SERVICE STATION MANUAL

664502(IT)-664503(EN)-664504(FR)-664505
(DE)-664506(ES)-664507(PT)-664508(NL)-664509
(EL)

MP3 400 i.e.

 SERVICE STATION
MANUAL

MP3 400 i.e.

The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of single
versions should be checked at the official Piaggio sales network.
"© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited.
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
 SERVICE STATION MANUAL
MP3 400 i.e.
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio
vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any
significant changes to vehicle characteristics or to specific repair operations will be communicated by
updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment
and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special
tools, along with the special tool catalogue.

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

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

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

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

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

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
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
MP3 400 i.e. Characteristics

This section describes the general specifications of the vehicle.

Rules

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

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well-
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spare parts may 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 scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.

CHAR - 7
Characteristics MP3 400 i.e.

Vehicle identification

Chassis prefix (A):

ZAPM59101 (MP3 400 i.e. version)
ZAPM59102 (MP3 400 i.e. RL version)

Engine prefix (B):

M474M

Dimensions and mass

MP3 400 i.e.

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity
Kerb weight 253 ± 5 kg
Maximum weight allowed 445 kg
Maximum height 1.225 mm
Width 745 mm
Wheelbase 1.550 mm
Length 2.180 mm
Track 420 mm

CHAR - 8
MP3 400 i.e. Characteristics

MP3 400 i.e. RL

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity
Kerb weight 253 ± 5 kg
Maximum weight allowed 445 kg
Maximum height 1.225 mm
Width 745 mm
Wheelbase 1.550 mm
Length 2.180 mm
Track 425 mm

CHAR - 9
Characteristics MP3 400 i.e.

Engine

ENGINE
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Cubic capacity 399 cm³
Bore x stroke 85.8 X 69 mm
Compression ratio 10.6 ± 0.5 : 1
Engine idle speed 1,500 ± 100 rpm
Timing system Four valves, single overhead camshaft, chain-driven.
Valve clearance Inlet: 0.15 mm
Outlet: 0.15 mm
MAX Power 24 kW at 7,250 rpm
MAX torque 38 Nm at 5,250 rpm
LUBRICATION Engine lubrication with trochoidal pump (inside the crankcase),
oil filter and pressure adjustment by-pass.
Lubrication pressure 3.5 ÷ 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel supply Electronic injection with Ø 38-mm throttle body and electric fuel
pump.
Cooling Forced coolant circulation system.
Fuel Unleaded petrol (95 RON)

CHAR - 10
MP3 400 i.e. Characteristics

Transmission

TRANSMISSION
Specification Desc./Quantity
TRANSMISSION Automatic expandable pulley variator with torque server, V-
belt, automatic clutch.
Final reduction
Gear reduction unit in oil bath.

Capacities

CAPACITY
Specification Desc./Quantity
Engine oil 1.7 l
Transmission oil 250 cm³
Cooling system fluid ~ 1.8 l
Fuel tank (reserve) approx. 12 l (approx. 2 l)

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Start-up Electric
Ignition Electronic, inductive, high efficiency ignition, integrated with the
injection system, with variable advance and separate HV coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug (MP3 400 i.e.) CHAMPION RG 6 YC
Alternative spark plug (MP3 400 i.e.) NGK CR7EKB
Spark plug (MP3 400 i.e. RL) CHAMPION RG 6 Y
Battery 12V/14 Ah, sealed battery
Generator Alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification Desc./Quantity
Chassis Tubular and sheet steel
Front suspension The tilt mechanism is composed of an articulated parallelogram
suspension with die-cast aluminium control arms and two side
headstocks plus shock absorbers with hydraulic locking sys-
tem.
Front suspension travel 85 mm
Rear suspension Two double-acting shock absorbers, adjustable to four posi-
tions at preloading.
Rear suspension travel 110 mm

Brakes

BRAKES
Specification Desc./Quantity
Front brake Ø 240 mm double disc brake with hydraulic control activated
by the handlebar right-hand lever.
Rear brake Ø 240 mm disc brake, with hydraulic control activated by the
handlebar left-hand lever.

CHAR - 11
Characteristics MP3 400 i.e.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity
Wheel rim type Light alloy rims.
Front rim 12'' x 3.00
Rear rim 14'' x 4.50
Front tyre Tubeless, 120/70-12" 51S or 51P
Rear tyre (MP3 400 i.e.) Tubeless 140/70 -14" 68S or 68P reinf.
Rear tyre (MP3 400 i.e. RL) Tubeless, 140/70 -14" 68S or 68P
Front tyre pressure with passenger (MP3 400 i.e.) 1.6 bar (1.8 bar)
Rear tyre pressure with passenger (MP3 400 i.e.) 2.4 bar (2.6 bar)
Front tyre pressure (MP3 400 i.e. RL) 1.6 bar
Rear tyre pressure (MP3 400 i.e. RL) 2.5 bar

Tightening Torques

STEERING
Name Torque in Nm
Steering lower ring nut (central headstock) 22 ÷ 27 loosen by 90°
Steering upper ring nut (central headstock) 27 ÷ 33
Handlebar fixing screw 50 ÷ 55
Fixing screws for the handlebar control unit U-bolts 7 ÷ 10

CHASSIS
Name Torque in Nm
Swinging arm set screw bushing 5÷7
Engine arm bolt - frame arm 32.5 ÷ 40
Swinging arm set screw bushing nut 54 ÷ 60
Engine-swinging arm bolt 98 ÷ 118
Frame-swinging arm bolt 54 ÷ 60
Centre stand bolt 31 ÷ 39

FRONT SUSPENSION
Name Torque in Nm
Lower shock absorber clamp 19 ÷ 26
Upper shock absorber clamp 19 ÷ 29
Front wheel fixing screws 19 ÷ 24
Steering arm bolt nut 20 ÷ 25
Tilt gripper fixing screws 20 ÷ 25
Front wheel axle 74 ÷ 88
Arm coupling screws 45 ÷ 50
Screws fixing arms to side headstocks 45 ÷ 50
Screws fixing arms to central headstock 45 ÷ 50
Screws fixing the half-arm coupling flange 20 ÷ 25
Screws fixing tilt locking disc section 20 ÷ 25
Side headstock upper ring nut 20 ÷ 24
Side headstock lower ring nut 12 ÷ 15
Screw fixing sliding stem to shock absorber 45 ÷ 50
Clamp for sliding stem locking device 6.5 ÷ 10.5
Fixing nuts for constant-velocity universal joints 18 ÷ 20
Potentiometer to anti-tilting device clamp 8 ÷ 10
Electric motor to anti-tilting device clamp 11 ÷ 13
Clamp fixing pump bolt to anti-tilting device 11 ÷ 13
Pump to anti-tilting device clamp 11 ÷ 13
Pressure switch to distribution frame 18 ÷ 20
Sensor to tilt gripper clamp 2.5 ÷ 2.9
Pipe terminals to fifth wheel check spring 7 ÷ 11
Joint to anti-tilting device pump 20 ÷ 25
Lower fitting for shock absorber sliding locking clamp pipes 20 ÷ 25

CHAR - 12
MP3 400 i.e. Characteristics

Name Torque in Nm
Upper fitting for shock absorber sliding locking clamp pipes 20 ÷ 25

REAR SUSPENSION
Name Torque in Nm
Upper shock absorber clamp 33 ÷ 41
Lower shock absorber clamp 33 ÷ 41
Shock absorber-crankcase attachment bracket 20 ÷ 25
Rear wheel axle 104 ÷ 126
Muffler arm clamping screws 27 ÷ 30

FRONT BRAKE
Name Torque in Nm
Calliper coupling screw 22 ÷ 27
Oil bleed screw 8 ÷ 12
Disc tightening screw (°) 5÷6
Brake fluid pump-hose fitting 16 ÷ 20
Brake fluid pipe-calliper fitting 20 ÷ 25
Screw tightening calliper to support 20 ÷ 25
Calliper upper pipe fitting 20 ÷ 25

REAR BRAKE
Name Torque in Nm
Oil bleed screw 12÷16
Rear brake disc screws(°) 5 ÷ 6.5
Rear brake calliper-pipe fitting 20 ÷ 25
Rigid / flexible pipe fitting 13 ÷ 18
Rear brake pump-pipe fitting 16 ÷ 20
Rear brake calliper fixing screws 20 ÷ 25
pad fastening pin screws 20 ÷ 25

REAR BRAKE
Product Description Specifications
(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-strength
threadlock

MUFFLER
Name Torque in Nm
Muffler heat guard fixing screw 4÷5
Screw for fixing muffler to the support arm 20 ÷ 25
Lambda probe tightening on exhaust manifold 40 ÷ 50
Exhaust manifold-muffler joint tightening 12÷13
Manifold - muffler diaphragm tightening clamp 16 ÷ 18

LUBRICATION
Name Torque in Nm
Oil pump cover screws 0.7 ÷ 0.9
Screws fixing oil pump to the crankcase 5÷6

THERMAL GROUP AND TIMING SYSTEM

Name Torque in Nm
Spark plug 12 ÷ 14
Head fixing stud bolts ***
Head fixing nuts 10 - 12
Exhaust / intake head fixing nuts 10 - 12
Head lubrication control jet 5-7
Coolant temperature sensor: 10 - 12
Lambda probe on exhaust manifold 10 - 12
injector fixing screw 3÷4
Counterweight screw 7 ÷ 8.5
Tensioner sliding block fixing screw 10 - 14
Rpm timing sensor fixing screw 3-4

CHAR - 13
Characteristics MP3 400 i.e.

Name Torque in Nm
Valve lifter mass stop bell fixing screws 30 - 35
Inlet manifold screws 11 ÷ 13
Tappet cover fixing screws 7-9
Throttle body fixing screws 11 ÷ 13
Head fixing screws 10 - 12
Camshaft retaining bracket screws: 4÷6
Tightener screw: 5÷6
Tightener fastening screws: 11 ÷ 13
*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90° in a crossed sequence. - tighten again by 90° in
a criss-crossed sequence.

TRANSMISSION COVER
Name Torque in Nm
Driven pulley nut 92 - 100
Drive pulley nut 160 - 175
Anti-vibration roller screw 16.7 ÷ 19.6
M8 retainers for transmission cover 23 ÷ 26
M6 retainer 11 ÷ 13
Anti-vibration roller retainer 17 - 19
Clutch ring nut 65 - 75
Air conveyor screws 11 ÷ 12
Water pump cover screws 3÷4
External transmission cover screws 7÷9
Flywheel cover screws 11 - 13

FLYWHEEL COVER
Name Torque in Nm
Chain guide sliding block retain plate fastening screws 3÷4
Flywheel fixing nut 115 - 125
Stator retainers 8 - 10
Blow-by recovery duct fixing screws 3-4
Screw fixing freewheel to flywheel 13 ÷ 15
Stator cable harness guide bracket screws 3-4
Supporting screws with bulkhead 0.3 - 0.4
Minimum oil pressure sensor 12 ÷ 14
Water pump impeller 4÷5

CRANKCASE AND CRANKSHAFT

Name Torque in Nm
Countershaft fixing nut 25 ÷ 29
Engine oil filter 12 - 16
Engine oil drainage plug 24 ÷ 30
Engine-crankcase coupling screws 11 ÷ 13
Oil pump screws 5÷6
Gear mounting on crankshaft screws 10 -12
Bulkhead screws for oil pump housing cover 8 - 10

COOLING
Name Torque in Nm
Water pump impeller 4÷5
Water pump cover screws 3÷4
Thermostat cover screws 3÷4
Bleed screw 3

Overhaul data

Assembly clearances

CHAR - 14
MP3 400 i.e. Characteristics

Cylinder - piston assy.

HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED

Specification Desc./Quantity
A 43.2 mm
B 43 mm

CYLINDER- PISTON
Specification Desc./Quantity
Cylinder diameter C 85.8 - +0.018 -0.01 mm
Piston Ø P 85.768 ± 0.014 mm
CYLINDER - PISTON

COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder- Piston A 85.790÷85.797 85.754÷85.761 0.029÷0.043
Cylinder- Piston B 85.797÷85.804 85.761 ÷ 85.768 0.029÷0.043
Cylinder- Piston C 85.804÷85.811 85.768÷85.775 0.029÷0.043
Cylinder- Piston D 85.811÷85.818 85.775÷85.782 0.029÷0.043
CATEGORIES OF COUPLING

N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.

CHAR - 15
Characteristics MP3 400 i.e.

Piston rings

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

Check the size of the sealing ring opening:

Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm

Rings/housing coupling clearances:

Carefully clean the sealing ring housings.
Place a thickness gauge between the ring and the
housing as shown in the drawing and check the
coupling clearances.
Top ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Intermediate ring Standard coupling clear-
ance:0.02÷0.07 mm
Maximum clearances allowed after use: 0.10
mm

CHAR - 16
MP3 400 i.e. Characteristics

Oil scraper ring Standard coupling clearance:

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

Crankcase - crankshaft - 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.

Characteristic
Diameter clearance
0.025 ÷ 0.043 mm

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

CRANKSHAFT
Specification Desc./Quantity
Category 1 40.020÷40.026
Category 2 40.026÷40.032

If the crankshaft is within the set limits, replace the crankshaft half-bearings mounting the crankcase
so as to suit the specified couplings. The crankcase halves can be mounted with four types of crankshaft
half-bearings identified by letters A (red), B (blue), C (yellow), D (green).

CRANKCASE
Specification Desc./Quantity
Category 1 43.974 ÷ 43.980
Category 2 43.980 ÷ 43.986
Category 3 43.986 ÷ 43.992

CHAR - 17
Characteristics MP3 400 i.e.

CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGS

Specification Desc./Quantity
Crankshaft category 1 - Crankcase category 1 B+B, A+C
Crankshaft category 2 - Crankcase category 1 A+A
Crankshaft category 1 - Crankcase category 2 C+C, B+D
Crankshaft category 2 - Crankcase category 2 B+B, A+C
Crankshaft category 1 - Crankcase category 3 D+D
Crankshaft category 2 - Crankcase category 3 C+C, B+D

Characteristic
crankshaft / crankcase axial clearance:
0.1 ÷ 0.405 mm

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

CRANKSHAFT
Specification Desc./Quantity
Cat. 1 Standard diameter: 40.020÷40.026
Cat. 2 Standard diameter: 40.026÷40.032

Crankshaft alignment

Specific tooling
020335Y Magnetic support for dial gauge

CHAR - 18
MP3 400 i.e. Characteristics

MAX. ADMISSIBLE DISPLACEMENT

Specification Desc./Quantity
A= 0.15 mm
B= 0.010 mm
C= 0.010 mm
D= 0.10 mm

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Transmission-side 1±0.025 A D = 0.20 - 0.50
shoulder
Half-shaft, transmission 20.9 -0.05 B D = 0.20 - 0.50
side
Connecting rod 22 -0.10 -0.15 C D = 0.20 - 0.50
Flywheel-side shoulder 1.8±0.025 F D = 0.20 - 0.50
Flywheel-side half-shaft 19.6 -0.05 E D = 0.20 - 0.50
Complete crankshaft 65.5 +0.10 -0.05 G D = 0.20 - 0.50

Slot packing system

Shimming system for keeping the compression ra-

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

Characteristic
Compression ratio

CHAR - 19
Characteristics MP3 400 i.e.

10.6 ± 0.5 : 1

BASE GASKET THICKNESS

Name Measure A Thickness
«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05
«A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05
«A» MEASURE TAKEN + 0.10 ÷ + 0.185 0.8 ± 0.05
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE
CYLINDER PLANE.
N.B.
DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»

Products

RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP GEAR 80W-90 Oil for speed gearbox SAE 80W-90, API GL-4 mineral multi-
grade oil
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 4-stroke engines
(throttle control)
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
AUTOSOL METAL POLISH Muffler cleaning paste special product for cleaning and polishing
stainless steel muffler
AGIP GREASE PV2 Grease for steering bearings, pin seats Soap-based lithium and zinc oxide
and swinging arm grease containing NLGI 2; ISO-L-
XBCIB2 of the swinging arm

CHAR - 20
INDEX OF TOPICS

TOOLING TOOL
Tooling MP3 400 i.e.

SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats

001467Y002 Driver for OD 73 mm bearing

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54-mm bearings

001467Y008 Pliers to extract 17 mm ø bearings

001467Y014 Pliers to extract ø 15-mm bearings

TOOL - 22
MP3 400 i.e. Tooling

Stores code Description

001467Y031 Bell

001467Y034 Pliers to extract ø 15-mm bearings

001467Y035 Bearing housing, outside ø 47 mm

002465Y Pliers for circlips

006029Y Punch for fitting fifth wheel seat on steer-

ing tube

020004Y Punch for removing fifth wheels from

headstock

TOOL - 23
Tooling MP3 400 i.e.

Stores code Description

020055Y Wrench for steering tube ring nut

020150Y Air heater support

020151Y Air heater

020193Y Oil pressure check gauge

020201Y Spacer bushing driving tube

020262Y Crankcase splitting plate

020306Y Punch for assembling valve seal rings

TOOL - 24
MP3 400 i.e. Tooling

Stores code Description

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020648Y Single battery charger

020335Y Magnetic support for dial gauge

020357Y 32x35-mm Adaptor

020358Y 37x40-mm Adaptor

TOOL - 25
Tooling MP3 400 i.e.

Stores code Description

020359Y 42x47-mm Adaptor

020360Y 52x55-mm Adaptor

020364Y 25-mm guide

020376Y Adaptor handle

020382Y012 bush (valve removing tool)

020412Y 15-mm guide

020424Y Driven pulley roller casing fitting punch

TOOL - 26
MP3 400 i.e. Tooling

Stores code Description

020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

020439Y 17-mm guide

020444Y Tool for fitting/ removing the driven pulley

clutch

020456Y Ø 24 mm adaptor

TOOL - 27
Tooling MP3 400 i.e.

Stores code Description

020458Y Puller for lower bearing on steering tube

020459Y Punch for fitting bearing on steering tube

020460Y Scooter diagnosis and tester

020467Y Flywheel extractor

020468Y Piston assembly band

TOOL - 28
MP3 400 i.e. Tooling

Stores code Description

020469Y Reprogramming kit for scooter diagnostic
tester

020470Y Pin retainers installation tool

020471Y Pin for countershaft timing

020472Y Flywheel lock wrench

020474Y Driving pulley lock wrench

TOOL - 29
Tooling MP3 400 i.e.

Stores code Description

020475Y Piston position checking tool

020476Y Stud bolt set

020478Y Punch for driven pulley roller casing

020479Y Countershaft lock wrench

020480Y Petrol pressure check set

020481Y Control unit interface wiring

TOOL - 30
MP3 400 i.e. Tooling

Stores code Description

020482Y Engine support

020483Y 30-mm guide

020512Y Piston fitting fork

020527Y Engine support base

020604Y011 Fitting adapter

020565Y Flywheel lock calliper spanner

020640y software euro 3

TOOL - 31
Tooling MP3 400 i.e.

Stores code Description

020481Y004 Parking control unit interface wiring

Marelli MIU diagnosis software Marelli MIU diagnosis software

020646Y Parallelogram and steering positioning

tool

020647Y Toe-in checking tool

020661Y Water pump overall seal replacement kit

TOOL - 32
INDEX OF TOPICS

MAINTENANCE MAIN
Maintenance MP3 400 i.e.

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 TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Replace every 2 years

km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
Safety locks I I I I I
Throttle control A A A A A A A A A
Engine oil filter R R R R R R R R R
Electrical system and battery I I I I I
Coolant level * I I I I I I I I I
Brake oil level* I I I I I I I I I
Engine oil R I R I R I R I R I R I R I R I R
Brake pads I I I I I I I I I I I I I I I I I
Tyre pressure and wear I I I I I I I I I
Vehicle and brake test - test ride I I I I I I I I I
Hub oil R I R R I R I R
Steering I I I I I I I I I
Parking control unit software upgrading I I I I I I I I I I I I I I I I I
(if available)
Centre stand L L L L L L L L L L L L L L L L
Driving belt R R R R R R R R
Air filter C I C I C I C I
Sliding blocks / variable speed rollers R R R R R R R R
Suspensions I I I I I I I I
Spark plugs R R R R R R R R
Tilt locking caliper control cable A A A A A A A A
Valve clearance I I I I
Electrical system and battery I I I

MAIN - 34
MP3 400 i.e. Maintenance

Checking the spark advance

The ignition advance is determined electronically

on the basis of parameters known by the control
unit. For this reason it is not possible to interpret
the reference values based on the engine rpm.
The ignition advance value is detectable at any
time using the diagnostic tester. It is possible to
check whether the ignition advance determined by
the injection system matches the value actually
activated on the engine, by means of the strobo-
scopic light.

Proceed as follows:
- Remove the spark plug.
- Remove the transmission crankcase.
- Rotate the driving pulley fan until the reference
marks between the flywheel and flywheel cover
meet as shown in the photograph.

- Bring the reference mark onto the transmission

side between the fan and the transmission cover
as shown in the photograph.

- Refit the spark plug.

- Refit the plastic cap on the flywheel cover.
- Adjust the spark gap to the contact position (no
reference mark visible) and install it on the engine
between the spark plug and spark plug cap
- Connect the induction clamp on the spark gap
cable respecting the proper polarity (the arrow on
the clamp must be pointing at the spark plug).

MAIN - 35
Maintenance MP3 400 i.e.

- Connect the diagnostic tester.

- Start the engine.
- Select the «parameters» function in this menu.
- Select the stroboscopic light control in the tradi-
tional four-stroke engine position (1 spark, 2 revs).
- Check that the real values of rpm and ignition
advance match those measured using the diag-
nostic tester.

If the values do not correspond, check:

- distribution timing
- revolution timing sensor
- injection control unit

Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light to check timing
020621Y HV cable extraction adaptor

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

MAIN - 36
MP3 400 i.e. Maintenance

THE SPARK PLUG MUST BE REMOVED WHEN THE EN-

GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-
TED IN THE SCHEDULED MAINTENANCE TABLE. THE
USE OF ELECTRONIC CENTRAL UNITS AND OF NON-
COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGS
OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY
DAMAGE THE ENGINE.
N.B.
USING SPARK PLUGS OTHER THAN THE INDICATED
TYPE OR SHIELDLESS SPARK PLUG CAPS CAN CAUSE
ELECTRICAL SYSTEM FAILURES.

Characteristic
Spark plug
CHAMPION RG 6 YC
Alternative spark plug
NGK CR7EKB

Electric characteristic
Electrode gap
0.7 ÷ 0.8 mm

Hub oil

Check

-Park the vehicle on its centre stand on flat ground;

- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;

Remove the dipstick and check that the oil level is

slightly over the second notch starting from the
lower end; if the level is 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.

MAIN - 37
Maintenance MP3 400 i.e.

Replacement

-Remove the oil filler cap «A».

- Unscrew the oil drainage cap «B» and drain out
all the oil.
- Screw in the drainage cap again and fill the hub
with the prescribed oil.

Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications

Characteristic
Rear hub oil
Capacity approximately 250 cc

Air filter

Proceed as follows:
Unscrew the nine fixing screws «A» and remove
the air filter cover.

- Wash the sponge with water and mild soap.

- Dry it with a clean cloth and short blasts of compressed air.
- Soak it in a mixture of 50% petrol and 50% specified oil.
- Gently squeeze the filtering element with your hands but do not wring it; allow it to drip dry and then
refit.
CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE

CONTROLS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
Recommended products

MAIN - 38
MP3 400 i.e. Maintenance

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil

In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the
thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be con-
sidered normal, especially if during the run-in period. Consumption levels in particular can be influenced
by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Change oil and replace filter as indicated in the

scheduled maintenance table. Empty the engine
by draining the oil through drainage plug «B».

To facilitate oil drainage, loosen the cap/dipstick

«A».

Once all the oil has drained through the drainage

hole, unscrew and remove the oil cartridge filter
«C ».

MAIN - 39
Maintenance MP3 400 i.e.

Make sure the pre-filter and drainage plug O-rings

are in good conditions.
Lubricate them and refit the mesh filter and the oil
drainage plug, screwing them up to the prescribed
torque.
Refit the new cartridge filter being careful to lubri-
cate the O-ring before fitting it.
Change the engine oil.
Since a certain quantity of oil still remains in the
circuit, engine oil must be added through plug
«A». Then start the scooter, leave it running for a
few minutes and switch it off: after five minutes
check the level and if necessary top up without
exceeding the MAX level. The cartridge filter must
be replaced every time the oil is changed. Use new
oil of the recommended type for topping up and
changing purposes.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the require-
ments of API SL, ACEA A3, JASO MA specifica-
tions

Locking torques (N*m)

Engine oil filter 12 - 16 Engine oil drainage plug
24 ÷ 30

Check

This operation must be carried out with the engine

cold and following the procedure below:
- Place the vehicle on its centre stand and on flat
ground.
- Unscrew the cap/dipstick «A», dry it with a clean
cloth and reinsert it, screwing it all the way
down.

MAIN - 40
MP3 400 i.e. Maintenance

- Remove the cap/dipstick again and check that

the level is between the min and max reference
marks; top-up, if required.
If the check is carried out after the vehicle has
been used, and therefore with a hot engine, the
level line will be lower; in order to carry out a cor-
rect check, wait at least 10 minutes after the en-
gine has been stopped so as to get the correct
level.

Oil top up
The oil should be topped up after having checked
the level and in any case by adding oil without
ever exceeding the MAX. level.
Restoring the level from the MIN to the MAX marks
requires approx. 400 m³ of oil.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
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 products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

MAIN - 41
Maintenance MP3 400 i.e.

Oil pressure warning light

The vehicle is equipped with a warning light on the

instrument panel that lights up when the key is
turned to the «ON» position. However, this light
should switch off once the engine has been star-
ted.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication sys-
tem.

Checking the ignition timing

- Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark «T» on
the rotor matches the reference mark on the fly-
wheel cover as shown in the figure (TDC). Make
sure that the 4V reference point on the camshaft
control pulley is aligned with the reference point on
the head as shown in the second figure. If the ref-
erence is opposite the indicator on the head, turn
the crankshaft once more.
For the use of this reference mark, remove the
spark plug and turn the engine in the direction that
is the reverse of the normal direction using a cal-
liper spanner applied to the camshaft command
pulley casing.

Cooling system

Adding engine coolant.

Check coolant level when the engine is cold as in-
dicated in the scheduled maintenance table, fol-
lowing the steps below:
Place the scooter on its centre stand and on flat
ground.

MAIN - 42
MP3 400 i.e. Maintenance

- Undo the screw shown in the figure and remove

the expansion tank cap on RHS.
- Top up if the fluid level is near or below the MIN
level edge. The liquid level must always be be-
tween the MIN and MAX level.
-The coolant consists of an ethylene glycol and
corrosion inhibitor based 50% de-ionised water-
antifreeze solution mix.
CAUTION
DO NOT EXCEED THE MAX LEVEL WHEN FILLING SO
THAT COOLANT DOES NOT SPILL OVER THE EXPAN-
SION TANK WHEN THE VEHICLE IS BEING USED.

Recommended products
SPECIAL AGIP PERMANENT fluid Coolant
Monoethylene glycol based antifreeze solution,
CUNA NC 956-16

Braking system

Level check

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 certain lowering of the level is caused by
wear on the pads.

Top-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 reservoir cover; top-up with the rec-
ommended fluid without exceeding the 'MAX.'
mark.

MAIN - 43
Maintenance MP3 400 i.e.

This procedure applies to the rear brake pump top-

up operation; follow the same procedure for the
front brake pump.
Under standard climatic conditions, replace cool-
ant as indicated in the scheduled maintenance
table.
WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. BRAKING CIR-

CUIT FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE
THAT IT DOES NOT COME INTO CONTACT WITH THE
PAINTWORK.
CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR

EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.

Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT4 Synthetic fluid

Headlight adjustment

Proceed as follows:
- Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pres-
sure, onto a flat surface 10 m away from a half-lit
white screen; make sure the scooter axis is per-
pendicular to the screen;
- Remove the headlight assembly central cover.
- Turn on the headlight and check that the border
of the projected light beam on the screen is not
higher than 9/10 or lower than 7/10 f the height
from the ground to the centre of vehicle headlamp;
- Otherwise, adjust the headlight with the screws
« A» indicated in the figure
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.

MAIN - 44
INDEX OF TOPICS

TROUBLESHOOTING TROUBL
Troubleshooting MP3 400 i.e.

This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Misshapen/worn valve seats Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil guard Replace the valve oil guard
Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation
By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

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

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation
Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

TROUBL - 46
MP3 400 i.e. Troubleshooting

Possible Cause Operation

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
scooter.

Brakes overheating

BRAKES OVERHEATING
Possible Cause Operation
Defective plunger sliding Check calliper and replace any damaged part.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial deviation
of the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING
Possible Cause Operation
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation
Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.

Noisy suspension

NOISY SUSPENSION
Possible Cause Operation
Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front
shock absorber; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers; and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disc in the
attachment to the hub and the steering tube.

TROUBL - 47
Troubleshooting MP3 400 i.e.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation
Faulty or broken seals Replace the shock absorber Check the condition of wear of the
steering covers and the adjustments.

TROUBL - 48
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system MP3 400 i.e.

MP3 400 i.e.

KEY
1. Injection ECU
2. Immobilizer aerial
3. Lambda sensor
4. Magneto flywheel
5. Voltage regulator
6. Engine stop switch
7. Radiator electric fan
8. Electric fan remote control
9. Main fuses
10. Socket 12V
11. Key switch contacts
12. Auxiliary fuses
13. Key switch contacts
14. Fuse
15. Battery
16. Starter motor
17. Starter remote control switch
18. Start-up enabling remote control switch

ELE SYS - 50
MP3 400 i.e. Electrical system

19. Boot actuator

20. Saddle opening actuator
21. Saddle opening receiver
22. Starter button
23. Stop button on rear brake
24. Stop button on front brake
25. Turn indicator switch
26. Hazard button
27. Turn indicator control device and hazard
28. Pre-installation for anti-theft device
29. Helmet compartment light button
30. Helmet compartment light button
31. Light switch
32. Headlight remote control
33. Helmet compartment internal light
34. Rear left light
A. Rear left turn indicator bulbs
B. Stop light bulb
C. Tail light bulb
35. License plate light
36. Rear right light
A. Tail light bulb
B. Stop light bulb
C. Rear right turn indicator bulbs
37. Front left turn indicator
38. Headlight
A. Tail light bulbs
B. Low-beam light bulb
C. High-beam light bulb
39. Front right turn indicator
40. Pressure sensor
41. Horn remote control
42. Horn
43. Horn button
44. Oil pressure sensor
45. Parking brake button
46. Coolant temperature sensor:
47. External temperature sensor

ELE SYS - 51
Electrical system MP3 400 i.e.

48. Instrument panel

49. Parking control ECU
50. Brake calliper sensor
51. Geared motor
52. Fuel level transmitter
53. «MODE» button
54. Rider presence sensor
55. Locking/unlocking switch
56. Injection load remote control
57. Fuel pump
58. Fuel injector
59. Potentiometer
60. Right wheel turning sensor
61. Left wheel turning sensor
62. HV coil
63. Diagnostics socket
64. Engine rpm sensor
MP3 400 i.e. RL

KEY
1. Instrument panel
2. Rear right turn indicator bulbs
3. Front right turn indicator bulbs
4. Turn indicator switch
5. Front left turn indicator bulbs
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 12V-55W twin-filament bulb
11.Front position light bulbs
12. License plate bulb
13. Tail light bulbs
14. Headlight remote control
15. Saddle opening actuator
16.Boot actuator
17.Light switch
18. Stop buttons

ELE SYS - 52
MP3 400 i.e. Electrical system

19.Auxiliary fuses unit

20. Fuel level transmitter
21.Oil pressure sensor
22. Pressure sensor
23. Immobilizer aerial
24. External temperature sensor
25. Key switch contacts
26. MODE button
27. Diagnosis socket
28. Injection ECU
29. Fuel pump
30. Engine temperature sensor
31. Fuel injector
32. HV coil
33. Engine rpm sensor
34. Engine stop switch
35. Lambda sensor
36. Right speed sensor
37. Left speed sensor
38. Potentiometer
39. Parking control ECU
40. Brake calliper sensor
41. Rider presence sensor
42. Geared motor
43. Hand brake
44. Tilt locking/unlocking switches
45. Horn remote control
46. Saddle opening receiver
47. Horn
48.Horn button
49. Injection load remote control
50. 12V - 10W stop light bulbs
51. Battery
52. Starter remote control
53.Starter motor
54. Start-up enabling remote control switch
55.Starter button
56.Main fuses unit

ELE SYS - 53
Electrical system MP3 400 i.e.

57. Magneto flywheel

58. Voltage regulator
59. Helmet compartment light switch
60. Boot light switch
61. Boot and helmet compartment light bulb
62. Socket 12V
63. Radiator electric fan
64. Electric fan remote control
65. Key switch contacts

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 - 54
MP3 400 i.e. Electrical system

1 - Relays for lights / horn / injection load / electric

fan: remove the front shield to reach it.

2 - Auxiliary fuses: remove the footrest flap to

reach these fuses.

ELE SYS - 55
Electrical system MP3 400 i.e.

3 / 4 / 19 - Electronic control unit for injection

(MIU) / Start-up relay / Start-up enabling switch
relay: remove the lid of the helmet compartment to
reach these relays.
N.B. when fitting the Start-up relay make sure to
connect the two "power" terminals correctly:
Battery Cable on terminal "B"
Starter motor cable on terminal "M"

5 / 6 / 10 - Fuel pump / Fuel level sensor / coil:

remove the chassis central cover to reach these
components.

ELE SYS - 56
MP3 400 i.e. Electrical system

7 - Voltage regulator: remove the right side fairing

to reach them.

8 - Immobilizer aerial: remove the shield back plate

to reach it.

9 / 18 - Saddle opening receiver/ Turn indicator

control device: to reach it, remove the left fairing.

ELE SYS - 57
Electrical system MP3 400 i.e.

11 / 12 - Diagnostics socket/ main fuses: these

components are found in the battery compartment.

13 - Lambda probe: The lambda probe is mounted

on the exhaust manifold.

14 - Engine oil pressure sensor: remove the ex-

haust end to reach it.

15 - Centralina comando stazionamento: per ac-

cedervi rimuovere il controscudo.

ELE SYS - 58
MP3 400 i.e. Electrical system

16 - Rider presence sensor: open the saddle and

remove the cover to reach the rider presence sen-
sor.

17 - Coolant temperature sensor: remove the lid of

the helmet compartment and disconnect the con-
nector to reach it.

20 - Horn: remove the shield back plate lower side

to reach it.

21 - Geared motor assembly: remove the legshield

to reach it.

Conceptual diagrams

Ignition

MP3 400 i.e.

ELE SYS - 59
Electrical system MP3 400 i.e.

KEY
1. Injection ECU
2. Immobilizer aerial
9. Main fuses
11. Key switch contacts
12. Auxiliary fuses
15. Battery
56. Injection load remote control
62. HV coil
MP3 400 i.e. RL

KEY
1. Instrument panel
19. Auxiliary fuses unit
23. Immobilizer aerial
28. Injection ECU
32. HV coil
33.Engine rpm sensor
49.Injection load remote control
51. Battery

ELE SYS - 60
MP3 400 i.e. Electrical system

56. Main fuses unit

65. Key switch contacts

Battery recharge and starting

MP3 400 i.e.

KEY
1. Injection ECU
4. Magneto flywheel
5. Voltage regulator
6. Engine stop switch
9. Main fuses
11. Key switch contacts
12. Auxiliary fuses
14. Fuse
15. Battery
16. Starter motor
17. Starter remote control switch
18. Start-up enabling remote control switch
22. Starter button
23. Stop button on rear brake

ELE SYS - 61
Electrical system MP3 400 i.e.

24. Stop button on front brake

34. Rear left light
B. Stop light bulb
36. Rear right light
B. Stop light bulb

MP3 400 i.e. RL

KEY
1. Instrument panel
18. Stop buttons
19.Auxiliary fuses unit
28.Injection ECU
34. Engine stop switch
50. 12V - 10W stop light bulbs
51. Battery
52. Starter remote control
53.Starter motor
54.Start-up enabling remote control switch
55. Starter button
56. Main fuses unit
57. Magneto flywheel
58. Voltage regulator
65. Key switch contacts

Level indicators and enable signals section

MP3 400 i.e.

ELE SYS - 62
MP3 400 i.e. Electrical system

KEY
1. Injection ECU
2. Immobilizer aerial
3. Lambda sensor
9. Main fuses
11. Key switch contacts
12. Auxiliary fuses
15. Battery
44. Oil pressure sensor
46. Coolant temperature sensor:
47. External temperature sensor
48. Instrument panel
49. Parking control ECU
50. Brake calliper sensor
52. Fuel level transmitter
54. Rider presence sensor
56. Injection load remote control
58. Fuel injector
59. Potentiometer
60. Right wheel turning sensor

ELE SYS - 63
Electrical system MP3 400 i.e.

61. Left wheel turning sensor

64. Engine rpm sensor

MP3 400 i.e. RL

KEY
1. Instrument panel
19.Auxiliary fuses unit
20.Fuel level transmitter
24. External temperature sensor
28. Injection ECU
29. Fuel pump
30.Engine temperature sensor
31. Fuel injector
33. Engine rpm sensor
35.Lambda sensor
36.Right speed sensor
37. Left speed sensor
38. Potentiometer
39.Parking control ECU
40. Brake calliper sensor
41. Rider presence sensor
44. Tilt locking/unlocking switches
49. Injection load remote control
51. Battery
56.Main fuses unit
65. Key switch contacts

ELE SYS - 64
MP3 400 i.e. Electrical system

Devices and accessories

MP3 400 i.e.

KEY
1. Injection ECU
7. Radiator electric fan
8. Electric fan remote control
9. Main fuses
10. Socket 12V
11. Key switch contacts
12. Auxiliary fuses
13. Key switch contacts
15. Battery
19. Boot actuator
20. Saddle opening actuator
21. Saddle opening receiver
28. Pre-installation for anti-theft device
29. Helmet compartment light button
30. Helmet compartment light button
33. Helmet compartment internal light

ELE SYS - 65
Electrical system MP3 400 i.e.

40. Pressure sensor

41. Horn remote control
42. Horn
43. Horn button
45. Parking brake button
48. Instrument panel
49. Parking control ECU
51. Geared motor
53. «MODE» button
54. Rider presence sensor
55. Locking/unlocking switch
56. Injection load remote control
57. Fuel pump
63. Diagnostics socket

MP3 400 i.e. RL

ELE SYS - 66
MP3 400 i.e. Electrical system

KEY
1. Instrument panel
2. Rear right turn indicator bulbs
3. Front right turn indicator bulbs
5. Front left turn indicator bulbs
6.Rear left turn indicator bulbs
9. Pre-installation for anti-theft device
15. Saddle opening actuator
16. Boot actuator
19. Auxiliary fuses unit
22. Pressure sensor
25. Key switch contacts
26. MODE button
28. Injection ECU

ELE SYS - 67
Electrical system MP3 400 i.e.

29.Fuel pump
39. Parking control ECU
42.Geared motor
43. Hand brake
45. Horn remote control
46. Saddle opening receiver
47. Horn
48. Horn button
49.Injection load remote control
51.Battery
56.Main fuses unit
59. Helmet compartment light switch
60. Boot light switch
61. Boot and helmet compartment light bulb
62.Socket 12V
63. Radiator electric fan
64. Electric fan remote control
65. Key switch contacts

Lights and turn indicators

MP3 400 i.e.

ELE SYS - 68
MP3 400 i.e. Electrical system

KEY
9. Main fuses
11. Key switch contacts
12. Auxiliary fuses
13. Key switch contacts
15. Battery
25. Turn indicator switch
26. Hazard button
27. Turn indicator control device and hazard
31. Light switch
32. Headlight remote control
34. Rear left light
A. Rear left turn indicator bulbs
C. Tail light bulb
35. License plate light
36. Rear right light
A. Tail light bulb
C. Rear right turn indicator bulbs
37. Front left turn indicator
38. Headlight

ELE SYS - 69
Electrical system MP3 400 i.e.

A. Tail light bulbs

B. Low-beam light bulb
C. High-beam light bulb
39. Front right turn indicator
48. Instrument panel
49. Parking control ECU

MP3 400 i.e. RL

KEY
1. Instrument panel
2. Rear right turn indicator bulbs
3. Front right turn indicator bulbs
4. Turn indicator switch
5.Front left turn indicator bulbs
6. Rear left turn indicator bulbs
7.Hazard button
8.Turn indicator control device with hazard
10. Headlight with 12V-55W twin-filament bulb
11.Front position light bulbs
12. License plate bulb
13. Tail light bulbs
14. Headlight remote control
17.Light switch
19. Auxiliary fuses unit
25.Key switch contacts
51. Battery
56.Main fuses unit
65.Key switch contacts

Checks and inspections

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

ELE SYS - 70
MP3 400 i.e. Electrical system

Immobiliser

The electronic ignition system is controlled by the

control unit with the integrated Immobilizer sys-
tem. The immobilizer is an anti-theft system that
allows the vehicle to be operated only when it is
started with coded keys recognised by the control
unit. The code is integrated in a transponder in the
key block. This allows the driver clear operation
without having to do anything other than just turn-
ing the key. The Immobilizer system consists of the
following components:
- an electronic control unit
- immobilizer aerial
- Master key with incorporated transponder (red
key)
- service key with incorporated transponder (black
key)
- HV coil
- diagnosis LED
The diagnosis LED also works as a theft-deterrent
blinker. This function is activated every time the
ignition switch is turned to the "OFF" position, or
the emergency stop switch is turned to the "OFF"
position. It remains activated for 48 hours in order
not to affect the battery charge. When the ignition
switch is turned to the "ON" position, the theft-de-
terrent blinker function is deactivated. Subse-
quently, a flash confirms the switching to the "ON"
status. The duration of the flash depends on the
programming of the electronic control unit If the
LED is off regardless of the position of the ignition-
key switch and/or the instrument panel is not initi-
ated, check if:

• there is battery voltage

• fuses 1,7,10 are in working order
• there is power to the control unit as
specified below:

ELE SYS - 71
Electrical system MP3 400 i.e.

Remove the connector support bracket shown in

the photograph and disconnect the connector from
the control unit. Check the following conditions:

With the key switch set to OFF:

• if there is battery voltage between ter-

minals 6-26 and terminal 6-chassis
ground (fixed power supply). If there is
no voltage, check that fuse 1 and its
cable harness for the MP3 400 i.e. ver-
sion and fuse 6 and its cable harness
for the MP3 400 i.e. RL version are in
working order.

With the key switch in the OFF position:

• there is battery voltage between termi-

nals 5-26 and terminal 5-frame earth
(fixed power supply). If there is no volt-
age, check the key switch contacts,
that fuse no. 10 and its cable are in
working order.

• There is continuity between terminals

12-18 with the emergency cut-off
switch in the RUN position. If there is
no continuity check the contacts of the
switch.

If no faults are found, replace the electronic control

unit.

After removing the shield back plate, remove the

electrical connection from the aerial as shown in
the picture.

ELE SYS - 72
MP3 400 i.e. Electrical system

Remove the protective base from the connector.

With the ignition key in ON check if there is battery

voltage between the Red-White and Black cables
for the MP3 400 i.e. version and between the Red-
Black and Orange cables for the MP3 400 i.e. RL
version.

With MIU connector disconnected, check the con-

tinuity between the Orange-White cable and pin 7
of the interface wiring.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

Virgin circuit
When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The
keys can only be recognised if the control unit has been programmed properly. The data storage pro-
cedure for a previously not programmed control unit provides for the recognition of the master as the
first key to be stored to memory: this becomes particularly important because it is the only key that

ELE SYS - 73
Electrical system MP3 400 i.e.

enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3
seconds).
- Insert the service key and turn it to «ON» for 2 seconds.
- If you have copies of the key, repeat the operation with each key.
- Insert the MASTER key again and turn it to «ON» for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys can be programmed at one time.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, the master key transponder is strictly matched with the control
unit. With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore
necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key
becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In
any case it is advisable to use resistive spark plugs.

Characteristic
MASTER key:
RED KEY
SERVICE key.
BLACK KEY

Diagnostic codes

The Immobilizer system is tested each time the

key switch is turned from «OFF» to «ON». During
this diagnosis phase a number of control unit sta-
tuses can be identified and various light codes
displayed. Regardless of the code transmitted, if
at the end of the diagnosis the LED remains off
permanently, the ignition is enabled. If, however,
the LED remains on permanently, it means the ig-
nition is 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
MP3 400 i.e. Electrical system

ted but with a limitation imposed on the number of

revs.
2. Previously unused control unit - transpond-
er absent or cannot be used: The LED is per-
manently ON; in this condition, no operations are
possible, not even starting the vehicle.

3. Programmed control unit - service key in-

serted (normal conditions 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 inser-
ted: a 0.7-sec flash is displayed followed by the
LED remaining 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
Electrical system MP3 400 i.e.

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.

Battery recharge circuit

The recharge circuit is provided with a three-phase generator with permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
This, in its turn, is connected directly to the ground and the battery positive terminal passing through
the 30A protective fuse.
The three-phase generator provides good recharge power and at low revs, a good compromise is ach-
ieved between generated power and idle stability.

Stator check
Checking the stator windings
WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Remove the right side panel.
2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the
photograph.

ELE SYS - 76
MP3 400 i.e. Electrical system

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

Electric characteristic
Resistance:
0.2 - 1 Ω

4) Check that there is insulation between the each

yellow cable and the ground.
5) If values are incorrect, replace the stator.

Recharge system voltage check

Look for any leakage

1) Access the battery by removing its cover under the saddle.
2) Check that the battery does not show signs of losing fluid before checking the output voltage.
3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole
(-) of the battery and the black cable and only then disconnect the black cable from the negative pole
(-) of the battery.
4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

Charging current check

WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK-
ING ORDER.
1) Park 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 characteristic
Voltage ranging between 14.0 and 15.0V at 5000 rpm.
Maximum current output check.
- With the engine off and the panel at «ON» with the lights on, allow the battery voltage to stop at 12V.
- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.
- Start the engine and rev it up to a high engine speed while reading the value on the pincer.
With an efficient battery a value must be detected: > 20A

ELE SYS - 77
Electrical system MP3 400 i.e.

VOLTAGE REGULATOR/RECTIFIER
Specification Desc./Quantity
Type Non-adjustable three-phase transistor
Voltage 14 ÷ 15V at 5000 rpm with lights off

Fuses

The electrical system has twelve fuses divided into

two fuse boxes to protect the different installation
circuits. One of them is inside the battery compart-
ment «A» and the other is at the internal side of
the right footrest «B».To have access, loosen the
screw «C» and remove the plastic cover. The chart
shows the position and characteristics of the fuses
in the vehicle.
CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE

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

ELE SYS - 78
MP3 400 i.e. Electrical system

The fuse No. 13 is located on the start-up remote

control switch.

FUSE TABLE
Specification Desc./Quantity
1 Fuse No. 1 Capacity: 7.5 A
Protected circuits:Injection ECU battery power
2 Fuse No. 2 Capacity: 15 A
Protected circuits:Battery-powered injection loads,
electrical fan
3 Fuse No. 3 Capacity: 15 A
Protected circuits:Battery power for saddle opening re-
ceiver, case lighting, headlight relay, turn indicator con-
trol device
4 Fuse No. 4 Capacity: 20A
Protected circuits:battery-powered ECU for parking
control
5 Fuse No. 5 Capacity: 20A
Protected circuits:battery-powered fuse No. 7, live
fuses No. 8 - 9 - 10 - 11
6 Fuse No. 6 Capacity: 15 A
Protected circuits:L.V. socket.
7 Fuse No. 7 Capacity: 7.5 A
Protected circuits:Battery-powered instrument panel
8 Fuse No. 8 Capacity: 10A
Protected circuits:Live stop, start-up and start-up ena-
bling lights.
9 Fuse No. 9 Capacity: 7.5 A
Protected circuits:live passing and horn
10 Fuse No. 10 Capacity: 7.5A
Protected circuits:Live injection ECU, immobilizer aer-
ial, electric fan remote control, injection load remote
control
11 Fuse No. 11 Capacity: 7.5A
Protected circuits:Live parking control ECU, pre-instal-
lation for anti-theft device, instrument panel, headlight
remote control, horn remote control
12 Fuse No. 12 Capacity: 7.5A
Protected circuits:Live turn indicator control, saddle
opening switch, tail lights, panel lighting

ELE SYS - 79
Electrical system MP3 400 i.e.

LIGHT BULBS TABLE

Specification Desc./Quantity
1 Helmet compartment light bulb Type: Incandescent (SV 8.5)
Power: 12V - 5W
Quantity: 1
2 High/low beam light bulb Type: Halogen (H1)
Power: 12V - 55W
Quantity: 2
3 Front tail light bulb Type: Incandescent (W2.1x9.5d)
Power: 12V-3W
Quantity: 2
4 Stop light bulb Type: Incandescent (BA 15s)
Power: 12V - 10W
Quantity: 2
5 License plate bulb Type: Incandescent (W2.1x9.5d)
Power: 12V - 5W
Quantity: 1
6 Rear tail light bulb Type: Incandescent (W2.1x9.5d)
Power: 12V - 5W
Quantity: 2
7 Rear turn indicator bulb Type: Incandescent (W2.1x9.5d)
Power: 12V - 5W
Quantity: 4
8 Font turn indicator bulb Type: Incandescent (BAU 15s)
Power: 12V-10W
Quantity: 2

Dashboard

ELE SYS - 80
MP3 400 i.e. Electrical system

A = Led immobilizer / anti-theft device

B= Speedometer with twin scale (km/h and mph)
C = CLOCK switch
D = Digital display
E = Front suspension locking system warning light
(if available)
F = SET switch
G = Rpm indicator
H = Fuel gauge
I = Warning light for helmet compartment courtesy
light on
L = Engine control telltale light and injection sys-
tem failure warning light
M = Low fuel warning light
N = Engine stop warning light
O= Turn indicator warning light
P = Low oil pressure warning light
Q = Front suspension locking system failure warn-
ing light (if available)
R = Warning light for parking brake engaged
S = High-beam warning light

A = Total odometer gauge

B = «BELT» maintenance icon
C = «SERVICE» maintenance icon
D = Engine coolant temperature indicator
E = Trip odometer (A-B) and ambient temperature gauge (selected with the MODE button)
F = TIME-DATE indicator
G = Low fuel warning light
H = Trip odometer gauge (B)
I = Trip odometer gauge (A)
L = Kilometre - mile indicator

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is checking its charge
and recharging, when necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.

ELE SYS - 81
Electrical system MP3 400 i.e.

Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
- Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h

Connectors

INJECTION ELECTRONIC CONTROL UNIT

CONNECTOR
1. Injection telltale light LED (Brown-Black)
2. Rpm indicator on instrument panel (Yellow)
3. CAN "L" Line (White-Blue)
4. Lambda probe (-) (White-Green)
5. Live supply (Red-White)
6. Battery-powered (Orange-Black)
7. Immobilizer aerial (Orange-White)
8. Electric fan remote control (Blue-Yellow)
9. Coolant temperature sensor (Sky blue-Green)
10. CAN "H" Line (Pink-White)
11. Lambda probe (+) (Sky blue-Black)
12. Engine stop switch (Green-Black)
13. Engine rpm sensor positive (Red)
14. Fuel injector (Red-Yellow)
15. Engine rpm sensor negative (Brown)
16. Diagnosis (Purple-White)

ELE SYS - 82
MP3 400 i.e. Electrical system

17. Immobilizer LED (Red-Green)

18. Engine stop switch, coolant temperature sen-
sor (Grey-Green)
19. Not connected
20. Injection load remote control (Black-Purple)
21. Not connected
22. HV coil (Pink-Black)
23. Not connected
24. Start-up enabling switch (Orange-Blue)
25. Not connected
26. Ground lead (Black)

PICK-UP CONNECTOR
1. Injection ECU (Red)
2. Injection ECU (Brown)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red-Black)
2. Ground lead (Black)
3. Battery positive (Red-Black)
4. Ground lead (Black)

SADDLE OPENING RECEIVER 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)
7. Ground lead
8. Not connected
9. Not connected

ELE SYS - 83
Electrical system MP3 400 i.e.

10. Boot actuator (Yellow)

11. Channels 1/3 selector (Green-Blue)
12. Alarm code (Orange-Black)

TURN INDICATOR CONTROL DEVICE CON-

NECTOR
1. Hazard button (Brown)
2. Left Switch (White-Pink)
3. RHS Switch (Blue-Black)
4. Left turn indicators (Pink)
5. Right turn indicators (White-Blue)
6. Battery-powered (Blue)
7. Not connected
8. Live supply (Yellow-Black)
9. Ground lead (Black)
10. Not connected
11. Not connected
12. Not connected

HV COIL CONNECTOR
1. Injection load remote control (Black-Green)
2. Injection ECU (Pink-Black) for the MP3 400 i.e.
version and (Red-Black) for the MP3 400 i.e. RL
version.

ANTI-THEFT DEVICE PRE-INSTALLATION

CONNECTOR
1. Left turn indicators (Pink)
2. Right turn indicators (White-Blue)
3. Ground lead (Black)
4. Battery-powered (Blue)
5. Live supply (Yellow-Red)
6. Helmet compartment lighting warning light
(Blue-Black)
7. Channels 1/3 selector (Green-Blue)
8. Alarm code (Orange-Black)

ELE SYS - 84
MP3 400 i.e. Electrical system

FUEL PUMP CONNECTOR

1. Injection load remote control (Black-Green)
2. Not connected
3. Not connected
4. Ground lead (Black)
5. Not connected

INSTRUMENT PANEL CONNECTOR "A"

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
11. Ground lead (Black)
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 (Sky blue-Black)
4. Water temperature sensor ground lead (Brown-
White)
5. «MODE» remote button (Green)
6. Oil pressure sensor (Pink-White)
7. Left turn indicator warning light (Pink)
8. Right turn indicator warning light (White-Blue)
9. High-beam warning light (Purple)
10. Boot open warning light (Blue-Black)
11. Rpm sensor (-)
12. Ambient temperature sensor (Yellow-Blue)
13. Ambient temperature sensor ground (White-
Yellow)

ELE SYS - 85
Electrical system MP3 400 i.e.

14. Engine disabled warning light (Orange-Blue)

15. Immobilizer warning light (Red-Green)
16. Engine check warning light (Brown-Black)
17. Parking brake warning light (Yellow-Grey)
18. Tilt locking activated warning light (Pink-Black)
19. Tilt locking system failure warning light (Grey-
Black)
20. Live supply from the parking control ECU (Yel-
low-Green)

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-
Black)
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 (White-Red)
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 - 86
MP3 400 i.e. Electrical system

Remote seat opening

Zeroing

- Remove the left side fairing to access the saddle

opening receiver control unit indicated in the pho-
tograph
- Remove the metal terminal and connect it to a
good earth point, or to terminal 7 (black), for at
least 10 seconds.
- In this operation all the remote controls stored in
the control unit will be deleted.
WARNING
THE CONTROL UNIT CAN PROGRAMME UP TO 8 REMOTE
CONTROLS.

Programming

Follow these steps to program the remote controls:

1. Insert the remote control key to be programmed in the steering lock key block.
2. Turn the key to «ON», press the button on the remote control, release the button, then turn the key
back to «OFF» within four seconds of turning «ON».
3. Wait 1 to 8 seconds.
4. Repeat steps 2 and 3 four more times without removing the key.
The control unit confirms the programming has been successful by opening the saddle.
WARNING

TO STORE THE OTHER REMOTE CONTROLS TO MEMORY (8 MAXIMUM) YOU NEED TO RE-
PEAT THE WHOLE PROCEDURE AGAIN. FAILURE TO CARRY OUT THESE OPERATIONS
WITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE
PROCESS FOR PROGRAMMING THE REMOTE-CONTROLLED KEYS.
WARNING

AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FAR AWAY
FROM THE SCOOTER. THE SYNCHRONISM BETWEEN THE REMOTE CONTROL AND THE RE-

ELE SYS - 87
Electrical system MP3 400 i.e.

CEIVER CAN BE IMPAIRED. SHOULD THIS BE THE CASE, REPEAT THE PROGRAMMING
PROCEDURE. DO NOT KEEP THE REMOTE CONTROL IN PLACES WITH TEMPERATURES EX-
CEEDING 60° C THE BATTERY WILL RUN DOWN TOO QUICKLY.
WARNING

TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTE CONTROL RADIO RE-
CEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLE WAS SHUT OFF.
JUST TURN THE KEY TO «ON» TO REACTIVATE THE RECEIVER.

ELE SYS - 88
INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle MP3 400 i.e.

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

Exhaust assy. Removal

- Remove the side fairings.
- Remove the central frame cover.
- Remove the exhaust end.
- Disconnect the lambda probe connector.

- Unscrew the probe.

- Working from both sides, release the two clamps

securing the exhaust manifold to the head.
- Detach the exhaust manifold making it pass
through the swinging arm.
CAUTION
SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUF-
FLER TIP, ALWAYS REPLACE THE GRAPHITE GASKET
BETWEEN STUB AND TIP.

To fit, follow the removal steps but in reverse order; be careful to tighten to the correct locking torques
once the muffler silencer has been refitted.

Removal of the engine from the vehicle

- Use a jack to support the vehicle properly.
- Disconnect the battery.
- Remove the engine cover inside the helmet compartment.
- Remove the side fairings.
- Remove the footrests.
Remove the full muffler unit.

ENG VE - 90
MP3 400 i.e. Engine from vehicle

CAUTION

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

- Remove the rear wheel.

- Remove the bracket supporting the rear brake

callipers and the callipers as well.
- After removing the air filter from the crankcase,
undo the screws fixing the bracket that secures the
rear brake pipes.

- Remove the pipe that feeds coolant into the pump

as shown in the photograph and then empty the
system.
- Remove the engine coolant outlet pipe as indi-
cated.

- Disconnect the fuel delivery pipe from the injector

by removing the screw locking the retainer clamp.
- Disconnect the injector wiring and the throttle
body control unit wiring.

- Remove the coolant outlet pipe from the motor

as indicated.

ENG VE - 91
Engine from vehicle MP3 400 i.e.

- Remove the spark plug caps.

- Remove the coolant temperature sensor con-
nector indicated in the photograph.

- Remove the throttle cables from the throttle body

by undoing the nuts indicated in the photograph.
- Remove the negative terminal cable from the
starter motor.

- Remove the positive terminal cable from the

starter motor as shown in the photograph.
- Remove the engine ground lead.

- Disconnect the connectors from the flywheel wir-

ing as shown in the photo.
- Remove the cable from the retaining clip on the
flywheel cover.

ENG VE - 92
MP3 400 i.e. Engine from vehicle

Remove the lower screw of the left-hand shock

absorber.

- Remove the engine-swinging arm fixing pin by

undoing the nut and operating on the head of the
pin as shown in the photograph.
- The engine is now free.

When refitting the engine onto the scooter, carry out the removal operations but in reverse order and
respect the tightening torques shown in the Specifications Chapter.
- Check the engine oil level and if necessary, top it up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct functioning.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION
PROPERLY.

ENG VE - 93
INDEX OF TOPICS

ENGINE ENG
MP3 400 i.e. Engine

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

Automatic transmission

Transmission cover

- Loosen the 4 fastening screws

- Extract the outside plastic transmission cover.

- Using a screwdriver, remove the driven pulley

axle cover near the bottom of the cap.

- Loosen the driven pulley shaft fastening nut using

a misaligned wrench and prevent the pulley shaft
rotation using a machine hexagon bush.
- Remove the nut and the two washers.
N.B.
DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-
ENT WRENCHES - SUCH AS A CONVENTIONAL POLYG-
ONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED
ON THE SHAFT OR BREAK THE BUSH ITSELF.

ENG - 95
Engine MP3 400 i.e.

- Remove the six M6 screws.

- Remove the four M8 screws.

- Remove the transmission cover.
- Check that the bearing rotates freely, otherwise
replace it.

Air duct

- Remove the transmission cover.

- Unscrew the two screws shown in the figure to
remove the air conveyor.

Locking torques (N*m)

Air conveyor screws 11 ÷ 12

- Remove the external transmission cover.

- Unscrew the 4 fastening screws shown in the fig-
ure to remove the external air conveyor.

ENG - 96
MP3 400 i.e. Engine

Air duct filter

- Remove the external air conveyor.

- Unscrew the 2 fastening screws shown in the fig-
ure to remove the conveyor filter.

Removing the driven pulley shaft bearing

- Remove the transmission cover.

- Remove the Seeger ring.

- Place transmission cover on a wood surface and

use the special tool so that it is adequately sup-
ported.
- Pull out the bearing using the special tool.
N.B.
BELL MUST BE PLACED INTO THE TRANSMISSION COV-
ER, CLOSE TO THE BEARING SEAT AND THE WOODEN
SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER
STRUCTURE WOULD BEND. NOT ONLY IN THE AREA OF
MAXIMUM STURDINESS.

Specific tooling
001467Y002 Driver for OD 73 mm bearing
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020439Y 17-mm guide

ENG - 97
Engine MP3 400 i.e.

Refitting the driven pulley shaft bearing

- Heat the transmission cover interior using the

heat gun.
N.B.
BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS
WOULD DAMAGE THE OUTSIDE PAINTED SURFACE.

Specific tooling
020151Y Air heater

- Place the bearing onto the special tool with a little

grease to prevent it from coming out.
- Install the new bearing using the special tool.
N.B.
PROPERLY SUPPORT THE OUTSIDE COVER TO PRE-
VENT DAMAGING THE PAINTED SURFACE.

Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm Adaptor
020439Y 17-mm guide

Baffle roller

Plastic roller

- Check that the roller does not show signs of wear

and that it turns freely.
- Loosen the retaining bolt using a 13 mm spanner.
- Remove the complete roller with bearing.
N.B.
IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE
THE COMPLETE ROLLER.

Installation of belt anti-vibration roller

- Install the anti-flapping roller with the lip facing the engine crankcase.
- Tighten the central screw to the prescribed torque.
N.B.
TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT
IS OBTAINED.
Locking torques (N*m)

ENG - 98
MP3 400 i.e. Engine

Anti-vibration roller screw 16.7 ÷ 19.6

Removing the driven pulley

- Remove the clutch bell.

- Remove the fixed driving half-pulley.

- Remove the driven pulley assembly with the belt.

Inspecting the clutch drum

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

- Measure the clutch bell inside diameter.
N.B.
CHECK THE ECCENTRICITY MEASURED, 0.2 MM MAX.

Characteristic
Max. value:
160.5 mm
Standard value:
160.2 mm

ENG - 99
Engine MP3 400 i.e.

Removing the clutch

- To remove the clutch with the driven pulley it is

necessary to use the special tool;
- Arrange the tool with the mean pins screwed in
position "E" on the inside;
- Fit the adapter ring to the clutch assembly as
shown in the photograph.
- Install the driven pulley unit onto the tool inserting
the pins into the ventilation holes;
- Move the rear stop screw in abutment against the
fixed driven pulley as shown in the figure.

CAUTION
THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIAL TOOL. DO NOT
TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD IRRETRIEVABLY DEFORM THE
TOOL.
USING THE SPECIAL 55-MM WRENCH, REMOVE THE FASTENING RING NUT.
LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT, CLUTCH, SPRING
WITH SHEATH.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction material.

Characteristic
Minimum thickness permitted:
1 mm

- The masses must not show traces of lubricants. Otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH
TO TEAR.

ENG - 100
MP3 400 i.e. Engine

- Do not open the masses using tools to prevent a

variation in the return spring load.

Pin retaining collar

- Extract the collar using 2 screwdrivers.

- Remove the 4 guide pins.

- Extract the moving driven half-pulley.

Removing the driven half-pulley bearing

- Check that the bushing is free from wear and

damage; otherwise replace the fixed driven half-
pulley.
- Remove the lock ring using pliers.

ENG - 101
Engine MP3 400 i.e.

- Using the special tool inserted through the roller

bearing, pull out the ball bearing.
N.B.
PROPERLY SUPPORT THE PULLEY TO PREVENT DAM-
AGING THE THREADING.

Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20-mm guide
N.B.
IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS
NECESSARY TO SUPPORT THE UNIT BY THE BELL
Specific tooling
001467Y002 Driver for OD 73 mm bearing

- Remove the roller bearing using the special tool,

supporting the fixed half-pulley with the bell.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020364Y 25-mm guide
001467Y002 Driver for OD 73 mm bearing

Inspecting the driven fixed half-pulley

- Check that the belt contact surface is free from

wear.
- Measure the outer diameter of the pulley bushing.

Characteristic
Minimum admissible diameter
49.91 mm
Standard diameter:
50.00 -0.015 -0.035 mm

ENG - 102
MP3 400 i.e. Engine

Inspecting the driven sliding half-pulley

- Check that the belt contact surface is free from

wear.
- Remove the 2 inside sealing rings and the 2 out-
side O-rings.
- Measure the movable half-pulley bushing inside
diameter.

Characteristic
Maximum admissible diameter:
50.05 mm
Standard diameter:
50.00 +0.035 0.00 mm

Refitting the driven half-pulley bearing

- Install a new roller bearing using the special tool.

N.B.
PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUT-
WARDS.
- Properly support the half-pulley to prevent damaging the threading.
If you are working on the driven pulley unit fully assembled, use the special tool.

Specific tooling
020478Y Punch for driven pulley roller casing
001467Y002 Driver for OD 73 mm bearing

- Install a new ball bearing using the special tool.

Specific tooling
020376Y Adaptor handle
020477Y 37 mm adaptor
020363Y 20-mm guide

- Insert the Seeger lock ring.

ENG - 103
Engine MP3 400 i.e.

Refitting the driven pulley

- Insert the new oil guards

- Insert the new O-rings
N.B.
O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RA-
DIUS, AT THE BASE OF THE HALF-PULLEY.
- Install the half-pulley on the bushing being careful
not to damage the top sealing ring during the in-
troduction.
- Make sure the pins and collar are not worn, re-
assemble the pins and collar.

- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of grease, this operation
should be carried out through one of the two holes into the bushing to obtain the exit of the grease from
the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.

Recommended products
AGIP GREASE SM 2 Grease for the C-ring of the tone wheel
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Inspecting the clutch spring

- Measure the length of the movable driven half-

pulley spring while it is unloaded.

Characteristic
Standard length:
125.5 mm
Admissible limit after use:
120 mm

ENG - 104
MP3 400 i.e. Engine

Refitting the clutch

- Prepare the special tool as for removal;

- Preassemble the driven pulley unit with the drive
belt according to its direction of rotation;
- Insert the driven pulley unit, the spring with
sheath and clutch into the tool.

Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch

- Compress the spring and insert the clutch on the driven pulley bushing.
N.B.
BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END.
- Tighten the ring nut by hand and complete the
tightening using the special wrench to the prescri-
bed torque.

Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch

Locking torques (N*m)

Clutch ring nut 65 - 75

- To facilitate reassembly on the engine, turn the moving driven pulley and insert the belt onto the smaller
diameter.

Refitting the driven pulley

- Install the driven pulley assembly with belt.

ENG - 105
Engine MP3 400 i.e.

Drive-belt

- Check that the driving belt is not damaged.

- Check the width of the belt.

Characteristic
Minimum width:
27 mm
Standard width:
28.2 mm

Removing the driving pulley

- Using a 27 mm wrench, turn the central pulley nut

to horizontally align the central inside holes and
install the special tool.

Specific tooling
020474Y Driving pulley lock wrench

- First fit the 2 retainer clamps of the special tool

onto the pulley so that the splines are completely
engaged.
- Then, insert the tool so as to insert the stud bolts
on the ring into the holes obtained onto the tool
itself.
- Tighten the two tool fixing screws, also manually.
- Loosen the central nut.
- Remove the spring washer and the flat washer.
- Remove the fixed driving half-pulley.
- Remove the bushing connection washer.

ENG - 106
MP3 400 i.e. Engine

- Move the belt downwards.

- Suitable support the roller contrast and extract
the movable driving half-pulley with the relevant
bushing and the rear washer, being careful not to
make the rollers come out.

Inspecting the rollers case

- Check that the inside bushings shown in the figure exhibit no signs of abnormal wear and measure
the inside diameter.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHINGS
Characteristic
Maximum admissible diameter:
30.12 mm
Standard diameter:
30.021 mm

- Measure the pulley sliding bushing outside di-

ameter shown in the figure.

Characteristic
Minimum admissible diameter
Ø 29.95 mm
Standard diameter:
Ø 29.959 mm

- Check that the rollers are not damaged or worn.

Characteristic
Minimum admissible diameter
Ø 24.5 mm
Standard diameter:
Ø 24.9 mm

ENG - 107
Engine MP3 400 i.e.

- Check the guide shoes for the variator back-plate

are not worn.
- Check the wear of the roller housings and of the
belt contact surfaces on both pulley halves.

Refitting the driving pulley

Installing the roller container

- Install the spacer with the internal chamfer facing
towards the inside.

- Position the rollers on the half-pulley as shown in

the figure.
- The closed side must rest on the inside thrust
face of the roller container.

- Assembly the half-pulley with the roller contrast

plate and sliding blocks.

ENG - 108
MP3 400 i.e. Engine

- Insert the half-pulley on the crankshaft.

- Insert the spacer bushing.

Installing the fixed driving half-pulley

- Insert the spacer.

- Install the fixed driving half-pulley and check that

it is in contact with the spacer and with the guide
bushing of the movable driving pulley.

- Remove the flat washer and the spring washer

as shown in the figure.

ENG - 109
Engine MP3 400 i.e.

- Insert the nut in the original position (nut side in

contact with the belleville washer).

- Turn the central pulley nut to horizontally align

the holes and install the special tool.
N.B.
CHECK THAT THE STOP WRENCH TOOL IS EASILY IN-
SERTED INTO THE PULLEY AND IN THE ENGINE CRANK-
CASE.

Specific tooling
020474Y Driving pulley lock wrench

- Install the lock ring from the rear so that the

splines are completely engaged.
- Finally install the tool by siding the nuts by hand
and ensuring the tool is resting flatly.
- Tighten the driving pulley fastening nut to the
prescribed torque
- Remove the special tool.

Locking torques (N*m)

Drive pulley nut 160 - 175

Refitting the transmission cover

- Ensure the correct installation on the crankcase

of the 2 centring dowels.

ENG - 110
MP3 400 i.e. Engine

- Insert the transmission cover with the bearing

and install the relevant retainers.
- Lock the four M8 retainers.

Locking torques (N*m)

M8 retainers for transmission cover 23 ÷ 26

- Lock the 7 M6 retainers.

Locking torques (N*m)

M6 retainer 11 ÷ 13

- Insert the washers on the driven pulley shaft.

N.B.
INSERT THE SMALLER WASHER FIRST, THEN THE LARGER ONE.
- Insert the flanged nut.
- Prepare the torque wrench for LHS locking using
a machine hexagon wrench.
- Tighten the driven pulley shaft fastening nut using
an offset wrench.
N.B.
DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-
ENT WRENCHES - SUCH AS A CONVENTIONAL POLYG-
ONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED
ON THE SHAFT OR BREAK THE BUSH ITSELF.

Locking torques (N*m)

Driven pulley nut 92 - 100
- Install the driving pulley shaft cover, positioning
the tooth gap on the lower part with the reference
mark on the transmission crankcase.

N.B.
ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE.

ENG - 111
Engine MP3 400 i.e.

- Install the outside plastic transmission cover.

- Tighten the 4 fastening screws to the prescribed
torque.

Locking torques (N*m)

External transmission cover screws 7 ÷ 9

End gear

Removing the hub cover

- Drain the rear hub oil through the oil drainage cap
located under the engine.
-Remove the 7 fastening screws. Remove the hub
cover and the relevant gasket.

Removing the wheel axle

- Remove the countershaft.

- Remove the wheel axis complete with gear.

ENG - 112
MP3 400 i.e. Engine

Removing the hub bearings

- Check all bearings (wear, clearance and noise).

In case of anomalies, proceed as follows.
To remove the gear shaft bearing on the engine
crankcase, use the following parts.

Specific tooling
001467Y014 Pliers to extract ø 15-mm bearings
001467Y034 Pliers to extract ø 15-mm bearings
001467Y031 Bell
- Use the special extractor to disassemble the
bearing on the engine chassis of the countershaft.

Specific tooling
001467Y006 Pliers to extract 20 mm bearings
001467Y035 Bearing housing, outside ø 47 mm

- Support the hub cover using the stud bolt set.

- Pull out the bearing using the special tool.

Specific tooling
020476Y Stud bolt set
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54-mm bearings

Removing the wheel axle bearings

- Take out the clip on the outside of the gearbox

cover.

ENG - 113
Engine MP3 400 i.e.

- Support the hub cover using the stud bolt set.

- Pull out the bearing using the special tool.

Specific tooling
020476Y Stud bolt set
020376Y Adaptor handle
020477Y 37 mm adaptor
020483Y 30-mm guide

- Remove the oil guard using a screwdriver.

Removing the driven pulley shaft bearing

- If you have to remove the driven pulley shaft, the

relevant bearing and the oil guard, remove the
transmission cover and the clutch unit as descri-
bed in the « Automatic transmission» chapter.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver into the
hub gear box.
- Remove the Seeger ring shown in the figure.

- Pull out the driven pulley shaft bearing from the

engine crankcase using the special tool.

Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm Adaptor
020364Y 25-mm guide

ENG - 114
MP3 400 i.e. Engine

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 guards.
- In case of faults, replace the damaged parts.

Characteristic
Connection diameter for countershaft:
A = diameter 20 - 0.01 -0.02 mm
Connection diameter for wheel shaft:
B = diameter 30 - 0.010 -0.023 mm
C = diameter 15 - 0.01 -0.02 mm
Bearing diameter for driven pulley shaft:
D = diameter 17 - 0.01 -0.02 mm
E = diameter 20 - 0.01 -0.02 mm
F = diameter 25 - 0.01 -0.02 mm

Inspecting the hub cover

- Check that the mounting surface is not damaged or deformed.

ENG - 115
Engine MP3 400 i.e.

- Check the capacity of the bearings.

In case of faults, replace the hub cover.

Refitting the driven pulley shaft bearing

- Heat the crankcase using the heat gun.

Specific tooling
020151Y Air heater

- Insert the driven pulley shaft bearing until it abuts

against the bottom of the seat using the special
tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-
PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020364Y 25-mm guide
- Heat the intermediate gear bearing seat.
- Insert the intermediate shaft bearing using the
special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-
PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020363Y 20-mm guide

ENG - 116
MP3 400 i.e. Engine

- Heat the gear shaft bearing seat on the crank-

case.
- Insert the gear shaft bearing in the upper crank-
case seat using the special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-
PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020412Y 15-mm guide
- Place the safety lock Seeger ring of the driven
pulley shaft bearing.
N.B.
PLACE IT IN THE POSITION SHOWN IN THE FIGURE.

- Insert the pulley shaft oil guard on the transmis-

sion side.

Refitting the hub cover bearings

- Heat the bearing seats on the cover using the

heat gun.
- Support the hub cover using the stud bolt set.

Specific tooling
020151Y Air heater
020476Y Stud bolt set

ENG - 117
Engine MP3 400 i.e.

- Insert the intermediate shaft bearing on the cover

using the special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-
PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020363Y 20-mm guide
- Heat the gear shaft bearing seat from the cover
outside.
- Insert the gear shaft bearing on the cover using
the special punch until abutment.

Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020483Y 30-mm guide
- Replace the snap ring

- Support the hub cover using the stud bolt set.

- Insert the wheel shaft oil guard with the sealing
lip facing the inside of the cover.
- Place the oil guard flush with the crankcase.

Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020476Y Stud bolt set

ENG - 118
MP3 400 i.e. Engine

Refitting the hub bearings

- Place the 3 shafts as shown in the figure.

Refitting the ub cover

- Check the proper position of the centring dowels.

- Install a new gasket.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.

- Position the 7 set screws, tighten them to the prescribed torque, being careful of the position of the
bands holding the vent tube, and the position of the 3 shortest screws as indicated in the figure.
- Refill with the prescribed oil to the Max. level.

Recommended products
AGIP ROTRA 80W-90 rear hub oil
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic
Quantity:
approx. 250 cc

Locking torques (N*m)

Rear hub cover screws 24 ÷ 27

ENG - 119
Engine MP3 400 i.e.

Flywheel cover

- Remove the three bands shown in the figure for

an easier removal of the flywheel cover, remove
the feed hoses and disconnect the return hose
from the pump cover.
N.B.
THE BANDS MUST BE REPLACED. TO REMOVE THEM,
OPEN WITH A SCREWDRIVER OR CUT THEM.
BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.

Removing the hub cover

- Drain the engine oil by removing the drainage

cap.
- Prepare a suitable container to collect the oil.

- Remove the pre-filter.

- Remove the oil filter using a filter tape or shaped

cup wrench.

ENG - 120
MP3 400 i.e. Engine

- Loosen the 14 fastening screws.

- Remove the flywheel cover with the relevant gas-
ket and the cooling system sleeve support.
N.B.
THE SCREWS ARE OF 4 DIFFERENT LENGTHS. NOTE
THE RELEVANT POSITIONS.

CAUTION
REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND
ROTOR.
CAUTION
BE CAREFUL TO PREVENT SLIPPAGE OF THE BY-PASS VALVE AND OF THE RELEVANT
SPRING.

Removing the flywheel cover components

- Loosen the six mounting screws and remove the

water pump cover.

- Remove the by-pass and the relevant spring.

- Remove the oil pump seal.

ENG - 121
Engine MP3 400 i.e.

Removing the stator

- Remove the two retaining screws and the cable

guide bracket.

- Unscrew the 3 fastening screws and remove sta-

tor and its wiring.

Inspecting the cover components

- Loosen the two retaining screws and remove the

reed valve support with bulkhead.

- Remove the blow-by reed valve with the relevant

sealing gasket.

ENG - 122
MP3 400 i.e. Engine

- Unscrew the fastening screw and remove the gas

outlet union with the relevant O-ring.

- Check that the mounting surface of the crankcase

is not worn or deformed.
- Check that the by-pass valve seat, the torque
limiter and the water pump shaft are free from
wear.

Characteristic
By-pass housing hole diameter:
13.9 mm
Connection diameter for start-up gear shaft:
12 mm
Connection diameter for pump shaft:
8 mm

- Check that the oil filter union and matching sur-

face exhibit no deformations or wear.

- Check the condition of the stator and the relevant

cable harness.

ENG - 123
Engine MP3 400 i.e.

- Check the continuity between the 3 phases.

N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERA-
TURE MAY RESULT IN VALUES HIGHER THAN THOSE
STATED.

Electric characteristic
Resistance:
0.2 - 1 Ω

- Check the ground insulation of each phase.

- If a fault is found, carry out a thorough check of
the cable harness that contains two types of cable:
Rigid cables close to the stator and flexible cables
close to the connector.

- Check that the winding is positioned so as not to

interfere with the heads of the retaining screws.

Refitting the stator

- Install the stator assembly together with the wir-

ing harness, tightening the 3 screws to the pre-
scribed torque.
N.B.
INSERT THE RUBBER WIRING SEALING GASKET INTO
THE SPECIAL SEAT ON THE CRANKCASE.

Locking torques (N*m)

Stator retainers 8 - 10

ENG - 124
MP3 400 i.e. Engine

- Install the wiring guide bracket tightening the 2

screws to the prescribed torque.

Locking torques (N*m)

Stator cable harness guide bracket screws 3 - 4

Refitting the flywheel cover components

- Before reassembling, check that all components

are perfectly clean.
- For the cover, carefully check all lubrication chan-
nels, in particular:
- The 3 by-pass channels.

- Oil pressure sensor feeding duct.

- Oil vapour decantation chamber

ENG - 125
Engine MP3 400 i.e.

- Temporarily install the distribution timing check

hole cover and the engine oil filling cap/bar.
- Insert the blow-by recovery duct using a new O-
ring.
- Tighten the screws to the prescribed torque.

Locking torques (N*m)

Blow-by recovery duct fixing screws 3 - 4

- Insert the spring and the by-pass piston on the

flywheel cover.
N.B.
LUBRICATE THE BY-PASS VALVE.

- Reinstall the blow-by reed valve using a new

sealing gasket.
- Reinstall the support with head and tighten the
screws to the prescribed torque.

Locking torques (N*m)

Supporting screws with bulkhead 0.3 - 0.4

- Correctly fit a new O-ring, do not allow it to come into contact with grease or oil.
FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O-RING.
- Refit the water pump cover and tighten the 6 fix-
ing screws to the prescribed torque.

Locking torques (N*m)

Pump cover fixing screws: 3 ÷ 4

ENG - 126
MP3 400 i.e. Engine

Refitting the flywheel cover

- Install a new oil filter, lubricate the gasket, screw

on and finally tighten to the prescribed torque.

Locking torques (N*m)

Engine oil filter 12 - 16

- Install the supply hose to the cylinder and con-

nect the return hose to the pump cover using 3 new
clamps.
N.B.
TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS,
PAYING ATTENTION NOT TO CONSTRICT THE HOSES
BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUF-
FICIENTLY.

- Install the pre-filter again and insert the engine oil

drain plug, tightening to the prescribed torque.
- Refill the engine with the prescribed type of oil.

Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40, API SL, ACEA A3, JASO MA Syn-
thetic oil

Locking torques (N*m)

Engine oil drainage plug 24 ÷ 30
- Lubricate the intermediate gear seat with torque
limiter on the flywheel cover.
- Align the water pump movement sensor with a
reference and install the flywheel cover as descri-
bed in the Flywheel cover chapter.

ENG - 127
Engine MP3 400 i.e.

- Install a new gasket on the engine crankcase.

- Check the presence of the three centring dowels.

- Turn the crankshaft in order to align the counter-

shaft movement sensor with a reference point on
the crankcase (see figure).

- Repeat the alignment for the water pump crank-

shaft using the same reference point on the en-
gine.
N.B.
THIS PREPARATION IS USEFUL PARTICULARLY IN THE
EVENT OF REPAIRS WITH THE WATER PUMP COVER IN-
STALLED.

- Install the flywheel cover on the engine, paying attention to avoid interference between the stator and
rotor.
WARNING
FAILURE TO OBSERVE THIS PRECAUTION MAY RESULT IN DESTRUCTION OF THE CERAMIC
MAGNETS.
- Tighten the 14 retaining bolts of the cover to the
prescribed torque.
N.B.
THE BOLTS HAVE FOUR LENGTHS:
- THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE
FIGURE.
- THE LONGEST IS INSERTED UNDER THE ENGINE OIL
FILLER PLUG.

ENG - 128
MP3 400 i.e. Engine

N.B.
- THE INTERMEDIATE BOLTS FOR THE REMAINING
MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT
FOR THE MANIFOLD SUPPORT (SHOWN IN THE FIGURE)
ARE SLIGHTLY LONGER.

Locking torques (N*m)

Flywheel cover screws 11 - 13

Flywheel and starting

- Remove the three bands shown in the figure for
an easier removal of the flywheel cover, remove
the feed hoses and disconnect the return hose
from the pump cover.
N.B.
THE BANDS MUST BE REPLACED. TO REMOVE THEM,
OPEN WITH A SCREWDRIVER OR CUT THEM.
BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.

The starter is sold as a complete part.

Before deciding to replace it, carry out the follow-
ing tests:
1 - Battery
Check the voltage after not running (a few hours):
Voltage >12.5V
Check the density of the electrolyte of each cell:
Bé = 30 ÷ 32
Specific weight: 1.25 - 1.26
YES go to 2 NO go to 3
2 - Make sure the negative terminals (battery neg-
ative and starter negative) are correctly connected
to each other and to the frame.
YES go to 4 NO go to 5
3 - Recharge and if necessary replace the battery.
4 - Connect the diagnostic tester (see chapter "Injection system").
Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor.
Remove the 10A fuse no. 12 (see "fuses" chapter).
Switch in position "ON" with interrupt switch in position "RUN" and side stand raised.
Select the "PARAMETERS" function.

ENG - 129
Engine MP3 400 i.e.

Start the engine (so that it cannot move) long enough to measure the rpm and starter absorption.
N.B.
THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER, THE RPM READING IS NOT
THE REAL ONE, BUT IS VALID FOR DIAGNOSTIC PURPOSES.
Specific tooling
020460Y Scooter diagnosis and tester
Electric characteristic
Absorption at trailing speed:
80 - 120 A
Revolution speed =
approx. 300-400 rpm

YES go to 6 NO go to 7 NO go to 8 NO go to 9

5 - Restore the connections

6- The values are correct.
Finally carry out a check of the power consumption at idle speed.
Remove the starter motor (see the flywheel and starter system).
Reconnect the earth and positive and perform the test.

Electric characteristic
Current consumption at idle speed:
<40 A

YES go to 10 NO go to 11
7- Low trailing speed
High electrical absorption
Carry out a test of the engine rotation (example: possible melting of the bushes) and if no anomalies
are found, replace the starter motor.
8- Low trailing speed
Low electrical absorption
Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing
them.
Check the new values.
YES go to 12 NO go to 13

ENG - 130
MP3 400 i.e. Engine

9 - High trailing speed

Low electrical absorption
The engine turns too freely, check the compression end pressure.
If the values are not correct proceed as follows.
10 - The starter motor works properly.
11 - Check the rotation of the armature.
12 - Replace the starter remote control switch.
13 - Test the battery again and if necessary replace the starter motor.
N.B.
IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE
NOISE, CHECK THE FREEWHEEL OF THE TORQUE LIMITER (SEE THE "FLYWHEEL AND
STARTER SYSTEM" CHAPTER).

STARTER MOTOR
Specification Desc./Quantity
Type Mitsuba sm13d
Power 0.9 kW

BATTERY
Specification Desc./Quantity
Capacity 14 Ah
Starting current 125 A

START-UP REMOTE CONTROL SWITCH

Specification Desc./Quantity
Type SEALED
Maximum load 150 A continuous

STARTER TRANSMISSION
Specification Desc./Quantity
Ring gear and freewheel coaxial to the flywheel. Intermediate gear with built-in torque limiter.

The starter system has a transmission between the motor armature and engine shaft equipped with
freewheel coaxial to the flywheel and torque limiter on the intermediate shaft.
The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and
the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations.
The freewheel is used for a sufficiently silent starting.
The starter control (energised remote control) is slaved to enabling signals by the side stand and the
emergency OFF/RUN switch, which does not allow starting given dangerous conditions.
The starter control circuit is not controlled by the immobilizer system, therefore before insisting on the
starter system, check the consensus of the immobilizer.
In order to check the enabling switches circuit, see the «Electrical system» chapter, whereas to check
the engine shaft control transmission, follow what is described in the «Flywheel and starter system»
chapter.

Removing the starter motor

N.B.

ENG - 131
Engine MP3 400 i.e.

THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED.
- Loosen the two fastening screws.
- Extract the complete starter motor.

Removing the flywheel magneto

N.B.
IF YOU MUST REMOVE THE FLYWHEEL, IT IS NECESSARY TO REMOVE THE CHAIN GUIDE
SLIDING BLOCK RETAIN PLATE FIRST.
- Unscrew the 3 fastening screws and remove the
chain guide sliding block retain plate and the start-
up rim.

- Align the holes obtained on the flywheel with the

crankcase housing to allow the introduction of the
special tool.

- Tighten the bushing of the flywheel lock tool on

the removing tool threading.

ENG - 132
MP3 400 i.e. Engine

- Insert the special tool as shown in the figure,

making sure that the pins are perfectly inserted in-
to the previously aligned holes and that it is per-
fectly abutted and almost flush with the flywheel.

Specific tooling
020472Y Flywheel lock wrench

- Loosen the magneto flywheel fastening nut.

- Remove the special tool and the fastening nut.

- Remove the washer.

- Insert the nut again so as to slightly uncover the

shaft and free the space that was occupied by the
washer.
CAUTION
THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS
STRONGLY LOCKED; THE CONE DETACHMENT MAY
THEREFORE CAUSE THE ROTOR SLIPPAGE, WITH THE
CONSEQUENT BREAKAGE OF THE MAGNETS.

ENG - 133
Engine MP3 400 i.e.

- Insert the special removing tool.

- Using a 27-mm wrench and a 19-mm bushing,
release the flywheel.

Specific tooling
020467Y Flywheel extractor

- Remove the extractor.

- Remove the nut and extract the flywheel with the
start-up rim.
- Remove the crankshaft key.

- To remove the start-up rim from the freewheel it

is necessary to turn it clockwise and pull it out.

- Remove the freewheel from the flywheel by loos-

ening the 6 fastening screws.
SINCE THE FREEWHEEL MUST BE REMOVED, IT IS AD-
VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN
ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON
THE CRANKSHAFT.

ENG - 134
MP3 400 i.e. Engine

- The freewheel is coupled to the flywheel with high

precision; if removal is difficult, use 2 screws as
gripping points and as removing tools, if required.

- Extract the intermediate gear provided with tor-

que limiter.

Inspecting the flywheel components

- Check the integrity of the magnets.

- Check that the magnet support cage is free from
deformation or cracks.
- Check that the flywheel splines exhibit no loos-
ening.

Starter gear rim

- Check that there is no wear or abnormal impres-

sions on the "rollers" of the freewheel and on the
surface of the starter ring gear hub.
- Check the hub outside diameter.

Characteristic
Hub outside diameter:
Diameter 45.665 + 0.008 +0.005 mm

ENG - 135
Engine MP3 400 i.e.

- Check the inside diameter of the bushing of the

starter gearing.
- Check that the toothing is not worn.

Characteristic
Inside diameter of the bushing:
Diameter 27 + 0.020 +0.041 mm

N.B.
IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND
FREEWHEEL.
IF ONLY THE BUSHING IS WORN, IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE START-
ING RING GEAR. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE
CONNECTION ON THE CRANKSHAFT. IN CASE OR IRREGULARITIES, REPLACE THE CRANK-
SHAFT.

Intermediate gear

- Check that the toothing is not worn.

- Check the diameter of the two bearings.

Characteristic
Gear bearing diameter:
12 - 0 0.011 mm

Also check the shaft diameter on the flywheel cov-

er and on the engine crankcase.

Characteristic
Bearing diameter on the flywheel cover
12 + 0.034 -0.016 mm
Bearing diameter on the engine crankcase:
12 + 0.034 -0.016 mm

N.B.
THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH
DRIVE PLATES.

ENG - 136
MP3 400 i.e. Engine

Driven plates consist of 4 Belleville springs provi-

ded with grooved profiles; this assembly allows
transmitting torque lower than 10 kg.
In case of incorrect start-up manoeuvres, the lim-
iter prevents any kicks, with consequent reversal
of direction of the crankshaft which would impair
the engine structure.

The limiter assembly cannot be overhauled. In case of irregularities on the toothed discs, replace the
assembly.

Refitting the free wheel

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

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-
wheel itself, i.e. with wheel Seeger ring visible.
- Lock the 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".

ENG - 137
Engine MP3 400 i.e.

Refitting the intermediate gear

- Lubricate the gear housing on the engine crank-

case.

- Insert the intermediate gear with torque limiter

- Lubricate the inside bushing and the starter ring

gear hub surface.

- Install the start-up rim on the flywheel turning it

clockwise and inserting at the same time.

ENG - 138
MP3 400 i.e. Engine

Refitting the flywheel magneto

- Insert the key on the crankshaft.

- Install the flywheel checking the proper insertion
of the key and engaging the torque limiter gear
with the start-up rim.

- Insert washer and nut on the crankshaft.

- Tighten thoroughly the guide bushing of the fly-

wheel lock tool and loosen by 1/4 turn.
N.B.
FAILURE TO OBSERVE THIS PRECAUTION CAUSES THE
LOCKING OF THE GUIDE ON THE FLYWHEEL.

Specific tooling
020472Y Flywheel lock wrench

- Align the 2 holes of the flywheel with the case

housing to allow the introduction of the special tool.

ENG - 139
Engine MP3 400 i.e.

- Insert the special tool checking that the pins are

perfectly introduced into the seat.

Specific tooling
020472Y Flywheel lock wrench

- Tighten the flywheel lock nut to the prescribed

torque.

Locking torques (N*m)

Flywheel fixing nut 115 - 125

- Install the chain guide retain plate tightening the

3 screws to the prescribed torque.
N.B.
BEFORE TIGHTENING THE SCREWS, MOVE THE START-
UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK
THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC-
TION.

Locking torques (N*m)

Chain guide sliding block retain plate fasten-
ing screws 3 ÷ 4

Refitting the starter motor

- Check that the O-ring is in good working order

and lubricate it.
- Insert the starter motor.
- Tighten the 2 fastening screws to the prescribed
torque.

Locking torques (N*m)

Starter screws 11 ÷ 13

ENG - 140
MP3 400 i.e. Engine

Cylinder assy. and timing system

- Remove the external and internal transmission

cover.

- Remove the flywheel cover, the flywheel and the

torque limiter.

Removing the intake manifold

- Remove the 3 mounting screws.

- Remove the intake manifold unit.

Removing the rocker-arms cover

- Loosen the 6 special screws with stop and the

relevant rubber gaskets.
- Remove the tappet cover with relevant gasket.

ENG - 141
Engine MP3 400 i.e.

Removing the timing system drive

- Turn the engine to close the intake valves.

- Remove the central screw and the valve lifting

device mass stop bell using the special tool.

Specific tooling
020565Y Flywheel lock calliper spanner

- Remove the return spring and the valve lifting

mass with relevant travel end washer.
N.B.
BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING
TO FALL INTO THE ENGINE THROUGH THE CHAIN COM-
PARTMENT.

- Align the reference marks on the timing chain rim

with those on the head.

ENG - 142
MP3 400 i.e. Engine

- Loosen the central screw on the tensioner first.

- Unscrew the 2 fastening screws and remove the
tensioner with relevant gasket.

Remove the inside hexagon screw and the coun-

terweight as shown in the figure.

- Remove the timing belt rim from the camshaft.

- Remove the timing belt rim.

Removing the cam shaft

- Unscrew the 3 fastening screws and remove

camshaft retaining bracket.
N.B.
REMOVING THE FASTENING SCREWS MAY BE DIFFI-
CULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEX-
AGON. IF NECESSARY, SEPARATE THE THREADS IN
ADVANCE.

ENG - 143
Engine MP3 400 i.e.

- Remove the cam shaft.

- Remove pins and rocking levers by the transmis-

sion side holes.

Removing the cylinder head

- Remove the spark plug.

- Remove the cooling system outlet sleeve with
thermostat.

- Remove the coolant temperature sensor.

N.B.
THE SENSOR CONTROLS BOTH INJECTION AND THE AN-
ALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS
COMPONENT, SEE THE INJECTION CHAPTER.

ENG - 144
MP3 400 i.e. Engine

- Remove the 2 fastening nuts on the head, on the

exhaust and on the intake side.

- Remove the two M6 screws into the distribution

channel and the M6 screw on the spark plug side
with the thermostat support.

N.B.
THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKING LEVER PINS AND FITTING
BRACKET IF NECESSARY.
- Loosen the 4 head-cylinder fastening nuts in 2 or
3 times and in a crossed sequence.
- Remove the head, the 2 centring dowels, the
gasket and the lower chain guide sliding block.
N.B.
DO NOT REMOVE THE DOWELS IF THEY ARE FORCED
INTO THEIR SEAT.

CAUTION
WHEN YOU HAVE TO REMOVE THE HEAD, PREPARE A SUITABLE CONTAINER SINCE THE
THERMAL GROUP CONTAINS COOLANT.

ENG - 145
Engine MP3 400 i.e.

Removing the valves

- Using the appropriate tool fitted with an adaptor,

remove the cotters, caps, springs and valves.

Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)

CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD (FLY-
WHEEL SIDE AND TRANSMISSION SIDE).
- Remove the oil guards using the special tool.

Specific tooling
020431Y Valve oil seal extractor

- Remove the spring supports.

N.B.
BLOW THE SEATS WITH COMPRESSED AIR TO FACILI-
TATE THE SPRING SUPPORT REMOVAL.

ENG - 146
MP3 400 i.e. Engine

Removing the cylinder - piston assy.

- Remove the timing chain.

- Loosen the fastening screw and remove the
spacer and the tightening sliding block.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.

- Extract the cylinder with the relevant gasket and

the centring dowel.
N.B.
THE SECOND CENTRING IS ENSURED BY A PIN SET INTO
THE CYLINDER.
CAUTION
TO PREVENT DAMAGING THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.

- Remove the 2 piston pin locking rings by the spe-

cific housings.
- Extract the pin and remove the piston.
N.B.
USE PAPER OR A CLOTH TO CLOSE THE CYLINDER
HOUSING MOUTH ON THE CRANKCASE TO PREVENT
SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO
THE CASE.

- Remove the piston sealing rings and the oil scra-

per.
CAUTION
NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO
PREVENT INVERTING THE POSITION IN CASE OF REUSE.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.

ENG - 147
Engine MP3 400 i.e.

Inspecting the small end

- Using a bore gauge, measure the connecting rod

small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANK-
SHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.

Characteristic
Standard diameter:
22 + 0.025 +0.015 mm

Inspecting the wrist pin

- Check the pin outside diameter using a micrometer.

Characteristic
Standard diameter:
22 0 -0.004 mm

- Calculate the coupling clearance between pin

and connecting rod end.

Characteristic
Standard clearance:
0.015 ÷ 0.029 mm

Inspecting the piston

- Measure the diameter of the bearings on the pis-

ton.

Characteristic
Standard diameter:
22 + 0.006 + 0.001 mm

- Calculate the piston pin coupling clearance.

N.B.

ENG - 148
MP3 400 i.e. Engine

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 ÷ 0.010 mm

- Measure the outside diameter of the piston, per-

pendicular to the gudgeon pin axis.
- Take the measurement in the position shown in
the figure.
N.B.
REFER TO THE «SPECIFICATIONS» SECTION FOR THE
SIZES OF THE PISTON AND THE CYLINDER-PISTON COU-
PLING CLEARANCES.

Characteristic
A:
10 mm
Piston diameter:
85.8 mm nominal value

- Using a bore meter, measure the cylinder inner

diameter at a given height according to the direc-
tions shown in the figure.

Characteristic
B:
43 mm
Standard diameter:
85.8 mm nominal value

- Check that coating is free from flakes.

- Check that the head matching surface exhibits no deformations or wear.

Characteristic
Maximum allowable run-out:
0.05 mm

ENG - 149
Engine MP3 400 i.e.

- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried
out in pairs (A-A, B-B, C-C, D-D).
N.B.
REFER TO THE «SPECIFICATIONS» SECTION FOR THE SIZES OF THE CYLINDER AND THE
CYLINDER-PISTON COUPLING CLEARANCES.

Inspecting the piston rings

- Alternately insert the three sealing rings into the

cylinder, in the area where it retains its original di-
ameter. Using the piston, insert the rings perpen-
dicularly to the cylinder axis.
- Make sure that each single sealing ring evenly
adheres to the cylinder liner. If it does not, this
means the ring is worn. Replace it.
- Measure the opening (see figure) of the sealing
rings using a feeler gauge.
- If higher values than those prescribed are meas-
ured, replace the linings.

Check the size of the sealing ring opening:

Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm

Rings/housing coupling clearances:

Carefully clean the sealing ring housings.
Place a thickness gauge between the ring and the
housing as shown in the drawing and check the
coupling clearances.
Top ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Intermediate ring Standard coupling clear-
ance:0.02÷0.07 mm
Maximum clearances allowed after use: 0.10
mm
Oil scraper ring Standard coupling clearance:
0.01÷0.06 mm

ENG - 150
MP3 400 i.e. Engine

Maximum clearances allowed after use: 0.10

mm
Replace the piston if clearances exceed the max-
imum limits specified in the table.

Removing the piston

- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards the exhaust.

- Insert the locking ring into the special tool, with

the opening in the position indicated on the tool.
S = left
D= right

- Place the wrist pin stop ring into position using a

punch

ENG - 151
Engine MP3 400 i.e.

- Install the pin lock using the key shown in the

figure.

Specific tooling
020470Y Pin retainers installation tool

N.B.
THE TOOL FOR INSTALLING THE SNAP RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.

Choosing the gasket

- Provisionally fit the piston into the cylinder, without any base gasket.
- Install a dial gauge on the special tool using the short union, as shown in the figure.

Specific tooling
020475Y Piston position checking tool

- Using an abutment plane, reset the dial gauge

with a preload of a few millimetres.
- Finally fix the dial gauge.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the dial gauge position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inver-
sion point of the dial gauge rotation)
- Measure the deviation from the reset value.

- Identify the thickness of the cylinder base gasket to be used for reassembly by the table below. Cor-
rectly identify the cylinder base gasket thickness to keep the correct compression ratio.
- Remove the special tool and the cylinder.
N.B.

ENG - 152
MP3 400 i.e. Engine

IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY

ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.
Characteristic
Recess / Projection measured 1
- 0.185 - - 0.10
Gasket thickness 1
0.4 ± 0.05
Recess / Projection measured 2
- 0.10 - + 0.10
Gasket thickness 2
0.6 ± 0.05
Recess / Projection measured 3
+ 0.10 ÷ + 0.185
Gasket thickness 3
0.8 ± 0.05

Refitting the piston rings

- Place the scraper ring spring on the piston.

- Install the scraper ring keeping the opening op-
posed to the spring junction and with the writing
"top" facing the piston top. The chamfered side of
the oil scraper ring should always be facing the
piston crown.
- Fit the second lining with the identification letter
or the writing "top" facing the piston crown. In any
case, the step must be facing opposite the piston
top.
- Install the first compression lining in the direction
imposed by the housing.
- It is advisable to use a fitter to facilitate the in-
stallation of the linings.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.

- Misalign the lining openings at 120° as shown in the figure.

- Lubricate the components with engine oil.
- The engine uses the first compression lining with an L section.

ENG - 153
Engine MP3 400 i.e.

Refitting the cylinder

- Insert the cylinder base gasket with the thickness

determined above.
- Using the fork and the ring clamp, fit the cylinder
as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
THE LUBRICATION DUCT AND LUBRICATE THE CYLIN-
DER LINER. CHECK THE PRESENCE OF THE TWO REF-
ERENCE DOWELS.

Specific tooling
020468Y Piston assembly band
020512Y Piston fitting fork

Inspecting the cylinder head

- Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or
distorted.

Characteristic
Maximum allowable run-out:
0.1 mm

- In case of irregularities, replace the head.

- Check the sealing surfaces for the intake and ex-
haust manifold.
- Check 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 sealing pad exhibits no
oxidation.

Inspecting the timing system components

- Check that the guide shoe and the tensioner shoe

are not worn out.
- Check that the crankshaft pinion and the cam-
shaft timing gear and crankshaft pinion exhibit no
wear.
In case of wear of the sliding blocks, replace them.
In case of wear of the chain or rim, replace the en-
tire unit.

ENG - 154
MP3 400 i.e. Engine

N.B.
IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED IN
CHAPTER CRANKCASE AND CRANKSHAFT.
Chain tensioner:
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
unit.

Inspecting the valve sealings

- Visually inspect the valve sealing surface.

CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
- If the sealing surface of the valve is found to be
interrupted at one or more points or is not flat, re-
place the valve.

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.

ENG - 155
Engine MP3 400 i.e.

Inspecting the valve housings

- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the
impression on the valve seat "V".

Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm

- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damage, replace the head.

Inspecting the valves

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

STANDARD DIAMETER
Specification Desc./Quantity
Inlet: 4.987 - 4.972 mm
Outlet: 4.975 - 4.960 mm

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity
Inlet: 4.96 mm
Outlet: 4.945 mm

- Calculate the clearance between valve and valve guide.

ENG - 156
MP3 400 i.e. Engine

- 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.

Characteristic
Limit values admitted:
0.1 mm

- Check the concentricity of the valve head by ar-

ranging a dial gauge at right angle relative to the
valve head and rotate it on a "V" shaped abutment.

Characteristic
Admissible limit:
0.03 mm

Inspecting the valve stem guide clearance

- After measuring the valve guide diameter and the valve stem diameter, check clearance between
guide and stem.

INLET
Specification Desc./Quantity
Standard clearance: 0.013 - 0.04 mm
Admissible limit: 0.08 mm

OUTLET
Specification Desc./Quantity
Standard clearance: 0.025 ÷ 0.052 mm
Admissible limit: 0.09 mm

ENG - 157
Engine MP3 400 i.e.

STANDARD VALVE LENGTH

Specification Desc./Quantity
Inlet: 95.0 ± 0.3 mm
Outlet: 94.2 ± 0.3 mm

- Check that there are no signs of wear on the surface of contact with the articulated register terminal.

- 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 NO
LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES
WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

Inspecting the springs and half-cones

- 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.

ENG - 158
MP3 400 i.e. Engine

- Measure the unloaded spring length.

Characteristic
Standard length:
44.4 mm
Admissible limit after use:
42.4 mm

Refitting the valves

- Place the valve spring support washers on the

head.
- Alternately insert the 4 oil guards using the spe-
cial tool.
- Lubricate the oil guards and the valve guides.

Specific tooling
020306Y Punch for assembling valve seal
rings

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

the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.

Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)

N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF-
ERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).

Inspecting the cam shaft

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

- Using a micrometer, measure the camshaft bearings.

STANDARD DIAMETER
Specification Desc./Quantity
Bearing A Ø: 42 - 0.060 -0.085 mm
Bearing B diameter: 20 - 0.020 -0.041 mm

ENG - 159
Engine MP3 400 i.e.

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity
Bearing A Ø: 41.910 mm
Bearing B diameter: 19.940 mm

-Using a gauge, measure the cam height.

STANDARD HEIGHT
Specification Desc./Quantity
intake 33.774 mm
discharge 33.273

ADMISSIBLE LIMITS
Specification Desc./Quantity
intake 33.526 mm
discharge 33.026 mm
Standard axial clearance: 0 - 0.22 mm
Maximum admissible axial clearance: 0.3 mm

- If any of the above dimensions are outside the

specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- Check that the retaining plate seat shown in the
figure exhibits no wear.

ENG - 160
MP3 400 i.e. Engine

- Check that the automatic valve lifting device cam,

the travel end roller and the rubber abutment on
the containment bell are free from wear.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.

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

Characteristic
Standard diameter:
13 - 0.010 -0.018 mm

- Measure the inside diameter of each rocking lev-

er.

Characteristic
Standard diameter:
13 + 0.026 +0.015 mm

- Check that the cam contact sliding block and the articulated register plate is free from wear.
- In case of wear, replace the component.

Refitting the head and timing system components

- Insert the chain guide sliding block.

- Insert the two centring dowels between head and
cylinder.
- Install the head gasket.

N.B.
THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN
HEAD AND CYLINDER. THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY
THE DOWELS.

ENG - 161
Engine MP3 400 i.e.

- The head gasket is made of steel and has a

standard thickness.

- Check that the head lubrication channel is per-

fectly clean. Clean with compressed air jets, if
required.
- Insert the head.
- Lubricate the stud bolts and the 4 fixing stud
bolts.

- Tighten the 4 fixing stud bolts crosswise to the prescribed torque as shown in the figure.

Locking torques (N*m)

Head fixing stud bolts ***
*** Apply a preliminary torque of 7 Nm in a crossed
sequence.
- Tighten by 90° in a crossed sequence.
- tighten again by 90° in a crossed sequence.

- Tighten the fastening nuts on the exhaust and on

the intake side to the prescribed torque.

Locking torques (N*m)

Exhaust / intake head fixing nuts 10 - 12

ENG - 162
MP3 400 i.e. Engine

- Tighten the 3 side screws to the prescribed tor-

que.

Locking torques (N*m)

Head fixing screws 10 - 12

- Install the coolant temperature sensor with the

washer and tighten to the prescribed torque.
CAUTION
FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN
DAMAGE THE SENSOR.

Locking torques (N*m)

Coolant temperature sensor: 10 - 12

- Install the spark plug and tighten to the prescribed torque.

Locking torques (N*m)

Spark plug 12 ÷ 14
- Insert the timing control belt on the crankshaft
according to the initial direction of rotation.
- Install the tensioner shoe with its spacer, tight-
ening the bolt to the prescribed torque, using the
recommended product.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Tensioner sliding block fixing screw 10 - 14
- Insert pins and rocking levers on the flywheel
side.
- Lubricate the two rocking levers through the
holes at the top.

ENG - 163
Engine MP3 400 i.e.

- Clean the camshaft by blowing with little com-

pressed air jets, especially the retaining plate
housing.
- Lubricate the 2 shafts.
- Insert the camshaft into the head with the cams
opposite the rocking levers.

- Remove any LOCTITE residues from the screws

fixing the camshaft retaining bracket using a
brush.
- Apply the recommended product to the fixing
screws and tighten to the prescribed torque.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

- Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the
prescribed torque, being careful not to damage the inside hexagon.

Locking torques (N*m)

Camshaft retaining bracket screws: 4 ÷ 6
- Install the intermediate gear with torque limiter,
the flywheel and its cover, as described in Chapter
"Flywheel and start-up system", and in Chapter
"Flywheel cover".
N.B.
FOR MORE CONVENIENCE, INSTALL THE FLYWHEEL
COVER WITHOUT THE COOLING SYSTEM SLEEVES.

- Using the TORX wrench, remove the timing

check cap.

ENG - 164
MP3 400 i.e. Engine

- Insert the belt on the camshaft control timing rim.

- Insert the timing rim on the camshaft checking
that the references are aligned.
N.B.
DURING THE STROKE CHECK, KEEP THE BELT TEN-
SIONED BY PRESSING ON THE TIGHTENER COMPART-
MENT SIDE.

- Keeping the belt slightly pulled, turn the crank-

shaft using the driving pulley to make the reference
on the magnet support collimate with that on the
flywheel cover.

- Install the counterweight mass.

- Centre using the bell fastening screw.
- Lock the mass fixing screws to the prescribed
torque, using the recommended product.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Counterweight screw 7 ÷ 8.5
- Remove the central screw.
- Install the valve lifting mass being careful to the
proper positioning of the travel end ring.
- Lubricate the mass and de-compressor control
pin.

ENG - 165
Engine MP3 400 i.e.

- Install the return spring and load it by about 3/4

turn.

- Turn the engine to move the references to the top

as shown in the figure (intake end).

- Insert the valve lifting device mass stop bell.

- Tighten the retaining screw to the prescribed torque, using the recommended product.
N.B.
THE BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD.
Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

- Check that the decompression mass is free and

that it is pulled by the spring.

Locking torques (N*m)

Valve lifter mass stop bell fixing screws 30 - 35

ENG - 166
MP3 400 i.e. Engine

- Place the tightener cursor in the rest position,

keeping the retain tab pressed.

- Install a new tightener on the cylinder using a new

gasket.
- Tighten the two fastening screws to the prescri-
bed torque.

Locking torques (N*m)

Tightener fastening screws: 11 ÷ 13

- Insert the spring with the central screw and the

washer.
- Tighten the central screw to the prescribed tor-
que.

Locking torques (N*m)

Tightener screw: 5 ÷ 6

- Place the engine with the valve clearance adjustment timing references aligned with the head.
- Check the clearance between valve and rocking lever using a thickness gauge.

PRESCRIBED CLEARANCE
Specification Desc./Quantity
Inlet 0.15 mm (engine cold)
drainage 0.15 mm (engine cold)

- In case different values are found, adjust by loos-

ening the lock nut and use a screwdriver for the set
screw as shown in the figure.

ENG - 167
Engine MP3 400 i.e.

Refitting the timing chain

The ignition advance is determined electronically on the basis of parameters known by the control unit.
For this reason it is not possible to interpret the reference values based on the engine rpm.
The ignition advance value is detectable at any time using the diagnostic tester.
It is possible to check whether the ignition advance determined by the injection system matches the
value actually activated on the engine, by means of the stroboscopic light.

Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light to check timing

Proceed as follows:
- Remove the outside transmission cover as de-
scribed in the automatic transmission chapter.

- Remove the TDC reference inspection cap be-

tween flywheel and crankcase cover. See the fly-
wheel cover chapter.

- By the driving pulley, turn the engine to find the

alignment of the references to identify the TDC.

ENG - 168
MP3 400 i.e. Engine

- Repeat for the reference between driving pulley

and transmission housing.

- Refit the inspection cap on the flywheel side.

- Connect the diagnostic tester.
- Start the engine.
- Select the «parameters» function in this menu.
- Select the stroboscopic light control in the tradi-
tional four-stroke engine position (1 spark, 2 revs).
- Check that the real values of rpm and ignition
advance match those measured using the diag-
nostic tester.

Specific tooling
020460Y Scooter diagnosis and tester
If the values do not match, check:
- distribution timing
- revolution timing sensor
- injection control unit

Refitting the rocker-arms cover

- Check that the gasket is in good working order.

ENG - 169
Engine MP3 400 i.e.

- Tighten the two screws indicated in the figure with

«1» and «2» to limit the reciprocal sliding of the
cover surface with the head surface.
- Tighten the remaining 4 screws in a crossed se-
quence (3, 4, 5, 6).
N.B.
CHECK THE PROPER POSITION OF THE GASKET.

Locking torques (N*m)

Tappet cover fixing screws 7 - 9
- Install the transmission cover and the relevant
mesh filter and the outside transmission cover as
described in the "Automatic transmission" chapter.

- Install the cooling system sleeves using new

bands, as described in the "Flywheel cover" chap-
ter.

Refitting the intake manifold

- Install the intake manifold on the engine.
- Insert the 3 fastening screws, one of which with
a support band for the cooling system sleeve, and
tighten to the prescribed torque.

Locking torques (N*m)

Inlet manifold screws 11 ÷ 13

Crankcase - crankshaft
- Remove the outside and inside transmission cover and the complete driving pulley as described in
"Automatic transmission".

ENG - 170
MP3 400 i.e. Engine

- Remove the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover"
chapter.

- Remove the flywheel with the starting system following the instruction given in "Flywheel and Starting
system".

- Remove the thermal group (cylinder, head, piston) as described in the «Thermal group and timing
system chapter».

- Before opening the crankcase, check the crankshaft axial clearance.

For this purpose, use a plate (e.g. the special tool) and a support with special tool comparator.

Specific tooling
020262Y Crankcase splitting plate
020335Y Magnetic support for dial gauge

Characteristic
Standard clearance:
0.10 - 0.50 mm
Admissible increase limit after use:
0.60 mm

- Upper clearances are an indication of wear on the surfaces of the crankshaft casing support.
- To carry out an accurate measurement, measure the clearance in both directions between crankcase
and crankshaft.

Splitting the crankcase halves

- Remove the engine support retain screw on the

flywheel side half-crankcase.

ENG - 171
Engine MP3 400 i.e.

- Remove the 14 crankcase coupling screws.

N.B.
THE FASTENING SCREWS ARE OF 3 DIFFERENT
LENGTHS. NOTE THEIR CORRECT POSITION.

- Split the crankcases while keeping the crankshaft

inserted on the flywheel side half-crankcase.
- Remove the coupling gasket.
N.B.
THE BUSHING SUPPORT CAN BE LEFT IN THE FLY-
WHEEL SIDE HALF-CRANKCASE.

Removing the crankshaft

- Before removing the crankshaft, check the timing

with the countershaft. To carry out this check, turn
the crankshaft to align the two holes obtained on
the crankshaft with the hole on the countershaft
control gear.
This is an optimal position also to remove the
crankshaft.

- Remove the crankshaft with the shim adjustment

washer on the flywheel side.
CAUTION
WHILE OPENING THE CRANKCASE AND REMOVING THE
CRANKSHAFT, CHECK THAT THE SHAFT THREADED
ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS.
FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE
THE MAIN BEARING.

ENG - 172
MP3 400 i.e. Engine

Removing the oil pump and countershaft con-

trol gear.
- To remove the control gear, loosen the 4 fasten-
ing screws.
Remove the gear only if actually required.
CAUTION
THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR
THREADING IS LOCKED BY LOCTITE. BE CAREFUL NOT
TO DAMAGE THE CONTROL HEXAGON. TO OBTAIN BET-
TER RESULTS IT IS PREFERABLE TO USE AN INSIDE
HEXAGON SOCKET WRENCH.

Removing the countershaft

- Place the special tool as shown in the figure.

Specific tooling
020479Y Countershaft lock wrench

- Remove the fastening nut with relevant washer.

- Remove the special tool and extract the counter-

shaft with the control gear.

ENG - 173
Engine MP3 400 i.e.

Replacing the countershaft bearings

- Check that the bearings are free from irregular

noise or clearance. If it does, replace it.
Flywheel-side half-crankcase
- Remove the inside Seeger ring.

- Upturn the half-crankcase.

- Remove the bearing from the flywheel side half-
crankcase using the special tool and a mallet.

Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm Adaptor
020439Y 17-mm guide

- Remove the bearing from the transmission side

half-crankcase using the special tool.

Specific tooling
001467Y008 Pliers to extract 17 mm ø bearings
001467Y007 Driver for OD 54-mm bearings

- Before installing a new bearing, heat the flywheel

side half-crankcase using the special tool.
- Place the half-crankcase on a wooden base.

Specific tooling
020151Y Air heater

ENG - 174
MP3 400 i.e. Engine

- Insert a new bearing on the special tool after

greasing the guide seat.
- Install the new bearing on the half-crankcase us-
ing the special tool.
N.B.
IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE
BALLS VISIBLE FROM THE CRANKCASE INTERNAL
SIDE.

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020439Y 17-mm guide
- Fit the Seeger ring.

- Before installing the new bearing on the trans-

mission side crankcase, heat the seat using the
special tool.

Specific tooling
020151Y Air heater

- Insert a new bearing on the special tool after

greasing the guide seat.
- Install the new bearing on the engine crankcase
using the special tool.
N.B.
IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE
BALLS VISIBLE FROM THE CRANKCASE INTERNAL
SIDE.

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor

ENG - 175
Engine MP3 400 i.e.

020439Y 17-mm guide

Inspecting the crankshaft components

- Check the axial clearance on the connecting rod.

Characteristic
Standard clearance:
0.20 ÷ 0.40 mm

- Check the connecting rod diametrical clearance.

Characteristic
Standard clearance:
0.046 ÷ 0.076 mm

-Check the surfaces that limit the axial free-play

are not scored and measure the width of the crank-
shaft between these surfaces, as shown in the
diagram.
N.B.
BE CAREFUL NOT TO LET THE MEASUREMENT BE AF-
FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.

Characteristic
Standard dimensions:
63.6 - 63.45 mm
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VAL-
UES AND THE SURFACES ARE FREE FROM SCRATCHES.
Shimming
- Check the overall height of the crankshaft - shoulders - gear assembly.

Characteristic
Standard thickness:
71.804 - 72.000 mm

- Check that shim adjustment is free from scratches.

N.B.

ENG - 176
MP3 400 i.e. Engine

IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FITTING POSITION.

Specific tooling
020074Y Support base for checking crankshaft alignment

- If the crankshaft - crankcase axial clearance is higher than the standard value and the crankshaft
exhibits no irregularity, the problem is caused by wear or by a wrong machining on the engine crankcase.

- Check the diameters of both bearings of the

crankshaft in accordance with the axes and surfa-
ces shown in the figure. Half shafts are classified
into two categories, Cat 1 and Cat. 2. Refer to the
chart below.

STANDARD DIAMETER
Specification Desc./Quantity
Cat. 1 40.010 ÷ 40.016
Cat. 2 40.016 ÷ 40.022

Inspecting the crankshaft alignment

- Install the crankshaft on the support and measure the displacement at the 4 points shown in the figure.

Specific tooling
020074Y Support base for checking crankshaft alignment

MAX ADMISSIBLE DISPLACEMENT:

Specification Desc./Quantity
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm

- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded
tangs are in good working order.
- In case of failures, replace the crankshaft.

ENG - 177
Engine MP3 400 i.e.

N.B.
MAIN BEARINGS CANNOT BE MODIFIED.
The connecting rod cannot be replaced. To check the connecting rod small end diameter, see chapter
"Thermal group and timing system".
- When cleaning the crankshaft, be careful to prevent any impurity from entering into the shaft lubrication
hole.
N.B.
IN CASE OF REPLACEMENT OF A CRANKSHAFT CONSISTING OF TWO HALF-SHAFTS OF DIF-
FERENT CATEGORY, REPLACE THE TWO HALF-CRANKCASES AS WELL, COUPLING THE TWO
COMPONENTS (SHAFT AND CRANKCASE) WITH THE SAME CATEGORY.
- To check the gearing of the crankshaft, see sec-
tion "Thermal group and timing system".

See also
Cylinder assy. and timing system

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.
- For the transmission-side half-crankcase, special
attention should be given to the bushings, to the
cooling jet on the transmission side (see figure)
and to the lubrication duct.

N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES THE
PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAK CAN CONSIDERABLY DE-
CREASE THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.

ENG - 178
MP3 400 i.e. Engine

- For the flywheel side half-crankcase, special at-

tention should be given to the lubrication channels
for the main bearings and to the compartment and
the channels for the oil pump, as well as to the duct
for the by-pass located on the flywheel cover.
N.B.
AS ALREADY DESCRIBED IN THE "LUBRICATION" CHAP-
TER, IT IS ESPECIALLY IMPORTANT THAT THE BY-PASS
HOUSING ON THE FLYWHEEL COVER IS FREE FROM
WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE
LUBRICATION PRESSURE ADJUSTMENT PISTON. THE
HEAD LUBRICATION CHANNEL IS EQUIPPED WITH A
SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION. THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP.

The jet clogging impairs the head lubrication and the timing mechanisms.
A jet failure causes a decrease in the main bearing and connecting rod lubrication pressure.
- Check that the surfaces exhibit no dents or deformations, with special attention to the crankcase
coupling and the crankcase-cylinder surfaces.
- Any defects in the crankcase gasket or matching surfaces (see Flywheel cover coupling) can cause
pressurised oil leaks, thereby affecting the connecting rod and main bearing lubrication pressure.
- Check the main bearing seats that limit axial clearance in the crankshaft exhibit no wear. For the
dimensional check, refer to the instructions about checking the axial clearance and the dimensions on
the crankshaft

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is neces-
sary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are 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 obstructions in the oil feeding channels, the matching surface of the two half-bearings must
be perfectly perpendicular to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION, DRIVING IS FORCED ON
CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.

ENG - 179
Engine MP3 400 i.e.

- Check the inside diameter of the main bushings

in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing
half. see diagram.
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.

Before assembling, check that the clearance between the engine crankcase bushing and the crankshaft
is within the predetermined limits.

Characteristic
Crankshaft-bushing maximum clearance admitted:
0.08 mm

- The standard bushing diameter after driving is variable on the basis of a coupling selection.
- The crankcase bushing seats are classified into 3 categories while the crankshaft ones, into 2 cate-
gories.
- Bushings are subdivided into 4 categories according to their thickness (see the table).

CHECK THE BENCH BUSH

Name Description Dimensions Initials Quantity
Type A - Red 1.971 ÷ 1.974
Type B - Blue 1.974 ÷ 1.977
Type C - Yellow 1.977 ÷ 1.980
Type D - Green 1.980 ÷ 1.983

Coupling chart

The following kinds of bushings indicated in the table must be used according to the kind of coupling
between the crankshaft and the crankcase.

ENG - 180
MP3 400 i.e. Engine

KEY
X = Crankshaft category
Y = Crankcase half-shell category
A = Red
B = Blue
C = Yellow
D = Green
In case of breakdown, crankcases are together with bushings and are classified according to the centre
to centre distance of the countershaft. Find below the possible couplings.
- Complete FC1 type crankcase equipped with bushings for housing a category 1 crankshaft and a
countershaft with centre to centre distance A.
- Complete FC2 type crankcase equipped with bushings for housing a category 2 crankshaft and a
countershaft with centre to centre distance A.
- Complete FC3 type crankcase equipped with bushings for housing a category 1 crankshaft and a
countershaft with centre to centre distance B.
- Complete FC4 type crankcase equipped with bushings for housing a category 2 crankshaft and a
countershaft with centre to centre distance B.
N.B.
THE CRANKSHAFT CATEGORY IS STAMPED ON THE COUNTERWEIGHT SHOULDER.
A spare crankcase cannot be combined with a driving shaft with mixed categories. Spare shafts have
half-shafts of the same category.
N.B.
TO REPLACE THE HALF-SHAFTS, REMOVE THE COUNTERSHAFT BEARINGS AS DESCRIBED
ABOVE. REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI-FLAPPING ROLLER FROM

ENG - 181
Engine MP3 400 i.e.

THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN CHAPTER "AUTOMATIC

TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS
DESCRIBED IN CHAPTER "FINAL REDUCTION".

Countershaft

- Using a micrometer, measure the 2 bearings of

the countershaft as shown in the figure.

Characteristic
Standard diameter:
17 - 0.01 - 0.02 mm

- Check that the water pump drive is not worn.

Refitting the crankshaft

- Check that the oil pump and countershaft control gear are free from deformations or dents. Replace,
if required.
N.B.
IF YOU HAVE TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NEC-
ESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL.
- Before installing the gear on the crankshaft, care-
fully clean the two matching surfaces removing
any residues of LOCTITE from the holes using a
brush.

Blow with compressed air and degrease the mounting holes on both surfaces to make the new LOCTITE
grip.
Apply the recommended product to the holes again.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

- Repeat the same procedure for the 4 fastening screws.

- Insert the control gear on the crankshaft with the hole countersink visible.
- Tighten the 4 fastening screws to the prescribed torque.
N.B.

ENG - 182
MP3 400 i.e. Engine

TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN IN-

SIDE HEXAGON SOCKET WRENCH.
Locking torques (N*m)
Gear mounting on crankshaft screws 10 -12
- Lubricate the main bearing on the flywheel side
half-crankcase.
- Lubricate the shim adjustment washer.
- Insert the shim adjustment washer on the crank-
shaft in its original position.
- Insert the special timing tool in the hole on the
countershaft.

Specific tooling
020471Y Pin for countershaft timing
- Insert the crankshaft on the pin and into the bush-
ing.
- Before inserting thoroughly, make the oil pump
gear align with the control gear.
- Insert thoroughly and remove the special tool.

N.B.
WHEN INSERTING THE SHAFT ON THE HALF-CRANKCASE, BE CAREFUL NOT TO DAMAGE
THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIM-
ING CONTROL TOOTHED PINION.
- Install the oil pump closing plate.
- Tighten the 2 flanged fastening screws to the
prescribed torque.

Locking torques (N*m)

Bulkhead screws for oil pump housing cover 8
- 10

ENG - 183
Engine MP3 400 i.e.

Refitting the crankcase halves

- Remove the oil guard from the transmission side
half-crankcase using a screwdriver.

- Install a new oil guard after lubricating it, using

the special tool, arranging it at a 0.5 mm recess
from the crankcase plane.
CAUTION
A WRONG POSITIONING OF THE OIL GUARD AFFECTS
THE LUBRICATION OIL CIRCULATION.

Specific tooling
020360Y 52x55-mm Adaptor
020376Y Adaptor handle
- Insert the gasket on the flywheel side half-crank-
case.

- Lubricate the main bearing on the transmission

side half-crankcase.
- Couple the 2 half-crankcases being careful
not to damage the bushing on the transmis-
sion side half-crankcase with the threaded
tang of the crankshaft.
- Insert the engine support retain screw on the fly-
wheel side half-crankcase without tightening.
- Insert the 14 fastening screws by arranging the
single shorter screw «A» and the single longer
screw «B» as shown in the figure.
- Tighten the screws thoroughly and tighten to the prescribed torque.

ENG - 184
MP3 400 i.e. Engine

- Check that the crankshaft rotates freely.

N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER
PLANE, TO ENSURE BETTER SEALING PERFORMANCE.
Locking torques (N*m)
Engine-crankcase coupling screws 11 ÷ 13
- Install the thermal group (cylinder, head, piston) as described in section «Thermal group and timing
system».

- Install the flywheel with start-up control as described in the "Flywheel and start-up" chapter.

- Install the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover chapter".

- Install the complete driving pulley, the transmission cover and the relevant mesh filter and the outside
transmission cover as described in the «Automatic transmission» chapter.

See also
Cylinder assy. and timing system
Flywheel cover

Lubrication

TECHNICAL SPECIFICATIONS

SUMP CAPACITY
Specification Desc./Quantity
Overhaul 1.7 l
Oil and filter replacement 1.5 l

RECOMMENDED ENGINE OIL

Product Description Specifications
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil

OIL PUMP
Specification Desc./Quantity
Type Trochoidal
Rotor washers 8 mm
Assembly clearances Lobe ends 0.05-0.008 mm
External rotor radial clearance 0.05- 0.12 mm
Rotor axial clearance 0.025 - 0.065 mm

BY-PASS
Specification Desc./Quantity
Type with piston
Plunger diameter 13.9 - 0.039 -0.057 mm
Spring free length 62.5 mm
Calibration pressure 4 bar

PRE-FILTER
Specification Desc./Quantity
Type mesh, plastic

ENG - 185
Engine MP3 400 i.e.

OIL FILTER
Specification Desc./Quantity
Type Paper with pressure relief and anti-drain back by-pass valves

OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH

Specification Desc./Quantity
Calibration 0.3 - 0.6 bar

HEAD LUBRICATION CONTROL JET

Specification Desc./Quantity
Diameter 1 ± 0.05 mm *
* Tightening torque 5÷7 N·m

PISTON COOLING NOZZLE

Specification Desc./Quantity
Diameter 0.8 ± 0.05 mm

CRANKCASE VENTILATION CHECK

Specification Desc./Quantity
Device metal reed valve and decantation chamber

Conceptual diagrams

PRINCIPLE DIAGRAM
Specification Desc./Quantity
A Camshaft
B Cylinder-head plane
C Cylinder-crankcase plane
D Water pump impeller
E Minimum oil pressure sensor

ENG - 186
MP3 400 i.e. Engine

Specification Desc./Quantity
F Oil filter cartridge
G To the oil sump
H By-pass valve
L Oil pump
M Mesh pre-filter
N Crankshaft
O Connecting rod

General characteristics

The lubrication system is divided into two sections:

- High pressure
- Low pressure
The high pressure section includes all components located on the engine crankcase whereas the low
pressure section only refers to the thermal group.
The trochoidal pump is installed in the sump and is controlled by a pair of gears.
To guarantee the integrity of the pump, a pre-filter is fitted.
This is a screw-in type pre-filter and the relevant plug serves at the same time as an engine oil drain
plug.
The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the
cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the
pressure of the circuit.
The by-pass located before the cartridge filter improves the operating conditions for the filter, particularly
with cold oil.
The filter is equipped with an anti-drain back valve and a pressure-relief valve; the latter intervenes
when the filtering mass causes a pressure drop above 1 ± 0.2 bar.
These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged.
The filtered oil is used to lubricate the water pump shaft and once at the engine crankcase, to lubricate
the main bearings, the connecting rod head and the piston cooling nozzle, on the transmission-side
bearing.
The main bearing on the transmission side is fitted with an oil seal and the respective drain line.
The supply line for the timing system comes from the flywheel-side bearing; the supply to the head is
controlled by the respective spray jets in the engine crankcase.
The components of the timing system function with low-pressure oil lubrication.
The camshaft bearings are installed directly on the aluminium of the head; the camshaft axial clearance
is partially compensated by the oil supplied to the smaller diameter bearing.
The camshaft supplies the lubricant to the rocking levers via the holes provided; these are installed in
a position to ensure that the lubrication is maintained even after the scooter has stopped. This is ach-
ieved when the camshaft reaches its most usual and likely position when the engine is shut off.
The oil used to lubricate the head returns to the sump via the chain casing channel and therefore it also
provides lubrication for the chain.

ENG - 187
Engine MP3 400 i.e.

A one-way valve and a decantation chamber are used so that gases from the crankcase do not carry
any oil. The one-way valve is a metal reed valve; the decantation chamber has a drainage hole. A failure
in these components implies oil getting into the line supplying air to the engine.
Excessive oil vapours may result in clogged ducts on the throttle body.
In order to signal low oil pressure in the system, a pressure switch is used, located immediately after
the oil filter outlet.
The lubrication circuit does not include the countershaft. The countershaft is lubricated by the oil trans-
ported by the gears or by the centrifugal effect of the crankshaft
The same applies to the piston or the pin, but in this case the cooling nozzle is particularly important.

Diagnosis guide

1 - Minimum oil pressure warning light on with hot engine.

AHEAD - go to 2
2 - Remove the minimum pressure switch electric connector.
Check that the warning light turns off.
YES - go to 3 NO go to 11
3 Check the actual oil pressure.
AHEAD - go to 4
4 - Remove the switch and fit the special tool with the relevant gasket.

Specific tooling
020193Y Oil pressure check gauge
020434Y Oil pressure check fitting

- Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied
with the special tool. Insert the probe to feel contact with the crankcase bottom and pull back a few
millimetres.

Specific tooling
020331Y Digital multimeter

AHEAD - go to 5

5 - Measure the pressure with cold and idling engine.

ENG - 188
MP3 400 i.e. Engine

STANDARD VALUES
Specification Desc./Quantity
20°C Temperature
1400 rpm
approx. 4.5 bar

N.B.
RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE DIAGNOSTIC
TESTER
Specific tooling
020460Y Scooter diagnosis and tester
YES go to 6 NO go to 12
6 - Let the engine warm up and repeat the check with hot oil.

STANDARD VALUES
Specification Desc./Quantity
80°C Temperature
1400 rpm
approx. 1.5 bar

YES go to 7 NO go to 8
7 - Replace the oil minimum pressure switch.
8 - If pressure lower than 1.3 ÷ 1.5 bar is measured.
AHEAD go to 9
9 - Replace the oil filter and repeat the pressure check with oil at 80°C.
YES go to 10 NO go to 13
10 - The failure was fixed.
It is recommended to respect the suggested number of kilometres covered.
11 - Check and restore the electrical system.
12 - If pressure lower than 4 bar is measured.
AHEAD go to 9
13 - Remove the flywheel cover and check the by-pass and the cover sealing gasket efficiency towards
the case internal side, as described in the "Flywheel cover" chapter.
YES go to 14 NO go to 15
14 - Check whether there is an irregular clearance on the crankshaft:
- axial clearance (see the "Crankcase and crankshaft" chapter)
- radial clearance, especially in the direction of the cylinder axis
- clearance according to the direction of rotation with the connecting rod in quadrature
YES go to 16 NO go to 17
15 - Replace the faulty components ("Flywheel cover" chapter).
16 - Overhaul the engine ("Crankcase and crankshaft" chapter).
17 - Open the engine crankcase and remove the oil pump as described in the "Crankcase and crank-
shaft" chapter.

ENG - 189
Engine MP3 400 i.e.

- Check the oil pump as described in the following pages.

- Check that the cooling nozzle and the timing system feeding jet are properly installed.
- Visually inspect the crankshaft couplings and their size ("Crankcase and crankshaft" chapter).
N.B.
POTENTIAL IRREGULARITIES IN COUPLINGS AND THE TIMING SYSTEM COMPONENTS CAN-
NOT BE DETECTED WHEN INSPECTING THE LUBRICATION PRESSURE. THEY MAY BECOME
EVIDENT BY AN INCREASE IN NOISE.
N.B.
IN CASE OF IRREGULAR PRESSURE ON THE CRANKCASE, CARRY OUT A VISUAL AND DI-
MENSIONAL INSPECTION OF THE TIMING SYSTEM COMPONENTS (SEE "THERMAL GROUP
AND TIMING SYSTEM" CHAPTER).

Oil pressure check

1 - In case of oil leaks from the oil filter or from the flywheel cover coupling gasket, check the lubrication
pressure.
AHEAD go to 2
2 - Install the special tool.

Specific tooling
020193Y Oil pressure check gauge
020434Y Oil pressure check fitting

AHEAD go to 3
3 - Check the system pressure with cold engine and medium - high speed.
Standard pressure < 6 bar
YES go to 4 NO go to 5
4 - Replace the damaged components.
5 - Check the working order of the adjustment by-pass (see "flywheel cover" chapter) and restore proper
sliding.
N.B.
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY. A
HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE.
1 - If oil consumption is above 250 g/1000 km on a run-in engine, proceed as follows.
AHEAD go to 2
2 - Check the presence of oil in the scavenge duct on the filter box.
YES go to 3 NO go to 4
3 - Check the one-way reed valve and the decantation chamber drainage hole.
YES go to 5 NO go to 4
4 - Check the thermal group seals (piston rings, valve guides and oil guards), see "Thermal group and
Timing system" chapter.
5 - Restore the valve or the drainage hole efficiency.

ENG - 190
MP3 400 i.e. Engine

Oil pump

Removal

- Remove the closing plate of the oil pump housing

by loosening the 2 retaining screws with their
washers.

- Remove the oil pump complete with the gearing

by loosening the 2 retaining screws through the
eyes machined in the gearing proper.

- Remove the gasket.

- Remove the two screws and the oil pump cover.

ENG - 191
Engine MP3 400 i.e.

- Remove the inside rotor retaining snap ring turn-

ing it to move the opening at the shaft face.

- Remove and wash the rotors thoroughly with pet-

rol and compressed air.
- Extract the shaft with its gear and check that it is
in good working order and free from wear.

- Reassemble the rotors in the pump body, keep-

ing the two reference marks visible
- Insert the shaft with the gear and install the lock
ring; then, turn it with the opening opposed to the
shaft face.
- Check any irregular clearance between shaft and
pump body.

- Using a thickness gauge, check the distance be-

tween the rotors in the position shown in the figure.

Characteristic
Admissible limit clearance:
0.012 mm

ENG - 192
MP3 400 i.e. Engine

- Check the distance between external rotor and

pump body; see figure.

Characteristic
Admissible limit clearance:
0.25 mm

- Check the rotor axial clearance using a rectified

bar as reference plane, as shown in the figure.

Characteristic
Limit values admitted:
0.1 mm

Refitting
- Make sure the gasket is in the correct position.
N.B.
THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.

- Lubricate the internal rotors.

- Check there are no signs of scoring or wear on
the oil pump cover.
- If non-conforming values or signs of wear are
found, replace the pump.
- Fit the pump cover in the position that permits the
crankcase fixing screws to be aligned.
- Tighten the two fastening screws to the prescri-
bed torque.

Locking torques (N*m)

Oil pump cover screws 0.7 ÷ 0.9
- Insert the oil pump with gear

ENG - 193
Engine MP3 400 i.e.

- Insert the 2 retaining screws through the slots on the gear and tighten to the prescribed torque.
N.B.
THE ASSEMBLY POSITION OF THE PUMP IS FIXED BY INSTALLATION OF THE SCREWS.
Failure to observe the tightening torque may alter
the coupling clearance of the rotors with the pump
body.

Locking torques (N*m)

Screws fixing oil pump to the crankcase 5 ÷ 6

- Insert the countershaft with gearing into the fly-

wheel-side half-crankcase.
- Install the special tool in the position shown in the
figure.

Specific tooling
020479Y Countershaft lock wrench

- Keep the countershaft in position and insert the

washer with the nut.
- Tighten the nut to the prescribed torque, using
the recommended product.
- Remove the special tool.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Countershaft fixing nut 25 ÷ 29

Water pump

Removal

Specific tooling
020661Y Water pump overall seal replacement kit

ENG - 194
MP3 400 i.e. Engine

- Remove the six screws and the pump cover with

a screwdriver.

- Unscrew the water pump rotor with an 8-mm

wrench.

- Place two flat blade screwdrivers as shown in the

figure so as to lever on the marked crankcase
edge and disassemble the overall seal, pressure-
fitted on the rotor shaft.
CAUTION
USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO
DAMAGE THE WATER PUMP COVER SEALING SUR-
FACE. SMALL SCRATCHES ON THE SEAT EDGE DO NOT
POSE FUNCTIONAL PROBLEMS.

- Change the position of the screwdrivers if nec-

essary.
- During seal disassembly, the ceramic may split.

ENG - 195
Engine MP3 400 i.e.

- Clean all the parts thoroughly before removing

them.

- Place the extractor together with the pin on the

fixed part of the ceramic seal.
- Without modifying the extractor position, make
three holes on the fixed part of the seal using the
pin supplied and a hammer.
N.B.
MAKE THE HOLES WITH A STRONG HIT.
MULTIPLE LIGHT BLOWS COULD DEFORM THE PART
WITHOUT PASSING THROUGH.

- Fix the extractor to the fixed part of the sealing

using the screws supplied with the tool.
CAUTION
FIX IT PROPERLY WITHOUT "TEARING" THE PLATE

- Complete the tool by fitting the bracket, the screw

and the nut.

ENG - 196
MP3 400 i.e. Engine

- Hold the screw in position and operate the nut

until the fixed part of the sealing is completely re-
moved.
- Remove the extractor with the fixed part of the
overall seal.

Fitting

OVERALL SEAL FITTING

CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.
CAUTION
LUBRICATE THE ROTOR SHAFT WITH ENGINE OIL.

- Fit the tie rod by screwing it to the rotor shaft.

CAUTION
TIGHTEN MANUALLY UNTIL IT STOPS.
- Place the overall seal on the shaft.

ENG - 197
Engine MP3 400 i.e.

- Place the calibrated punch (at preloading value).

- Fit the nut to the tie rod.
- Keep the tie rod in position and screw the nut up
to the end of stroke.
- The tool will drive the fixed part seat on the crank-
case and the movable part seat on the shaft, thus
obtaining the correct ceramic seal preloading.

- Screw the rotor.

Locking torques (N*m)

Water pump impeller 4 ÷ 5

- Fit the pump cover with a new gasket, lubricate

the gasket previously with petroleum jelly grease.
- Tighten the six cover screws to the prescribed
torque.
N.B.
TO AVOID DEFORMATION, DO NOT LUBRICATE THE O-
RING WITH PETROLEUM GREASE.

Locking torques (N*m)

Water pump cover screws 3 ÷ 4

ENG - 198
INDEX OF TOPICS

INJECTION INJEC
Injection MP3 400 i.e.

KEY:
1. Battery
2. Throttle body and electronic injection control unit (MIU)
3. Instrument panel
4. Injection load remote control
5. Coolant temperature sensor:
6. Fuel pump
7. HV coil
8. Lambda sensor
9. Engine rpm sensor
10. Fuel injector
11. Diagnostics socket connector

MIU injection system

This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the
crankshaft (24-2 teeth) and pick-up sensor.
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature.
- Intake air temperature

INJEC - 200
MP3 400 i.e. Injection

- Lambda probe
The system implements an idle feeding correction with cold engine through a Stepper motor on a by-
pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening
time, thereby ensuring the idle steadiness and the proper combustion.
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel supply pressure is kept constant based on the ambient pressure.

The fuel supply circuit consists of:

- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by a pipe with fast-release fittings. The pressure regulator is located at the
beginning of the circuit.
The fuel pump is controlled by the MIU control unit; this ensures the scooter safety

The ignition circuit consists of:

- HV coil
- HV cable
- Shielded cap
- MIU control unit
- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector

INJEC - 201
Injection MP3 400 i.e.

The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-
strument panel.

Failures are detected and restored by the diag-

nostic tester.
In any case, when the fault is no longer present,
the data storage is automatically cleared after 16
cycles of use (cold start, running at regular engine
temperature, stop).
The diagnostic tester is also required to adjust the
idle mixture.

Specific tooling
020460Y Scooter diagnosis and tester
The MIU injection-ignition system carries out
checks on the rpm indicator and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the anti-
theft immobilizer system.
The MIU control unit is connected to a diagnostic
LED on the instrument panel, that also carries out
the deterrent flashing functions.

The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide
further safety for the scooter.

Precautions

1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel supply system is pressurised at 300 kPa (3 BAR). Before disconnecting the fast-release
fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to
avoid spraying fuel to your eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.

INJEC - 202
MP3 400 i.e. Injection

5. Before any attempt to start the vehicle, check to make sure there is at least two litres of fuel in the
tank. Failure to respect this norm will damage the fuel pump.
6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and cable harnesses.
8. When an ignition problem is detected, start the checks from the battery and the injection system
connections.
9. Before disconnecting the MIU ECU connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the poles when fitting the battery.
11. To avoid causing any damage, disconnect and reconnect the MIU system connectors only if re-
quired. Before reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, remember to protect the system
connector with its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
Troubleshooting hints
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
c. Remote controls
d. Connectors
B: Chassis earthing
C: Fuel supply
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

INJEC - 203
Injection MP3 400 i.e.

b. Dirty by-pass circuit

c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing
b. Wrong idle mixture
c.Incorrect reset of the throttle valve position sensor
2 MIU system faults may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connections as follows:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,
install the original control unit again and check if the fault occurs again.
4 When troubleshooting use a multimeter with an internal resistance over 10 Ohm /V. Instruments that
are not suitable might damage the MIU control unit. Instruments must be used with definitions over 0.1V
and 0.5 W , the precision must be greater than 2%.

Terminals setup

TERMINAL LAYOUT
Specification Desc./Quantity
1 Injection telltale light
2 Rpm indicator signal
3 Can «L» Line
4 - Lambda probe
5 + battery under permanent power supply
6 + Battery
7 Immobilizer aerial
8 Electric fan remote control
9 Water temperature sensor
10 Can «H» Line

INJEC - 204
MP3 400 i.e. Injection

Specification Desc./Quantity
11 + Lambda probe
12 Engine stop switch
13 Engine rpm sensor (+)
14 Fuel injector
15 Engine rpm sensor (-)
16 Diagnostics socket output
17 Immobilizer LED
18 Ground lead Connected to the engine stop switch and the water tem-
perature sensor.
19 -
20 Injection load remote control
21 -
22 HV coil
23 -
24 Start up enabling
25 -
26 Ground lead

EMS circuit diagram

SYSTEM SCHEMATIC
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Engine rpm sensor
3 Water temperature sensor
4 Immobilizer aerial
5 Stop button
6 Fuse 20 A
7 Fuse 7.5 A
8 Key switch contacts
9 Engine stop switch
10 Fuse 7.5 A
11 Fuse 15A
12 Fuse 10 A
13 Starter button

INJEC - 205
Injection MP3 400 i.e.

Specification Desc./Quantity
14 Injection load remote control
15 Start-up remote control relay
16 Electric fan remote control
17 Starter motor
18 Electric fan
19 Fuel pump
20 HV coil
21 Fuel injector
22 Lambda sensor
23 Rpm indicator
24 "WARNING" light
25 Immobilizer LED
26 Diagnostics socket connector
27 Starter remote control

Troubleshooting procedure

Engine does not start

ENGINE DOES NOT START IF ONLY PULLED

Possible Cause Operation
Immobiliser enabling signal System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Fuel supply Fuel in the tank
Fuel pump activation
Fuel pressure (low)
Injector capacity (low)
Power to the spark plug Shielded spark-plug cap HV coil (secondary insulation)
Parameter reliability Coolant temperature
Distribution timing - injection ignition
Intake air temperature
End of compression pressure End of compression pressure

Starting difficulties

ENGINE START-UP PROBLEMS

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Start-up speed Starter motor and remote control
Battery
Ground connections
End of compression pressure End of compression pressure
Power to the spark plug Spark plug
Shielded cap
HV coil
Rpm-timing sensor
Ignition advance
Fuel supply Fuel pressure (low)
Injector capacity (low)
Injector sealing (poor)

INJEC - 206
MP3 400 i.e. Injection

Possible Cause Operation

Correctness of the parameters Coolant temperature
Stepper throttle valve position intake air temperature (steps
and actual opening)
Cleaning of the auxiliary air pipe and throttle valve; air filter ef-
ficiency

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel feed (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity

Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel feed (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity

INJEC - 207
Injection MP3 400 i.e.

Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATING

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda sensor
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel feed (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Exhaust system sealing (infiltrations) Manifold - head
Manifold - muffler
Muffler welding

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN

Possible Cause Operation
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing Intake sleeve
Filter box
Ignition system Spark plug wear check
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
TPS reset successful TPS reset successful
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda sensor

Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-

ANCE ON PICKUP
Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature

INJEC - 208
MP3 400 i.e. Injection

Possible Cause Operation

Lambda sensor
Spark plug power supply Spark plug
Shielded cap
HV cable
HV coil
Intake system Air filter
Filter box (sealing)
Intake sleeve (sealing)
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Fuel supply Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity

Engine knocking

PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda sensor
Ignition efficiency Spark plug
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Intake system sealing Intake sleeve
Filter box
TPS reset successful TPS reset successful
Fuel supply Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

Fuel supply system

The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.

INJEC - 209
Injection MP3 400 i.e.

Removing the butterfly valve

Remove the fuel piping clamping screw indicated

in the figure.

Remove the fast-release fitting from the injector

support

INJEC - 210
MP3 400 i.e. Injection

Remove the injector connector.

Remove the three screws fixing the manifold to the

cylinder head and the clip fixing the throttle body
to the manifold.

Remove the MIU ECU connector.

INJEC - 211
Injection MP3 400 i.e.

Remove the gas command fitting as indicated in

the photograph

Pump supply circuit

INJEC - 212
MP3 400 i.e. Injection

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse 15A
3 Fuse 20A
4 Key switch contacts
5 Fuse 7.5 A
6 Injection load remote control
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda sensor
11 Electric fan remote control

When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine
starts up, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA

• Pump winding resistance ~ 1.8 Ohm

• Input current during regular functioning 2.8 A

Check that the injection load 15A fuse No. 2 for the
MP3 400 i.e. version and the injection load 15A
fuse No. 5 for the MP3 400 i.e. RL version are in
good conditions.
Check that the live control unit power supply 7.5A
fuse No. 10 works properly.

Check the efficiency of the injection load remote

control: Check the resistance of the energising coil
between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.

INJEC - 213
Injection MP3 400 i.e.

Check the power supply line of the injection load

remote control energising coil: after switching to
«ON», make sure there is battery voltage, for 2
seconds, between the Red-White cable and the
Black-Purple cable of the remote control base. If
there is not, check the continuity of the Red-White
cable between the fuse box and the remote control
base and of the Black-Purple cable between the
pin 20 of the control unit and the remote control
base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
CONTROL UNIT, FUSES ETC.).

INJEC - 214
MP3 400 i.e. Injection

Check the presence of fixed voltage between the

grey/black cable of the remote control base and
earth. Otherwise, check the continuity of the Grey-
Black cable between the fuse box (No. 2, 15 A) and
the remote control base for the MP3 400 i.e. ver-
sion and between the fuse box (No. 5, 15 A) and
the remote control base for the MP3 400 i.e. RL
version.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
CONTROL UNIT, FUSES ETC.).

INJEC - 215
Injection MP3 400 i.e.

After switching to «ON», check that there is battery

voltage, for about 2 seconds, between the Black-
Green cable of the pump connector and the
ground lead with the pump connector disconnec-
ted. Otherwise, check the continuity of the Black-
Green cable between the pump connector and the
remote control base.
Check the efficiency of the earth line of the fuel
pump by measuring the continuity between the
pump connector black cable, system side, and the
earth.
If, when switching to «ON», the pump continues to
turn after 2 seconds of activation, check, with the
control unit disconnected and the injection load re-
mote control disconnected, that the Black-Purple
cable (pin 20 on the interface wiring) is insulated
from the ground.

Specific tooling
020331Y Digital multimeter

Circuit leak test

Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.

Check during regular operation by placing the ap-

propriate tool between the pump and the injector.
With battery voltage > 12 V check that the fuel
pressure is 3 BAR and that the input current is ~2.8
A

With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Get a graded burette with a flow rate of
approximately 1 L. Rotate the pump using the active diagnoses of the palm top computer. Using a pair
of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.9 ÷ 3 BAR.
Pay attention not to choke the pipe too much, as the pressure remains equal to 3 BAR while the flow
diminishes. Check that within 15 seconds the pump has a flow rate of approx. 300 cm³.

Specific tooling

INJEC - 216
MP3 400 i.e. Injection

020480Y Petrol pressure check set

Fuel filter check

Disconnect the terminals from the electric pump

Remove the screw shown in the picture

Remove the clip fixing the piping to the filter shown

in the picture

Separate the lower part of the pump support as

shown in the picture.

INJEC - 217
Injection MP3 400 i.e.

Remove the filter from the pump support

Inspecting the injector circuit

INJEC - 218
MP3 400 i.e. Injection

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse 15A
3 Fuse 20A
4 Key switch contacts
5 Fuse 7.5 A
6 Injection load remote control
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda sensor
11 Electric fan remote control

When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine
starts up, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA

• Pump winding resistance ~ 0.8 Ohm

• Input current during regular functioning ~ 2.8 A

Check that the injection load 15A fuse No. 2 for the
MP3 400 i.e. version and the injection load 15A
fuse No. 5 for the MP3 400 i.e. RL version are in
good conditions.
Check that the live control unit power supply 7.5A
fuse No. 10 works properly.

Check the efficiency of the injection load remote

control: Check the resistance of the energising coil
between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.

INJEC - 219
Injection MP3 400 i.e.

Check the power supply line of the injection load

remote control energising coil: after switching to
"ON", make sure there is battery voltage, for two
seconds, between the Red-White cable and Black-
Purple cable of the remote control base. If there is
not, check the continuity of the Red-White cable
between the fuse box and the remote control base
and of the Black-Purple cable between the pin 20
of the control unit and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
CONTROL UNIT, FUSES ETC.).

INJEC - 220
MP3 400 i.e. Injection

Check the presence of fixed voltage between the

grey/black cable of the remote control base and
earth. Otherwise, check the continuity of the Grey-
Black cable between the fuse box (No. 2, 15 A) and
the remote control base for the MP3 400 i.e. ver-
sion and between the fuse box (No. 5, 15 A) and
the remote control base for the MP3 400 i.e. RL
version.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
CONTROL UNIT, FUSES ETC.).

INJEC - 221
Injection MP3 400 i.e.

With the control unit and the injector disconnected,

check the continuity of the Red-Yellow cable be-
tween pin 14 of the interface wiring and the injector
connector

Switch to «ON» and check if there is voltage, with

injector disconnected and control unit connected,
between the Black-Green cable of the injector con-
nector and the ground lead

With injector disconnected and the injector load

remote control disconnected, check the continuity
of the Black-Green cable between the injector con-
nector and remote control base.

Inspecting the injector hydraulics

To check the injector, remove the inlet manifold by

removing the three fixing screws at the head and
the three screws connecting the control unit to the
manifold.

INJEC - 222
MP3 400 i.e. Injection

Install the appropriate tool for the fuel pressure

check and position the manifold over a container
graduated by at least 100 cc. Connect the injector
with the cable making up part of the supply for the
injection tester. Connect the clamps of the cable
to an auxiliary battery. Activate the fuel pump with
the active diagnosis. Check that within 15 approx.
70 cm³ of fuel is delivered with adjustment pres-
sure of approx. 3 BAR.

Specific tooling
020480Y Petrol pressure check set

Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute

Immobiliser circuit

The electronic ignition system is controlled by the

control unit with the integrated Immobilizer sys-
tem. The immobilizer is an anti-theft system that
allows the vehicle to be operated only when it is
started with coded keys recognised by the control
unit. The code is integrated in a transponder in the
key block. This allows the driver clear operation
without having to do anything other than just turn-
ing the key. The Immobilizer system consists of the
following components:
- an electronic control unit

INJEC - 223
Injection MP3 400 i.e.

- immobilizer aerial
- Master key with incorporated transponder (red
key)
- service key with incorporated transponder (black
key)
- HV coil
- diagnosis LED
The diagnosis LED also works as a theft-deterrent
blinker. This function is activated every time the
ignition switch is turned to the "OFF" position, or
the emergency stop switch is turned to the "OFF"
position. It remains activated for 48 hours in order
not to affect the battery charge. When the ignition
switch is turned to the "ON" position, the theft-de-
terrent blinker function is deactivated. Subse-
quently, a flash confirms the switching to the "ON"
status. The duration of the flash depends on the
programming of the electronic control unit If the
LED is off regardless of the position of the ignition-
key switch and/or the instrument panel is not initi-
ated, check if:

• there is battery voltage

• fuses 1,7,10 for the MP3 400 i.e. ver-
sion and fuses 2,6,10 for the MP3 400
i.e. RL version are in working order
• there is power to the control unit as
specified below:

Remove the connector support bracket shown in

the photograph and disconnect the connector from
the control unit. Check the following conditions:

INJEC - 224
MP3 400 i.e. Injection

With the key switch set to OFF:

• if there is battery voltage between ter-

minals 6-26 and terminal 6-chassis
ground (fixed power supply). If there is
no voltage, check that fuse 1 and its
cable harness for the MP3 400 i.e. ver-
sion and fuse 6 and its cable harness
for the MP3 400 i.e. RL version are in
working order.

With the key switch in the OFF position:

• there is battery voltage between termi-

nals 5-26 and terminal 5-frame earth
(fixed power supply). If there is no volt-
age, check the key switch contacts,
that fuse no. 10 and its cable are in
working order.

• There is continuity between terminals

12-18 with the emergency cut-off
switch in the RUN position. If there is
no continuity check the contacts of the
switch.

If no faults are found, replace the electronic control

unit.

After removing the shield back plate, remove the

electrical connection from the aerial as shown in
the picture.

INJEC - 225
Injection MP3 400 i.e.

Remove the protective base from the connector.

With the ignition key switch at ON check there is

battery voltage between the Red-White and Black
cables

With MIU connector disconnected, check the con-

tinuity between the Orange-White cable and pin 7
of the interface wiring.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

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

INJEC - 226
MP3 400 i.e. Injection

first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3
seconds).
- Insert the service key and turn it to «ON» for 2 seconds.
- If you have copies of the key, repeat the operation with each key.
- Insert the MASTER key again and turn it to «ON» for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys can be programmed at one time.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, the master key transponder is strictly matched with the control
unit. With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore
necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key
becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In
any case it is advisable to use resistive spark plugs.

Characteristic
MASTER key:
RED KEY
SERVICE key.
BLACK KEY

Diagnostic codes

The Immobilizer system is tested each time the

key switch is turned from «OFF» to «ON». During
this diagnosis phase a number of control unit sta-
tuses can be identified and various light codes
displayed. Regardless of the code transmitted, if
at the end of the diagnosis the LED remains off
permanently, the ignition is enabled. If, however,
the LED remains on permanently, it means the ig-
nition is 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-

INJEC - 227
Injection MP3 400 i.e.

ted but with a limitation imposed on the number of

revs.
2. Previously unused control unit - transpond-
er absent or cannot be used: The LED is per-
manently ON; in this condition, no operations are
possible, not even starting the vehicle.

3. Programmed control unit - service key in-

serted (normal conditions 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 inser-
ted: a 0.7-sec flash is displayed followed by the
LED remaining 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

The LED indication is divided into 3 steps:

1st step: A flash: "ON" switching recognition
2nd step: Series of flashes: diagnosis code indication
3rd step: Steady light on or off:
- ON = start-up disabled
- OFF = start-up enabled

INJEC - 228
MP3 400 i.e. Injection

Code 1

A one-flash code indicates a system where the se-

rial line is not present or is not detected. Check the
Immobilizer aerial wiring and change it if necessa-
ry.

Code 2

A two-flash code shows a system where the con-

trol unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
Turn the switch to ON using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. If this
is not the case, replace the defective key and/or
reprogram the control unit. Replace the control unit
if the problem continues.

Code 3

A three-flash code indicates a system where the

control unit does not recognise the key. Turn the
switch to ON using several keys: if the error code
is repeated even with the Master key, replace the
control unit. If this is not the case, reprogram the
decoder.

INJEC - 229
Injection MP3 400 i.e.

Tachometer

With wiring disconnected from the control unit and

connected to the system, check that the sensor
resistance between pins 13 - 15 is between 100
and 150 Ohm at an engine temperature of approx-
imately 20°

Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring connected
to the control unit and system try to start up the engine and check that the voltage between pins 13 and
15 is around 2.8 V

With the interface cable harness disconnected

from the control unit, check continuity between pin
13 and the red cable of the rpm sensor connector
and between pin 15 and the brown cable of the rpm
sensor connector

INJEC - 230
MP3 400 i.e. Injection

With the interface cable harness disconnected

from the control unit and the rpm sensor connector
disconnected, check that the red and brown cables
(pin 13 - 15) are isolated from each other and in-
sulated from the ground lead.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

HT coil

INJEC - 231
Injection MP3 400 i.e.

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse 15A
3 Fuse 20A
4 Key switch contacts
5 Fuse 7.5 A
6 Injection load remote control
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda sensor
11 Electric fan remote control

The ignition system combined with the injection is the high-efficiency induction type.
The control unit controls two important parameters:
- Ignition advance
This is optimised from moment to moment in accordance with the engine revs, engine load, temperature
and environmental pressure.
With the engine at idle, the ignition advance is optimised to stabilise the speed at 1500 ± 100 rpm.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The power of the ignition is increased during
the engine start-up phase.
The injection system recognises the four-stroke cycle so the ignition is only commanded in the com-
pression phase.

Specific tooling
020331Y Digital multimeter

Check that the injection load 15A fuse No. 2 for the
MP3 400 i.e. version and the injection load 15A
fuse No. 5 for the MP3 400 i.e. RL version are in
good conditions.
Check that the live control unit power supply 7.5A
fuse No. 10 works properly.

INJEC - 232
MP3 400 i.e. Injection

Check the efficiency of the injection load remote

control: Check the resistance of the energising coil
between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.

Check the power supply line of the injection load

remote control energising coil: after switching to
"ON", make sure there is battery voltage, for two
seconds, between the Red-White cable and Black-
Purple cable of the remote control base. If there is
not, check the continuity of the Red-White cable
between the fuse box and the remote control base
and of the Black-Purple cable between the pin 20
of the control unit and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
CONTROL UNIT, FUSES ETC.).

INJEC - 233
Injection MP3 400 i.e.

Check the presence of fixed voltage between the

grey/black cable of the remote control base and
earth. Otherwise, check the continuity of the Grey-
Black cable between the fuse box (No. 2, 15 A) and
the remote control base for the MP3 400 i.e. ver-
sion and between the fuse box (No. 5, 15 A) and
the remote control base for the MP3 400 i.e. RL
version.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
CONTROL UNIT, FUSES ETC.).

INJEC - 234
MP3 400 i.e. Injection

Check there is voltage between pins 22 and 26 of

the interface wiring for around two seconds when
switching to «ON».

Check the resistance of the primary coil between

pin 22 of the interface wiring and the green black
cable of the injection load remote control base with
the control unit disconnected and the remote con-
trol disconnected.
Primary resistance ~ 1 Ohm

Inspecting the spark plug shielded cap

Measure the shielded cap resistance.
Electric characteristic
Resistance:
5 KΩ

INJEC - 235
Injection MP3 400 i.e.

If different values are measured (<1; >20KΩ), replace the shielded cap.
N.B.
A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM.
FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTE-
NANCE» CHAPTERS.

Spark advance

The ignition advance is determined electronically on the basis of parameters known by the control unit.
For this reason it is not possible to interpret the reference values based on the engine rpm.
The ignition advance value is detectable at any time using the diagnostic tester.
It is possible to check whether the ignition advance determined by the injection system matches the
value actually activated on the engine, by means of the stroboscopic light.

Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light to check timing

Proceed as follows:
- Remove the transmission compartment cover as
described in the "automatic transmission" chapter.

- Remove the TDC reference inspection cap be-

tween flywheel and crankcase cover. See the "fly-
wheel cover" chapter

INJEC - 236
MP3 400 i.e. Injection

- By the driving pulley, turn the engine to find the

alignment of the references to identify the TDC.

- Repeat for the reference between driving pulley

and engine crankcase.

- Refit the inspection cap on the flywheel side.

- Connect the diagnostic tester.
- Start the engine.
- Select the «parameters» function in this menu.
- Select the stroboscopic light control in the tradi-
tional four-stroke engine position (1 spark, 2 revs).
- Check that the real values of rpm and ignition
advance match those measured using the diag-
nostic tester.

If the values do not match, check:

- distribution timing
- revolution timing sensor
- injection control unit

INJEC - 237
Injection MP3 400 i.e.

Coolant temperature sensor

TEMPERATURE SENSOR
Specification Desc./Quantity
1 Water temperature sensor
2 Engine stop switch
3 Electronic control unit

With the control unit side connector disconnected

and the coolant temperature sensor connector
connected, check that the resistance values be-
tween pin 9 and ground correspond to the engine
temperature.
20° = 2500 ± 100 Ω
80° = 308 ± 6 Ω
With the control unit side connector disconnected
and the coolant temperature connector discon-
nected, check the insulation between the light
blue/green cable and ground.

INJEC - 238
MP3 400 i.e. Injection

With the control unit side connector disconnected

and the coolant temperature connector discon-
nected, check the continuity between pin 9 of the
interface wiring harness and the light blue/green
cable of the connector.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

Zeroing the throttle

Resetting the throttle valve position signal (TPS reset)

The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.

INJEC - 239
Injection MP3 400 i.e.

Connect the diagnostic tester.

Switch to «ON».
Select the functions of the diagnostic tester on
«TPS RESET».

Specific tooling
020460Y Scooter diagnosis and tester

Make sure that the throttle valve with the control is

supporting the stop screw.

Guaranteeing that this position will be kept, send

a confirmation for the TPS reset procedure.

INJEC - 240
MP3 400 i.e. Injection

Reset should be performed in the following cases:

- on first fitting.
- if the injection control unit is replaced.
N.B.
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.

INJEC - 241
Injection MP3 400 i.e.

Lambda probe

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse 15A
3 Fuse 20A
4 Key switch contacts
5 Fuse 7.5 A
6 Injection load remote control
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda sensor
11 Electric fan remote control

INJEC - 242
MP3 400 i.e. Injection

The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen
content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type,
i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic
converter in an area where the gas temperature is always high. The temperature at which the sensor
works is at least 350°C at 600°C and it has a reaction time of just 50 milliseconds. The signal generated
passes from a high value to a low value with a mixture with lambda =1.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

Check that the injection load 15A fuse No. 2 for the
MP3 400 i.e. version and the injection load 15A
fuse No. 5 for the MP3 400 i.e. RL version are in
good conditions.
Check that the live control unit power supply 7.5A
fuse No. 10 works properly.

Check the efficiency of the injection load remote

control: Check the resistance of the energising coil
between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.

INJEC - 243
Injection MP3 400 i.e.

Check the power supply line of the injection load

remote control energising coil: after switching to
"ON", make sure there is battery voltage, for two
seconds, between the Red-White cable and Black-
Purple cable of the remote control base. If there is
not, check the continuity of the Red-White cable
between the fuse box and the remote control base
and of the Black-Purple cable between the pin 20
of the control unit and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
CONTROL UNIT, FUSES ETC.).

INJEC - 244
MP3 400 i.e. Injection

Install the electronic control unit interface wiring.

Start the engine and warm up until the electric fan
switches on.
Use an analogue multimeter with a direct voltage
scale measuring down to 2 V.
Place the tips of the multimeter between pins 4 (-)
and 11 (+)

With the engine running at idle speed, check that

the voltage oscillates between 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 - 245
INDEX OF TOPICS

SUSPENSIONS SUSP
MP3 400 i.e. Suspensions

This section is devoted to operations that can be carried out on the suspensions.

Front

Removing the front wheel

- Remove the 5 fixing screws indicated in the pic-

ture.

Locking torques (N*m)

Wheel fixing screw 20 ÷ 25

Front wheel hub overhaul

- Remove the ball bearing check Seeger ring indi-

cated in the picture

Extract the ball bearing using the specific tool

Specific tooling
001467Y014 Pliers to extract ø 15-mm bearings
001467Y017 Bell for bearings, OD 39 mm

SUSP - 247
Suspensions MP3 400 i.e.

- Remove the oil seal on the roller bearing side

using a screwdriver.

- Remove the roller bearing using the specific tool

Specific tooling
020376Y Adaptor handle
020456Y 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 tooling
020151Y Air heater
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020412Y 15-mm guide
- Use the specific tool to fit and push the roller cas-
ing until it stops
- Refit the oil seal on the roller bearing side
- Lubricate the area between the roller bearing and
the ball bearing

Specific tooling
020038Y Punch

Recommended products
AGIP GREASE MU3 Grease for odometer
transmission gear case

SUSP - 248
MP3 400 i.e. Suspensions

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

XBCHA3, DIN K3K-20

Handlebar

Removal

- Remove the 2 handlebar covers working as ex-

plained in the Bodywork Chapter.
- Remove the handlebar wiring retaining straps
and disconnect the electric connectors from the
brake levers.
- Unscrew the fittings, then remove the front and
rear brake pump piping.
- Remove the flexible transmission of the throttle
grip and remove the throttle control.
- Loosen the clamp fixing the handlebar to the
steering tube and remove the handlebar by pulling
it upwards; then remove the lower plastic cover.
N.B.
IF THE HANDLEBAR IS BEING REMOVED TO REMOVE
THE STEERING, IT IS ONLY NECESSARY TO TILT THE
HANDLEBAR FORWARD ONTO THE FRONT PART OF THE
VEHICLE WITHOUT REMOVING THE PARTS FITTED SO
AS TO AVOID DAMAGING THE SHAFTS.

Refitting

Carry out the above operations by working in the reverse order from that used for removal.

Locking torques (N*m)

Handlebar fixing screw 50 ÷ 55

The tilt mechanism

SUSP - 249
Suspensions MP3 400 i.e.

Hydraulic system layout

When tilting is locked, the geared motor activates

the hydraulic pump indicated in the photograph
and pressurises the circuit.

The pressurised oil reaches the distribution frame

«T» and the pressure sensor «A». Then, the pipes
branch out to reach the upper joints on the side
steering tubes.

Through the rigid-flexible pipes inside the side

steering tubes, the oil reaches the stem sliding
locking device placed parallel to the shock absorb-
er.

Steering tubes

Remove the brake calliper pipe retainers and the

hydraulic pipe fitting from the brake calliper making
sure there is a container to collect the brake fluid.

SUSP - 250
MP3 400 i.e. Suspensions

Disconnect the tone wheel connector indicated in

the picture.

Remove the hydraulic pipe fitting from the sliding

locking device, making sure again that the liquid
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 - 251
Suspensions MP3 400 i.e.

Remove the suspension tilt locking device pipes

from the headstock.

Remove first the flexible part of the calliper from

the steering tube as shown in the picture, and then
remove the rigid part.

Remove the tone wheel wiring by disconnecting

the connector on the fuel tank after removing the
chassis central cover.
After that, remove the retainers indicated in the
figure.

SUSP - 252
MP3 400 i.e. Suspensions

Remove the constant-velocity universal joint from

the steering bar by undoing the nut indicated in the
picture.

Use a specific tool to remove the upper tightening

ring nut of the steering tube.

Specific tooling
020055Y Wrench for steering tube ring nut

Remove the hydraulic pipe support bracket.

SUSP - 253
Suspensions MP3 400 i.e.

Remove the steering tube lower ring nut and the

protection cap indicated in the picture.

Now the steering tube can be removed.

Check that the roller tapered bearing does not

show signs of abnormal wear. If it does, replace it.

SUSP - 254
MP3 400 i.e. Suspensions

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 - 255
Suspensions MP3 400 i.e.

For refitting, follow the operations for removal but

in reverse order, observing the prescribed torques
and greasing the bearings and their seats.

STEERING TUBES
Name Torque in Nm
Side headstock upper ring nut 20 ÷ 24
Side headstock lower ring nut 12 ÷ 15
Screw fixing sliding stem to shock absorber 45 ÷ 50
Clamp for sliding stem locking device 6.5 ÷ 10.5
Fixing nuts for constant-velocity universal joints 18 ÷ 20

Parallelogram device

Remove the steering tubes.

To facilitate removal operations of the brake disc
sector, loosen the 3 fixing screws in the hydraulic
electro-actuator indicated in the picture.

Remove the hydraulic pipe retainers from the par-

allelogram.

SUSP - 256
MP3 400 i.e. Suspensions

Remove the 4 screws fixing the tilt brake disc sec-

tor indicated in the picture.

Remove the retainers indicated in picture of the

half-arms joint flange.

To facilitate the operations indicated below, re-

move the suspension locking electronic control
unit indicated in the picture.

SUSP - 257
Suspensions MP3 400 i.e.

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 - 258
MP3 400 i.e. Suspensions

Carry out a visual check of the upper and lower

bearings on the headstocks and their seats. Re-
place them in case of signs of abnormal wear.

SUSP - 259
Suspensions MP3 400 i.e.

Check the ball bearings on the parallelogram

arms. Replace them in case of signs of abnormal
wear.

Check the inside tracks of the parallelogram bear-

ings on the chassis.

For refitting, follow the operations for removal but

in reverse order, lubricating the locking pins on the
parallelogram half-arms and observing the pre-
scribed torques.

PARALLELOGRAM DEVICE
Name Torque in Nm
Arm coupling screws 45 ÷ 50
Screws fixing arms to side headstocks 45 ÷ 50
Screws fixing arms to central headstock 45 ÷ 50
Screws fixing the half-arm coupling flange 20 ÷ 25
Screws fixing tilt locking disc section 20 ÷ 25

SUSP - 260
MP3 400 i.e. Suspensions

Geared motor and Suspension locking system

Select the SYSTEM RESET option from the main

menu

Turn the key switch to ON

Select the LOWER STOP SEARCH option from
the SYSTEM RESET menu
WAIT
PROCEDURE IN PROGRESS

SUSP - 261
Suspensions MP3 400 i.e.

The hand-held computer indicates the outcome of

the stop search operation:
POSSIBLE LIMIT STOP VALUES. TO EXIT,
PRESS A KEY AND TURN OFF AND ON. SE-
LECT PARAMETERS TO ADJUST AT 12°.
Check the geared motor if the hand-held computer
does not indicate this.

Select the PARAMETERS option from the main

menu

The hand-held computer displays the option: REL-

ATIVE POTENTIOMETER ANGLE
This function is active coming from the LOWER
STOP SEARCH procedure.
NOTE: a slight oscillation of the angle value be-
tween 0.00° and 0.50° is considered normal

Remove the protection cap of the geared motor set

screw
Use a plain slot screwdriver to turn the set screw
anticlockwise until replicating the 12° condition on
the hand-held computer
RELATIVE POTENTIOMETER ANGLE 12° (a
slight value oscillation is considered normal)
Refit the protection cap

SUSP - 262
MP3 400 i.e. Suspensions

Remove the protection cap, align the pump control

and lock the screw to the prescribed torque

Locking torques (N*m)

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

Select the SYSTEM RESET option from the MAIN

menu

SUSP - 263
Suspensions MP3 400 i.e.

Select the POTENTIOMETER RESET option from

the SYSTEM RESET menu and press OK.
WAIT....
PROCEDURE IN PROGRESS

The hand-held computer displays the words:

CHECK THAT THE CONTROL IS SET AT 12°
FROM THE LOWER STOP. PRESS OK TO CON-
TINUE
Press OK
The hand-held computer displays the words: POS-
SIBLE LIMIT STOP VALUES. PRESS A KEY AND
SHIFT OFF AND ON
If this is not successful, the tilt locking mechanism
remains locked for safety.

Adjust the flexible transmission so that a small

clearance is left to guarantee switch activation on
the tilt locking calliper

Remove the two bracket screws after releasing the

spring and freeing the flexible transmission adjust-
ment.
CAUTION: A FIRST PRODUCTION BATCH WILL
BE EQUIPPED WITH DOUBLE COAXIAL
SPRING.
It is very important to remove the flexible trans-
mission from its fitting only for replacement.

SUSP - 264
MP3 400 i.e. Suspensions

When refitting, tighten the two bracket screws and

the flexible transmission lever nut to the prescribed
torque.

Locking torques (N*m)

Bracket tightening screws 8 ÷ 12

Undo the Allen screw and remove the switch.

Upon refitting, place the switch with the button ori-
ented to the stop indicated on the calliper lever,
observing the reference indicated on the switch
supporting bracket.
After refitting, check in detail that the switch is reg-
ularly activated by the stop on the lever.

SUSP - 265
Suspensions MP3 400 i.e.

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.

Refit the spring/toothed sector unit, hold the crank-

case in a perfectly horizontal and stable position,
place the spring/toothed sector unit keeping it per-
fectly perpendicular to the bearing already fitted on
the crankcase; if necessary, slightly hit the unit
shaft end with a mallet and protect the thread by
screwing in a nut.

SUSP - 266
MP3 400 i.e. Suspensions

Fit the pinion and align the reference on the pinion

teeth with the reference indicated on the second
slot of the toothed sector.
Grease the pinion and the toothed sector with spe-
cific grease.
Refit the toothed sector spacer.

Recommended products
MONTBLANC MOLYBDENUM GREASE MON-
TBLANC MOLYBDENUM GREASE
Grease with molybdenum disulphide

Lubricate the interference areas, match the crank-

case halves with slight hits of a mallet to get them
into contact.
Place the flexible transmission supporting bracket,
refit the four screws, screw them to the prescribed
torque.

Locking torques (N*m)

Geared motor crankcase halves coupling
screws 11 ÷ 13
Refit the electric motor; check the position is cor-
rect by means of the reference indicated during
removal.
The motor should be so positioned that it does not
protrude from the reduction unit mould, see figure.
Tighten the screws to the prescribed torque.

Locking torques (N*m)

Electric motor coupling screws 11 ÷ 13

SUSP - 267
Suspensions MP3 400 i.e.

Place the moulded washer of the flexible trans-

mission control lever shaft and the tongue.
Refit the flexible transmission control lever as
shown in the figure.

Refit the potentiometer (not forcing in the D-type

connector ensures a sole position) with the con-
nector directed to the opposite side of the hydraulic
pump.

Refit the hydraulic pump on the geared motor body

and tighten the screws to the prescribed torque.
Fit but not tighten the pump stem coupling screw
and refit the plastic protection cap.
The synchronisation procedure should be com-
plete when the installation is finished.

Locking torques (N*m)

Geared motor hydraulic pump tightening
screws 11 ÷ 13

Remove the retaining Seeger ring of the bearing

of the flexible transmission lever control shaft
bearing.
Remove the bearing with the specific tool.

Specific tooling
020376Y Adaptor handle
020441Y 26 x 28 mm adaptor
020362Y 12 mm guide

SUSP - 268
MP3 400 i.e. Suspensions

Extract the electric motor bearing with the specific

tool.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20-mm guide

Hold the crankcase in a perfectly horizontal posi-

tion, heat it with a specific heat gun at about 120 °
C, use the specific tool to fit the bearing of the flex-
ible transmission lever control shaft. Hit slightly
with a mallet if necessary.
Refit the bearing check Seeger ring.

Specific tooling
020151Y Air heater
020376Y Adaptor handle
020362Y 12 mm guide
020357Y 32x35-mm Adaptor
Hold the crankcase in a perfectly horizontal posi-
tion, heat it with a specific heat gun at about 120 °
C, use the specific tool to fit the bearing of the
electric motor. Hit slightly with a mallet if necessa-
ry.

Specific tooling
020363Y 20-mm guide
020358Y 37x40-mm Adaptor
020151Y Air heater

SUSP - 269
Suspensions MP3 400 i.e.

020376Y Adaptor handle

Remove the spring/toothed sector unit from its fit-
ting, slightly hit with a mallet if necessary to release
the unit.

Extract the bearing of the spring/toothed sector

unit with the specific tool.

Specific tooling
001467Y002 Driver for OD 73 mm bearing

Extract the bearing of the electric motor with the

specific tool.

Hold the crankcase in a perfectly horizontal posi-

tion, heat it with a specific heat gun at about 120 °
C, use the specific tool to fit the bearing of the
spring/toothed sector unit. Hit slightly with a mallet
if necessary.

Specific tooling
020360Y 52x55-mm Adaptor
020151Y Air heater
020376Y Adaptor handle

SUSP - 270
MP3 400 i.e. Suspensions

Hold the crankcase in a perfectly horizontal posi-

tion, heat it with a specific heat gun at about 120 °
C, use the specific tool to fit the bearing of the
electric motor. Hit slightly with a mallet if necessa-
ry.

Specific tooling
020363Y 20-mm guide
020151Y Air heater
020376Y Adaptor handle
020477Y 37 mm adaptor

Before removing the geared motor:

Disable the suspension lock.
- Remove the legshield.
With the set nut indicated in the picture, remove
the tensioning cable of the suspension locking me-
chanical calliper.

Remove the electrical connection of the geared

motor position potentiometer.

Remove the electrical connection of the geared

motor electric motor.

SUSP - 271
Suspensions MP3 400 i.e.

Disconnect the hydraulic pipes between the pump

and the sliding stem locking clamps. Empty the
system and use a container to collect the brake
fluid.
CAUTION
ELIMINATE ANY REMAINING BRAKE FLUID SPILLS.

WARNING: BRAKE FLUID IS HIGHLY POISONOUS. DO

NOT INGEST OR SWALLOW. IF ACCIDENTALLY SWAL-
LOWED, DRINK LARGE QUANTITIES OF MILK OR WATER
AND SEEK MEDICAL ADVICE IMMEDIATELY. BRAKE
FLUID DESTROYS SKIN AND OCULAR TISSUE. IF YOU
ACCIDENTALLY SPILL BRAKE FLUID ON YOURSELF,
TAKE OFF YOUR CLOTHES, WASH WITH HOT WATER
AND SOAP AND SEEK MEDICAL ADVICE IMMEDIATELY.
IF BRAKE LIQUID GETS ACCIDENTALLY IN CONTACT
WITH YOUR EYES, RINSE WITH ABUNDANT FRESH WA-
TER AND SEEK MEDICAL ADVICE IMMEDIATELY. KEEP
BRAKE FLUID OUT OF THE REACH OF CHILDREN.

Remove the 3 fixing screws indicated and remove

the whole geared motor.

Use a screwdriver to remove the plastic access

cover to the pump joint/geared motor
Undo the pump joint screw.
Undo the two geared motor pump locking screws.

SUSP - 272
MP3 400 i.e. Suspensions

For the new solution to fix the pump to the sus-

pension lock assembly, the retainers attaching the
pump body to the assembly and the clamp fixing
the pump joint have been modified as shown the
figures below.
A safety screw "A" on the lower part of the pump
been also added to be tightened after the main
lockings have been carried out.

SUSP - 273
Suspensions MP3 400 i.e.

Undo the two potentiometer screws.

Upon refitting, plug the potentiometer in D-type
connector, afterwards place it with its electric con-
nection directed to the opposite side of the pump.

Remove the nut indicated in the figure, if neces-

sary lock the lever with a vice making sure not to
spoil the surface.
In case of difficulties when removing the lever, use
the specific tool.
Remove the tongue and then, the moulded wash-
er.

Specific tooling
020234y extractor

SUSP - 274
MP3 400 i.e. Suspensions

Remove the three fixing screws of the electric mo-

tor.
It is important to mark the direction of the electric
motor position in order to refit it correctly.

Remove the four screws indicated in the figure,

remove the flexible transmission supporting brack-
et, separate the two crankcase halves, if neces-
sary, use a rubber mallet to hit the flexible
transmission lever in order to separate the two
crankcases.

Electrical devices test

PRINCIPLE DIAGRAM FOR TILT LOCKING ELECTRICAL SYSTEM

KEY
1. Geared motor

SUSP - 275
Suspensions MP3 400 i.e.

2. Brake calliper sensor

3. Tilt unlocking-locking control switch
4. Potentiometer
5. Rider presence sensor
6. Left speed sensor
7. Right speed sensor
8. Diagnostic tester series line
9. Engine control unit
10. + Direct battery
11. + Live battery
12. To light switch
13. Fuse No. 4; 20A
14. Light remote control
15. Pressure switch
16. Horn remote control
17. Instrument panel
18. Tilt locking system control unit

GEARED MOTOR

SUSP - 276
MP3 400 i.e. Suspensions

1: GEARED MOTOR

With the interface wiring disconnected from the

control unit, check the continuity between pin 28
and the white-red cable, between pin 38 and the
blue cable on the geared motor connector

With the interface wiring disconnected from the

control unit, check the continuity of the geared mo-
tor winding placing the multimeter probes on pins
28 and 38 as indicated in the figure.

TILT LOCKING-UNLOCKING SWITCH

SUSP - 277
Suspensions MP3 400 i.e.

0: REST POSITION
1: LOCKING POSITION
2: UNLOCKING POSITION
3: TILT LOCKING-UNLOCKING SWITCH

With the interface wiring disconnected from the

control unit, check the continuity of the electrical
lines between the interface wiring and the tilt lock-
ing-unlocking switch:
Pin 26 and green - grey cable
Pin 35 and violet - black cable
Pin 33 and yellow - blue cable
Also check that the above indicated electrical lines
are insulated from the earth.

SUSP - 278
MP3 400 i.e. Suspensions

Check the continuity between the black cable on

the connector and an earth point on the chassis.

With a multimeter, check the operation of the tilt

locking-unlocking switch referring to the diagram
indicated in the figure.
KEY
1. GROUND
2. LOCK
3. REST
4. UNLOCK

POTENTIOMETER

1: POTENTIOMETER

SUSP - 279
Suspensions MP3 400 i.e.

With the interface wiring connected to the control

unit, secure the vehicle on its centre stand and
switch to "ON". Select the reading scale on 20 V.
Insert the multimeter probes on pins 17 and 25.
Check that the voltage in the activated locking
condition is 4V and 1V in the locking rest condition.

With the interface wiring disconnected from the

control unit, check the continuity between pin 17
and the yellow cable of the potentiometer connec-
tor, between pin 25 and the green-blue cable,
between pin 11 and the orange-blue cable. Also
check that these lines are insulated from each oth-
er and earth.

RIDER PRESENCE SENSOR

SUSP - 280
MP3 400 i.e. Suspensions

1: RIDER PRESENCE SENSOR

With the interface wiring disconnected from the

control unit and connected to the system, check
the following conditions:
pin 17 - 36: resistance 15 ÷ 18 kOhm when the
rider is not seated on the saddle.
pin 17 - 36: resistance of about 3 kOhm when the
rider is seated on the saddle

Check the continuity between the interface wiring

pin 17 and the yellow cable of the rider presence
connector.
Check the continuity between the interface wiring
pin 36 and violet cable of the rider presence con-
nector.

TILT LOCKING CALLIPER SENSOR

SUSP - 281
Suspensions MP3 400 i.e.

1: TILT LOCKING CALLIPER SENSOR

The tilt locking calliper sensor is a normally opened

switch. Check its correct operation with a multi-
meter.

With the interface wiring disconnected from the

control unit, check the continuity between pin 34
and the brown cable of the tilt locking gripper sen-
sor connector on the system side.
Check the continuity of the connector black cable
and an earth point on the chassis

SUSP - 282
MP3 400 i.e. Suspensions

Also check that the flexible transmission control

lever activates the limit stop switch properly.

TONE WHEEL SENSOR

1: Right tone wheel

2: Left tone wheel

SUSP - 283
Suspensions MP3 400 i.e.

With the interface wiring disconnected from the

parking electrical control unit and connected to the
system, check that the sensor resistance between
pins 23 - 17 and 24 - 17 is between 774 and 946
Ohm at approximately 20°

With the interface wiring disconnected from the

control unit, check the continuity between pin 23
and the red cable of the LEFT wheel turning sen-
sor connector; the continuity between pin 17 and
the brown cables of the LEFT and RIGHT wheel
turning sensors; and between pin 24 and the red
cable of the RIGHT wheel turning sensor.

SUSP - 284
MP3 400 i.e. Suspensions

In case of failures, check the continuity between

pin 23 and the connector green cable on the fuel
tank after removing the chassis central cover; be-
tween pin 17 and the yellow cables on both con-
nectors; between pin 24 and the red cable on the
connector.

With the interface wiring disconnected from the

control unit and the connectors disconnected from
wheel turning sensors, check that pin 23 - 17 and
24 - 17 are insulated from each other and from
earth.

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

tween the screw head and the sensor is between
0.35 and 1 mm

PRESSURE SWITCH

SUSP - 285
Suspensions MP3 400 i.e.

1: PRESSURE SWITCH
2: HORN REMOTE CONTROL
3: FUSE No. 11, 7.5A

Check 7.5 A fuse No. 11 for efficiency. 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
remote control base as indicated in the picture.
Check the continuity between pin 27 and the re-
mote control base white cable.

SUSP - 286
MP3 400 i.e. Suspensions

Check the continuity of the yellow-red cable be-

tween the pressure switch connector and the fuse
box (7.5A fuse No. 11) and between the remote
control base and the fuse box (7.5A fuse No. 11).
With a multimeter, also check the pressure switch
operation as well as the continuity at rest as this is
normally closed switch.

Wheel alignment

Tool fitting

How to use the tools

• Check that tyre pressure is correct.

• Park the vehicle on level, smooth and
even ground.
• Rest the vehicle on its centre stand.
• Make sure that the parking system is
disengaged.
• Lift the front wheels as shown in the
photograph

SUSP - 287
Suspensions MP3 400 i.e.

• Check that the wheel rims rotate even-

ly and whether there is abnormal clear-
ance in bearings and suspensions.
• Make sure that the steering control
shows no signs of abnormal clearance
in joints and bearings. Otherwise, cor-
rect this and then adjust them.

Characteristic
Front tyre pressure (with passenger)
1.6 bar (1.8 bar)
Rear tyre pressure (with passenger)
2.4 bar (2.6 bar)

• 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 - 288
MP3 400 i.e. Suspensions

• Fit the bracket locking the parallelo-

gram in the holes of the previously re-
moved screws; use the screws sup-
plied with the tool and be careful to
correctly centre the spacer in the bear-
ing.

• Remove the nut fixing the steering con-

trol arm and keep the original washer
in position.

• Fit the steering guiding bracket in a

straight riding position, fix one end to
the attachment of the half-arm coupling
flange and the other end to the screw
fixing the steering control arm.

SUSP - 289
Suspensions MP3 400 i.e.

• Place the frame so that the sliders

come into contact with the rim maxi-
mum diameter but without interfering
with the tyre. If required, reposition the
frame by operating the 3 adjustable
support feet.

• Fit the frame locking bracket

• Make sure the frame is adequately

centred by checking with a gauge that
the lugs along the vertical axis show
the standard protrusion.

SUSP - 290
MP3 400 i.e. Suspensions

• Check that the pointers of both tyres

are correctly aligned, as shown in the
picture. Maximum misalignment al-
lowed: 4 notches

Specific tooling
020646Y Parallelogram and steering position-
ing tool
020647Y Toe-in checking tool

Rear

Removing the rear wheel

Before removing the rear wheel, support the vehi-

cle properly and operate the parking brake so as
to facilitate removing the wheel fixing screws.
- Remove the exhaust silencer.
- Undo the screw fixing the right shock absorber to
the clamp.

- Undo the two screws fixing the clamp to the en-

gine.

SUSP - 291
Suspensions MP3 400 i.e.

- Undo the two screws fixing the clamp to the cen-

tre stand.

- Remove the cotter pin and collect the cap.

- Unscrew the wheel fixing nut and collect the
spacer.

- Unscrew the clamp.

- Collect the conical spacer.

- Undo the five wheel fixing screws and remove the
wheel.

SUSP - 292
MP3 400 i.e. Suspensions

Refitting the rear wheel

To fit, follow the removal steps but in the reverse

sequence, being careful to fit the spacers on the
wheel axle as shown in the picture.

Locking torques (N*m)

Muffler arm clamping screws 27 ÷ 30 Rear wheel
axle nut 104 ÷ 126 Shock absorber-crankcase at-
tachment bracket 20 ÷ 25 Lower shock absorber
clamping screw 33 ÷ 41 Nm Rear brake calliper
fixing screws 25 ÷ 30 Nm

Swing-arm

Removal

- Rest the scooter on its centre stand.

- Remove the retainer fixing the swinging arm to
the engine, unscrew the nut and remove the bolt.

SUSP - 293
Suspensions MP3 400 i.e.

- Remove the silent-blocks.

- Remove the retainer fixing the swinging arm to

the frame: undo the screw.

- Remove the pin.

- Unscrew the nut of the set screw bushing.

SUSP - 294
MP3 400 i.e. Suspensions

- From the inside loosen the set screw bushing

until the swinging arm is free.
- Remove the swinging arm.

- Check the entire swinging arm assembly.

- Check all the components- Teflon bushings, si-
lent-blocks, roller bushings, spacers.
- Replace the work components that cause exces-
sive clearance on the rear suspension.

Overhaul

- Properly support the swinging arm in the vice.

- Check there is no jamming in the movement of the joint connecting the swinging arm on the engine
side to the swinging arm on the frame side.

- 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 frame side

Characteristic
Standard clearance
0.40 ÷ 0.60 mm
Allowable limit after use:
1.5 mm

SUSP - 295
Suspensions MP3 400 i.e.

- 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.

- Remove the pin connecting the engine swinging

arm - frame swinging arm.

The operations below are described once but ap-

ply to both sides of the swinging arm.
- Remove the internal spacer.
- Using a suitable pin remove the roller casings as
shown in the photographs

- Using an appropriate tool plant new roller cas-

ings, being careful to position the bearings with the
O-rings facing outwards

Specific tooling
020244Y 15-mm diameter punch

Characteristic
Length of the swinging arm tube on the engine
side:
L 140.5 ± 0.7 mm
Frame side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the frame side:

SUSP - 296
MP3 400 i.e. Suspensions

L182.5 ± 0.3 mm
Length of the swinging arm tube on the frame
side:
L 222.5 ± 0.2 mm

- Lubricate roller casings and the plastic bushings

with grease
- Insert the spacers
- Assembly both arms with the appropriate bolt
- Adjust the bolt as shown in the photograph
- Place the swinging arm, frame side, with the pro-
truding part facing the transmission side

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2 of the swinging arm

- Check that the silent block is not broken. Other-

wise, replace it.

- Unscrew the retainer to the frame in order to re-

move the silent block supporting clamp.

SUSP - 297
Suspensions MP3 400 i.e.

Refitting

For correct installation of the swinging arm on the

scooter, proceed as follows:
1. Position the silent bloc support bracket with part
3 inserted and lightly tighten part 1
2. Position the swinging arm, inserting part 2
3. Tighten part 3 to the prescribed torque
4. Screw on and tighten part 4 to the prescribed
torque
5. Screw on and tighten part 5 to the prescribed
torque
6. Tighten part 1 to the prescribed torque
Insert the swinging arm - engine bolt and tighten
to the prescribed torque

SUSP - 298
MP3 400 i.e. Suspensions

SWINGING ARM FITTING

Name Torque in Nm
Part 1 98 ÷ 118
Part 3 5÷7
Part 4 88.5 ÷ 108
Part 5 54 ÷ 60
Bolt for swinging arm, engine side / swinging arm, frame side 32.5 ÷ 40

Shock absorbers

Removal

Proceed as follows:
- place the scooter on its centre stand;
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the exhaust silencer;
- undo the shock absorber spring assembly clamp-
ing screw from the support fixed to the engine on
the one side and from that fixed to the muffler on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.

Refitting

Carry out the previous operations but in reverse order.

Locking torques (N*m)

SUSP - 299
Suspensions MP3 400 i.e.

Lower shock absorber clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41

Centre-stand

- Use a jack to support the vehicle properly.

- Remove the two stand return springs.

- Working from both sides, unscrew the two bolts

connecting it to the supporting plate.

- To refit, follow the removal steps but in reverse order; be careful to tighten to the prescribed torque.

Locking torques (N*m)

Centre stand bolt 31 ÷ 39

SUSP - 300
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Braking system MP3 400 i.e.

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

Rear brake calliper

Removal

- Remove the rear wheel.

- Undo the screws connecting the air filter to the
crankcase so that the wrenches can be inserted.
- Undo the two fixing screws and remove the cal-
liper.
N.B.
IF IT IS NECESSARY TO REPLACE OR SERVICE THE
BRAKE CALLIPER, BEFORE REMOVING THE FITTINGS
FIXING THE CALLIPER TO THE SUPPORT BRACKET,
FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING
EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM-
INED.

Overhaul

Proceed as follows:
1) remove the two male hexagonal screws (1) and
take out the two pads (10);
2) remove the two male hexagonal screws (2) and
remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating
body (5) with the help of short blows of com-
pressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
- that the cylinder and the floating body of the cal-
liper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched
or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
Refitting

BRAK SYS - 302

MP3 400 i.e. Braking system

1) insert the pistons (6) and the sealing rings (7) in

the body;
2) place the guide rubbers (8) and refit the fixed
plate (4);
3) assemble the reaction plate (3) tightening the
screws (2), insert the brake pad check spring (9)
and then the pads, fixing them with the corre-
sponding screws (1);
5) place the calliper on the disc and lock it to the
strut by tightening the fixing screws;
6) fix the pipe joint on the calliper at the prescribed
torque.
Functioning
This is a floating type calliper.
It takes advantage of the action and reaction prin-
ciple to obtain the thrust for both pads.
The body and the reaction plate body work inte-
grally and can move axially with respect of the
fixed plate that is integral to the strut.
The pistons, forced by pressure to push the pad to
the disc, cause the reaction plate to push in turn
the other pad towards the disc.
The brake pad lock spring
1. Pad fixing screws
2. Reaction plate fixing screws
3. Reaction plate
4. Fixed plate
5. Floating body
6. Piston
7. Piston sealing rings
8. Guide protection rubber rings
9. Brake pad check spring
10. Brake pads
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EV-
ERY TIME THE CALLIPER IS SERVICED.

Locking torques (N*m)

Brake fluid tube-calliper fitting 20 ÷ 25 Pad fas-
tening pin 20 ÷ 25

BRAK SYS - 303

Braking system MP3 400 i.e.

Refitting

- To fit the rear brake calliper, follow the removal steps but in reverse order; be careful to tighten the
screws to the prescribed torque.

Locking torques (N*m)

Screw tightening calliper to support 20 ÷ 25

Front brake calliper

Removal

- The operations described refer to only one cal-

liper but apply to both.
- Remove the wheel.
- Undo the two fixing screws to the plate and re-
move the calliper.

Overhaul

- Remove the rear brake calliper.

- Suitably hold the brake calliper in a clamp
- Remove the two calliper coupling screws as
shown in the photo
- Remove the two pistons from the calliper body
with the aid of short blasts of compressed air
through the brake fluid holes
- Remove the dust ring and the O-ring of each half
calliper.
- Remove the O-rings in the half calliper.
N.B.
WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO
SCRATCH THE HALF CALLIPER SEATS

BRAK SYS - 304

MP3 400 i.e. Braking system

- Check that the pistons and their seats show no

scratches.
- Wash and blow all the components carefully
- Fit the O-rings and new dust guards
- Refit the pistons in their seats being careful to
lubricate with brake fluid
- Re-couple the half callipers and lock the two
screws at the specified torque

Locking torques (N*m)

Calliper coupling screw 22 ÷ 27

Refitting

- To fit the front brake callipers, follow the removal steps but in reverse order; be careful to tighten the
screws to the prescribed torque.

Locking torques (N*m)

Screw tightening calliper to support 20 ÷ 25

Rear brake disc

Removal

- Remove the rear wheel.

- Loosen the nuts fixing the safety washers.
- Undo the two screws fixing the plate supporting
the calliper to the frame.

BRAK SYS - 305

Braking system MP3 400 i.e.

- Remove the calliper supporting clamp.

- Remove the brake disc

Refitting

- To fit the rear brake disc, follow the removal steps but in reverse order; be careful to tighten the screws
to the prescribed torque using threadlock.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Rear disc screws 5 - 6.5 Nm

Disc Inspection

Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-
er dirt, and must show no signs of deep scoring.

Characteristic
New rear disc thickness
5 mm
Disc thickness at wear limit (rear)
3.5 mm

BRAK SYS - 306

MP3 400 i.e. Braking system

- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.

Characteristic
Max. axial run-out
0.1 mm

Front brake disc

Removal

- The operations described refer to only one disc

but apply to both.
- Remove the wheel.
- Remove the brake calliper.
- Remove the cotter pin and remove the cap.

- Unscrew the fixing nut.

BRAK SYS - 307

Braking system MP3 400 i.e.

- Remove the wheel hub.

- Unscrew the six bolts securing the disc to the

wheel hub.
- Remove the disc.

Refitting

- To fit the front brake disc, follow the removal steps but in reverse order; be careful to tighten the screws
to the prescribed torque using threadlock.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Front disc screws 5 ÷ 6 Nm

Disc Inspection

Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or any other
dirt, and must show no signs of deep scoring.

Characteristic
Thickness of a new front disc
4.0 mm
Disc thickness at wear limit (front)
3.5 mm

BRAK SYS - 308

MP3 400 i.e. Braking system

- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.

Characteristic
Max. axial run-out
0.1 mm

Front brake pads

Removal

- Remove the brake calliper.

- Remove the Benzing snap ring of the pad pin.

- Slide off the pin paying attention to collect the

retaining spring of the pads.

BRAK SYS - 309

Braking system MP3 400 i.e.

- Remove the pads.

Characteristic
Minimum value
1.5 mm

Refitting

- Follow the removal steps but in reverse order; check that the Benzing snap ring of the pads is in good
conditions.

Rear brake pads

Removal

Proceed as follows:
- Remove the rear brake calliper
- Remove the two pins holding the brake pads.
- Remove the pads, paying attention to the pad re-
taining spring.
- Check the thickness of the pads.
If the thickness is less than the minimum value,
replace the pads with new pads.

Characteristic
Minimum value
1.5 mm

Refitting

- To fit the rear brake pads, follow the removal steps but in reverse order; be careful to tighten the screws
to the prescribed torque.

Locking torques (N*m)

Screws tightening the pad fixing pin 20 ÷ 25 Nm

Fill

BRAK SYS - 310

MP3 400 i.e. Braking system

Rear - combined

Proceed as follows:
- Position the vehicle on a flat surface and on the
stand
- Loosen the two screws shown in the figure and
open the front brake fluid reservoir.

- Through the bleed screw on the brake calliper,

bleed the system using a hose of adequate diam-
eter.
- Collect the used fluid in a container.

- Pump on the brake lever to completely drain the system of all used fluid.
- Tighten the bleed valve.
- Refill the brake system tank up to the maximum level with the prescribed fluid.
- Attach the tube of the special tool to the bleed fitting.
- Actuate the tool at the bleed fitting, at the same time constantly topping up the brake system tank to
prevent air being drawn into the system, until no more air escapes at the bleed fitting. The operation is
finished when only brake fluid comes out of the bleed screw.
- Close the bleed screw and tighten to the prescribed torque.
- Close the brake system tank.
N.B.
IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-
TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUT
THE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER AND
ON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE
DISC.
Specific tooling
020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)

Oil bleed screw 12 - 16

BRAK SYS - 311

Braking system MP3 400 i.e.

Front

- The operations described refer to only one cal-

liper but are valid and must be observed for both.
- Remove the rubber cap from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.

- With the right-hand brake lever, load the system and bring it up to the required pressure.
- Keeping the right-hand brake lever pulled, loosen the bleed screw to permit the air in the system to
escape. Then tighten the bleed screw.
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
If necessary, bleeding can be done using a special vacuum pump

Specific tooling
020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)

Oil bleed screw 8 ÷ 12

Brake pipes
Front brake pipes removal

Unscrew the braking splitter screw.

Disconnect the brake pipes removing the two met-
allic 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 - 312

MP3 400 i.e. Braking system

Front brake pipes removal

Remove legshield.
Remove front wheel and mudguard.
Disconnect the brake pipes from the calliper and
drain the brake fluid.
Then, remove the plastic and metallic straps.
Unscrew the brake pump pipes as indicated in the
figure.

Parking brake

Remove the rear wheel.

Loosen the transmission set screw and release the
cable from the calliper.

BRAK SYS - 313

Braking system MP3 400 i.e.

Remove the two fixing screws of the mechanic

calliper and remove the calliper. To check calliper
components, refer to the chapter on the tilt locking
calliper.
When refitting, tighten to the specified torque.

Locking torques (N*m)

Screw tightening calliper to support 20 ÷ 25

After removing the shield back plate, remove the

engaging cable for the safety mechanism remov-
ing it from its fitting.
Remove the 4 screws shown in the figure.
When refitting, pay attention to insert the metallic
cable peg in the fitting marked «A» as indicated in
the enlarged picture.

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 - 314

INDEX OF TOPICS

COOLING SYSTEM COOL SYS

Cooling system MP3 400 i.e.

Circuit diagram

This is a forced circulation cooling system, with continuous venting and air pressurisation.
Circulation takes places by a centrifugal pump driven by the countershaft.
The pump delivers the coolant to the thermal group.
The two-way thermostat support is connected in output to the head. One way is connected to the pump
and the other to the radiator (of the horizontal circulation type).
The radiator output is directly connected to the pump.
The expansion tank is connected in parallel to the radiator.
The radiator hot box is connected to the upper side of the expansion tank (in air).
The radiator cold box is connected to the lower side of the expansion tank (in the fluid).
When the engine is cold, the thermostat output to the radiator is closed, even though there is still a little
flow for de-aeration obtained by a hole into the closing plate.
In this case, the circulation into the thermal group is active to ensure an even heating.
Once the working temperature has been reached, the main circulation on radiator and expansion tank
starts.
With the small openings in the thermostat there is a flow overlapping (recirculation and main one).
When the temperature is higher, the thermostat allows excluding the recirculation to favour the main
circulation.
In this case, the flow is consistent in the expansion tank as well, and this ensures a continuous automatic
venting.

COOL SYS - 316

MP3 400 i.e. Cooling system

For the system venting during the circuit filling step, there is a special union at the top of the head (see
filling rules).
To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection
system.

TECHNICAL SPECIFICATIONS
Specification Desc./Quantity
Cooling system capacity 1.8 l
Prescribed fluid Mixture of 50% water and 50% fluid for sealed circuits
Sealing pressure Cap calibrated at 0.9 bar

THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening 82 ± 2°C

ELECTRIC VENTILATION
Specification Desc./Quantity
Type With piston
Electric ventilation starts at 107°C
Electric ventilation stops at 103°C

WATER PUMP
Specification Desc./Quantity
Type Centrifugal
Control Coaxial at the countershaft

RADIATOR
Specification Desc./Quantity
Type Aluminium, with horizontal circulation

EXPANSION TANK
Specification Desc./Quantity
Calibration Automatic bleeding, in parallel with the radiator

Electric fan check

- Connect the injection diagnostic tester and select

the «ERRORS» function in this menu.
- Check any failures in the electric fan control cir-
cuit (see «Injection»chapter)

Specific tooling
020460Y Scooter diagnosis and tester

COOL SYS - 317

Cooling system MP3 400 i.e.

- Select the menu on the "ACTIVE DIAGNOSIS"

function and start the electric fan operation simu-
lation (see "Injection" chapter).
- If the electric fan is certainly efficient, check the
ventilation start and stop temperatures.

- Select the «PARAMETERS» function in this

menu to display the coolant temperature.
Electric fan starts: 107°C
Electric fan stops: 103°C
- If non-conforming values are detected, replace
the injection control unit (see «Injection» Chapter).
- If the analogue instrument temperature is close
to the red zone, but the degrees indicated by the
diagnostic tester are below the electric fan start
temperature, check the temperature sensor on the
head and the relevant injection circuit (see «Injec-
tion» chapter);
N.B.
THE ELECTRIC FAN TEMPERATURE AT 107° C CAN ONLY BE MANAGED BY A SYSTEM SUP-
PLIED WITH A 50% MIXTURE AND PRESSURISED AT 0.9 BAR.
AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOIL-
ING TEMPERATURE BEFORE THE ELECTRIC FAN STARTS WORKING.
IN CASE OF AN INCREASE OF THE ELECTRIC FAN START TIME, CHECK THE THERMOSTAT
OPENING TEMPERATURE AND CHECK THAT THE COOLANT DENSITY IS CORRECT. THE OP-
TIMUM DENSITY IS OBTAINED WITH A 50% WATER / 50% COOLING CIRCUIT FLUID MIXTURE.

System sealing check

- Check the proper circuit sealing when it is under

pressure and at the temperature.
- For a more accurate check, wait until the system
has cooled down since small leaks may not be
visible due to evaporation
- The water pump is provided with a drainage hole
in case of leaks from the cooling system mechan-
ical seal, or from the shaft sealing oil guard.

- If coolant or oil leaks are detected, replace the pump (see «Flywheel Cover» Chapter).
N.B.

COOL SYS - 318

MP3 400 i.e. Cooling system

DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OB-
SERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE SEALING GASKETS.

Coolant replacement

System filling instructions

- Prepare the mixture of 50% water and 50% cool-
ant.
- Fill the system to reach a level ranging between
the MIX and MAX levels indicated in the expansion
tank filler.
- Do not close the expansion tank with the cap.

- Use a transparent hose to connect the venting

union with the expansion tank filler.
- Loosen the vent and start the engine.

- Keep it open until the air has been fully vented.

- Close the bleed screw.
- Stop the engine.
- Restore the level into the expansion tank and tighten the cap.
- Start the engine and let it warm up to reach the electric ventilation temperature.
- Stop the engine.
- Restore the level with cold engine.
CAUTION
ELECTRIC VENTILATION IS CONTROLLED BY THE TEMPERATURE MEASURED AT THE HEAD.
THE ELECTRIC VENTILATION START DOES NOT MEAN THAT THE VENTING HAS BEEN COM-
PLETED.
VENTING IS COMPLETE WHEN THE EXPANSION TANK TEMPERATURE RISES.

Water pump

Water pump

If noise or loss of liquid at the drain hole of the water pump is discovered, replace the flywheel cover
and the water pump as described in the "Flywheel Cover" Chapter.

Proceed to carry out a few preliminary operations as described below:

COOL SYS - 319

Cooling system MP3 400 i.e.

• Place the vehicle on its centre stand and on flat ground.

• Remove the bodywork components as described in the "Bodywork" Chapter.
• Remove the muffler to access the flywheel cover as described in the "Removing the Engine
from the Vehicle" Chapter.
• Empty the cooling system, removing the hoses located on the water pump cover and the
loading cap located on the expansion tank.
CAUTION

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

• Remove the water pump cover shown
in the figure by loosening the 6 fasten-
ing screws.
• Proceed to partially drain the circuit as
described in the "Engine" Chapter.
• Once the fault has been fixed and all
components have been replaced, fill
and purge the system again.
N.B.
FOR CHANGING THE COOLANT AND BLEEDING THE
SYSTEM, SEE THE "COOLANT CHANGE" SECTION.

Characteristic
Cooling system
approx. 1.8 l

Removing the water pump cover:

- Check that the water pump cover is not deformed
or dented.
- Check that the sealing O-ring is in good working
order.
- Otherwise, replace the component.

- Correctly fit a new O-ring, do not allow it to come into contact with grease or oil.
CAUTION
FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O-RING.
- Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque.

Locking torques (N*m)

Water pump cover screws 3 ÷ 4
See also
Engine

COOL SYS - 320

MP3 400 i.e. Cooling system

Flywheel cover

Water pump - overhaul

If noise or loss of liquid at the drain bore of the

water pump is discovered, it will be necessary to
overhaul the pump as described in the «Engine/
Water pump» Chapter.
Proceed to carry out a few preliminary operations
as described below:
- Place the vehicle on its centre stand and on flat
ground.
- Remove the tail section as described in the
«Bodywork» Chapter.
- Empty the cooling system by removing the cou-
plings on the pump cover and the filler plug on the
expansion tank.
CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE

ENGINE IS COLD.

- Remove the water pump cover as indicated in the

figure by loosening the six fixing screws.
- Follow the instructions provided in the «Engine/
Water pump» chapter to inspect the pump.
- Refill and drain the system again once after hav-
ing repaired the damage and reinstalled all the
components.
N.B.
FOR CHANGING THE COOLANT AND BLEEDING THE
SYSTEM, SEE CHAPTER "COOLING SYSTEM".

Removing the water pump cover:

- Check that the water pump cover is not deformed
or dented.
- Check that the sealing O-ring is in good working
order.
- Otherwise, replace the component.

- Adequately fit a new O-ring, be careful to lubricate it with petroleum jelly grease.

COOL SYS - 321

Cooling system MP3 400 i.e.

N.B.
TO AVOID DEFORMATION, DO NOT LUBRICATE THE O-RING WITH PETROLEUM GREASE.
CAUTION
FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O-RING.
- Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque.
N.B.
FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM, SEE THE "COOLANT CHANGE"
SECTION.
Locking torques (N*m)
Water pump cover screws 3 ÷ 4

diagnosis

Excessive system pressure

1 - Check the expansion tank cap efficiency.

N.B.
THE CAP IS EQUIPPED WITH A PRESSURE-RELIEF VALVE CALIBRATED AT 0.9 BAR.
There is also a valve that must allow air inlet during the cooling step.
YES go to 2 NO go to 3
2 - Check the head gasket seal (see «Thermal group and timing system» chapter)
3 - Replace the cap.

Cooling fluid consumption

1 - Check the system outer seals as described above.

YES go to 2 NO go to 3
2 - Check the head gasket seal (see «Thermal group and timing system» chapter)
- If water leaks are detected in the engine oil, inspect the pad on the head cooling circuit.
3 - Fix any damaged seals.

Oil in the fluid

1 - Presence of oil in the coolant.

YES go to 2
2 - Check the head gasket seal (see «Thermal group and timing system» chapter)

COOL SYS - 322

INDEX OF TOPICS

CHASSIS CHAS
Chassis MP3 400 i.e.

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

Seat

- Raise the saddle.

- Undo the screw shown in the figure, remove the
cover and disconnect the rider presence sensor
connector.

- Remove the three fixing screws shown in the fig-

ure.

Rear handlebar cover

After removing the front part of the handlebar cov-

er, access the two screws fixing the rear part to the
handlebar, as indicated in the picture.

CHAS - 324
MP3 400 i.e. Chassis

Instrument panel

- Remove the front handlebar cover.

- Remove the legshield.
- Remove the shield back plate upper side.
- Unscrew the six fixing screws and remove the
instrument panel.

Front handlebar cover

- Remove the upper cap by operating on the Allen

screw indicated in the figure.

- Remove the two brake pump caps.

- Remove the two screws under the brake pump

caps previously removed.

CHAS - 325
Chassis MP3 400 i.e.

- Unscrew the two pairs of screws in the lower part

of the half-handlebar.

- Release the handlebar control locks.

- Remove the front handlebar cover.

Headlight assy.

Remove the radiator cover.

Remove the two wheelhouses with the turn indi-
cator.
Unscrew the two screws fixing the wheelhouse to
the shield.
Disconnect the cable guide; after that, turn the
wheelhouse anticlockwise (inwards) to release it
from the shield supports.

To remove the shield central finishing, remove the

PIAGGIO clip-on badge paying attention not to
spoil the paint, unscrew the screw underneath and
remove the finish carefully.

CHAS - 326
MP3 400 i.e. Chassis

Remove the four screws «A» and disconnect the

wiring.

See also
Radiator cover

Frame central cover

Remove the three screws on the right and the left

side.
Open the refuelling compartment and remove the
tank cap so as to remove the central cover.
Disconnect the cable, refuelling compartment
opening.

See also
Seat
Handles and top side fairings
Knee-guard

CHAS - 327
Chassis MP3 400 i.e.

Legshield

Remove the front headlight assembly.

Remove the spoiler.
Remove the two front screws and the two screws
under the wheelhouse.

Remove the four screws on the shield back plate.

See also

Headlight assy.
spoiler

Knee-guard

- Remove the legshield.

- Remove the spoiler.
- Remove the two central screws and the coolant
cap cover screw.

CHAS - 328
MP3 400 i.e. Chassis

- Remove the expansion tank fixing screw and the

frame from the instrument panel and manually re-
lease the unions with the shield back plate.
- Unhook the instrument panel wiring.

- Remove the six screws and the cable guide strap

in the front part of the shield back plate.

CHAS - 329
Chassis MP3 400 i.e.

- Remove the key switch plastic ring and the two

plastic covers near the footrest.

- Remove the five screws on the shield back plate

rear part.

- Remove the two shield back plate front screws,

see figure.

- Remove the two shield back plate lower screws.

- Remove the external temperature sensor con-
nection.

See also
spoiler
Legshield

CHAS - 330
MP3 400 i.e. Chassis

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

CHAS - 331
Chassis MP3 400 i.e.

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.

CHAS - 332
MP3 400 i.e. Chassis

Helmet bay

Remove the chassis central cover.

Remove the four external screws and the two
screws inside the rear case to remove the frame.

Remove the upper frame, unscrewing the ten up-

per screws, the two saddle closing screws and the
case light wiring.

CHAS - 333
Chassis MP3 400 i.e.

Remove the rear case internal screws indicated in

the picture, to detach the supporting plates of the
voltage regulator on one side and the saddle open-
ing switch on the other.
Remove the six upper screws.
Release the case latch.
Remove the case light front and rear switch con-
nections, the HV coil, the battery leads and the
fuse-box.

See also
Frame central cover

spoiler
Remove the shield central finish; then, screw the
six screws indicated in the figure.

Remove the five screws indicated in the figure.

See also

CHAS - 334
MP3 400 i.e. Chassis

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 also
Footrest

CHAS - 335
Chassis MP3 400 i.e.

Top-case

Rear

Remove the four fixing screws of the cover and

release it from the two leverages.

Handles and top side fairings

- Operating from the rear case remove the two

screws indicated in the photograph.
- Remove the ceiling fitting indicated in the photo-
graph and remove the internal screw indicated in
the photograph.
- Remove the backrest cushion.

CHAS - 336
MP3 400 i.e. Chassis

Remove the six screws indicated in the figure.

Radiator cover

MP3 400 i.e.

- Remove the two front screws indicated in the

photograph

Remove the two lower retainers with the bushing

- Remove the two rear retainers and then, the two

wheelhouse front retainers.

CHAS - 337
Chassis MP3 400 i.e.

- Remove the two screws fixing the radiator lower

protection to the shield back plate.
- After that, press up and pull the protection front
part so as to release it from the radiator frame.

MP3 400 i.e. RL

- Remove the two front screws indicated in the

photograph

- Remove the two lower retainers together with

bushing from under the grille.
- Remove the two screws located at the back of
the grille.

CHAS - 338
MP3 400 i.e. Chassis

- Remove the two rear retainers and then, the two

wheelhouse front retainers.

- Remove the two screws fixing the radiator lower

protection to the shield back plate.
- After that, press up and pull the protection front
part so as to release it from the radiator frame.

CHAS - 339
INDEX OF TOPICS

PRE-DELIVERY PRE DE
MP3 400 i.e. Pre-delivery

Carry out the listed tests before delivering the vehicle.

Warning - Be very careful when handling fuel.

Position the plastic cover supplied with the cou-

pling on the steering tube as shown in the figure.

If a customer wishes to have mudflaps installed,

proceed as follows:

• Place the flap in the mudguard inner

side as shown in the figure, making the
4 securing holes coincide.
• Fit the 4 washers on the mudguard out-
er side and, always on the same side,
insert the 4 screws and tighten to the
prescribed torque.

Locking torques (N*m)

flap fixing screws 2 ÷ 3

Aesthetic inspection

Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt

Tightening torques inspection

Lock check
- Safety locks
- Fixing screws
Safety locks

• Rear shock absorber upper fixing

• Rear shock absorber lower fixing

PRE DE - 341
Pre-delivery MP3 400 i.e.

• Front shock absorber upper fixing

• Front shock absorber lower fixing
• Sliding stems fixing
• Break callipers fixing
• Front wheels fixing screws
• Front wheels axle nut
• Rear wheel axle nut
• Chassis - engine swinging arm fixing
• Handlebar lock nut
• Lower ring nut for side steering tubes
• Upper ring nut for side steering tubes
• Lower ring nut for central steering tube
• Upper ring nut for central steering tubes
• Constant-velocity universal joints

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
• Electrical start up
• Engine stopping with emergency stop switch
• Electric opening of saddle with remote control
• Tilting system locking - unlocking button
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.

PRE DE - 342
MP3 400 i.e. Pre-delivery

IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE
OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

Levels check

Level check:
- Hydraulic brake system liquid level.
- Tilt locking system fluid level
- Rear hub oil level
- Engine coolant level
- Engine oil level

Road test

Test ride
- Cold start
- Instrument operations
- Response to the gas command
- Stability on acceleration and braking
- Rear and front brake efficiency
- Parking brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
- Tilting system locking - unlocking efficiency

Static test

Static control after the test ride:

• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION

PRE DE - 343
Pre-delivery MP3 400 i.e.

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

PRE DE - 344
INDEX OF TOPICS

TIME TIME
Time MP3 400 i.e.

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

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

Engine

ENGINE
Code Action Duration
1 001001 Engine to chassis - Replacement

TIME - 346
MP3 400 i.e. Time

ENGINE
Code Action Duration
1 001001 Engine to chassis - Replacement

Crankcase

TIME - 347
Time MP3 400 i.e.

CRANKCASE
Code Action Duration
1 001100 Oil seal, clutch side - Replacement
2 001133 Engine crankcase - Replacement
3 001153 Crankcase half gasket - Replace-
ment

Crankshaft

CRANKSHAFT
Code Action Duration
1 001117 Crankshaft - Replacement
2 001098 Countershaft - Replacement

TIME - 348
MP3 400 i.e. Time

Cylinder assy.

CYLINDER GROUP
Code Action Duration
1 001002 Cylinder / Piston - Replacement
2 001154 Pistonsrings-pin assembly - Service
3 001129 Chain tensioner - Service and Re-
placement

TIME - 349
Time MP3 400 i.e.

Cylinder head assy.

HEAD UNIT
Code Action Duration
1 001045 Valves - Replacement
2 001049 Valves - Adjustments
3 001056 Head gasket - Replacement
4 001126 Head - Replacement
5 001083 Thermistor - Replacement
6 007012 Coolant bleed valve - Replacement

TIME - 350
MP3 400 i.e. Time

Rocker arms support assy.

ROCKING LEVER SUPPORT UNIT

Code Action Duration
1 001044 Camshaft - Replacement
2 001148 Valve rocking levers - Replacement
3 001169 Pressure reducer - Replacement

TIME - 351
Time MP3 400 i.e.

Cylinder head cover

HEAD COVER
Code Action Duration
1 001089 Head cover - Replacement
2 001093 Spark plug - Replacement
3 001088 Head cover gasket - Replacement

TIME - 352
MP3 400 i.e. Time

Flywheel cover

FLYWHEEL COVER
Code Action Duration
1 001087 Flywheel cover - Replacement
2 001113 Water pump - Replacement
3 001123 Oil filter -Replacement
4 001124 By-pass valve - Replacement
5 001057 Thermostat - Replacement
6 001062 Water pump command shaft - Re-
placement
7 001150 Flywheel cover gasket - change
8 001160 Minimum oil pressure sensor - Re-
placement
9 007011 By-pass manifold - thermostat - drain
valve - Replacement
10 001074 Oil vapour recovery pipe - Replace-
ment

TIME - 353
Time MP3 400 i.e.

Driven pulley

DRIVEN PULLEY
Code Action Duration
1 001022 Clutch - Replacement
2 001012 Driven pulley - Overhaul
3 001110 Driven pulley - Replacement
4 001155 Clutch bell housing - Replacement

TIME - 354
MP3 400 i.e. Time

Oil pump

OIL PUMP
Code Action Duration
1 001042 Oil pump - Service
2 001051 Belt/ Timing chain - Replacement
3 001112 Oil pump - Replacement
4 001125 Chain guide sliders - Replacement
5 001071 Start-up pinion - Replacement
6 001020 Starter motor - Replacement
7 001102 Net oil filter - Replacement / Cleaning
8 003064 Engine oil - change
9 005045 Starter motor cable harness - Re-
placement

TIME - 355
Time MP3 400 i.e.

Final gear assy.

FINAL REDUCTION GEAR ASSEMBLY

Code Action Duration
1 001010 Geared reduction unit - Service
2 001156 Gear reduction unit cover - Replace-
ment
3 003065 Gearcase oil - Replacement
4 004125 Rear wheel axle - Replacement
5 002031 Rear wheel hub bearings - Replace-
ment

TIME - 356
MP3 400 i.e. Time

Driving pulley

DRIVING PULLEY
Code Action Duration
1 001086 Driving half-pulley - Replacement
2 001011 Driving belt - Replacement
3 001006 Driving pulley - Service
4 001141 Belt anti-flapping roller - Replace-
ment
5 001066 rear-view pulley - Replacement
6 001177 Variator rollers / shoes - Replace-
ment

TIME - 357
Time MP3 400 i.e.

Transmission cover

TRANSMISSION COVER
Code Action Duration
1 001065 Internal transmission cover - Re-
placement
2 001096 External transmission cover - Re-
placement
3 001131 Transmission air intake - Replace-
ment
4 001135 Transmission cover bearing - Re-
placement
5 001170 Air manifold - replacement

TIME - 358
MP3 400 i.e. Time

Flywheel magneto

MAGNETO FLYWHEEL
Code Action Duration
1 001173 Rotor - Replacement
2 001067 Stator - Removal and Refitting
3 001058 Complete flywheel - change
4 001104 Start-up freewheel - Replacement
5 001151 Start-up driven gearing - Replace-
ment

TIME - 359
Time MP3 400 i.e.

Butterfly valve

THROTTLE BODY
Code Action Duration
1 001013 Intake manifold - Replacement
2 001047 Injector - Replacement
3 001023 Control unit - Replacement

TIME - 360
MP3 400 i.e. Time

Exhaust pipe

MUFFLER
Code Action Duration
1 001009 Muffler - Replacement
2 001092 Exhaust manifold - Replacement
3 001095 Muffler guard - Replacement
4 004169 Muffler guard - Replacement
5 005138 Lambda probe - Replacement

TIME - 361
Time MP3 400 i.e.

Air cleaner

AIR CLEANER
Code Action Duration
1 001015 Air filter box - Replacement
2 001014 Air filter - Replacement / cleaning
3 004122 Air cleaner/ carburettor union - Re-
placement

TIME - 362
MP3 400 i.e. Time

Frame

FRAME
Code Action Duration
1 004146 Front frame - Replacement
2 004116 Rear frame - Replacement
3 004001 Frame - Replacement
4 004147 footboard support bracket one side -
Replacement
5 004143 Footrest support - Replacement

TIME - 363
Time MP3 400 i.e.

Centre-stand

STAND
Code Action Duration
1 004004 Stand - Replacement
2 004179 Stand buffer - Replacement

Legshield spoiler

TIME - 364
MP3 400 i.e. Time

LEGSHIELD
Code Action Duration
1 004020 Headlight frame - Replacement
2 004064 Legshield - Replacement
3 004055 Turning indicator frame - Replace-
ment
4 004149 Shield central cover - Replacement
5 004022 Shield lower section - Replacement
6 004167 Grille / radiator cover - Replacement

Side fairings

SIDE COVERS
Code Action Duration
1 004036 Lower chassis cover - Replacement
2 004129 Rear fairing - Replacement
3 004085 Fairing (1) - Replacement
4 004068 Passenger handgrip - Replacement
5 004037 Side aprons-Replacement

TIME - 365
Time MP3 400 i.e.

Rear cover

REAR SHIELD
Code Action Duration
1 004065 Legshield, rear part - Removal and
refitting

TIME - 366
MP3 400 i.e. Time

Central cover

CENTRAL COVER
Code Action Duration
1 004059 Spark plug inspection flap - Replace-
ment
2 004135 Fuel tank port - Replacement
3 004011 Central frame cover - Replacement
4 004012 Rear fairings - Removal and refitting
5 004015 Footrest - Removal and Refitting
6 004075 Front mat - Replacement

TIME - 367
Time MP3 400 i.e.

Mudguard

MUDGUARDS
Code Action Duration
1 007015 Radiator air intake - Replacement
2 004009 Rear mudguard - Replacement
3 004181 Lower cover - Replacement
4 004184 Front mudguard support - replace-
ment
5 004002 Front mudguard - change

TIME - 368
MP3 400 i.e. Time

Fuel tank

FUEL TANK
Code Action Duration
1 004137 Injector pump pipe - Replacement
2 005010 Tank float - Replacement
3 004109 Fuel tank breather - change
4 004168 Fuel tank cap - Replacement
5 004138 Fuel reverse pipe - Replacement
6 004005 Fuel tank - Replacement
7 004073 Fuel pump - Replacement

TIME - 369
Time MP3 400 i.e.

Rear shock-absorber

REAR SHOCK ABSORBERS

Code Action Duration
1 003007 Rear shock absorber - Removal and
Refitting
2 003035 Shock absorber support and brake
calliper - Replacement
3 003077 muffler/rear shock absorber support
arm - Service

TIME - 370
MP3 400 i.e. Time

Handlebar covers

HANDLEBAR COVERS
Code Action Duration
1 000307 RIGHT OR LEFT CONTROL AS-
SEMBLY REPLACEMENT
2 004019 Rear handlebar covers - Replace-
ment
3 004026 Handlebar cover - Replacement
4 004018 Front handlebar covers - Replace-
ment

TIME - 371
Time MP3 400 i.e.

Handlebar components

HANDLEBAR COMPONENTS
Code Action Duration
1 002059 Right-hand knob - Replacement
2 002060 Complete throttle control - Replace-
ment
3 002063 Complete throttle transmission - Re-
placement
4 003001 Handlebar - Replacement
5 002071 Left knob - Replacement
6 003059 Counterweight - Replacement
7 002037 Brake lever - Replacement
8 002048 Rear brake calliper - Replacement
9 002067 Rear brake pump - Replacement
10 002080 Rear brake oil bleed system -
Change
11 004162 Mirror support and/or brake pump fit-
ting U-bolt - Replacement
12 002024 Front brake pump - Replacement
13 002047 Front brake fluid and air bleed sys-
tem - Replacement

TIME - 372
MP3 400 i.e. Time

Swing-arm

SWINGING ARM
Code Action Duration
1 004058 Silent block - Replac.
2 003081 Swinging arm support flange - Re-
placement
3 001072 Engine-frame connection swinging
arm - Replacement
4 003080 Swinging arm on frame - Replace-
ment

TIME - 373
Time MP3 400 i.e.

Seat

SADDLE
Code Action Duration
1 004003 Saddle - Replacement

TIME - 374
MP3 400 i.e. Time

Instrument panel

INSTRUMENT PANEL
Code Action Duration
1 004021 Shield upper section - Replacement
2 005014 Odometer - Replacement
3 004099 Odometer housing - Replacement
4 004035 Instrument panel - Replacement

TIME - 375
Time MP3 400 i.e.

Locks

LOCKS
Code Action Duration
1 004172 Rear case lock catch - Replacement
2 005099 Saddle opening electric-actuator -
Replacement
3 004054 Saddle lock catch - Replacement
4 004001 Frame - Replacement
5 005072 Immobilizer aerial - Replacement

Turn signal lights

Rear lights

TIME - 376
MP3 400 i.e. Time

REAR TURNING INDICATOR LIGHTS

Code Action Duration
1 005005 Taillight - change
2 005022 Rear turning indicators - Replace-
ment
3 005031 number plate light bulb - Replace-
ment
4 005032 number plate light glass - Replace-
ment
5 005131 number plate light support - Replace-
ment
6 005066 Rear light bulbs - Replacement
7 005068 Rear turning indicator bulb - Re-
placement

Front lights

TIME - 377
Time MP3 400 i.e.

FRONT TURNING INDICATOR LIGHTS

Code Action Duration
1 005067 Front turning indicator bulb - replace-
ment
2 005012 Front turning indicators - Replace-
ment
3 005002 Front light - replacement
4 005008 Headlight bulbs - Replacement

TIME - 378
MP3 400 i.e. Time

Front wheel

FRONT WHEELS
Code Action Duration
1 003047 Front tyre - Replacement
2 003033 Front wheel hub- Replacement
3 003037 Front wheel rim - Replacement
4 005089 Tone wheel - Replacement
5 002041 Front brake disc - Replacement
6 004123 Front wheel - Replacement

TIME - 379
Time MP3 400 i.e.

Rear wheel

REAR WHEEL
Code Action Duration
1 002070 Rear brake disc - Replacement
2 001016 Rear wheel - Replacement
3 001071 Front wheel rim - Removal and Re-
fitting
4 004126 Rear wheel tyre - Replacement

TIME - 380
MP3 400 i.e. Time

Electric devices

ELECTRIC DEVICES
Code Action Duration
1 005075 Stop remote control - Replacement
2 005035 Headlight remote control - Replace-
ment
3 005011 Starter remote control switch - Re-
placement
4 005007 Battery - change
5 005003 Horn - Replacement

TIME - 381
Time MP3 400 i.e.

CABLE HARNESS
Code Action Duration
1 005001 Electrical system - Replacement
2 005114 Electrical system - Service

Electronic controls

TIME - 382
MP3 400 i.e. Time

HANDLEBAR CONTROLS
Code Action Duration
1 005017 Stop switch - Replacement
2 005077 Emergency stop switch - Replace-
ment
3 005041 Starter button - Replacement
4 004010 Antitheft lock - Replacement
5 005040 Horn button - Replacement
6 005006 Light or turning indicator switch - Re-
placement
7 005039 Lights switch - Replacement
8 005142 Unlocking switch - Replacement
9 005143 Mode button - Replacement
10 005084 Emergency light switch - Replace-
ment

Transmissions

LOCKS TRANSMISSIONS
Code Action Duration
1 003094 Tilt locking calliper control cable - re-
placement
2 002082 Fuel tank door opening drive - Re-
placement
3 002083 Saddle opening transmission - Re-
placement
4 002093 Top box opening transmission - Re-
placement
5 003061 Accelerator transmission - adjust

TIME - 383
Time MP3 400 i.e.

Helmet bay

HELMET COMPARTMENT
Code Action Duration
1 005046 Battery cover - change
2 005026 Helmet compartment bulb - Replace-
ment
3 005027 Helmet compartment bulb support -
Replacement
4 004016 Helmet compartment - Replacement
5 004142 electric socket - Replacement

TIME - 384
MP3 400 i.e. Time

Rear side fairings

REAR COVERS
Code Action Duration
1 004081 Top box lid - Replacement
2 004174 Top box leverage
3 004141 Cat's eye - Replacement
4 005048 number plate holder - Replacement
5 004082 Top box gasket - Replacement

TIME - 385
Time MP3 400 i.e.

Front suspension

FRONT SUSPENSION
Code Action Duration
1 003010 Front suspension - Service
2 003111 Side steering tube - replacement
3 003038 Front wheel axle - Remov. and refitt.
4 003040 Front wheel bearings - Replacement
5 003107 Sliding stems - replacement
6 003113 Front shock absorber - replacement

TIME - 386
MP3 400 i.e. Time

Cooling system

COOLING SYSTEM
Code Action Duration
1 007013 Radiator expansion tank connection
pipe - change
2 001052 Coolant and air bleed - Replacement
3 007001 Expansion tank - Replacement
4 007024 Expansion tank cap - Replacement
5 007003 Coolant delivery and return pipe -
change
6 007016 Fan with support - Replacement
7 007002 Water radiator - replacement

TIME - 387
Time MP3 400 i.e.

Braking system

BRAKE SYSTEM
Code Action Duration
1 002025 Brake piping - Replacement
2 003096 Tilt locking calliper- replacement
3 003100 Tilt locking calliper pads - replace-
ment
4 003108 Parking brake flexible transmission -
replacement
5 003109 Parking brake mechanical calliper -
replacement
6 002002 Shoes - Rear brake pads - Replace-
ment
7 002020 Rear brake pipes - Removal and re-
fitting
8 002081 Rear brake disc piping - Replace-
ment
9 003118 Tilt locking disc section - replace-
ment
10 003103 Splitter for suspension locking sys-
tem pipes- replacement
11 003102 Pipes for the splitter-calliper suspen-
sion locking system - replacement

TIME - 388
MP3 400 i.e. Time

Code Action Duration

12 003088 Tilt locking hydraulic pump - replace-
ment
13 002021 Front brake piping - Replacement
14 002007 Front brake pads - Replacement
15 002039 Front brake calliper - Replacement
16 003104 Suspension system locking calliper-
replacement
17 003119 Pipes for the pump-splitter suspen-
sion locking system - replacement
18 003105 Suspension locking system brake
fluid - repl.
19 003106 Suspension locking system pressure
sensor - Replacement
20 003121 Parking brake control lever - replace-
ment
21 003122 Parking brake control lever micro-
switch - replacement

Windscreen

WINDSCREEN
Code Action Duration
1 004101 Windscreen - Replacement

TIME - 389
Time MP3 400 i.e.

Stickers

TRANSFERS
Code Action Duration
1 004066 Driving mirror - Replacement
2 004159 Plates / Stickers - Replacement

TIME - 390
MP3 400 i.e. Time

The tilt mechanism

TILT MECHANISM
Code Action Duration
1 003073 Steering clearance - Adjustment
2 003112 Central steering tube - replacement
3 003002 Steering fifth wheels - Replacement
4 003115 Parallelogram arms - replacement
5 003114 Parallelogram bearings - replace-
ment
6 003116 Steering rod - replacement
7 003117 Constant-velocity universal joint - re-
placement

TIME - 391
Time MP3 400 i.e.

Geared motor

GEARED MOTOR
Code Action Duration
1 003101 Tilt locking calliper control lever - re-
placement
2 005009 Voltage regulator - Replacement
3 003095 Tilt locking calliper support bracket -
replacement
4 001069 HV coil - Replacement
5 001094 Spark plug cap - Replacement
6 003120 Tilt locking control unit - replacement
7 003093 Geared motor crankcase - replace-
ment
8 003090 Geared electric motor - replacement
9 003092 Geared motor bearings - replace-
ment
10 003091 Geared motor pinion - replacement
11 003089 Geared motor potentiometer - re-
placement
12 003097 Tilt locking caliper micro-switch - re-
placement

TIME - 392
A
Air filter: 38

B
Battery: 61, 76, 81
Brake: 302, 304, 305, 307, 309, 310, 312, 313

C
Coolant: 238, 319

E
Engine oil: 39

F
Fuel: 209, 217, 335, 369
Fuses: 78

H
Headlight: 44, 326, 328, 335
Hub oil: 37

I
Identification: 8
Instrument panel: 325, 375

L
Light switch:

M
Maintenance: 7, 34

O
Oil filter: 41

S
Saddle:
Shock absorbers: 299
Spark plug: 36, 235
Stand:
Start-up:

T
Tank: 335, 369
Transmission: 11, 46, 95, 110, 358
Turn indicators: 68
Tyres: 12