Valve clearance Electrical system and battery 2 2 2 gt 20 D m 3 x x r m mx xr MAIN 33 Maintenance MP3 LT 400 i e Checking the spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to interpret 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 the injection system matches the value actually activated on the eng
61. A one way valve and a decantation chamber are used so that gases from the crankcase do not carry any oil The one way valve is a metal reed valve the decantation chamber has a drainage hole A failure in these components implies oil getting into the line supplying air to the engine Excessive oil vapours may result in clogged ducts on the throttle body In order to signal low oil pressure in the system a pressure switch is used located immediately after the oil filter outlet The lubrication circuit does not include the countershaft The countershaft is lubricated by the oil trans ported by the gears or by the centrifugal effect of the crankshaft The same applies to the piston or the pin but in this case the cooling nozzle is particularly important Diagnosis guide 1 Minimum oil pressure warning light on with hot engine AHEAD go to 2 2 Remove the minimum pressure switch electric connector Check that the warning light turns off YES go to 3 NO go to 11 3 Check the actual oil pressure AHEAD go to 4 4 Remove the switch and fit the special tool with the relevant gasket Specific tooling 020193Y Oil pressure check gauge 020434Y Oil pressure check fitting Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied with the special tool Insert the probe to feel contact with the crankcase bottom and pull back a few millimetres Specific tooling 020331 Y Digital multime
62. ENCHES SUCH AS A CONVENTIONAL POLYG ONAL BUSH MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF ENG 91 Engine MP3 LT 400 i e Remove the six M6 screws Remove the four M8 screws Remove the transmission cover Check that the bearing rotates freely otherwise replace it Air duct Remove the transmission cover Unscrew the two screws shown in the figure to remove the air conveyor Locking torques N m Air conveyor screws 11 12 Remove the external transmission cover Unscrew the 4 fastening screws shown in the fig ure to remove the external air conveyor ENG 92 MP3 LT 400 i e Engine Air duct filter Remove the external air conveyor Unscrew the 2 fastening screws shown in the fig ure to remove the conveyor filter Removing the driven pulley shaft bearing Remove the transmission cover Remove the Seeger ring Place transmission cover on a wood surface and use the special tool so that it is adequately sup ported Pull out the bearing using the special tool N B BELL MUST BE PLACED INTO THE TRANSMISSION COV ER CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND NOT ONLY IN THE AREA OF MAXIMUM STURDINESS Specific tooling 001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020439Y 17 mm guide ENG 9
63. ER HAND THE MORE THE PISTON TOP IS RE CESSED INTO THE CYLINDER TOP PLANE THE SMALL ER THE GASKET THICKNESS Characteristic Compression ratio CHAR 18 MP3 LT 400 i e Characteristics 10 6 0 5 1 BASE GASKET THICKNESS Name Measure A Thickness A MEASURE TAKEN 0 185 0 10 0 4 0 05 MEASURE 0 10 0 10 0 6 0 05 MEASURE 0 10 0 185 0 8 0 05 VALUES INDICATED WITH REFER PISTON CROWN RECESSES WITH RESPECT THE CYLINDER PLANE N B DISTANCE A MUST BE MEASURED WITHOUT ANY GASKET FITTED AT B Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the re quirements of API GL3 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 4 stroke engines throttle control AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased adhesiveness AGIP GP 330 Grease for brake levers throttle White calcium complex soap based spray grease with NLGI 2 ISO L XBCIB2 AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid AGIP PERMANENT SPEZIAL coolant Monoethylene glycol based antifreeze fluid CUNA NC 956 16 CHAR 19 INDEX OF TOPICS Tooune TOOL MP3 LT 400 i e Stores code SPECIFIC TOOLS Description
64. FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM SEE CHAPTER COOLING SYSTEM Removing the water pump cover Check that the water pump cover is not deformed or dented Check that the sealing O ring is in good working order Otherwise replace the component Adequately fit a new O ring be careful to lubricate it with petroleum jelly grease COOL SYS 324 MP3 LT 400 i e Cooling system N B TO AVOID DEFORMATION DO NOT LUBRICATE THE O RING WITH PETROLEUM GREASE CAUTION FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O RING Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque N B FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM SEE THE COOLANT CHANGE SECTION Locking torques N m Water pump cover screws 3 4 diagnosis Excessive system pressure 1 Check the expansion tank cap efficiency N B THE CAP IS EQUIPPED WITH A PRESSURE RELIEF VALVE CALIBRATED AT 0 9 BAR There is also a valve that must allow air inlet during the cooling step YES go to 2 NO go to 3 2 Check the head gasket seal see Thermal group and timing system chapter 3 Replace the cap Cooling fluid consumption 1 Check the system outer seals as described above YES go to 2 NO go to 3 2 Check the head gasket seal see Thermal group and timing system chapter If water leaks are detected in the engine oil inspect the pad on the head cooling circuit
65. FT CATEGORY IS STAMPED ON THE COUNTERWEIGHT SHOULDER A spare crankcase cannot be combined with a driving shaft with mixed categories Spare shafts have half shafts of the same category N B TO REPLACE THE HALF SHAFTS REMOVE THE COUNTERSHAFT BEARINGS AS DESCRIBED ABOVE REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI FLAPPING ROLLER FROM ENG 177 Engine MP3 LT 400 i e THE TRANSMISSION SIDE HALF CRANKCASE AS DESCRIBED IN CHAPTER AUTOMATIC TRANSMISSION AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS DESCRIBED IN CHAPTER FINAL REDUCTION Countershaft Using a micrometer measure the 2 bearings of the countershaft as shown in the figure Characteristic Standard diameter 17 0 01 0 02 mm Check that the water pump drive is not worn Refitting the crankshaft Check that the oil pump and countershaft control gear are free from deformations or dents Replace if required N B IF YOU HAVE TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NEC ESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL Before installing the gear on the crankshaft care fully clean the two matching surfaces removing any residues of LOCTITE from the holes using a brush Blow with compressed air and degrease the mounting holes on both surfaces to make the new LOCTITE grip Apply the recommended product to the holes again Recommended products Loctite 243 Medium strength threadlock Medium Loctite
66. G CLEARANCES Inspecting the piston rings Alternately insert the three sealing rings into the cylinder in the area where it retains its original di ameter Using the piston insert the rings perpen dicularly to the cylinder axis Make sure that each single sealing ring evenly adheres to the cylinder liner If it does not this means the ring is worn Replace it Measure the opening see figure of the sealing rings using a feeler gauge If higher values than those prescribed are meas ured replace the linings Check the size of the sealing ring opening Compression ring 0 15 0 35 Max value 0 5 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Rings housing coupling clearances Carefully clean the sealing ring housings Place a thickness gauge between the ring and the housing as shown in the drawing and check the coupling clearances Top ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Intermediate ring Standard coupling clear 0 02 0 07 mm Maximum clearances allowed after use 0 10 mm Oil scraper ring Standard coupling clearance 0 01 0 06 mm ENG 146 MP3 LT 400 i e Engine Maximum clearances allowed after use 0 10 mm Replace the piston if clearances exceed the max imum limits specified in the table Removing the piston Install piston and wrist pin o
67. H PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020359Y 42x47 mm Adaptor 020363Y 20 mm guide ENG 112 MP3 LT 400 i e Engine Heat the gear shaft bearing seat on the crank case Insert the gear shaft bearing in the upper crank case seat using the special tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020359Y 42x47 mm Adaptor 020412Y 15 mm guide Place the safety lock Seeger ring of the driven pulley shaft bearing N B PLACE IT IN THE POSITION SHOWN IN THE FIGURE Insert the pulley shaft oil guard on the transmis sion side Refitting the hub cover bearings Heat the bearing seats on the cover using the heat gun Support the hub cover using the stud bolt set Specific tooling 020151Y Air heater 020476Y Stud bolt set ENG 113 Engine MP3 LT 400 i e Insert the intermediate shaft bearing on the cover using the special tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020360Y 52x55 mm Adaptor 020363Y 20 mm guide Heat the gear shaft bearing seat from the cover outside Insert the gear shaft bearing on the cover using the special punch until abutment Specific tooling 020376Y Adaptor handle 020360Y 52x55 mm Adaptor 020483Y 30 mm guide
68. HS 5 Rear tail light bulb Type Incandescent W2 1 x 9 5 d Power 12V 5W Quantity 1 RHS 1 LHS 6 Stop light bulb Type Incandescent BAU 15s Power 12V 10W Quantity 2 7 License plate bulb Type Incandescent Power 12V 5W Quantity 2 8 Front turn indicator bulb Type Incandescent BAU 15s Power 12V 10W Quantity 1 RHS 1 LHS 9 Front tail light bulb Type Incandescent W2 1x9 5d Power 12V 5W Quantity 1 10 Instrument panel bulb Type Incandescent Power 12V 2W Quantity 4 Fuses The electrical system has twelve fuses divided into two fuse boxes to protect the different installation circuits One of them is inside the battery compart ment A and the other is at the internal side of the right footrest B To have access loosen the screw C and remove the plastic cover The chart shows the position and characteristics of the fuses in the vehicle CAUTION BEFORE REPLACING A BLOWN FUSE FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL E G A PIECE OF ELECTRIC WIRE ELE SYS 76 MP3 LT 400 i e Electrical system La Prt ear t t9 FUSE TABLE Specification Desc Quantity Fuse No 1 Capacity 7 5 A Protected circuits Injection ECU battery power Fuse No 2 Capacity 15 A Protected circuits Battery powered injection loads electrical fan Fuse No 3 Capacity 15 A Protected c
69. ILATION IS CONTROLLED BY THE TEMPERATURE MEASURED AT THE HEAD THE ELECTRIC VENTILATION START DOES NOT MEAN THAT THE VENTING HAS BEEN COM PLETED VENTING IS COMPLETE WHEN THE EXPANSION TANK TEMPERATURE RISES Water pump Water pump If noise or loss of liquid at the drain hole of the water pump is discovered replace the flywheel cover and the water pump as described in the Flywheel Cover Chapter Proceed to carry out a few preliminary operations as described below COOL SYS 322 MP3 LT 400 i e Cooling system Place the vehicle on its centre stand and on flat ground Remove the bodywork components as described in the Bodywork Chapter Remove the muffler to access the flywheel cover as described in the Removing the Engine from the Vehicle Chapter Empty the cooling system removing the hoses located on the water pump cover and the loading cap located on the expansion tank CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the water pump cover shown in the figure by loosening the 6 fasten ing screws Proceed to partially drain the circuit as described in the Engine Chapter Once the fault has been fixed and all components have been replaced fill and purge the system again N B FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM SEE THE COOLANT CHANGE SECTION Characteristic Cooling system approx 1 81 Removing the water pump cover Check tha
70. ION ON THE SPARK PLUG SEE THE SPECIFICATIONS AND MAINTE NANCE CHAPTERS Spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to interpret 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 Specific tooling 020680Y Diagnosis Tool 020330Y Stroboscopic light to check timing Proceed as follows Remove the transmission compartment cover as described in the automatic transmission chapter Remove the TDC reference inspection cap be tween flywheel and crankcase cover See the fly wheel cover chapter INJEC 232 MP3 LT 400 i e Injection By the driving pulley turn the engine to find the alignment of the references to identify the TDC Repeat for the reference between driving pulley and engine crankcase Refit the inspection cap on the flywheel side Connect the diagnostic tester Start the engine Select the parameters function in this menu Select the stroboscopic light control in the tradi tional four stroke engine position 1 spark 2 revs Check that the real values of rpm and ignition advance match thos
71. IONS Removing the hub cover Drain the engine oil by removing the drainage cap Prepare a suitable container to collect the oil Remove the pre filter Remove the oil filter using a filter tape or shaped cup wrench ENG 116 MP3 LT 400 i e Engine Loosen the 14 fastening screws Remove the flywheel cover with the relevant gas ket and the cooling system sleeve support N B THE SCREWS ARE OF 4 DIFFERENT LENGTHS NOTE THE RELEVANT POSITIONS CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR CAUTION BE CAREFUL TO PREVENT SLIPPAGE OF THE BY PASS VALVE AND OF THE RELEVANT SPRING Removing the flywheel cover components Loosen the six mounting screws and remove the water pump cover Remove the by pass and the relevant spring Remove the oil pump seal ENG 117 Engine MP3 LT 400 i e Removing the stator Remove the two retaining screws and the cable guide bracket Unscrew the 3 fastening screws and remove sta tor and its wiring Inspecting the cover components Loosen the two retaining screws and remove the reed valve support with bulkhead Remove the blow by reed valve with the relevant sealing gasket ENG 118 MP3 LT 400 i e Engine Unscrew the fastening screw and remove the gas outlet union with the relevant O ring Check that the mounting surface of the
72. ITH THE WATER PUMP COVER IN STALLED Install the flywheel cover on the engine paying attention to avoid interference between the stator and rotor WARNING FAILURE TO OBSERVE THIS PRECAUTION MAY RESULT IN DESTRUCTION OF THE CERAMIC MAGNETS Tighten the 14 retaining bolts of the cover to the prescribed torque N B THE BOLTS HAVE FOUR LENGTHS THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE FIGURE THE LONGEST IS INSERTED UNDER THE ENGINE OIL FILLER PLUG ENG 124 MP3 LT 400 i e Engine N B THE INTERMEDIATE BOLTS FOR THE REMAINING MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT FOR THE MANIFOLD SUPPORT SHOWN IN THE FIGURE ARE SLIGHTLY LONGER Locking torques N m Flywheel cover screws 11 13 Flywheel and starting Remove the three bands shown in the figure for 4 EF N gi i an easier removal of the flywheel cover remove the feed hoses and disconnect the return hose from the pump cover N B THE BANDS MUST BE REPLACED TO REMOVE THEM OPEN WITH A SCREWDRIVER OR CUT THEM BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS The starter is sold as a complete part Before deciding to replace it carry out the follow ing tests 1 Battery Check the voltage after not running a few hours Voltage gt 12 5V Check the density of the electrolyte of each cell B 30 32 Specific weight 1 25 1 26 YES go to 2NO go to 3 2 Make sure the negative termin
73. Make sure the pins and collar are not worn re assemble the pins and collar Using a bent beak greaser lubricate the driven pulley unit with about 10 gr of grease this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole This operation is necessary to avoid the presence of grease beyond the O rings Recommended products AGIP GREASE SM 2 Grease for the C ring of the tone wheel Soap based lithium grease containing NLGI 2 Molybdenum disulphide ISO L XBCHB2 DIN KF2K 20 Inspecting the clutch spring Measure the length of the movable driven half pulley spring while it is unloaded Characteristic Standard length 125 5 mm Admissible limit after use 120 mm ENG 100 MP3 LT 400 i e Engine Refitting the clutch Prepare the special tool as for removal Preassemble the driven pulley unit with the drive belt according to its direction of rotation Insert the driven pulley unit the spring with sheath and clutch into the tool Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Compress the spring and insert the clutch on the driven pulley bushing N B BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END Tighten the ring nut by hand and complete the tightening using the special wrench to the prescri bed torque Specific tooling 020444Y Tool for fitting re
74. NG SWITCH With the interface wiring disconnected from the control unit check the continuity of the electrical lines between the interface wiring and the tilt lock ing unlocking switch Pin 26 and green grey cable Pin 35 and violet black cable Pin 33 and yellow blue cable Also check that the above indicated electrical lines are insulated from the earth SVS lt SUSP 272 MP3 LT 400 i e Suspensions Check the continuity between the black cable on the connector and an earth point on the chassis With a multimeter check the operation of the tilt locking unlocking switch referring to the diagram indicated in the figure f KEY ara n 1 GROUND 0 2 LOCK 3 REST 4 UNLOCK POTENTIOMETER 3 5V 1 POTENTIOMETER SUSP 273 Suspensions MP3LT 400 i e With the interface wiring connected to the control unit secure the vehicle on its centre stand and switch to ON Select the reading scale on 20 V Insert the multimeter probes on pins 17 and 25 Check that the voltage in the activated locking condition is 4V and 1V in the locking rest condition With the interface wiring disconnected from the control unit check the continuity between pin 17 and the yellow cable of the potentiometer connec tor between pin 25 and the green blue cable between pin 11 and the orange blue cable Also check that these lines are insulated from
75. NGK CR7EKB Battery 12V 14 Ah sealed battery Generator alternating current Frame and suspensions CHASSIS AND SUSPENSIONS Specification Chassis Desc Quantity Tubular and sheet steel Front suspension The tilt mechanism is composed of an articulated parallelogram suspension with die cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking sys tem Front suspension travel 85 mm Rear suspension Two double acting shock absorbers adjustable to four posi tions at preloading Rear suspension travel Brakes Specification Front brake 110 mm BRAKES Desc Quantity 240 mm double disc brake with hydraulic control activated by the handlebar right hand lever Rear brake 240 mm disc brake with hydraulic control activated by the handlebar left hand lever Integral braking system CHAR 10 The system operates all three discs simultaneously and is con trolled hydraulically via the pedal on the footrest MP3LT 400 i e Wheels and tyres Characteristics WHEELS AND TYRES Specification Desc Quantity Wheel rim type Light alloy rims Front rim 12 x 3 00 Rear rim 14 x 4 50 Front tyre Tubeless 120 70 12 51S or 51P Rear tyre Tubeless 140 70 14 68S or 68P Front tyre pressure 1 6 bar Rear tyre pressure 2 5 bar Tightening Torques STEERING Name Steering lower ring nut central headstock Torque in Nm 22
76. NITIAL DIRECTION OF ROTATION IS MAINTAINED Extract the cylinder with the relevant gasket and the centring dowel N B THE SECOND CENTRING IS ENSURED BY A PIN SET INTO THE CYLINDER CAUTION TO PREVENT DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER Remove the 2 piston pin locking rings by the spe cific housings Extract the pin and remove the piston N B USE PAPER OR A CLOTH TO CLOSE THE CYLINDER HOUSING MOUTH ON THE CRANKCASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE Remove the piston sealing rings and the oil scra per CAUTION NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO PREVENT INVERTING THE POSITION IN CASE OF REUSE N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL ENG 143 Engine MP3 LT 400 i e Inspecting the small end Using a bore gauge measure the connecting rod small end diameter N B IF THE CONNECTING ROD SMALL END DIAMETER EX CEEDS THE STANDARD DIAMETER EXHIBITS WEAR OR OVERHEATING PROCEED TO REPLACE THE CRANK SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER Characteristic Standard diameter 22 0 025 0 015 mm Inspecting the wrist pin Check the pin outside diameter using a micrometer Characteristic Standard diameter 22 0 0 004 mm Calculate the coupling clearance between pin and connecting rod end Characteristic Standard clearance 0 015 0 029
77. OD 39 mm SUSP 241 Suspensions MP3LT 400 i e Remove the oil seal on the roller bearing side using a screwdriver Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020363Y 20 mm guide Heat the roller bearing seat with a heat gun Use the specific tool to introduce and push the bearing until it stops with the shielded side facing out Refit the ball bearing check Seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42x47 mm Adaptor 020412Y 15 mm guide Use the specific tool to fit and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch Recommended products GREASE MUS Grease for odometer transmission gear case SUSP 242 MP3 LT 400 i e Suspensions Soap based lithium grease with NLGI 3 ISO L DIN K3K 20 Handlebar Removal Remove the 2 handlebar covers working as ex plained in the Bodywork Chapter Remove the handlebar wiring retaining straps and disconnect the electric connectors from the brake levers Unscrew the fittings then remove the front and rear brake pump piping Remove the flexible transmission of the throttle grip and remove the throttle control Loosen the clamp fixing the handlebar
78. OGRESS The hand held computer displays the words CHECK THAT THE CONTROL IS SET AT 12 FROM THE LOWER STOP PRESS OK TO CON TINUE Press OK The hand held computer displays the words POS SIBLE LIMIT STOP VALUES PRESS A KEY AND SHIFT OFF AND ON If this is not successful the tilt locking mechanism remains locked for safety Adjust the flexible transmission so that a small clearance is left to guarantee switch activation on the tilt locking calliper Remove the two bracket screws after releasing the spring and freeing the flexible transmission adjust ment CAUTION A FIRST PRODUCTION BATCH WILL BE EQUIPPED WITH DOUBLE COAXIAL SPRING It is very important to remove the flexible trans mission from its fitting only for replacement SUSP 258 MP3 LT 400 i e Suspensions When refitting tighten the two bracket screws and the flexible transmission lever nut to the prescribed torque Locking torques N m Bracket tightening screws 8 12 Undo the Allen screw and remove the switch Upon refitting place the switch with the button ori ented to the stop indicated on the calliper lever observing the reference indicated on the switch supporting bracket After refitting check in detail that the switch is reg ularly activated by the stop on the lever SUSP 259 Suspensions MP3LT 400 i e Undo the two pad pin screws remove the pads with the spring Upon refitting tighten the two screws
79. OUT THE CHECK MAKE SURE THAT THE BATTERY IS IN GOOD WORK ING ORDER 1 Park the vehicle on its centre stand ELE SYS 69 Electrical system MP3 LT 400 i e 2 With the battery correctly connected to the circuit place the multimeter leads between the battery terminals 3 Turn on the engine increase the engine rpm and at the same time measure the voltage Electric characteristic Voltage ranging between 14 0 and 15 0V at 5000 rpm Maximum current output check With the engine off and the panel at ON with the lights on allow the battery voltage to stop at 12V Connect ammeter pliers to the 2 recharge positive poles in output from the regulator Start the engine and rev it up to a high engine speed while reading the value on the pincer With an efficient battery a value must be detected gt 20A VOLTAGE REGULATOR RECTIFIER Specification Desc Quantity Type Non adjustable three phase transistor Voltage 14 15V at 5000 rpm with lights off Starter motor 4 A KEY 1 Battery 2 Fuse No 5 3 Start up remote control switch 4 Starter motor 5 Key switch contacts ELE SYS 70 MP3 LT 400 i e Electrical system 6 Fuse No 8 7 Start up enabling remote control switch 8 Stop buttons 9 Starter button 10 Injection ECU WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Check fuses No 5 and 8 the key switch cont
80. PIAGGIO SERVICE STATION MANUAL XXX NL xxx EL MP3 LT 400 i e SERVICE STATION PIAGGIO MANUAL MP3 LT 400 i e The descriptions and illustrations given in this publication are not binding While the basic specifications as described and illustrated in this manual remain unchanged PIAGGIO GILERA reserves the right at any time and without being required to update this publication beforehand to make any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions 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 2008 PIAGGIO amp C S p A Pontedera All rights reserved Reproduction of this publication in whole or in part is prohibited PIAGGIO amp S p A After Sales V le Rinaldo Piaggio 23 56025 PONTEDERA Pi SERVICE STATION MANUAL MP3 LT 400 i e This service station manual has been drawn up by Piaggio amp C SpA to be used by the workshops of Piaggio Gilera dealers This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle repairing techniques and procedures Any significant changes made to the vehicle character
81. RCUIT FLUID MIXTURE System sealing check Check the proper circuit sealing when it is under pressure and at the temperature For amore accurate check wait until the system has cooled down since small leaks may not be visible due to evaporation The water pump is provided with a drainage hole in case of leaks from the cooling system mechan ical seal or from the shaft sealing oil guard If coolant or oil leaks are detected replace the pump see Flywheel Cover Chapter N B COOL SYS 321 Cooling system MP3 LT 400 i e DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM FAILURE TO OB SERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE SEALING GASKETS Coolant replacement System filling instructions Prepare the mixture of 50 water and 50 cool ant Fill the system to reach a level ranging between the MIX and MAX levels indicated in the expansion D tank filler J Do not close the expansion tank with the cap Use a transparent hose to connect the venting union with the expansion tank filler Loosen the vent and start the engine Keep it open until the air has been fully vented Close the bleed screw Stop the engine Restore the level into the expansion tank and tighten the cap Start the engine and let it warm up to reach the electric ventilation temperature Stop the engine Restore the level with cold engine CAUTION ELECTRIC VENT
82. RE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Level check Hydraulic brake system liquid level Tilt locking system fluid level Rear hub oil level Engine coolant level Engine oil level Road test Test ride Cold start Instrument operations Response to the gas command Stability on acceleration and braking Rear and front brake efficiency Parking brake efficiency Rear and front suspension efficiency Abnormal noise Tilting system locking unlocking efficiency Static test Static control after the test ride Hot engine restart Minimum seal turning the handlebar Uniform steering rotation Possible losses electric radiator fan operation PRE DE 345 Pre delivery MP3 LT 400 i e CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check frame and engine number check tools and equipment licence plate fitting lock check tyr
83. Remove the special tool and the cylinder N B ENG 148 MP3 LT 400 i e Engine IF DEVIATIONS OR RECESSES OR PROJECTIONS CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED REPEAT THE MEASUREMENT AT THE OPPOSED SIDE TO DO SO REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION Characteristic Recess Projection measured 1 0 185 0 10 Gasket thickness 1 0 4 0 05 Recess Projection measured 2 0 10 0 10 Gasket thickness 2 0 6 0 05 Recess Projection measured 3 0 10 0 185 Gasket thickness 3 0 8 0 05 Refitting the piston rings Place the scraper ring spring on the piston gt Install the scraper ring keeping the opening op 2 3 posed to the spring junction and with the writing top facing the piston top The chamfered side of 2 the oil scraper ring should always be facing the piston crown Fit the second lining with the identification letter or the writing top facing the piston crown In any case the step must be facing opposite the piston top Install the first compression lining in the direction imposed by the housing It is advisable to use a fitter to facilitate the in stallation of the linings N B THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS SECTION THIS IS TO ACHIEVE A BETTER BEDDING Misalign the lining openings at 120 as shown in the figure Lubricate the components with engine oil The engine uses the fir
84. SYS 68 MP3 LT 400 i e Electrical system This in its turn is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse The three phase generator provides good recharge power and at low revs a good compromise is ach ieved between generated power and idle stability Stator check Checking the stator windings WARNING THIS CHECK UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED 1 Remove the right side panel 2 Disconnect the connector between stator and regulator with the three yellow cables as shown in the photograph 3 Measure the resistance between each of the yellow terminals and the other two Electric characteristic Resistance 0 2 10 4 Check that there is insulation between the each yellow cable and the ground 5 If values are incorrect replace the stator Recharge system voltage check Look for any leakage 1 Access the battery by removing its cover under the saddle 2 Check that the battery does not show signs of losing fluid before checking the output voltage 3 Turn the ignition key to position OFF connect the terminals of the tester between the negative pole of the battery and the black cable and only then disconnect the black cable from the negative pole of the battery pom m 4 With the ignition key always at OFF the reading indicated by the ammeter must be lt 0 5 mA Charging current check WARNING BEFORE CARRYING
85. VEN WHEN THE SUSPENSION IS FITTED Remove the lower retainer of the sliding stem shown in the picture Remove the sliding stem locking device retainers indicated in the picture Check that the sliding stem locking device does not show signs of abnormal wear SUSP 249 Suspensions MP3 LT 400 i e For refitting follow the operations for removal but in reverse order observing the prescribed torques and greasing the bearings and their seats STEERING TUBES Name Torque in Nm Side headstock upper ring nut 20 24 Side headstock lower ring nut 12 15 Screw fixing sliding stem to shock absorber 45 50 Clamp for sliding stem locking device 6 5 10 5 Fixing nuts for constant velocity universal joints 18 20 Parallelogram device Remove the steering tubes To facilitate removal operations of the brake disc sector loosen the 3 fixing screws in the hydraulic electro actuator indicated in the picture Remove the hydraulic pipe retainers from the par allelogram SUSP 250 MP3 LT 400 i e Suspensions Remove the 4 screws fixing the tilt brake disc sec tor indicated in the picture Remove the retainers indicated in picture of the half arms joint flange To facilitate the operations indicated below re move the suspension locking electronic control unit indicated in the picture SUSP 251 Suspensions MP3 LT 400 i e Remove the arm coupli
86. XED BY INSTALLATION OF THE SCREWS Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body Locking torques N m P Screws fixing oil pump to the crankcase 5 6 KL Insert the countershaft with gearing into the fly wheel side half crankcase Installthe special tool in the position shown in the figure Specific tooling 020479Y Countershaft lock wrench Keep the countershaft in position and insert the washer with the nut Tighten the nut to the prescribed torque using the recommended product Remove the special tool Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Countershaft fixing nut 25 29 Water pump Removal Specific tooling 020661Y Water pump overall seal replacement kit ENG 190 MP3 LT 400 i e Engine Remove the six screws and the pump cover with a screwdriver Unscrew the water pump rotor with an 8 mm wrench Place two flat blade screwdrivers as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal pressure fitted on the rotor shaft CAUTION USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COVER SEALING SUR FACE SMALL SCRATCHES ON THE SEAT EDGE DO NOT POSE FUNCTIONAL PROBLEMS Change the position of the screwdrivers if nec essary During sea
87. Y 42x47 mm Adaptor 020439Y 17 mm guide Fitthe Seeger ring Before installing the new bearing on the trans mission side crankcase heat the seat using the special tool Specific tooling 020151Y Air heater Insert a new bearing on the special tool after greasing the guide seat Install the new bearing on the engine crankcase using the special tool N B IF A BEARING WITH PLASTIC CAGE IS USED KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE Specific tooling 020376Y Adaptor handle 020359Y 42x47 mm Adaptor ENG 171 Engine MP3 LT 400 i e 020439Y 17 mm guide Inspecting the crankshaft components Check the axial clearance on the connecting rod Characteristic Standard clearance 0 20 0 40 mm Check the connecting rod diametrical clearance Characteristic Standard clearance 0 046 0 076 mm Check the surfaces that limit the axial free play are not scored and measure the width of the crank shaft between these surfaces as shown in the diagram N B BE CAREFUL NOT TO LET THE MEASUREMENT BE AF FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS Characteristic Standard dimensions 63 6 63 45 mm CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VAL UES AND THE SURFACES ARE FREE FROM SCRATCHES Shimming Check the overall height of the crankshaft shoulders gear assembly Characteristic Standard thickness
88. Yellow Red CAN H Line Pink White Left wheel turning sensor Green Right wheel turning sensor Red Potentiometer signal Green Blue Locking unlocking switch Green Grey Horn remote control for alarms White Geared motor White Red Battery powered Blue Red Diagnosis Purple White Locking unlocking switch Yellow Blue Calliper sensor Brown Locking unlocking switch Purple Black Rider presence sensor Purple Scooter speed signal Sky blue Geared motor Blue ELE SYS 84 MP3 LT 400 i e INDEX OF TOPICS FROM VEHICLE ENG VE Engine from vehicle MP3 LT 400 i e This section describes the operations to carry out when removing the engine from the vehicle Exhaust assy Removal Remove the side fairings Remove the central frame cover Remove the exhaust end Disconnect the lambda probe connector Unscrew the probe Working from both sides release the two clamps securing the exhaust manifold to the head Detach the exhaust manifold making it pass through the swinging arm CAUTION SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUF FLER TIP ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP To fit follow the removal steps but in reverse order be careful to tighten to the correct locking torques once the muffler silencer has been refitted Removal of the engine from the vehicle Use a jack to support the vehicle properly Disconnect the battery
89. ack 4 Water temperature sensor ground lead Brown White 5 MODE remote button Green 6 Oil pressure sensor Pink White 7 Left turn indicator warning light Pink 8 Right turn indicator warning light White Blue 9 High beam warning light Purple 10 Boot open warning light Blue Black 11 sensor 12 Ambient temperature sensor Yellow Blue 13 Ambient temperature sensor ground White Yellow 14 Engine disabled warning light Orange Blue 15 Immobilizer warning light Red Green 16 Engine check warning light Brown Black 17 Parking brake warning light Yellow Grey 18 Tilt locking activated warning light Pink Black 19 Tilt locking system failure warning light Grey Black 20 Live supply from the parking control ECU Yel low Green NY pale M O PARKING CONTROL ECU CONNECTOR 1A Potentiometer power supply Orange Blue 2A CAN L Line White Blue 3A Warning light power supply Yellow Green Tilt locking activated warning light Pink White 5A Tilt locking system failure warning light Grey Black 6A Headlight remote control White Black ELE SYS 83 Electrical system TA Potentiometer ground lead rpm sensor rider presence sensor Yellow 8A 1B 2B 3B 4B 5B 6B 7B 8B 1C 2C 3C 4C 5C 6C 7C 8C Ground lead Black Live supply
90. acts the stop buttons and the starter button 2 Check the start up enabling remote control switch and the start up remote control switch 3 Check the following wiring for continuity Red Black cable between fuse box fuse No 5 and key switch Orange cable between key switch and fuse box fuse No 8 Red cable between fuse box fuse No 8 stop buttons and start up enabling remote control switch White Black cable between stop buttons and starter button and Orange White cable between starter button and start up enabling remote control switch Orange Blue cable between start up enabling remote control switch and ECU pin 24 Green Blue cable between start up enabling remote control switch and start up remote control switch Red cable between battery and start up remote control switch and between the latter and the starter motor 4 Check the ground connections for the start up remote control switch and the starter motor Black cables ELE SYS 71 Electrical system MP3 LT 400 i e Horn control A 2 4 N Fuse 5 ai Fuse 9 Rs I Rs Ne fu Ar I Bl ZZ KEY 1 Battery 2 Fuse No 5 3 Key switch contacts 4 Fuse No 9 5 Horn button 6 Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Check fuses No 5 and 9 the key switch contacts and the horn button 2 Check the following wiring for continuity Red Black cable between
91. ake 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 filer being careful to lubricate the O ring before fitting it Change the engine oil Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceed the requirements of API SL ACEA JASO MA specifications MAIN 40 MP3 LT 400 i e Maintenance Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the ON position However this light should switch off once the engine has been star ted 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 sys tem 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 fly wheel 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 ref erence 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 th
92. alliper supporting clamp BRAK SYS 306 MP3 LT 400 i e Braking system Remove the brake disc Refitting To fit the rear brake disc follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque using threadlock Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Brake disc screws 8 10 Disc Inspection Checking the disc is important it must be perfectly clean with no sign of rust oil or grease or any oth er dirt and must show no signs of deep scoring Characteristic New rear disc thickness 5mm Disc thickness at wear limit rear 3 5mm Remove the wheel and check using the appro priate tools that the axial run out of the brake surface is within the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axial run out 0 1 mm BRAK SYS 307 Braking system Front brake disc Removal MP3 LT 400 i e The operations described refer to only one disc but apply to both Remove the wheel Remove the brake calliper Remove the cotter pin and remove the cap Unscrew the fixing nut Remove the wheel hub Unscrew the six bolts securing the disc to the wheel hub Remove the disc BRAK SYS 308 MP3 LT 400 i e Brak
93. als battery neg ative and starter negative are correctly connected to each other and to the frame YES go to 4 NO go to 5 3 Recharge and if necessary replace the battery 4 Connect the diagnostic tester see chapter Injection system Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor Remove the 10 fuse no 12 see fuses chapter Switch in position ON with interrupt switch in position RUN and side stand raised Select the PARAMETERS function ENG 125 Engine MP3 LT 400 i e Start the engine so that it cannot move long enough to measure the rpm and starter absorption N B THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER THE RPM READING IS NOT THE REAL ONE BUT IS VALID FOR DIAGNOSTIC PURPOSES Specific tooling 020680Y Diagnosis Tool Electric characteristic Absorption at trailing speed 80 120A Revolution speed approx 300 400 rpm YES go to 6 NO goto 7 NO goto 8 NO go to 9 5 Restore the connections 6 The values are correct Finally carry out a check of the power consumption at idle speed Remove the starter motor see the flywheel and starter system Reconnect the earth and positive and perform the test Electric characteristic Current consumption at idle speed lt 40A YES go to 10 NO go to 11 7 Low trailing speed High electrical absorption Carry out a test of the engine rotation example possible melting of
94. als to fifth wheel check spring 7 11 Joint to anti tilting device pump 20 25 Lower fitting for shock absorber sliding locking clamp pipes 20 25 Upper fitting for shock absorber sliding locking clamp pipes 20 25 CHAR 11 Characteristics REAR SUSPENSION MP3 LT 400 i e Name Torque in Nm Upper shock absorber clamp 33 41 Lower shock absorber clamp 33 41 Shock absorber crankcase attachment bracket 20 25 Rear wheel axle 104 126 Muffler arm clamping screws 27 30 FRONT BRAKE Name Torque in Nm Calliper coupling screw 22 27 Oil bleed screw 8 12 Brake disc screws 8 10 Brake fluid pump hose fitting 16 20 Brake fluid pipe calliper fitting 20 25 Screw tightening calliper to support 20 25 Calliper upper pipe fitting 20 25 REAR BRAKE Name Torque in Nm Oil bleed screw 12 16 Brake disc screws 8 10 Rear brake calliper pipe fitting 20 25 Rigid flexible pipe fitting 13 18 Rear brake fitting 16 20 Rear brake calliper fixing screws 20 25 pad fastening pin screws 20 25 REAR BRAKE Product Description Specifications Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium strength threadlock MUFFLER Name Torque in Nm Muffler heat guard fixing screw 4 5 Screw for fixing muffler to supporting arm 20 25 Lambda probe tightening exhaust manifold 40 50 Exhaust manifold muffler joint tightening 12 13 Manifold muffler dia
95. aps indicated in the figure Remove the brake oil tube fitting from the rigid pipe inside the front suspension arm and loosen the hydraulic joint fixing nut of the suspension locking to release the brake pipes Front brake pipes removal Remove legshield Remove front wheel and mudguard Disconnect the brake pipes from the calliper and drain the brake fluid Then remove the plastic and metallic straps Unscrew the brake pump pipes as indicated in the figure BRAK SYS 315 Braking system MP3 LT 400 i e Parking brake Remove the rear wheel Loosen the transmission set screw and release the cable from the calliper Remove the two fixing screws of the mechanic calliper and remove the calliper To check calliper components refer to the chapter on the tilt locking _ g calliper When refitting tighten to the specified torque Locking torques N m Screw tightening calliper to support 20 25 After removing the shield back plate remove the engaging cable for the safety mechanism remov ing it from its fitting Remove the 4 screws shown in the figure When refitting pay attention to insert the metallic cable peg in the fitting marked A as indicated in the enlarged picture BRAK SYS 316 MP3 LT 400 i e Braking system Remove the electric connection from the engaged parking brake warning light switch Remove the parking brake cable from the lever by operating the se
96. bited 1 Previously unused control unit key inser ted a single 2 second flash is displayed after which the LED remains off permanently The keys can be stored to memory the vehicle can be star ted but with a limitation imposed on the number of revs 2 Previously unused control unit transpond er absent or cannot be used The LED is per manently ON in this condition no operations are possible including starting of the vehicle INJEC 223 Injection MP3 LT 400 i e 3 Programmed control unit the service key in 3 normal condition of use a single 0 7 second 0 7 flash is displayed after which the LED remains off steadily The engine can be started 4 Programmed control unit Master key in a 4 0 7 sec flash is displayed followed by the LED re 1 0 7 maining off for 2 sec and then by short 0 46 sec 0 4 flashes the same number of times as there are 2 0 3 keys stored in the memory including the Master key When the diagnosis has been completed the LED remains permanently OFF The engine can be started 5 Programmed control unit fault detected a light code is displayed according to the fault detected after which the LED remains on steadily The engine cannot be started The codes that can be trans mitted are 1 flash code e 2 code 3 flash code The LED indication is divided into 3 steps 1st step A flash ON switching recognition 2nd step Series of
97. 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 Malfunctions 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 TROUBL 47 Troubleshooting MP3 LT 400 i e 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 TROUBL 48 INDEX OF TOPICS Evectrica SYSTEM ELE SYS Electrical system MP3 LT 400 i e
98. but apply to both Remove the wheel Undo the two fixing screws to the plate and re move the calliper Overhaul Remove the rear brake calliper Suitably hold the brake calliper in a clamp Remove the two calliper coupling screws as shown in the photo Remove the two pistons from the calliper body with the aid of short blasts of compressed air through the brake fluid holes Remove the dust ring and the O ring of each half calliper Remove the O rings in the half calliper N B WHEN REMOVING THE O RINGS BE CAREFUL NOT TO SCRATCH THE HALF CALLIPER SEATS Check that the pistons and their seats show no scratches Wash and blow all the components carefully Fit the O rings and new dust guards Co Refit the pistons in their seats being careful to Co lubricate with brake fluid Re couple the half callipers and lock the two screws at the specified torque Locking torques N m BRAK SYS 305 Braking system MP3 LT 400 i e Calliper coupling screw 22 27 Refitting To fit the front brake callipers follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque Locking torques N m Screw tightening calliper to support 20 25 Rear brake disc Removal Remove the rear wheel Loosen the nuts fixing the safety washers Undo the two screws fixing the plate supporting the calliper to the frame Remove the c
99. button Key switch contacts Auxiliary fuses Electrical system ELE SYS 61 Electrical system MP3 LT 400 i e Lights and turn indicators KEY Instrument panel Rear turn indicator bulbs Front turn indicator bulbs Turn indicator switch Hazard button Turn indicator control device with Hazard Headlight with twin filament bulb Tail light bulbs 10 License plate bulb o o o Oc BoD Front position light bulbs Headlight remote control N e Light switch N Main fuses N Battery Cc Key switch contacts Parking control ECU A O N Key switch contacts ELE SYS 62 MP3 LT 400 i e 66 Auxiliary fuses Checks and inspections This section is devoted to the checks on the electrical system components Immobiliser Electrical system The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys tem The immobilizer is an anti theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit The code is integrated in a transponder in the key block This allows the driver clear operation without having to do anything other than just turn ing the key The Immobilizer system consists of the following components an electronic control unit immobilizer aerial Master key with incorporated transponder red
100. cator H Fuel gauge Warning light for helmet compartment courtesy light on L Engine control telltale light and injection system failure warning light M Low fuel warning light ELE SYS 78 Capacity 7 5A Protected circuits Live turn indicator control saddle opening switch tail lights panel lighting MP3 LT 400 i e Electrical system N Engine stop warning light O Turn indicator warning light P Low oil pressure warning light Q Front suspension locking system failure warning light if available R Warning light for parking brake engaged S High beam warning light A Total odometer gauge N E F B BELT maintenance icon VY ani C SERVICE maintenance icon 90000 m i H BRE en 6 x R U 98 LO D Engine coolant temperature indicator oO lt Ne Fi S S lt m 4 y E Trip odometer A B and ambient temperature iz NINE us ROF E A B IL c A N gauge selected with the MODE button lel CY AAR Mey F TIME DATE indicator a c i 2 G Low fuel warning light ii H Trip odometer gauge B Trip odometer gauge A L Kilometre mile indicator Sealed battery If the vehicle is provided with a sealed battery the only maintenance required is checking its charge and recharging when necessary These operations should be carried out before delivering the vehicle and on a six month basis wh
101. characteristics on the three masses Check that the clutch casing 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 change 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 TROUBL 46 MP3 LT 400 i e Troubleshooting 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 scooter Brakes overheating BRAKES OVERHEATING 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 deviation 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
102. cooling system sleeves as described in the Flywheel cover chapter Install the complete driving pulley the transmission cover and the relevant mesh filter and the outside transmission cover as described in the Automatic transmission chapter See also Cylinder assy and timing system Flywheel cover Lubrication TECHNICAL SPECIFICATIONS SUMP CAPACITY Specification Desc Quantity Overhaul 1 71 Oil and filter replacement 1 51 RECOMMENDED ENGINE OIL Product Description Specifications AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil OIL PUMP Specification Desc Quantity Type Trochoidal Rotor washers 8mm Assembly clearances Lobe ends 0 05 0 008 mm External rotor radial clearance 0 05 0 12 mm Rotor axial clearance 0 025 0 065 mm BY PASS Specification Desc Quantity Type with piston Plunger diameter 13 9 0 039 0 057 mm Spring free length 62 5 mm Calibration pressure 4 bar PRE FILTER Specification Desc Quantity Type mesh plastic ENG 181 Engine MP3 LT 400 i e OIL FILTER Specification Desc Quantity Type Paper with pressure relief and anti drain back by pass valves OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH Specification Desc Quantity Calibration 0 3 0 6 bar HEAD LUBRICATION CONTROL JET Specification Desc Quantity Diameter 1 0 05 mm Tightening torque 5 7 N m PISTON COOLING NOZZLE Specification Desc Quantity Diamete
103. crank case and the movable part seat on the shaft thus obtaining the correct ceramic seal preloading Screw the rotor Locking torques N m Water pump impeller 4 5 Fit the pump cover with a new gasket lubricate the gasket previously with petroleum jelly grease Tighten the six cover screws to the prescribed torque N B TO AVOID DEFORMATION DO NOT LUBRICATE THE O RING WITH PETROLEUM GREASE Locking torques N m Water pump cover screws 3 4 ENG 194 INDEX OF TOPICS INJEC Injection MP3 LT 400 i e KEY Battery Throttle body and electronic injection control unit MIU Instrument panel Injection load remote control Coolant temperature sensor Fuel pump HV coil Lambda sensor O ON oO a hb ON Engine rpm sensor 10 Fuel injector 11 Diagnostics socket connector MIU injection system This vehicle is fitted with an integrated injection and ignition system Injection is indirect in the manifold through an electro injector The injection and ignition are timed on the four stroke cycle by means of a tone wheel keyed on to the crankshaft 24 2 teeth and pick up sensor Combustion and ignition are managed on the basis of engine revs and throttle valve opening Further corrections are made according to the following parameters Coolant temperature Intake air temperature INJEC 196 MP3 LT 400 i e Injection Lambda probe The syst
104. d of two half bearings one with holes and channels for lubrica tion whereas the other is solid The solid half bearing is intended to stand the thrusts caused by combustion and for this reason it is arranged opposite the cylinder To prevent obstructions in the oil feeding channels the matching surface of the two half bearings must be perfectly perpendicular to the cylinder axis as shown in the figure The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface N B TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION DRIVING IS FORCED ON CAST IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES ENG 175 Engine MP3 LT 400 i e Check the inside diameter of the main bushings in the three directions indicated in the diagram gt ni m M Repeat the measurements for the other bushing PF Piana di half see diagram accoppiamento N B DO NOT TAKE THE MEASUREMENT ON THE TWO HALF SHELL COUPLING SURFACE SINCE THE ENDS ARE RE LIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION 3 Before assembling check that the clearance between the engine crankcase bushing and the crankshaft is within the predetermined limits Characteristic Crankshaft bushing maximum clearance admitted 0 08 mm The standard bushing diameter after driving is variable on the basis of a coupling selection The crankcas
105. diameter 49 91 mm Standard diameter 50 00 0 015 0 035 mm ENG 98 MP3 LT 400 i e Engine Inspecting the driven sliding half pulley Check that the belt contact surface is free from wear Remove the 2 inside sealing rings and the 2 out side O rings Measure the movable half pulley bushing inside diameter Characteristic Maximum admissible diameter 50 05 Standard diameter 50 00 0 035 0 00 mm Refitting the driven half pulley bearing Install a new roller bearing using the special tool N B PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUT WARDS Properly support the half pulley to prevent damaging the threading If you are working on the driven pulley unit fully assembled use the special tool Specific tooling 020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing Install a new ball bearing using the special tool Specific tooling 020376Y Adaptor handle 020477Y 37 mm adaptor 020363Y 20 mm guide Insert the Seeger lock ring ENG 99 Engine MP3 LT 400 i e Refitting the driven pulley Insert the new oil guards Insert the new O rings N B O RINGS ARE OF TWO SIZES THE LARGE ONE IS INSTALLED ON THE MACHINING END RA DIUS AT THE BASE OF THE HALF PULLEY Install the half pulley on the bushing being careful not to damage the top sealing ring during the in troduction
106. diate shaft The limiter is calibrated to 10 kgm 100 Nm this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations The freewheel is used for a sufficiently silent starting The starter control energised remote control is slaved to enabling signals by the side stand and the emergency OFF RUN switch which does not allow starting given dangerous conditions The starter control circuit is not controlled by the immobilizer system therefore before insisting on the starter system check the consensus of the immobilizer In order to check the enabling switches circuit see the Electrical system chapter whereas to check the engine shaft control transmission follow what is described in the Flywheel and starter system chapter Removing the starter motor N B ENG 127 Engine MP3 LT 400 i e THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED Loosen the two fastening screws if NY Extract the complete starter motor Removing the flywheel magneto N B IF YOU MUST REMOVE THE FLYWHEEL IT IS NECESSARY TO REMOVE THE CHAIN GUIDE SLIDING BLOCK RETAIN PLATE FIRST Unscrew the 3 fastening screws and remove the x 1 C chain guide sliding block retain plate and the up rim Align the holes obtained on the flywheel with the crankcase housing to allow the introduction
107. e sponding screws 1 5 place the calliper on the disc and lock it to the strut by tightening the fixing screws 6 fix the pipe joint on the calliper at the prescribed torque Functioning This is a floating type calliper BRAK SYS 303 Braking system MP3 LT 400 i e It takes advantage of the action and reaction prin ciple to obtain the thrust for both pads The body and the reaction plate body work inte grally and can move axially with respect of the fixed plate that is integral to the strut The pistons forced by pressure to push the pad to the disc cause the reaction plate to push in turn the other pad towards the disc The brake pad lock spring 1 Pad fixing screws 2 Reaction plate fixing screws 3 Reaction plate 4 Fixed plate 5 Floating body 6 Piston 7 Piston sealing rings 8 Guide protection rubber rings 9 Brake pad check spring 10 Brake pads CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EV ERY TIME THE CALLIPER IS SERVICED Locking torques N m Brake fluid pipe calliper fitting 20 25 Pad fas tening pin 20 25 Refitting To fit the rear brake calliper follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque Locking torques N m Screw tightening calliper to support 20 25 Front brake calliper BRAK SYS 304 MP3 LT 400 i e Braking system Removal The operations described refer to only one cal liper
108. e OFF position It remains activated for 48 hours in order not to affect the battery charge When the ignition switch is turned to the ON position the theft de terrent blinker function is deactivated Subse quently a flash confirms the switching to the ON status 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 key switch and or the instrument panel is not initi ated check if there is battery voltage fuses 1 7 10 are in working order there is power to the control unit as specified below Remove the connector support 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 ter minals 6 26 and terminal 6 chassis ground fixed power supply If there is 13 3 no voltage check that fuse 1 and its ca 16 3 ble are in working order A INJEC 220 MP3 LT 400 i e Injection With the key switch in the OFF position 2 Eva there is battery voltage between termi x H nals 5 26 and terminal 5 frame earth H H fixed power supply If there is no volt age check the key switch contacts He E that fuse no 10 and its cable are in E working order There is continuity between terminals 7 12 18 with the emergency cut off ER Q switch in the RUN position If
109. e bracket tightening the 2 screws to the prescribed torque Locking torques N m Stator cable harness guide bracket screws 3 4 Refitting the flywheel cover components Before reassembling check that all components are perfectly clean For the cover carefully check all lubrication chan nels in particular The 3 by pass channels Oil pressure sensor feeding duct Oil vapour decantation chamber ENG 121 Engine MP3 LT 400 i e Temporarily install the distribution timing check hole cover and the engine oil filling cap bar Insert the blow by recovery duct using a new O ring Tighten the screws to the prescribed torque Locking torques N m Blow by recovery duct fixing screws 3 4 Insert the spring and the by pass piston on the flywheel cover N B LUBRICATE THE BY PASS VALVE Reinstall the blow by reed valve using a new sealing gasket Reinstall the support with head and tighten the screws to the prescribed torque Locking torques N m Supporting screws with bulkhead 0 3 0 4 Correctly fit a new O ring do not allow it to come into contact with grease or oil FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O RING Refit the water pump cover and tighten the 6 fix Vs ing screws to the prescribed torque Locking torques N m Pump cover fixing screws 3 4 ENG 122 MP3 LT 400 i e Engine Refitting the fly
110. e bushing seats are classified into 3 categories while the crankshaft ones into 2 cate gories Bushings are subdivided into 4 categories according to their thickness see the table CHECK THE BENCH BUSH Name Description Dimensions Initials Quantity Type A Red 1 971 1 974 Type B Blue 1 974 1 977 Type C Yellow 1 977 1 980 D Green 1 980 1 983 Coupling chart The following kinds of bushings indicated in the table must be used according to the kind of coupling between the crankshaft and the crankcase ENG 176 MP3 LT 400 i e Engine KEY X Crankshaft category Y Crankcase half shell category A Red B Blue C Yellow D Green In case of breakdown crankcases are together with bushings and are classified according to the centre to centre distance of the countershaft Find below the possible couplings Complete FC1 type crankcase equipped with bushings for housing a category 1 crankshaft and a countershaft with centre to centre distance A Complete FC2 type crankcase equipped with bushings for housing a category 2 crankshaft and a countershaft with centre to centre distance A Complete FC3 type crankcase equipped with bushings for housing a category 1 crankshaft and a countershaft with centre to centre distance B Complete FC4 type crankcase equipped with bushings for housing a category 2 crankshaft and a countershaft with centre to centre distance B N B THE CRANKSHA
111. e diameter of the two bearings Characteristic Gear bearing diameter 12 00 011 mm Also check the shaft diameter on the flywheel cov pP er and on the engine crankcase Characteristic Bearing diameter on the flywheel cover 12 0 034 0 016 mm Bearing diameter on the engine crankcase 12 0 034 0 016 mm N B THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH DRIVE PLATES ENG 132 MP3 LT 400 i e Engine Driven plates consist of 4 Belleville springs provi ded with grooved profiles this assembly allows transmitting torque lower than 10 kg In case of incorrect start up manoeuvres the lim iter prevents any kicks with consequent reversal of direction of the crankshaft which would impair the engine structure The limiter assembly cannot be overhauled In case of irregularities on the toothed discs replace the assembly Refitting the free wheel Make sure the freewheel faying surfaces are in good condition Thoroughly clean the free wheel to remove LOCTITE residue Degrease the threading of the holes in the free wheel and the clamping screws Apply the recommended product to the end of the screws Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly wheel itself i e with wheel Seeger ring visible Lock the s
112. e inserted Undo the two fixing screws and remove the cal liper N B IF IT IS NECESSARY TO REPLACE OR SERVICE THE BRAKE CALLIPER BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM INED BRAK SYS 302 MP3 LT 400 i e Braking system Overhaul Proceed as follows 1 remove the two male hexagonal screws 1 and take out the two pads 10 2 remove the two male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal elements from the floating body 5 with the help of short blows of com pressed air through the brake fluid pipe in order to facilitate the expulsion of pistons 6 5 Check that the plates and the body are whole and in good condition that the cylinder and the floating body of the cal liper do not show signs of scratches or erosion otherwise replace the entire calliper that the guides of the fixed plate are not scratched or eroded otherwise replace the entire plate that the brake pad check spring works properly Refitting 1 insert the pistons 6 and the sealing rings 7 in the body 2 place the guide rubbers 8 and refit the fixed plate 4 3 assemble the reaction plate 3 tightening the screws 2 insert the brake pad check spring 9 and then the pads fixing them with the corr
113. e measured using the diag nostic tester If the values do not match check distribution timing revolution timing sensor injection control unit INJEC 233 Injection Coolant temperature sensor OQ TEMPERATURE SENSOR Specification Water temperature sensor MP3 LT 400 i e Desc Quantity 2 Engine stop switch 3 Electronic control unit PIN RELATIONSHIP PIN PIN Component Reference value 9 26 Engine temperature sensor 2500 100 Ohm at 20 C 308 6 Ohm at 80 C With the control unit side connector disconnected and the coolant temperature sensor connector ran Ban J connected check that the resistance values be oec tween pin 9 and ground correspond to the engine temperature 20 2500 100 Q 80 308 6 With the control unit side connector disconnected and the coolant temperature connector discon nected check the insulation between the light blue green cable and ground INJEC 234 MP3 LT 400 i e Injection With the control unit side connector disconnected and the coolant temperature connector discon nected check the continuity between pin 9 of the interface wiring harness and the light blue green cable of the connector Specific tooling 020481Y Control unit interface wiring 020331 Y Digital multimeter Zeroing the throttle Resetting the throttle valve position signal TPS reset The MIU control unit is s
114. e normal direction using a cal liper spanner applied to the camshaft command pulley casing Cooling system Adding engine coolant Check coolant level when the engine is cold as in dicated in the scheduled maintenance table fol lowing the steps below Place the scooter on its centre stand and on flat ground MAIN 41 Maintenance MP3LT 400 i e Undo the screw shown in the figure and remove the expansion tank cap on RHS Top up if the fluid level is near or below the MIN level edge The liquid level must always be be tween the MIN and MAX level The coolant consists of an ethylene glycol and corrosion inhibitor based 50 de ionised water antifreeze solution mix CAUTION DO NOT EXCEED THE MAX LEVEL WHEN FILLING SO THAT COOLANT DOES NOT SPILL OVER THE EXPAN SION TANK WHEN THE VEHICLE IS BEING USED Recommended products SPECIAL AGIP PERMANENT fluid Coolant Monoethylene glycol based antifreeze solution CUNA NC 956 16 Braking system 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 on its centre stand with the han dlebars perfectly horizontal Check the fluid level through the sight glass C 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
115. e pressure check rear view mirror and any accessory fitting PRE DE 346 INDEX OF TOPICS Time TIME Time MP3 LT 400 i e This section is devoted to the time necessary to carry out repairs For each operation the description code and time envisages are specified Engine ENGINE Code Action 001001 Duration Engine to chassis Replacement TIME 348 MP3 LT 400 i e Crankcase Time CRANKCASE Code Action Duration 1 001100 Oil seal clutch side Replacement 2 001133 Engine crankcase Replacement 3 001153 Crankcase half gasket Replace ment TIME 349 Time MP3LT 400 i e Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001098 Countershaft Replacement TIME 350 MP3 LT 400 i e Time Cylinder assy CYLINDER ASSEMBLY Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pistonsrings pin assembly Service 9 001129 Chain tensioner Service and Re placement TIME 351 Time MP3LT 400 i e Cylinder head assy N er we HEAD ASSEMBLY Code Action Duration 1 001045 Valves Replacement 2 001049 Valves adjust 3 001056 Head gasket change 4 001126 Head Replacement 5 005081 Temperature sensor Replacement 6 007012 Coolant bleed valve Replacement 7 001057 Thermostat Replacement 8 007025 Thermostat head tubing replace ment TIME 352 MP3 LT 400 i e Rocker arm
116. eck the connecting rod small end diameter see chapter Thermal group and timing system When cleaning the crankshaft be careful to prevent any impurity from entering into the shaft lubrication hole N B IN CASE OF REPLACEMENT OF A CRANKSHAFT CONSISTING OF TWO HALF SHAFTS OF DIF FERENT CATEGORY REPLACE THE TWO HALF CRANKCASES AS WELL COUPLING THE TWO COMPONENTS SHAFT AND CRANKCASE WITH THE SAME CATEGORY To check the gearing of the crankshaft see sec tion Thermal group and timing system See also Oylinder assy and timing system Inspecting the crankcase halves Before proceeding to check the crankcase halves thoroughly clean all surfaces and oil ducts Forthe transmission side half crankcase special attention should be given to the bushings to the cooling jet on the transmission side see figure and to the lubrication duct N B THE JET IS FED THROUGH THE MAIN BUSHINGS PROP ER OPERATION OF THIS COMPONENT IMPROVES THE PISTON TOP COOLING CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT PISTON TEMPERATURE IN CREASE FAILURE OR LEAK CAN CONSIDERABLY DE CREASE THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE ENG 174 MP3 LT 400 i e Engine For the flywheel side half crankcase special at tention should be given to the lubrication channels for the main bearings and to the compartment and the channels for the oil pump as well as to the duct for the by pass located o
117. eep ing the two reference marks visible Insert the shaft with the gear and install the lock ring then turn it with the opening opposed to the shaft face Check any irregular clearance between shaft and pump body Using a thickness gauge check the distance be tween the rotors in the position shown in the figure Characteristic Admissible limit clearance 0 012 mm ENG 188 MP3 LT 400 i e Engine Check the distance between external rotor and pump body see figure Characteristic Admissible limit clearance 0 25 mm Check the rotor axial clearance using a rectified bar as reference plane as shown in the figure Characteristic Limit values admitted 0 1 mm Refitting Make sure the gasket is in the correct position N B THE TOOTH OF THE GASKET MUST IN ITS SEAT Lubricate the internal rotors Check there are no signs of scoring or wear on the oil pump cover If non conforming values or signs of wear are found replace the pump Fitthe pump cover in the position that permits the crankcase fixing screws to be aligned Tighten the two fastening screws to the prescri bed torque Locking torques N m Oil pump cover screws 0 7 0 9 Insert the oil pump with gear ENG 189 Engine MP3 LT 400 i e Insert the 2 retaining screws through the slots on the gear and tighten to the prescribed torque N B THE ASSEMBLY POSITION OF THE PUMP IS FI
118. ehicle 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 cap A of the spark plug Unscrew the spark plug using the wrench sup plied Upon refitting place the spark plug at the re quired 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 plug Refit the port making sure the rear hook is inser ted WARNING MAIN 35 Maintenance MP3 LT 400 i e THE SPARK PLUG MUST BE REMOVED WHEN THE EN GINE IS COLD REPLACE THE SPARK PLUG AS INDICA TED IN THE SCHEDULED MAINTENANCE TABLE THE USE OF ELECTRONIC CENTRAL UNITS AND OF NON COMPLIANT 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 CHAMPION RG 6 YC Alternative spark plug NGK CR7EKB Electric characteristic Electrode gap 0 7 0 8 mm Hub oil Check Park the vehicle on its centre stand on flat ground Remove the oil dipstick A dry it with a clean cloth and put it back into its hole tightening it completely Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end if the level is be
119. em implements an idle feeding correction with cold engine through a Stepper motor on a by pass circuit of the throttle valve The control unit manages the Stepper motor and the injector opening time thereby ensuring the idle steadiness and the proper combustion In all conditions of use mixture preparation is managed by modifying the injector opening time The fuel supply pressure is kept constant based on the ambient pressure The fuel supply circuit consists of Fuel pump Fuel filter Injector Pressure regulator The pump the filter and the regulator are placed inside the fuel tank on a single support The injector is connected by a pipe with fast release fittings The pressure regulator is located at the beginning of the circuit The fuel pump is controlled by the MIU control unit this ensures the scooter safety The ignition circuit consists of HV coil HV cable Shielded cap MIU control unit Spark plug The MIU control unit manages ignition with the best advance ensuring four stroke timing ignition only in the compression phase at the same time The MIU injection ignition system controls engine functions by means of a pre set program Should any input signals fail an acceptable working order of the engine is ensured to allow the user to reach a service station Of course this cannot happen when the rpm timing signal is missing or when the failure involves the control circuits Fuel pump HV c
120. en sion locking system replacement 12 003088 Tilt locking hydraulic pump replace ment 13 002021 Front brake piping Replacement 14 002007 Front brake pads Replacement TIME 395 Time MP3 LT 400 i e Code Action Duration 15 002039 Front brake calliper Replacement 16 003104 Suspension system locking calliper replacement 17 003119 Pipes for the pump splitter suspen sion locking system replacement 18 003105 Suspension locking system brake fluid repl 19 003106 Suspension locking system pressure sensor Replacement 20 003121 Parking brake control lever replace ment 21 003122 Parking brake control lever micro switch replacement 22 002048 Rear brake calliper Replacement 23 002080 Rear brake oil bleed system Change 24 002047 Front brake fluid and system bleed ing plug Repl Windscreen Z D T WINDSCREEN Code Action Duration 1 004101 Windscreen Replacement TIME 396 MP3LT 400 i e Time Stickers Sax lt ZEN hy gt 2 La 2 Re 2 zz TRANsFERS Code Action Duration 1 004066 Driving mirror Replacement 2 004159 Plates Stickers Replacement TIME 397 Time MP3 LT 400 i e The tilt mechanism TILT MECHANISM Code Action Duration 1 003073 Steering clearance Adjustment 2 003112 Central steering tube replacement 9 003002 Steering fifth wheels Replacement 4 003115 Parallelo
121. er the rear cover Remove the screw on the fairing front part pull the fairing to release the hooks Follow the same procedure for both fairings Remove the five screws on the right side and the five on the left side indicated in the figure CHAS 335 Chassis MP3 LT 400 i e License plate holder Remove the two lateral screws and the two screws inside the rear case Operate a slight upwards thrust on the case to re lease license plate support from the chassis Helmet bay Remove the chassis central cover Remove the four external screws and the two screws inside the rear case to remove the frame CHAS 336 MP3 LT 400 i e Chassis Remove the upper frame unscrewing the ten up per screws the two saddle closing screws and the case light wiring Remove the rear case internal screws indicated in the picture to detach the supporting plates of the voltage regulator on one side and the saddle open ing switch on the other Remove the six upper screws Release the case latch Remove the case light front and rear switch con nections the HV coil the battery leads and the fuse box See also Frame central cover spoiler Remove the shield central finish then screw the six screws indicated in the figure CHAS 337 Chassis MP3 LT 400 i e Remove the five screws indicated in the figure See also Headlight assy Fuel tank Remove the cha
122. er to re move the silent block supporting clamp SUSP 291 Suspensions MP3 LT 400 i e Refitting For correct installation of the swinging arm on the scooter proceed as follows 1 Position the silent bloc support bracket with part 3 inserted and lightly tighten part 1 2 Position the swinging arm inserting part 2 3 Tighten part 3 to the prescribed torque 4 Screw on and tighten part 4 to the prescribed torque 5 Screw on and tighten part 5 to the prescribed torque 6 Tighten part 1 to the prescribed torque Insert the swinging arm engine bolt and tighten to the prescribed torque SUSP 292 MP3 LT 400 i e Suspensions SWINGING ARM FITTING Name Torque in Nm Part 1 98 118 Part 3 5 7 Part 4 88 5 108 Part 5 54 60 Bolt for swinging arm engine side swinging arm frame side 32 5 40 Shock absorbers Removal Proceed as follows place the scooter on its centre stand lift the engine a little with a jack so as to free the two shock absorbers remove the exhaust silencer undo the shock absorber spring assembly clamp ing screw from the support fixed to the engine on the one side and from that fixed to the muffler on the other unscrew the two upper nuts one on each side fixing the shock absorber spring assembly to the frame and remove the shock absorbers Refitting Carry out the previous operations but in reverse order Locking torques N m
123. er to the pump joint geared motor Undo the pump joint screw Undo the two geared motor pump locking screws SUSP 266 MP3 LT 400 i e Suspensions For the new solution to fix the pump to the sus pension lock assembly the retainers attaching the pump body to the assembly and the clamp fixing the pump joint have been modified as shown the figures below A safety screw A on the lower part of the pump been also added to be tightened after the main lockings have been carried out SUSP 267 Suspensions MP3LT 400 i e Undo the two potentiometer screws Upon refitting plug the potentiometer in D type connector afterwards place it with its electric con nection directed to the opposite side of the pump Remove the nut indicated in the figure if neces sary lock the lever with a vice making sure not to spoil the surface In case of difficulties when removing the lever use the specific tool Remove the tongue and then the moulded wash er Specific tooling 020234y extractor SUSP 268 MP3 LT 400 i e Suspensions Remove the three fixing screws of the electric mo tor It is important to mark the direction of the electric motor position in order to refit it correctly Remove the four screws indicated in the figure remove the flexible transmission supporting brack et separate the two crankcase halves if neces sary use a rubber mallet to hit the flexible transmission lever in o
124. eservoir operate the brake lever and keep the system under pressure Remove the legshield upper cover With a glass pipe connect the bleed valve to the front valve 5 and loosen it until the brake fluid begins to drain Close the valve and restore system pressure Perform this operation until brake fluid without air bubbles comes out of the pipe Restore reservoir level with the recommended brake fluid type and the front brake upper cover Remove the inspection cover and while checking that the reservoir is filled with brake fluid operate the integral brake 14 and keep the system under pressure Restore reservoir level with the recommended brake fluid type and the inspection cover BRAK SYS 313 Braking system MP3 LT 400 i e With a glass pipe connect the bleed valve to the front brake calliper 6 and loosen it until the brake fluid begins to drain Close the valve and restore system pressure Perform this operation until brake fluid without air bubbles comes out of the pipe Repeat the operation with the front calliper 8 With a glass pipe connect the bleed valve to the rear brake calliper 19 and loosen it until the brake fluid begins to drain Close the valve and restore system pressure Perform this operation until brake fluid without air bubbles comes out of the pipe Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Front T
125. f faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda sensor Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake system sealing Intake sleeve Filter box TPS reset successful TPS reset successful Fuel supply Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness Fuel supply system The fuel supply circuit includes the electric pump the filter the pressure regulator the electro injector and the fuel delivery pipes The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through the filter The pressure is controlled by the pressure regulator situated in the pump assembly in the tank INJEC 205 Injection MP3 LT 400 i e Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure Remove the fast release fitting from the injector support INJEC 206 MP3 LT 400 i e Injection Remove the injector connector cylinder head and the clip fixing the throttle body to the manifold Remove the MIU ECU connector INJEC 207 Injection MP3 LT 400 i e Remove the gas command fitting as
126. ft Hit slightly with a mallet if necessary Refit the bearing check Seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020362Y 12 mm guide 020357Y 32x35 mm Adaptor Hold the crankcase in a perfectly horizontal posi tion heat it with a specific heat gun at about 120 C use the specific tool to fit the bearing of the electric motor Hit slightly with a mallet if necessa ry Specific tooling 020363Y 20 mm guide 020358Y 37x40 mm Adaptor 020151Y Air heater SUSP 263 Suspensions MP3 LT 400 i e 020376Y Adaptor handle Remove the spring toothed sector unit from its fit ting slightly hit with a mallet if necessary to release the unit Extract the bearing of the spring toothed sector unit with the specific tool Specific tooling 001467Y002 Driver for OD 73 mm bearing Extract the bearing of the electric motor with the specific tool Hold the crankcase in a perfectly horizontal posi tion heat it with a specific heat gun at about 120 C use the specific tool to fit the bearing of the spring toothed sector unit Hit slightly with a mallet if necessary Specific tooling 020360Y 52x55 mm Adaptor 020151Y Air heater 020376Y Adaptor handle SUSP 264 MP3 LT 400 i e Suspensions Hold the crankcase in a perfectly horizontal posi tion heat it with a specific heat gun at about 120 C use the specific tool to fit the bearing of the electric motor Hit s
127. g position ing tool 020647Y Toe in checking tool 020647Y028 MP3 LT Toe in tool tricycle Rear Removing the rear wheel Before removing the rear wheel support the vehi cle properly and operate the parking brake so as to facilitate removing the wheel fixing screws Remove the exhaust silencer Undo the screw fixing the right shock absorber to the clamp Undo the two screws fixing the clamp to the en gine SUSP 285 Suspensions MP3 LT 400 i e Undo the two screws fixing the clamp to the cen tre stand Remove the cotter pin and collect the cap Unscrew the wheel fixing nut and collect the spacer Unscrew the clamp Collect the conical spacer Undo the five wheel fixing screws and remove the wheel SUSP 286 MP3 LT 400 i e Suspensions Refitting the rear wheel To fit follow the removal steps but in the reverse sequence being careful to fit the spacers on the wheel axle as shown in the picture Locking torques N m Muffler arm clamping screws 27 30 Rear wheel axle nut 104 126 Shock absorber crankcase at tachment bracket 20 25 Lower shock absorber clamping screw 33 41 Nm Rear brake calliper fixing screws 25 30 Nm Swing arm Removal Rest the scooter on its centre stand Remove the retainer fixing the swinging arm to the engine unscrew the nut and remove the bolt SUSP 287 Suspensions MP3 LT 400 i e
128. ge the MIU control unit 14 Before reconnecting the quick couplers of the power supply system check that the terminals are perfectly clean Troubleshooting hints 1 A MIU failure is more likely to be due to the connections than to the components Before troubleshooting the MIU system carry out the following checks A Electrical power supply a Battery voltage Blown fuse Remote controls Connectors Chassis earthing Fuel supply Broken fuel pump Dirty fuel filter Ignition system Faulty spark plug Broken coil Broken shielded cap Intake circuit o moon To Dirty air filter INJEC 199 Injection MP3 LT 400 i e b Dirty by pass circuit c Faulty Stepper motor F Other a Incorrect distribution timing b Wrong idle mixture c Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors Make sure that all connections have been correctly made Check the connections as follows A check that the terminals are not bent B check that the connectors have been properly connected C check whether the malfunction can be fixed by shaking the connector slightly 3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit install the original control unit again and check if the fault occurs again 4 When troubleshooting use a multimeter with an internal resistance over 10 Ohm V Instruments that a
129. gnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Start up speed Starter motor and remote control Battery INJEC 202 MP3 LT 400 i e Possible Cause Injection Operation Ground connections End of compression pressure End of compression pressure Power to the spark plug Spark plug Shielded cap HV coil Rpm timing sensor Ignition advance Fuel supply Fuel pressure low Injector capacity low Injector sealing poor Correctness of the parameters Engine stops at idle Coolant temperature Stepper throttle valve position intake air temperature steps and actual opening Cleaning of the auxiliary air pipe and throttle valve air filter ef ficiency ENGINE DOES NOT IDLE IDLING IS UNSTABLE IDLING TOO LOW Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Ignition efficiency Spark plug Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve Filter box Fuel feed low pressure Engine does not rev dow
130. gram arms replacement 5 003114 Parallelogram bearings replace ment 6 003116 Steering rod replacement 7 003117 Constant velocity universal joint re placement 8 003110 Side headstock fifth wheels Repl TIME 398 MP3 LT 400 i e Geared motor GEARED MOTOR Time Code Action Duration 1 003101 Tilt locking calliper control lever re placement 2 005009 Voltage regulator Replacement 3 003095 Tilt locking calliper support bracket replacement 4 001069 HV coil Replacement 5 001094 Spark plug cap Replacement 6 003120 Tilt locking control unit replacement 7 003093 Geared motor crankcase replace ment 8 003090 Geared electric motor replacement 9 003092 Geared motor bearings replace ment 10 003091 Geared motor pinion replacement 11 003089 Geared motor potentiometer re placement 12 003097 Tilt locking caliper micro switch re placement TIME 399 A Air filter 37 Battery 58 68 79 Brake 297 302 304 306 308 310 315 316 C Coolant 234 322 E Engine oil 38 F Fuel 205 213 338 374 386 Fuses 76 H Headlight 44 329 331 338 Horn 72 Hub oil 36 Identification 8 Instrument panel 328 380 L Light switch Maintenance 7 33 O Oil filter 40 S Saddle Shock absorbers 293 Spark plug 35 231 Stand Start up T Tank 338 374 Transmission 10 46 91 106 360 Turn indicators 62 Tyres 17
131. half crankcase using a screwdriver Install a new oil guard after lubricating it using the special tool arranging it at a 0 5 mm recess from the crankcase plane CAUTION A WRONG POSITIONING OF THE OIL GUARD AFFECTS THE LUBRICATION OIL CIRCULATION Specific tooling 020360Y 52x55 mm Adaptor 020376Y Adaptor handle Insert the gasket on the flywheel side half crank case Lubricate the main bearing on the transmission side half crankcase Couple the 2 half crankcases being careful not to damage the bushing on the transmis sion side half crankcase with the threaded tang of the crankshaft Insert the engine support retain screw on the fly wheel side half crankcase without tightening Insert the 14 fastening screws by arranging the single shorter screw A and the single longer screw B as shown in the figure Tighten the screws thoroughly and tighten to the prescribed torque ENG 180 MP3 LT 400 i e Engine Check that the crankshaft rotates freely N B REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE TO ENSURE BETTER SEALING PERFORMANCE Locking torques N m Engine crankcase coupling screws 11 13 Install the thermal group cylinder head piston as described in section Thermal group and timing system Install the flywheel with start up control as described in the Flywheel and start up chapter Install the flywheel cover with the
132. he engine Insert the 3 fastening screws one of which with a support band for the cooling system sleeve and tighten to the prescribed torque Locking torques N m Inlet manifold screws 11 13 Crankcase crankshaft Remove the outside and inside transmission cover and the complete driving pulley as described in Automatic transmission ENG 166 MP3 LT 400 i e Engine Remove the flywheel cover with the cooling system sleeves as described in the Flywheel cover chapter Remove the flywheel with the starting system following the instruction given in Flywheel and Starting system Remove the thermal group cylinder head piston as described in the Thermal group and timing system chapter Before opening the crankcase check the crankshaft axial clearance For this purpose use a plate e g the special tool and a support with special tool comparator s Specific tooling 020262Y Crankcase splitting plate 020335Y Magnetic support for dial gauge Characteristic Standard clearance 0 10 0 50 mm Admissible increase limit after use 0 60 mm Upper clearances are an indication of wear on the surfaces of the crankshaft casing support To carry out an accurate measurement measure the clearance in both directions between crankcase and crankshaft Splitting the crankcase halves Remove the engine support retain screw on the flywheel side half crankcase
133. he exhaust and on the intake side to the prescribed torque Locking torques N m Exhaust intake head fixing nuts 10 12 ENG 158 MP3 LT 400 i e Engine Tighten the 3 side screws to the prescribed tor que Locking torques N m Head fixing screws 10 12 Install the coolant temperature sensor with the washer and tighten to the prescribed torque CAUTION FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN DAMAGE THE SENSOR Locking torques N m Coolant temperature sensor 10 12 Install the spark plug and tighten to the prescribed torque Locking torques N m Spark plug 12 14 Insert the timing control belt on the crankshaft according to the initial direction of rotation Install the tensioner shoe with its spacer tight ening the bolt to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Tensioner sliding block fixing screw 10 14 Insert pins and rocking levers on the flywheel side Lubricate the two rocking levers through the holes at the top ENG 159 Engine MP3 LT 400 i e Clean the camshaft by blowing with little com pressed air jets especially the retaining plate housing Lubricate the 2 shafts Insert the camshaft into the head with the cams opposite the rocking levers Remove any LOCTITE residues from the
134. he operations described refer to only one cal liper but are valid and must be observed for both Remove the rubber cap from the bleed screw Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered With the right hand brake lever load the system and bring it up to the required pressure Keeping the right hand brake lever pulled loosen the bleed screw to permit the air in the system to escape Then tighten the bleed screw Repeat the operation until only brake fluid comes out of the rubber pipe Remove the fluid recovery pipe and refit the rubber cap over the bleed screw Top up the brake fluid to the right level in the reservoir N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM If necessary bleeding can be done using a special vacuum pump BRAK SYS 314 MP3 LT 400 i e Braking system Specific tooling 020329Y Mity Vac vacuum operated pump Locking torques N m Oil bleed screw 8 12 Brake pipes Front brake pipes removal Unscrew the braking splitter screw Disconnect the brake pipes removing the two met allic str
135. iator cover Remove the two wheelhouses with the turn indi cator Unscrew the two screws fixing the wheelhouse to the shield Disconnect the cable guide after that turn the wheelhouse anticlockwise inwards to release it from the shield supports To remove the shield central finishing remove the PIAGGIO clip on badge paying attention not to spoil the paint unscrew the screw underneath and remove the finish carefully CHAS 329 MP3LT 400 i e Chassis Remove the four screws A and disconnect the wiring See also Radiator cover Frame central cover Remove the three screws on the right and the left side Open the refuelling compartment and remove the tank cap so as to remove the central cover Disconnect the cable refuelling compartment opening See also Seat Handles and top side fairings Knee guard CHAS 330 MP3 LT 400 i e Chassis Legshield Remove the front headlight assembly Remove the spoiler Remove the two front screws and the two screws under the wheelhouse Remove the four screws on the shield back plate See also Headlight assy spoiler Knee guard Remove the legshield Remove the spoiler Remove the two central screws and the coolant Cap cover screw CHAS 331 Chassis MP3 LT 400 i e Remove the expansion tank fixing screw and the frame from the instrument panel and manually re lease the unions with the shield
136. icated in the diagram STANDARD DIAMETER Specification Desc Quantity Inlet 4 987 4 972 mm Outlet 4 975 4 960 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc Quantity Inlet 4 96 mm Outlet 4 945 mm Calculate the clearance between valve and valve guide ENG 152 MP3 LT 400 i e Engine Check the deviation of the valve stem by resting iton a V shaped abutment and measuring the extent of the deformation with a dial gauge Characteristic Limit values admitted 0 1 mm Check the concentricity of the valve head by ar ranging a dial gauge at right angle relative to the valve head and rotate it on a V shaped abutment Characteristic Admissible limit 0 03 mm Inspecting the valve stem guide clearance After measuring the valve guide diameter and the valve stem diameter check clearance between guide and stem INLET Specification Desc Quantity Standard clearance 0 013 0 04 mm Admissible limit 0 08 mm OUTLET Specification Desc Quantity Standard clearance 0 025 0 052 mm Admissible limit 0 09 mm ENG 153 MP3LT 400 i e Engine STANDARD VALVE LENGTH Specification Desc Quantity Inlet 95 0 0 3 mm Outlet 94 2 0 3 Check that there are no signs of wear on the surface of contact with the articulated register terminal SI NO If no anomalies are found during the above checks you can use the same valves To obtain
137. ile the vehicle is stored in open circuit Besides upon pre delivery it is therefore necessary to check the battery charge and recharge it if required before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN CIRCUIT STORAGE 1 Voltage check up Before installing the battery on the vehicle check the open circuit voltage with a standard tester If voltage exceeds 12 60 V the battery can be installed without any renewal recharge If voltage is below 12 60 V a renewal recharge is required as explained in 2 2 Constant voltage battery charge mode Constant voltage charge equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for Nominal capacity Charge time 10 to 12 h recommended Minimum 6 h Maximum 24 h 3 Constant current battery charge mode ELE SYS 79 Electrical system MP3 LT 400 i e Charge current equal to 1 10 of the battery rated capacity Charge time Maximum 5 h Remote controls check To check the operation of a remote control 1 Check that given regular conditions there is no continuity between terminals 87 and 30 87 E 6 30 2 Apply a 12V voltage to power terminals 86 and 85 of the remote control 3 With the remote control fed check that there is continuity between terminals 87 and 30 4 Ifthese conditions are not met the remote con trol is surely damaged and therefore it should be replaced Connector
138. indicated in the picture Pump supply circuit INJEC 208 MP3 LT 400 i e Injection INJECTION LOADS Specification Desc Quantity Battery 12V 14Ah Fuse 15A Fuse 20A Key switch contacts Fuse 7 5A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan remote control lt When switched to ON the fuel pump starts to rotate for 2 seconds and then stops When the engine starts up in the presence of rpm timing signal the pump is continuously supplied ELECTRICAL DATA Pump winding resistance 1 8 Ohm Input current during regular functioning 2 8 A Check thatthe injection load 15A fuse No 2 works popo 0009000 Check that the live control unit power supply 7 5A fuse No 10 works properly Check the efficiency of the injection load remote control Check the resistance of the energising coil between pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the remote control INJEC 209 Injection MP3 LT 400 i e Check the power supply line of the injection load remote control energising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and the Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the f
139. ine by means of the strobo scopic light Proceed as follows Remove the spark plug 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 plug 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 plug and spark plug cap Connect the induction clamp on the spark gap cable respecting the proper polarity the arrow on the clamp must be pointing at the spark plug MAIN 34 MP3 LT 400 i e Maintenance Connect the diagnostic tester Start the engine Select the parameters function in this menu Select the stroboscopic light control in the tradi tional four stroke engine position 1 spark 2 revs Check that the real values of rpm and ignition advance match those measured using the diag nostic tester If the values do not correspond check distribution timing revolution timing sensor injection control unit Specific tooling 020680Y Diagnosis Tool 020330Y Stroboscopic light to check timing 020621Y HV cable extraction adaptor Spark plug Remove the port on the left hand side panel of the v
140. ing system Refitting To fit the front brake disc follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque using threadlock Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Brake disc screws 8 10 Disc Inspection Checking the disc is important it must be perfectly clean with no sign of rust oil or grease or any other dirt and must show no signs of deep scoring Characteristic Thickness of a new front disc 4 0 Disc thickness at wear limit front 3 5 mm Remove the wheel and check using the appro priate tools that the axial run out of the brake surface is within the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axial run out 0 1 mm Front brake pads BRAK SYS 309 Braking system MP3 LT 400 i e Removal Remove the brake calliper Remove the Benzing snap ring of the pad pin Slide off the pin paying attention to collect the retaining spring of the pads Remove the pads Characteristic Minimum value 1 5mm Refitting Follow the removal steps but in reverse order check that the Benzing snap ring of the pads is in good conditions Rear brake pads BRAK SYS 310 MP3 LT 400 i e Braking system Removal
141. ircuits Saddle opening receiver battery power supply glove box lighting headlight turn indicator command device pre installation for anti theft device Live fuse No 12 saddle opening and boot Fuse No 4 Capacity 20A Protected circuits battery powered ECU for parking control Fuse No 5 Capacity 20A Protected circuits battery powered fuse No 7 live fuses No 8 9 10 11 Fuse No 6 Capacity 15 A Protected circuits L V socket Fuse No 7 Capacity 7 5 A Protected circuits Battery powered instrument panel Fuse No 8 Capacity 10A ELE SYS 77 Electrical system Specification MP3 LT 400 i e Desc Quantity Protected circuits Live stop start up and start up ena bling lights Fuse No 9 Capacity 7 5 A Protected circuits live passing and horn 10 Fuse No 10 Capacity 7 5A Protected circuits Live injection ECU immobilizer aer ial electric fan remote control injection load remote control 11 Fuse No 11 Capacity 7 5A Protected circuits Live parking control ECU pre instal lation for anti theft device instrument panel headlight remote control horn remote control 12 Dashboard Fuse No 12 a y H um A Led immobilizer anti theft device B Speedometer with twin scale km h and mph C CLOCK switch D Digital display E Front suspension locking system warning light if available SET switch G Rpm indi
142. istance between pins 13 15 is between 100 and 150 Ohm at an engine temperature of approx imately 20 Disconnect the fuel pipe connector Start up the engine and wait for it to stop With the wiring connected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2 8 V With the interface cable harness disconnected from the control unit check continuity between pin 13 and the red cable of the rpm sensor connector and between 15 and the brown cable of the rom sensor connector With the interface cable harness disconnected from the control unit and the rpm sensor connector disconnected check that the red and brown cables pin 13 15 are isolated from each other and insulated from the ground lead Specific tooling 020481 Y Control unit interface wiring 020331 Y Digital multimeter INJEC 226 MP3 LT 400 i e Injection HT coil INJECTION LOADS Specification Desc Quantity Battery 12V 14Ah Fuse 15A Fuse 20A Key switch contacts Fuse 7 5A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan remote control OD Or BR Po INJEC 227 Injection MP3 LT 400 i e PIN RELATIONSHIP PIN PIN Component Reference value 22 Live supply HV coil 1 Ohm The ignition system combined with the injection is the high efficiency induction
143. istic crankshaft crankcase axial clearance 0 1 0 405 mm Diameter of crankshaft bearings Measure the bearings on both axes x y CRANKSHAFT Specification Desc Quantity Cat 1 Standard diameter 40 020 40 026 Cat 2 Standard diameter 40 026 40 032 Crankshaft alignment Specific tooling 020335Y Magnetic support for dial gauge CHAR 17 Characteristics MP3 LT 400 i e MAX ADMISSIBLE DISPLACEMENT Specification Desc Quantity A 0 15 mm 0 010 0 010 0 10 AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission side 1 0 025 A D 0 20 0 50 shoulder Half shaft transmission 20 9 0 05 B D 0 20 0 50 side Connecting rod 22 0 10 0 15 0 20 0 50 Flywheel side shoulder 1 840 025 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 10 0 05 G D 0 20 0 50 Slot packing system Shimming system for keeping the compression ra tio pod DISTANCE A IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE A lt DISTANCE A HELPS DETERMINE THE THICKNESS OF GASKET B THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE COMPRESSION RATIO BASE GASKET B MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD ON THE OTH
144. istics or to specific repair operations will be promptly 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 z u x U o CHARACTERISTICS TOOLING 7 c 2 vs 2 o I 2 a 2 Q ELECTRICAL SYSTEM CHAR TOOL MAIN TROUBL ELE SYS ENGINE FROM VEHICLE 2 a m O 2 ENG VE ENG INJEC SUSP COOLING SYSTEM O w x 2 2 2 o O o lt o m U 20 m r lt m 2 lt m BRAK SYS COOL SYS
145. ith inter face wiring disconnected from the control unit check the continuity of the blue black cable be tween pressure sensor connector and the horn remote control base as indicated in the picture Check the continuity between pin 27 and the re mote control base white cable SUSP 280 MP3 LT 400 i e Suspensions Check the continuity of the yellow red cable be tween the pressure switch connector and the fuse box 7 5A fuse No 11 and between the remote control base and the fuse box 7 5A fuse No 11 With a multimeter also check the pressure switch operation as well as the continuity at rest as this is normally closed switch Wheel alignment Tool fitting How to use the tools Check that tyre pressure is correct Park the vehicle on level smooth and even ground Rest the vehicle on its centre stand Make sure that the parking system is disengaged Lift the front wheels as shown in the photograph SUSP 281 Suspensions Check thatthe wheel rims rotate even ly and whether there is abnormal clear ance in bearings and suspensions Make sure that the steering control shows no signs of abnormal clearance in joints and bearings Otherwise cor rect this and then adjust them Characteristic Front tyre pressure with passenger 1 6 bar 1 8 bar Rear tyre pressure with passenger 2 4 bar 2 6 bar MP3 LT 400 i e Get the vehicle off the sta
146. ix clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers ENG 133 Engine MP3 LT 400 i e Refitting the intermediate gear Lubricate the gear housing on the engine crank case Insert the intermediate gear with torque limiter Lubricate the inside bushing and the starter ring gear hub surface Install the start up rim on the flywheel turning it clockwise and inserting at the same time ENG 134 MP3 LT 400 i e Engine Refitting the flywheel magneto Insert the key on the crankshaft Install the flywheel checking the proper insertion of the key and engaging the torque limiter gear with the start up rim Insert washer and nut on the crankshaft Tighten thoroughly the guide bushing of the fly wheel lock tool and loosen by 1 4 turn N B FAILURE TO OBSERVE THIS PRECAUTION CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL Specific tooling 020472Y Flywheel lock wrench Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool ENG 135 Engine MP3 LT 400 i e Insert the special tool checking that the pins are perfectly introduced into the seat Specific tooling 020472Y Flywheel lock wrench Tighten the flywheel lock nut to the prescribed torque Locking torques N m
147. jector Engine temperature sensor Fuel pump Diagnosis socket Injection ECU Electrical system ELE SYS 51 Electrical system 57 Immobilizer Aerial 58 External temperature sensor 59 Pressure sensor 60 Fuel level transmitter 61 Oil pressure sensor 62 Mode button 63 Horn 64 Horn button 65 Key switch contacts 66 Auxiliary fuses Key Ar Orange Az Sky Blue Bi White BI Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Components arrangement ELE SYS 52 MP3 LT 400 i e MP3 LT 400 i e Electrical system 1 Immobilizer Aerial Remove the shield back plate to reach it 2 Geared motor Remove the legshield to reach it 3 Remote control switches Remove the legshield to reach it 4 Auxiliary fuses Remove the of the right side footrest to reach these fuses ELE SYS 53 Electrical system MP3 LT 400 i e 5 Horn Remove the shield back plate lower side to reach it 6 Fuel level transmitter 7 HV coil Remove the central chassis cover to reach it 8 Lambda probe The lambda probe is mounted on the exhaust manifold ELE SYS 54 MP3 LT 400 i e Electrical system 9 Oil pressure sensor Remove the exhaust end to reach it 10 Turn indicator control device Remove the left side fairing to reach it 11 Voltage regulator Remove the right side fairing to reach it 12 Diagn
148. l disassembly the ceramic may split ENG 191 Engine MP3 LT 400 i e Clean all the parts thoroughly before removing them Place the extractor together with the pin on the fixed part of the ceramic seal Without modifying the extractor position make three holes on the fixed part of the seal using the pin supplied and a hammer N B MAKE THE HOLES WITH A STRONG HIT MULTIPLE LIGHT BLOWS COULD DEFORM THE PART WITHOUT PASSING THROUGH Fix the extractor to the fixed part of the sealing using the screws supplied with the tool CAUTION FIX IT PROPERLY WITHOUT TEARING THE PLATE Complete the tool by fitting the bracket the screw and the nut ENG 192 MP3 LT 400 i e Engine Hold the screw in position and operate the nut until the fixed part of the sealing is completely re moved Remove the extractor with the fixed part of the overall seal Fitting OVERALL SEAL FITTING CAUTION CLEAN ALL THE COMPONENTS THOROUGHLY CAUTION LUBRICATE THE ROTOR SHAFT WITH ENGINE OIL Fit the tie rod by screwing it to the rotor shaft CAUTION TIGHTEN MANUALLY UNTIL IT STOPS Place the overall seal on the shaft ENG 193 Engine MP3 LT 400 i e Place the calibrated punch at preloading value Fit the nut to the tie rod Keep the tie rod in position and screw the nut up to the end of stroke The tool will drive the fixed part seat on the
149. lect the LOWER STOP SEARCH option from the SYSTEM RESET menu WAIT PROCEDURE IN PROGRESS SUSP 255 Suspensions MP3LT 400 i e The hand held computer indicates the outcome of the stop search operation POSSIBLE LIMIT STOP VALUES TO EXIT PRESS A KEY AND TURN OFF AND ON SE LECT PARAMETERS TO ADJUST AT 12 Check the geared motor if the hand held computer does not indicate this Select the PARAMETERS option from the main menu The hand held computer displays the option REL ATIVE POTENTIOMETER ANGLE This function is active coming from the LOWER STOP SEARCH procedure NOTE a slight oscillation of the angle value be tween 0 00 and 0 50 is considered normal Remove the protection cap ofthe geared motor set screw Use a plain slot screwdriver to turn the set screw anticlockwise until replicating the 12 condition on the hand held computer RELATIVE POTENTIOMETER ANGLE 12 a slight value oscillation is considered normal Refit the protection cap SUSP 256 MP3 LT 400 i e Suspensions Remove the protection cap align the pump control and lock the screw to the prescribed torque Locking torques N m Clamp fixing pump bolt to anti tilting device 11 13 Select the SYSTEM RESET option from the MAIN menu SUSP 257 Suspensions MP3 LT 400 i e Select the POTENTIOMETER RESET option from the SYSTEM RESET menu and press OK WAIT PROCEDURE IN PR
150. lightly with a mallet if necessa ry Specific tooling 020363Y 20 mm guide 020151Y Air heater 020376Y Adaptor handle 020477Y 37 mm adaptor Before removing the geared motor Disable the suspension lock Remove the legshield With the set nut indicated in the picture remove the tensioning cable of the suspension locking me chanical calliper Remove the electrical connection of the geared motor position potentiometer Remove the electrical connection of the geared motor electric motor SUSP 265 Suspensions MP3LT 400 i e Disconnect the hydraulic pipes between the pump and the sliding stem locking clamps Empty the system and use a container to collect the brake fluid CAUTION ELIMINATE ANY REMAINING BRAKE FLUID SPILLS WARNING BRAKE FLUID IS HIGHLY POISONOUS DO NOT INGEST OR SWALLOW IF ACCIDENTALLY SWAL LOWED DRINK LARGE QUANTITIES OF MILK OR WATER AND SEEK MEDICAL ADVICE IMMEDIATELY BRAKE FLUID DESTROYS SKIN AND OCULAR TISSUE IF YOU ACCIDENTALLY SPILL BRAKE FLUID ON YOURSELF TAKE OFF YOUR CLOTHES WASH WITH HOT WATER AND SOAP AND SEEK MEDICAL ADVICE IMMEDIATELY IF BRAKE LIQUID GETS ACCIDENTALLY IN CONTACT WITH YOUR EYES RINSE WITH ABUNDANT FRESH WA TER AND SEEK MEDICAL ADVICE IMMEDIATELY KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Remove the 3 fixing screws indicated and remove the whole geared motor Use a screwdriver to remove the plastic access cov
151. load remote control 15 Start up remote control relay 16 Electric fan remote control 17 Starter motor 18 Electric fan 19 Fuel pump 20 HV coil 21 Fuel injector 22 Lambda sensor 23 Rpm indicator 24 WARNING light 25 Immobilizer LED 26 Diagnostics socket connector 27 Start up remote control switch PIN RELATIONSHIP PIN PIN Component Reference value 13 15 Engine rpm sensor 100 150 Ohm 20 C 22 Live supply HV coil 1 Ohm 9 26 Engine temperature sensor 2500 100 Ohm at 20 C 308 6 Ohm at 80 C 4 11 Lambda sensor OV with throttle valve closed 1V with throttle valve fully opened Troubleshooting procedure Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient repair according to the indications of the self diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Fuel supply Fuel in the tank Fuel pump activation Fuel pressure low Injector capacity low Power to the spark plug Shielded spark plug cap HV coil secondary insulation Parameter reliability Coolant temperature Distribution timing injection ignition Intake air temperature End of compression pressure End of compression pressure Starting difficulties ENGINE START UP PROBLEMS Possible Cause Operation Presence of faults detected by the self dia
152. low the MAX 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 MAIN 36 MP3 LT 400 i e Maintenance Replacement Remove the oil filler cap 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 ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Characteristic Rear hub oil Capacity approximately 250 cc Air filter Proceed as follows 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 Soak it in a mixture of 50 petrol and 50 specified oil 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 SERVICE THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE Recommended products MAIN 37 Maintenance MP3 LT 400 i e AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness Engine oil In 4T engines the engine oil is used to lubricate the distribution elements the bench bearings and the thermal group An insufficient quantit
153. mm Inspecting the piston Measure the diameter of the bearings on the pis ton Characteristic Standard diameter 22 0 006 0 001 mm Calculate the piston pin coupling clearance N B ENG 144 MP3 LT 400 i e Engine THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS FOR THIS REASON MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS Characteristic Standard clearance 0 001 0 010 mm Measure the outside diameter of the piston per pendicular to the gudgeon pin axis Take the measurement in the position shown in the figure N B REFER TO THE SPECIFICATIONS SECTION FOR THE SIZES OF THE PISTON AND THE CYLINDER PISTON COU PLING CLEARANCES Characteristic A 10mm Piston diameter 85 8 mm nominal value m Using a bore meter measure the cylinder inner diameter at a given height according to the direc tions shown in the figure Characteristic B 43 mm Standard diameter 85 8 mm nominal value Check that coating is free from flakes Check that the head matching surface exhibits no deformations or wear Characteristic Maximum allowable run out 0 05 mm ENG 145 Engine MP3 LT 400 i e Pistons and cylinders are classified into categories based on their diameter The coupling is carried out in pairs A A B B C C D D N B REFER TO THE SPECIFICATIONS SECTION FOR THE SIZES OF THE CYLINDER AND THE CYLINDER PISTON COUPLIN
154. moving the driven pulley clutch Locking torques N m Clutch ring nut 65 75 To facilitate reassembly on the engine turn the moving driven pulley and insert the belt onto the smaller diameter Refitting the driven pulley Install the driven pulley assembly with belt ENG 101 Engine MP3 LT 400 i e Drive belt Check that the driving belt is not damaged Check the width of the belt Characteristic Minimum width 27mm Standard width 28 2 mm Removing the driving pulley Using a 27 mm wrench turn the central pulley nut to horizontally align the central inside holes and install the special tool Specific tooling 020474Y Driving pulley lock wrench First fit the 2 retainer clamps of the special tool onto the pulley so that the splines are completely engaged Then insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself Tighten the two tool fixing screws also manually Loosen the central nut Remove the spring washer and the flat washer Remove the fixed driving half pulley Remove the bushing connection washer ENG 102 MP3 LT 400 i e Engine Move the belt downwards Suitable support the roller contrast and extract the movable driving half pulley with the relevant bushing and the rear washer being careful not to make the rollers come out Inspecting the rollers case Check that the in
155. n Fuel pump Pressure regulator Fuel filter Injector capacity ENGINE DOES NOT RETURN TO IDLING SPEED IDLING SPEED TOO HIGH Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Ignition efficiency Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve Filter box INJEC 203 Injection MP3 LT 400 i e Possible Cause Operation Fuel feed low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda sensor Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve Filter box Fuel feed low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system sealing infiltrations Manifold head Manifold muffler Muffler welding Engine re
156. n Brown LHS Switch White Pink RHS Switch Blue Black Left turn indicators Pink Right turn indicators White Blue Battery powered Blue Not connected Live supply Yellow Black Ground lead Black Not connected Not connected ELE SYS 81 Electrical system 12 Not connected MP3 LT 400 i e HV COIL CONNECTOR 1 Injection load remote control Black Green 2 Injection ECU Pink Black ANTI THEFT DEVICE PRE INSTALLATION CONNECTOR Left turn indicators Pink Right turn indicators White Blue Ground lead Black Battery powered Blue Live supply Yellow Red Helmet compartment lighting Blue Black Channels 1 3 selector Green Blue ON oO a RA ON Alarm code Orange Black FUEL PUMP CONNECTOR 1 Injection load remote control Black Green 2 Not connected 3 Not connected 4 Ground lead Black 5 Not connected INSTRUMENT PANEL CONNECTOR A Not connected Not connected Not connected Not connected Battery powered Red Blue Not connected 1 2 3 4 5 Instrument panel lighting Yellow Black 6 7 8 Not connected 9 Not connected ELE SYS 82 MP3 LT 400 i e 10 Not connected 11 Ground lead Black 12 Live supply Yellow Red Electrical system INSTRUMENT PANEL CONNECTOR B 1 Scooter speed signal Sky blue 2 Fuel level indicator White Green 3 Water temperature sensor Sky blue Bl
157. n of the service keys The master and service keys must be used to code the system as follows Insert the Master key turn it to ON and keep this position for two seconds limit values 1 to 3 seconds Insert the service key and turn it to ON for 2 seconds If you have copies of the key repeat the operation with each key Insert the MASTER key again and turn it to ON for 2 seconds The maximum time to change keys is 10 seconds A maximum of 7 service keys can be programmed at one time It is essential to adhere to the times and the procedure If you do not start again from the beginning Once the system has been programmed the master key transponder is strictly matched with the control unit With this link established it is now possible to encode new service keys in the event of losses replacements etc Each new programming deletes the previous one to add or delete a key it is therefore necessary to repeat the procedure using all the keys that you intend to keep in use If a service key becomes uncoded the efficiency of the high voltage circuit shielding must be thoroughly inspected In any case it is advisable to use resistive spark plugs Characteristic MASTER key RED KEY SERVICE key BLACK KEY ELE SYS 66 MP3 LT 400 i e Diagnostic codes Electrical system The Immobilizer system is tested each time the key switch is turned from OFF to ON During this diagnosis phase a number of contr
158. n steadily The engine cannot be started The codes that can be trans mitted are 1 flash code 2 flash code ELE SYS 67 Electrical system MP3 LT 400 i e 3 flash code Diagnostic code 1 flash A one flash code indicates a system where the se rial line is not present or is not detected Check the Immobilizer aerial wiring and change it if necessa 7 0 z T T Diagnostic code 2 flashes A two flash code shows a system where the con trol unit does not show the transponder signal This might depend on the inefficiency of the immobiliser aerial or the transponder Ar i Turn the switch to ON using several keys if the code is repeated even with the Master key check E UEM Wa um o9 the aerial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Diagnostic code 3 flashes A three flash code indicates a system where the control unit does not recognise the key Turn the switch to ON using several keys if the error code 07 05 0 5 0 5 is repeated even with the Master key replace the control unit If this is not the case reprogram the decoder 2 0 5 0 5 2 Battery recharge circuit The recharge circuit is provided with a three phase generator with permanent magneto flywheel The generator is directly connected to the voltage regulator ELE
159. n the flywheel cover N B AS ALREADY DESCRIBED IN THE LUBRICATION CHAP TER IT IS ESPECIALLY IMPORTANT THAT THE BY PASS HOUSING ON THE FLYWHEEL COVER IS FREE FROM WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON THE HEAD LUBRICATION CHANNEL IS EQUIPPED WITH A SHUTTER JET THIS GIVES A LOW PRESSURE HEAD LUBRICATION THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP The jet clogging impairs the head lubrication and the timing mechanisms A jet failure causes a decrease in the main bearing and connecting rod lubrication pressure Check that the surfaces exhibit no dents or deformations with special attention to the crankcase coupling and the crankcase cylinder surfaces Any defects in the crankcase gasket or matching surfaces see Flywheel cover coupling can cause pressurised oil leaks thereby affecting the connecting rod and main bearing lubrication pressure Check the main bearing seats that limit axial clearance in the crankshaft exhibit no wear For the dimensional check refer to the instructions about checking the axial clearance and the dimensions on the crankshaft Inspecting the crankshaft plain bearings To obtain a good bushing lubrication it is neces sary to have both an optimal lubricating pressure 4 bar and a good oil flow rate the bushings must be correctly positioned so as not to obstruct the oil supply channels The main bushings are comprise
160. nd back on the ground Remove the right lower coupling plate of the half arm by undoing the screws indicated in the picture SUSP 282 Remove the right upper screw and the left bottom screw of the parallelogram unit MP3 LT 400 i e Suspensions Fit the bracket locking the parallelo gram in the holes of the previously re moved screws use the screws sup plied with the tool and be careful to correctly centre the spacer in the bear ing Remove the nut fixing the steering con trol arm and keep the original washer in position Fit the steering guiding bracket in a straight riding position fix one end to the attachment of the half arm coupling flange and the other end to the screw fixing the steering control arm SUSP 283 MP3 LT 400 i e Suspensions Place the frame so that the sliders come into contact with the rim maxi mum diameter but without interfering with the tyre If required reposition the frame by operating the 3 adjustable support feet Fit the frame locking bracket Make sure the frame is adequately centred by checking with a gauge that the lugs along the vertical axis show the standard protrusion SUSP 284 MP3 LT 400 i e Suspensions Check that the pointers of both tyres are correctly aligned as shown in the picture Maximum misalignment al lowed 4 notches Specific tooling 020646Y Parallelogram and steerin
161. ng retainers from the par allelogram by loosening the retainers indicated For easy refitting operations remember to take note of the positions of the components Separate the half arms by hitting slightly with a wooden mallet where possible alternately to the left and right side of the parallelogram Remove the headstocks SUSP 252 MP3 LT 400 i e Suspensions Carry out a visual check of the upper and lower bearings on the headstocks and their seats Re place them in case of signs of abnormal wear SUSP 253 Suspensions MP3 LT 400 i e Check the ball bearings on the parallelogram arms Replace them in case of signs of abnormal wear Check the inside tracks of the parallelogram bear ings on the chassis For refitting follow the operations for removal but in reverse order lubricating the locking pins on the parallelogram half arms and observing the pre 5 scribed torques F c Boy m A wm PARALLELOGRAM DEVICE Name Torque in Nm Arm coupling screws 45 50 Screws fixing arms to side headstocks 45 50 Screws fixing arms to central headstock 45 50 Screws fixing the half arm coupling flange 20 25 Screws fixing tilt locking disc section 20 25 SUSP 254 MP3 LT 400 i e Suspensions Geared motor and Suspension locking system PIAGGIO Select the SYSTEM RESET option from the main menu Turn the key switch to ON Se
162. nnel and the M6 screw on the spark plug side with the thermostat support THE HEAD MAY BE REMOVED WITH THE CAMSHAFT ROCKING LEVER PINS AND FITTING BRACKET IF NECESSARY Loosen the 4 head cylinder fastening nuts in 2 or 3 times and in a crossed sequence Remove the head the 2 centring dowels the gasket and the lower chain guide sliding block N B DO NOT REMOVE THE DOWELS IF THEY ARE FORCED INTO THEIR SEAT CAUTION WHEN YOU HAVE TO REMOVE THE HEAD PREPARE A SUITABLE CONTAINER SINCE THE THERMAL GROUP CONTAINS COOLANT ENG 141 Engine MP3 LT 400 i e Removing the valves Using the appropriate tool fitted with an adaptor remove the cotters caps springs and valves Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush valve removing tool CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD FLY WHEEL SIDE AND TRANSMISSION SIDE Remove the oil guards using the special tool Specific tooling 020431Y Valve oil seal extractor Remove the spring supports N B BLOW THE SEATS WITH COMPRESSED AIR TO FACILI TATE THE SPRING SUPPORT REMOVAL ENG 142 MP3 LT 400 i e Engine Removing the cylinder piston assy Remove the timing chain Loosen the fastening screw and remove the spacer and the tightening sliding block N B IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE I
163. nto the connecting rod aligning the piston arrow the arrow facing to wards the exhaust Insert the locking ring into the special tool with the opening in the position indicated on the tool S left D right Place the wrist pin stop ring into position using a punch ENG 147 Engine MP3 LT 400 i e Install the pin lock using the key shown in the figure Specific tooling 020470Y Pin retainers installation tool N B THE TOOL FOR INSTALLING THE SNAP RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUSING Choosing the gasket Provisionally fit the piston into the cylinder without any base gasket Install a dial gauge on the special tool using the short union as shown in the figure Specific tooling 020475Y Piston position checking tool Using an abutment plane reset the dial gauge with a preload of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Install the tool on the cylinder without changing the dial gauge position Lock the tool using the original head fixing nuts Rotate the crankshaft up to the TDC the inver sion point of the dial gauge rotation Measure the deviation from the reset value Identify the thickness of the cylinder base gasket to be used for reassembly by the table below Cor rectly identify the cylinder base gasket thickness to keep the correct compression ratio
164. oil Injector INJEC 197 Injection MP3LT 400 i e The control unit is provided with a self diagnosis system connected to an indicator light in the in strument panel Failures are detected and restored by the diag nostic tester In any case when the fault is no longer present the data storage is automatically cleared after 16 cycles of use cold start running at regular engine temperature stop The diagnostic tester is also required to adjust the idle mixture Specific tooling 020680Y Diagnosis Tool The MIU injection ignition system carries out checks on the rpm indicator and the electric fan for radiator cooling The MIU control unit has a decoder for the anti theft immobilizer system The MIU control unit is connected to a diagnostic LED on the instrument panel that also carries out the deterrent flashing functions The MIU control unit power supply is furthermore controlled by the emergency switch to allow further safety of the scooter Precautions 1 Before fixing any part of the injection system check to see if there are any registered faults Do not disconnect the battery before checking for faults 2 The fuel supply system is pressurised at 300 kPa 3 BAR Before disconnecting the fast release fitting of the fuel supply pipe check that there are no naked flames Do not smoke Act with caution to avoid spraying fuel to your eyes 3 When fixing electric components ope
165. ol unit sta tuses can be identified and various light codes displayed Regardless of the code transmitted if at the end of the diagnosis the LED remains off permanently the ignition is enabled If however the LED remains on permanently it means the ig nition is inhibited 1 Previously unused control unit key inser ted a single 2 second flash is displayed after which the LED remains off permanently The keys can be stored to memory the vehicle can be star ted but with a limitation imposed on the number of revs 2 Previously unused control unit transpond er absent or cannot be used The LED is per manently ON in this condition no operations are possible including starting of the vehicle 3 Programmed control unit the service key in normal condition of use a single 0 7 second flash is displayed after which the LED remains off steadily The engine can be started 4 Programmed control unit Master key in a 0 7 sec flash is displayed followed by the LED re maining off for 2 sec and then by short 0 46 sec flashes the same number of times as there are keys stored in the memory including the Master key When the diagnosis has been completed the LED remains permanently OFF The engine can be started 2 3 4 0 7 0 46 0 46 I 2 ill 0 3 LL 5 Programmed control unit fault detected a light code is displayed according to the fault detected after which the LED remains o
166. osis connector 13 Main fuses These components are found in the battery com partment ELE SYS 55 Electrical system MP3 LT 400 i e 14 Electronic control unit 15 Start up remote control switch 16 Start up enabling remote control switch Remove the lid of the helmet compartment to reach it 17 Rider presence sensor Open the saddle and remove the cover to reach the rider presence sensor ELE SYS 56 MP3 LT 400 i e Electrical system 18 Parking control ECU Remove the shield back plate to reach it Conceptual diagrams Ignition 2 KEY 29 Main fuses 32 Battery 35 Key switch contacts 37 Injection load remote control 50 Engine rpm sensor 51 HV coil 56 Injection ECU ELE SYS 57 Electrical system 57 Immobilizer Aerial 66 Auxiliary fuses Battery recharge and starting KEY 1 Instrument panel 14 15 21 27 28 29 30 31 32 33 34 35 36 56 Brake pedal button Stop buttons Engine stop switch Magneto flywheel Voltage regulator Main fuses Starter button Start up enabling remote control switch Battery Start up remote control switch Starter motor Key switch contacts Stop bulbs Injection ECU ELE SYS 58 MP3LT 400 i e MP3 LT 400 i e 66 Level indicators and enable signals section Auxiliary fuses KEY 1 Instrument panel 29 32 35 37 41 42 43 45 46 47
167. p screw Guaranteeing that this position will be kept send a confirmation for the TPS reset procedure INJEC 236 MP3 LT 400 i e Injection Reset should be performed in the following cases on first fitting if the injection control unit is replaced N B THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE CALIBRATION INJEC 237 Injection MP3 LT 400 i e Lambda probe INJECTION LOADS Specification Desc Quantity Battery 12V 14Ah Fuse 15A Fuse 20A Key switch contacts Fuse 7 5A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan remote control lt OD Or BR po o INJEC 238 MP3 LT 400 i e Injection PIN RELATIONSHIP PIN PIN Component Reference value 4 11 Lambda sensor OV with throttle valve closed 1V with throttle valve fully opened The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas The signal generated is not of the proportional type but of the ON OFF type i e there is oxygen or there is not The sensor is positioned on the exhaust manifold before the catalytic converter in an area where the gas temperature is always high The temperature at which the sensor works is at
168. pacer shown in the picture Remove the pin connecting the engine swinging arm frame swinging arm The operations below are described once but ap ply to both sides of the swinging arm Remove the internal spacer Using a suitable pin remove the roller casings as shown in the photographs Using an appropriate tool plant new roller cas ings being careful to position the bearings with the O rings facing outwards Specific tooling 020244Y 15 mm diameter punch Characteristic Length of the swinging arm tube on the engine side 140 5 0 7 mm Frame side swinging arm plastic bushing shim 3 5 0 05 mm Length of the internal swinging arm spacer on the frame side SUSP 290 MP3 LT 400 i e L182 5 0 3 mm Length of the swinging arm tube on the frame side 222 5 0 2 mm Suspensions Lubricate roller casings and the plastic bushings with grease Insert the spacers Assembly both arms with the appropriate bolt Adjust the bolt as shown in the photograph Place the swinging arm frame side with the pro truding part facing the transmission side Recommended products AGIP GREASE PV2 Grease for steering bear ings pin seats and swinging arm Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 of the swinging arm Check that the silent block is not broken Other wise replace it Unscrew the retainer to the frame in ord
169. pensions MP3 LT 400 i e With the interface wiring disconnected from the parking electrical control unit and connected to the system check that the sensor resistance between pins 23 17 and 24 17 is between 774 and 946 Ohm at approximately 20 With the interface wiring disconnected from the control unit check the continuity between pin 23 and the red cable of the LEFT wheel turning sen sor connector the continuity between pin 17 and the brown cables of the LEFT and RIGHT wheel turning sensors and between pin 24 and the red cable of the RIGHT wheel turning sensor SUSP 278 MP3 LT 400 i e Suspensions In case of failures check the continuity between pin 23 and the connector green cable on the fuel tank after removing the chassis central cover be tween pin 17 and the yellow cables on both con nectors between pin 24 and the red cable on the connector With the interface wiring disconnected from the control unit and the connectors disconnected from wheel turning sensors check that pin 23 17 and 24 17 are insulated from each other and from earth With a thickness gauge check that the air gap be tween the screw head and the sensor is between 0 35 and 1 mm PRESSURE SWITCH SUSP 279 Suspensions MP3 LT 400 i e 1 PRESSURE SWITCH 2 HORN REMOTE CONTROL 3 FUSE No 11 7 5A Check 7 5 A fuse No 11 for efficiency W
170. phragm tightening clamp 16 18 LUBRICATION Name Torque in Nm Oil pump cover screws 0 7 0 9 Screws fixing pump to the crankcase 5 6 THERMAL GROUP AND TIMING SYSTEM Name Torque in Nm Spark plug 12 14 Head fixing stud bolts pe Head fixing nuts 10 12 Exhaust intake head fixing nuts 10 12 Head lubrication control jet 5 7 Coolant temperature sensor 10 12 Lambda probe on exhaust manifold 10 12 injector fixing screw 3 4 Counterweight screw 7 8 5 Tensioner sliding block fixing screw 10 14 Rpm timing sensor fixing screw 3 4 Valve lifter mass stop bell fixing screws 30 35 Inlet manifold screws 11 13 CHAR 12 MP3 LT 400 i e Characteristics Name Torque in Nm Tappet cover fixing screws 7 9 Throttle body fixing screws 11 13 Head fixing screws 10 12 Camshaft retaining bracket screws 4 6 5 6 Tightener screw Tightener fastening screws 11 13 Apply a preliminary torque of 7 Nm a crossed sequence Tighten by 90 in a crossed sequence tighten again by 90 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 8 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 7 9 External transmi
171. power supply If there is no volt age check the key switch contacts that fuse no 10 and its cable are in working order There is continuity between terminals 12 18 with the emergency cut off switch in the RUN position If there is no continuity check the contacts of the switch If no faults are found replace the electronic control unit ELE SYS 64 MP3 LT 400 i e Electrical system After removing the shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base from the connector With the ignition key switch at ON check there is battery voltage between the Red White and Black cables With MIU connector disconnected check the con tinuity between the Orange White cable and pin 7 of the interface wiring Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter ELE SYS 65 Electrical system MP3 LT 400 i e Virgin circuit When the ignition system is not encrypted any key will start the engine but limited to 2000 rpm The keys can only be recognised if the control unit has been programmed properly The data storage pro cedure for a previously not programmed control unit provides for the recognition of the master as the first key to be stored to memory this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisatio
172. r 0 8 0 05 mm CRANKCASE VENTILATION CHECK Specification Desc Quantity Device metal reed valve and decantation chamber Conceptual diagrams PRINCIPLE DIAGRAM Specification Desc Quantity A Camshaft B Cylinder head plane Cylinder crankcase plane D Water pump impeller E Minimum oil pressure sensor ENG 182 MP3 LT 400 i e Engine Specification Desc Quantity F Oil filter cartridge G To the oil sump H By pass valve L Oil pump M Mesh pre filter N Crankshaft O Connecting rod General characteristics The lubrication system is divided into two sections High pressure Low pressure The high pressure section includes all components located on the engine crankcase whereas the low pressure section only refers to the thermal group The trochoidal pump is installed in the sump and is controlled by a pair of gears To guarantee the integrity of the pump a pre filter is fitted This is a screw in type pre filter and the relevant plug serves at the same time as an engine oil drain plug The pump is controlled by means of a piston by pass calibrated to 4 bar This is located before the cartridge filter and both are installed on the flywheel cover so that the seal of the filter is subject to the pressure of the circuit The by pass located before the cartridge filter improves the operating conditions for the filter particularly with cold oil The filter is equipped with an an
173. rained is collected Remove the upper fittings on the parallelogram of the brake hydraulic pipes and the suspension lock indicated in the picture Remove the hydraulic pipe fitting fixing nuts indi cated in the figure from the support bracket SUSP 245 Suspensions MP3LT 400 i e Remove the suspension tilt locking device pipes from the headstock Remove first the flexible part of the calliper from the steering tube as shown in the picture and then remove the rigid part Remove the tone wheel wiring by disconnecting the connector on the fuel tank after removing the chassis central cover After that remove the retainers indicated in the figure SUSP 246 MP3 LT 400 i e Suspensions Remove the constant velocity universal joint from the steering bar by undoing the nut indicated in the picture Use a specific tool to remove the upper tightening ring nut of the steering tube Specific tooling 020055Y Wrench for steering tube ring nut Remove the hydraulic pipe support bracket SUSP 247 Suspensions MP3LT 400 i e Remove the steering tube lower ring nut and the protection cap indicated in the picture Now the steering tube can be removed Check that the roller tapered bearing does not show signs of abnormal wear If it does replace it SUSP 248 MP3 LT 400 i e Suspensions THE OPERATIONS DESCRIBED BELOW CAN ALSO BE CARRIED OUT E
174. rate with the battery connected only when actually required 4 When functional checks are performed check that the battery voltage is over 12V INJEC 198 MP3 LT 400 i e Injection 5 Before any attempt to start the vehicle check to make sure there is at least two litres of fuel in the tank Failure to respect this norm will damage the fuel pump 6 If the scooter is expected to remain unused for a long time refill the tank up to a little over half the level This will ensure the pump will be covered by fuel 7 When washing the vehicle be careful with the electric components and cable harnesses 8 When an ignition problem is detected start the checks from the battery and the injection system connections 9 Before disconnecting the MIU ECU connector perform the following steps in the order shown Set the switch to OFF Disconnect the battery Failure to respect this norm may damage the control unit 10 Do not invert the poles when fitting the battery 11 To avoid causing any damage disconnect and reconnect the MIU system connectors only if re quired Before reconnecting check that the connectors are dry 12 When carrying out electric inspections do not force the tester probes into the connectors Do not take measurements not specifically foreseen by the manual 13 At the end of every check performed with the diagnostic tester remember to protect the system connector with its cap Failure to observe this precaution may dama
175. rder to separate the two crankcases Electrical devices test PRINCIPLE DIAGRAM FOR TILT LOCKING ELECTRICAL SYSTEM KEY 1 Geared motor SUSP 269 Suspensions Brake calliper sensor Tilt unlocking locking control switch Potentiometer Rider presence sensor Left speed sensor Right speed sensor Diagnostic tester series line ON OD C1 F O NM Engine control unit 10 Direct battery 11 Live battery 12 To light switch 13 Fuse No 4 20A 14 Light remote control 15 Pressure switch 16 Horn remote control 17 Instrument panel 18 Tilt locking system control unit GEARED MOTOR MP3 LT 400 i e 8B 8C 28 38 SUSP 270 MP3 LT 400 i e Suspensions 1 GEARED MOTOR With the interface wiring disconnected from the eus control unit check the continuity between pin 28 eoooa lees and the white red cable between pin 38 and the 5 blue cable on the geared motor connector 9 Soc 2 I EE S LI U C With the interface wiring disconnected from the control unit check the continuity ofthe geared Ez arzt tor winding placing the multimeter probes on pins 9t 28 and 38 as indicated the figure D See a E TILT LOCKING UNLOCKING SWITCH SUSP 271 Suspensions MP3LT 400 i e 12V 12V 12V 26 35 33 6B 5C 3C 0 REST POSITION 1 LOCKING POSITION 2 UNLOCKING POSITION 3 TILT LOCKING UNLOCKI
176. re not suitable might damage the MIU control unit Instruments must be used with definitions over 0 1V and 0 5 W the precision must be greater than 2 Terminals setup TERMINAL LAYOUT Specification Desc Quantity Injection telltale light Rpm indicator signal Can L Line Lambda probe battery under permanent power supply Battery Immobilizer aerial Electric fan remote control Water temperature sensor Can H Line 00 Nj On R O PO INJEC 200 MP3 LT 400 i e Injection Specification Desc Quantity 11 Lambda probe 12 Engine stop switch 13 Engine rpm sensor 14 Fuel injector 15 Engine rpm sensor 16 Diagnostics socket output 17 Immobilizer LED 18 Ground lead Connected to the engine stop switch and the water tem perature sensor 19 20 Injection load remote control 21 22 HV coil 23 24 Start up enabling 25 26 Ground lead EMS circuit diagram SYSTEM DIAGRAM Specification Desc Quantity 1 Battery 12V 14Ah 2 Engine rpm sensor 3 Water temperature sensor 4 Immobilizer aerial 5 Stop button 6 Fuse 20A 7 Fuse 7 5A 8 Key switch contacts 9 Engine stop switch 10 Fuse 7 5A 11 Fuse 15A 12 Fuse 10A 13 Starter button INJEC 201 Injection MP3 LT 400 i e Specification Desc Quantity 14 Injection
177. recommended product Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Counterweight screw 7 8 5 Remove the central screw Install the valve lifting mass being careful to the proper positioning of the travel end ring Lubricate the mass and de compressor control pin ENG 161 Engine MP3 LT 400 i e Install the return spring and load it by about 3 4 turn Turn the engine to move the references to the top as shown in the figure intake end Insert the valve lifting device mass stop bell Tighten the retaining screw to the prescribed torque using the recommended product N B THE BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Check that the decompression mass is free and that it is pulled by the spring Locking torques N m Valve lifter mass stop bell fixing screws 30 35 ENG 162 MP3 LT 400 i e Engine Place the tightener cursor in the rest position keeping the retain tab pressed Install a new tightener on the cylinder using a new gasket Tighten the two fastening screws to the prescri bed torque Locking torques N m Tightener fastening screws 11 13 Insert the spring with the central screw and the washer Tighten the central screw to the prescribed
178. rench for LHS locking using a machine hexagon wrench Tighten the driven pulley shaft fastening nut using an offset wrench N B DUE TO THE HIGH TIGHTENING TORQUE USING DIFFER ENT WRENCHES SUCH AS A CONVENTIONAL POLYG ONAL BUSH MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF Locking torques N m Driven pulley nut 92 100 Install the driving pulley shaft cover positioning the tooth gap on the lower part with the reference mark on the transmission crankcase N B ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE ENG 107 Engine MP3 LT 400 i e Install the outside plastic transmission cover Tighten the 4 fastening screws to the prescribed torque Locking torques N m External transmission cover screws 7 9 End gear Removing the hub cover Drain the rear hub oil through the oil drainage cap located under the engine Remove the 7 fastening screws Remove the hub cover and the relevant gasket Removing the wheel axle Remove the countershaft Remove the wheel axis complete with gear ENG 108 MP3 LT 400 i e Removing the hub bearings Engine Check all bearings wear clearance and noise In case of anomalies proceed as follows To remove the gear shaft bearing on the engine crankcase use the following parts Specific tooling 001467Y014 Pliers to extract o 15 mm bearings 001467Y034 Pliers
179. rque Locking torques N m Electric motor coupling screws 11 13 SUSP 261 Suspensions MP3LT 400 i e Place the moulded washer of the flexible trans mission control lever shaft and the tongue Refit the flexible transmission control lever as shown in the figure Refit the potentiometer not forcing in the D type connector ensures a sole position with the con nector directed to the opposite side ofthe hydraulic pump Refit the hydraulic pump on the geared motor body and tighten the screws to the prescribed torque Fit but not tighten the pump stem coupling screw and refit the plastic protection cap The synchronisation procedure should be com plete when the installation is finished Locking torques N m Geared motor hydraulic pump tightening Screws 11 13 Remove the retaining Seeger ring of the bearing of the flexible transmission lever control shaft bearing Remove the bearing with the specific tool Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020362Y 12 mm guide SUSP 262 MP3 LT 400 i e Suspensions Extract the electric motor bearing with the specific tool Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20 mm guide Hold the crankcase in a perfectly horizontal posi tion heat it with a specific heat gun at about 120 C use the specific tool to fit the bearing of the flex ible transmission lever control sha
180. s INJECTION ELECTRONIC CONTROL UNIT CONNECTOR D Injection telltale light LED Brown Black 8 MROOOOO B S aee 19 Rpm indicator on instrument panel Yellow Tel wi CAN L Line White Blue Lambda probe White Green Live supply Red White Battery powered Orange Black Immobilizer aerial Orange White ON oO a F amp F WO DN Electric fan remote control Blue Yellow Coolant temperature sensor Sky blue Green 10 CAN H Line Pink White 11 Lambda probe Sky blue Black 12 Engine stop switch Green Black 13 Engine rpm sensor positive Red 14 Fuel injector Red Yellow 15 Engine rpm sensor negative Brown 16 Diagnosis Purple White 17 Immobilizer LED Red Green 18 Engine stop switch coolant temperature sen sor Grey Green ELE SYS 80 MP3 LT 400 i e 19 20 21 22 23 24 25 26 Not connected Injection load remote control Black Purple Not connected HV coil Pink Black Not connected Start up enabling switch Orange Blue Not connected Ground lead Black Electrical system PICK UP CONNECTOR 1 2 Injection ECU Red Injection ECU Brown VOLTAGE REGULATOR CONNECTOR 1 2 3 4 Battery positive Red Black Ground lead Black Battery positive Red Black Ground lead Black TURN INDICATOR CONTROL DEVICE CON NECTOR O N oO a 5h OON 9 10 11 Hazard butto
181. s 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 Replace the piston cylinder unit or just the piston rings fitted properly Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal Worn valve oil guard Replace the valve oil guard 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
182. s support assy GRUPPO SUPPORTO BILANCERI Time Code Action Duration 1 001044 Camshaft Replacement 2 001148 Valve rocking levers Replacement 3 140021 Camshaft timing system pulley Re plac TIME 353 Time MP3 LT 400 i e Cylinder head cover HEAD COVER Code Action Duration 1 001089 Head cover Replacement 2 001093 Spark plug Replacement 3 001088 Head cover gasket Replacement TIME 354 MP3 LT 400 i e Flywheel cover Time COPERCHIO VOLANO Code Action Duration 1 001087 Flywheel cover Replacement 2 001123 Oil filter Replacement 3 001124 By pass valve Replacement 4 001062 Water pump command shaft Re placement 5 001187 Overall sealing Replac 6 007007 Water pump rotor Replacement 7 001188 Water pump shaft sealing ring Re plac 8 001150 Flywheel cover gasket change 9 001160 Minimum oil pressure sensor Re placement 10 001074 Oil vapour recovery pipe Replace ment 11 001102 Net oil filter change Cleaning 12 003064 Engine oil change TIME 355 Time Driven pulley MP3LT 400 i e DRIVEN PULLEY Code Action Duration 1 001022 Clutch Replacement 2 001012 Driven pulley overhaul 3 001110 Driven pulley Replacement 4 001155 Clutch bell Replacement TIME 356 MP3 LT 400 i e Time OIL PUMP Code Action Duration 1 001042 Oil pump overhaul 2 001051 Belt Timing chain Replacement
183. screws fixing the camshaft retaining bracket using a brush Apply the recommended product to the fixing screws and tighten to the prescribed torque Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque being careful not to damage the inside hexagon Locking torques N m Camshaft retaining bracket screws 4 6 Install the intermediate gear with torque limiter the flywheel and its cover as described in Chapter i i PSU Wm Flywheel and start up system and in Chapter Flywheel cover N B FOR MORE CONVENIENCE INSTALL THE FLYWHEEL COVER WITHOUT THE COOLING SYSTEM SLEEVES Using the TORX wrench remove the timing check cap ENG 160 MP3 LT 400 i e Engine Insert the belt on the camshaft control timing rim Insert the timing rim on the camshaft checking that the references are aligned N B DURING THE STROKE CHECK KEEP THE BELT TEN SIONED BY PRESSING ON THE TIGHTENER COMPART MENT SIDE Keeping the belt slightly pulled turn the crank shaft using the driving pulley to make the reference on the magnet support collimate with that on the flywheel cover Install the counterweight mass Centre using the bell fastening screw Lock the mass fixing screws to the prescribed torque using the
184. ses N B THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceed the require ments of API SL ACEA A3 JASO MA specifica tions Locking torques N m Engine oil filter 12 16 Engine oil drainage plug 24 30 Check MAX MIN 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 MAIN 39 Maintenance MP3 LT 400 i e 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 line will be lower in order to carry out a cor rect check wait at least 10 minutes after the en gine has been stopped so as to get the correct level 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 bns Restoring the level from the MIN to the MAX marks ID E x requires approx 400 m of oil Engine oil filter 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 M
185. shown in the photo Remove the cable from the retaining clip on the flywheel cover ENG VE 88 MP3 LT 400 i e Engine from vehicle Remove the lower screw of the left hand shock absorber Remove the engine swinging arm fixing pin by undoing the nut and operating on the head of the pin as shown in the photograph The engine is now free When refitting the engine onto the scooter carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter Check the engine oil level and if necessary top it up with the recommended type Fill and bleed the cooling circuit Check accelerator and electric devices for correct functioning CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY ENG VE 89 INDEX OF TOPICS MP3 LT 400 i e Engine This section describes the operations to be carried out on the engine and the tools to be used Automatic transmission Transmission cover Loosen the 4 fastening screws Extract the outside plastic transmission cover Using a screwdriver remove the driven pulley axle cover near the bottom of the cap Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush Remove the nut and the two washers N B DUE TO THE HIGH TIGHTENING TORQUE USING DIFFER ENT WR
186. side bushings shown in the figure exhibit no signs of abnormal wear and measure the inside diameter CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHINGS Characteristic Maximum admissible diameter 30 12 mm Standard diameter 30 021 mm Measure the pulley sliding bushing outside di ameter shown in the figure Characteristic Minimum admissible diameter 29 95 mm Standard diameter 29 959 mm Check that the rollers are not damaged or worn Characteristic Minimum admissible diameter 24 5 mm Standard diameter 24 9 mm ENG 103 Engine MP3 LT 400 i e Check the guide shoes for the variator back plate are not worn Check the wear of the roller housings and of the belt contact surfaces on both pulley halves Refitting the driving pulley Installing the roller container Install the spacer with the internal chamfer facing towards the inside Position the rollers on the half pulley as shown in the figure The closed side must rest on the inside thrust face of the roller container Assembly the half pulley with the roller contrast plate and sliding blocks ENG 104 MP3 LT 400 i e Engine Insert the half pulley on the crankshaft Insert the spacer bushing Installing the fixed driving half pulley Insert the spacer Install the fixed driving half pulley and check that it is in contact with the spacer and with the guide
187. specting the injector circuit INJEC 214 MP3 LT 400 i e Injection INJECTION LOADS Specification Desc Quantity Battery 12V 14Ah Fuse 15A Fuse 20A Key switch contacts Fuse 7 5A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan remote control Check that the injection load 15A fuse No 2 works gt properly Check that the live control unit power supply 7 5A fuse No 10 works properly Check the efficiency of the injection load remote control Check the resistance of the energising coil between pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the remote control INJEC 215 Injection MP3 LT 400 i e Check the power supply line of the injection load remote control energising coil after switching to ON make sure there is battery voltage for two seconds between the Red White cable and Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC INJEC 216 MP3 LT 400 i e Injection
188. ssion cover screws Flywheel cover screws FLYWHEEL COVER 11 13 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 14 4 5 Water pump impeller CRANKCASE AND CRANKSHAFT Name Torque in Nm Countershaft fixing nut 25 29 Engine oil filter 12 16 Engine oil drainage plug 24 30 Engine crankcase coupling screws 11 13 Oil pump screws 5 6 Gear mounting on crankshaft screws 10 12 Bulkhead screws for oil pump housing cover 8 10 COOLING Name Torque in Nm Water pump impeller 4 5 Water pump cover screws 3 4 Thermostat cover screws 3 4 3 Bleed screw Overhaul data Assembly clearances CHAR 13 Characteristics MP3 LT 400 i e Cylinder piston assy HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED Specification Desc Quantity A 43 2 mm B 43 mm CYLINDER PISTON Specification Desc Quantity Cylinder diameter C 85 8 0 018 0 01 mm Piston P 85 768 0 014 mm CYLINDER PISTON COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder Piston A 85 790 85 797 85 754 85 761 0 029 0 043 Cylinder Piston B 85 797 85 804 85 761 85 76
189. ssis central cover Remove the footrest Remove the three tank retainers CHAS 338 MP3 LT 400 i e Chassis Remove the two lower bracket retainers indicated in the figure Disconnect the electric wiring and the fuel pipes See also Footrest Top case Rear Remove the four fixing screws of the cover and release it from the two leverages Handles and top side fairings Operating from the rear case remove the two screws indicated in the photograph Remove the ceiling fitting indicated in the photo graph and remove the internal screw indicated in the photograph Remove the backrest cushion CHAS 339 Chassis MP3LT 400 i e Remove the six screws indicated in the figure Radiator cover Remove the two front screws indicated in the photograph Remove the two lower retainers with the bushing CHAS 340 MP3 LT 400 i e Chassis Remove the two rear retainers and then the two wheelhouse front retainers Remove the two screws fixing the radiator lower protection to the shield back plate After that press up and pull the protection front part so as to release it from the radiator frame CHAS 341 INDEX OF TOPICS MP3 LT 400 i e Pre delivery Carry out the listed tests before delivering the vehicle Warning Be very careful when handling fuel Position the plastic cover supplied with the cou pling on the steering tube as sho
190. st compression lining with an L section ENG 149 Engine MP3 LT 400 i e Refitting the cylinder Insert the cylinder base gasket with the thickness determined above Using the fork and the ring clamp fit the cylinder as shown in the figure N B BEFORE FITTING THE CYLINDER CAREFULLY BLOW THE LUBRICATION DUCT AND LUBRICATE THE CYLIN DER LINER CHECK THE PRESENCE OF THE TWO REF ERENCE DOWELS Specific tooling 020468Y Piston assembly band 020512Y Piston fitting fork Inspecting the cylinder head Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or distorted Characteristic Maximum allowable run out 0 1 mm In case of irregularities replace the head Check the sealing surfaces for the intake and ex haust manifold Check thatthe camshaft and the rocking lever pin capacities exhibit no wear Check that the head cover surface is not worn Check that the coolant sealing pad exhibits no oxidation Inspecting the timing system components Check that the guide shoe and the tensioner shoe are not worn out Check that the crankshaft pinion and the cam shaft timing gear and crankshaft pinion exhibit no wear In case of wear of the sliding blocks replace them In case of wear of the chain or rim replace the en tire unit ENG 150 MP3 LT 400 i e Engine N B IF THE CHAIN HAS DAMAGED THE PINION REPLACE THE
191. switch re placement 12 005149 Brake pedal switch Repl Transmissions X 5 LOCKS TRANSMISSIONS Code Action Duration 1 003094 Tilt locking calliper control cable re placement 2 002082 Fuel tank door opening drive Re placement 3 002083 Saddle opening transmission Re placement 4 002093 Top box opening transmission Re placement 5 002026 Parking brake transmission re placement TIME 389 Time MP3 LT 400 i e Helmet bay PORTACASCO Code Action Duration 1 005046 Battery cover change 2 005026 Helmet compartment bulb Replace ment 3 005027 Helmet compartment bulb support Replacement 4 004016 Helmet compartment Replacement 5 004142 electric socket Replacement 6 005033 Glove box light switch Replace ment TIME 390 MP3 LT 400 i e Rear side fairings Time REAR COVERS Code Action Duration 1 004081 Top box lid Replacement 2 004174 Top box leverage 3 005048 number plate holder Replacement 4 004082 Top box gasket Replacement TIME 391 Time Front suspension MP3 LT 400 i e FRONT SUSPENSION Code Action Duration 1 003010 Front suspension Service 2 003111 Side steering tube replacement 3 003038 Front wheel axle Remov and refitt 4 003040 Front wheel bearings Replacement 5 003107 Sliding stems replacement 6 003113 Front shock absorber replacement TIME 392 MP3 LT 400 i e Cooling system
192. t 2 002059 Right hand knob Replacement 9 003001 Handlebar Replacement 4 003061 Accelerator transmission adjust 5 002063 Complete throttle transmission Re placement 6 002071 Left knob Replacement 7 002037 Brake lever Replacement 8 002067 Rear brake pump Replacement 9 002024 Front brake pump Replacement 10 004162 Mirror support and or brake pump fit ting U bolt Replacement 11 003059 Counterweight Replacement TIME 377 Time MP3 LT 400 i e Swing arm 1 1 1 po EA 25 SWINGING ARM Code Action Duration 1 004058 Silent block Replacement 2 003081 Swinging arm support flange Re placement 9 001072 Engine frame connection swinging arm Replacement 4 003080 Swinging arm on frame Replace ment TIME 378 Time MP3 LT 400 i e Seat m 2d N Ps n NA PA Pd p T He ii _ A A E 9 d T 2 f EN Pr R UC y i 4 V wW N N _ az SADDLE Action Duration Code Saddle Replacement 004003 TIME 379 Time Instrument panel MP3 LT 400 i e INSTRUMENT PANEL Code Action Duration 1 004021 Shield upper section Replacement 2 005014 Odometer Replacement 3 004099 Odometer housing Replacement 4 004035 TIME 380 Instrument panel Replacement MP3 LT 400 i e Time Locks 4 E g uU eX d Locks Code Action Duration
193. t screw indicated in the picture BRAK SYS 317 INDEX OF TOPICS Cooue SYSTEM lere je MP3 LT 400 i e Cooling system Circuit diagram This is a forced circulation cooling system with continuous venting and air pressurisation Circulation takes places by a centrifugal pump driven by the countershaft The pump delivers the coolant to the thermal group The two way thermostat support is connected in output to the head One way is connected to the pump and the other to the radiator of the horizontal circulation type The radiator output is directly connected to the pump The expansion tank is connected in parallel to the radiator The radiator hot box is connected to the upper side of the expansion tank in air The radiator cold box is connected to the lower side of the expansion tank in the fluid When the engine is cold the thermostat output to the radiator is closed even though there is still a little flow for de aeration obtained by a hole into the closing plate In this case the circulation into the thermal group is active to ensure an even heating Once the working temperature has been reached the main circulation on radiator and expansion tank starts With the small openings in the thermostat there is a flow overlapping recirculation and main one When the temperature is higher the thermostat allows excluding the recirculation to favour the main circulation In this case the flow is consistent in the e
194. t the water pump cover is not deformed or dented Check that the sealing O ring is in good working order Otherwise replace the component Correctly fit a new O ring do not allow it to come into contact with grease or oil CAUTION FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O RING Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque Locking torques N m Water pump cover screws 3 4 See also Engine COOL SYS 323 Cooling system Flywheel cover Water pump overhaul MP3 LT 400 i e If noise or loss of liquid at the drain bore of the water pump is discovered it will be necessary to overhaul the pump as described in the Engine Water pump Chapter Proceed to carry out a few preliminary operations as described below Place the vehicle on its centre stand and on flat ground Remove the tail section as described in the Bodywork Chapter Empty the cooling system by removing the cou plings on the pump cover and the filler plug on the expansion tank CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the water pump cover as indicated in the figure by loosening the six fixing screws Follow the instructions provided in the Engine Water pump chapter to inspect the pump Refill and drain the system again once after hav ing repaired the damage and reinstalled all the components N B
195. tenance AIR INSIDE THE INTEGRAL CIRCUIT IS SPECIALLY DAN GEROUS 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 FMVSS DOT 4 Synthetic fluid See also Rear combined Headlight adjustment MP3 LT 400 i e Proceed as follows Position the unloaded vehicle in running order sure onto a flat surface 10 m away from a half lit and with the tyres inflated to the prescribed pres 10m e white screen make sure the scooter axis is per 2 5 pendicular 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 N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED MAIN 44 INDEX OF TOPICS TroustesHooTINe TROUBL Troubleshooting MP3 LT 400 i e 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 i
196. ter AHEAD go to 5 5 Measure the pressure with cold and idling engine ENG 184 MP3 LT 400 i e Engine STANDARD VALUES Specification Desc Quantity 20 C Temperature 1400 rpm approx 4 5 bar N B RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE DIAGNOSTIC TESTER Specific tooling 020680Y Diagnosis Tool YES go to 6 NO go to 12 6 Let the engine warm up and repeat the check with hot oil STANDARD VALUES Specification Desc Quantity 80 C Temperature 1400 rom approx 1 5 bar YES go to 7 NO go to 8 7 Replace the oil minimum pressure switch 8 If pressure lower than 1 3 1 5 bar is measured AHEAD go to 9 9 Replace the oil filter and repeat the pressure check with oil at 80 C YES go to 10 NO go to 13 10 The failure was fixed It is recommended to respect the suggested number of kilometres covered 11 Check and restore the electrical system 12 If pressure lower than 4 bar is measured AHEAD go to 9 13 Remove the flywheel cover and check the by pass and the cover sealing gasket efficiency towards the case internal side as described in the Flywheel cover chapter YES go to 14 NO go to 15 14 Check whether there is an irregular clearance on the crankshaft axial clearance see the Crankcase and crankshaft chapter radial clearance especially in the direction of the cylinder axis clearance according to the direction of rotation with the connec
197. th the Hazard button pressed 5 If there is no voltage check that there is continuity in the relevant cable harness 6 Check that the turn indicator control device is powered by make sure there is voltage between the Blue and Black cables between the Yellow Black cable and the Black cable with the key switch set to ON 7 Check that the cable harnesses are not interrupted wherever no voltage is detected 8 Check that the cable harness connecting the bulbs to the turn indicator control device White Blue and Pink cables are not interrupted 9 Check the bulbs ground connection Lights list KEY 1 Battery 2 Fuse No 5 3 Key switch contacts 4 Fuse No 3 5 Fuse No 9 6 Fuse No 11 ELE SYS 74 MP3 LT 400 i e Electrical system 7 Headlight remote control 8 Key switch contacts 9 Fuse No 12 10 Tail light bulbs 11 License plate bulbs 12 Front tail light bulb 13 Parking control ECU 14 Headlight with twin filament bulb 15 Light switch WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED TAIL LIGHT LINE CHECK 1 Check that bulbs operate properly 2 Check fuses No 3 and 12 3 Check key switch contacts 4 Check there is voltage between the Yellow Black of fuse No 12 and the ground lead Otherwise check the continuity of cable harnesses 5 Check the continuity of the bulb cable harnesses using fuse No 12 Yellow Black cables
198. the Black Purple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC INJEC 229 MP3LT 400 i e Injection Check the presence of fixed voltage between the grey black cable of the remote control base and earth Ifthere is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC INJEC 230 MP3 LT 400 i e Injection Check there is voltage between pins 22 and 26 of the interface wiring for around two seconds when switching to ON Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con trol disconnected Primary resistance 1 Ohm Inspecting the spark plug shielded cap Measure the shielded cap resistance Electric characteristic Resistance 5 KQ INJEC 231 Injection MP3 LT 400 i e If different values are measured lt 1 gt 20 replace the shielded cap N B A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM FOR INFORMAT
199. the bushes and if no anomalies are found replace the starter motor 8 Low trailing speed Low electrical absorption Repeat the test bridging the power terminals of the starter remote control switch or even better replacing them Check the new values YES go to 12 NO goto 13 ENG 126 MP3 LT 400 i e Engine 9 High trailing speed Low electrical absorption The engine turns too freely check the compression end pressure If the values are not correct proceed as follows 10 The starter motor works properly 11 Check the rotation of the armature 12 Replace the starter remote control switch 13 Test the battery again and if necessary replace the starter motor N B IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE NOISE CHECK THE FREEWHEEL OF THE TORQUE LIMITER SEE THE FLYWHEEL AND STARTER SYSTEM CHAPTER STARTER MOTOR Specification Desc Quantity Type Mitsuba sm13d Power 0 9 kW BATTERY Specification Desc Quantity Capacity 14 Ah Starting current 125A START UP REMOTE CONTROL SWITCH Specification Desc Quantity Type SEALED Maximum load 150 A continuous STARTER TRANSMISSION Specification Desc Quantity Ring gear and freewheel coaxial to the flywheel Intermediate gear with built in torque limiter The starter system has a transmission between the motor armature and engine shaft equipped with freewheel coaxial to the flywheel and torque limiter on the interme
200. the clamps of the cable to an auxiliary battery Activate the fuel pump with the active diagnosis Check that within 15 approx 70 cm of fuel is delivered with adjustment pres sure of approx 3 BAR Specific tooling 020480Y Petrol pressure check set Proceed with the injector seal test Dry the injector outlet with a blast of compressed air Activate the fuel pump Wait for one minute making sure there are no leaks coming from the injector Slight oozing is normal Value limit 1 drop per minute Immobiliser circuit The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys tem The immobilizer is an anti theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit The code is integrated in a transponder in the key block This allows the driver clear operation without having to do anything other than just turn ing the key The Immobilizer system consists of the following components an electronic control unit INJEC 219 Injection MP3 LT 400 i e immobilizer aerial Master key with incorporated transponder red key service key with incorporated transponder black key HV coil diagnosis LED The diagnosis LED also works as a theft deterrent blinker This function is activated every time the ignition switch is turned to the OFF position or the emergency stop switch is turned to th
201. ti drain back valve and a pressure relief valve the latter intervenes when the filtering mass causes a pressure drop above 1 0 2 bar These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged The filtered oil is used to lubricate the water pump shaft and once at the engine crankcase to lubricate the main bearings the connecting rod head and the piston cooling nozzle on the transmission side bearing The main bearing on the transmission side is fitted with an oil seal and the respective drain line The supply line for the timing system comes from the flywheel side bearing the supply to the head is controlled by the respective spray jets in the engine crankcase The components of the timing system function with low pressure oil lubrication The camshaft bearings are installed directly on the aluminium of the head the camshaft axial clearance is partially compensated by the oil supplied to the smaller diameter bearing The camshaft supplies the lubricant to the rocking levers via the holes provided these are installed in a position to ensure that the lubrication is maintained even after the scooter has stopped This is ach ieved when the camshaft reaches its most usual and likely position when the engine is shut off The oil used to lubricate the head returns to the sump via the chain casing channel and therefore it also provides lubrication for the chain ENG 183 Engine MP3 LT 400 i e
202. ting rod in quadrature YES go to 16 NO go to 17 15 Replace the faulty components Flywheel cover chapter 16 Overhaul the engine Crankcase and crankshaft chapter 17 Open the engine crankcase and remove the oil pump as described in the Crankcase and crank shaft chapter ENG 185 Engine MP3 LT 400 i e Check the oil pump as described in the following pages Check that the cooling nozzle and the timing system feeding jet are properly installed Visually inspect the crankshaft couplings and their size Crankcase and crankshaft chapter N B POTENTIAL IRREGULARITIES IN COUPLINGS AND THE TIMING SYSTEM COMPONENTS CAN NOT BE DETECTED WHEN INSPECTING THE LUBRICATION PRESSURE THEY MAY BECOME EVIDENT BY AN INCREASE IN NOISE N B IN CASE OF IRREGULAR PRESSURE ON THE CRANKCASE CARRY OUT A VISUAL AND DI MENSIONAL INSPECTION OF THE TIMING SYSTEM COMPONENTS SEE THERMAL GROUP AND TIMING SYSTEM CHAPTER Oil pressure check 1 Incase of oil leaks from the oil filter or from the flywheel cover coupling gasket check the lubrication pressure AHEAD go to 2 2 Install the special tool Specific tooling 020193Y Oil pressure check gauge 020434Y Oil pressure check fitting AHEAD go to 3 3 Check the system pressure with cold engine and medium high speed Standard pressure lt 6 bar YES go to 4 NO go to 5 4 Replace the damaged components 5 Check the working order of the adjustment by pass see
203. to the pre scribed torque and use Threadlock Upon refitting adjust the cable properly so thatthe switch is pushed when the system is unlocked Refit the spring toothed sector unit hold the crank case in a perfectly horizontal and stable position place the spring toothed sector unit keeping it per fectly perpendicular to the bearing already fitted on the crankcase if necessary slightly hit the unit shaft end with a mallet and protect the thread by screwing in a nut SUSP 260 MP3 LT 400 i e Suspensions Fit the pinion and align the reference on the pinion teeth with the reference indicated on the second slot of the toothed sector Grease the pinion and the toothed sector with spe cific grease Refit the toothed sector spacer Recommended products MONTBLANC MOLYBDENUM GREASE MON TBLANC MOLYBDENUM GREASE Grease with molybdenum disulphide Lubricate the interference areas match the crank case halves with slight hits of a mallet to get them into contact Place the flexible transmission supporting bracket refit the four screws screw them to the prescribed torque Locking torques N m Geared motor crankcase halves coupling Screws 11 13 Refit the electric motor check the position is cor rect by means of the reference indicated during removal The motor should be so positioned that it does not protrude from the reduction unit mould see figure Tighten the screws to the prescribed to
204. tters equipped with part 012 removal tool 020382Y012 bush valve removing tool N B DO NOT CHANGE THE VALVE FITTING POSITION FIT THE VALVE SPRINGS WITH THE REF ERENCE COLOUR ON COTTER SIDE TURNS WITH GREATER PITCH Inspecting the cam shaft Check that the camshaft bearings exhibit no scores or abnormal wear Using a micrometer measure the camshaft bearings STANDARD DIAMETER Specification Desc Quantity Bearing A 42 0 060 0 085 mm Bearing B diameter 20 0 020 0 041 mm ENG 155 Engine MP3 LT 400 i e MINIMUM ADMISSIBLE DIAMETER Specification Desc Quantity Bearing 41 910 Bearing diameter 19 940 mm A Using a gauge measure the cam height STANDARD HEIGHT Specification Desc Quantity intake 33 774 mm discharge 33 273 ADMISSIBLE LIMITS Specification Desc Quantity intake 33 526 mm discharge 33 026 mm Standard axial clearance 0 0 22 mm Maximum admissible axial clearance 0 3 mm If any of the above dimensions are outside the specified limits or there are signs of excessive wear replace the defective components with new ones Check that the retaining plate seat shown in the figure exhibits no wear ENG 156 MP3 LT 400 i e Engine Check that the automatic valve lifting device cam the travel end roller and the rubber abutment on the containment bell are free from wear Check that the valve lifting spring
205. type The control unit controls two important parameters Ignition advance This is optimised from moment to moment in accordance with the engine revs engine load temperature and environmental pressure With the engine at idle the ignition advance is optimised to stabilise the speed at 1500 100 rpm Magnetisation time The coil magnetisation time is controlled by the control unit The power of the ignition is increased during the engine start up phase The injection system recognises the four stroke cycle so the ignition is only commanded in the com pression phase Specific tooling 020331Y Digital multimeter Check that the injection load 15A fuse No 2 works properly Check that the live control unit power supply 7 5A fuse No 10 works properly INJEC 228 MP3 LT 400 i e Injection Check the efficiency of the injection load remote control Check the resistance of the energising coil between pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the remote control Check the power supply line of the injection load remote control energising coil after switching to ON make sure there is battery voltage for two seconds between the Red White cable and Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of
206. ulated from the ground Specific tooling 020331 Y Digital multimeter Circuit leak test Install the specific tool for checking the fuel pressure with the pipe fitted with the gauge Check during regular operation by placing the ap propriate tool between the pump and the injector With battery voltage gt 12 V check that the fuel pressure is 3 BAR and that the input current is 2 8 A With the battery voltage 12 V check the pump flow rate by disconnecting from the injector the pipe equipped with the pressure gauge of the appropriate tool Get a graded burette with a flow rate of approximately 1 L Rotate the pump using the active diagnoses of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilise at approx 2 9 BAR Pay attention not to choke the pipe too much as the pressure remains equal to 3 BAR while the flow diminishes Check that within 15 seconds the pump has a flow rate of approx 300 Specific tooling INJEC 212 MP3 LT 400 i e Injection 020480Y Petrol pressure check set Fuel filter check Disconnect the terminals from the electric pump Remove the screw shown in the picture Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump support as shown in the picture INJEC 213 Injection MP3 LT 400 i e Remove the filter from the pump support In
207. upplied with a throttle valve position sensor that is pre calibrated Pre calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre set reference conditions Pre calibration ensures optimal air flow to control idling This regulation must not be tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition advance The throttle body after the pre calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor can also assume various fitting positions For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another To obtain the optimum fuel mixture especially at small openings of the throttle valve it is essential to match the throttle body with the control unit following the procedure known as TPS resetting With this operation we inform the control unit as the starting point of the mV value corresponding to the pre calibrated position To reset proceed as follows INJEC 235 Injection MP3 LT 400 i e Connect the diagnostic tester Switch to ON Select the functions of the diagnostic tester on TPS RESET Specific tooling 020680Y Diagnosis Tool Make sure that the throttle valve with the control is supporting the sto
208. use box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC INJEC 210 MP3 LT 400 i e Injection Check the presence of fixed voltage between the grey black cable of the remote control base and earth If there is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC INJEC 211 Injection MP3 LT 400 i e After switching to ON check that there is battery voltage for about 2 seconds between the Black Green cable of the pump connector and the ground lead with the pump connector disconnec ted Otherwise check the continuity of the Black Green cable between the pump connector and the remote control base Check the efficiency of the earth line of the fuel pump by measuring the continuity between the pump connector black cable system side and the earth If when switching to ON the pump continues to turn after 2 seconds of activation check with the control unit disconnected and the injection load re mote control disconnected that the Black Purple cable pin 20 on the interface wiring is ins
209. ut of the bleed screw Close the bleed screw and tighten to the prescribed torque Close the brake system tank N B IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION EXAMINE ALL THE FIT TINGS IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS WHEN CARRYING OUT THE OPERATION BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER AND ON THE DISC IN THIS CASE CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE DISC Specific tooling 020329Y Mity Vac vacuum operated pump Locking torques N m Oil bleed screw 12 16 N B TO AVOID THAT THE AIR INSIDE THE SYSTEM BE PUMPED FROM ONE PIPE TO ANOTHER BLEED FOLLOWING THIS PROCEDURE Remove the rear brake reservoir cover 2 While checking that there is brake fluid inside the reservoir operate the brake lever and keep the system under pressure BRAK SYS 312 MP3 LT 400 i e Braking system With a glass pipe connect the bleed valve to the rear brake calliper 19 and loosen it until the brake fluid begins to drain Close the valve and restore system pressure Perform this operation until brake fluid without air bubbles comes out of the pipe Restore reservoir level by topping up with the recommended brake fluid and assemble the brake cover Remove the front brake reservoir cover 3 While checking that there is brake fluid inside the r
210. vel end washer N B BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING TO FALL INTO THE ENGINE THROUGH THE CHAIN COM PARTMENT Align the reference marks on the timing chain rim with those on the head ENG 138 MP3 LT 400 i e Engine Loosen the central screw on the tensioner first Unscrew the 2 fastening screws and remove the tensioner with relevant gasket Remove the inside hexagon screw and the coun terweight as shown in the figure Remove the timing belt rim from the camshaft Remove the timing belt rim Removing the cam shaft Unscrew the 3 fastening screws and remove camshaft retaining bracket N B REMOVING THE FASTENING SCREWS MAY BE DIFFI CULT BE CAREFUL NOT TO DAMAGE THE INSIDE HEX AGON IF NECESSARY SEPARATE THE THREADS IN ADVANCE ENG 139 Engine MP3 LT 400 i e Remove the cam shaft Remove pins and rocking levers by the transmis sion side holes Removing the cylinder head Remove the spark plug Remove the cooling system outlet sleeve with thermostat Remove the coolant temperature sensor N B THE SENSOR CONTROLS BOTH INJECTION AND THE AN ALOGUE INSTRUMENT ON THE PANEL TO CHECK THIS COMPONENT SEE THE INJECTION CHAPTER ENG 140 MP3 LT 400 i e Engine Remove the 2 fastening nuts on the head on the exhaust and on the intake side Remove the two M6 screws into the distribution cha
211. vs irregularly ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing Intake sleeve Filter box Ignition system Spark plug wear check Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance TPS reset successful TPS reset successful Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda sensor INJEC 204 MP3 LT 400 i e Injection Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER ENGINE IRREGULAR PERFORM ANCE ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda sensor Spark plug Shielded cap HV cable HV coil Air filter Filter box sealing Intake sleeve sealing Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Fuel supply Fuel level in the tank Fuel pressure Fuel filter Injector capacity Spark plug power supply Intake system Engine knocking PRESENCE OF KNOCKING COMBUSTION SHOCKS Possible Cause Operation Presence o
212. wheel cover Install a new oil filter lubricate the gasket screw on and finally tighten to the prescribed torque Locking torques N m Engine oil filter 12 16 Install the supply hose to the cylinder and con nectthe return hose to the pump cover using 3 new clamps N B TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS PAYING ATTENTION NOT TO CONSTRICT THE HOSES BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUF FICIENTLY Install the pre filter again and insert the engine oil drain plug tightening to the prescribed torque Refill the engine with the prescribed type of oil Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Syn thetic oil Locking torques N m Engine oil drainage plug 24 30 Lubricate the intermediate gear seat with torque limiter on the flywheel cover Align the water pump movement sensor with a reference and install the flywheel cover as descri bed in the Flywheel cover chapter ENG 123 Engine MP3 LT 400 i e Install a new gasket on the engine crankcase Check the presence of the three centring dowels Turn the crankshaft in order to align the counter shaft movement sensor with a reference point on the crankcase see figure Repeat the alignment for the water pump crank shaft using the same reference point on the en gine N B THIS PREPARATION IS USEFUL PARTICULARLY IN THE EVENT OF REPAIRS W
213. wn in the figure If a customer wishes to have mudflaps installed proceed as follows e Place the flap in the mudguard inner du side as shown in the figure making the 4 securing holes coincide Fit the 4 washers on the mudguard out er side and always on the same side insert the 4 screws and tighten to the prescribed torque Locking torques N m flap fixing screws 2 Aesthetic inspection Appearance check Paintwork Fitting of plastics Scratches Dirt Tightening torques inspection Safety locks check Visually check that there is a yellow mark on the following clamps Front suspension Front left wheel fixing screws Front right wheel fixing screws Speed sensor fixing screws Screw pipe coupling tilt locking gripper PRE DE 343 Pre delivery MP3 LT 400 i e rear suspension Shock absorbers upper fixing screw Lower screw fixing right shock absorber to supporting plate Lower screw fixing left shock absorber to engine Screws fixing muffler supporting arm to engine Front brake Screws fixing brake disc to left wheel Screws fixing brake disc to right wheel Screws fixing front brake callipers Screws fixing brake pipe coupling to callipers Rear brake Parking rake calliper fixing screws Screws fixing calliper to muffler supporting arm Screws fixing brake pipe coupling to calliper Chassis Swinging arm pin to engine nut Electrical system
214. xpansion tank as well and this ensures a continuous automatic venting COOL SYS 319 Cooling system MP3 LT 400 i e For the system venting during the circuit filling step there is a special union at the top of the head see filling rules To ensure cooling in case of poor dynamic ventilation there is an electric fan controlled by the injection system TECHNICAL SPECIFICATIONS Specification Cooling system capacity Desc Quantity 1 81 Prescribed fluid Mixture of 50 water and 50 fluid for sealed circuits Sealing pressure Cap calibrated at 0 9 bar THERMOSTAT Specification Desc Quantity Type Wax type with deviator Starts opening 82 2 C ELECTRIC VENTILATION Specification Desc Quantity Type With piston Electric ventilation starts at 107 C Electric ventilation stops at 103 C WATER PUMP Specification Desc Quantity Type Centrifugal Control Coaxial at the countershaft RADIATOR Specification Desc Quantity Type Aluminium with horizontal circulation EXPANSION TANK Specification Desc Quantity Calibration Automatic bleeding in parallel with the radiator Electric fan check Connect the injection diagnostic tester and select the ERRORS function in this menu Check any failures in the electric fan control cir cuit see Injection chapter p Este Dr Specific tooling ERNE HORTA RAN 020680Y Diagnosis Tool E COOL SYS
215. y of oil can cause serious damage to the engine In all 4T engines the deterioration of the oil characteristics or a certain consumption should be con sidered 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 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 and remove the oil cartridge filter C MAIN 38 MP3 LT 400 i e Maintenance 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 lubri cate 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 the scooter leave it running for a few minutes and switch it off after five minutes check the level and if necessary top up without exceeding the MAX level The cartridge filter must be replaced every time the oil is changed Use new oil of the recommended type for topping up and changing purpo
216. you have copies of the key repeat the operation with each key Insert the MASTER key again and turn it to ON for 2 seconds INJEC 222 MP3 LT 400 i e The maximum time to change keys is 10 seconds A maximum of 7 service keys can be programmed at one time Injection It is essential to adhere to the times and the procedure If you do not start again from the beginning Once the system has been programmed the master key transponder is strictly matched with the control unit With this link established it is now possible to encode new service keys in the event of losses replacements etc Each new programming deletes the previous one to add or delete a key it is therefore necessary to repeat the procedure using all the keys that you intend to keep in use If a service key becomes uncoded the efficiency of the high voltage circuit shielding must be thoroughly inspected In any case it is advisable to use resistive spark plugs Characteristic MASTER key RED KEY SERVICE key BLACK KEY Diagnostic codes The Immobilizer system is tested each time the key switch is turned from OFF to ON During this diagnosis phase a number of control unit sta tuses can be identified and various light codes displayed Regardless of the code transmitted if at the end of the diagnosis the LED remains off permanently the ignition is enabled If however the LED remains on permanently it means the ig nition is inhi

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