PIAGGIO MP3 400 i.e.

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CABLE HARNESS

Code Action Duration

1 005001 Electrical system - Replace-

ment

2 005114 Electrical system - Service

Time MP3 400 i.e.

TIME - 38

Main Page

Index of Topics5
Characteristics7
Maintenance Rules8
Safety Rules8
Dimensions and Mass9
Vehicle Identification9
Weights and Dimensions9
Engine10
Tightening Torques12
Wheels and Tyres12
Table of Contents13
Transmission Cover15
Coupling Categories16
Cylinder- Piston16
Height at Which the Diameter Should be Measured16
Piston Rings16
Crankcase - Crankshaft - Connecting Rod17
Crankcase / Countershaft Coupling17
Rings/Housing Coupling Clearances17
Diameter of Crankshaft Bearings18
Axial Clearance between Crankshaft and Connecting Rod19
Crankshaft Alignment19
Max. Admissible Displacement19
Base Gasket Thickness20
Recommended Products Table20
Slot Packing System20
Tooling23
Maintenance35
After 1,000 Km36
Every 2 Years36
Maintenance Chart36
After 10,000 Km; 50,000 Km; 70,000 Km37
After 15,000 Km; 45,000 Km; 75,000 Km37
Checking the Spark Advance38
Transmission Cover39
Spark Plug40
- Hub Oil41
- Replacement41
- Air Filter42
- Engine Oil42
- Engine Oil Filter45
- Oil Pressure Warning Light45
- Oil Top up45
- Adding Engine Coolant46
- Checking the Ignition Timing46
- Cooling System46
- Braking System47
- Level Check47
- Top-Up47
- Headlight Adjustment48
- Troubleshooting49
- Excessive Consumption50
- Excessive Oil Consumption/Exhaust Smoke50
- Irregular Clutch Performance or Slippage50
- Poor Lubrication Pressure50
- Brakes Overheating51
- Heavy Steering51
- Inefficient Braking System51
- Insufficient Braking51
- Noisy Suspension52
- Suspension Oil Leakage52
- Electrical System53
- Components Arrangement57
- Ignition63
- Battery Recharge and Starting64
- Level Indicators and Enable Signals Section65
- Devices and Accessories66
- Lights and Turn Indicators68
- Checks and Inspections69
- Immobiliser69
- With the Key Switch in the off Position70
- With the Key Switch Set to off70
- Virgin Circuit72
- Diagnostic Codes73
- Diagnostic Code - 1 Flash74
- Diagnostic Code - 2 Flashes74
- Battery Recharge Circuit75
- Diagnostic Code - 3 Flashes75
- Stator Check75
- Stator Winding Check-Up75
- Recharge System Voltage Check76
- Voltage Regulator/Rectifier76
- Fuses77
- Fuse Table78
- Dashboard79
- Sealed Battery80
- Connectors81
- Injection Electronic Control Unit81
- Pick-Up Connector81
- Saddle Opening Receiver Connector82
- Turn Indicator Control Device Connector82
- Voltage Regulator Connector82
- Anti-Theft Device Pre-Installation Connector83
- Fuel Pump Connector83
- Hv Coil Connector83
- Instrument Panel Connector "A"83
- Instrument Panel Connector "B"84
- Parking Control Ecu Connector84
- Remote Seat Opening85
- Zeroing85
- Programming86
- Engine from Vehicle87
- Exhaust Assy. Removal88
- Removal of the Engine from the Vehicle88
- Automatic Transmission94
- Transmission Cover94
- Air Duct95
- Transmission Cover95
- Air Duct Filter96
- Removing the Driven Pulley Shaft Bearing96
- Transmission Cover96
- Baffle Roller97
- Plastic Roller97
- Refitting the Driven Pulley Shaft Bearing97
- Transmission Cover97
- Anti-Vibration Roller Screw 16.7 -98
- Inspecting the Clutch Drum98
- Removing the Driven Pulley98
- Inspecting the Clutch99
- Removing the Clutch99
- Pin Retaining Collar100
- Removing the Driven Half-Pulley Bearing100
- Inspecting the Driven Fixed Half-Pulley101
- Inspecting the Driven Sliding Half-Pulley102
- Refitting the Driven Half-Pulley Bearing102
- Inspecting the Clutch Spring103
- Refitting the Driven Pulley103
Clutch Ring Nut104
- Refitting the Clutch104
- Drive-Belt105
- Removing the Driving Pulley105
- Inspecting the Rollers Case106
- Refitting the Driving Pulley107
- Installing the Fixed Driving Half-Pulley108
Drive Pulley Nut109
Refitting the Transmission Cover109
M8 Retainers for Transmission Cover110
- End Gear111
- Removing the Hub Cover111
- Removing the Hub Bearings112
- Removing the Wheel Axle112
- Removing the Wheel Axle Bearings113
- Inspecting the Hub Shaft114
- Inspecting the Hub Cover115
- Refitting the Hub Cover Bearings117
- Refitting the Hub Bearings118
- Refitting the Ub Cover118
- Flywheel Cover119
- Removing the Flywheel Cover Components120
- Inspecting the Cover Components121
- Removing the Stator121
- Refitting the Flywheel Cover Components124
- Refitting the Stator124
- Refitting the Flywheel Cover126
- Battery130
- Start-Up Remote Control Switch130
- Starter Motor130
- Starter Transmission130
- Removing the Flywheel Magneto131
- Removing the Starter Motor131
- Inspecting the Flywheel Components135
- Starter Gear Rim135
- Intermediate Gear136
- Refitting the Free Wheel136
- Loctite 243 Medium-Strength Threadlock137
- Refitting the Intermediate Gear137
- Refitting the Flywheel Magneto138
- Cylinder Assy. and Timing System140
- Refitting the Starter Motor140
- Removing the Intake Manifold141
- Removing the Rocker-Arms Cover141
- Removing the Timing System Drive141
- Removing the Cam Shaft143
- Removing the Cylinder Head144
- Removing the Valves145
- Removing the Cylinder - Piston Assy.146
- Inspecting the Small End147
- Inspecting the Wrist Pin147
- Inspecting the Piston148
- Inspecting the Piston Rings149
- Removing the Piston150
- Choosing the Gasket151
- Inspecting the Cylinder Head153
- Refitting the Cylinder153
- Refitting the Piston Rings153
- Inspecting the Timing System Components154
- Inspecting the Valve Sealings154
- Inspecting the Valve Housings155
- Inspecting the Valves155
- Standard Diameter155
- Inspecting the Valve Stem Guide Clearance156
- Minimum Admissible Diameter156
- Standard Valve Length157
- Inspecting the Springs and Half-Cones158
- Refitting the Valves158
- Admissible Limits159
- Inspecting the Cam Shaft159
- Standard Height159
- Refitting the Head and Timing System Components161
Exhaust / Intake Head Fixing Nuts:162
Coolant Temperature Sensor:163
Camshaft Retaining Bracket Screws:164
Valve Lifter Mass Stop Bell Fixing Screws:166
- Prescribed Clearance167
- Refitting the Timing Chain167
- 020330Y Stroboscopic Light for Timing Control168
- 020460Y Scooter Diagnosis and Tester168
- Refitting the Rocker-Arms Cover169
- Tappet Cover Fixing Screws:169
Screws Fixing Oil Pump to the Crankcase195
- Injection197
- Lambda Probe Strength199
- Pressure Regulator199
- Precautions200
- Troubleshooting Hints201
- Terminal Layout202
- Terminals Setup202
- EMS Circuit Diagram203
- Engine Does Not Start204
- Engine Does Not Start if Only Pulled204
- Troubleshooting Procedure204
- Engine Does Not Hold Idling/ Idling Is Unstable/ Idling too Low205
- Engine Start-Up Problems205
- Engine Stops at Idle205
- Starting Difficulties205
- Engine Does Not Return to the Idling Speed/Idling Speed too High206
- Engine Does Not Rev down206
- Exhaust Backfires in Deceleration206
- Exhaust Backfires When Decelerating206
- Engine Irregular Progress with Valve Slightly Open207
- Engine Revs Irregularly207
- Poor Performance at Full Throttle207
- Engine Knocking208
- Fuel Supply System208
- Presence of Knocking (Head Knocking)208
- Removing the Butterfly Valve209
- Pump Supply Circuit211
- Electrical Data212
- Injection Loads212
- Circuit Leak Test215
- Fuel Filter Check216
- Inspecting the Injector Circuit218
- HT Coil231
- Spark Advance236
- Coolant Temperature Sensor238
- Temperature Sensor238
- Resetting the Throttle Valve Position Signal (TPS Reset)239
- Zeroing the Throttle239
- Lambda Probe242
- Suspensions247
- Front Wheel Hub Overhaul248
- Removing the Front Wheel248
- Handlebar250
- The Tilt Mechanism250
- Hydraulic System Layout251
- Steering Tubes251
Side Headstock Lower Ring Nut257
Screws Fixing the Half-Arm Coupling Flange261
Fixing Screws for Tilt Locking Disc Section262
Geared Motor and Suspension Locking System262
Clamp Fixing Pump Bolt to Anti-Tilting Device264
- Before Removing the Geared Motor272
- Geared Motor276
- Tilt Locking-Unlocking Switch277
- Potentiometer279
- Rider Presence Sensor280
- Tilt Locking Calliper Sensor282
- Tone Wheel Sensor283
- Wheel Alignment287
- Removing the Rear Wheel291
- Rear Wheel Axle293
- Shock Absorber Lower Clamp300
Rear Brake Calliper302
Brake Fluid Pipe-Calliper Fitting304
- Front Brake Calliper304
- Rear Brake Disc305
- Disc Inspection307
- Front Brake Disc307
- Front Brake Pads309
- Rear Brake Pads310
- Oil Bleed Screw311

PIAGGIO MP3 400 i.e. - Page 382

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