PIAGGIO 633929(IT)

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Stores code Description

020074Y Support base for checking crank-

shaft alignment

020150Y Air heater support

020151Y Air heater

020193Y Oil pressure gauge

020262Y Crankcase splitting strip

020263Y Sheath for driven pulley fitting

MP3 125 Tooling

TOOL - 3

Main Page

Index of Topics5
Characteristics7
Safety Rules8
Maintenance Rules8
Vehicle Identification9
Dimensions and Mass9
Weights and Dimensions9
Data10
Capacities10
Electrical Components10
Electrical System10
Frame and Suspensions11
Brakes11
Wheels and Tyres11
Tyre Pressure11
Tightening Torques12
Rear Suspension12
Front Brake13
Rear Brake13
Muffler13
Lubrication13
Engine - Transmission14
Engine - Flywheel14
Crankcase and Crankshaft14
Engine - Cooling14
Assembly Clearances14
Cylinder - Piston Assy15
Engine Coupling Categories15
Crankcase - Crankshaft - Connecting Rod16
Crankshaft/ Crankcase Axial Clearance16
Slot Packing System16
Tooling21
Index of Topics21
Appropriate Tool22
Maintenance35
Index of Topics35
Maintenance Chart36
Every 2 Years36
Every 3.000 Km36
Carburettor40
Checking the Spark Advance40
Spark Plug42
Hub Oil43
Air Filter44
Engine Oil45
Checking the Ignition Timing47
Checking the Valve Clearance47
Headlight Adjustment48
SAS Filters Inspection and Cleaning48
Troubleshooting53
Index of Topics53
Poor Performance54
Starting Difficulties54
Difficult Starting54
Excessive Oil Consumption/Exhaust Smoke55
Insufficient Lubrication Pressure55
Poor Lubrication Pressure55
Engine Tends to Cut-Off at Full Throttle56
Engine Tends to Cut-Off at Idle56
Engine Stop Idling56
Excessive Exhaust Noise56
High Fuel Consumption57
SAS Malfunctions57
Transmission and Brakes57
Clutch Grabbing or Performing Inadequately57
Insufficient Braking58
Brakes Overheating58
Electrical System58
Turn Signal Lights Malfunction58
Rear Wheel59
Rear Wheel Rotates with Engine at Idle59
Steering Controls and Suspensions59
Electrical System61
Conceptual Diagrams65
Ignition65
Battery Recharge and Starting66
Level Indicators and Enable Signals Section67
Devices and Accessories68
Lights and Turn Indicators70
Checks and Inspections71
Immobiliser71
Virgin Circuit73
Diagnostic Codes73
Diagnostic Code - 2 Flashes74
Ignition Circuit74
No Spark Plug75
HV Primary Coil Check75
HV Coil Secondary Check75
Pick-Up76
H.V. Coil76
Battery Recharge Circuit77
Stator Check77
Voltage Regulator Check78
Recharge System Voltage Check79
Choke Inspection79
Lights List80
Light Bulbs Table80
Fuses81
Fuse Chart81
Dashboard82
Sealed Battery83
Voltage Check83
Constant Voltage Battery Charge Mode83
Constant Current Battery Charge Mode84
Dry-Charge Battery84
Commissioning a New Dry-Charged Battery84
Connectors85
20-Way Instrument Connector85
12-Way Instrument Connector86
Remote Seat Opening86
Zeroing86
Engine from Vehicle89
Index of Topics89
Exhaust Assy. Removal90
Removal of the Engine from the Vehicle91
Engine95
Automatic Transmission96
Transmission Cover96
Air Duct96
Removing the Driven Pulley Shaft Bearing97
Refitting the Driven Pulley Shaft Bearing97
Removing the Driven Pulley98
Inspecting the Clutch Drum98
Removing the Clutch99
Clutch Removal99
Inspecting the Clutch100
Pin Retaining Collar100
Removing the Driven Half-Pulley Bearing101
Inspecting the Driven Fixed Half-Pulley101
Inspecting the Driven Sliding Half-Pulley102
Movable Driven Half-Pulley Dimensions102
Refitting the Driven Half-Pulley Bearing103
Refitting the Driven Pulley103
Inspecting the Clutch Spring105
Refitting the Clutch105
Drive-Belt107
Removing the Driving Pulley107
Inspecting the Rollers Case108
Refitting the Driving Pulley109
Refitting the Transmission Cover110
End Gear111
Removing the Hub Cover111
Removing the Wheel Axle111
Removing the Hub Bearings111
Removing the Wheel Axle Bearings112
Inspecting the Hub Shaft113
Inspecting the Hub Cover113
Refitting the Wheel Axle Bearing114
Refitting the Hub Cover Bearings115
Refitting the Hub Bearings115
Refitting the Ub Cover116
Flywheel Cover117
Removing the Stator117
Refitting the Stator118
Refitting the Flywheel Cover118
Flywheel and Starting118
Removing the Flywheel Magneto119
Inspecting the Flywheel Components119
Refitting the Flywheel Magneto119
Refitting the Starter Motor120
Cylinder Assy. and Timing System120
Removing the Intake Manifold120
Removing the Rocker-Arms Cover121
Removing the Timing System Drive121
Removing the Cam Shaft123
Removing the Cylinder Head124
Removing the Valves124
Removing the Cylinder - Piston Assy.124
Inspecting the Small End126
Inspecting the Wrist Pin127
Inspecting the Piston129
Removing the Piston129
Choosing the Gasket130
Refitting the Piston Rings131
Refitting the Cylinder132
Inspecting the Cylinder Head132
Inspecting the Timing System Components133
Inspecting the Valve Sealings133
Inspecting the Valve Housings134
Inspecting the Valves134
Inspecting the Springs and Half-Cones136
Refitting the Valves136
Inspecting the Cam Shaft137
Refitting the Head and Timing System Components138
Insert the Spacer on the Cam Shaft139
Fit the End-Of Stroke Ring on the Valve-Lifting Mass139
Set the Tensioner Cursor to the Rest Position140
Timing System Components Assembly140
Refitting the Rocker-Arms Cover142
Refitting the Intake Manifold142
Crankcase - Crankshaft142
Splitting the Crankcase Halves142
Fitting Clearance144
Check the Radial Clearance on the Connecting Rod144
Inspecting the Crankshaft Alignment145
Standard Diameter145
Inspecting the Crankcase Halves147
Inspecting the Crankshaft Plain Bearings148
Refitting the Crankcase Halves150
Studs150
Oil Pressure Check153
Crankshaft Oil Seals153
Oil Pump155
Removing the Oil Sump155
Inspecting the By-Pass Valve156
Refitting the Oil Sump156
SAS Valve157
Inspecting the One-Way Valve157
Inspecting the Cut-Off158
Fuel Supply159
Removing the Carburettor159
Level Check168
Inspecting the Valve and Needle168
Inspecting the Automatic Choke Device169
Adjusting the Idle171
Suspensions173
Index of Topics173
Removing the Front Wheel174
Front Wheel Hub Overhaul174
Handlebar176
The Tilt Mechanism176
Hydraulic System Layout177
Steering Tubes177
Parallelogram Device183
Geared Motor and Suspension Locking System188
Geared Motor205
Potentiometer206
Tilt Locking-Unlocking Switch207
Rider Presence Sensor214
Wheel Alignment215
Tool Fitting215
Removing the Rear Wheel219
Refitting the Rear Wheel220
Shock Absorbers226
Centre-Stand227
Braking System229
Index of Topics229
Rear Brake Calliper230
Brake Pipes232
Front Brake Pipes Removal233
Parking Brake234
Cooling System237
System Bleed238
Chassis239
Seat240
Front Handlebar Cover240
Headlight Assy.241
Frame Central Cover242
Legshield243
Knee-Guard243
Taillight Assy.246
Footrest246
Side Fairings247
License Plate Holder248
Helmet Bay248
Spoiler249
Fuel Tank250
Top-Case252
Rear252
Handles and Top Side Fairings252
Radiator Cover253
Pre-Delivery255
Aesthetic Inspection256
Tightening Torques Inspection256
Lock Check256
Safety Locks256
Levels Check257
Road Test258
Static Test258
Functional Inspection258
Time261
Crankcase263
Crankshaft264
Cylinder Assy.265
Cylinder Group265
Cylinder Head Assy.266
Rocker Arms Support Assy.267
Cylinder Head Cover268
Oil Filter269
Driven Pulley270
Oil Pump271
Final Gear Assy.272
Driving Pulley273
Transmission Cover274
Water Pump275
Starter Motor276
Electrical Start up276
Flywheel Magneto277
Exhaust Pipe279
Air Cleaner280
Frame281
Legshield Spoiler283
Rear Cover285
Rear Shield285
Central Cover286
Mudguard287
Rear Shock Absorber289
Handlebar Covers290
Handlebar Components291
Swinging Arm292
Instrument Panel294
Locks295
Turn Signal Lights295
Front Wheel298
Rear Wheel299
Electric Devices300
Electronic Controls302
Front Suspension306
Cooling System307
Braking System308
Secondary Air Box310
Windshield310
Stickers311

PIAGGIO 633929(IT) - Page 23

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