PIAGGIO MP3 500 i.e. SPORT Mode d’emploi

SERVICE STATION MANUAL

1Q000267 EN

MP3 500 i.e. SPORT Business_LT_ ABS-

ASR_EU_USA (2015)

SERVICE STATION

MANUAL

MP3 500 i.e. SPORT Business_LT_ ABS-

ASR_EU_USA (2015)

Thedescriptionsandimagesinthispublicationaregivenforillustrativepurposesonlyandarenotbinding.

While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &

C.S.p.A.reservestheright,atanytimeandwithoutbeingrequiredtoupdatethispublicationbeforehand,

to make any changes to components, parts or accessories, which it considers necessary to improve the

product or which are required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of each

model should be checked at the official PIAGGIO sales network.

in part is prohibited.

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

www.piaggio.com

SERVICE STATION MANUAL

MP3 500 i.e. SPORT

Business_LT_ ABS-

ASR_EU_USA (2015)

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of

Piaggio 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 indicate the 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

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

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

Safety rules

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

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

fumes are toxic.

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

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

and seek immediate medical attention.

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

or flames near the battery, especially when charging it.

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

area, and avoid naked flames or sparks.

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

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

contains no asbestos, inhaling dust is harmful.

Maintenance rules

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

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

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

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

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

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

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,

nuts and screws are not interchangeable with coupling members using English measurements. Using

unsuitable coupling members and tools may damage the vehicle.

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

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

tions.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 7

Vehicle identification

The identification registration numbers consist of

a prefix stamped on the chassis and engine "B"

respectively, followed by a number. These num-

bers must always be indicated on spare parts re-

quests. To read the chassis number, remove the

relevant port "A" in the helmet compartment. We

recommend checking that the chassis registration

number stamped on the vehicle corresponds with

that on the vehicle documentation.

CAUTION

PLEASE REMIND THAT ALTERING IDENTIFICATION REG-

ISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL

SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Frame prefix (VERSION EQUIPPED WITH ABS - ASR SYS-

TEM) ZAPM86100

Frame prefix (VERSION NOT EQUIPPED WITH ABS - ASR

SYSTEM) ZAPM86101

Frame prefix USA/CND ZAPM860X

Engine prefix M861M

Engine prefix USA/CND M863M

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 8

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity

Length 2205 mm (86.8 in)

Width 775 mm (30.5 in)

Maximum height 1460 mm (57.5 in)

Wheelbase 1540 mm (60.6 in)

Track 465 mm (18.3 in)

Kerb weight 266 kg (586 lb)

Maximum weight limit 460 kg (1014 lb)

Engine

ENGINE TECHNICAL DATA

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Engine capacity 493 cm³

Bore x Stroke 94 x 71 mm

Compression ratio 10.5 ± 0.5 : 1

Engine idle speed 1,600 ± 100 rpm

Timing system Four valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.15 mm

Outlet: 0.15 mm

MAX. power 29.5 kW at 7,250 rpm

MAX. torque 45.5 Nm at 5,250 rpm

Transmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmission

housing with forced-circulation air cooling.

Final reduction with gear reduction unit in oil bath.

Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.

MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015)

Characteristics

CHAR - 9

Specification Desc./Quantity

Cooling Forced coolant circulation system.

Electric Electric starter

Ignition Highly efficient electronic inductive ignition, integrated with the

injection system, with variable advance, separate HV coil and

double spark plug.

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EKB

Electrode gap 0.7 ÷ 0.9 mm

Fuel system By electronic injection with electric fuel pump.

Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter and

lambda probe.

Emissions compliance EURO 2

Transmission

TRANSMISSION

Specification Desc./Quantity

TRANSMISSION Automatic expandable pulley variator with torque server, V-

belt, automatic clutch.

Final reduction with gear reduction unit in oil bath.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 0.44 gal (1.7 l)

Transmission oil 15.3 in³ (250 cm³)

Cooling system fluid ~ 0.47 gal (~ 1.8 l)

Fuel tank 3.2 gal ± 0.1 (12.0 ± 0.5 l)

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Electric Electric starter

Ignition Electronic, inductive, high efficiency, integrated with the injec-

tion system, with variable advance separate HV coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EKB

Alternative spark plug -

Battery 12V-12Ah

Alternator alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification Desc./Quantity

Chassis Tubular and sheet steel

Front suspension The roll system is composed of an articulated parallelogram

suspension with die-cast aluminium control arms and two side

headstocksplusshockabsorberswithhydrauliclockingsystem

Front suspension travel 85 mm

Rear suspension Two double-acting shock absorbers, adjustable to four posi-

tions at preloading.

Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA

(2015)

CHAR - 10

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