PIAGGIO MP3 400 i.e. Manuel utilisateur

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 shown in this publication are available in all Countries. The availability of single versions

should be checked at the official Piaggio sales network.

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 Sectionsmarked with this symbol indicatethe correct use of thevehicle

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

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 open flames or sparks.

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

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

contains no asbestos, inhaling dust is harmful.

Maintenance rules

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

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

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

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

work surfaces except the tapered couplings before refitting.

- 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

suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.

Characteristics MP3 400 i.e.

CHAR - 2

Vehicle identification

Chassis prefix (A)

ZAPM59101

Engine prefix (B):

M474M

Dimensions and mass

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

MP3 400 i.e. Characteristics

CHAR - 3

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 Fourvalves, single overhead camshaft, chaindriv-

en.

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 Enginelubrication with trochoidal pump(insidethe

crankcase), oil filter and pressure adjustment by-

pass.

Lubrication pressure 3.5 ÷ 4 bar

Minimum lubrication pressure (100° C) 0.8 bar

Fuel supply Electronicinjection with Ø38-mm throttle bodyand

electric fuel pump.

Cooling Forced coolant circulation system.

Fuel Unleaded petrol (95 RON)

Characteristics MP3 400 i.e.

CHAR - 4

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