Piaggio MP3 125 ie (EN)

SERVICE STATION MANUALxxx(IT)-xxx(EN)-xxx(FR)-xxx(DE)-xxx(ES)-xxx(PT)-

xxx(NL)-xxx(EL)

MP3 125 ie

SERVICE STATIONMANUAL

MP3 125 ie

The descriptions and images in this publication are given for illustrative purposes only and are not binding.While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,to make any changes to components, parts or accessories, which it considers necessary to improve the

product or which are required for manufacturing or construction reasons.Not all versions/models shown in this publication are available in all countries. The availability of each

model should be checked at the official PIAGGIO sales network.© Copyright 2011 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or

in part is prohibited.Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

http://www.piaggio.com/

SERVICE STATION MANUALMP3 125 ie

This service station manual has been drawn up by Piaggio & C. SpA to be used by the workshops ofPiaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggiovehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Anysignificant change to vehicle characteristics or to specific repair operations will be communicated byupdates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipmentand tools are unavailable. It is therefore advisable to read the sections of this manual concerning specialtools, 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 personalinjury.

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

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

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

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

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

area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English measurement. Using unsuitable

coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

sure the electrical connections have been made properly, particularly the ground and battery connec-

tions.

MP3 125 ie Characteristics

CHAR - 7

Vehicle identification

Chassis prefix:

ZAPM63100

Engine prefix:

M631M

Dimensions and mass

WEIGHTS AND DIMENSIONSSpecification Desc./QuantityKerb weight 210 ± 8 kg

Characteristics MP3 125 ie

CHAR - 8

Specification Desc./QuantityMaximum weight allowed 410 kg

Engine

ENGINESpecification Desc./Quantity

Type Single-cylinder, 4-strokeEngine capacity 124 cm³

Bore x stroke 57 x 48.6 mmCompression ratio 11.5 ± 13.0: 1

Minimo motore 1.650 ± 100 giri/minTiming system 4 valves, single overhead camshaft, chain-driven.

Valve clearance Intake: 0.10 mm Exhaust: 0.15 mmMax. power 11.0 kW at 9,500 rpmMAX. torque 12.0 Nm at 8000 rpmTransmission Automatic expandable pulley variator with torque server, V-

belt, self-ventilating dry automatic centrifugal clutch and trans-mission housing with forced-circulation air cooling.

Final reduction gear Gear reduction unit in oil bath.Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.Cooling Forced-circulation coolant with electric pump commanded by

the control unit.Starter starter, with freewheel in oil bath

Fuel system ELDOR KUBO01 electronic injection with 32 mm diam. throttlebody and electric fuel pump.

Fuel Unleaded petrol (95 RON)Exhaust silencer Absorption-type exhaust silencer with a 3-way catalytic con-

verter and lambda probe.Emissions compliance EURO 3

Transmission

TRANSMISSIONSpecification Desc./QuantityTransmission Automatic expandable pulley CVT with torque server, V-belt,

automatic clutch, gear reduction unit and transmission com-partment with forced air circulation cooling

Capacities

CAPACITYSpecification Desc./Quantity

Engine oil Capacity: 1.3 l (dry); 1.2 l (when changing oil and filter)Transmission oil 250 cm³

Cooling system fluid ~ 2 lFuel tank (reserve) 12.0 ± 0.5 l (-)

Electrical system

ELECTRICAL COMPONENTSSpecification Desc./Quantity

Ignition Electronic inductive discharge ignition, high efficiency, withseparate HV coil.

Starter starter, with freewheel in oil bath


CHAR - 9

Specification Desc./QuantitySpark plug NGK CR8EB

Battery 12 V-12Ah SEALED BATTERYGenerator alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONSpecification Desc./Quantity

Chassis Tubular and steel sheets.Rear suspension Single arm with two double-acting hydraulic shock absorbers

and preloading adjustment in 4 positions.Front suspension The roll system is composed of an articulated parallelogram

suspension with die-cast aluminium control arms and two sideheadstocks plus shock absorbers with hydraulic locking sys-

tem.

Brakes

BRAKESSpecification Desc./QuantityFront brake Ø 240-mm double disc brake with hydraulic control operated

by the handlebar right-hand lever.Rear brake Ø 240-mm disc brake with hydraulic control operated by the

handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRESSpecification Desc./Quantity

Front wheel rim 12" x 3.00"Rear wheel rim 14" x 3.75"

Front tyre 120/70-12", without inner tubeRear tyre Without inner tube: 140/60-14"

TYRE INFLATION PRESSURESpecification Desc./Quantity

Front tyre pressure 1.8 barRear tyre pressure 2.8 bar

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-LATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES

Tightening Torques

STEERINGName Torque in Nm

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

Handlebar fixing screw 50 ÷ 55Fixing screws for the handlebar control unit U-bolts 7 to 10


CHAR - 10

CHASSISName Torque in Nm

Engine arm bolt - frame arm 33 to 41Swinging arm buffer nut 64 - 72Engine-swinging arm pin 55 - 61Frame-swinging arm bolt 55 - 61

Centre stand bolt 31 - 39

FRONT SUSPENSIONName Torque in Nm

Shock absorber lower clamping 19 - 26Shock absorber upper clamp 19 - 29

Front wheel fixing screws 19 ÷ 24Steering arm bolt nut 20 to 25

Tilt gripper fixing screws 20 to 25Front wheel axle 74 - 88

Arm coupling screws 45 to 50Screws fixing arms to side headstocks 45 to 50

Screws fixing arms to central headstock 45 to 50Screws fixing the half-arm coupling flange 20 to 25

Screws fixing roll lock disc section 20 to 25Side headstock upper ring nut 20 - 24Side headstock lower ring nut 12 ÷ 15

Screw fixing sliding stem to shock absorber 45 to 50Clamp for sliding stem locking device 6.5 - 10.5

Fixing nuts for constant-velocity universal joints 18 - 20Potentiometer to anti-tilting device clamp 8 to 10Electric motor to anti-tilting device clamp 11 to 13

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

Pressure switch to distribution frame 18 - 20Sensor to tilt gripper clamp 2.5 - 2.9

Pipe terminals to fifth wheel check spring 7 - 11Joint to anti-tilting device pump 20 to 25

Lower fitting for shock absorber sliding locking clamp pipes 20 to 25Upper fitting for shock absorber sliding locking clamp pipes 20 to 25

REAR SUSPENSIONName Torque in Nm

Shock absorber upper clamp 33 to 41Shock absorber lower clamping 33 to 41

Shock absorber-crankcase attachment bracket 20 to 25Rear wheel axle 104 to 126

Silencer arm clamping screws 27 - 30

FRONT BRAKEName Torque in Nm

Oil bleed screw 8 - 12Brake disc screws 8 to 10

Brake fluid pump-hose fitting 16 - 20Brake fluid pipe-calliper fitting 20 to 25

Screw tightening calliper to support 20 to 25Calliper upper pipe fitting 20 to 25

REAR BRAKEName Torque in Nm

Brake disc screws 8 to 10Rear brake calliper-pipe fitting 20 to 25

Rigid / flexible pipe fitting 13 - 18Rear brake pump-pipe fitting 16 - 20

Rear brake retainer screw 20 to 25


CHAR - 11

SILENCERName Torque in Nm

Silencer heat guard fixing screw 4 to 5Screw for fixing silencer to supporting arm 20 to 25

Lambda probe tightening on exhaust manifold 40 to 50Exhaust manifold-silencer joint tightening 12 to 13

Manifold - silencer diaphragm tightening clamp 16 to 18

LUBRICATIONName Torque in Nm

Oil engine drainage plug/ engine 12 - 16Oil filter on crankcase fitting 27 to 33

Engine oil drainage plug/ mesh filter 24 to 30Oil filter 4 to 6

Oil pump cover screws 7 - 9Screws fixing oil pump to the crankcase 5 to 6

Oil pump command sprocket screw 10 to 14Oil pump cover plate screws 4 to 6

Oil sump screws 10 to 14Minimum oil pressure sensor 12 to 14

CYLINDER HEADName Torque in Nm

Spark plug 12 to 14Head cover screws 6 - 7

Nuts fixing head to cylinder 7±1 + 10±1 + 270°Head fixing side screws 11 - 12

Starter ground screw 7 to 8.5Tappet adjustment check nut 6 - 8

Intake manifold screws 11 to 13Timing chain tensioner slider screw 10 to 14Starter counterweight support screw 11 to 15Timing chain tensioner support screw 11 to 13Timing chain tensioner central screw 5 to 6

Camshaft retention plate screw 4 to 6

TRANSMISSIONName Torque in Nm

Belt support roller screw 11 to 13Clutch unit nut on driven pulley 45 to 50

Drive pulley nut 75 - 83Transmission cover screws 11 to 13

Driven pulley shaft nut 54 ÷ 60Rear hub cap screws 24 to 27

FLYWHEELName Torque in Nm

Flywheel cover screw 11 to 13Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock)

Flywheel nut 94 - 102Pick-up fixing screws 3 to 4

Screw fixing freewheel to flywheel 13 - 15

CRANKCASE AND CRANKSHAFTName Torque in Nm

Internal engine crankcase bulkhead (transmission-side halfshaft) screws

4 to 6

Engine-crankcase coupling screws 11 to 13Starter screws 11 to 13

Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)


CHAR - 12

COOLINGName Torque in Nm

Water pump rotor cover 3 to 4Thermostat cover screws 3 to 4

Bleed screw 3

Overhaul data

Assembly clearances

Cylinder - piston assy.

- Calculate the coupling clearance between pin

and connecting rod small end.

CharacteristicStandard diameter:Ø 14.996 - 15.0 mm

Standard clearance:0.015 ÷ 0.029 mm

- Measure the diameter of the bearings on the pis-

ton.

CharacteristicStandard diameter:15 +0.006 + 0.001mm

- Calculate the piston pin coupling clearance.N.B.

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENTMUST BE MADE ACCORDING TO THE PISTON AXIS.

CharacteristicStandard clearance:

0.001 - 0.010 mm


CHAR - 13

- Check that coating is free from flakes.

- Check that the head matching surface exhibits no

deformations or wear.

CharacteristicMaximum allowable run-out:0.05 mm

- 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).

*Fit rings «2» and «3» with the word «TOP» facing upwards.

** Position the port of the rings as shown here.

*** Value «A» of the sealing ring inside the cylinder (fitting clearance).

Check the size of the sealing ring opening:

Compression ring 0.15 - 0.30 mm. Max. value 0.5 mm

Oil scraper ring 0.10 - 0.30 mm. Max. value 0.65 mm

Oil scraper ring 0.15 - 0.35 mm. Max. value 0.65 mmN.B.

FITTING CLEARANCE VALUES ARE THE SAME FOR BOTH THE STANDARD SEALING RINGSAND THE OVERSIZES.


CHAR - 14

ENGINE COUPLING CATEGORIESName Initials Cylinder Piston Play on fitting

Cylinder A 56.997 to 57.004 56.945 - 56.952 0.045 - 0.059Cylinder B 57.004 to 57.011 56.952 - 56.959 0.045 - 0.059Piston C 57.011 to 57.018 56.959 - 56.966 0.045 - 0.059Piston D 57.018 to 57.025 56.966 - 56.973 0.045 - 0.059

Cylinder 1st Oversize A1 57.197 to 57.204 57.145 - 57.152 0.045 - 0.059Cylinder 1st Oversize B 1 57.204 to 57.211 57.152 - 57.159 0.045 - 0.059Piston 1st Oversize C 1 57.211 to 57.218 57.159 - 57.166 0.045 - 0.059Piston 1st Oversize D 1 57.218 to 57.225 57.166 - 57.173 0.045 - 0.059

Cylinder 2nd Oversize A2 57.397 to 57.404 57.345 - 57.352 0.045 - 0.059Cylinder 2nd Oversize B 2 57.404 to 57.411 57.352 - 57.359 0.045 - 0.059Piston 2nd Oversize C 2 57.411 to 57.418 57.359 - 57.366 0.045 - 0.059Piston 2nd Oversize D 2 57.418 to 57.425 57.366 - 57.373 0.045 - 0.059

Cylinder 3rd Oversize A 3 57.597 to 57.604 57.545 - 57.552 0.045 - 0.059Cylinder 3rd Oversize B 3 57.604 to 57.611 57.552 - 57.559 0.045 - 0.059Piston 3rd Oversize C 3 57.611 to 57.618 57.559 - 57.566 0.045 - 0.059Piston 3rd Oversize D 3 57.618 to 57.625 57.566 - 57.573 0.045 - 0.059

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 MARKFACING UPWARDS.


CHAR - 15

Crankcase - crankshaft - 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-

tween the pre-set interval.

CharacteristicDiameter clearance0.023 - 0.041 mm

If value «A-B» is above the limit, check that value «B» is within the admissible values of the categories.

CRANKSHAFTSpecification Desc./Quantity

Category 1 28.998 to 29.004Category 2 29.004 to 29.010

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- B (blue), C (yellow), E (green).

CRANKCASESpecification Desc./Quantity

Category 1 32.959 - 35.965Category 2 32.953 to 32.959

CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGSSpecification Desc./Quantity

Crankshaft category 1 - Crankcase category 1 E+ECrankshaft category 2 - Crankcase category 1 C+CCrankshaft category 1 - Crankcase category 2 C+CCrankshaft category 2 - Crankcase category 2 B+B


CHAR - 16

CharacteristicAxial crankshaft/crankcase clearance:

0.5 - 0.40 mm

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCEName Description Dimensions Initials Quantity

Transmissionside half-shaft

16.6 +0-0.05 A D = 0.20 ÷ 0.50

Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 ÷ 0.50Connecting rod 18 -0.10 -0.15 C D = 0.20 ÷ 0.50

Spacer tool 51.4 +0.05 E D = 0.20 ÷ 0.50


CHAR - 17

THE CRANKSHAFT is available in two CATEGO-

RIES:

CharacteristicCrankshaft category:CAT. 1 - CAT. 2

CRANKSHAFT CATEGORY IDENTIFICATION:

The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.

Otherwise, «1 - 2» if done manually with an electric pen. The spare part identification is located on the

package with a drawing number plus FC1/FC2 or (001/002).

If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both

crankcase halves, combining the two components (Shaft and Crankcase) featuring the same category.

Cylinder Head

Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of

the springs and the valves so as not to change the original position during refitting

- Using a trued bar and a feeler gauge check that

the cylinder head surface is not worn or distorted.

CharacteristicMaximum allowable run-out0.09 mm

- In case of faults, replace the head.

- Check the sealing surfaces for the intake and exhaust manifold.

- Check that the camshaft and the rocking lever pin capacities exhibit no wear.

- Check that the head cover surface is not worn.

- Check that the coolant seal plug exhibits no oxidation.


CHAR - 18

- 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.

Measure the camshaft bearing seats and rocking

lever support pins with a bore meter

HEAD BEARINGSSpecification Desc./Quantity

Bearing "A" 37 +0.025Bearing "B" 20 +0.021Bearing "C" 12 +0.018

- Measure the unloaded spring length.

CharacteristicStandard length40.5 mm

Allowable limit after use:39.7 mm

- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the

impression on the valve seat "V".

CharacteristicAdmissible limit:1.6 mm

- If the width of the impression on the valve seat exceeds the specified limits, replace the cylinder head.


CHAR - 19

- In case of excessive wear or damage, replace the head.

STANDARD VALVE LENGTHSpecification Desc./Quantity

Intake 84.5 mmExhaust 94.5 mm

- Measure the diameter of the valve stems in the three positions indicated in the diagram.

STANDARD DIAMETERSpecification Desc./Quantity

Intake: 4.987 - 4.972 mmExhaust: 4.975 - 4.960 mm

MINIMUM ADMISSIBLE DIAMETERSpecification Desc./Quantity

Intake: 4.96 mmExhaust: 4.945 mm

- Calculate the clearance between the valve and

the valve guide.

- Check the deviation of the valve stem by resting

it on a «V» shaped abutment and measuring the

extent of the deformation with a dial gauge.

CharacteristicLimit values admitted:0.1 mm


CHAR - 20

- 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.

CharacteristicAdmissible limit:0.03 mm

Measure the valve guide.

CharacteristicValve guide:5 +0.012 mm

- After measuring the valve guide diameter and the

valve stem diameter, check clearance between

guide and stem.

OUTLETSpecification Desc./Quantity

Standard clearance: 0.025 to 0.052 mmAdmissible limit: 0.09 mm

INTAKESpecification Desc./Quantity

Standard clearance: 0.013 - 0.04 mmAdmissible limit: 0.08 mm

- Check that there are no signs of wear on the faying surface with the articulated set screw terminal.


CHAR - 21

- If no anomalies are found during the above

checks, you can use the same valves. To obtain

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 NOLAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVESWITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.CAUTION

DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

- Check that the camshaft bearings exhibit no scores or abnormal wear.

- Using a micrometer, measure the camshaft bearings.

STANDARD DIAMETERSpecification Desc./QuantityBearing A Ø: 37 - 0.025 -0.050 mm

Bearing B diameter: 19 - 0.020 -0.041 mm

MINIMUM ADMISSIBLE DIAMETERSpecification Desc./QuantityBearing A Ø: 36.940 mm

Bearing B diameter: 19.950 mm


CHAR - 22

-Using a gauge, measure the cam height.

STANDARD HEIGHTSpecification Desc./Quantity

intake 17.382 mmExhaust 16.563 mm

ADMISSIBLE LIMITSSpecification Desc./Quantity

intake 17.130 mmExhaust 16.310 mm

standard axial clearance 0.11 - 0.41 mmmaximum admissible axial clearance 0.42 mm

- Check that the rocking lever pins exhibit no scores or wear.

CharacteristicStandard diameter

Diameter 11.977 - 11.985 mm

- Measure the inside diameter of each rocker.

CharacteristicStandard diameter

Ø 12 +0.011 mm


CHAR - 23

- Check that the cam contact sliding block and the

articulated register cap is free from wear.

- In case of wear, replace the component.

Slot packing system

CharacteristicCompression ratio

Cr: 11.50 - 13:1

Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed

by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the

piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression

ratio) and vice versa.N.B.

NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL-INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FORMEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION ANDON A RECTIFIED PLANE.


CHAR - 24

MODELS WITH METAL HEAD GASKET (0.3)Name Measure A Thickness

Shimming 125 - Cylinder 67.8 - Headgasket 0.3 - Base gasket 0.6

1.40 - 1.60 0.60 ± 0.05

Shimming 125 - Cylinder 67.8 - Headgasket 0.3 - Base gasket 0.8

1.60 - 1.80 0.80 ± 0.05

Products

RECOMMENDED PRODUCTS TABLEProduct 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(throttle control)

Oil for 4-stroke engines

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-creased adhesiveness

AGIP GP 330 Grease for brake lever, gas White calcium complex soap-basedspray grease with NLGI 2; ISO-L-XBCIB2

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MASynthetic oil

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluidAGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze

fluid, CUNA NC 956-16


CHAR - 25

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y014 Calliper to extract ø 15-mm bearings

005095Y Engine support

002465Y Calliper for circlips

006029Y Punch for fitting steering bearing seat onsteering tube

020004Y Punch for removing steering bearingsfrom headstock

020055Y Wrench for steering tube ring nut

MP3 125 ie Tooling

TOOL - 27

Stores code Description020074Y Support base for checking crankshaft

alignment

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure check gauge

020262Y Crankcase splitting plate

020263Y Driven pulley assembly sheath

Tooling MP3 125 ie

TOOL - 28

Stores code Description020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020332Y Digital rpm indicator

MP3 125 ie Tooling

TOOL - 29

Stores code Description020648Y Single battery charger

020335Y Magnetic mounting for dial gauge

020357Y 32x35-mm Adaptor020359Y 42x47-mm Adaptor

020360Y 52x55-mm Adaptor

020363Y 20-mm guide

Tooling MP3 125 ie

TOOL - 30

Stores code Description020375Y 28 x 30 mm adaptor

020376Y Adaptor handle

020382Y Valve cotters equipped with part 012 re-moval tool

020382Y011 adapter for valve removal tool

020393Y Piston assembly band

020412Y 15-mm guide

MP3 125 ie Tooling

TOOL - 31

Stores code Description020423Y Driven pulley lock wrench

020424Y Driven pulley roller casing fitting punch

020426Y Piston fitting fork

020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

020444Y Tool for fitting/ removing the driven pulleyclutch

Tooling MP3 125 ie

TOOL - 32

Stores code Description020456Y Ø 24 mm adaptor020477Y 37 mm adaptor

020483Y 30-mm guide

020489Y Hub cover support stud bolt kit

020428Y Piston position check mounting

020680Y Diagnosis Tool

MP3 125 ie Tooling

TOOL - 33

Stores code Description020621Y HV cable extraction adaptor

001467Y035 Bearing housing, external ø 47 mm

020626Y Driving pulley lock wrench

020626Y008 Driving pulley lock wrench001467Y013 Calliper to extract ø 15-mm bearings

020627Y Flywheel lock wrench

020467Y Flywheel extractor

Tooling MP3 125 ie

TOOL - 34

Stores code Description020430Y Pin lock fitting tool

020622Y Transmission-side oil seal punch

020480Y Petrol pressure check kit

020244Y 15-mm diameter punch

020115Y Ø 18 punch

020271Y Tool for removing-fitting silent bloc

MP3 125 ie Tooling

TOOL - 35

Stores code Description020469Y Reprogramming kit for scooter diagnostic

tester

020481Y004 Parking control unit interface wiring

020639Y Roll lock control unit software

001467Y017 Driver for OD 36 mm bearings

020234y extractor020441Y 26 x 28 mm adaptor

Tooling MP3 125 ie

TOOL - 36

Stores code Description020362Y 12 mm guide

020358Y 37x40-mm Adaptor001467Y002 Driver for OD 73 mm bearing

020646Y Parallelogram and steering positioningtool

020647Y Toe-in checking tool

020688Y Dial gauge support

MP3 125 ie Tooling

TOOL - 37

INDEX OF TOPICS

MAINTENANCE MAIN

ADJUSTMENT PROCEDURE OF THE RING NUTS OF THE SIDE HEADSTOCKS

Remove the Piaggio clip-on badge with a flat-

headed screwdriver

Undo the screw under the badge and remove the

centre headlight cover

Undo the screws "A" fastening the front grille

On both sides of the vehicle, undo the screw "B"

at the bottom of the front grille surround and re-

trieve the shim

On both sides of the vehicle, undo the screws "C"

inside the front wheel housing

MP3 125 ie Maintenance

MAIN - 39

Undo the screws "D" and remove the front grille

surround

Undo the two upper fastener screws "E" for the

headlight assembly

Undo the two lower fastener screws "F" and re-

move the headlight assembly from its seat

Undo the indicated screws and remove the wind-

screen

Undo the indicated screws and remove the spoiler

Undo the indicated screws

Maintenance MP3 125 ie

MAIN - 40

Undo the indicated screws and remove the com-

plete shield

Once the plastics have been remove the ring nuts

of the side headstock of the front suspension can

be reached

Unscrew the upper ring nut

Bring the upper ring nut to the end of the headstock

thread of the side suspension

Tighten the lower ring nut to the specified torque

with the appropriate key.

Locking torques (N*m)Side headstock lower ring nut 12 ÷ 15

Screw the upper ring nut until it stops


MAIN - 41

Tighten upper ring nut to the specified torque with

the appropriate key.

Carry out the assembly of the plastic covers in re-

verse order to the disassembly.

Specific tooling020892y Steering side headstock ring nut key

Locking torques (N*m)Side headstock upper ring nut 20 - 24

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

SCHEDULED MAINTENANCE TABLEI: 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 1 5 10 15 20 25 30 35 40 45 50 55 60Roller bearing - Driven pulley L L L L L LSafety fasteners I I I I ISpark plug R R R R R RDrive belt I R I R I R I RThrottle control A A A A A A AAir filter C C C C C COil filter R R R R R R RCVT Filter C C C C C CValve clearance A A AElectrical system and battery I I I I I I IBrake levers L L L L L L LBrake fluid * I I I I I I ICoolant * I I I I I I IEngine oil R I R I R I R I R I R I RHub oil R I R I R I RHeadlight direction adjustment A A A ABrake pads I I I I I I I I I I I I I


MAIN - 42

Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60Sliding shoes / CVT rollers R R R R R RTyre pressure and wear I I I I I I IVehicle road test I I I I I I IRadiator (external cleaning) I I I ISuspension I I I I I I ISteering A A A A A A ARoll lock gripper control cable A A A A A A ATransmission L L L LOperation time 12

0'10' 16

5'75' 13

5'10' 18

5'10' 13

5'75' 16

5'10' 16

5'

Spark plug

Remove the port on the left-hand side panel of the

vehicle 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

THE SPARK PLUG MUST BE REMOVED WHEN THE EN-GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-TED IN THE SCHEDULED MAINTENANCE TABLE. THEUSE OF ELECTRONIC CENTRAL UNITS AND OF NON-COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGSOTHER THAN THOSE PRESCRIBED MAY SERIOUSLYDAMAGE THE ENGINE.N.B.USE OF SPARK PLUGS OTHER THAN THE INDICATEDTYPE OR UNSHIELDED SPARK PLUG CAPS CAN LEADTO FAULTS IN THE VEHICLE'S ELECTRICAL SYSTEM.

CharacteristicSpark plugNGK CR8EB

Electric characteristic


MAIN - 43

Electrode gap0.7 to 0.8 mm

Hub oil

Check

-Place the vehicle on the 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 below 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.

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 productsAGIP ROTRA 80W-90 Rear hub oilSAE 80W/90 Oil that exceeds the requirements of

API GL3 specifications

CharacteristicRear hub oilCapacity approximately 250 cc

Locking torques (N*m)Hub oil drainage screw 15 to 17 Nm


MAIN - 44

Air filter

- Undo the fixing screws «A» (two of which are on

the knob-type head) and remove the air-box cover.

Cleaning:

- 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 CARRY OUT MAINTENANCECHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

Recommended productsAGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

CVT filter removal

- Undo the three screws «1» and remove the

crankcase cover «2».


MAIN - 45

- Undo the three screws «3» and remove the filter

cover in the transmission housing «4».

- Take out the filtering element «5» from the cover.

CVT filter cleaning

1. Wash the sponge with water and mild soap.

2. Dry it with a clean cloth and short blasts of com-

pressed air.CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS SERVICETHE CVT FILTER MORE OFTEN TO AVOID DAMAGINGTHE ENGINE.

Engine oil

In four stroke engines, the engine oil is used to lubricate the distribution elements, the bench bearings

and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.

In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should

be considered 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".


MAIN - 46

Replacement

Change oil and replace filter as indicated in the

scheduled maintenance table. The engine should

be emptied by draining the oil through the drainage

cap «B» and by removing the mesh pre-filter.

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 ».

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 vehicle, leave it running for a


MAIN - 47

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 purposes.N.B.THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended productsAGIP CITY HI TEC 4T Engine oilSAE 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 plug24 to 30

Check

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.

- 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.


MAIN - 48

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.

Restoration of the level from MIN to MAX requires

approximately 200 cc.

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.

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 lubricate the O-ring before fitting it. Change the engine oil.

Recommended productsAGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Oil pressure warning light

The vehicle is equipped with a telltale light on the

dashboard that lights up when the key is turned to

the «ON» position. However, this light should

switch off once the engine has been started.

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.

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 vehicle on its centre stand and on flat

ground.


MAIN - 49

- 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.CAUTIONDO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO ASTO AVOID THE COOLANT ESCAPING FROM THE EXPAN-SION TANK WHEN THE VEHICLE IS IN USE.

Recommended productsAGIP PERMANENT SPEZIAL CoolantMonoethylene 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.


MAIN - 50

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 fluid

as indicated in the scheduled maintenance table.WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. BRAKING CIR-CUIT FLUIDS ARE HIGHLY CORROSIVE. MAKE SURETHAT IT DOES NOT COME INTO CONTACT WITH THEPAINTWORK.CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUREYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTALCONTACT, WASH WITH WATER.

Recommended productsAGIP BRAKE 4 Brake fluidFMVSS DOT4 Synthetic fluid

Headlight adjustment


MAIN - 51

Proceed as follows:

1. Position the unloaded vehicle, in running order

and with the tyres inflated to the prescribed pres-

sure, on a flat surface 10 m away from a half-lit

white screen; ensure that the longitudinal axis of

the vehicle is perpendicular to the screen;

2. Remove the headlight assembly central cover

3. Turn on the headlight and check that the limit of

the projected light beam is not over 9/10 or below

7/10 of the distance from the ground to the centre

of the vehicle headlight;

4. Otherwise, adjust the headlight with the

screws«A» indicated in the figureN.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 COUNTRYWHERE THE VEHICLE IS USED.


MAIN - 52

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

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 is given.

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTIONPossible Cause Operation

Wrong valve adjustment Adjust the valve clearance properlyOverheated valves Remove the head and the valves, grind or replace the valves

Misshapen/worn valve seats Replace the head unitWorn 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 beenfitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling sealWorn valve oil seal Replace the valve oil sealWorn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

LOW LUBRICATION PRESSUREPossible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean theBy-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump componentsOil filter too dirty Replace the cartridge filterOil level too low Restore the level by adding the recommended oil type.

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation

Faulty clutch Check that there is no grease on the masses. Check that theclutch mass faying surface with the bell is mainly in the centrewith equivalent characteristics on the three masses. Check thatthe clutch casing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT BRAKING SYSTEMPossible Cause Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs arenot worn, scored or warped. Check the correct level of fluid inthe pumps and change brake fluid if necessary. Check there isno 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

Troubleshooting MP3 125 ie

TROUBL - 54

Possible Cause OperationBrake 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 thevehicle.

Brakes overheating

BRAKE OVERHEATPossible 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 shift ofthe disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed airSwollen or stuck rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENINGPossible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-larities continue in turning the steering even after making theabove adjustments, check the seats in which the ball bearingsrotate: replace them if they are recessed or if the balls are flat-

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible 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 theabove adjustments, check the seats in which the ball bearingsrotate: replace them if they are recessed or if the balls are flat-

tened.

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

Faults in the suspension system If the front suspension is noisy, check: the efficiency of the frontshock absorber; the condition of the ball bearings and relevantlock-nuts, the limit switch rubber buffers; and the movementbushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disc in theattachment to the hub and the steering tube.

MP3 125 ie Troubleshooting

TROUBL - 55

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSIONPossible Cause Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of thesteering covers and the adjustments.

Troubleshooting MP3 125 ie

TROUBL - 56

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

1. Instrument panel

2. Rear right turn indicator bulbs

3. Front right turn indicator bulb

4. Turn indicator switch

5. Front left turn indicator bulb

6. Rear left turn indicator bulbs

7. Hazard button

8. Turn indicator control device with Hazard

9. Pre-installation for anti-theft device

10. Headlight with twin-filament bulb

11. Front position light bulbs

12. License plate bulb

13. Tail light bulbs

14. Key switch contacts

15. Headlight remote control

16. Stop buttons

17. Saddle opening button

18. Boot opening switch

19. Boot opening actuator

20. Saddle opening actuator

Electrical system MP3 125 ie

ELE SYS - 58

21. Light switch

22. Engine stop switch

23. Electric fan

24. Electric fan remote control

25. Boot and helmet compartment light bulb

26. Boot light switch

27. Helmet compartment light switch

28. Magneto flywheel

29. Voltage regulator

30. Main fuses

31. Battery

32. Starter remote control switch

33. Starter button

34. Starter motor


36. Stop light bulbs

37. Injection load remote control

38. Pre-installation for saddle opening receiver

39. Horn remote control

40. Geared motor

41. Brake calliper sensor

42. Parking control ECU

43. Tilt locking/unlocking switch

44. Hand brake

45. Rider presence sensor

46.Potentiometer

47. Lambda sensor

48. Left speed sensor

49. Right speed sensor

50. Engine rpm sensor

51. HV coil

52. Fuel injector

53. Water pump

54. Engine temperature sensor

55. Fuel pump

56. Diagnosis socket

57. Injection ECU

58. Immobilizer Aerial

MP3 125 ie Electrical system

ELE SYS - 59

59. External temperature sensor

60. Pressure sensor

61. MODE button

62. Fuel level transmitter

63. Oil pressure sensor

64. Horn

65. Horn button


67. Auxiliary fuses

Key

Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey

Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Components arrangement


ELE SYS - 60

1. Injection ECU

Remove the inspection cover placed in the helmet

compartment to reach it.

2. Turn indicator control device

Remove the left side fairing to reach it.

3. Rider detection sensor

The sensor is placed under the saddle.

4. Ignition switch

5. Immobilizer antenna

Remove the leg shield back plate to reach it.


ELE SYS - 61

6. Pressure sensor

Remove the shield to reach it.

7. Gear motor


8. Solenoids


A. Injection load solenoid

B. Electric fan solenoid

C. Horn solenoid

D. Headlight solenoid


The sensor is fixed to the front wheel compart-

ment.


ELE SYS - 62

10. Right and left speed sensors

The sensors are located the internal section of the

front wheel.

11. Horn

Remove the front wheel housing to reach it.


Remove the leg shield back plate to reach it.

13. Auxiliary fuses

Remove the cover placed on the vehicle RHS,

lower part, to reach them.


ELE SYS - 63


Remove the central cover to reach it.

15. HV coil

Remove the helmet compartment to reach it.


17. Engine speed sensor

The cable harness of these components exit from

the flywheel, the connectors are fixed to the chas-

sis on the vehicle right hand side.


Remove the right side fairing to reach it.

19. Starter relay

Remove the right side fairing to reach it.

20. Battery

21. Main fuses

Remove the battery cover placed in the helmet compartment to reach them.


ELE SYS - 64

Ground points

1. Ground point on engine

Remove the plastic cover placed on the engine left

side to reach it.

2. Ground point on chassis

Remove the left footrest to reach them.

Conceptual diagrams


ELE SYS - 65

Ignition

1. Instrument panel

30. Main fuses

31. Battery




51. HV coil

57. Injection ECU


67. Auxiliary fuses


ELE SYS - 66

Battery recharge and starting

1. Instrument panel

16. Stop buttons




30. Main fuses

31. Battery


33. Starter button

34. Starter motor


36. Stop light bulbs

57. Injection ECU


67. Auxiliary fuses


ELE SYS - 67

Level indicators and enable signals section

1. Instrument panel

30. Main fuses

31. Battery



41. Brake calliper sensor


43. Tilt locking/unlocking switch

46. Potentiometer

47. Lambda sensor

48. Left speed sensor

49. Right speed sensor


52. Fuel injector


57. Injection ECU




ELE SYS - 68

63. Oil pressure sensor

67. Auxiliary fuses

Devices and accessories

1. Instrument panel





9. Pre-installation for anti-theft device


17. Saddle opening button

18. Boot opening switch

19. Boot opening actuator

20. Saddle opening actuator

23. Electric fan


25. Boot and helmet compartment light bulb

26. Boot light switch

27. Helmet compartment light switch


ELE SYS - 69

30. Main fuses

31. Battery



38. Pre-installation for saddle opening receiver

39. Horn remote control

40. Geared motor


44. Hand brake

53. Water pump

55. Fuel pump

57. Injection ECU

60. Pressure sensor

61. MODE button

64. Horn

65. Horn button


67. Auxiliary fuses

Lights and turn indicators


ELE SYS - 70

1. Instrument panel






7. Hazard button



11. Front position light bulbs


13. Tail light bulbs

15. Headlight remote control

21. Light switch

30. Main fuses

31. Battery




67. Auxiliary fuses

Checks and inspections

This section is dedicated to the checks on the electrical system components.

Immobiliser

The electronic ignition system is managed by the control unit in which the immobiliser system is inte-

grated. The immobiliser is an antitheft system which allows the vehicle to function only if it is activated

by means of the coded keys that the control unit recognises. 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

turning the key. The Immobilizer system consists of the following components:

- an electronic control unit

- 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 key is set to «OFF» or the emergency stop switch is set to «OFF». It remains activated for 48


ELE SYS - 71

hours in order not to affect the battery charge. When the ignition key is turned to «ON», the deterring

blinker function is deactivated. Subsequently, a flash confirms the switching to « ON». 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 and/or the instrument panel is not initiated, check if:

• there is battery voltage

• fuses No. 2, 5 and 10 are in working order

• there is power to the control unit as specified below:

With the ignition key set to « OFF»:

• check whether there is battery voltage

between terminals 10-38 and terminal

10-chassis ground (fixed power sup-

ply). If there is no voltage, check that

fuse 5 and its cable harness are in

working order.

With the ignition key set to «ON»:

• check whether there is battery voltage

between terminals 18-38 and terminal

18-ground chassis (fixed power sup-

ply). If there is no voltage, check the

ignition key contacts and that fuses No.

2 and 10 and their cables are in work-

ing order.

• whether there is voltage between ter-

minal 24 and ground with the emer-

gency stop switch set to «RUN». If

there is no voltage, check the contacts

of the switch.


ELE SYS - 72

After removing the leg 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 at ON check there is battery

voltage between the Red-White and Black cables

With ECU connector disconnected, check if there

is continuity between the aerial Orange-White ca-

ble and pin 29 of the control unit.

Specific tooling020331Y 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


ELE SYS - 73

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 2 seconds (limit values 1-3 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 resistor spark plugs.

CharacteristicMASTER key:

RED KEY

SERVICE key.

BLACK KEY

Diagnostic codes

The Immobilizer system is tested each time the ig-

nition key 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 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-


ELE SYS - 74

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 on

permanently. In this condition no operations are

possible including the start up 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.

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

• 2-flash code

• 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-

ry.


ELE SYS - 75

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.

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.

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

is repeated even with the Master key, replace the

control unit. If this is not the case, reprogram the

decoder.

No spark plugWARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.

HV coil primary resistance value:

Disconnect the connector of the HV coil and re-

move the protective base shown in the figure.

Measure the resistance present between the Red-

Black and Black-Green terminals.

Repeat checks between pin 1 of the control unit

connector and the Black-Green cable of the injec-

tion load solenoid. If the value measured is incor-

rect, check cable harness for integrity.

Electric characteristicHV coil resistance primary value:


ELE SYS - 76

260 ± 26 mΩ

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel.

The generator is directly connected to the voltage regulator.

This, in its turn, is connected directly to the ground and the battery positive terminal passing through

the 30A protective fuse.

The three-phase alternator provides good recharge power and at low revs a good compromise is ach-

ieved between generated power and idle stability.

Remote controls check

To check the operation of a relay:

1) Check that, given regular conditions, there is no

continuity between terminals 87 and 30.

2) Apply a 12V voltage to power terminals 86 and

85 of the relay.

3) With the relay fed, check that there is continuity

between terminals 87 and 30.

4) If these conditions are not met, the relay is sure-

ly damaged and, therefore, it should be replaced.

Switches check

To check buttons and switches, check that, according to their position, the continuity of contacts is

correct as indicated in the following charts.

KEY

Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

ENGINE STOP SWITCH


ELE SYS - 77

STARTER BUTTON

LIGHT SWITCH

TURN INDICATOR SWITCH

HORN BUTTON


ELE SYS - 78

HELMET COMPARTMENT LIGHT SWITCH

SADDLE OPENING SWITCH

CASE OPENING SWITCH

HAZARD BUTTON


ELE SYS - 79

MODE BUTTON

Stator check

Checking the stator windingsWARNING

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 Black cables as shown in the

picture.

3) Measure the resistance between each of the Black terminals and the other two.

Electric characteristicResistance:

0.2 - 1 Ω

4) Ensure that each Black cable is isolated from

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.

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.


ELE SYS - 80

Charging current checkWARNINGBEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK-ING ORDER.1) Place the vehicle on its centre stand

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 characteristicVoltage 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: > 20A

VOLTAGE REGULATOR/RECTIFIERSpecification Desc./Quantity

Type Non-adjustable three-phase transistorVoltage 14 to 15V at 5000 rpm with lights off

Starter motor

KEY

1. Battery


ELE SYS - 81

2. Fuse No. 2


4. Fuse No. 8

5. Stop buttons

6. Injection ECU

7. Starter button


9. Starter motorWARNING


1) Check fuses No. 2 and 8.

2) Check key switch contacts.

3) Check the contacts of the stop buttons and the starter button.

4) With the key switch set to «ON», the brake pulled and the starter button pressed, check if there is

voltage between the Orange-White cable of the starter remote control base and the ground connection.

5)If no voltage is detected, check cable harnesses for continuity.

6) Check if there is continuity of the Orange-Blue cable between the starter remote control base and

pin 20 of the control unit.

7) Check the starter remote control switch.

8) Check if there is continuity of the Red cable between the battery and the remote control base. Also

check if there is continuity between the latter and the starter motor.


ELE SYS - 82

Horn control

KEY

1. Battery

2. Fuse No. 2


4. Fuse No. 9

5. Horn button

6. HornWARNING




3)Check the horn button contacts.

4) With the key switch set to «ON» and the horn button pressed, check whether there is voltage between

the Yellow-Pink cable of the horn connector and the ground connection.

5)If no voltage is detected, check cable harnesses for continuity.

6) Check that the Black cable of the horn connector is grounded.


ELE SYS - 83

Turn signals system check

KEY

1. Battery

2. Fuse No. 4


4. Fuse No. 12


6. Hazard button





11. Rear left turn indicator bulbsWARNING


1) Check that bulbs operate properly.


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 whether there is 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 - 84

- 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, with 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 if there is continuity of the cable harnesses that connect the bulbs to the turn indicator control

device.

9) Check the bulbs ground connection.

level indicators

KEY

1. Instrument panel

2. Fuel level transmitterWARNING


1) With a multimeter, check resistance values between the White-Green cable and the Black cable of

the fuel level transmitter under different conditions.


ELE SYS - 85

2) If the values measured are correct but the indication on the instrument panel is not exact, check if

there is continuity of the White-Green cable.

Electric characteristicResistance value when the tank is full<= 5 ΩResistance value when the tank is empty98 ± 5 Ω

Lights list

KEY

1. Battery

2. Fuse No. 2


4.Fuse No. 4

5.Fuse No. 9

6. Fuse No. 11

7.Headlight remote control


9.Fuse No. 12

10.Front position light bulbs

11.Tail light bulbs



ELE SYS - 86



15. Light switchWARNING


TAIL LIGHT LINE CHECK




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).


HIGH-/ LOW-BEAM LIGHTS LINE - CHECK


2) Check fuses No. 2, 4, 9 and 11.


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 Sky 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 if there is 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).


LIGHT BULBS TABLESpecification Desc./Quantity

1 Low beam bulb Type: HALOGEN (H1)Power: 12V - 55W

Quantity: 12 High beam light bulb Type: HALOGEN (H1)

Power: 12V - 55WQuantity: 1

3 Helmet compartment light bulb Type: Incandescent (SV 8.5)Power: 12V - 5W

Quantity: 14 Rear turn indicator light bulb Type: Incandescent (W2.1 x 9.5D)

Power: 12V - 5WQuantity: 2 RHS + 2 LHS


ELE SYS - 87

Specification Desc./Quantity5 Rear tail light bulb Type: Incandescent (W2.1 x 9.5D)

Power: 12V - 5WQuantity: 1 RHS + 1 LHS

6 Stop light bulb Type: Incandescent (BAU 15s)Power: 12V - 10W

Quantity: 27 License plate bulb Type: Incandescent (W2.1 x 9.5D)

Power: 12V - 5WQuantity: 1

8 Front turn indicator light bulb Type: Incandescent (BAU 15s)Power: 12V - 10W

Quantity: 1 RHS + 1 LHS9 Front side light bulb Type: Incandescent (W2.1 x 9.5D)

Power: 12V - 3WQuantity: 1 Right - 1 Left

10 Instrument panel lighting bulbs Type: IncandescentPower: 12V - 2W

Quantity: 4

Fuses

The electrical system has twelve fuses divided in

two fuse boxes to protect the different installation

circuits. One of them is inside the battery compart-

ment and the other is at the right internal side of

the footrest. To be able to reach, loosen the screw

"A" 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 SOLVETHE FAILURE THAT CAUSED IT TO BLOW. NEVER TRYTO REPLACE THE FUSE WITH ANY OTHER MATERIAL(E.G., A PIECE OF ELECTRIC WIRE).

FUSE TABLESpecification Desc./Quantity

1 Fuse No. 1 Capacity: 30 AProtected circuits: Battery recharge circuit.

2 Fuse No. 2 Capacity:20AProtected circuits: Fuse No. 7.Live: Fuses No. 8, 9,10 and 11.

3 Fuse No. 3 Capacity: 20AProtected circuits: Parking electronic control unit.

4 Fuse No. 4 Capacity: 15A


ELE SYS - 88

Specification Desc./QuantityProtected circuits:Pre-installation for saddle openingreceiver, pre-installation for anti-theft device, boot andhelmet compartment lights, high-beam and low-beam

lights (via remote control), turn indicator control device.Live: Fuse No. 12, saddle and boot opening.

5 Fuse No. 5 Capacity: 15AProtected circuits: Injection ECU, injection load (via re-

mote control).6 Fuse No. 6 Capacity:15A

Protected circuits: Electric fan (via remote control)7 Fuse No. 7 Capacity: 7.5 A

Protected circuits:Instrument panel.8 Fuse No. 8 Capacity:10 A

Protected circuits: Start-up circuit, stop light.9 Fuse No. 9 Capacity: 7.5 A

Protected circuits: High-beam light in flashing mode,horn.

10 Fuse No. 10 Capacity: 7.5 AProtected circuits: Injection ECU, immobilizer aerial,

electric fan remote control, injection load remote control.11 Fuse No. 11 Capacity: 7.5 A

Protected circuits: Horn (via remote control), headlightremote control, horn remote control, pre-installation for

anti-theft device, instrument panel.12 Fuse No. 12 Capacity: 7.5 A

Protected circuits: Turn indicator control device, instru-ment panel lighting, pre-installation for saddle openingreceiver, engine stop switch, tail light, license plate light.

Dashboard

A = Immobilizer / anti-theft LED

B= Speedometer with twin scale (km/h and mph)


ELE SYS - 89

C = CLOCK switch

D = Digital display

E= SET switch

F= Rpm indicator

G = Fuel gauge

H = Warning light for helmet compartment courtesy light on

I = Engine control telltale light and injection system failure warning light

L = Low fuel warning light

M = Engine stop warning light

N= Turn indicator warning light

O = Low oil pressure warning light

P = Front suspension locking system failure warning light

Q = Front suspension locking system warning light

R = High beam warning light

S = Warning light for parking brake engaged

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge

and recharging, if necessary.

These operations should be carried out before delivering the vehicle, and on a six-month basis while

the vehicle is stored in open circuit.

Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-

quired, 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 to 14.70V

- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity

- Charge time:

10 to 12 h recommended

Minimum 6 h

Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity


ELE SYS - 90

- Charge time: Maximum 5 h

Battery installation

VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTOCONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN.AND SEEK IMMEDIATE MEDICAL ATTENTION.IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGEQUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.SEEK IMMEDIATE MEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS ORCIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.KEEP OUT OF REACH OF CHILDREN

1) Battery preparation

Position the battery on a flat surface. Remove the

adhesive sheet closing cells and proceed as quick-

ly as possible to run the subsequent activation

phases.

2) Electrolyte preparation.

Remove the container of the electrolyte from the

pack. Remove and preserve cover strips from the

container, in fact, the strip will later be used as a

closing cover.

Note: Do not pierce the sealing of the container or

the container itself because inside there is sulphu-

ric acid.


ELE SYS - 91

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with

the six areas sealed in line with the six battery filler

holes. Push the container down with enough force

to break the seals. The electrolyte should start to

flow inside the battery.

Note: Do not tilt the container to prevent the flow

of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20

minutes or more.

Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container

two or three times. Do not remove the container from the battery.

5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte

remains in the container. Now, gently pull the container out from the battery, only do this when the

container is completely empty, and proceed immediately to the next point.

6) Battery closing.

Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure

that the strip is levelled with the top part of the battery.

Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect

your hands and do not bring your face close to the battery.

The filling process is now complete.

Do not remove the strip of caps under any circumstances, do not add water or electrolyte.

Place the battery down for 1 to 2 hours prior to the charging from the battery.

7) Recharging the new battery

With the above-mentioned procedure, the battery

will have gained around 70% - 75% of its total

electrical capacity. Before installing the battery on

the vehicle, it must be fully charged and then must

be recharged.

If the battery is to be installed on the vehicle

prior to this pre-charged one, the battery will

not be able to exceed 75% charge without jeop-

ardising its useful life on vehicle.

The dry charge battery MF like the completely loa-

ded YTX, must have a no-load voltage between


ELE SYS - 92

12.8 - 13.15 V Bring the battery to full charge, us-

ing the 020648Y battery charger:

a - select the type of battery with the red switch on

the left of the panel battery charger panel

b - select NEW on the yellow timer

c - connect the clamps of the battery charger to the

battery poles (black clamp to negative pole (-) and

red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-

ure.

f - Check the ignition of the green LED indicated

with a red arrow in figure.


ELE SYS - 93

g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED

has taken place

h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less

than 12.8 V, proceed with a new recharge of the

battery starting from point c of the recharge pro-

cedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,

disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

Connectors

INJECTION ELECTRONIC CONTROL UNIT

CONNECTOR

1. HV coil (Red-Black)

2. Electric fan remote control (Blue-Yellow)

3. Injection load remote control (Black-Purple)

4. Engine rpm sensor positive (Red)

5. Engine rpm sensor negative (Brown)

6. Not connected

7. Shield

8. Engine temperature sensor ground (Orange-

Black)

9. Not connected

10. Battery-powered (Grey-Black)

11. Not connected

12. Fuel injector (Red-Yellow)

13. Not connected


ELE SYS - 94

14. Not connected

15. Not connected

16. Not connected

17. Engine temperature sensor (Sky blue-Green)

18. Live supply (Red-White)

19. Fuel pump (Sky blue)

20. Start-up enabling switch (Orange-Blue)

21. Injection telltale light (Brown-Black)

22. Rpm indicator (Yellow)

23. Diagnosis (Purple-White)

24. Engine stop switch (Green-Black)

25. Ground lead (Grey-Green)

26. Engine temperature indicator (Brown-White)

27. Not connected

28. HV coil (White-Black)

29. Immobilizer aerial (Orange-White)

30. Immobilizer warning light (Red-Green)

31. CAN "H" Line (Pink-White)

32. CAN "L" Line (White-Blue)

33. Not connected

34. Not connected

35. Lambda probe positive (Sky blue- Black)

36. Not connected

37. Lambda probe negative (White-Green)

38. Ground lead (Black)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red)


3. Battery positive (Red)



ELE SYS - 95

SADDLE OPENING RECEIVER PRE-INSTAL-

LATION CONNECTOR

1. Aerial (Purple)

2. Saddle opening actuator (Yellow-Grey)

3. Reset (Blue-Black)

4. Battery-powered (Blue)

5. Not connected

6. Live supply (Yellow-Black)


8. Not connected

9. Not connected

10. Boot actuator (Yellow)

11. Channels 1/3 selector (Green-Blue)

12. Alarm code (Orange-Black)

TURN INDICATOR CONTROL DEVICE CON-

NECTOR

1. Hazard switch (Brown)

2. LHS Switch (White-Pink)

3. RHS Switch (Blue-Black)

4. LHS Turn indicators (Pink)

5. RHS Turn indicators (White-Blue)

6. Battery powered (Blue)

7. Not connected

8. Key-on power (Yellow-Black)


10. Not connected

11. Not connected

12. Not connected

ANTI-THEFT DEVICE PRE-INSTALLATION

CONNECTOR

1. Left turn indicators (Pink)

2. Right turn indicators (White-Blue)


4. Battery-powered (Blue)

5. Live supply (Yellow-Red)

6. Helmet compartment lighting (Blue-Black)

7. Channels 1/3 selector (Green-Blue)


ELE SYS - 96

8. Alarm code (Orange-Black)

FUEL PUMP CONNECTOR

1. Injection load remote control (Black-Green)

2. Not connected

3. Not connected


5. Not connected

INSTRUMENT PANEL CONNECTOR "A"

1. Not connected

2. Not connected

3. Not connected

4. Not connected

5. Instrument panel lighting (Yellow-Black)

6. Battery-powered (Red-Blue)

7. Not connected

8. Not connected

9. Not connected

10. Not connected


12. Live supply (Yellow-Red)

INSTRUMENT PANEL CONNECTOR "B"

1. Scooter speed signal (Sky blue)

2. Fuel level indicator (White-Green)

3. Water temperature sensor (Brown-White)

4. Water temperature sensor ground (Grey-

Green)

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. Rpm sensor (-)

12. Ambient temperature sensor (Yellow-Blue)


ELE SYS - 97

13. Ambient temperature sensor ground (White-

Yellow)

14. Engine disabled warning light (Green-Black)

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)

20. Live positive from the parking control ECU

(Yellow-Green)

PARKING CONTROL ECU CONNECTOR

1A. Potentiometer power supply (Orange-Blue)

2A. CAN "L" Line (White-Blue)

3A. Warning light power supply (Yellow-Green)

4A. Tilt locking activated warning light (Pink-Black)

5A. Tilt locking system failure warning light (Grey)

6A. Headlight remote control (White-Black)

7A. Potentiometer ground lead, rpm sensor, rider

presence sensor (Yellow)

8A. Ground lead (Black)

1B. Live supply (Yellow-Red)

2B. CAN "H" Line (Pink-White)

3B. Left wheel turning sensor (Green)

4B. Right wheel turning sensor (Red)

5B. Potentiometer signal (Green-Blue)

6B. Locking/unlocking switch (Green-Grey)

7B. Horn remote control for alarms (White)

8B. Geared motor (Yellow)

1C. Battery powered (Blue-Red)

2C. Diagnosis (Purple-White)

3C. Locking/unlocking switch (Yellow-Blue)

4C. Calliper sensor (Brown)

5C. Locking/unlocking switch (Purple-Black)

6C. Rider presence sensor (Purple)

7C. Scooter speed signal (Sky blue)

8C. Geared motor (Blue)


ELE SYS - 98

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

This section describes the operations to carry out when removing the engine from the vehicle.

Exhaust assy. Removal

- Remove the Lambda probe from its support and

disconnect it.

- Undo the two exhaust manifold fixings on the

head. To unscrew the nuts that fix the silencer

flange to the head properly, use a jointed wrench

that allows, according to the travel direction, to get

also at the right nut. That is difficult to do with a

traditional straight wrench.

- Undo the three screws that fix the silencer to the

supporting arm.

- Remove the full silencer unit.

Engine from vehicle MP3 125 ie

ENG VE - 100

Remove the lambda probe from the manifold.

CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS RE-

PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

Removal of the engine from the vehicleCAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.CAUTION

SUPPORT THE VEHICLE ADEQUATELY.

- Remove the battery.

- Remove the side fairings.

- Remove the full silencer unit.

- Remove the air filter.

- Working on the vehicle right side, remove the

coolant inlet pipes and empty the system.N.B.LET THE COOLANT DRAIN INTO A CONTAINER OF ADE-QUATE CAPACITY.

CharacteristicCooling system fluid~ 2 l

MP3 125 ie Engine from vehicle

ENG VE - 101

- Remove the coolant outlet pipe from the engine.

- Disconnect the fuel pipe and the fitting to the

control unit.

- Disconnect the connector of the injector.

- Disconnect the coolant temperature sensor.

- Undo the fixing screws of the cable harness and

disconnect the control unit connector by rotating

the ring nut.


ENG VE - 102

- Remove the indicated clamp, unscrew the posi-

tive and negative cable harnesses of the starter

motor.

- Unscrew the control unit - intake manifold fixing

clamp to facilitate reaching both screws indicated.

- Remove the throttle grip cable harness cover.

- Remove the indicated pipe.

- Disconnect the throttle grip cables by undoing the

set screws.

- Remove the control unit.

- Release the cable harness from the cable grom-

met clamp and remove the clamp indicated.

- Disconnect the oil minimum pressure sensor.


ENG VE - 103

- Disconnect the voltage regulator connector and

release the cable harness.

- Take out the ground retainer on the engine.

- Remove the rear left shock absorber lower re-

tainer.


ENG VE - 104

- Remove the pin fixing the engine to the swinging

arm.

- The engine is now free.

When refitting the engine onto the vehicle, 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 TRANSMISSIONPROPERLY.


ENG VE - 105

INDEX OF TOPICS

ENGINE ENG

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- Remove the air duct.

- With the specific tool lock the driven pulley, undo

the indicated nut and collect the washer.

Specific tooling020423Y Driven pulley lock wrench

- Undo the eleven fixings screws to the engine and

remove the transmission coverN.B.WHEN YOU ARE REMOVING THE TRANSMISSION COVERYOU MUST BE CAREFUL NOT TO DROP THE CLUTCHHOUSING.

Air duct

- Undo the three screws «1» and remove the

crankcase cover «2».

MP3 125 ie Engine

ENG - 107

- Undo the three screws «3» and remove the filter

cover in the transmission housing «4».

- Take out the filtering element «5» from the cover.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by

means of:

Specific tooling020376Y Adaptor handle

020375Y 28 x 30 mm adaptor

020412Y 15-mm guide

Refitting the driven pulley shaft bearing

- Heat the crankcase from the inside.

- Insert the bearing in its seat.

- Refit the Seeger ring.CAUTIONUSE AN APPROPRIATE SUPPORT TO AVOID DAMAGINGTHE COVER SURFACE.N.B.ALWAYS REPLACE THE BEARING WITH A NEW ONEUPON REFITTING.



Engine MP3 125 ie

ENG - 108

020412Y 15-mm guide

Removing the driven pulley

- Remove the stationary driving half-pulley and the

clutch housing.

- Remove the driven pulley together with the belt.

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

CharacteristicMax. value clutch bellMax. value: Ø 134.5 mm

clutch housing standard valueStandard value: Ø 134 - 134.2 mm

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2

bearings (inside diameter: 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft unit on the support to check

the crankshaft alignment.

MP3 125 ie Engine

ENG - 109

- Using a feeler dial gauge and the magnetic base,

measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central,

internal, external).

- If faults are found, replace the bell.

Specific tooling020074Y Support base for checking crankshaftalignment


Characteristicclutch bell inspection: Limit eccentricity.Admissible limit eccentricity: 0.15 mm

Removing the clutch

Fit the driven pulley spring compressor specific

tool with medium length pins screwed in position

«C» on the tool internal side.

- Introduce the adapter ring 11 with the chamfering

facing the inside of the tool.

- Fit the driven pulley unit on the tool with the in-

sertion of the 3 pins in the ventilation holes in the

mass holder support.

- Make sure that the clutch is perfectly inserted into

the adapter ring before proceeding to loosen/tight-

en the clutch nut.

- Use the special 46x55 wrench component 9 to

remove the nut fixing the clutch in place.

- Dismantle the driven pulley components (Clutch

and spring with its plastic holder)CAUTIONTHE TOOL MUST BE FIRMLY FIXED IN THE CLAMP ANDTHE CENTRAL SCREW MUST BE BROUGHT INTO CON-TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSETHE SPECIFIC TOOL TO BUCKLE.

Specific tooling020444Y011 adapter ring

020444Y009 wrench 46 x 55

020444Y Tool for fitting/ removing the drivenpulley clutch

Engine MP3 125 ie

ENG - 110

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.

- 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 CEN-TRAL FAYING SURFACE AND MUST NOT BE DIFFERENTFROM ONE ANOTHER.VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TOTEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS TO PREVENTA VARIATION IN THE RETURN SPRING LOAD.

CharacteristicCheck minimum thickness1 mm

Pin retaining collar

- Simultaneously turn and pull the collar manually

to remove it.N.B.USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL-TY.N.B.BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOOFAR TO AVOID DAMAGE THAT COULD COMPROMISETHE O-RING SEAL.

- Remove the 4 torque server pins and pull the

pulley halves apart.

MP3 125 ie Engine

ENG - 111

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisi-

ness; - Replace with a new one if there are.

- Remove the retainer ring using two flat blade

screwdrivers.

- Support the pulley bushing adequately from the

threaded side using a wooden surface.

- Using a hammer and pin, knock the ball bearing

out as shown in the figure.

- Support the pulley properly using the bell as

shown in the figure.

Specific tooling001467Y035 Bearing housing, external ø 47mm

- Remove the roller bearing using the modular punch.


020456Y Ø 24 mm adaptor

020363Y 20-mm guide

Inspecting the driven fixed half-pulley

Version 250

- Measure the outside diameter of the pulley bush-

ing.

- Check the faying surface with the belt to make

sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

CharacteristicHalf-pulley minimum diameterMinimum admissible diameter: Ø 40.96 mm

Engine MP3 125 ie

ENG - 112

Half-pulley standard diameterStandard diameter: Ø 40.985 mm

Wear limit0.3 mm

Inspecting the driven sliding half-pulley

- Remove the two seal rings and the two O-rings.

- Measure the movable half-pulley bushing inside

diameter.

- Check the faying surface with the belt to make

sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONSSpecification Desc./Quantity

Wear limit 0.3 mmstandard diameter Ø 41.000 - 41.035 mm

maximum allowable diameter Ø 41.08 mm

MP3 125 ie Engine

ENG - 113

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the

threaded side using a wooden surface.

- Fit a new roller bearing as shown in the figure.

- For the fitting of the new ball bearing, follow the

example in the figure using a modular punch.

Fit the retainer ringWARNINGN.B.FIT THE BALL BEARING WITH THE VISIBLE SHIELDING



020424Y Driven pulley roller casing fittingpunch

Refitting the driven pulley

- Insert the new oil seals and O-rings on the mov-

able half-pulley.

- Lightly grease the O-rings «A» shown in the fig-

ure.

- Fit the half-pulley over the bushing using the spe-

cific tool.

- Check that the pins are not worn and proceed to

refitting them in their slots.

- Refit the torque server closure collar.

- Using a curved-spout grease gun, lubricate the

driven pulley unit with approximately 6 grams of

grease. Apply grease through one of the holes in

the bushing until it comes out through the hole on

the opposite side. This operation is necessary to

avoid the presence of grease beyond the O-rings.N.B.

Engine MP3 125 ie

ENG - 114

THE TORQUE SERVER CAN BE GREASED WHETHERWITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-PLACED; UNDERTAKING THE OPERATION WHEN THEBEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling020263Y Driven pulley assembly sheath

Recommended productsAGIP GREASE SM 2 Grease for the C-ring ofthe tone wheelSoap-based lithium grease containing NLGI 2 Mo-

lybdenum disulphide; ISO-L-XBCHB2, DIN

KF2K-20

Inspecting the clutch spring

- Measure the length of the spring when it is re-

laxed.

CharacteristicStandard length145 mm

Acceptable limit after use140 mm

Refitting the clutch

- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.

- Arrange the tool with the medium length pins

screwed in position "C" on the inside.

- Introduce the adapter ring No. 11 with the cham-

fering facing upwards.

- Insert the clutch on the adapter ring.

- Lubricate the end of the spring that abuts against

the torque server closing collar.

- Insert the spring with its plastic holder in contact

with the clutch.

- Insert the drive belt into the pulley unit according

to their direction of rotation.

- Insert the pulley unit with the belt into the tool.

- Slightly preload the spring.

MP3 125 ie Engine

ENG - 115

- Make sure that the clutch is perfectly inserted into

the adapter ring before proceeding to tighten the

clutch nut.

- Place the tool in the clamp with the control screw

on the horizontal axis.

- Fully preload the spring.

- Apply the clutch fixing nut and tighten it to the

prescribed torque using the special 46x55 wrench.

- Loosen the tool clamp and insert the belt accord-

ing to its direction of rotation.

- Lock the driven pulley again using the specific

tool.

- Preload the clutch return spring with a traction/

rotation combined action and place the belt in the

smaller diameter rolling position.

- Remove the driven pulley /belt unit from the tool.N.B.DURING THE SPRING PRELOADING PHASE, BE CARE-FUL NOT TO DAMAGE THE PLASTIC SPRING STOP ANDTHE BUSHING THREADING.N.B.FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-TED IN CONTACT WITH THE CLUTCH.

Specific tooling020444Y Tool for fitting/ removing the drivenpulley clutch

020444Y011 adapter ring

020444Y009 wrench 46 x 55

Locking torques (N*m)Clutch unit nut on driven pulley 45 to 50

Engine MP3 125 ie

ENG - 116

Refitting the driven pulley

- Fit the clutch housing on the driven pulley paying

attention to the position of the washer indicated.

Drive-belt

- Make sure the drive belt is not damaged and does not show abnormal wear.

- Replace as indicated in the scheduled maintenance table.

Removing the driving pulley

- Turn the crankshaft until the ropes of the pulley

are on a horizontal axis

MP3 125 ie Engine

ENG - 117

- Insert the adaptor sleeve of the appropriate tool

in the hole shown in the picture

- Insert the tool in the hollows and apply the reten-

tion ring

- Bring in the ring's clamping screws while keeping

the tool to support the pulley

- Remove the fixing nut and the washer

- Remove the stationary drive pulley half.

Specific tooling020626Y008 Driving pulley lock wrench

- Remove nut «1», Belleville spring «2», and wash-

er «3».

- Remove the stationary driving half-pulley.

Engine MP3 125 ie

ENG - 118

- Detach the drive belt from the crankshaft, remove

the sliding bushing and the entire roller housing.

Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner

diameter A.

- Measure outer diameter B of the pulley sliding

bushing shown in the figure.

- Check that the rollers are not damaged or worn.

- Check the guide shoes for the variator back-plate

are not worn.

- Check the wear of the roller housings and of the

belt faying surfaces on both pulley halves.

- Check that stationary driving pulley does not

show signs of abnormal wear on the grooved edge

and on the surface in contact with the belt.

- Check that the O-ring is not pushed out of shape.CAUTIONDO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristicmovable driving half-pulley bushing: StandardDiameter26.000 - 26.021 mm

movable driving half-pulley bushing: Maxi-mum allowable diameterØ 26.12 mm

Sliding bushing: Standard DiameterØ 25.959 ÷ 25.98 mm

Sliding bushing: Minimum diameter permittedØ 25.95 mm

Roller: Standard diameter

MP3 125 ie Engine

ENG - 119

Ø 19.5 - 20.1 mm

Roller: Minimum admissible weight5.4 ± 0.15 g

Refitting the driving pulley

- Preassemble the movable half-pulley with the

roller contrast plate by putting the rollers in their

housings with the larger support surface touching

the pulley according to the direction of rotation.

- Check that the roller contact plate does not have

flaws and is not damaged on the grooved edge.

- Mount the complete bushing unit on the crank-

shaft.

- Fit the driven pulley/Clutch/belt unit on the en-

gine.

Engine MP3 125 ie

ENG - 120

- Fit the steel shim in contact with the bushing and

the stationary drive pulley.

- Install the appropriate tool as described in the re-

moval phase.

-Tighten the nut with washer to the prescribed tor-

que.

Specific tooling020626Y008 Driving pulley lock wrench

Locking torques (N*m)Drive pulley nut 75 - 83

Refitting the transmission cover

- Check that there are two alignment dowels and

that the sealing gasket for the oil sump on the

transmission cover is adequately fitted.

- Refit the cover and tighten the «12» screws to the

specified torque.

- Refit the steel washer and the driven pulley nut.

- Tighten the nut to the prescribed torque using the

lock wrench and the torque wrench tools.

- Refit the plastic cover.

Specific tooling020423Y Driven pulley lock wrench

Locking torques (N*m)Transmission cover screws 11 to 13 Driven pul-ley shaft nut 54 ÷ 60

End gear

MP3 125 ie Engine

ENG - 121

Removing the hub cover

- Empty the reduction oil through the drain screw

«1».

- Undo the six screws «2», and the screw «3».

- Remove gasket «4» and make sure that align-

ment dowels «5» are adequately positioned.

Removing the wheel axle

- Remove the wheel axis complete with gear.

- Remove the intermediate gear.

Engine MP3 125 ie

ENG - 122

Removing the hub bearings

- Check the state of the bearings being examined

(wear, clearance and noisiness). If faults are de-

tected, do the following.

- Use the specific bearing extractor to remove the

three 15 mm bearings (2 in the crankcase and 1 in

the hub cover).

Specific tooling001467Y013 Calliper to extract ø 15-mm bear-ings

Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover.

- Support the hub cover and expel the bearing.

By means of the appropriate tools, remove the oil

guard as in the figure.


020477Y 37 mm adaptor

020483Y 30-mm guide


020489Y Hub cover support stud bolt kit

MP3 125 ie Engine

ENG - 123

Removing the driven pulley shaft bearing

- Extract the driven pulley shaft from its bearing.

- Remove the oil seal using a screwdriver and be

careful not to damage the seat.

- Remove the Seeger ring indicated.



020363Y 20-mm guide

- Remove the driven pulley shaft bearing using the

modular punch.



020363Y 20-mm guide

Inspecting the hub shaft

- Check that the 3 shafts exhibit no wear or defor-

mation on the grooved surfaces, at the bearings

and at the oil seals.

- In case of faults, replace the damaged parts.

Engine MP3 125 ie

ENG - 124

CharacteristicConnection diameter for countershaft:

A = Ø 15 - 0.01 -0.02 mm

Connection diameter for wheel shaft:

B = Ø 25 - 0.020 -0.035 mm

C = diameter 15 - 0.01 -0.02 mmBearing diameter for driven pulley shaft:

D = Ø 15 - 0.01 -0.02 mm

E = 19.8 ± 0.1F = Ø 20 - 0.01 -0.02 mm

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.

- In case of faults, replace the damaged components.

MP3 125 ie Engine

ENG - 125

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat

gun.

- Fit the wheel shaft bearing with a modular punch

as shown in the figure.

- Fit the Seeger ring.

- Fit the oil guard with seal lip towards the inside

of the hub and place it flush with the internal sur-

face by means of the appropriate tool used from

the 52-mm side.

The 52-mm side of the adapter must be turned to-

wards the bearing.



020483Y 30-mm guide

Engine MP3 125 ie

ENG - 126

Refitting the hub cover bearings

In order to fit the hub box bearings, the engine

crankcase and the cover must be heated with the

special heat gun.

- The three 15-mm bearings must be fitted using

the appropriate tools:

- The 42-mm side of the adapter must be turned

towards the bearing.

Specific tooling020150Y Air heater mounting

020151Y Air heater



020412Y 15-mm guide

N.B.

TO FIT THE BEARING ON THE COVER, ADEQUATELY SUPPORT THE COVER WITH THE STUDBOLT KIT.

- Refit the driven pulley shaft bearing with a mod-

ular punch as shown in the figure.N.B.IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROMTHE HUB INNER SIDE.



020363Y 20-mm guideN.B.

WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASEPREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.

- Refit the Seeger ring with the opening facing the bearing and fit a new oil seal flush with the crankcase

from the pulley side.

MP3 125 ie Engine

ENG - 127

Refitting the hub bearings

- Install the three shafts in the engine crankcase

as shown in the figure.

Refitting the ub cover

- Fit a new gasket together with the alignment

dowels.

- Seal the gasket of the breather pipe using black

silicone sealant.

- Fit the gearbox cover, making sure the breather

pipe is in the correct position.

- Position the shorter screw that can also be rec-

ognised from the different colour as shown in the

figure.

- Fix the breather tube support by means of the

lower screw.

- Fit the remaining screws and tighten the seven

screws to the prescribed torque.

Locking torques (N*m)Hub cover fixing screws 24 to 27 Hub oil drainscrews 15 to 17

Flywheel cover

Engine MP3 125 ie

ENG - 128

Removing the hub cover

- Remove the clamp fastening the pipe to the cyl-

inder, undo the two screws fixing it to the engine

and remove the electric pump together with its

support.

- Remove the seven screws fixing the flywheel

cover.

- Remove the flywheel cover.

- Remove the gasket and be careful with the two

alignment dowels.

MP3 125 ie Engine

ENG - 129

Removing the stator

- Remove the two pickup screws and the screw

holding the wiring support and the three stator

clamping screws shown in the figure.

- Remove the stator and its wiring.

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-

ers to the specified torque.

Locking torques (N*m)Stator fixing screws 8 to 10 Pickup fixingscrews 3 to 4

Refitting the flywheel cover

- Fit the gasket and be careful with the two align-

ment dowels.

Engine MP3 125 ie

ENG - 130

- Fit the entire flywheel cover.

- Undo the seven screws fixing the flywheel cover,

observing the position of the plate indicated.

- Fasten the electric pump together with its support

with the two screws indicated and fasten the pipes

to the cylinder.

Locking torques (N*m)Transmission cover screw 11 to 13

Flywheel and starting

Removing the starter motor

- Remove the two screws indicated in the figure

- Take the starter motor out of its seat

MP3 125 ie Engine

ENG - 131

Removing the flywheel magneto

- Remove the screw and the plate of the starting

sprocket.

- Fit the specific tool, screw the guide bushing to

the flywheel, insert the flywheel stop tool as shown

in the picture.

Specific tooling020627Y Flywheel lock wrench

- Undo the flywheel screw and remove the washer.

- Manually screw the nut without washer, being

careful not to leave the first threads uncovered.CAUTION

SCREWING UP THE NUT WITHOUT WASHER HELPS PRO-TECT THE THREAD AGAINST THE STRAIN EXERTED BYTHE EXTRACTOR AND ALSO PREVENTS DROPPING THEFLYWHEEL ACCIDENTALLY UPON EXTRACTING IT. PO-TENTIAL DROPS MAY DAMAGE THE CERAMIC INSERTS.

Engine MP3 125 ie

ENG - 132

- Insert the extractor.

Specific tooling020467Y Flywheel extractor

- Act on the extractor to remove the flywheel to-

gether with the starting sprocket.

Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pick-up control plate.

Starter gear rim

See alsoRemoving the flywheel magneto

Intermediate gear

- Remove the flywheel cover.

- Remove the intermediate gear and take it out of

its housing.

Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.

MP3 125 ie Engine

ENG - 133

- 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 productsLoctite 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 six 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".

Refitting the flywheel magneto

- Remove the freewheel retaining plate indicated

in the picture

- Remove the transmission gear and the freewheel

Engine MP3 125 ie

ENG - 134

- Insert the free wheel on the flywheel as shown in

the picture

- Then refit the flywheel with free wheel and trans-

mission gear

- Using the special flywheel lock wrench, tighten

up the flywheel fixing nut to the prescribed torque

- Refit the retention plate

Specific tooling020627Y Flywheel lock wrench

Locking torques (N*m)Flywheel nut 94 - 102

Refitting the starter motor

- Fit a new O-ring on the starter motor and lubricate

it.

- Fit the starter motor on the crankcase and lock

the 2 screws to the specified torque.

Locking torques (N*m)Starter screws 11 to 13

Cylinder assy. and timing system

MP3 125 ie Engine

ENG - 135

Removing the intake manifold

- Undo the three screws with an anti-tampering

device.

Removing the rocker-arms cover

- Remove the five screws shown in the figure.

- Remove the entire head cover.

Removing the timing system drive

- Remove the oil pump control gear and the pinion

separation washer as described in the «Engine/

Lubrication/Oil pump» section.

- Undo the central screw and collect the washer.

Undo the two fixing screws to the cylinder and re-

move the tensioner together with the gasket.

Engine MP3 125 ie

ENG - 136

- Undo the two screws indicated.

- Detach the timing chain and remove the camshaft

control pulley and the corresponding washer.

- Remove the screws indicated in the figure, the

spacer bar and the tensioner slider.

- Remove the control sprocket wheel and the tim-

ing chain.

- As regards the chain guide slider, it may only be

removed after the head has been removed.N.B.IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

Removing the cam shaft

- Undo the two indicated fixing screws to the cyl-

inder and remove the fixing plate.

MP3 125 ie Engine

ENG - 137

- Remove the camshaft.

- Acting on flywheel-side holes, push and slide off

the rocking lever pins.N.B.IF NEEDED, THE HEAD MAY BE REMOVED WITH THECAMSHAFT, ROCKER PINS AND FIXING BRACKET. THEHEAD CAN ALSO BE REMOVED WITHOUT REMOVINGTHE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

Removing the cylinder head

- Undo the two screws «1» fixing the head to the

transmission-side crankcase half.

- Unscrew the four nuts «2» by loosening them in

two or three stages and in a crossed sequence.

Engine MP3 125 ie

ENG - 138

- Remove the head.N.B.IF NEEDED, THE HEAD MAY BE REMOVED WITH THECAMSHAFT, ROCKER PINS AND FIXING BRACKET. THEHEAD CAN ALSO BE REMOVED WITHOUT REMOVINGTHE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

- Remove the gasket.

Removing the valvesN.B.

CHECK RESIDUAL STROKE IN ORDER TO AVOID RESONANCES IN THE INTAKE VALVES ASDESCRIBED IN THE PAGE ON «ENGINE/THERMAL GROUP AND TIMING SYSTEM/VALVECHECK» EVERY TIME THAT EITHER THE INTAKE VALVES OR THEIR COMPONENTS ARE RE-MOVED.

- Use the specific tool to remove the cotters, cap

and spring.CAUTIONREPLACE THE VALVES IN SUCH A WAY AS TO RECOG-NISE THEIR ORIGINAL POSITION ON THE HEAD.

Specific tooling020382Y011 adapter for valve removal tool

020382Y Tool to extract valve cotters

MP3 125 ie Engine

ENG - 139

- Use the specific tool to remove the valve oil seal.

Specific tooling020306Y Punch for assembling valve sealrings

- Slide off the valve and remove the lower support.

Specific tooling020382Y Tool to extract valve cotters

Engine MP3 125 ie

ENG - 140

- Remove the calibrated washer and replace, if re-

quired, as indicated above for checking residual

stroke as described in the page on «Engine/Ther-

mal group and timing system/valve check».

See alsoInspecting the valves

Removing the cylinder - piston assy.

- Remove the chain guide slider; be careful with

the two alignment dowels and remove the cylinder.

- Remove the base gasket; be careful with the two

centring dowels and the dowel pin.

- Remove the sealing rings, the pin and remove

the piston.CAUTIONTO PREVENT DAMAGING THE PISTON, SUPPORT ITWHILE REMOVING THE CYLINDER.N.B.BE CAREFUL NOT TO DAMAGE THE SEALING RINGSDURING REMOVAL.

MP3 125 ie Engine

ENG - 141

Inspecting the small endN.B.

TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-TER.

See alsoCrankcase - crankshaft - connecting rod

Inspecting the wrist pinN.B.


See alsoCylinder - piston assy.

Inspecting the pistonN.B.


See alsoCylinder - piston assy.

Inspecting the piston ringsN.B.


See alsoPiston rings

Removing the piston

- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-

wards the exhaust.

Engine MP3 125 ie

ENG - 142

- Fit the pin retainer ring onto the appropriate tool

- With opening in the position indicated on the tool

S = left

D= right

- Place the wrist pin retainer ring into position using

a punch

- Fit the wrist pin retainer ring using the plug as

shown in the figureN.B.THE TOOL FOR INSTALLING THE RETAINER RINGS MUSTBE USED MANUALLY.CAUTIONUSING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-ING.

Specific tooling020430Y Pin lock fitting tool

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 tooling020475Y 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.

MP3 125 ie Engine

ENG - 143

- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to

be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-

sion ratio.

- Remove the special tool and the cylinder.N.B.

IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORYARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEATTHE TOOL INSTALLATION BY INVERTING ITS POSITION.

See alsoSlot packing system

Refitting the piston rings

- Pistons (like cylinders) are supplied in 4 catego-

ries: A, B, C and D, and must be fitted so that the

reference arrow faces the exhaust duct. The letter

is found at the centre of the piston.

- Fit the sealing rings with the word TOP or the

identification letter facing upwards. In any case,

the step must be facing opposite the piston crown.

- Sealing rings are manufactured with a cylinder

contact conical cross-section and piston gaps

must be offset by 120° in order to obtain a better

bedding.

- Lubricate rings with engine oil when fitting them.

Engine MP3 125 ie

ENG - 144

Refitting the cylinderN.B.

BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OILTHE CYLINDER BARREL.

- Check the position of the alignment dowels and

dowel pin and fit a gasket with a thickness previ-

ously determined.

- Using the specific tool fit the cylinder paying at-

tention that the chain does not remain in the timing

system compartment.

Specific tooling020426Y Piston fitting fork

020393Y Piston assembly band

Inspecting the cylinder headN.B.


See alsoCylinder Head

MP3 125 ie Engine

ENG - 145

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.

- Ensure that the camshaft control pulley chain as-

sembly and the sprocket wheel are not worn.

- If you detect wear, replace the parts or, if the

chain, sprocket wheel and pulley are worn, replace

the whole unit.

- Remove the centre screw with the washer and

the tensioner spring. Check that the one-way

mechanism is not worn.

- Check the condition of the tensioner spring.

- If examples of wear are found, replace the whole

unit.

Inspecting the valve sealingsN.B.



Inspecting the valves

RESIDUAL STROKE CHECK

- Check the residual stroke and afterwards make sure that it falls within the predetermined limits.

CharacteristicResidual stroke:

0.8 - 1.8 mm

Engine MP3 125 ie

ENG - 146

RESIDUAL STROKE OVER 1.7 mm

- Replace the calibrated washer with a thicker one

so that it is within the residual stroke values.

RESIDUAL STROKE SMALLER THAN 0.9 mm

- Replace the calibrated washer with a thinner one

so that it is within the residual stroke values. -

USE LIMITS

- Replace the head if values exceed the use limits

of the residual stroke.CAUTIONCHECK BOTH INTAKE VALVES.ADJUST EACH TIME A VALVE OR ANY COMPONENT OFTHE VALVE RETURN MECHANISM HAS TO BE RE-PLACED.WHEN THE CALIBRATED WASHER IS REPLACED, THEVALVE SEAL RING MUST BE REPLACED AS WELL.WHEN A NEW HEAD OR VALVE IS FITTED, THE 0.8-mmWASHER HAS TO BE CHECKED.NEVER INSERT MORE THAN ONE WASHER IN THE SAMESEAT.

CharacteristicResidual stroke:0.8 - 1.8 mm

- Refer to the «Engine / Thermal group and timing system / Valve removal» page to see the re-

placement steps

See alsoRemoving the valves

N.B.THE RESIDUAL STROKE OF THE INTAKE SPRINGS MUSTRANGE BETWEEN 0.8 - 1.8 MM SO THAT THERE ARE NORESONANCES. TO SOLVE THIS, THE SPRING IS SHIM-MED WITH CALIBRATED WASHERS: 0.4 - 0.8 - 1.2 MM

MP3 125 ie Engine

ENG - 147

RESIDUAL STROKE CHECK

Follow these steps to check the residual stroke:

- Fit the specific tool on the head and fasten the

dial gauge

Specific tooling020688Y Dial gauge support

- Check that the dial gauge is adequately posi-

tioned, that is as parallel as possible to the valve

axis, and the cap must be within the level area.

- Turn the crankshaft until the Intake valves are at their maximum lift.N.B.

USING A DIAL GAUGE IDENTIFY THE MAXIMUM LIFT AND LOCATE THE EXACT POINT ATWHICH THE NEEDLE STARTS TURNING IN THE OPPOSITE SENSE.

- Reset the dial gauge.

Engine MP3 125 ie

ENG - 148

- Unscrew the stop nut of the set screw.

- Using the dial gauge measure the residual stroke

value by undoing the set screw until the end of

stroke.

CharacteristicResidual stroke:0.8 - 1.8 mm

- Check residual stroke by comparing it with the data contained in the next page.

N.B.



Inspecting the springs and half-cones

- Check that 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.

N.B.



MP3 125 ie Engine

ENG - 149

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.

- Using the special punch, fit the four valve seal

rings.

- Fit the valves, the springs and the caps. Using

the appropriate tool with adapter, compress the

springs and insert the cotters in their seats.N.B.DO NOT CHANGE THE VALVE FITTING POSITION. FIT THEVALVE SPRINGS WITH THE REFERENCE COLOUR ONCOTTER SIDE (TURNS WITH GREATER PITCH).

Specific tooling020306Y Punch for assembling valve sealrings

020382Y011 adapter for valve removal tool

020382Y Tool to extract valve cotters

Inspecting the cam shaftN.B.



Refitting the head and timing system components

Assemble the timing chain sprocket wheel on the

crankshaft with the chamfering facing the insertion

side and observing the position of the reference

dowel.

Engine MP3 125 ie

ENG - 150

- Loop the timing control chain «1» around the

crankshaft.

- Fit the guide slider and the tensioner pad «2» on

the head side.

- Fit spacer «5» with fixing screw «6».

- Tighten the screws to the prescribed torque.

Locking torques (N*m)Slider screw 10 - 14 Nm

- Fit the head gasket and check that the alignment

dowels work properly.

- Insert the head.

- Lubricate the stud bolt threads with engine oil.

- Tighten up the nuts to an initial pre-torque of 7±1

Nm.

- Tighten up the nuts to a second pre-torque of 10

±1 Nm

- To carry out the operations described above, fol-

low the tightening sequence in the figure.

- Fit the two screws on the outside of the timing

chain side and tighten them to the specified torque.N.B.BEFORE INSTALLING THE HEAD, MAKE SURE THAT THELUBRICATION CHANNEL IS CLEAN USING A COM-PRESSED AIR JET.

Locking torques (N*m)Timing chain tensioner support screw 11 to 13

Fit the pins and rocking levers.

- Lubricate the two rocking levers through the

holes at the top.

- Lubricate the 2 bearings and insert the camshaft

in the cylinder head with the cams corresponding

to the rocking levers.

- Insert the retention plate and tighten the two

screws shown in the figure to the prescribed tor-

que.

Locking torques (N*m)Plate screws 4 - 6 Nm

MP3 125 ie Engine

ENG - 151

Insert the spacer on the cam shaft.

- Rotate the engine so that the piston is at top dead

centre, using the reference marks on the flywheel

and the crankcase.

- Insert the pulley on the camshaft while keeping

the reference 4V in correspondence with the ref-

erence mark on the head.

- Holding this position insert the chain on the cam-

shaft control pulley.

- Lock the fixing screws.

Locking torques (N*m)Counterweight screw 7 to 8.5

Set the tensioner cursor to the rest position.

- Fit the chain tensioner on the cylinder, using a

new gasket, and tight the two screws to the pre-

scribed torque.

Insert the chain tensioning screw, together with the

spring and washer, tightening it to the prescribed

torque.

Locking torques (N*m)Tensioner screws 11 to 13 Tensioner cover 5 - 6Nm

- Check valve clearance.

CharacteristicValve clearance

Intake: 0.10 mm Exhaust: 0.15 mm

Engine MP3 125 ie

ENG - 152

Refitting the rocker-arms cover

- Refit the cylinder head cover and tighten the 5

clamping screws to the prescribed torque.

- Make sure the gasket is positioned properly.

Locking torques (N*m)Tappet cover screws 5 - 6 Nm

Refitting the intake manifold

- Fit the intake manifold and do up the three

screws.

Locking torques (N*m)Intake manifold screws 11 to 13

Crankcase - crankshaft

Splitting the crankcase halves

AXIAL CLEARANCE CHECK

- Before opening the engine crankcase, it is ad-

visable to check the axial clearance of the crank-

shaft. Use a specific tool to check axial clearance.

- Higher clearances are signs of wear on the crank-

shaft - crankcase supporting surfaces.

Specific tooling020262Y Crankcase splitting plate


CharacteristicAxial crankshaft/crankcase clearance: Stand-ard clearance0.15 - 0.40 mm (when cold)

MP3 125 ie Engine

ENG - 153

Axial connecting rod - crankshaft clearanceStandard clearance0.20 to 0.50 mm

CRANKCASE OPENING

- Undo the ten crankshaft coupling screws.

- Separate the crankcase halves while keeping the

crankshaft in one of these two halves.

- Only after the halves have been separated, can

the crankshaft be checked.CAUTIONWHILE OPENING THE CRANKCASES AND REMOVINGTHE CRANKSHAFT, CHECK THAT THE THREADEDSHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-INGS. FAILURE TO OBSERVE THIS PRECAUTION CANDAMAGE THE MAIN BUSHINGS.CAUTIONKEEP THE CRANKSHAFT IN ONE OF THE TWO HALVESOF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAILTO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLYFALL.

- Remove the crankcase halves gasket and be

careful with the two alignment dowels.

Engine MP3 125 ie

ENG - 154

- Unscrew the oil filter fitting if required.

- Once the crankcase halves have been separa-

ted, reach and remove the internal bulkhead and

the protection bulkhead for the mesh pre-filter.

Inspecting the crankshaft componentsN.B.



Inspecting the crankshaft alignmentN.B.



MP3 125 ie Engine

ENG - 155

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.

- On the transmission-side crankcase half, take

particular care when handling the oil pump com-

partment and the oil ducts, the by-pass duct, the

main bushings and the cooling jet on the trans-

mission side (see diagram).

- Take particular care, also, that there are no signs

wear in the oil by-pass valve housing (see Chapter

Lubrication), as this could prevent a good seal in

the piston, which regulates the oil pressure.

- On the flywheel side crankcase half, take partic-

ular care cleaning the oil ducts for the main bush-

ings, the oil duct for the jet that lubricates the

cylinder head and the oil drainage duct at the fly-

wheel side oil seal.

- Inspect the coupling surfaces on the crankcase

halves for scratches or deformation, taking partic-

ular care with the cylinder/crankcase surfaces and

the crankcase halves surfaces.

- Defects in the crankcase coupling gasket be-

tween the crankcase halves or the mating surfaces

shown in the diagram, could cause a drop in the

oil pressure lubricating the main bushings and

connecting rod.

- Check the main bearing seats that limit axial

clearance in the crankshaft show no signs of wear.

The dimension between these seats is measured

by way of the procedure described previously for

measuring the crankshaft axial clearance and di-

mensions.N.B.THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-ER OPERATION OF THIS COMPONENT IMPROVES PIS-TON CROWN COOLING. CLOGGING HAS EFFECTS THATARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-ERABLE DROP IN THE LUBRICATION PRESSURE FORMAIN BUSHINGS AND CONNECTING ROD.N.B.

Engine MP3 125 ie

ENG - 156

THE HEAD LUBRICATION CHANNEL IS PROVIDED WITHA SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEADLUBRICATION; THIS CHOICE WAS MADE TO REDUCETHE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-ING MECHANISMS. A JET FAILURE CAUSES A DE-CREASE OF THE MAIN BUSHING AND CONNECTING RODLUBRICATION PRESSURE.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure

(3.2 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 comprised 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 shutters in the oil feeding channels,

the matching surface of the two half-bearings must

be perfectly orthogonal to the cylinder axis, as


- 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.



Coupling chartN.B.



MP3 125 ie Engine

ENG - 157

Refitting the crankcase halves

- Fit the internal bulkhead and lock the two screws

to the prescribed torque.

- Fit the oil filter fitting and tighten it to the prescri-

bed torque.

- Position the oil pre-filter element as shown in the

picture.

- Place a new gasket on one of the crankcase

halves, preferably on the transmission side, to-

gether with the alignment dowels.

Engine MP3 125 ie

ENG - 158

- Lubricate the main bushings with engine oil and

insert the crankshaft in the transmission-side

crankcase half.

- Reassemble both crankcase halves.

- Fit the ten screws and tighten them to the pre-

scribed torque.

- Assemble a new O-Ring on the pre-filter and lu-

bricate it with engine oil.

- Insert the filter on the engine with the relative cap.

- Tighten to the specified torque.

Locking torques (N*m)Internal engine crankcase bulkhead (transmis-sion-side half shaft) screws 4 to 6 Engine-crank-case coupling screws 11 to 13 Oil filter oncrankcase fitting 27 to 33 Engine oil drainageplug/ mesh filter 24 to 30

Studs

Check that the stud bolts have not worked loose

from their seat in the crankcase.

Check the depth of stud bolt driving with a gauge,

as indicated in the picture. If it varies significantly

from the driving depth indicated, it means that the

stud bolt has yielded.

In this case, replace it.

By working on two fitted cylinder head fixing nuts,

nut and lock nut, as shown in the picture, remove

the stud bolt from its seat.

Clean the threaded seat on the carter thoroughly.

Refit a new stud bolt and apply the special product

on the threading crankcase side.

Tighten up to the depth of the driving indicated.

Recommended productsLoctite Quick Set Loctite 270 high strengththreadlockLoctite 270 high strength threadlock

MP3 125 ie Engine

ENG - 159

Lubrication

Conceptual diagrams

The high pressure circuit is highlighted in blue. The low pressure circuit is highlighted in green

The lobe pump «1» sucks in oil from the sump through the mesh pre-filter «2», pushes it into the car-

tridge filter «3»; the main bushings and the big end are lubricated (with high pressure) through the

suitable passages found in the crankcase halves «4» whereas the piston pin and connecting rod small

end are lubricated via jet «5».

Afterwards, the oil, through a nozzle «6» whose function is to reduce the flow rate, reaches the timing

system where it lubricates the camshaft and from there, the valves and rockers «7». The oil passes

through the timing chain conduit and returns to the sump «8» by gravity

Engine MP3 125 ie

ENG - 160

Oil pressure check

- Remove the electrical minimum oil pressure

switch connection and remove the switch.

- Check that the oil pressure reading is between

0.5 and 1.2 atm with the engine idling at 1650 rpm

and the oil at the required temperature (wait for at

least one electric ventilation).

- Check that the oil pressure is between 3.2 and

4.2 atm with the engine running at 6000 rpm and

the oil at the required temperature.

- Remove the appropriate tools once the meas-

urement is complete, refit the oil pressure switch

and washer, tightening it to the specified torque

and fit the flywheel cover.

- If the oil pressure is not within the specified limits,

in the following order, check: the oil filter, the oil

by-pass valve, the oil pump and the crankshaft

seals.N.B.THE CHECK MUST BE CARRIED OUT WITH OIL AT THECORRECT LEVEL AND WITH AN OIL FILTER IN PROPERCONDITION.

CharacteristicOil pressureMinimum pressure admitted at 6000 rpm: 3.2 atm.

Locking torques (N*m)Minimum oil pressure sensor 12 to 14

Crankshaft oil seals

MP3 125 ie Engine

ENG - 161

Removal

- Remove the transmission cover and the com-

plete drive pulley beforehand

- Install the base of the appropriate tool on the oil

seal using the screws provided.

Specific tooling020622Y Transmission-side oil seal punch

- Screw the threaded bar onto the base of the tool

and extract the oil seal.


Refitting

- Always use a new oil seal upon refitting

- Prepare the new oil guard by lubricating the seal-

ing lip.

- Preassemble the oil seal with the appropriate tool

by positioning the screws.

- Insert the sheath over the crankshaft.

- Insert the tool with the oil seal on the crankshaft

until it comes into contact with the crankcase.

- Insert the adaptor bushing of the tool in the hole

on the crankcase.

Engine MP3 125 ie

ENG - 162

- Orientate the oil seal by inserting the bracket

which is part of the appropriate tool.

- Tighten the threaded bar onto the crankshaft as

far as it will go.

- Use the nut to move the base of the tool until you

can see the end of the oil seal driving stroke

- Remove all the tool components following the

procedure but in reverse orderCAUTIONDO NOT LUBRICATE THE KEYING SURFACE ONTO THEENGINE CRANKCASE.CAUTIONORIENT THE OIL SEAL BY POSITIONING THE CHAINHOUSING CHANNEL FACING DOWNWARDS. WHEN THEPOSITION IS REACHED, DO NOT RETRACT THE OILSEAL. FAILURE TO COMPLY WITH THIS RULE CANCAUSE A WRONG POSITIONING OF THE OIL SEALSHEATH.CAUTIONFAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TOTHE WRONG TENSIONING OF THE OIL PUMP CONTROLCHAIN.


Oil pump

MP3 125 ie Engine

ENG - 163

Removal

- Undo the two clamping screws in the figure and

remove the cover over the pump control sprocket.

- Block the rotation of the oil pump control pulley

with a screwdriver inserted through one of its two

holes.

- Remove the central screw with Belleville washer,

as shown in the diagram.

- Remove the chain with the crown.

- Remove the control sprocket wheel with relative

O-ring.

- Remove the oil pump by undoing the two screws

in the figure.

- Remove the oil pump seal.N.B.IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

Inspection

- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.

- Remove and wash the rotors thoroughly with pet-

rol and compressed air.

- Reassemble the rotors in the pump body, keep-

ing the two reference marks visible Replace the

retainer ring.

Engine MP3 125 ie

ENG - 164

- Check the clearance between the rotors in the

position shown in the diagram using a feeler

gauge.

Measure the distance between the outer rotor and

the pump body (see figure).

- Check the axial clearance of the rotors using a

trued bar as shown in the figure.

CharacteristicAxial rotor clearanceLimit values admitted: 0.09 mm

Distance between the outer rotor and the pumpbodyAdmissible limit clearance: 0.20 mm

Distance between the rotorsAdmissible limit clearance: 0.12 mm

Refitting

- Check there are no signs of wear on the oil pump

shaft or body.

- Check there are no signs of scoring or wear on

the oil pump cover.

- If you detect non-conforming measurements or

scoring, replace the faulty parts or the unit.

- Fit the pump cover in the position that permits the

crankcase clamping screws to be aligned.

- Make sure the gasket is positioned properly and

refit the pump on the engine crankcase. The pump

can only be fitted in one position. - Tighten the

screws to the prescribed torque.

MP3 125 ie Engine

ENG - 165

- Fit the sprocket wheel with a new O-ring.

- Fit the chain.

- Fit the central screw and the cup washer. Tighten

to the prescribed torque.

-Fit the oil pump cover, by tightening the two

screws to the prescribed torque.N.B.FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIMTOUCHES THE PULLEY. MAKE SURE THAT THE PUMPTURNS FREELY.

Locking torques (N*m)Screws fixing oil pump to the crankcase 5 to 6Oil pump command sprocket screw 10 to 14 Oilpump cover screws 0.7 - 0.9

Removing the oil sump

- Drain the oil from the sump.

- Remove the seven screws indicated in the figure

and the bracket of the rear brake pipes.

- Check the correct position of the three alignment

dowels «1» and remove gasket «2», spring and

by-pass piston «3».

Engine MP3 125 ie

ENG - 166

Inspecting the by-pass valve

- Check the unloaded spring length.

- Check that the small piston is not scored.

- Ensure that it slides freely on the crankcase and

that it guarantees a good seal.

- If not, eliminate any impurities or replace defec-

tive parts.

CharacteristicBy-pass check up: Standard length54.2 mm

Refitting the oil sump

- Check the correct position of alignment dowels

«1».

- Fit a new gasket «2».

- Fit the by-pass piston and spring «3».

- Assemble the oil sump by tightening the seven

fixing screws and be careful with the plate indica-

ted.

- Tighten to the specified torque.

Locking torques (N*m)Oil sump screws 10 to 14

MP3 125 ie Engine

ENG - 167

INDEX OF TOPICS

INJECTION INJEC

INJECTION COMPONENTSSpecification Desc./Quantity

1 Battery 12V - 12 Ah2 Injection ECU3 Fuel injector4 Electric fan relay5 Injection load relay6 Electric fan7 Fuel pump8 H.V. coil9 Lambda probe10 Water pump11 Water temperature sensor12 Speed sensor13 Diagnostics socket connector

The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-

strument panel.

MP3 125 ie Injection

INJEC - 169

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 tooling020680Y Diagnosis Tool

PrecautionsTroubleshooting hints

1. An injection system fault is more likely to be caused by a connection than a component.

Before troubleshooting the system, carry out the following checks:

A: Electrical power supply

a. Battery voltage

b. Blown fuse

c. Solenoids

d. Connectors

B: Chassis ground

C. Fuel system

a. Broken fuel pump

b. Dirty fuel filter

D: Ignition system

a. Faulty spark plug

b. Broken coil

c. Broken shielded cap

E: Intake circuit

a. Dirty air filter

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. EMS faults may be caused by loose connectors. Make sure that all connections are properly imple-

mented.

Injection MP3 125 ie

INJEC - 170

Check the connectors taking into consideration the following point:

A: check that the terminals are not bent.

B: check that the connectors have been properly connected.

C. check whether the failure changes if the connector is slightly vibrating.

3. Before replacing the EMS ECU, check the whole system thoroughly. If the fault is fixed even by

replacing the control unit, install the original control unit again and check if the fault occurs again.

4. Use a multimeter with an internal resistance over 10 KW/V for troubleshooting. Using unsuitable

instruments may damage the ECU. The instruments to be preferred have a definition over 0.1V and

0.5W and an accuracy over ± 2%.

1. Before repairing any part of the injection system, check if any faults have been stored. Do not dis-

connect the battery before checking for faults.

2. The fuel supply system is pressurised at 250 kPa (2.5 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 repairing electric components, the battery must always be disconnected unless it is strictly

necessary for the battery to be connected.

4. When carrying out functional tests, ensure that battery voltage is above 12V.

5. Before attempting to start the vehicle, ensure that there are at least two litres of fuel in the tank.

Failure to respect this norm will damage the fuel pump.

6. If a long period is envisaged with the vehicle not in use, fill the tank to at least the halfway mark. This

will ensure the pump will be covered by fuel.

7. When washing the vehicle, do not spray excessive water on electric components and wiring.

8. In the event of ignition problems, begin troubleshooting from the battery and the injection system

connections.

9. Before disconnecting the 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 system connectors only if required.

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 damage the control unit.

14. Before reconnecting the quick couplers of the power supply system, check that the terminals are

perfectly clean.


INJEC - 171

EMS circuit diagram

1. Instrument panel


23. Electric fan


30. Main fuses

31. Battery





47. Lambda sensor


51. HV coil

52. Fuel injector

53. Water pump


55. Fuel pump

56. Diagnosis socket


INJEC - 172

57. Injection ECU



67. Auxiliary fuses

PIN RELATIONSHIPPIN PIN Component Reference value

1 +Live supply HV coil 260 ± 26 mΩ4 5 Engine Speed sensor 100 - 150 Ω a ~ 20°C8 17 Engine temperature sensor 3502 ± 237 Ω at 20°C; 357 ± 19 Ω at 80°C12 +Live supply Fuel injector -19 +Live supply Water pump -35 37 Lambda probe ~ 0V with throttle valve closed; ~ 1V with

throttle valve fully opened

Troubleshooting procedure

Engine does not start

ENGINE DOES NOT START IF ONLY PULLEDPossible Cause Operation

Immobiliser enabling signal System not encodedSystem not efficient, repair according to the indications of the

self-diagnosisPresence of faults detected by the self diagnosis Pump relay

HV coilInjector

Revolution timing sensorFuel system Fuel in the tank

Fuel pump activationFuel pressure (low)

Injector capacity (low)Power to the spark plug Shielded spark plug cap HV coil (secondary insulation)

Parameter reliability Coolant temperatureDistribution timing - injection ignition

Intake air temperatureEnd of compression pressure End of compression pressure

Starting difficulties

ENGINE START-UP PROBLEMSPossible Cause Operation

Presence of faults detected by the self diagnosis Pump relayHV coilInjector

Revolution timing sensorAir temperature

Coolant temperatureStart-up speed Starter motor and solenoid

BatteryGround connections

End of compression pressure End of compression pressurePower to the spark plug Spark plug

Shielded capHV coil

Speed-timing sensorIgnition advance


INJEC - 173

Possible Cause OperationFuel system Fuel pressure (low)

Injector capacity (low)Injector sealing (poor)

Correctness of the parameters Coolant temperatureStepper throttle valve position intake air temperature (steps

and actual opening)Cleaning of the auxiliary air pipe and throttle valve; air filter ef-

ficiency

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOWPossible Cause Operation



Coolant temperatureIgnition efficiency Spark plug

Ignition timingCorrectness of the parameters Throttle valve position sensor

StepperCoolant temperature sensor

Intake air temperature sensorIntake system cleaning Air filter

Diffuser and throttle valveAdditional air pipe and Stepper

Intake system sealing (infiltrations) Intake manifold - headThrottle body - manifold

Intake sleeveFilter box

Fuel system (low pressure) Fuel pumpPressure regulator

Fuel filterInjector capacity

Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGHPossible Cause Operation



Coolant temperatureIgnition efficiency Ignition timing

Correctness of the parameters Throttle valve position sensorStepper

Coolant temperature sensorIntake air temperature sensor






INJEC - 174

Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATINGPossible Cause Operation



Coolant temperatureLambda probe

Correctness of the parameters Throttle valve position sensorStepper

Coolant temperature sensorIntake air temperature sensor





Exhaust system sealing (infiltrations) Manifold - headManifold - silencersilencer welding

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPENPossible Cause Operation

Intake system cleaning Air filterDiffuser and throttle valve

Additional air pipe and StepperIntake system sealing Intake sleeve

Filter boxIgnition system Spark plug wear check

Parameter reliability Throttle valve position signalCoolant temperature indicator

Intake air temperature indicatorIgnition advance

TPS reset successful TPS reset successfulPresence of faults detected by the self diagnosis Pump relay

HV coilInjector



Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-ANCE ON PICKUP

Possible Cause OperationPresence of faults detected by the self diagnosis Pump relay

HV coilInjector


Coolant temperature


INJEC - 175

Possible Cause OperationLambda probe

Spark plug power supply Spark plugShielded cap

HV cableHV coil

Intake system Air filterFilter box (sealing)

Intake sleeve (sealing)Parameter reliability Throttle valve position signal

Coolant temperature indicatorIntake air temperature indicator

Ignition advanceFuel system Fuel level in the tank

Fuel pressureFuel filter

Injector capacity

Engine knocking

PRESENCE OF KNOCKING (COMBUSTION SHOCKS)Possible Cause Operation




Ignition efficiency Spark plugParameter reliability Throttle valve position signal

Coolant temperature indicatorIntake air temperature indicator

Ignition advanceIntake system sealing Intake sleeve

Filter boxTPS reset successful TPS reset successful

Fuel system Fuel pressureFuel filter

Injector capacityFuel quality

Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

Fuel supply system

The fuel system 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 - 176

Removing the butterfly valve

Remove the screws fixing the fuel pipes indicated

in the figure.

Remove the fast-release fitting from the injector

support.


INJEC - 177

Remove the injector connector and the injector it-

self.

Remove the ECU connector.

Remove the three screws fixing the manifold to the

cylinder head and the clip fixing the throttle body

to the manifold.

Remove the clip fixing the throttle body to the air

cleaner bellows.


INJEC - 178

Remove the throttle control retainer.

Refitting the butterfly valve

To refit, perform the operations in the reverse or-

der from the removal operations being careful to

position the clip fixing the throttle body to the air

filter bellows at 45° as shown in the photograph.


INJEC - 179

Pump supply circuit


INJEC - 180

INJECTION LOADSSpecification Desc./Quantity

1 Battery 12V - 12 Ah2 Electronic control unit3 Fuse 20A4 Ignition switch contacts5 Fuse 7.5 A6 Fuse 15A7 Injection load relay8 Fuel pump9 Fuel injector10 H.V. coil11 Water pump

When switched to «ON », the fuel pump starts to rotate for 2 seconds and then stops. When the engine

starts, in the presence of rpm timing signal the pump is continuously supplied.

Electric characteristicPump winding resistance value

~ 1.5 Ω

Input current during regular functioning

1.4 - 1.8 A

Input current with hydraulic circuit closed

~ 2 A

Check the efficiency of injection load 15 A fuse No.

5.

Check that the live control unit power supply 7.5A

fuse No. 10 works properly.

Check the efficiency of the injection load solenoid

as described in the Electrical system chapter.


INJEC - 181

Check the power supply line of the injection load

solenoid energising coil: after switching to «ON»,

make sure there is battery voltage, for 2 seconds,

between the Red-White cable and the Black-Pur-

ple cable of the solenoid base. If there is not, check

the continuity of the Red-White cable between the

fuse box and the solenoid base and of the Black-

Purple cable between the pin 3 of the control unit

and the solenoid base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).


INJEC - 182

Check the presence of fixed voltage between the

grey/black cable of the solenoid base and earth. If

there is none check the continuity of the grey/black

cable between the fuse box (No. 5 15 A) and the

solenoid base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).

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

solenoid 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

ground lead.

If, when switching to «ON», the pump continues to

turn after 2 seconds of activation, check, with the


INJEC - 183

control unit disconnected and the injection load

solenoid disconnected, that the Black-Purple ca-

ble (pin 3 of the control unit connector) is insulated

from the ground lead.


Circuit leak test

Install the appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the

delivery pipe..

Check during regular operation by placing the ap-

propriate tool between the pump and the injector.

With the battery voltage> 12 V check that the fuel

pressure is 2.5 BAR and that the input current is

1.4 to 1.8 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. 2.5 BAR.

Check that within 15 seconds the pump has a flow rate of approx. 110 cm³.

Specific tooling020480Y Petrol pressure check kit


INJEC - 184

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 mounting as

shown in the picture.


INJEC - 185

Remove the filter from the pump mounting


INJEC - 186

Inspecting the injector circuit


INJEC - 187




5.













and the solenoid base.


INJEC - 188

N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).







INJEC - 189

With the control unit and the injector disconnected,

check if there is continuity in the Red-Yellow cable

between pin 12 of the control unit connector 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


INJEC - 190

With injector disconnected and the injector load

solenoid disconnected, check the continuity of the

Black-Green cable between the injector connector

and solenoid base.

Inspecting the injector hydraulics

To carry out the injector check, remove the intake

manifold by removing the three clamping screws

at the head and the clip connecting the control unit

to the manifold.

Install the appropriate tool for checking fuel pres-

sure and position the manifold over a container

graduated by at least 100 cm³. Connect the injec-

tor with the cable making up part of the supply for

the injection tester. Connect the clamps of the ca-

ble to an auxiliary battery. Activate the fuel pump

with the active diagnosis. Check that, within fifteen

seconds, approximately 40 cm³ of fuel is dis-

pensed with an adjustment pressure of approxi-

mately 2.5 BAR.

Specific tooling020480Y Petrol pressure check kit


INJEC - 191

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

Components location

INJECTION COMPONENTSSpecification Desc./Quantity

1 Battery 12V - 12 Ah2 Injection ECU3 Fuel injector4 Electric fan relay5 Injection load relay6 Electric fan7 Fuel pump8 H.V. coil9 Lambda probe10 Water pump11 Water temperature sensor12 Speed sensor13 Diagnostics socket connector


INJEC - 192

Tachometer


4 5 Engine Speed sensor 100 - 150 Ω a ~ 20°C

With the control unit disconnected, check that the sensor resistance between pins 4 and 5 is between

100 and 150 Ω at an engine temperature of approximately 20°.

Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. Try to start the engine

and check that the voltage between pins 4 and 5 is ~ 2.8 V.

With the control unit disconnected, check if there

is continuity between pin 4 and the red cable of the

speed sensor connector and between pin 5 and

the brown cable of the speed sensor connector.


INJEC - 193

With the control unit and the speed sensor disconnected, check that the red and brown cables (pins 4

and 5) are isolated from each other and insulated from the ground lead.



INJEC - 194

HT coil


INJEC - 195




1 +Live supply HV coil 260 ± 26 mΩ

The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.

The control unit manages two important parameters:

- Ignition advance

This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure

With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.

- Magnetisation time

The coil magnetisation time is controlled by the control unit. The ignition power is increased during the

engine start-up phase.

The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during

compression.



5.




INJEC - 196

After switching to «ON», check that there is volt-

age, for about 2 seconds, between the Black-

Green cable of the coil connector and the ground

lead with the coil connector disconnected.

Check the resistance of the coil primary between

pin 1 of the control unit connector and the Black-

Green cable of the injection load solenoid base,

with the control unit disconnected and the solenoid

disconnected.

Electric characteristicHV coil resistance primary value:260 ± 26 mΩ











and the solenoid base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).


INJEC - 197







INJEC - 198

Coolant temperature sensor

TEMPERATURE SENSORSpecification Desc./Quantity

1 Water temperature sensor2 Electronic control unit


INJEC - 199


8 17 Engine temperature sensor 3502 ± 237 Ω at 20°C; 357 ± 19 Ω at 80°C

With the connector on the control unit side disconnected and the coolant temperature sensor connector

connected, check that the resistance values between pins 8 and 17 correspond to the engine temper-

ature.

With the connector on the control unit side disconnected and the coolant temperature sensor connector

disconnected, check the insulation between the two Orange-Black and Sky blue-Green cables.

Electric characteristicResistance value at 20° C

3502 ± 237 Ω

Resistance value at 80° C

357 ± 19 Ω

With the connector on the control unit side discon-

nected and the coolant temperature sensor con-

nector disconnected, check if there is continuity

between pin 17 of the control unit connector and

the Sky blue-Green cable of the sensor, and be-

tween pin 8 of the control unit connector and the

Orange-Black cable of the sensor.



INJEC - 200

Lambda probe

LAMBDA PROBESpecification Desc./Quantity

1 Lambda probe2 Injection ECU


35 37 Lambda probe ~ 0V with throttle valve closed; ~ 1V withthrottle valve fully opened

The Lambda probe 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 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.

SIGNAL CONTROL

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 multimeter leads between pins 37 (-) and 35 (+) of the control unit.


INJEC - 201

With the engine running at idle speed, check that

the voltage oscillates between 0V and 1V

With the throttle valve completely open, the volt-

age is approx. 1V.

During the closing phase, the voltage is approx.

0V.

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 - 202

INDEX OF TOPICS

SUSPENSIONS SUSP

This section is dedicated 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 to 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 tooling001467Y014 Calliper to extract ø 15-mm bear-ings

001467Y017 Bell for bearings, OD 39 mm

Suspensions MP3 125 ie

SUSP - 204

- Remove the oil seal on the roller bearing side

using a screwdriver.

- Remove the roller bearing using the specific tool


020456Y Ø 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 tooling020151Y Air heater



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 tooling020038Y Punch

Recommended productsAGIP GREASE MU3 Grease for odometertransmission gear case

MP3 125 ie Suspensions

SUSP - 205

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20

Handlebar

Removal

• Remove the two handlebar covers as

explained in the Bodywork Chapter.

• Remove the handlebar wiring fixing

clips and disconnect the electric con-

nectors from the brake levers.

• Unscrew the fittings, then remove the

front and rear brake pump piping.

• Remove the flexible transmission of

the accelerator and remove the throt-

tle.

• Loosen the clamp fixing the handlebar

to the steering tube and pulling up-

wards, remove the handlebar, then re-

move the lower plastic cover.N.B.IF THE HANDLEBAR IS BEING REMOVED TO REMOVETHE STEERING, IT IS ONLY NECESSARY TO TILT THEHANDLEBAR FORWARD ONTO THE FRONT PART OF THEVEHICLE WITHOUT REMOVING THE PARTS FITTED SOAS 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 - 206

Hydraulic system layout

Roll lock system purge

- Remove the legshield upper cover.

- Unscrew the cap and check that there is always

oil inside the reservoir along the whole process.

- Using a specific tool purge the calliper.

- Connect the pipe to the fitting and keep purging

the system until air bubble free brake fluid flows

out.CAUTIONCARRY OUT THE FOLLOWING OPERATIONS ON BOTHCALLIPERS

Specific tooling020329Y Mity-Vac vacuum-operated pump

- Restore the correct level inside the chamber adding oil of the recommended type.

Recommended productsAGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

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 - 207

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

drained 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 - 208

Remove the suspension roll lock 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 - 209

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 tooling020055Y Wrench for steering tube ring nut

Remove the hydraulic pipe support bracket.


SUSP - 210

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 - 211

THE OPERATIONS DESCRIBED BELOW CAN

ALSO BE CARRIED OUT EVEN 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 - 212

For refitting, follow the operations for removal but

in reverse order, observing the prescribed torque

and greasing the bearings and their seats.

STEERING TUBESName Torque in Nm

Side headstock upper ring nut 20 - 24Side headstock lower ring nut 12 ÷ 15

Screw fixing sliding stem to shock absorber 45 to 50Clamp 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 - 213

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 - 214

Remove the arm coupling 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 - 215

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 - 216

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 reference dowels

on the parallelogram half-arms and observing the

prescribed torque.

PARALLELOGRAM DEVICEName Torque in Nm

Arm coupling screws 45 to 50Screws fixing arms to side headstocks 45 to 50

Screws fixing arms to central headstock 45 to 50Screws fixing the half-arm coupling flange 20 to 25

Screws fixing roll lock disc section 20 to 25


SUSP - 217

Geared motor and Suspension locking system

Before removing the gear 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 gear mo-

tor position potentiometer.

Remove the electrical connection of the geared

motor electric motor.

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.CAUTIONELIMINATE ANY REMAINING BRAKE FLUID SPILLS.

WARNING: BRAKE FLUID IS HIGHLY POISONOUS. DONOT INGEST OR SWALLOW. IF ACCIDENTALLY SWAL-LOWED, DRINK LARGE QUANTITIES OF MILK OR WATERAND SEEK MEDICAL ADVICE IMMEDIATELY. BRAKEFLUID DESTROYS SKIN AND OCULAR TISSUE. IF YOUACCIDENTALLY SPILL BRAKE FLUID ON YOURSELF,TAKE OFF YOUR CLOTHES, WASH WITH HOT WATERAND SOAP AND SEEK MEDICAL ADVICE IMMEDIATELY.


SUSP - 218

IF BRAKE FLUID GETS ACCIDENTALLY IN CONTACTWITH YOUR EYES, RINSE WITH ABUNDANT FRESH WA-TER AND SEEK MEDICAL ADVICE IMMEDIATELY. KEEPBRAKE FLUID OUT OF THE REACH OF CHILDREN.

Remove the 3 fixing screws indicated and remove

the whole gear motor.

Use a screwdriver to remove the plastic access

cover to the pump joint/gear motor

Undo the pump joint screw.

Undo the two gear motor pump locking screws.


SUSP - 219

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 tooling020234y extractor

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.


SUSP - 220

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 order to separate the two

crankcases.

Remove the retaining Seeger ring of the bearing

of the flexible transmission lever control shaft

bearing.

Remove the bearing with the specific tool.



020362Y 12 mm guide

Extract the electric motor bearing with the specific

tool.



020363Y 20-mm guide


SUSP - 221

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 shaft. Hit slightly

with a mallet if necessary.

Refit the bearing check Seeger ring.

Specific tooling020151Y Air heater


020362Y 12 mm guide




C, use the specific tool to fit the bearing of the

electric motor. Hit slightly with a mallet if necessa-

ry.

Specific tooling020363Y 20-mm guide


020151Y Air heater


Remove the spring/toothed sector unit from its fit-

ting, slightly hit with a mallet if necessary to release

the unit.


SUSP - 222

Extract the bearing of the spring/toothed sector

unit with the specific tool.

Specific tooling001467Y002 Driver for OD 73 mm bearing

Extract the bearing of the electric motor with the

specific tool.




spring/toothed sector unit. Hit slightly with a mallet

if necessary.

Specific tooling020360Y 52x55-mm Adaptor

020151Y Air heater





electric motor. Hit slightly with a mallet if necessa-

ry.

Specific tooling020363Y 20-mm guide

020151Y Air heater


020477Y 37 mm adaptor


SUSP - 223

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.

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 productsMONTBLANC MOLYBDENUM GREASE MON-TBLANC MOLYBDENUM GREASEGrease 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)Gear motor crankcase halves couplingscrews 11 to 13


SUSP - 224

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 torque.

Locking torques (N*m)Electric motor coupling screws 11 to 13

Place the moulded washer of the flexible trans-

mission control lever shaft and the tongue.

Refit the flexible transmission control lever as


Refit the potentiometer (not forcing in the D-type

connector ensures a sole position) with the con-

nector directed to the opposite side of the hydraulic

pump.

Refit the hydraulic pump on the gear 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)Gear motor hydraulic pump tighteningscrews 11 to 13


SUSP - 225

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.

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 to 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 - 226

Undo the two pad pin screws; remove the pads

with the spring.

Upon refitting, tighten the two screws to the pre-

scribed torque and use threadlock.

Upon refitting, adjust the cable properly so that the

switch is pushed when the system is unlocked.


SUSP - 227

Select the SYSTEM RESET option from the main

menu

Turn the ignition switch to ON

Select the LOWER STOP SEARCH option from

the SYSTEM RESET menu

WAIT

PROCEDURE IN PROGRESS


SUSP - 228

The palmtop 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 gear motor if the palmtop does not in-

dicate this.

Select the PARAMETERS option from the main

menu

The palmtop displays the option: RELATIVE PO-

TENTIOMETER 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 of the gear motor set

screw

Use a plain slot screwdriver to turn the set screw

anticlockwise until replicating the 12° condition on

the palmtop

RELATIVE POTENTIOMETER ANGLE 12° (a

slight value oscillation is considered normal)

Refit the protection cap


SUSP - 229

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 11to 13

Select the SYSTEM RESET option from the MAIN

menu


SUSP - 230

Select the POTENTIOMETER RESET option from

the SYSTEM RESET menu and press OK.

WAIT....

PROCEDURE IN PROGRESS

The palmtop displays the words: CHECK THAT

THE CONTROL IS SET AT 12° FROM THE LOW-

ER STOP. PRESS OK TO CONTINUE

Press OK

The palmtop displays the words: POSSIBLE LIMIT

STOP VALUES. PRESS A KEY AND SHIFT OFF

AND ON

If this is not successful, the roll lock mechanism

remains locked for safety.

Adjust the flexible transmission so that a small

clearance is left to guarantee switch activation on

the roll lock calliper

Electrical devices testPRINCIPLE DIAGRAM FOR TILT LOCKING ELECTRICAL SYSTEM


SUSP - 231

1. GEARED MOTOR

2. ROLL LOCK CALLIPER SWITCH

3. ROLL UNLOCK-LOCK CONTROL SWITCH

4. POTENTIOMETER

5. RIDER DETECTION SENSOR

6. LEFT SPEED SENSOR

7. RIGHT SPEED SENSOR

8. DIAGNOSTIC TESTER SERIAL LINE

9. ENGINE CONTROL UNIT

10.+ DIRECT BATTERY

11.+ LIVE BATTERY

12.LOW BEAM LIGHT

13.FUSE No. 3, 20A

14.LOW BEAM LIGHT SOLENOID

15.PRESSURE SWITCH

16.HORN SOLENOID

17.INSTRUMENT PANEL

18.ROLL LOCK SYSTEM CONTROL UNIT

TONE WHEEL SENSOR


SUSP - 232

1: Right tone wheel

2: Left tone wheel

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 interface wiring disconnected from the control

unit, check the continuity between pin 23 and the

brown cable of the LEFT wheel speed sensor con-

nector; between pin 17 and the red cables of the

LEFT wheel speed sensor and brown cable of the

RIGHT sensor; between pin 24 and the red cable

of the RIGHT wheel speed sensor


SUSP - 233

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 ground.


SUSP - 234

With a feeler gauge, check that the air gap be-

tween the screw head and the sensor is between

0.35 and 1 mm

RIDER PRESENCE SENSOR


SUSP - 235

1: RIDER DETECTION SENSOR


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


SUSP - 236

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

1: ROLL LOCK CALLIPER SENSOR


SUSP - 237

The roll lock calliper sensor is a normally opened

switch. Check its correct operation with a multi-

meter.


control unit, check the continuity between pin 34

and the brown cable of the roll lock gripper sensor

connector on the system side.

Check the continuity of the connector black cable

and a ground point on the chassis

Also check that the flexible transmission control

lever activates the limit stop switch properly.

POTENTIOMETER


SUSP - 238

1: POTENTIOMETER

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 (black) and

25 (red). Check that the voltage in the activated

locking condition is 4V and 1V in the locking rest

condition.


SUSP - 239



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 each oth-

er and ground.

TILT LOCKING-UNLOCKING SWITCH


SUSP - 240

0: REST POSITION

1: LOCKING POSITION

2: UNLOCKING POSITION

3: ROLL LOCK-UNLOCK SWITCH


control unit, check the continuity of the electrical

lines between the interface wiring and the roll lock-

unlock 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 ground.


SUSP - 241

Check the continuity between the black cable on

the connector and a ground point on the chassis.

With a multimeter, check the operation of the roll

lock-unlock switch referring to the diagram indica-

ted in the figure.

1. GROUND

2. LOCK

3. REST

4. UNLOCK

GEARED MOTOR


SUSP - 242

1: GEAR MOTOR



and the yellow cable, between pin 38 and the blue

cable on the gear motor connector


SUSP - 243


control unit, check the continuity of the gear motor

winding placing the multimeter probes on pins 28

and 38 as indicated in the figure

PRESSURE SWITCH

1: PRESSURE SWITCH

2: HORN SOLENOID

3: FUSE No. 11, 7.5A


SUSP - 244

Check 7.5 A fuse No. 11 for efficiency. With inter-

face wiring disconnected from the control unit,

check the continuity of the blue - black cable be-

tween pressure sensor connector and the horn

solenoid base as indicated in the picture. Check

the continuity between pin 27 and the solenoid

base white cable.

Check the continuity of the yellow - red cable be-

tween the pressure switch connector and the fuse-

box and between the solenoid base and the fuse-

box.

With a multimeter, also check the pressure switch

operation as well as the continuity at rest as this is

normally closed switch.


SUSP - 245

Wheel alignment

Tool fitting

How to use the tools

• Check that tyre pressure is correct.

• Park the vehicle on level, smooth and

even ground.

• Park the vehicle on its centre stand.

• Make sure that the parking system is

disengaged.

• Lift the front wheels as shown in the

picture

• Check that the wheel rims rotate even-

ly and whether there is abnormal clear-

ance in bearings and suspension.

• Make sure that the steering control

shows no signs of abnormal clearance

in joints and bearings. Otherwise, cor-

rect this and then adjust them.

CharacteristicFront tyre pressure (rider)Front tyre pressure (rider): 1.6 bar

Rear tyre pressure (rider)Rear tyre pressure (rider): 2 bar


SUSP - 246

• Get the vehicle off the stand, back on

the ground.

• Remove the right lower coupling plate

of the half-arm by undoing the screws

indicated in the picture.

• Remove the right upper screw and the

left bottom screw of the parallelogram

unit.


SUSP - 247

• 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.

• 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.


SUSP - 248

• 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.

• Check that the pointers of both tyres

are correctly aligned, as shown in the

picture. Maximum misalignment al-

lowed: 4 notches.

• Use tool 020647Y028 for LT version

with extended track.

Specific tooling020646Y Parallelogram and steering position-ing tool

020647Y Toe-in checking tool

020647Y028 MP3 LT Toe-in tool (tricycle)


SUSP - 249

Rear

Removing the rear wheel

Remove the full silencer assembly.

- Remove the screw fixing the right-hand shock

absorber to the bracket

- Remove the two screws supporting the brake

calliper on the bracket

- Remove the cotter pin, the cap, the wheel axle

fixing nut and the outer one of the two spacers.


SUSP - 250

- Remove the mud guard clamping screw

- Remove the two screws fixing the bracket to the

engine

- Slide off the wheel axle bracket, using the heat gun if necessary.

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)Silencer arm clamping screws 27 - 30 Rearwheel axle nut 104 to 126 Shock absorber-crank-case attachment bracket 20 to 25 Lower shockabsorber clamping screw 33 - 41 Nm Rear brakecalliper fixing screws 25 - 30 Nm

Swing-arm

Removal

- Place the vehicle on its centre stand;

- Remove the swinging arm/engine fitting shown in

the picture

- Move the engine back


SUSP - 251

- Remove the spring anchoring the swinging arm

to the chassis as shown in the picture

- Remove the two screws fixing the buffer support

bracket to the chassis

- Undo the nut on the LHS shown in the figure and

remove the corresponding bolt from the opposite

side.

- Remove the swinging arm.

- Check the entire swinging arm assembly.

- Check all the centring bushing components and

silent block rubber buffers.

- Replace the work components that cause exces-

sive clearance on the rear suspension.


SUSP - 252

Overhaul

- Check there is no sticking in the movement of the

connection of the swinging arm on the engine side

to the swinging arm on the chassis side.

- Check the axial clearance between the two

swinging arms using a feeler gauge

CharacteristicStandard clearance0.40 - 0.60 mm


- In order to check the clearance of the swinging

arm on the frame side, prepare a retainer using the

fixing pin of the swinging arm on the frame and two

rings from the special tool 020229Y. Alternatively,

use two washers with 12-mm inside diameter for

pins, minimum 30-mm outside diameter and 4-mm

thick at least.

- Check there is no sticking in the rotation.

- Check the axial clearance of the swinging arm on

the chassis side

CharacteristicStandard clearance0.40 - 0.60 mm


- Separate the swinging arm on the engine side

from the vehicle side arm.

- Remove the plastic bushings and the internal

spacer shown in the picture.


SUSP - 253

- Using a suitable pin remove the roller casings as

shown in the pictures

- Using an appropriate tool plant new roller cas-

ings, being careful to position the bearings with the

seal rings facing outwards

Specific tooling020244Y 15-mm diameter punch

020115Y Ø 18 punch

CharacteristicLength of the swinging arm tube on the engineside:L 175.3 + 0.3 0

Length of the internal swinging arm spacer onthe engine side:L 183 + 0.3 0

Engine side swinging arm plastic bushingshim:3.5 ± 0.05 mm

Chassis side swinging arm plastic bushingshim:3.5 ± 0.05 mm

Length of the internal swinging arm spacer onthe frame side:290 ± 0.1 mm

Length of the swinging arm tube on the chas-sis side:283 ± 0.1 mm


SUSP - 254

- Lubricate roller casings and the plastic bushings

with grease

- Insert the spacers

- Assemble the two arms with the relative bolt in

the position shown in the picture

- Adjust the bolt as shown in the picture

- Position the chassis side swinging arm with the

most protruding part pointing towards the silent

block side as shown in the picture

Recommended productsAGIP GREASE PV2 Grease for steering bear-ings, pin seats and swinging armSoap-based lithium and zinc oxide grease con-

taining NLGI 2; ISO-L-XBCIB2 of the swinging arm

- Make sure the silent bloc is not broken. If it is,

replace the coupling.

- Remove the Seeger ring shown in the picture

- Remove the full silent bloc bracket

- Undo the silent bloc ring shown in the picture


SUSP - 255

- Hold the full silent bloc bracket in the clamp

- Using the appropriate tool, remove the silent bloc

from the bracket from the side corresponding to

the inside of the vehicle. This is to guarantee the

tool is centred properly on the support

- Install a new silent bloc, making sure it aligns

properly with the reference tooth.

- Fit the silent blocs, making sure the chamfered

part of the silent bloc matches the chamfered part

of the bracket

- Using the appropriate tool, fit the silent bloc as

shown in the picture


SUSP - 256

Refitting

For correct installation of the swinging arm on the

vehicle, proceed as follows:

1. Position the silent block supporting clamp with

part 3 inserted, and slightly 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 - 257

SWINGING ARM FITTINGName Torque in NmPart 1 64 - 72Part 3 5 - 7Part 4 90 - 110Part 5 64 - 72 Nm

Engine-swinging arm bolt 64 - 72

Shock absorbers

Removal

Proceed as follows:

- place the vehicle on its centre stand;

- lift the engine a little with a jack so as to free the

two shock absorbers;

- remove the 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 silencer 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)


SUSP - 258

Shock absorber lower clamping 33 to 41 Shock absorber upper clamp 33 to 41

Centre-stand

REMOVAL

- Use a jack to support the vehicle properly.

- Remove the two return springs from the centre

stand.

- Undo the nut shown in the figure.

- Remove the pin from the right side.

- Remove the centre stand.

FITTING

- On refitting tighten the nut to the specified torque.

Locking torques (N*m)Centre stand bolt 31 - 39


SUSP - 259

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

This section è is dedicated to the description of the braking system components.

Rear brake calliper

Removal

- Remove the silencer.

- Remove the two rear brake calliper devices fas-

tening them to the support as shown in the picture.N.B.IF IT IS NECESSARY TO REPLACE OR SERVICE THEBRAKE CALLIPER, BEFORE REMOVING THE FITTINGSFIXING THE CALLIPER TO THE SUPPORT BRACKET,FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVINGEMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM-INED.

Front brake calliper

Removal

Place a container under the calliper, unscrew the

tube-calliper joint and empty the braking system.

For easy draining of the braking system fluid, open

the pump reservoir cap.

Loosen the two screws indicated in the figure and

remove the calliper from the support.

When refitting, tighten the two calliper retainers to

the prescribed torque.

Locking torques (N*m)Screw tightening calliper to support 24 to 27

Front brake disc

MP3 125 ie Braking system

BRAK SYS - 261

Removal

Remove the cotter pin.

Use new split pins when refitting.

Undo the wheel hub nut.

- Upon refitting, secure to the specified torque.

Locking torques (N*m)Wheel axle nut 74 - 88

Remove the Seeger ring, after that, remove the

hub with the help of a rubber mallet slightly hitting

on the brake disc side, turning the wheel hub at the

same time.

Loosen the 6 screws indicated in the figure and

remove the brake disc from the wheel hub.

- Upon refitting, secure to the specified torque.

Recommended productsLoctite 242 product descriptionApply LOCTITE medium type 242 threadlock

Braking system MP3 125 ie

BRAK SYS - 262

Removal

Rest the vehicle on its centre stand and use the

corresponding jack to lift the two front wheels; un-

screw the five Allen screws indicated in the figure

Remove the pad upper closing cap.

Remove the pad pin lock with a screwdriver, pay-

ing attention not to spoil the calliper surface treat-

ment.

Use a corresponding measuring punch to extract

the pad pin, if necessary move the brake pipes

manually to release the pin.

Then, remove the spring and the pads.

Fit a new pad kit following the procedure but in re-

verse order.

Locking torques (N*m)Wheel fixing screw 20 to 25

Rear brake pads

Fill

Rear - combined

For the procedure in question see «Highlighted operations» section.


BRAK SYS - 263

Front

For the procedure in question see «Highlighted operations» section.

Brake pipesFront 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.

Front brake pipes removal

Unscrew the braking splitter screw.

Disconnect the brake pipes removing the two met-

allic straps 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.


BRAK SYS - 264

Parking brake

Remove the silencer loosening the 3 screws and

the strap on the exhaust tube indicated in the pic-

ture.

When refitting, place the parking brake flexible

transmission retaining strap correctly.

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 roll lock

calliper.

When refitting, tighten to the specified torque.

Locking torques (N*m)Screw tightening calliper to support 20 to 25


BRAK SYS - 265

After removing the leg shield back plate, remove

the engaging cable for the safety mechanism re-

moving 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.

Remove the electric connection from the engaged

parking brake warning light switch.

Remove the parking brake cable from the lever by

operating the set screw indicated in the picture.


BRAK SYS - 266

INDEX OF TOPICS

COOLING SYSTEM COOL SYS

Circuit diagram

Key

A = entering the engine (cold)

B = electric pump

C = thermostat with by-pass

D = leaving the engine (hot)

E = radiator

F = expansion tank

This is a forced circulation cooling system, with continuous purging and air pressurisation. Circulation

takes place by means of an electric centrifugal pump which sends coolant to the thermal group. The

thermostat is connected at the head output. The radiator output is directly connected to the pump. The

expansion tank is connected 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

fluid).

CharacteristicCooling system capacity:

~ 2 l

TECHNICAL SPECIFICATIONSSpecification Desc./Quantity

Cooling system capacity: ~ 2 l

Cooling system MP3 125 ie

COOL SYS - 268

Specification Desc./QuantityRecommended fluid AGIP PERMANENT SPECIAL (ready for use)

Sealing pressure Cap calibrated at 0.9 bar

THERMOSTATSpecification Desc./Quantity

Type Wax-type, with deviatorStarts opening at 85 ± 2°C

ELECTRIC VENTILATIONSpecification Desc./Quantity

Electric ventilation starts at 100° CElectric ventilation stops at 90° C

WATER PUMPSpecification Desc./Quantity

Type CentrifugalControl Electric, commanded by the control unit

RADIATORSpecification Desc./Quantity

Type Aluminium, with horizontal circulation

EXPANSION TANKSpecification Desc./Quantity

Calibration Automatic bleeding, in parallel with the radiator

System bleed

- Start up the engine until the operating tempera-

ture is reached.

- Remove the rubber hood over the bleed valve

- Obtain a rubber tube that is of the right length to

connect the valve to the expansion tank

- Place one end of the pipe on the bleed valve and

the other in the expansion tank

- Loosen the screw by two turns until the commu-

nication hole is revealed with the head as shown

in the picture

- Wait until only coolant comes out of the rubber

pipe so as to eliminate any air bubbles inside the

circuit.

- Tighten the bleed valve respecting the maximum

torque.

- Bring the coolant up to the correct level inside the

expansion tank

Locking torques (N*m)

MP3 125 ie Cooling system

COOL SYS - 269

Bleed screw 3

Water pump

KEY

1. Battery

2. Fuse No. 2

3. Ignition key contacts

4. Fuse No. 10

5. Fuse No. 5

6. Injection load solenoid

7. Water pump

8. Injection ECUWARNINGALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.WATER PUMP CIRCUIT CHECK

1) Check that fuses No. 2, 5 and 10 operate properly.

2) Check the contacts of the ignition key and the injection load solenoid as described in the "Electrical

system" chapter.

3) Check whether there is voltage:

- between the Grey-Black cable of the base of the injection load solenoid and the ground lead.

- between the Red-White cable of the base of the injection load solenoid and the ground lead, with the

ignition key set to «ON».

Cooling system MP3 125 ie

COOL SYS - 270

4) Check that the cable harnesses are in good condition whenever no voltage is detected.

5) Check whether there is voltage in:

- the Black-Purple cable between the base of the injection load solenoid and the control unit (pin 3).

- the Black-Green cable between the base of the injection load solenoid and the water pump connector.

- the Sky blue cable between the water pump connector and the control unit (pin 19).

6) Check the pump ground connection (Black cable).

MP3 125 ie Cooling system

COOL SYS - 271

INDEX OF TOPICS

CHASSIS CHAS

This section è is dedicated to the operations that can be carried out on the vehicle's bodywork.

Seat

Lift the saddle and disconnect the rider detection

sensor.

Remove the three fixing screws.

Front handlebar cover

Remove the upper cap by operating on the Allen

screw indicated in the figure.

Remove the two brake pump caps.

MP3 125 ie Chassis

CHAS - 273

Remove the two screws under the brake pump

caps previously removed.

Unscrew the two pairs of screws in the lower part

of the half-handlebar.

After removing the front part of the handlebar cov-

er, access the two screws fixing the rear part to the

handlebar, as indicated in the picture.

Headlight assy.

Remove the radiator cover.

Remove the two wheelhouses with the turn indi-

cator.

Unscrew the two screws fixing the wheelhouse to

the shield.

Disconnect the cable grommet; after that, turn the

wheelhouse anticlockwise (inwards) to release it

from the shield supports.

Chassis MP3 125 ie

CHAS - 274

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.

Remove the four screws "A" and disconnect the

wiring.

See alsoRadiator 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 alsoSeatKnee-guardHandles and top side fairings

MP3 125 ie Chassis

CHAS - 275

Legshield

Remove the headlight assembly.

Remove the spoiler.

Remove the two front screws and the two screws

under the wheelhouse.

Remove the four screws on the leg shield back

plate.

See alsospoiler

Headlight assy.

Knee-guard

- Remove the legshield.

- Remove the spoiler.

- Remove the two central screws and the coolant

cap cover screw.

Chassis MP3 125 ie

CHAS - 276

- Remove the expansion tank fixing screw and the

frame from the instrument panel and manually re-

lease the unions with the leg shield back plate.

- Unhook the instrument panel wiring.

- Remove the six screws and the cable grommet

strap in the front part of the leg shield back plate.

MP3 125 ie Chassis

CHAS - 277

- Remove the ignition switch plastic ring and the

two plastic covers near the footrest.

- Remove the five screws on the leg shield back

plate rear part.

- Remove the two leg shield back plate front

screws, see figure.

- Remove the two leg shield back plate lower

screws.

- Remove the external temperature sensor con-

nection.

See alsoLegshieldspoiler

Chassis MP3 125 ie

CHAS - 278

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 screws and extract the half-foot-

rest.

Follow the same procedure for both half-footrests.

Release the fuse-box

See also

MP3 125 ie Chassis

CHAS - 279

Frame central cover

Side fairings

Remove the rear screw under 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.

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.

Chassis MP3 125 ie

CHAS - 280

Helmet bay

Remove the chassis central cover.

Remove the four external screws and the two

screws inside the rear case to remove the frame.

Remove the upper frame, unscrewing the ten up-

per screws, the two saddle closing screws and the

case light wiring.

MP3 125 ie Chassis

CHAS - 281

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 alsoFrame central cover

spoiler

Remove the shield central finish; then, screw the

six screws indicated in the figure.

Remove the five screws indicated in the figure.

See also

Chassis MP3 125 ie

CHAS - 282

Headlight assy.

Fuel tank

Remove the chassis central cover.

Remove the footrest.

Remove the three tank retainers.

Remove the two lower bracket retainers indicated

in the figure.

Disconnect the electric wiring and the fuel pipes.

See alsoFootrest

MP3 125 ie Chassis

CHAS - 283

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 figure.

• Remove the case light bulb indicated in

the picture and remove the internal

screw indicated in the picture.

• Remove the backrest cushion

Chassis MP3 125 ie

CHAS - 284

Remove the six screws indicated in the figure.

Radiator cover

- Remove the two front screws indicated in the pic-

ture

- Remove the two lower retainers together with

bushing from under the grille.

- Remove the two screws located at the back of

the grille.

MP3 125 ie Chassis

CHAS - 285

- Remove the two rear retainers and then, the two

wheelhouse front retainers.

- Remove the two screws fixing the radiator lower

protection to the leg shield back plate.

- After that, press up and pull the protection front

part so as to release it from the radiator frame.

Chassis MP3 125 ie

CHAS - 286

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Carry out the listed tests before delivering the vehicle.

Warning - Handle fuel with care.

Fit the plastic cover supplied on the joint on the

steering tube as shown in the figure.

Proceed as follows if the customer requests in-

stallation of splash guards on the vehicle:

• Fit the flap inside the mudguard shown

in the figure, matching up the 4 anchor

holes.

• Fit the 4 washers and the 4 screws on

the outer side of the mudguard, then

tighten to the specified torque.

Locking torques (N*m)splash guard fastener screws 2 - 3

Aesthetic inspection

Appearance check:

- Paintwork

- Fitting of plastics

- Scratches

- Dirt

Tightening torques inspection

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 - roll lock gripper

rear suspension

- Shock absorbers upper and lower retainer screw

Pre-delivery MP3 125 ie

PRE DE - 288

- Screws fixing silencer supporting arm to engine

- Rear wheel axle nut

Front brake

- Screws fixing brake disc to left wheel

- Screws fixing brake disc to right wheel

- Screws fixing brake callipers and suspension

- Screws fixing brake pipe coupling to callipers

Rear brake

- Parking brake calliper fixing screws

- Parking brake calliper fixing screws - brake cable

- Screws fixing brake pipe coupling to calliper

Chassis

- Swinging arm to engine pin locknut

- Swinging arm to chassis pin locknut

- Side stand to engine bolt nut

Electrical system

• 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

• Electric starter

• Engine stopping with emergency stop switch

• Electric opening of saddle with solenoid

• Tilting system locking - unlocking buttonCAUTIONTO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFOREIT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.CAUTIONWHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-ATIVE ONE.WARNINGBATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.

MP3 125 ie Pre-delivery

PRE DE - 289

IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FORABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER ORVEGETABLE 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 CARETO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKINGCLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDRENCAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSEOF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

Levels check

Level check:

- Hydraulic brake system liquid level.

- Roll lock 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 operationCAUTION

Pre-delivery MP3 125 ie

PRE DE - 290

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, tyre pressure check, rear-view mirror and any accessory fitting

MP3 125 ie Pre-delivery

PRE DE - 291

INDEX OF TOPICS

TIME TIME

This section is dedicated to the time necessary to carry out repairs.

For each operation, the description, code and time envisages are specified.

Engine

ENGINECode Action Duration

1 001001 Engine from chassis - Removal andrefit.

2 001127 Engine - Complete service

MP3 125 ie Time

TIME - 293

Crankcase

CRANKCASECode Action Duration

1 001133 Engine crankcase - Replacement2 001099 Flywheel-side oil seal - Replacement3 001100 Clutch-side oil seal - Replacement4 001124 Lubrication by pass - Replacement5 001153 Crankcase halves gasket - Replace-

ment

Time MP3 125 ie

TIME - 294

Crankshaft

CRANKSHAFTCode Action Duration

1 001117 Crankshaft - Replacement

MP3 125 ie Time

TIME - 295

Cylinder assy.

CYLINDER ASSEMBLYCode Action Duration

1 001002 Cylinder / Piston - Replacement2 001154 Pistonsrings-pin assembly - Service3 001176 Rings / Pin - Replacement4 000212 Cylinder gasket - Repl.

Time MP3 125 ie

TIME - 296

Cylinder head assy.

HEAD ASSEMBLYCode Action Duration

1 001057 Thermostat - Replacement2 007012 Coolant bleed valve - Replacement3 000235 Coolant temperature sensor - Repl.4 001056 Head gasket - change5 001045 Valves - Replacement6 001049 Valves - adjust7 001202 Residual stroke - Check8 001203 Calibrated washer - Replacement

MP3 125 ie Time

TIME - 297

Rocker arms support assy.

ROCKERS MOUNTING UNITCode Action Duration

1 001148 Rockers valves - Replacement2 001126 Head - Replacement3 001044 Camshaft - Replacement4 140021 Camshaft timing system pulley - Re-

plac

Time MP3 125 ie

TIME - 298

Cylinder head cover

HEAD COVERCode Action Duration

1 001089 Head cover - Replacement2 001093 Spark plug - Replacement3 001088 Head cover gasket - Replacement4 001074 Oil vapour recovery pipe - Replace-

ment5 001159 Oil vapour recovery tank - Service

MP3 125 ie Time

TIME - 299

Flywheel cover

FLYWHEEL COVERCode Action Duration

1 001150 Flywheel cover gasket - change2 001160 Oil pressure sensor - change3 001123 Oil filter -Replacement4 001102 Net oil filter - change / Cleaning5 003064 Engine oil - change6 001087 Flywheel cover - Replacement

Time MP3 125 ie

TIME - 300

Driven pulley

DRIVEN PULLEYCode Action Duration

1 001012 Driven pulley - overhaul2 001022 Clutch - Replacement3 001110 Driven pulley- Replacement4 001155 Clutch housing - Replacement

MP3 125 ie Time

TIME - 301

Oil pump

OIL PUMPCode Action Duration

1 001129 Chain tensioner - Service and Re-placement

2 001125 Chain guide pads - Replacement3 001122 Oil pump chain - Replacement4 001172 Chain cover flap - change5 001130 Oil sump - change6 001042 Oil pump - overhaul7 001112 Oil pump - change8 001051 Belt/Timing chain - Change

Time MP3 125 ie

TIME - 302

Final gear assy.

FINAL REDUCTION GEARCode Action Duration

1 002031 Rear wheel hub bearings - Replace-ment

2 003065 Gear box oil - Replacement3 004180 Reduction gear pipe - replace4 004125 Rear wheel axle - Replacement5 001179 Hub drive shaft - replacement6 001156 Gear reduction unit cover - Replace-

ment

MP3 125 ie Time

TIME - 303

Driving pulley

DRIVING PULLEYCode Action Duration

1 001177 CVT rollers / sliders - Replacement2 001086 Driving half-pulley - Replacement3 001011 Drive belt - Replacement4 001066 Driving pulley - Removal and refitting5 001006 Driving pulley - Service

Time MP3 125 ie

TIME - 304

Transmission cover

TRANSMISSION COVERCode Action Duration

1 001135 Transmission cover bearing - Re-placement

2 001096 Transmission crankcase cover - Re-placement

3 001131 Transmission air intake - Replace-ment

4 001145 Belt crankcase - Replacement5 001204 CVT Filter - Replacement

MP3 125 ie Time

TIME - 305

Water pump

WATER PUMPCode Action Duration

1 007009 Head-pump by-pass rubber sleeve -Replacement

2 001113 Water pump - Replacement3 005154 Power cable harness - Replacement

Time MP3 125 ie

TIME - 306

Starter motor

ELECTRIC STARTERCode Action Duration

1 001020 Starter motor - Replacement2 001017 Start-up pinion - Replacement3 001151 Starter driven gearing - Replacement

MP3 125 ie Time

TIME - 307

Flywheel magneto

MAGNETO FLYWHEELCode Action Duration

1 001173 Rotor - Replacement2 001058 Complete flywheel - change3 001067 Stator - Removal and Refitting4 001104 Start-up freewheel - Replacement

Time MP3 125 ie

TIME - 308

Butterfly valve

THROTTLE BODYCode Action Duration

1 001047 Injector - Replacement2 001023 Control unit - Replacement3 001013 Intake manifold - change

MP3 125 ie Time

TIME - 309

Exhaust pipe

SILENCERCode Action Duration

1 001095 Silencer heatshield - Replacement2 005138 Lambda probe - Replacement3 001092 Exhaust manifold - Replacement4 001009 Silencer - Replacement

Time MP3 125 ie

TIME - 310

Air cleaner

AIR CLEANERCode Action Duration

1 004122 Air cleaner carburettor fitting - Re-placement

2 001014 Air filter - Replacement / cleaning3 001015 Air filter box - Replacement

MP3 125 ie Time

TIME - 311

Frame

CHASSISCode Action Duration

1 004146 Front chassis - Replacement2 004116 Rear frame - Replacement3 004001 Chassis - Replacement4 004147 footrest support bracket one side -

Replacement5 004143 Footrest support - Replacement

Time MP3 125 ie

TIME - 312

Centre-stand

STANDCode Action Duration

1 001053 Stand pin - Replacement2 004179 Stand bumper - Replacement3 004004 Stand - Replacement

MP3 125 ie Time

TIME - 313

Legshield spoiler

LEGSHIELDCode Action Duration

1 004020 Headlight frame - Replacement2 004064 Legshield - Replacement3 004055 Turning indicator frame - Replace-

ment4 004149 Shield central cover - Replacement5 004022 Shield lower section - Replacement6 004167 Grille / radiator cover - Replacement

Time MP3 125 ie

TIME - 314

Side fairings

SIDE COVERSCode Action Duration

1 004036 Lower chassis cover - Replacement2 004129 Rear fairing - Replacement3 004085 Fairing (1) - Replacement4 004068 Passenger handgrip - Replacement5 004037 Side aprons-Replacement

MP3 125 ie Time

TIME - 315

Rear cover

REAR SHIELDCode Action Duration

1 004065 Legshield, rear part - Removal andrefitting

Time MP3 125 ie

TIME - 316

Central cover

CENTRAL COVERCode Action Duration

1 004059 Spark plug inspection flap - Replace-ment

2 004135 Fuel tank port - Replacement3 004011 Central chassis cover - Replacement4 004012 Rear fairings - Removal and refitting5 004015 Footrest - Removal and Refitting6 004075 Front mat - Replacement

MP3 125 ie Time

TIME - 317

Mudguard

MUDGUARDSCode Action Duration

1 007015 Radiator air duct - Replacement2 004009 Rear mudguard - Replacement3 004181 Lower cover - Replacement4 004184 Front mudguard support - replace-

ment5 004002 Front mudguard - change

Time MP3 125 ie

TIME - 318

Fuel tank

FUEL TANKCode Action Duration

1 004137 Injector pump pipe - Replacement2 005010 Tank float - Replacement3 004109 Fuel tank breather - change4 004168 Fuel tank cap - Replacement5 004005 Fuel tank - Replacement6 004073 Fuel pump - Replacement

MP3 125 ie Time

TIME - 319

Rear shock-absorber

REAR SHOCK ABSORBERSCode Action Duration

1 003007 Rear shock absorber - Removal andRefitting

2 003035 Shock absorber mounting and brakecalliper - Replacement

3 003077 silencer/rear shock absorber supportarm - Service

Time MP3 125 ie

TIME - 320

Handlebar covers

HANDLEBAR COVERSCode Action Duration

1 000307 RIGHT OR LEFT CONTROL AS-SEMBLY REPLACEMENT

2 004019 Rear handlebar covers - Replace-ment

3 004026 Handlebar cover - Replacement4 004018 Front handlebar covers - Replace-

ment

MP3 125 ie Time

TIME - 321

Handlebar components

HANDLEBAR COMPONENTSCode Action Duration

1 002060 Complete throttle control - Replace-ment

2 002059 Right-hand knob - Replacement3 003001 Handlebar - Replacement4 003061 Accelerator transmission - adjust5 002063 Complete throttle transmission - Re-

placement6 002071 Left knob - Replacement7 002037 Brake lever - Replacement8 002067 Rear brake pump - Replacement9 002024 Front brake pump - Replacement10 004162 Mirror mounting and/or brake pump

fitting U-bolt - Replacement11 003059 Counterweight - Replacement

Time MP3 125 ie

TIME - 322

Swing-arm

SWINGING ARMCode Action Duration

1 004058 Silent block - Replacement2 003081 Swinging arm support flange - Re-

placement3 001072 Engine-chassis connection swinging

arm - Replacement4 003080 Swinging arm on frame - Replace-

ment

MP3 125 ie Time

TIME - 323

Seat

SADDLECode Action Duration

1 004003 Saddle - Replacement

Time MP3 125 ie

TIME - 324

Instrument panel

INSTRUMENT PANELCode Action Duration

1 004021 Shield upper section - Replacement2 005014 Odometer - Replacement3 004099 Odometer housing - Replacement4 004035 Instrument panel - Replacement

MP3 125 ie Time

TIME - 325

Locks

LOCKSCode Action Duration

1 004172 Rear case lock catch - Replacement2 005099 Saddle opening electric-actuator -

Replacement3 004054 Saddle lock catch - Replacement4 004001 Chassis - Replacement5 005072 Immobilizer aerial - Replacement

Turn signal lightsRear lights

Time MP3 125 ie

TIME - 326

REAR TURNING INDICATOR LIGHTSCode Action Duration

1 005005 Taillight - change2 005022 Rear turning indicators - Replace-

ment3 005031 number plate light bulb - Replace-

ment4 005032 number plate light glass - Replace-

ment5 005131 number plate light support - Replace-

ment6 005066 Rear light bulbs - Replacement7 005068 Rear turning indicator bulb - Re-

placement

Front lights

MP3 125 ie Time

TIME - 327

FRONT TURNING INDICATOR LIGHTSCode Action Duration

1 005067 Front turning indicator bulb - replace-ment

2 005012 Front turning indicators - Replace-ment

3 005002 Front light - replacement4 005008 Headlight bulbs - Replacement

Time MP3 125 ie

TIME - 328

Front wheel

FRONT WHEELSCode Action Duration

1 003047 Front tyre - Replacement2 003033 Front wheel hub- Replacement3 003037 Front wheel rim - Replacement4 002041 Front brake disc - Replacement5 004123 Front wheel - Replacement

MP3 125 ie Time

TIME - 329

Rear wheel

REAR WHEELCode Action Duration

1 002070 Rear brake disc - Replacement2 001016 Rear wheel - Replacement3 001071 Front wheel rim - Removal and Re-

fitting4 004126 Rear wheel tyre - Replacement

Time MP3 125 ie

TIME - 330

Electric devices

ELECTRICAL DEVICESCode Action Duration

1 005075 Stop solenoid - Replacement2 005035 Headlight solenoid - Replacement3 005011 Starter relay - Replacement4 005007 Battery - change5 005003 Horn - Replacement

MP3 125 ie Time

TIME - 331

CABLE HARNESSCode Action Duration

1 005001 Electrical system - Replacement

Electronic controls

Time MP3 125 ie

TIME - 332

HANDLEBAR CONTROLSCode Action Duration

1 005017 Stop switch - Replacement2 005077 Emergency stop switch - Replace-

ment3 005041 Starter button - Replacement4 004010 Anti-theft lock - Replacement5 005040 Horn button - Replacement6 005006 Light or turning indicator switch - Re-

placement7 005039 Lights switch - Replacement8 005143 Mode button - Replacement9 005142 Unlocking switch - Replacement10 005084 Emergency light switch - Replace-

ment11 888126 Helmet compartment light switch - re-

placement12 005132 Case opening button - Replacement13 005021 Saddle opening button - Replace-

ment

Transmissions

LOCKS TRANSMISSIONSCode Action Duration

1 003094 Roll lock calliper control cable - re-placement

2 002082 Fuel tank door opening drive - Re-placement

3 002083 Saddle opening transmission - Re-placement

4 002093 Case opening transmission - Re-placement

MP3 125 ie Time

TIME - 333

Code Action Duration5 002026 Parking brake transmission - re-

placement

Helmet bay

HELMET COMPARTMENTCode Action Duration

1 005046 Battery cover - change2 005026 Helmet compartment bulb - Replace-

ment3 005027 Helmet compartment bulb support -

Replacement4 004016 Helmet compartment - Replacement

Time MP3 125 ie

TIME - 334

Rear side fairings

REAR COVERSCode Action Duration

1 004081 Case lid - Replacement2 004174 Case leverage3 005048 number plate holder - Replacement4 004082 Case gasket - Replacement

MP3 125 ie Time

TIME - 335

Front suspension

FRONT SUSPENSIONCode Action Duration

1 003010 Front suspension - Service2 003111 Side steering tube - replacement3 003038 Front wheel axle - Remov. and refitt.4 003040 Front wheel bearings - Replacement5 003107 Sliding stems - replacement6 003113 Front shock absorber - replacement

Time MP3 125 ie

TIME - 336

Cooling system

COOLING SYSTEMCode Action Duration

1 007013 Radiator expansion tank connectionpipe - change

2 001052 Coolant and air bleed - Replacement3 007001 Expansion tank - Replacement4 007024 Expansion tank cap - Replacement5 007003 Coolant delivery and return pipe -

change6 007016 Fan with support - Replacement7 007002 Water radiator - replacement

MP3 125 ie Time

TIME - 337

Braking system

BRAKING SYSTEMCode Action Duration

1 002025 Brake piping - Replacement2 003096 Roll lock calliper- replacement3 003100 Roll lock calliper pads - replacement4 003108 Parking brake flexible transmission -

replacement5 003109 Parking brake mechanical calliper -

replacement6 002002 Shoes - Rear brake pads - Replace-

ment7 002020 Rear brake pipes - Removal and re-

fitting8 002081 Rear brake disc piping - Replace-

ment9 003118 Roll lock disc section - replacement10 003103 Splitter for suspension locking sys-

tem pipes- replacement11 003102 Pipes for the splitter-calliper suspen-

sion locking system - replacement12 003088 Roll lock hydraulic pump - replace-

ment13 002021 Front brake piping - Replacement

Time MP3 125 ie

TIME - 338

Code Action Duration14 002007 Front brake pads - Replacement15 002039 Front brake calliper - Replacement16 003104 Suspension system locking calliper-

replacement17 003119 Pipes for the pump-splitter suspen-

sion locking system - replacement18 003105 Suspension locking system brake

fluid - repl.19 003106 Suspension locking system pressure

sensor - Replacement20 003121 Parking brake lever - replacement21 003122 Parking brake lever micro-switch - re-

placement22 002048 Rear brake calliper - Replacement23 002080 Rear brake oil bleed system -

Change24 002047 Front brake fluid and system bleed-

ing plug - Repl.

Windscreen

WINDSCREENCode Action Duration

1 004101 Windscreen - Replacement

MP3 125 ie Time

TIME - 339

Stickers

TRANSFERSCode Action Duration

1 004066 Driving mirror - Replacement2 004159 Plates / Stickers - Replacement

Time MP3 125 ie

TIME - 340

The tilt mechanism

ROLL SYSTEMCode Action Duration

1 003073 Steering clearance - Adjustment2 003112 Central steering tube - replacement3 003002 Steering bearing - Replacement4 003115 Parallelogram arms - replacement5 003114 Parallelogram bearings - replace-

ment6 003116 Steering rod - replacement7 003117 Constant-velocity universal joint - re-

placement8 003110 Side headstock fifth wheels - Repl.

MP3 125 ie Time

TIME - 341

Geared motor

GEARED MOTORCode Action Duration

1 003101 Roll lock calliper control lever - re-placement

2 005009 Voltage regulator - Replacement3 003095 Roll lock calliper support bracket - re-

placement4 001069 HV coil - Replacement5 001094 Spark plug cap - Replacement6 003120 Roll lock control unit - replacement7 003093 Geared motor crankcase - replace-

ment8 003090 Gear electric motor - replacement9 003092 Geared motor bearings - replace-

ment10 003091 Geared motor pinion - replacement11 003089 Geared motor potentiometer - re-

placement12 000317 Turn indicators blinker - Replace-

ment13 003097 Roll lock calliper micro-switch - re-

placement

Time MP3 125 ie

TIME - 342

AAir filter: 45

BBattery: 67, 77, 90, 91Brake: 261, 263–265Bulbs:

CChecks: 71Coolant: 199

EElectric: 331Engine oil: 46

FFuel: 176, 185, 283, 319Fuses: 88

HHeadlight: 51, 274, 276, 283Horn: 83Hub oil: 44

IIdentification: 8Instrument panel: 325

MMaintenance: 7, 39, 42

OOil filter: 49

RRecommended products:

SSaddle: Shock absorbers: 258Spark plug: 43, 76Stand: Start-up: Suspension: 55, 56, 218, 336

TTank: 283, 319Transmission: 9, 54, 107, 121, 305Turn indicators: 70Tyres: 10

VVehicle: 8, 100, 101

Documents

Piaggio MP3 125 ie (EN)