SERVICE STATION MANUAL

XXXXXXX

MP3 LT 250 i.e.

SERVICE STATION MANUAL

MP3 LT 250 i.e.

The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official PIAGGIO sales network. Copyright 2011 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy www.piaggio.com

SERVICE STATION MANUAL

MP3 LT 250 i.e.
This service station manual has been drawn up by Piaggio & C. SpA to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle repairing techniques and procedures. Any significant changes made to the vehicle characteristics or to specific repair operations will be promptly 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 TOOLING MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE INJECTION SUSPENSIONS BRAKING SYSTEM COOLING SYSTEM CHASSIS PRE-DELIVERY TIME

CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG INJEC SUSP BRAK SYS COOL SYS CHAS PRE DE TIME

INDEX OF TOPICS

CHARACTERISTICS

CHAR

MP3 LT 250 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 spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.

CHAR - 7

Characteristics

MP3 LT 250 i.e.

Vehicle identification
Chassis prefix: M64100 Engine prefix: M632M

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification kerb weight Wheelbase Height Width Length Track Desc./Quantity 224 5 kg 1490 mm 1350mm 760 mm 2160 mm 465 mm

Engine
DATA
Specification Type Desc./Quantity single-cylinder, four-stroke and four liquid-cooled valves

CHAR - 8

MP3 LT 250 i.e.

Characteristics

Specification Timing system Bore Stroke Cubic capacity Compression ratio Air filter Starting system Lubrication Fuel system valve clearance Engine idle speed Max. speed

Desc./Quantity single overhead camshaft, chain-driven, on the left-hand side, three-arm rocking levers set up with threaded set screw 72 mm 60 mm 244.29 mm 10.5 11.5 sponge, impregnated with mixture (50% petrol and 50% oil) electric starter motor with freewheel with lobe pump (inside the crankcase) chain-driven and double filter: mesh and paper Electronic injection with electric fuel pump intake: 0.10 mm - exhaust: 0.15 mm approx. 1,600 - 1,800 rpm 125 km/h

Transmission
TRANSMISSION
Specification Transmission Desc./Quantity Automatic expandable pulley CVT with torque server, V-belt, automatic clutch, gear reduction unit and transmission compartment with forced air circulation cooling

Capacities
CAPACITY
Specification Engine oil Rear hub Fuel tank capacity Fuel reserve Cooling circuit Desc./Quantity approx. 1300 cm (recommended oil Selenia HI Scooter 4 Tech) 250 cm (recommended oil TUTELA MATRIX) Tank capacity: ~12 l (approximate value) ~ 2.5 litres (approx. value) Capacity: ~ 2.0 l

Electrical system
ELECTRICAL COMPONENTS
Specification Ignition/advance Spark plug Battery Generator Desc./Quantity Electronic, with inductive discharge and variable advance with three-dimensional mapping CHAMPION RG 4 PHP 12V-12Ah alternating current

Frame and suspensions

CHASSIS AND SUSPENSION
Specification Chassis Rear suspension Front suspension Desc./Quantity Tubular and steel sheets. Single arm with two double-acting hydraulic shock absorbers and preloading adjustment in 4 positions. The roll system is composed of an articulated parallelogram suspension with die-cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system.

CHAR - 9

Characteristics

MP3 LT 250 i.e.

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

Wheels and tyres

WHEELS AND TYRES
Specification Front wheel Rear wheel Front tyre Rear tyre Desc./Quantity Alloy wheel rims: 12" x 3.00" Alloy rim: 12"x3.00 without inner tube 120/70-12" Without inner tube: 130/70-12" 62P

TYRE PRESSURE
Specification Front tyre pressure (rider) Front tyre pressure (rider and passenger) Rear tyre pressure (rider) Rear wheel pressure (rider and passenger): N.B. Desc./Quantity Front tyre pressure (rider): 1.6 bar Front tyre pressure (rider and passenger): 1.8 bar Rear tyre pressure (rider): 2 bar Rear tyre pressure (rider and passenger): 2.4 bar

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

Tightening Torques
STEERING
Name Steering lower ring nut (central headstock) Steering upper ring nut (central headstock) Handlebar fixing screw Fixing screws for the handlebar control unit U-bolts Torque in Nm 10 to 12 22.5 to 25 50 55 7 to 10

CHASSIS
Name Engine arm bolt - frame arm Swinging arm buffer nut Engine-swinging arm pin Frame-swinging arm bolt Centre stand bolt Torque in Nm 33 to 41 64 - 72 55 - 61 55 - 61 31 - 39

FRONT SUSPENSION
Name Shock absorber lower clamping Shock absorber upper clamp Front wheel fixing screws Steering arm bolt nut Tilt gripper fixing screws Front wheel axle Arm coupling screws Screws fixing arms to side headstocks Torque in Nm 19 - 26 19 - 29 19 24 20 to 25 20 to 25 74 - 88 45 to 50 45 to 50

CHAR - 10

MP3 LT 250 i.e.

Characteristics

Name Screws fixing arms to central headstock Screws fixing the half-arm coupling flange Screws fixing roll lock disc section Side headstock upper ring nut Side headstock lower ring nut Screw fixing sliding stem to shock absorber Clamp for sliding stem locking device Fixing nuts for constant-velocity universal joints Potentiometer to anti-tilting device clamp Electric motor to anti-tilting device clamp Clamp fixing pump bolt to anti-tilting device Pump to anti-tilting device clamp Pressure switch to distribution frame Sensor to tilt gripper clamp Pipe terminals to fifth wheel check spring Joint to anti-tilting device pump Lower fitting for shock absorber sliding locking clamp pipes Upper fitting for shock absorber sliding locking clamp pipes

Torque in Nm 45 to 50 20 to 25 20 to 25 20 - 24 12 15 45 to 50 6.5 - 10.5 18 - 20 8 to 10 11 to 13 11 to 13 11 to 13 18 - 20 2.5 - 2.9 7 - 11 20 to 25 20 to 25 20 to 25

REAR SUSPENSION
Name Shock absorber upper clamp Shock absorber lower clamping Shock absorber-crankcase attachment bracket Rear wheel axle Silencer arm clamping screws Torque in Nm 33 to 41 33 to 41 20 to 25 104 to 126 27 - 30

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

REAR BRAKE
Name Rear brake disc screws() Rear brake calliper-pipe fitting Rigid / flexible pipe fitting Rear brake pump-pipe fitting Rear brake calliper fixing screws Torque in Nm 5 to 6.5 20 to 25 13 - 18 16 - 20 20 to 25

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

INTEGRAL BRAKE
Name Pipe joints to valves fitting Front valve oil bleed screw Fixing front and rear valves to chassis Torque in Nm 20 to 25 58 6-7

SILENCER
Name Silencer heat guard fixing screw Screw for fixing silencer to supporting arm Lambda probe tightening on exhaust manifold Exhaust manifold-silencer joint tightening Manifold - silencer diaphragm tightening clamp Torque in Nm 4 to 5 20 to 25 40 to 50 12 to 13 16 to 18

CHAR - 11

Characteristics

MP3 LT 250 i.e.

LUBRICATION
Name Hub oil drainage plug Oil filter on crankcase fitting Engine oil drainage plug/ mesh filter Oil filter Oil pump cover screws Screws fixing oil pump to the crankcase Oil pump command sprocket screw Oil pump cover plate screws Oil sump screws Minimum oil pressure sensor Torque in Nm 15 to 17 27 to 33 24 to 30 4 to 6 7-9 5 to 6 10 to 14 4 to 6 10 to 14 12 to 14

CYLINDER HEAD
Name Spark plug Head cover screws Nuts fixing head to cylinder Head fixing side screws Starter ground screw Tappet adjustment check nut Intake manifold screws Timing chain tensioner slider screw Starter counterweight support screw Timing chain tensioner support screw Timing chain tensioner central screw Camshaft retention plate screw Torque in Nm 12 to 14 6-7 71 + 101 + 270 11 - 12 7 to 8.5 6-8 11 to 13 10 to 14 11 to 15 11 to 13 5 to 6 4 to 6

TRANSMISSION
Name Belt support roller screw Clutch unit nut on driven pulley Drive pulley nut Transmission cover screws Driven pulley shaft nut Rear hub cap screws Torque in Nm 11 to 13 45 to 50 75 - 83 11 to 13 54 60 24 to 27

FLYWHEEL
Name Flywheel cover screw Stator assembly screws Flywheel nut Pick-up fixing screws Screw fixing freewheel to flywheel Torque in Nm 11 to 13 3 - 4 (Apply LOCTITE medium type 242 threadlock) 94 - 102 3 to 4 13 - 15

CRANKCASE AND CRANKSHAFT

Name Internal engine crankcase bulkhead (transmission-side half shaft) screws Engine-crankcase coupling screws Starter screws Crankcase timing cover screws Torque in Nm 4 to 6 11 to 13 11 to 13 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)

COOLING
Name Water pump rotor cover Thermostat cover screws Bleed screw Torque in Nm 3 to 4 3 to 4 3

CHAR - 12

MP3 LT 250 i.e.

Characteristics

Overhaul data Assembly clearances Cylinder - piston assy.

ENGINE COUPLING CATEGORY

Name Cylinder Cylinder Piston Piston Initials M N O P Cylinder 72.01 72.017 72.017 72.024 72.024 72.031 72.031 72.038 Piston 71.953 71.960 71.960 71.967 71.967 71.974 71.974 71.981 Play on fitting 0.050 - 0.064 0.050 - 0.064 0.050 - 0.064 0.050 - 0.064

Crankcase - crankshaft - connecting rod

CRANKSHAFT
Titolo Crankshaft Durata/Valore Testo Breve (< 4000 car.) Axial clearance between crankshaft and connecting rod Indirizzo Immagine

Axial clearance between crankshaft and connecting rod

CHAR - 13

Characteristics

MP3 LT 250 i.e.

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Transmissionside halfshaft Flywheel-side halfshaft Connecting rod Spacer tool Description Dimensions 16.6 +0-0.05 16.6 +0-0.05 18 -0.10 -0.15 51.4 +0.05 Initials A B C E Quantity D = 0.20 0.50 D = 0.20 0.50 D = 0.20 0.50 D = 0.20 0.50

Slot packing system

Characteristic
Compression ratio 10.5 11.5 : 1

CHAR - 14

MP3 LT 250 i.e.

Characteristics

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
N.B.

MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE, EQUIPPED WITH A SUPPORT, ON A GROUND PLANE

ENGINE 250 SHIMMING

Name SHIMMING SHIMMING SHIMMING Measure A 3.70 - 3.60 3.60 - 3.40 3.40 - 3.30 Thickness 0.4 0.05 0.6 0.05 0.8 0.05

CHAR - 15

Characteristics

MP3 LT 250 i.e.

Products
RECOMMENDED PRODUCTS TABLE
Product AGIP ROTRA 80W-90 AGIP CITY HI TEC 4T AGIP FILTER OIL AGIP GP 330 AGIP CITY HI TEC 4T AGIP BRAKE 4 AGIP PERMANENT SPEZIAL Description Rear hub oil Oil to lubricate flexible transmissions (throttle control) Oil for air filter sponge Grease for brake lever, gas Engine oil Brake fluid coolant Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Oil for 4-stroke engines Mineral oil with specific additives for increased adhesiveness White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2 SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil FMVSS DOT 4 Synthetic fluid Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16

CHAR - 16

INDEX OF TOPICS

TOOLING

TOOL

Tooling

MP3 LT 250 i.e.

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

001467Y014

Calliper to extract 15-mm bearings

005095Y

Engine support

002465Y

Calliper for circlips

006029Y

Punch for fitting steering bearing seat on steering tube

020004Y

Punch for removing steering bearings from headstock

020055Y

Wrench for steering tube ring nut

TOOL - 18

MP3 LT 250 i.e.

Tooling

Stores code 020074Y

Description Support base for checking crankshaft alignment

020150Y

Air heater mounting

020151Y

Air heater

020193Y

Oil pressure check gauge

020262Y

Crankcase splitting plate

020263Y

Driven pulley assembly sheath

TOOL - 19

Tooling

MP3 LT 250 i.e.

Stores code 020306Y

Description Punch for assembling valve seal rings

020329Y

Mity-Vac vacuum-operated pump

020330Y

Stroboscopic light to check timing

020331Y

Digital multimeter

020332Y

Digital rpm indicator

TOOL - 20

MP3 LT 250 i.e.

Tooling

Stores code 020333Y

Description Single battery charger

020334Y

Multiple battery charger

020335Y

Magnetic mounting for dial gauge

020357Y 020359Y

32x35-mm Adaptor 42x47-mm Adaptor

020360Y

52x55-mm Adaptor

TOOL - 21

Tooling

MP3 LT 250 i.e.

Stores code 020363Y

Description 20-mm guide

020375Y

28 x 30 mm adaptor

020376Y

Adaptor handle

020382Y

Valve cotters equipped with part 012 removal tool

020382Y011

adapter for valve removal tool

020393Y

Piston assembly band

TOOL - 22

MP3 LT 250 i.e.

Tooling

Stores code 020412Y

Description 15-mm guide

020423Y

Driven pulley lock wrench

020424Y

Driven pulley roller casing fitting punch

020426Y

Piston fitting fork

020431Y

Valve oil seal extractor

020434Y

Oil pressure check fitting

TOOL - 23

Tooling

MP3 LT 250 i.e.

Stores code 020444Y

Description Tool for fitting/ removing the driven pulley clutch

020456Y 020477Y

24 mm adaptor 37 mm adaptor

020483Y

30-mm guide

020489Y

Hub cover support stud bolt kit

020428Y

Piston position check mounting

TOOL - 24

MP3 LT 250 i.e.

Tooling

Stores code 020680Y

Description Diagnosis Tool

020621Y

HV cable extraction adaptor

020481Y

Control unit interface wiring

001467Y035

Bearing housing, out 47 mm

020626Y

Driving pulley lock wrench

001467Y013

Calliper to extract 15-mm bearings

TOOL - 25

Tooling

MP3 LT 250 i.e.

Stores code 020627Y

Description Flywheel lock wrench

020467Y

Flywheel extractor

020454Y

Tool for fitting piston pin stops (200 - 250)

020622Y

Transmission-side oil seal punch

020480Y

Petrol pressure check kit

020244Y

15-mm diameter punch

TOOL - 26

MP3 LT 250 i.e.

Tooling

Stores code 020115Y

Description 18 punch

020271Y

Tool for removing-fitting silent bloc

020469Y

Reprogramming kit for vehicle diagnostic tester

020481Y004

Parking control unit interface wiring

020639Y

Roll lock control unit software

TOOL - 27

Tooling

MP3 LT 250 i.e.

Stores code 020645Y

Description MIU software updating with CAN lines

001467Y017

Driver for OD 36 mm bearings

020234y 020441Y

extractor 26 x 28 mm adaptor

020362Y

12 mm guide

020358Y 001467Y002

37x40-mm Adaptor Driver for OD 73 mm bearing

TOOL - 28

MP3 LT 250 i.e.

Tooling

Stores code 020646Y

Description Parallelogram and steering positioning tool

020647Y

Toe-in checking tool

020647Y028

MP3 LT Toe-in tool (tricycle)

TOOL - 29

INDEX OF TOPICS

MAINTENANCE

MAIN

MP3 LT 250 i.e.

Maintenance

ADJUSTMENT PROCEDURE OF THE RING NUTS OF THE SIDE HEADSTOCKS Remove the Piaggio clip-on badge with a flatheaded screwdriver

Undo the screw under the badge and remove the centre headlight cover

Undo the screws "A" fastening the front grille

On both sides of the vehicle, undo the screw "B" at the bottom of the front grille surround and retrieve the shim

On both sides of the vehicle, undo the screws "C" inside the front wheel housing

MAIN - 31

Maintenance

MP3 LT 250 i.e.

Undo the screws "D" and remove the front grille surround

Undo the two upper fastener screws "E" for the headlight assembly

Undo the two lower fastener screws "F" and remove the headlight assembly from its seat

Undo the indicated screws and remove the windscreen

Undo the indicated screws and remove the spoiler

Undo the indicated screws

MAIN - 32

MP3 LT 250 i.e.

Maintenance

Undo the indicated screws and remove the complete shield

Once the plastics have been remove the ring nuts of the side headstock of the front suspension can be reached

Unscrew the upper ring nut

Bring the upper ring nut to the end of the headstock thread of the side suspension

Tighten the lower ring nut to the specified torque with the appropriate key.

Locking torques (N*m)

Side headstock lower ring nut 12 15

Screw the upper ring nut until it stops

MAIN - 33

Maintenance

MP3 LT 250 i.e.

Tighten upper ring nut to the specified torque with the appropriate key. Carry out the assembly of the plastic covers in reverse order to the disassembly.

Specific tooling
020892y Steering side headstock ring nut key

Locking torques (N*m)

Side headstock upper ring nut 20 - 24 Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequentially. 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 maintenance step and the icon is no longer displayed.

Maintenance chart
EVERY 2 YEARS
60'
Action Coolant - change Brake fluid - change

AFTER 1,000 KM
120
Action Safety fasteners - check Throttle lever - adjustment Engine oil filter - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - change Brake pads - check for condition and wear Tyre pressure and wear - check Vehicle test and brake test - Road test Hub oil - change Steering - Check Tilt locking gripper control cable - adjustment

MAIN - 34

MP3 LT 250 i.e.

Maintenance

AFTER 5,000 KM, 15,000 KM, 25,000 KM, 35000 KM, 45,000 KM, 55,000 KM, 65,000 KM, 75,000 KM
10'
Action Engine oil - level check/ top-up Brake pads - check for condition and wear

AFTER 10,000 KM 50,000 KM 70,000 KM

115'
Action Safety fasteners - check Throttle lever - adjustment Air filter - clean Engine oil filter - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - change Brake pads - check for condition and wear Sliding shoes / CVT rollers - replace Tyre pressure and wear - check Vehicle test and brake test - Road test Hub oil - check Suspension - check Steering - Check Centre stand - lubrication Tilt locking gripper control cable - adjustment

AFTER 20,000 KM, 35,000 KM, 50,000 KM, 65,000 KM, 80,000 KM
35'
Action Drive Belt - replacement

AFTER 20,000 KM, 40,000 KM, 80,000 KM

165'
Action Spark plug - replacement Throttle lever - adjustment Air filter - clean Engine oil filter - change Valve clearance - check Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - change Brake pads - check for condition and wear Sliding shoes / CVT rollers - replace Tyre pressure and wear - check Vehicle test and brake test - Road test Hub oil - change Suspension - check Steering - Check Tilt locking gripper control cable - adjustment

30,000 KM
155'
Action Safety fasteners - check Throttle lever - adjustment Air filter - clean

MAIN - 35

Maintenance

MP3 LT 250 i.e.

Action Engine oil filter - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - change Hub oil - check Brake pads - check for condition and wear Sliding shoes / CVT rollers - replace Tyre pressure and wear - check Vehicle test and brake test - Road test Suspension - check Steering - Check Tilt locking gripper control cable - adjustment

60,000 KM
205'
Action Spark plug - replacement Throttle lever - adjustment Air filter - clean Engine oil filter - change Valve clearance - check Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - change Hub oil - change Brake pads - check for condition and wear Sliding shoes / CVT rollers - replace Tyre pressure and wear - check Vehicle test and brake test - Road test Suspension - check Steering - Check Tilt locking gripper control cable - adjustment

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 stroboscopic light. Proceed as follows: - Remove the spark plug. - Remove the transmission crankcase.

MAIN - 36

MP3 LT 250 i.e.

Maintenance

- Rotate the driving pulley fan until the reference marks between the flywheel and flywheel cover coincide as shown in the photograph. - Bring the reference mark onto the transmission side between the fan and the transmission cover as shown in the picture. - 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). - Connect the diagnostic tester. - Start the engine. - Select the Parameters function in this menu. - Set the stroboscopic light control to the traditional four-stroke engine position (1 spark, 2 revs). - Check that the real values of rpm and ignition advance match those measured using the diagnostic tester. If the values do not correspond, check: - distribution timing - revolution timing sensor - injection control unit

Specific tooling
020680Y Diagnosis Tool 020330Y Stroboscopic light to check timing 020621Y HV cable extraction adaptor

MAIN - 37

Maintenance

MP3 LT 250 i.e.

Spark plug
Remove the port on the right-hand side panel of the scooter by undoing the clamping screw and using a small screwdriver in the rear recess shown in the figure, then do the following : 1.Disconnect spark plug HV wire cap A; 2.Unscrew the spark plug using the wrench supplied; 3. Upon refitting, place the spark plug into the hole at the required angle and tighten it by hand. 4.Use the wrench only to tighten it; 5.Push cap A fully over the spark plug. 6.Refit the flap ensuring that the rear fastener is engaged.
WARNING

THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 20,000 KM. USE OF ELECTRONIC CONTROL UNITS OR ELECTRONIC IGNITIONS DIFFERING FROM THOSE RECOMMENDED CAN SERIOUSLY DAMAGE THE ENGINE. N.B. USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR UNSHIELDED SPARK PLUG CAPS CAN LEAD TO FAULTS IN THE VEHICLE 'S ELECTRICAL SYSTEM.

Electric characteristic
Spark plug CHAMPION RG4 PHP Electrode gap 0.7 to 0.8 mm

MAIN - 38

MP3 LT 250 i.e.

Maintenance

Hub oil Check

-Place the vehicle on the centre stand on flat ground; - Remove the oil dipstick A, dry it with a clean cloth and put it back into its hole tightening it completely; Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end; if the level is under the MAX. mark, it needs to be filled with the right amount of hub oil. -Screw up the oil dipstick again and make sure it is locked properly into place.

Replacement
-Remove the oil filler cap A. - Unscrew the oil drainage cap B and drain out all the oil. - Screw in the drainage cap again and fill the hub with the prescribed oil.

Recommended 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

Locking torques (N*m)

Hub oil drainage screw 15 to 17 Nm

MAIN - 39

Maintenance

MP3 LT 250 i.e.

Air filter
Proceed as follows: Undo the clamping screws A (two of which are on the knob-type head) and remove the air-box cover.

1. Wash the sponge with water and neutral soap. 2. Dry it with a clean cloth and small blasts of compressed air. 3. Soak the sponge with a mixture of 50% petrol and 50% specified oil. 4. Gently squeeze the filter element without twisting it, let it drip and then refit it.
CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

Recommended products
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness

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

Replacement
At 1,000 km and after every 10,000 km, the oil and the filter must be changed. The engine must be drained by running off the oil from drainage cap "B" of the flywheel side gauze pre-filter; furthermore to facilitate oil drainage, loosen the cap/ dipstick "A". Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter "C" and remove it.

MAIN - 40

MP3 LT 250 i.e.

Maintenance

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. Since a certain quantity of oil still remains in the circuit, oil must be filled from cap "A". Then start up 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 requirements of API SL, ACEA A3, JASO MA specifications

Check
This operation must be carried out with the engine cold and following the procedure below: 1. Place the vehicle on its centre stand and on flat ground. 2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down completely. 3. Remove the cap/dipstick again and check that the level is between the min and max. marks; top-up, if required. The MAX level mark indicates a quantity of around 1300 cc of engine oil. If the check is carried out MAIN - 41

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after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine 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. Restoration of the level from MIN to MAX requires approximately 200 cc.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended 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

Oil pressure warning light

The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the ON position. However, this light should switch off once the engine has been started. If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

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Maintenance

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 flywheel 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 reference 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 calliper spanner applied to the camshaft command pulley casing.

Cooling system
Adding engine coolant. The fluid level must checked every 10,000 kilometres with a cold engine, in the way shown below: Place the scooter on its centre stand and on flat ground. - 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 between the MIN and MAX level. -The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised waterantifreeze solution mix.
CAUTION DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE VEHICLE IS IN USE.

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Braking system Level check

The front and rear brake fluid reservoirs are both positioned on the handlebar. Proceed as follows: - Rest the vehicle on its centre stand with the handlebars 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 recommended fluid without exceeding the 'MAX.' mark. This procedure applies to the rear brake pump topup operation; follow the same procedure for the front brake pump. Under normal climatic conditions, the fluid must be changed every 20,000 km or anyway every two years.
WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. BRAKING CIRCUIT 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.

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Maintenance

Headlight adjustment

Proceed as follows: 1. Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the vehicle is perpendicular to the screen; 2. Remove the headlight assembly central cover 3. Turn on the headlight and check that the limit of the projected light beam is not over 9/10 or below 7/10 of the distance from the ground to the centre of the vehicle headlight; 4. Otherwise, adjust the headlight with the screwsA indicated in the figure
N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

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INDEX OF TOPICS

TROUBLESHOOTING

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Troubleshooting

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 seal Replace the valve oil seal Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

LOW LUBRICATION PRESSURE
Possible Cause By-Pass remains open Oil pump with excessive clearance Oil filter too dirty Oil level too low Operation Check the By-Pass and replace if required. Carefully clean the By-Pass area. Perform the dimensional checks on the oil pump components Replace the cartridge filter Restore the level using the recommended oil type (Selenia HI Scooter 4 Tech)

Transmission and brakes Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause Faulty clutch Operation 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 housing is not scored or worn in an anomalous way

Insufficient braking
INEFFICIENT BRAKING SYSTEM
Possible Cause Inefficient braking system Operation 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. Failing elastic fittings, plunger or brake pump seals, replace

Fluid leakage in hydraulic braking system

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Possible Cause Brake disc slack or distorted

Operation Check the brake disc screws are locked; measure the axial shift of the disc with a dial gauge and with wheel mounted on the vehicle.

Brakes overheating
BRAKE OVERHEAT
Possible Cause Defective plunger sliding Brake disc slack or distorted Operation Check calliper and replace any damaged part. Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Clean carefully and blast with compressed air Replace gaskets.

Clogged compensation holes on the pump Swollen or stuck rubber gaskets

Steering and suspensions Heavy steering

STEERING HARDENING
Possible Cause Steering hardening Operation Check the tightening of the top and bottom ring nuts. If irregularities 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 flattened.

Excessive steering play

EXCESSIVE STEERING CLEARANCE
Possible Cause Torque not conforming Operation Check the tightening of the top and bottom ring nuts. If irregularities 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 flattened.

Noisy suspension
NOISY SUSPENSION
Possible Cause Faults in the suspension system Operation 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.

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Troubleshooting

Suspension oil leakage

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

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INDEX OF TOPICS

ELECTRICAL SYSTEM

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Electrical system

KEY 1. Immobilizer aerial 2. Injection electronic control unit 3. Engine rpm sensor 4. Magneto flywheel 5. Diagnosis socket 6. Voltage regulator 7. Key switch 8. Fuse box 9. Fuse box 10. Battery 11. Starter motor 12. Starter remote control switch 13. Starter button 14. Front brake stop button 15. Stop button on rear brake 16. Helmet compartment light switch 17. Helmet compartment light switch 18. Helmet compartment light bulb 19. Saddle opening actuator 20. Saddle opening receiver

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21. Pre-installation for anti-theft device 22. Turn indicator switch 23. Hazard button 24. Turn indicator control device 25. Rear left turn indicator bulbs 26. Rear light unit A. Tail light B. Stop light 27. License plate bulb 28. Rear right turn indicator bulbs 29. Front left turn indicator bulb 30. Front headlight assembly A. Low-beam light bulb B. Tail light C. High-beam light bulb 31. Front right turn indicator bulb 32. Light switch 33. Headlight remote control 34. Horn remote control 35. Horn 36. Horn button 37. Pressure sensor 38. Locking/unlocking switch 39. Geared motor 40. Right tone wheel 41. Left tone wheel 42. Brake calliper sensor 43. Parking electronic control unit 44. Oil pressure sensor 45. Hand brake 46. Rider presence sensor 47. Potentiometer 48. Instrument panel 49. External temperature sensor 50. Fuel level transmitter 51. Electric fan 52. Electric fan remote control 53. Injection load remote control ELE SYS - 52

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Electrical system

54. Engine stop switch 55. MODE button 56. Engine temperature sensor 57. Fuel pump 58. Fuel injector 59. Lambda probe 60. Spark plug 61. HV coil 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

Electrical system installation

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Conceptual diagrams Ignition

KEY 1. Immobilizer aerial 2. Injection electronic control unit 3. Engine rpm sensor 7. Key switch 8. Fuse box 9. Fuse box 10. Battery ELE SYS - 59

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53. Injection load remote control 60. Spark plug 61. HV coil

Battery recharge and starting

KEY 2. Injection electronic control unit 4. Magneto flywheel 6. Voltage regulator 7. Key switch 8. Fuse box 9. Fuse box 10. Battery 11. Starter motor 12. Starter remote control switch 13. Starter button 14. Front brake stop button 15. Stop button on rear brake 26. Rear light unit B. Stop light 54. Engine stop switch ELE SYS - 60

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Electrical system

Level indicators and enable signals section

KEY 1. Immobilizer aerial 2. Injection electronic control unit 3. Engine rpm sensor 7. Key switch 8. Fuse box 9. Fuse box 10. Battery 38. Locking/unlocking switch 39. Geared motor 40. Right tone wheel 41. Left tone wheel 42. Brake calliper sensor 43. Parking electronic control unit 44. Oil pressure sensor 45. Hand brake 46.Rider presence sensor 47. Potentiometer 48. Instrument panel ELE SYS - 61

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49.External temperature sensor 50. Fuel level transmitter 53. Injection load remote control 54. Engine stop switch 55. MODE button 56. Engine temperature sensor 57. Fuel pump 58. Fuel injector 59. Lambda probe

Devices and accessories

KEY 2. Injection electronic control unit 7. Key switch 8. Fuse box 9. Fuse box 10. Battery 19. Saddle opening actuator 20. Saddle opening receiver 21. Pre-installation for anti-theft device 34. Horn remote control ELE SYS - 62

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35. Horn 36. Horn button 37. Pressure sensor 43. Parking electronic control unit 51. Electric fan 52. Electric fan remote control

Lights and turn indicators

KEY 7. Key switch 8. Fuse box 9. Fuse box 10. Battery 21. Pre-installation for anti-theft device 22. Turn indicator switch 23. Hazard button 24. Turn indicator control device 25. Rear left turn indicator bulbs 26. Rear light unit A. Tail light B. Stop light ELE SYS - 63

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27. License plate bulb 28.Rear right turn indicator bulbs 29. Front left turn indicator bulb 30. Front headlight assembly A. Low-beam light bulb B. Tail light C. High-beam light bulb 31. Front right turn indicator bulb 32. Light switch 33. Headlight remote control 43. Parking electronic control unit 48. Instrument panel

Checks and inspections

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

Immobiliser
The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. 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 turning the key. The Immobilizer system consists of the following components: - an electronic control unit - immobilizer aerial - Master key with incorporated transponder (red key) - service key with incorporated transponder (black key) - HV coil - diagnosis LED The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the ELE SYS - 64

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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-deterrent blinker function is deactivated. Subsequently, 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 ignitionkey switch and/or the instrument panel is not initiated, check if: there is battery voltage fuses 6,7,10 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: With the key switch set to OFF: if there is battery voltage between terminals 6-26 and terminal 6-chassis ground (fixed power supply). If there is no voltage check that fuse 6 and its cable are in working order.

With the key switch in the OFF position: there is battery voltage between terminals 5-26 and terminal 5-frame earth (fixed power supply). If there is no voltage, check the key switch contacts, that fuse no. 10 and its cable are in working order.

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There is continuity between terminals 12-18 and 12-19 with the emergency cut-out switch in the RUN position. If there is no continuity check the contacts of the latter.

If no faults are found, replace the electronic control unit.

After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture.

Remove the protective base from the connector.

With the ignition key at ON check there is battery voltage between the Red-White and Black cables

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Electrical system

With MIU connector disconnected, check the continuity 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 procedure 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 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 (lower and upper limits 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, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any case it is advisable to use resistor spark plugs. ELE SYS - 67

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Characteristic
MASTER key: RED KEY SERVICE key. BLACK KEY

Diagnostic codes
The Immobilizer system is tested each time the ignition key is turned from OFF to ON. During this diagnosis phase a number of control unit statuses 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 ignition is inhibited: 1. Previously unused control unit - key inserted: 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 started but with a limitation imposed on the number of revs. 2. Previously unused control unit - transponder absent or cannot be used: the LED is on permanently. In this condition no operations are possible including the start up of the vehicle. 3. Programmed control unit - the service key in (normal condition of use): a single 0.7-second flash is displayed, after which the LED remains off steadily. The engine can be started. 4. Programmed control unit - Master key in: a 0.7-sec flash is displayed followed by the LED 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

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Electrical system

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 transmitted are: 1-flash code 2-flash code 3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessary.

Diagnostic code - 2 flashes

A two-flash code shows a system where the control 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.

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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 charging circuit consists of three-phase alternator and a permanent magneto flywheel. The generator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. The three-phase alternator provides good recharge power and at low revs a good compromise is achieved 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 picture. 3) Measure the resistance between each of the yellow terminals and the other two.

Electric characteristic
Resistance: 0.2 - 1

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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 WORKING ORDER. 1) Place the vehicle on its centre stand 2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals.. 3) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage.

Electric 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

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

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Fuses
The electrical system has twelve fuses divided in two fuse boxes to protect the different installation circuits. One of them is inside the battery compartment and the other is at the right internal side of the footrest. To be able to reach, loosen the screw "A" and remove the plastic cover. The chart shows the position and characteristics of the fuses in the vehicle.
CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND 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).

FUSE TABLE
1 Specification Fuse No. 1 Desc./Quantity Capacity: 30A Protected circuits:Voltage regulator Location:battery compartment Capacity: 20A Protected circuits:battery-powered fuse No. 7, live fuses No. 8 - No. 9 - No.10 - No.11 Location:battery compartment Capacity: 15 A Protected circuits:Battery-powered saddle opening switch, glove-box lighting, headlight, emergency turn indicator Location:battery compartment Capacity: 15 A Protected circuits:Battery-powered injection loads, electrical fan Location:battery compartment Capacity: 3A Protected circuits:Battery-powered injection control unit Location:battery compartment Capacity: 7.5 A Protected circuits:Battery-powered instrument panel Location:footrest Capacity: 10A Protected circuits:Live stop and start lights Location:footrest Capacity: 7.5 A Protected circuits:live passing and horn Location:footrest Capacity: 7.5A

Fuse No. 2

Fuse No. 4

Fuse No. 5

Fuse No. 6

Fuse No. 7

Fuse No. 8

Fuse No. 9

Fuse No. 10

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Specification

10

Fuse No. 11

11

Fuse No. 12

Desc./Quantity Protected circuits:Live injection, electrical fan remote control antenna, injection loads remote control Location:footrest Capacity: 7.5A Protected circuits:Live ECU parking lever, antitheft device, instrument panel, headlight solenoid, horn solenoid Location:footrest Capacity: 7.5A Protected circuits:Live turn indicator, saddle opening switch, tail lights, panel lighting Location:footrest

Dashboard
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 system 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 warning light (if available) R = Warning light for parking brake engaged S = High-beam warning light

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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 the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if 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 to 14.70V - Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity - Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode - Charge current equal to 1/10 of the battery rated capacity - Charge time: Maximum 5 h

Battery installation
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF) ELE SYS - 74

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WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN 1) Battery preparation Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.

2) Electrolyte preparation. Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulphuric acid. 3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping. 4) Control the flow of electrolyte Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery. ELE SYS - 75

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5) Take out the container. Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point. 6) Battery closing. Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery. 7) Recharging the new battery With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged. If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle. The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between 12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).

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Electrical system

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

e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.

f - Check the ignition of the green LED indicated with a red arrow in figure.

g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place

ELE SYS - 77

Electrical system

MP3 LT 250 i.e.

h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

Connectors
CONNETTORE CENTRALINA DI STAZIONAMENTO 1A Potentiometer power 2A CAN Line 3A Power to warning lights 4A Tilt locking system warning light 5A Warning light 6A Low-beam lights remote control output 7A Potentiometer ground lead 8A ECU ground lead 1B Live 2B CAN Line 3B Left wheel turning sensor 4B Right wheel turning sensor 5B Potentiometer signal 6B Tilt unlocking-locking control switch 7B Horn remote control (alarm) 8B Electroactuator motor output (A) 1C Power from battery 2C "K" Line 3C Tilt unlocking-locking control switch 4C Tilt gripper switch 5C Tilt unlocking-locking control switch 6C Rider presence sensor 7C Speed signal for the instrument panel 8C Electroactuator motor output (B) ELE SYS - 78

MP3 LT 250 i.e.

Electrical system

Dashboard

1/20 Speed sensor 2/20 Fuel level indicator 3/20 Coolant temperature sensor 4/20 Coolant temperature sensor ground lead 5/20 Remote mode button 6/20 Oil pressure warning light 7/20 Left turn indicator warning light 8/20 Right turn indicator warning light 9/20 High beam warning light 10/20 Open boot warning light 11/20 Rpm sensor 12/20 Ambient temperature sensor 13/20 Ambient temperature sensor ground lead 14/20 Engine disabled warning light 15/20 Immobilizer warning light 16/20 Engine control warning light 17/20 Parking brake warning light 18/20 Tilt locking system activated warning light 19/20 Tilt locking system failure warning light 20/20 Live positive from parking control ECU 5/12 Lighting 6/12 Battery positive 11/12 Ground lead 12/12 Live positive

Remote seat opening

ELE SYS - 79

Electrical system

MP3 LT 250 i.e.

Zeroing
- Remove the left side fairing to access the saddle opening receiver control unit indicated in the photograph - 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 REPEAT 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 RECEIVER CAN BE IMPAIRED. SHOULD THIS BE THE CASE, REPEAT THE PROGRAMMING PROCEDURE. DO NOT KEEP THE REMOTE CONTROL IN PLACES WITH TEMPERATURES EXCEEDING 60 C THE BATTERY WILL RUN DOWN TOO QUICKLY. ELE SYS - 80

MP3 LT 250 i.e.

Electrical system

WARNING

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

ELE SYS - 81

INDEX OF TOPICS

ENGINE FROM VEHICLE

ENG VE

MP3 LT 250 i.e.

Engine from vehicle

Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.

Exhaust assy. Removal

- Remove the Lambda probe from its support and disconnect it.

- Undo the two exhaust manifold fixings on the head. To unscrew the nuts that fix the silencer flange to the head properly, use a jointed wrench that allows, according to the travel direction, to get also at the right nut. That is difficult to do with a traditional straight wrench.

- Undo the three screws that fix the silencer to the supporting arm. - Remove the full silencer unit.

Remove the lambda probe from the manifold.

ENG VE - 83

Engine from vehicle

MP3 LT 250 i.e.

CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

Removal of the engine from the vehicle

Disconnect the battery. - Remove the engine cover inside the helmet compartment - Remove the side panels Remove the full muffler assembly.
CAUTION

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

- Remove the rear wheel. - 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 indicated.

- Disconnect the fuel delivery and return pipes from the injector by removing the screw locking the retaining clip. - Disconnect the injector wiring and the throttle body control unit wiring.

ENG VE - 84

MP3 LT 250 i.e.

Engine from vehicle

- Remove the coolant outlet pipe from the engine as indicated.

- Remove the spark plug caps. - Remove the coolant temperature sensor connector indicated in the photograph.

- Remove the throttle cable from the throttle body by undoing the nut shown in the photo.

- Remove the positive and negative wiring from the starter motor as shown in the picture.

ENG VE - 85

Engine from vehicle

MP3 LT 250 i.e.

- Disconnect the connectors from the flywheel wiring as shown in the photo. - Remove the cable from the retaining clip on the flywheel cover.

Remove the lower screw of the left-hand shock absorber.

- Use a jack to support the vehicle properly. Remove the engine-swinging arm fixing pin by undoing the nut and the head of the pin as shown in the photograph. - The engine is now free.

When refitting the engine onto the vehicle, carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter. - Check the engine oil level and if necessary, top it up with the recommended type. - Fill and bleed the cooling circuit. - Check accelerator and electric devices for correct functioning.
CAUTION

ENG VE - 86

MP3 LT 250 i.e.

Engine from vehicle

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.

ENG VE - 87

INDEX OF TOPICS

ENGINE

ENG

MP3 LT 250 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

- To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes. Using the clutch housing lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.

Specific tooling
020423Y Driven pulley lock wrench

- Remove the cap/dipstick from the engine oil filling hole. - Remove the ten screws. - Remove the transmission cover.
N.B. WHEN YOU ARE REMOVING THE TRANSMISSION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH HOUSING.

Air duct
Versione 250 - Remove the 5 screws, found on two different levels, as well as the small casing.

ENG - 89

Engine

MP3 LT 250 i.e.

- To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by means of:

Specific tooling
020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020412Y 15-mm guide

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase from the inside so as not to damage the painted surface. - Insert the bearing in its seat. - Refit the Seeger ring.
CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING.

Specific tooling
020376Y Adaptor handle 020357Y 32x35-mm Adaptor 020412Y 15-mm guide

Baffle roller

ENG - 90

MP3 LT 250 i.e.

Engine

Plastic roller
- Check that the roller does not show signs of wear and that it turns freely. - Remove the special clamping screws as indicated in the photograph

- Check the outer diameter of the roller does not have defects that could jeopardise belt functioning - For refitting, place the roller with the belt containment edge on the engine crankcase side - Tighten the wrench to the prescribed torque.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Removing the driven pulley

- Remove the clutch housing and the driven pulley assembly.
N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.

ENG - 91

Engine

MP3 LT 250 i.e.

Inspecting the clutch drum

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

Characteristic
Max. value clutch bell Max. value: 134.5 mm clutch housing standard value Standard value: 134 - 134.2 mm

Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft unit on the support to check the crankshaft alignment.

- Using a feeler dial gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell.

Specific tooling
020074Y Support base for checking crankshaft alignment 020335Y Magnetic mounting for dial gauge

Characteristic
clutch bell inspection: Limit eccentricity. Admissible limit eccentricity: 0.15 mm

ENG - 92

MP3 LT 250 i.e.

Engine

Removing the clutch

Fit the driven pulley spring compressor specific tool with medium length pins screwed in position C on the tool internal side. - Introduce the adapter ring 11 with the chamfering facing the inside of the tool. - Fit the driven pulley unit on the tool with the insertion of the 3 pins in the ventilation holes in the mass holder support. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to loosen/tighten the clutch nut. - Use the special 46x55 wrench component 9 to remove the nut fixing the clutch in place. - Dismantle the driven pulley components (Clutch and spring with its plastic holder)
CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE.

Specific tooling
020444Y011 adapter ring 020444Y009 wrench 46 x 55 020444Y Tool for fitting/ removing the driven pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.
N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic
ENG - 93

Engine

MP3 LT 250 i.e.

Check minimum thickness 1 mm

Pin retaining collar

- Simultaneously turn and pull the collar manually to remove it.
N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICULTY. N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.

- Remove the 4 torque server pins and pull the pulley halves apart.

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisiness; - Replace with a new one if there are. - Remove the retainer ring using two flat blade screwdrivers. - Support the pulley bushing adequately from the threaded side using a wooden surface. - Using a hammer and pin, knock the ball bearing out as shown in the figure.

ENG - 94

MP3 LT 250 i.e.

Engine

- Support the pulley properly using the bell as shown in the figure.

Specific tooling
001467Y035 Bearing housing, out 47 mm

- Remove the roller bearing using the modular punch.

Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020363Y 20-mm guide

Inspecting the driven fixed half-pulley

Version 250 - Measure the outside diameter of the pulley bushing. - Check the faying surface with the belt to make sure there are no flaws. - Check the riveted joints are functional. - Check the evenness of the belt contact surface.

Characteristic
Half-pulley minimum diameter Minimum admissible diameter: 40.96 mm Half-pulley standard diameter Standard diameter: 40.985 mm Wear limit 0.3 mm

ENG - 95

Engine

MP3 LT 250 i.e.

Inspecting the driven sliding half-pulley

- Remove the two seal rings and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the faying surface with the belt to make sure there are no flaws. - Check the riveted joints are functional. - Check the evenness of the belt contact surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Specification Wear limit standard diameter maximum allowable diameter Desc./Quantity 0.3 mm 41.000 - 41.035 mm 41.08 mm

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the threaded side using a wooden surface. - Fit a new roller bearing as shown in the figure. - For the fitting of the new ball bearing, follow the example in the figure using a modular punch. Fit the retainer ring
WARNING N.B. FIT THE BALL BEARING WITH THE VISIBLE SHIELDING

Specific tooling
020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020424Y Driven pulley roller casing fitting punch

ENG - 96

MP3 LT 250 i.e.

Engine

Refitting the driven pulley

- Insert the new oil seals and O-rings on the movable half-pulley. - Lightly grease the O-rings A shown in the figure. - Fit the half-pulley over the bushing using the specific tool. - Check that the pins are not worn and proceed to refitting them in their slots. - Refit the torque server closure collar. - Using a curved-spout grease gun, lubricate the driven pulley unit with approximately 6 grams of grease. Apply grease through one of the holes in the bushing until it comes out through the hole on the opposite side. This operation is necessary to avoid the presence of grease beyond the O-rings.
N.B. THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED; UNDERTAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling
020263Y Driven pulley assembly sheath

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

ENG - 97

Engine

MP3 LT 250 i.e.

Inspecting the clutch spring

- Measure the length of the spring when it is relaxed.

Characteristic
Standard length 123 mm Acceptable limit after use: 118 mm

Refitting the clutch

- Support the driven pulley spring compressor specific tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position "C" on the inside. - Introduce the adapter ring No. 11 with the chamfering facing upwards. - Insert the clutch on the adapter ring. - Lubricate the end of the spring that abuts against the torque server closing collar. - Insert the spring with its plastic holder in contact with the clutch. - Insert the drive belt into the pulley unit according to their direction of rotation. - Insert the pulley unit with the belt into the tool. - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut. - Place the tool in the clamp with the control screw on the horizontal axis. - Fully preload the spring. - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt according to its direction of rotation. ENG - 98

MP3 LT 250 i.e.

Engine

- Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool.
N.B. DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING. N.B. FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.

Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55

Locking torques (N*m)

Clutch unit nut on driven pulley 45 to 50

Refitting the driven pulley

- Refit the clutch bell.

ENG - 99

Engine

MP3 LT 250 i.e.

Drive-belt
- Check that the drive belt is not damaged. - Check the width of the belt.

Characteristic
250 four stroke Transmission belt - minimum width 19.5 mm 250 four stroke Transmission belt - standard width 21.3 0.2 mm During the wear checks in foreseen in the scheduled maintenance program, you are advised to check that the rim bottom of the toothing does not show signs of incisions or cracking (see figure): The rim bottom of the tooth must not have incisions or cracking; if it does, change the belt.

Removing the driving pulley

- Turn the crankshaft until the ropes of the pulley are on a horizontal axis

- Insert the adaptor sleeve of the appropriate tool in the hole shown in the picture

ENG - 100

MP3 LT 250 i.e.

Engine

- Insert the tool in the hollows and apply the retention ring - Bring in the ring's clamping screws while keeping the tool to support the pulley

Specific tooling
020626Y Driving pulley lock wrench

- Remove the fixing nut and the washer - Remove the stationary drive pulley half.

Inspecting the rollers case

- Check that the internal bushing shown in the figure is not abnormally worn and measure inner diameter A. - Measure outer diameter B of the pulley sliding bushing shown in the figure. - Check that the rollers are not damaged or worn. - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt faying surfaces on both pulley halves. - Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt. - Check that the O-ring is not pushed out of shape.
CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic
movable driving half-pulley bushing: Standard Diameter 26.000 - 26.021 mm ENG - 101

Engine

MP3 LT 250 i.e.

movable driving half-pulley bushing: Maximum allowable diameter 26.12 mm Sliding bushing: Standard Diameter 25.959 25.98 mm Sliding bushing: Minimum admissible diameter 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted 20 mm

Refitting the driving pulley

- Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation. - Check that the roller contact plate does not have flaws and is not damaged on the grooved edge. - Mount the complete bushing unit on the crankshaft. - Fit the driven pulley/Clutch/belt unit on the engine.

ENG - 102

MP3 LT 250 i.e.

Engine

- Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the removal phase. -Tighten the nut with washer to the prescribed torque.

Specific tooling
020626Y Driving pulley lock wrench

Locking torques (N*m)

Drive pulley nut 75 - 83

Refitting the transmission cover

- Check that there are 2 alignment dowels and that the sealing gasket for the oil sump on the transmission cover is adequately fitted. - Replace the cover and tighten the 10 screws to the specified torque. - Refit the oil loading cap/bar. - Refit the steel washer and the driven pulley nut. - Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools. - Refit the plastic cover.

Specific tooling
020423Y Driven pulley lock wrench

Locking torques (N*m)

Transmission cover screws 11 to 13 Driven pulley shaft nut 54 60

ENG - 103

Engine

MP3 LT 250 i.e.

End gear Removing the hub cover

- Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket.

Removing the wheel axle

- Remove the wheel axis complete with gear. - Remove the intermediate gear.

ENG - 104

MP3 LT 250 i.e.

Engine

Removing the hub bearings

- Check the state of the bearings being examined (wear, clearance and noisiness). If faults are detected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).

Specific tooling
001467Y013 Calliper to extract 15-mm bearings

Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover. - Support the hub cover and expel the bearing. By means of the appropriate tools, remove the oil guard as in the figure.

Specific tooling
020376Y Adaptor handle 020477Y 37 mm adaptor 020483Y 30-mm guide 020359Y 42x47-mm Adaptor 020489Y Hub cover support stud bolt kit

ENG - 105

Engine

MP3 LT 250 i.e.

Removing the driven pulley shaft bearing

- As you need to remove the driven pulley shaft, its bearing and oil seal, remove the transmission cover as described above. - Extract the driven pulley shaft from its bearing. - Remove the oil seal using a screwdriver, working from inside the bearing and being careful not to damage the housing, make it come out of the belt transmission side. - Remove the Seeger ring shown in the figure - Remove the driven pulley shaft bearing using the modular punch.

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

Inspecting the hub shaft

- Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - If faults are found, replace the damaged components.

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted. - Check the bearing bearings. - In case of faults, replace the damaged components.

ENG - 106

MP3 LT 250 i.e.

Engine

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure. - Fit the Seeger ring. - Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal surface by means of the appropriate tool used from the 52-mm side. The 52-mm side of the adapter must be turned towards the bearing.

Specific tooling
020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020483Y 30-mm guide

ENG - 107

Engine

MP3 LT 250 i.e.

Refitting the hub cover bearings

In order to fit the hub box bearings, the engine crankcase and the cover must be heated with the special heat gun. - The three 15-mm bearings must be fitted using the appropriate tools: - The 42-mm side of the adapter must be turned towards the bearing.

Specific tooling
020150Y Air heater mounting 020151Y Air heater 020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020412Y 15-mm guide

N.B.

TO FIT THE BEARING ON THE COVER, ADEQUATELY SUPPORT THE COVER WITH THE STUD BOLT KIT. - Refit the driven pulley shaft bearing with a modular punch as shown in the figure.
N.B. IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE.

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

WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY. - Refit the Seeger ring with the opening facing the bearing and fit a new oil seal flush with the crankcase from the pulley side.

ENG - 108

MP3 LT 250 i.e.

Engine

Refitting the hub bearings

- Install the three shafts in the engine crankcase as shown in the figure.

Refitting the ub cover

- Fit a new gasket together with the alignment dowels. - Seal the gasket of the breather pipe using black silicone sealant. - Fit the gearbox cover, making sure the breather pipe is in the correct position. - Position the shorter screw that can also be recognised from the different colour as shown in the figure. - Fix the breather tube support by means of the lower screw. - Fit the remaining screws and tighten the seven screws to the prescribed torque.

Flywheel cover

ENG - 109

Engine

MP3 LT 250 i.e.

Removing the hub cover

- Remove the clip fixing the sleeve to the cylinder. - Remove the 10 clamps - Remove the flywheel cover.

Removing the stator

- Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure. - Remove the stator and its wiring.

ENG - 110

MP3 LT 250 i.e.

Engine

Refitting the stator

- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.

Locking torques (N*m)

Stator assembly screws () 3 to 4

Refitting the flywheel cover

- Position the spline clip on the crankshaft and orient the end as shown in the figure.

- Orient the water pump shaft with reference to the transmission gear seat as shown in the picture.

- Refit the cover over the engine and tighten the screws to the prescribed torque. - Carry out the removal steps but in the reverse order.
CAUTION

TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CENTRING DOWELS ARE PRESENT.

Locking torques (N*m)

Flywheel cover screws 11 - 13

Flywheel and starting

ENG - 111

Engine

MP3 LT 250 i.e.

Removing the starter motor

- Remove the two screws indicated in the figure - Take the starter motor out of its seat

Removing the flywheel magneto

- Remove the water pump shaft and crankshaft spline clip

- Line up the two holes in the flywheel as shown in the picture

- Screw in the guide bushing that is part of the special flywheel stop tool on the flywheel as shown in the picture

ENG - 112

MP3 LT 250 i.e.

Engine

- Insert the special flywheel stop tool on the flywheel as shown in the picture

Specific tooling
020627Y Flywheel lock wrench

Remove the plate indicated in the picture.

- Remove the flywheel nut with its washer - Do up the flywheel nut by three or four threads so that the flywheel does not fall accidentally on extraction - Screw the extractor onto the flywheel and extract it as shown in the picture

Specific tooling
020467Y Flywheel extractor

Inspecting the flywheel components

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

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 ENG - 113

Engine

MP3 LT 250 i.e.

- Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the flywheel itself, i.e. with wheel Seeger ring visible. - Lock the six clamping screws in criss-cross fashion to the prescribed torque.

Locking torques (N*m)

Screw fixing freewheel to flywheel 13 - 15

- Oil the free wheel "rollers".

Refitting the flywheel magneto

- Remove the freewheel retaining plate indicated in the picture - Remove the transmission gear and the freewheel

- Insert the free wheel on the flywheel as shown in the picture - Then refit the flywheel with free wheel and transmission gear

ENG - 114

MP3 LT 250 i.e.

Engine

- Using the special flywheel lock wrench, tighten up the flywheel fixing nut to the prescribed torque - Refit the retention plate

Specific tooling
020627Y Flywheel lock wrench

Locking torques (N*m)

Flywheel nut 94 - 102

Refitting the starter motor

- Fit a new O-ring on the starter motor and lubricate it. - Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque.

Locking torques (N*m)

Starter screws 11 to 13

Cylinder assy. and timing system Removing the intake manifold

Loosen the 3 screws and remove the air intake manifold. - Upon refitting, secure to the specified torque.

ENG - 115

Engine

MP3 LT 250 i.e.

Removing the rocker-arms cover

- Remove the 5 screws indicated in the figure

Removing the timing system drive

- First remove the parts listed below: transmission cover, drive pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separation washer. - Remove the tappet cover. - Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the figure. - Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer.

ENG - 116

MP3 LT 250 i.e.

Engine

- Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket.

- Remove the internal hex screw and the counterweight shown in the figure.

- Remove the camshaft control pulley with its washer.

- Remove the control sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The chain tensioner slider must be removed from the transmission side. As regards the lower chain guide slider, it may only be removed after the head has been removed.
N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.

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Removing the cam shaft

- Remove the 2 screws and the camshaft retainer shown in the diagram. - Remove the camshaft. - Remove the pins and the rocking levers from the flywheel side holes.
N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

Removing the cylinder head

- Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two alignment dowels and the gasket.
N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

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Removing the valves

- Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool. - Remove the lower spring supports.
CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD.

Specific tooling
020382Y011 adapter for valve removal tool 020382Y Valve cotters equipped with part 012 removal tool 020431Y Valve oil seal extractor

Removing the cylinder - piston assy.

Removing cylinder and piston - Remove the chain guide slider. - Remove the 4 O-rings on the stud bolts. - Pull out the cylinder. - Remove the cylinder base gasket. - Remove the two stop rings, the wrist pin and the piston. - Remove the piston seals.
CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.

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Inspecting the small end

- Measure the internal diameter of the connecting rod small end using an internal micrometer.
N.B. REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.

Characteristic
Connecting rod small end check-up: Maximum diameter 15.030 mm Connecting rod small end check-up: Standard diameter 15+0.015+0.025 mm

Inspecting the wrist pin

- Measure the outer diameter of the gudgeon pin. - Calculate the coupling clearance between pin and connecting rod small end.

Characteristic
Pin diameter: Standard clearance 0.015 0.029 mm Pin diameter Standard diameter 14.996 - 15.000 mm

Inspecting the piston

- Measure the diameter of the wrist pin seat on the piston. - Calculate the piston pin coupling clearance. - Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis. - Take the measurement at 5 mm from the base in the position shown in the figure. - Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram.

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- If the clearance is greater than that indicated in the table, replace the piston.
N.B. MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.

Characteristic
Wrist pin seat on the piston: Standard diameter 15.001 15.006 mm Diameter of the wrist pin seat on the piston: Standard clearance 0.001 - 0.010 mm piston diameter 71.953 - 71.981 mm

Fitting clearance
Top piston ring - standard coupling clearance 0.015 - 0.06 mm Top piston ring - maximum clearance allowed after use 0.07 mm Middle piston ring - standard coupling clearance 0.015 - 0.06 mm Middle piston ring - maximum clearance allowed after use 0.07 mm oil scraper ring - standard coupling clearance 0.015 - 0.06 mm oil scraper ring - maximum clearance allowed after use
0.07 mm

Inspecting the cylinder

- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the head coupling surface is not worn or misshapen. - Pistons and cylinders are classified according to their diameter. The coupling must be made with those of the same type (M-M, N-N, O-O, P-P).

Characteristic
cylinder: standard diameter 71.990 - 72.018 mm (at 33 mm) Maximum allowable run-out: 0.05 mm

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Inspecting the piston rings

- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening (see figure) of the sealing rings using a feeler gauge. - If any measurements are greater than specified, replace the piston rings.
N.B.

BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.

Sealing rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening (see figure) of the sealing rings using a feeler gauge. - If any measurements are greater than specified, replace the piston rings.
N.B. BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.

Characteristic
Top piston ring ENG - 122

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Standard opening: 0.15 to 0.30 mm Middle piston ring Standard opening: 0.20 0.40 mm scraper ring Standard opening: 0.20 0.40 mm

Removing the piston

- Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin retainer ring onto the appropriate tool - With opening in the position indicated on the tool S = left D= right - Place the wrist pin retainer ring into position using a punch - Fit the pin retainer ring using the plug as shown in the figure
N.B. THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.

Specific tooling
020454Y Tool for fitting piston pin stops (200 250)

Choosing the gasket

Characteristic
Compression ratio 250 version CR: 10.5 11.5 : 1

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N.B.

MEASUREMENT "A" TO BE TAKEN IS A VALUE OF PISTON RE-ENTRY, IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.

ENGINE 250 SHIMMING

Name SHIMMING SHIMMING SHIMMING Measure A 3.70 - 3.60 3.60 - 3.40 3.40 - 3.30 Thickness 0.4 0.05 0.6 0.05 0.8 0.05

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Refitting the piston rings

Fitting the sealing rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the piston crown. The chamfered side of the oil scraper ring should always be facing the piston crown. - Fit the middle piston ring with the identification letter facing the piston crown. In any case, the step must be facing opposite the piston crown. - Fit the top piston ring with the word 'TOP' or the reference mark facing the crown of the piston. - Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure. - Lubricate the components with engine oil. - The top piston ring on the 250 engine has an L cross section.
N.B. THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO ACHIEVE A BETTER BEDDING.

Refitting the cylinder

- Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER LINER.

Specific tooling
020426Y Piston fitting fork ENG - 125

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020393Y Piston assembly band

Inspecting the cylinder head

- Using a trued bar and a feeler gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocking lever pin capacities exhibit no wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn.

Characteristic
bearing A 12.000 - 12.018 mm bearing B 20.000 20.021 mm bearing C 37.000 - 37.025 mm

Inspecting the timing system components

- Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft control pulley chain assembly and the sprocket wheel are not worn. - If you detect wear, replace the parts or, if the chain, sprocket wheel and pulley are worn, replace the whole unit. - Remove the centre screw with the washer and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole unit.

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Inspecting the valve sealings

- 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.

Inspecting the valve housings

- Check the width of the imprint on the valve seatV wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide. - Take the measurement at three different heights in the rocker arm push direction. - If the width of the impression on the valve seat or the diameter of the valve guide exceed the specified limits, replace the cylinder head.

Characteristic
Valve seat wear Intake guide limit accepted: 5.022 Valve seat wear Intake guide Standard diameter: 5.000 5.012 mm Valve seat wear Exhaust guide Accepted limit 5.022 Valve seat wear Exhaust guide Standard diameter: 5.000 5.012 mm

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Inspecting the valves

- Measure the width of the sealing surface on the valve seats and on the valves. Sealing surface width: After use: Intake and exhaust: 1.6 mm - If any of the sealing surfaces on the valves is wider than the specified limit or is damaged in one or more points, or curved, replace the valve with a new one.
CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

Characteristic
Valve wear check Standard: Intake and exhaust: 0.99 - 1.27 mm

- Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the faying surface with the articulated set screw terminal. - If no anomalies are found during the above checks, you can use the same valves. For best sealing results, it is advisable to grind the valves. 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.
N.B.

DO NOT CHANGE THE POSITIONS THE VALVES ARE FITTED IN

Characteristic
Valve check Standard length Exhaust: 94.4 mm Valve check Standard length Intake: 94.6 mm Valve check Maximum admissible clearance Exhaust: 0.072 mm Valve check Maximum admissible clearance Intake: 0.062 mm Valve check standard clearance Exhaust: 0.025 to 0.052 mm ENG - 128

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Valve check standard clearance Intake: 0.013 0.040 mm Valve check Minimum admissible diameter: Exhaust: 4.95 mm Valve check Minimum admissible diameter: Intake: 4.96 mm Valve check Standard diameter: Intake: 4.972 4.987 mm Valve check Standard diameter: Exhaust: 4.96 4.975 mm

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Inspecting the springs and half-cones

- Check that the upper spring caps and the cotter halves show no signs of abnormal wear.

Refitting the valves

- Lubricate the valve guides with engine oil. - Place the valve spring supports on the head. - Using the special punch, fit the four valve seal rings. - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
N.B. DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).

Specific tooling
020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool

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Inspecting the cam shaft

- Inspect the camshaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - 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 there are no signs of wear on the automatic valve-lifter cam, or the end-of stroke roller, or the rubber buffer on the automatic valve-lifter retaining cover. - Check that the valve lifter spring has not yielded. - Replace any defective or worn components. - Check the rocking lever pins do not show signs of wear or scoring. - Measure the internal diameter of each rocking lever. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate.

Characteristic
Rocking lever inside diameter: Standard diameter Diameter 12.000 - 12.011 mm Rocking lever pin diameter: Standard diameter ENG - 131

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Diameter 11.977 - 11.985 mm Camshaft check: Maximum admissible axial clearance 0.42 mm Camshaft check: Standard axial clearance: 0.11 - 0.41 mm Camshaft check: Standard height Exhaust: 29.209 mm Camshaft check: Standard height Intake: 30.285 mm Camshaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm Camshaft check: Minimum admissible diameter Bearing A : 36.94 mm Camshaft check: Standard diameter Bearing B diameter: 19.959 19.98 mm Camshaft check: Standard diameter Bearing A : 36.95 36.975 mm

Refitting the head and timing system components

- Fit the timing chain guide slider. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head. - Lubricate the stud bolt threading. - Tighten up the nuts to an initial pre-torque of 71 Nm - Tighten up the nuts to a second pre-torque of 10 1 Nm - Rotate by an angle of 270 - To carry out the operations described above, follow the tightening sequence in the figure. - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.
N.B. BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.

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Locking torques (N*m)

Timing chain tensioner support screw 11 to 13

- Refit the lower timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft. - Fit the chain tensioner slider from the cylinder head side. - Fit the spacer and the screw fastener. - Tighten the screws to the prescribed torque. - Fit the pins and rocking levers. - Lubricate the two rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the camshaft in the cylinder head with the cams corresponding to the rocking levers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed torque. - Refit the spacer on the camshaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the camshaft control pulley. - Insert the pulley on the camshaft while keeping the reference 4V in correspondence with the reference mark on the head. - Fit the counterweight and tighten the clamping screw to the prescribed torque. ENG - 133

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-Fit the end-stop ring on the automatic valve-lifter cam and fit the automatic valve-lifter cam to the camshaft. - Fit the automatic valve lifter return spring. - During this operation the spring must be loaded by approximately 180. - Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. - Tighten the clamping screw to the prescribed torque. - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque. - Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque. - Adjust the valve clearance. - Fit the spark plug. Electrode distance 0.8 mm
N.B. GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE.

Locking torques (N*m)

Timing chain tensioner support screw 11 to 13 Spark plug 12 to 14 Starter ground screw 7 to 8.5 Timing chain tensioner slider screw 10 to 14 Starter counterweight support screw 11 to 15 Timing chain tensioner central screw 5 to 6 Camshaft retention plate screw 4 to 6

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Refitting the rocker-arms cover

- Refit the cylinder head cover and tighten the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly.

Locking torques (N*m)

Tappet cover screws 6 - 7 Nm

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Refitting the intake manifold

- Fit the intake manifold and do up the three screws.

Locking torques (N*m)

Intake manifold screws 11 to 13

Crankcase - crankshaft Splitting the crankcase halves

- Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge. - Upper clearances are an indication of wear on the surfaces of the crankshaft casing support. - Remove the 10 crankshaft coupling screws. - Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase. - Remove the crankshaft. - Remove the half crankcase coupling gasket. - Remove the two screws and the internal shield shown in the diagram. - Remove the oil seal on the flywheel side. - Remove the oil filter fitting shown in the diagram. - Check the axial clearance on the connecting rod. - Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial free-play are not scored and measure the width of the crankshaft between these surfaces, as shown in the diagram. - If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does

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not have any defect, the problem must be due to either excessive wear or wrong machining on the crankcase. - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart below.
CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS OF SCORING. CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS. CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL. N.B. WHEN MEASURING THE WIDTH OF THE CRANKSHAFT, MAKE SURE THAT THE MEASUREMENTS ARE NOT MODIFIED BY THE RADIUSES OF FITTINGS WITH THE CRANKSHAFT BEARINGS.

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

Characteristic
Axial crankshaft/crankcase clearance: Standard clearance 0.15 - 0.40 mm (when cold) Axial connecting rod - crankshaft clearance Standard clearance 0.20 to 0.50 mm Radial connecting rod - crankshaft clearance Standard clearance 0.036 to 0.054 mm Width of crankshaft with integral washers: standard measurements 55.67 to 55.85 mm Crankshaft bearings: Standard diameter: Cat. 1 28.994 29.000

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Crankshaft bearings: Standard diameter: Cat. 2 29.000 29.006

Inspecting the crankshaft alignment

To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the crankshaft 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. The big end bushings cannot be replaced. For the same reason, the connecting rod may not be replaced and, when cleaning the crankshaft, be very careful that no impurities get in through the shaft's lubrication holes. In order to prevent damaging the connecting rod bushings, do not attempt cleaning the lubrication duct with compressed air. - Make sure that the 2 caps on the crankpin are properly fitted. - A wrong installation of a cap can seriously affect the bushing lubrication pressure.

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N.B. THE MAIN BEARINGS ARE NOT GRINDABLE

Specific tooling
020074Y Support base for checking crankshaft alignment

Characteristic
Off-line maximum admitted A = 0.15 mm
B = 0.01 mm C = 0.01 mm D = 0.10 mm

Inspecting the crankcase halves

- Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take particular care when handling the oil pump compartment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the transmission side (see diagram). - Take particular care, also, that there are no signs wear in the oil by-pass valve housing (see Chapter Lubrication), as this could prevent a good seal in the piston, which regulates the oil pressure. - On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the flywheel side oil seal. - Inspect the coupling surfaces on the crankcase halves for scratches or deformation, taking particular care with the cylinder/crankcase surfaces and the crankcase halves surfaces. - Defects in the crankcase coupling gasket between the crankcase halves or the mating surfaces shown in the diagram, could cause a drop in the oil pressure lubricating the main bushings and connecting rod.

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- Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and dimensions.
N.B. THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKS CAN CAUSE A CONSIDERABLE DROP IN THE LUBRICATION PRESSURE FOR MAIN BUSHINGS AND CONNECTING ROD. N.B. THE HEAD LUBRICATION CHANNEL IS PROVIDED 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 OF THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.

Inspecting the crankshaft plain bearings

-T o obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure (3.2 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels. - The main bushings are comprised of two halfbearings, one with holes and channels for lubrication 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 opposed the cylinder. - To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be perfectly orthogonal to the cylinder axis, as 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.

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- 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. - There are three crankcase versions: with RED main bushings, with BLUE main bushings and with YELLOW main bushings. - There is only one type of main bushing housing hole in the crankcase The standard bushing diameter after driving is variable on the basis of a coupling selection. - The bushing housings in the crankcase are available in two categories, Cat. 1 and Cat. 2, as are the crankshafts. - The main bushings are available in three thickness categories, identified by colour markings, as shown in the table below.
TYPE A B C Type "A" RED Main half-bearing Bushing category 1.970 1.973 Crankcase halves category A B 1 1 2 C 2 IDENTIFICATION RED BLUE YELLOW Type "B" BLUE 1.9703 1.976 Type "C" YELLOW 1.976 1.979 Possible fitting

Internal bushing diameter after fitting 29.025 29.040 29.019 29.034 29.028 29.043 29.022 29.037

Original Original and spare Original

Match the shaft with two category 1 crank webs with the category 1 crankcase (or cat. 2 with cat. 2) Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories.

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The spare crankshaft has half-shafts of the same category.

Crankcase halves Engine halfshaft Cat. 1 Cat. 2 Cat. 1 Cat. 2 N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALFSHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. N.B. CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS (BLUE) Cat. 1 Cat. 2 Cat. 2 Cat. 1 B B A C Bushing

Characteristic
Standard driving depth 1.35 to 1.6 Diameter of crankcase without bushing 32.953 32.963

Refitting the crankcase halves

- Fit the internal shield by locking the two screws to the prescribed torque. - Fit the oil filter fitting and tighten it to the prescribed torque. - Position the oil pre-filter element as shown in the picture. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, together with the alignment dowels. - Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half. - Reassemble both crankcase halves. - Fit the 10 screws and tighten them to the specified torque. - Fit a new O-ring on the pre-filter and lubricate it.

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- Insert the filter on the engine with the relative cap. Tighten to the prescribed torque.

Locking torques (N*m)

Internal engine crankcase bulkhead (transmission-side half shaft) screws 4 to 6 Engine-crankcase coupling screws 11 to 13 Oil filter on crankcase fitting 27 to 33 Engine oil drainage plug/ mesh filter 24 to 30

Studs
Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the picture. If it varies significantly from the driving depth indicated, it means that the stud bolt has yielded. In this case, replace it.

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By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the picture, remove the stud bolt from its seat. Clean the threaded seat on the carter thoroughly. Refit a new stud bolt and apply the special product on the threading crankcase side. Tighten up to the depth of the driving indicated.

Recommended products
Loctite Quick Set Loctite 270 high strength threadlock Loctite 270 high strength threadlock

Lubrication Conceptual diagrams

LUBRICATION CIRCUIT

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ENG - 145

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Oil pressure check

- Remove the electrical minimum oil pressure switch connection and remove the switch. - Check that the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation). - Check that the oil pressure is between 3.2 and 4.2 atm with the engine running at 6000 rpm and the oil at the required temperature. - Remove the appropriate tools once the measurement is complete, refit the oil pressure switch and washer, tightening it to the specified torque and fit the flywheel cover. - If the oil pressure is not within the specified limits, in the following order, check: the oil filter, the oil by-pass valve, the oil pump and the crankshaft seals.
N.B. THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER CONDITION.

Characteristic
Oil pressure Minimum pressure admitted at 6000 rpm: 3.2 atm.

Locking torques (N*m)

Minimum oil pressure sensor 12 to 14

Crankshaft oil seals

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Removal
- Remove the transmission cover and the complete drive pulley beforehand

- Install the base of the appropriate tool on the oil seal using the screws provided.

Specific tooling
020622Y Transmission-side oil seal punch

- Screw the threaded bar onto the base of the tool and extract the oil seal.

Specific tooling
020622Y Transmission-side oil seal punch

Refitting
- Always use a new oil seal upon refitting - Prepare the new oil guard by lubricating the sealing lip. - Preassemble the oil seal with the appropriate tool by positioning the screws. - Insert the sheath over the crankshaft. - Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase. - Insert the adaptor bushing of the tool in the hole on the crankcase.

ENG - 147

Engine

MP3 LT 250 i.e.

- Orientate the oil seal by inserting the bracket which is part of the appropriate tool. - Tighten the threaded bar onto the crankshaft as far as it will go. - Use the nut to move the base of the tool until you can see the end of the oil seal driving stroke - Remove all the tool components following the procedure but in reverse order
CAUTION DO NOT LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE. CAUTION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS. WHEN THE POSITION IS REACHED, DO NOT RETRACT THE OIL SEAL. FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL SEAL SHEATH. CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.

Specific tooling
020622Y Transmission-side oil seal punch

Oil pump

ENG - 148

MP3 LT 250 i.e.

Engine

Removal
- Undo the two clamping screws in the figure and remove the cover over the pump control sprocket.

- Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes. - Remove the central screw with Belleville washer, as shown in the diagram. - Remove the chain with the crown. - Remove the control sprocket wheel with relative O-ring. - Remove the oil pump by undoing the two screws in the figure. - Remove the oil pump seal.
N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.

Inspection
- Remove the two screws and the oil pump cover. - Remove the circlip retaining the innermost rotor. - Remove and wash the rotors thoroughly with petrol and compressed air. - Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the retainer ring.

ENG - 149

Engine

MP3 LT 250 i.e.

- Check the clearance between the rotors in the position shown in the diagram using a feeler gauge. Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure.

Characteristic
Axial rotor clearance Limit values admitted: 0.09 mm Distance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm Distance between the rotors Admissible limit clearance: 0.12 mm

Refitting
- Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit. - Fit the pump cover in the position that permits the crankcase clamping screws to be aligned. - Make sure the gasket is positioned properly and refit the pump on the engine crankcase. The pump can only be fitted in one position. - Tighten the screws to the prescribed torque. ENG - 150

MP3 LT 250 i.e.

Engine

- Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the cup washer. Tighten to the prescribed torque. -Fit the oil pump cover, by tightening the two screws to the prescribed torque.
N.B. FIT THE CUP WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP TURNS FREELY.

Locking torques (N*m)

Screws fixing oil pump to the crankcase 5 to 6 Oil pump command sprocket screw 10 to 14 Oil pump cover screws 0.7 - 0.9

Removing the oil sump

- Remove the oil filler plug, the transmission cover, the complete driving pulley assembly with belt and the sprocket wheel, as described in the "Transmission" chapter. - Drain the oil as described above. - Remove the 7 screws, shown in the diagram, and the 2 rear brake fluid pipe fixing brackets. - Remove the screw, the by-pass piston, the gasket and the centring dowels shown in the figure.

ENG - 151

Engine

MP3 LT 250 i.e.

Inspecting the by-pass valve

- Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defective parts.

Characteristic
By-pass check up: Standard length 54.2 mm

Refitting the oil sump

- Refit the by-pass piston in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump. - Refit the rear brake cable brackets and the screws in the reverse order from which they were removed. - Tighten the screws to the prescribed torque. - Refit the driving pulley assembly, the drive belt, the sprocket wheel and the transmission cover, as described in the "Transmission" chapter. - When testing the lubrication system, refer to chapter "Crankcase and Crankshaft", regarding lubrication of the crankshaft and connecting rod

Locking torques (N*m)

Oil sump screws 10 to 14

ENG - 152

INDEX OF TOPICS

INJECTION

INJEC

Injection

MP3 LT 250 i.e.

INJEC - 154

MP3 LT 250 i.e.

Injection

TRANSPARENCY
1 2 3 4 5 6 7 8 9 10 11 Specification Fuel injector Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Battery Engine Speed sensor HV coil Lambda probe Fuel pump Water temperature sensor Injection load solenoid Instrument panel Desc./Quantity

12V - 12 Ah

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 - Lambda probe The system implements an idle feeding correction with cold engine through a Stepper motor on a bypass 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 system 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 two pipes provided with quick couplings. This allows obtaining a continuous circulation, thereby avoiding the risk of fuel boiling. The pressure regulator is situated at the end of the circuit. The fuel pump is controlled by the MIU control unit; this ensures safety of the vehicle. The ignition circuit consists of: - HV coil - HV cable - Shielded cap INJEC - 155

Injection

MP3 LT 250 i.e.

- 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 The control unit is provided with a self-diagnosis system connected to an indicator light in the instrument panel.

Failures are detected and restored by the diagnostic 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
020680Y Diagnosis Tool

INJEC - 156

MP3 LT 250 i.e.

Injection

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 antitheft 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 vehicle.

Precautions
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 ground C: Fuel system a. Broken fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Broken coil c. Broken shielded cap E: Intake circuit a. Dirty air filter b. Dirty by-pass circuit c. Faulty Stepper motor F: Other a. Incorrect distribution timing b. Wrong idle mixture c.Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors. Make sure that all connections have been correctly made. INJEC - 157

Injection

MP3 LT 250 i.e.

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 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instruments that are not suitable might damage the MIU central control unit. Use instruments with definitions over 0.1V and 0.5 W , the precision must be greater than 2%.

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 feed system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to avoid spraying fuel to your eyes. 3. When 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. 5. Before trying 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 vehicle 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 wiring. 8. When an ignition problem is detected, start the checks from the battery and the injection system connections. 9. Before disconnecting the MIU control unit 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 polarity when fitting the battery. 11. To avoid damage, only disconnect and reconnect the MIU system connectors if required. Before reconnecting, check that the connectors are dry. 12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not take measurements not specifically foreseen by the manual. 13. At the end of every check performed with the diagnostic tester, 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.

INJEC - 158

MP3 LT 250 i.e.

Injection

EMS circuit diagram

1. Battery 12V - 12 Ah 2. Engine rpm sensor 3. coolant temperature sensor 4. Immobilizer aerial 5. Stop switches 6. Fuse No. 2 20A 7. Fuse No. 6 3A 8. Key switch contacts 9. Fuse No. 5 15A 10.Engine stop switch

INJEC - 159

Injection

MP3 LT 250 i.e.

11.Fuse No. 10 7.5A 12.CAN line connection with tilt locking electric control unit 13.Fuse No. 8 10A 14.Starter button 15.Injection load remote control 16.Starter remote control 17.Electric fan remote control 18.Starter motor 19.Electric fan motor 20.Fuel pump 21.HV coil 22.Fuel injector 23.Lambda sensor 24.Engine "WARNING" light 25.Immobilizer LED 26.Diagnostics connector

Troubleshooting procedure Engine does not start

ENGINE DOES NOT START IF ONLY PULLED
Possible Cause Immobiliser enabling signal Operation System not encoded System not efficient, repair according to the indications of the self-diagnosis Pump relay HV coil Injector Revolution timing sensor Fuel in the tank Fuel pump activation Fuel pressure (low) Injector capacity (low) Shielded spark plug cap HV coil (secondary insulation) Coolant temperature Distribution timing - injection ignition Intake air temperature End of compression pressure

Presence of faults detected by the self diagnosis

Fuel system

Power to the spark plug Parameter reliability

End of compression pressure

Starting difficulties
ENGINE STARTER PROBLEMS
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor

INJEC - 160

MP3 LT 250 i.e.

Injection

Possible Cause

Starter speed

End of compression pressure Power to the spark plug

Fuel system

Correctness of the parameters

Operation Air temperature Coolant temperature Starter motor and solenoid Battery Ground connections End of compression pressure Spark plug Shielded cap HV coil Speed-timing sensor Ignition advance Fuel pressure (low) Injector capacity (low) Injector sealing (poor) Coolant temperature Stepper throttle valve position intake air temperature (steps and actual opening) Cleaning of the auxiliary air pipe and throttle valve; air filter efficiency

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Spark plug Ignition timing Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel pump Pressure regulator Fuel filter Injector capacity

Ignition efficiency Correctness of the parameters

Intake system cleaning

Intake system sealing (infiltrations)

Fuel system (low pressure)

Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Ignition timing Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor

Ignition efficiency Correctness of the parameters

INJEC - 161

Injection

MP3 LT 250 i.e.

Possible Cause Intake system sealing (infiltrations)

Fuel system (low pressure)

Operation Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel pump Pressure regulator Fuel filter Injector capacity

Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATING
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel pump Pressure regulator Fuel filter Injector capacity Manifold - head Manifold - silencer silencer welding

Correctness of the parameters

Intake system sealing (infiltrations)

Fuel system (low pressure)

Exhaust system sealing (infiltrations)

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN
Possible Cause Intake system cleaning Operation Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake sleeve Filter box Spark plug wear check Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance TPS reset successful Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe

Intake system sealing Ignition system Parameter reliability

TPS reset successful Presence of faults detected by the self diagnosis

INJEC - 162

MP3 LT 250 i.e.

Injection

Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORMANCE ON PICKUP
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Spark plug Shielded cap HV cable HV coil Air filter Filter box (sealing) Intake sleeve (sealing) Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Fuel level in the tank Fuel pressure Fuel filter Injector capacity

Spark plug power supply

Intake system

Parameter reliability

Fuel system

Engine knocking
PRESENCE OF KNOCKING (COMBUSTION SHOCKS)
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Spark plug Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake sleeve Filter box TPS reset successful Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness

Ignition efficiency Parameter reliability

Intake system sealing TPS reset successful Fuel system

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 delivery and return 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 - 163

Injection

MP3 LT 250 i.e.

Removing the butterfly valve

Remove the fuel piping clamping screw indicated in the figure.

Remove the fast-release fittings from the injector support.

INJEC - 164

MP3 LT 250 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.

Remove the clip fixing the throttle body to the air cleaner bellows.

INJEC - 165

Injection

MP3 LT 250 i.e.

Remove the gas command fitting as indicated in the picture

Refitting the butterfly valve

To refit, perform the operations in the reverse order from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45 as shown in the photograph.

INJEC - 166

MP3 LT 250 i.e.

Injection

Pump supply circuit

INJECTION LOADS
1 2 3 4 5 6 7 8 9 10 Specification Battery Fuse Fuse Ignition switch contacts Fuse Injection load solenoid Fuel pump HV coil Fuel injector Lambda probe Desc./Quantity 12V - 12 Ah 15A 20A 7.5 A

INJEC - 167

Injection

MP3 LT 250 i.e.

11

Specification Electric fan solenoid

Desc./Quantity

When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts, in the presence of rpm timing signal the pump is continuously supplied. ELECTRICAL DATA Pump winding resistance ~ 1.5 Ohm Input current during normal functioning 1.4 to 1.8 A Input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel pressure control, choking the circuit on the return pipe) Check the efficiency of injection load 15 A fuse No. 5. Check that the live control unit power supply 7.5A fuse No. 10 works properly.

Check the efficiency of the injection load solenoid. 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 solenoid.

INJEC - 168

MP3 LT 250 i.e.

Injection

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 BlackPurple 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. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 169

Injection

MP3 LT 250 i.e.

Check the presence of fixed voltage between the grey/black cable of the solenoid base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the solenoid base.
N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 170

MP3 LT 250 i.e.

Injection

pump circuit 6

Check, on switching to "ON", that there is battery voltage, for about two seconds, to the Black-Green cable of the pump connector and ground with pump connector disconnected. Otherwise, check the continuity of the Black-Green cable between the pump connector and the remote control base. Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector black cable, system side, and the ground. If, when switching to "ON", the pump continues to turn after two seconds of activation, check, with the control unit disconnected and the injection load remote 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 appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the delivery pipe..

INJEC - 171

Injection

MP3 LT 250 i.e.

Check during regular operation by placing the appropriate tool between the pump and the injector. With the battery voltage> 12 V check that the fuel pressure is 2.5 BAR and that the input current is 1.4 to 1.8 A

With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe equipped with the pressure gauge of the appropriate tool. Get a graded burette with a flow rate of approximately 1 L. Rotate the pump using the active diagnoses of the palm top computer. Using a pair of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 BAR. Check that within 15 seconds the pump has a flow rate of approx. 110 cm.

Specific tooling
020480Y Petrol pressure check kit

Fuel filter check

Disconnect the terminals from the electric pump

Remove the screw shown in the picture

INJEC - 172

MP3 LT 250 i.e.

Injection

Remove the clip fixing the piping to the filter shown in the picture

Separate the lower part of the pump mounting as shown in the picture.

Remove the filter from the pump mounting

INJEC - 173

Injection

MP3 LT 250 i.e.

Inspecting the injector circuit

INJECTION LOADS
1 2 3 4 5 6 7 8 9 10 Specification Battery Fuse Fuse Ignition switch contacts Fuse Injection load solenoid Fuel pump HV coil Fuel injector Lambda probe Desc./Quantity 12V - 12 Ah 15A 20A 7.5 A

INJEC - 174

MP3 LT 250 i.e.

Injection

11

Specification Electric fan solenoid

Desc./Quantity

Check the resistance at the injector ends: 14.5 5% Ohm Check the efficiency of injection load 15 A fuse No. 5. Check that the live control unit power supply 7.5A fuse No. 10 works properly.

Check the efficiency of the injection load solenoid. 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 solenoid.

INJEC - 175

Injection

MP3 LT 250 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 BlackPurple 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. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

Check the presence of fixed voltage between the grey/black cable of the solenoid base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the solenoid base.
N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 176

MP3 LT 250 i.e.

Injection

Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 4 10 A) and the remote control base.
N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 177

Injection

MP3 LT 250 i.e.

With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable between 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 connector and the ground lead

With injector disconnected and the injector load solenoid disconnected, check the continuity of the Black-Green cable between the injector connector and solenoid base.

INJEC - 178

MP3 LT 250 i.e.

Injection

Inspecting the injector hydraulics

To carry out the injector check, remove the intake manifold by removing the three clamping screws at the head and the clip connecting the control unit to the manifold.

Install the appropriate tool for checking fuel pressure and position the manifold over a container graduated by at least 100 cm. 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 fifteen seconds, approximately 40 cm of fuel is dispensed with an adjustment pressure of approximately 2.5 BAR.

Specific tooling
020480Y Petrol pressure check kit

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

INJEC - 179

Injection

MP3 LT 250 i.e.

Components location

INJEC - 180

MP3 LT 250 i.e.

Injection

TRANSPARENCY
1 2 3 4 5 6 7 8 9 10 11 Specification Fuel injector Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Battery Engine Speed sensor HV coil Lambda probe Fuel pump Water temperature sensor Injection load solenoid Instrument panel Desc./Quantity

12V - 12 Ah

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 approximately 20

INJEC - 181

Injection

MP3 LT 250 i.e.

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 engine speed sensor connector and between pin 15 and the brown cable of the engine speed sensor connector

With the interface wiring and rpm sensor connector disconnected from the control unit, check that the Red and Brown cables (pin 13 - 15) are isolated from each other and insulated from the ground.

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

INJEC - 182

MP3 LT 250 i.e.

Injection

HT coil

INJECTION LOADS
1 2 3 4 5 6 7 8 9 10 Specification Battery Fuse Fuse Ignition switch contacts Fuse Injection load solenoid Fuel pump HV coil Fuel injector Lambda probe Desc./Quantity 12V - 12 Ah 15A 20A 7.5 A

INJEC - 183

Injection

MP3 LT 250 i.e.

11

Specification Electric fan solenoid

Desc./Quantity

The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two important parameters: - Ignition advance This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 50 R/1'. - Magnetisation time The coil magnetisation time is controlled by the control unit. The ignition power is increased during the engine start-up phase. The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during compression.

Specific tooling
020331Y Digital multimeter Check the efficiency of injection load 15 A fuse No. 5. Check that the live control unit power supply 7.5A fuse No. 10 works properly.

Check there is voltage between pins 22 and 26 of the interface wiring for around two seconds when switching to ON.

INJEC - 184

MP3 LT 250 i.e.

Injection

Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load solenoid base with the control unit disconnected and the solenoid disconnected. Resistance of the primary = 0.5 8% Ohm

Check the efficiency of the injection load solenoid. 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 solenoid.

INJEC - 185

Injection

MP3 LT 250 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 BlackPurple 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. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 186

MP3 LT 250 i.e.

Injection

Check the presence of fixed voltage between the grey/black cable of the solenoid base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 5 15 A) and the solenoid base.
N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 187

Injection

MP3 LT 250 i.e.

Coolant temperature sensor

TEMPERATURE SENSOR

1
Desc./Quantity

1 2

Specification Water temperature sensor engine stop switch

With the connector on the control unit side disconnected, and the coolant temperature sensor connector connected, check that the resistance values between pins 9 and 18 correspond to the engine temperature. 20 = 2500 100 80 = 308 6 With the control unit side connector disconnected, and the coolant temperature connector discon-

INJEC - 188

MP3 LT 250 i.e.

Injection

nected, check the insulation between the two light blue-green and grey-green cables With the connector on the control unit side disconnected and the coolant temperature sensor connector disconnected, check the continuity between pin 9 of the interface wiring and the bluegreen cable of the connector, and between pin 18 of the interface wiring and the grey-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 - 189

Injection

MP3 LT 250 i.e.

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

Specific tooling
020680Y Diagnosis Tool

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 - 190

MP3 LT 250 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. Given that the TPS resetting is also done when the control unit is replaced, place the control unit - filter box bellows at 45 during the refitting operation as shown in the picture.

Lambda probe
CONTROLLO DEL SEGNALE 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 (+)

INJEC - 191

Injection

MP3 LT 250 i.e.

With the engine running at idle speed, check that the voltage oscillates between 0V and 1V With the throttle valve completely open, the voltage 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 - 192

MP3 LT 250 i.e.

Injection

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

INJEC - 193

Injection

MP3 LT 250 i.e.

The Lambda probe or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type, i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic converter in an area where the gas temperature is always high. The temperature at which the sensor works is at least 350C at 600C 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. Since the sensor only works at high temperatures, it has an electric preheating element inside it, controlled by the control unit, to take it quickly to the functioning state.

Specific tooling
020481Y Control unit interface wiring 020331Y Digital multimeter Check the efficiency of injection load 15 A fuse No. 5. Check that the live control unit power supply 7.5A fuse No. 10 works properly.

Check there is voltage between pins 21 and 26 of the interface wiring, for around two seconds, when switching to ON.

INJEC - 194

MP3 LT 250 i.e.

Injection

With the engine cold, check the resistance of the Lambda sensor heater between pin 21 of the interface wiring and the black green cable of the injection load remote control base, with the control unit disconnected and the remote control disconnected. Resistance of the heater at approximately 20 = 9 Ohm 20%

Check the efficiency of the injection load solenoid. 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 solenoid.

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 BlackPurple 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. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 195

Injection

MP3 LT 250 i.e.

INJEC - 196

MP3 LT 250 i.e.

Injection

Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 4 10 A) and the remote control base.
N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (SOLENOIDS, CONTROL UNIT, FUSES ETC.).

INJEC - 197

INDEX OF TOPICS

SUSPENSIONS

SUSP

MP3 LT 250 i.e.

Suspensions

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

Front Removing the front wheel

- Remove the 5 fixing screws indicated in the picture.

Locking torques (N*m)

Wheel fixing screw 20 to 25

Front wheel hub overhaul

- Remove the ball bearing check Seeger ring indicated in the picture

Extract the ball bearing using the specific tool

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

SUSP - 199

Suspensions

MP3 LT 250 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 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 casing 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 - 200

MP3 LT 250 i.e.

Suspensions

Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20

Handlebar Removal
Remove the two handlebar covers as explained in the Bodywork Chapter. Remove the handlebar wiring fixing clips and disconnect the electric connectors from the brake levers. Unscrew the fittings, then remove the front and rear brake pump piping. Remove the flexible transmission of the accelerator and remove the throttle. Loosen the clamp fixing the handlebar to the steering tube and pulling upwards, remove the handlebar, 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 - 201

Suspensions

MP3 LT 250 i.e.

Hydraulic system layout

When roll is locked, the gear motor activates the hydraulic pump indicated in the picture 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 absorber.

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 - 202

MP3 LT 250 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 indicated in the figure from the support bracket.

SUSP - 203

Suspensions

MP3 LT 250 i.e.

Remove the suspension roll lock device pipes from the headstock.

Remove first the flexible part of the calliper from the steering tube as shown in the picture, and then remove the rigid part.

Remove the tone wheel wiring by disconnecting the connector on the fuel tank after removing the chassis central cover. After that, remove the retainers indicated in the figure.

SUSP - 204

MP3 LT 250 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 - 205

Suspensions

MP3 LT 250 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 - 206

MP3 LT 250 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 - 207

Suspensions

MP3 LT 250 i.e.

For refitting, follow the operations for removal but in reverse order, observing the prescribed torque and greasing the bearings and their seats.

STEERING TUBES

Name Side headstock upper ring nut Side headstock lower ring nut Screw fixing sliding stem to shock absorber Clamp for sliding stem locking device Fixing nuts for constant-velocity universal joints

Torque in Nm 20 - 24 12 15 45 to 50 6.5 - 10.5 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 parallelogram.

SUSP - 208

MP3 LT 250 i.e.

Suspensions

Remove the 4 screws fixing the tilt brake disc sector indicated in the picture.

Remove the retainers indicated in picture of the half-arms joint flange.

To facilitate the operations indicated below, remove the suspension locking electronic control unit indicated in the picture.

SUSP - 209

Suspensions

MP3 LT 250 i.e.

Remove the arm coupling retainers from the parallelogram 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 - 210

MP3 LT 250 i.e.

Suspensions

Carry out a visual check of the upper and lower bearings on the headstocks and their seats. Replace them in case of signs of abnormal wear.

SUSP - 211

Suspensions

MP3 LT 250 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 bearings on the chassis.

For refitting, follow the operations for removal but in reverse order, lubricating the reference dowels on the parallelogram half-arms and observing the prescribed torque.

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

SUSP - 212

MP3 LT 250 i.e.

Suspensions

Geared motor and Suspension locking system

Before removing the gear motor: Disable the suspension lock. Remove the legshield. With the set nut indicated in the picture, remove the tensioning cable of the suspension locking mechanical calliper.

Remove the electrical connection of the gear motor position potentiometer.

Remove the electrical connection of the geared motor electric motor.

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

WARNING: BRAKE FLUID IS HIGHLY POISONOUS. DO NOT INGEST OR SWALLOW. IF ACCIDENTALLY SWALLOWED, 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.

SUSP - 213

Suspensions

MP3 LT 250 i.e.

IF BRAKE FLUID GETS ACCIDENTALLY IN CONTACT WITH YOUR EYES, RINSE WITH ABUNDANT FRESH WATER AND SEEK MEDICAL ADVICE IMMEDIATELY. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN.

Remove the 3 fixing screws indicated and remove the whole gear motor.

Use a screwdriver to remove the plastic access cover to the pump joint/gear motor Undo the pump joint screw. Undo the two gear motor pump locking screws.

SUSP - 214

MP3 LT 250 i.e.

Suspensions

In the new solution to fix the pump to the suspension lock assembly, the retainers fixing 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 locking have been carried out.

SUSP - 215

Suspensions

MP3 LT 250 i.e.

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

Remove the nut indicated in the figure, if necessary 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 washer.

Specific tooling
020234y extractor Remove the three fixing screws of the electric motor. It is important to mark the direction of the electric motor position in order to refit it correctly.

SUSP - 216

MP3 LT 250 i.e.

Suspensions

Remove the four screws indicated in the figure, remove the flexible transmission supporting bracket, separate the two crankcase halves, if necessary, use a rubber mallet to hit the flexible transmission lever in order to separate the two crankcases.

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

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

Extract the electric motor bearing with the specific tool.

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

SUSP - 217

Suspensions

MP3 LT 250 i.e.

Hold the crankcase in a perfectly horizontal position, heat it with a specific heat gun at about 120 C, use the specific tool to fit the bearing of the flexible 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 position, 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 necessary.

Specific tooling
020363Y 20-mm guide 020358Y 37x40-mm Adaptor 020151Y Air heater 020376Y Adaptor handle Remove the spring/toothed sector unit from its fitting, slightly hit with a mallet if necessary to release the unit.

SUSP - 218

MP3 LT 250 i.e.

Suspensions

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 position, 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 Hold the crankcase in a perfectly horizontal position, 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 necessary.

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

SUSP - 219

Suspensions

MP3 LT 250 i.e.

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

Fit the pinion and align the reference on the pinion teeth with the reference indicated on the second slot of the toothed sector. Grease the pinion and the toothed sector with specific grease. Refit the toothed sector spacer.

Recommended products
MONTBLANC MOLYBDENUM GREASE MONTBLANC MOLYBDENUM GREASE Grease with molybdenum disulphide

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

Locking torques (N*m)

Gear motor crankcase halves coupling screws 11 to 13

SUSP - 220

MP3 LT 250 i.e.

Suspensions

Refit the electric motor; check the position is correct by means of the reference indicated during removal. The motor should be so positioned that it does not protrude from the reduction unit mould, see figure. Tighten the screws to the prescribed torque.

Locking torques (N*m)

Electric motor coupling screws 11 to 13 Place the moulded washer of the flexible transmission 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 connector directed to the opposite side of the hydraulic pump.

Refit the hydraulic pump on the gear motor body and tighten the screws to the prescribed torque. Fit but not tighten the pump stem coupling screw and refit the plastic protection cap. The synchronisation procedure should be complete when the installation is finished.

Locking torques (N*m)

Gear motor hydraulic pump tightening screws 11 to 13

SUSP - 221

Suspensions

MP3 LT 250 i.e.

Remove the two bracket screws after releasing the spring and freeing the flexible transmission adjustment. CAUTION: A FIRST PRODUCTION BATCH WILL BE EQUIPPED WITH DOUBLE COAXIAL SPRING. It is very important to remove the flexible transmission from its fitting only for replacement. When refitting, tighten the two bracket screws and the flexible transmission lever nut to the prescribed torque.

Locking torques (N*m)

Bracket tightening screws 8 to 12

Undo the Allen screw and remove the switch. Upon refitting, place the switch with the button oriented 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 regularly activated by the stop on the lever.

SUSP - 222

MP3 LT 250 i.e.

Suspensions

Undo the two pad pin screws; remove the pads with the spring. Upon refitting, tighten the two screws to the prescribed torque and use threadlock. Upon refitting, adjust the cable properly so that the switch is pushed when the system is unlocked.

SUSP - 223

Suspensions

MP3 LT 250 i.e.

Select the SYSTEM RESET option from the main menu

Turn the ignition switch to ON Select the LOWER STOP SEARCH option from the SYSTEM RESET menu WAIT PROCEDURE IN PROGRESS

SUSP - 224

MP3 LT 250 i.e.

Suspensions

The palmtop indicates the outcome of the stop search operation: POSSIBLE LIMIT STOP VALUES. TO EXIT, PRESS A KEY AND TURN OFF AND ON. SELECT PARAMETERS TO ADJUST AT 12. Check the gear motor if the palmtop does not indicate this.

Select the PARAMETERS option from the main menu

The palmtop displays the option: RELATIVE POTENTIOMETER ANGLE This function is active coming from the LOWER STOP SEARCH procedure. NOTE: a slight oscillation of the angle value between 0.00 and 0.50 is considered normal

Remove the protection cap of the gear motor set screw Use a plain slot screwdriver to turn the set screw anticlockwise until replicating the 12 condition on the palmtop RELATIVE POTENTIOMETER ANGLE 12 (a slight value oscillation is considered normal) Refit the protection cap

SUSP - 225

Suspensions

MP3 LT 250 i.e.

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
to 13

Select the SYSTEM RESET option from the MAIN menu

SUSP - 226

MP3 LT 250 i.e.

Suspensions

Select the POTENTIOMETER RESET option from the SYSTEM RESET menu and press OK. WAIT.... PROCEDURE IN PROGRESS

The palmtop displays the words: CHECK THAT THE CONTROL IS SET AT 12 FROM THE LOWER STOP. PRESS OK TO CONTINUE Press OK The palmtop displays the words: POSSIBLE LIMIT STOP VALUES. PRESS A KEY AND SHIFT OFF AND ON If this is not successful, the roll lock mechanism remains locked for safety.

Adjust the flexible transmission so that a small clearance is left to guarantee switch activation on the roll lock calliper

Electrical devices test

SCHEMA DI PRINCIPIO IMPIANTO ELETTRICO BLOCCO ROLLIO

SUSP - 227

Suspensions

MP3 LT 250 i.e.

1. GEARED MOTOR 2. ROLL LOCK CALLIPER SWITCH 3. ROLL UNLOCK-LOCK CONTROL SWITCH 4. POTENTIOMETER 5. RIDER DETECTION SENSOR 6. LEFT SPEED SENSOR 7. RIGHT SPEED SENSOR 8. DIAGNOSTIC TESTER SERIAL LINE 9. ENGINE CONTROL UNIT 10.+ DIRECT BATTERY 11.+ LIVE BATTERY 12.LOW BEAM LIGHT 13.FUSE No. 3, 20A 14.LOW BEAM LIGHT SOLENOID 15.PRESSURE SWITCH 16.HORN SOLENOID 17.INSTRUMENT PANEL 18.ROLL LOCK SYSTEM CONTROL UNIT SENSORE RUOTA FONICA

SUSP - 228

MP3 LT 250 i.e.

Suspensions

1: Right tone wheel 2: Left tone wheel With the interface wiring disconnected from the parking electrical control unit and connected to the system, check that the sensor resistance between pins 23 - 17 and 24 - 17 is between 774 and 946 Ohm at approximately 20

With interface wiring disconnected from the control unit, check the continuity between pin 23 and the brown cable of the LEFT wheel speed sensor connector; between pin 17 and the red cables of the LEFT wheel speed sensor and brown cable of the RIGHT sensor; between pin 24 and the red cable of the RIGHT wheel speed sensor

SUSP - 229

Suspensions

MP3 LT 250 i.e.

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; between pin 17 and the yellow cables on both connectors; between pin 24 and the red cable on the connector.

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

SUSP - 230

MP3 LT 250 i.e.

Suspensions

With a feeler gauge, check that the air gap between the screw head and the sensor is between 0.35 and 1 mm

SENSORE PRESENZA PILOTA

SUSP - 231

Suspensions

MP3 LT 250 i.e.

1: RIDER DETECTION 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

SUSP - 232

MP3 LT 250 i.e.

Suspensions

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 connector.

SENSORE PINZA BLOCCO ROLLIO

1: ROLL LOCK CALLIPER SENSOR

SUSP - 233

Suspensions

MP3 LT 250 i.e.

The roll lock calliper sensor is a normally opened switch. Check its correct operation with a multimeter.

With the interface wiring disconnected from the control unit, check the continuity between pin 34 and the brown cable of the roll lock gripper sensor connector on the system side. Check the continuity of the connector black cable and a ground point on the chassis

Also check that the flexible transmission control lever activates the limit stop switch properly.

POTENZIOMETRO

SUSP - 234

MP3 LT 250 i.e.

Suspensions

1: POTENTIOMETER With the interface wiring connected to the control unit, secure the vehicle on its centre stand and switch to "ON". Select the reading scale on 20 V. Insert the multimeter probes on pins 17 (black) and 25 (red). Check that the voltage in the activated locking condition is 4V and 1V in the locking rest condition.

SUSP - 235

Suspensions

MP3 LT 250 i.e.

With the interface wiring disconnected from the control unit, check the continuity between pin 17 and the yellow cable of the potentiometer connector, 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 other and ground.

PULSANTE BLOCCO - SBLOCCO ROLLIO

SUSP - 236

MP3 LT 250 i.e.

Suspensions

0: REST POSITION 1: LOCKING POSITION 2: UNLOCKING POSITION 3: ROLL LOCK-UNLOCK SWITCH With the interface wiring disconnected from the control unit, check the continuity of the electrical lines between the interface wiring and the roll lockunlock switch: Pin 26 and green - grey cable Pin 35 and violet - black cable Pin 33 and yellow - blue cable Also check that the above indicated electrical lines are insulated from the ground.

SUSP - 237

Suspensions

MP3 LT 250 i.e.

Check the continuity between the black cable on the connector and a ground point on the chassis.

With a multimeter, check the operation of the roll lock-unlock switch referring to the diagram indicated in the figure. 1. GROUND 2. LOCK 3. REST 4. UNLOCK

MOTORIDUTTORE

SUSP - 238

MP3 LT 250 i.e.

Suspensions

1: GEAR MOTOR With the interface wiring disconnected from the control unit, check the continuity between pin 28 and the yellow cable, between pin 38 and the blue cable on the gear motor connector

SUSP - 239

Suspensions

MP3 LT 250 i.e.

With the interface wiring disconnected from the control unit, check the continuity of the gear motor winding placing the multimeter probes on pins 28 and 38 as indicated in the figure

PRSSOSTATO

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

SUSP - 240

MP3 LT 250 i.e.

Suspensions

Check 7.5 A fuse No. 11 for efficiency. With interface wiring disconnected from the control unit, check the continuity of the blue - black cable between pressure sensor connector and the horn solenoid base as indicated in the picture. Check the continuity between pin 27 and the solenoid base white cable.

Check the continuity of the yellow - red cable between the pressure switch connector and the fusebox and between the solenoid base and the fusebox. With a multimeter, also check the pressure switch operation as well as the continuity at rest as this is normally closed switch.

SUSP - 241

Suspensions

MP3 LT 250 i.e.

Wheel alignment
Tool fitting

How to use the tools Check that tyre pressure is correct. Park the vehicle on level, smooth and even ground. Park the vehicle on its centre stand. Make sure that the parking system is disengaged. Lift the front wheels as shown in the picture Check that the wheel rims rotate evenly and whether there is abnormal clearance in bearings and suspension. Make sure that the steering control shows no signs of abnormal clearance in joints and bearings. Otherwise, correct this and then adjust them.

Characteristic
Front tyre pressure (rider) Front tyre pressure (rider): 1.6 bar Rear tyre pressure (rider) Rear tyre pressure (rider): 2 bar

SUSP - 242

MP3 LT 250 i.e.

Suspensions

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 - 243

Suspensions

MP3 LT 250 i.e.

Fit the bracket locking the parallelogram in the holes of the previously removed screws; use the screws supplied with the tool and be careful to correctly centre the spacer in the bearing.

Remove the nut fixing the steering control arm and keep the original washer in position.

Fit the steering guiding bracket in a straight riding position, fix one end to the attachment of the half-arm coupling flange and the other end to the screw fixing the steering control arm.

Place the frame so that the sliders come into contact with the rim maximum diameter but without interfering with the tyre. If required, reposition the frame by operating the 3 adjustable support feet.

SUSP - 244

MP3 LT 250 i.e.

Suspensions

Fit the frame locking bracket

Make sure the frame is adequately centred by checking with a gauge that the lugs along the vertical axis show the standard protrusion.

Check that the pointers of both tyres are correctly aligned, as shown in the picture. Maximum misalignment allowed: 4 notches.

Use tool 020647Y028 for LT version with extended track.

Specific tooling
020646Y Parallelogram and steering positioning tool 020647Y Toe-in checking tool 020647Y028 MP3 LT Toe-in tool (tricycle)

SUSP - 245

Suspensions

MP3 LT 250 i.e.

Rear Removing the rear wheel

Remove the full silencer assembly. - Remove the screw fixing the right-hand shock absorber to the bracket - Remove the two screws supporting the brake calliper on the bracket

- Remove the cotter pin, the cap, the wheel axle fixing nut and the outer one of the two spacers.

SUSP - 246

MP3 LT 250 i.e.

Suspensions

- Remove the mud guard clamping screw - Remove the two screws fixing the bracket to the engine

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

Refitting the rear wheel

To fit, follow the removal steps but in the reverse sequence, being careful to fit the spacers on the wheel axle as shown in the picture.

Locking torques (N*m)

Silencer arm clamping screws 27 - 30 Rear wheel axle nut 104 to 126 Shock absorber-crankcase attachment bracket 20 to 25 Lower shock absorber clamping screw 33 - 41 Nm Rear brake calliper fixing screws 25 - 30 Nm

Swing-arm Removal
- Place the vehicle on its centre stand; - Remove the swinging arm/engine fitting shown in the picture - Move the engine back

SUSP - 247

Suspensions

MP3 LT 250 i.e.

- Remove the spring anchoring the swinging arm to the chassis as shown in the picture

- Remove the two screws fixing the buffer support bracket to the chassis

- Undo the nut on the LHS shown in the figure and remove the corresponding bolt from the opposite side. - Remove the swinging arm.

- Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause excessive clearance on the rear suspension.

SUSP - 248

MP3 LT 250 i.e.

Suspensions

Overhaul
- Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the chassis side. - Check the axial clearance between the two swinging arms using a feeler gauge

Characteristic
Standard clearance 0.40 - 0.60 mm Allowable limit after use: 1.5 mm - In order to check the clearance of the swinging arm on the frame side, prepare a retainer using the fixing pin of the swinging arm on the frame and two rings from the special tool 020229Y. Alternatively, use two washers with 12-mm inside diameter for pins, minimum 30-mm outside diameter and 4-mm thick at least.

- Check there is no sticking in the rotation. - Check the axial clearance of the swinging arm on the chassis side

Characteristic
Standard clearance 0.40 - 0.60 mm Allowable limit after use: 1.5 mm - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the picture.

SUSP - 249

Suspensions

MP3 LT 250 i.e.

- Using a suitable pin remove the roller casings as shown in the pictures

- Using an appropriate tool plant new roller casings, being careful to position the bearings with the seal rings facing outwards

Specific tooling
020244Y 15-mm diameter punch 020115Y 18 punch

Characteristic
Length of the swinging arm tube on the engine side: L 175.3 + 0.3 0 Length of the internal swinging arm spacer on the engine side: L 183 + 0.3 0 Engine side swinging arm plastic bushing shim: 3.5 0.05 mm Chassis side swinging arm plastic bushing shim: 3.5 0.05 mm Length of the internal swinging arm spacer on the frame side: 290 0.1 mm Length of the swinging arm tube on the chassis side: 283 0.1 mm

SUSP - 250

MP3 LT 250 i.e.

Suspensions

- Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in the position shown in the picture - Adjust the bolt as shown in the picture - Position the chassis side swinging arm with the most protruding part pointing towards the silent block side as shown in the picture

Recommended products
AGIP GREASE PV2 Grease for steering bearings, pin seats and swinging arm Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2 of the swinging arm

- Make sure the silent bloc is not broken. If it is, replace the coupling. - Remove the Seeger ring shown in the picture

- Remove the full silent bloc bracket - Undo the silent bloc ring shown in the picture

SUSP - 251

Suspensions

MP3 LT 250 i.e.

- Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the tool is centred properly on the support

- Install a new silent bloc, making sure it aligns properly with the reference tooth. - Fit the silent blocs, making sure the chamfered part of the silent bloc matches the chamfered part of the bracket

- Using the appropriate tool, fit the silent bloc as shown in the picture

SUSP - 252

MP3 LT 250 i.e.

Suspensions

Refitting
For correct installation of the swinging arm on the vehicle, proceed as follows: 1. Position the silent block supporting clamp with part 3 inserted, and slightly tighten part 1 2. Position the swinging arm, inserting part 2 3. Tighten part 3 to the prescribed torque 4. Screw on and tighten part 4 to the prescribed torque 5. Screw on and tighten part 5 to the prescribed torque 6. Tighten part 1 to the prescribed torque Insert the swinging arm - engine bolt and tighten to the prescribed torque

SUSP - 253

Suspensions

MP3 LT 250 i.e.

SWINGING ARM FITTING

Name Part 1 Part 3 Part 4 Part 5 Engine-swinging arm bolt

Torque in Nm 64 - 72 5-7 90 - 110 64 - 72 Nm 64 - 72

Shock absorbers Removal

Proceed as follows: - place the vehicle on its centre stand; - lift the engine a little with a jack so as to free the two shock absorbers; - remove the silencer - undo the shock absorber spring assembly clamping screw from the support fixed to the engine on the one side and from that fixed to the silencer on the other; - unscrew the two upper nuts (one on each side) fixing the shock absorber spring assembly to the frame and remove the shock absorbers.

Refitting
Carry out the previous operations but in reverse order.

Locking torques (N*m)

SUSP - 254

MP3 LT 250 i.e.

Suspensions

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

Centre-stand
REMOVAL - Use a jack to support the vehicle properly. - Remove the two return springs from the centre stand. - Undo the nut shown in the figure. - Remove the pin from the right side. - Remove the centre stand. FITTING - On refitting tighten the nut to the specified torque.

Locking torques (N*m)

Centre stand bolt 31 - 39

SUSP - 255

INDEX OF TOPICS

BRAKING SYSTEM

BRAK SYS

MP3 LT 250 i.e.

Braking system

This section is dedicated to the description of the brake system components.

BRAK SYS - 257

Braking system

MP3 LT 250 i.e.

1. Front brake pipes 2. Rear brake pump 11 mm 3. Front brake pump 12 mm 4. Rear brake pipes (rear brake pump - rear valve) 5. Front valve 6. Front brake left calliper 30 mm 7. Front valve brake pipes (front valve - rigid pipes) 8. Front right brake calliper 30 mm 9. Brake pipes (front valve - rear valve) 10.Front brake right calliper pipes (fitting - wheel brake calliper) 11.Front brake left calliper pipes (fitting - wheel brake calliper) 12.Rear brake pipe on calliper side 13.Integral brake pump support bracket with pedal 14.Pedal fork 15.Brake pipes (pedal brake pump - rear valve) 16.Brake fluid reservoir 17.Brake fluid pipes fitting 18.Integral brake pump 15.87 mm 19.Rear brake calliper 22 mm 20.Rear valve 14 mm

Brake system fitting

1. LEFT PUMP PIPES TO REAR VALVE 2. RIGHT PUMP PIPES TO FRONT VALVE

BRAK SYS - 258

MP3 LT 250 i.e.

Braking system

BRAK SYS - 259

Braking system

MP3 LT 250 i.e.

1. LEFT PUMP PIPES TO REAR VALVE 2. RIGHT PUMP PIPES TO FRONT VALVE 3. FRONT VALVE PIPES TO REAR VALVE 4. FRONT BRAKE PIPES

1. FRONT PRESSURE ADJUSTMENT VALVE 2. FRONT BRAKE PIPES 3. RIGHT PUMP PIPES TO FRONT VALVE 4. FRONT VALVE PIPES TO REAR VALVE 5. LEFT PUMP PIPES TO REAR VALVE 6. RIGHT PUMP PIPES TO FRONT VALVE 7. FRONT BRAKE PIPES 8. FRONT VALVE PIPES TO REAR VALVE 9. LEFT PUMP PIPES TO REAR VALVE 10.FRONT VALVE PIPES TO REAR VALVE

BRAK SYS - 260

MP3 LT 250 i.e.

Braking system

11.REAR BRAKE PIPES 12.PEDAL PUMP PIPES TO REAR VALVE 13.REAR VALVE

BRAK SYS - 261

Braking system

MP3 LT 250 i.e.

1. PEDAL BRAKE PUMP 2. BRAKE FLUID RESERVOIR TO PEDAL BRAKE PUMP FITTING PIPES 3. BRAKE FLUID RESERVOIR 4. REAR VALVE 5. PEDAL PUMP - REAR VALVE PIPES

1. PEDAL VALVE - REAR PUMP PIPES 2. REAR BRAKE PIPES

BRAK SYS - 262

MP3 LT 250 i.e.

Braking system

Rear brake calliper Removal

- Remove the silencer. - Remove the two rear brake calliper devices fastening them to the support as shown in the picture.
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 EXAMINED.

BRAK SYS - 263

Braking system

MP3 LT 250 i.e.

Removal
Place a container under the calliper, unscrew the tube-calliper joint and empty the braking system. For easy draining of the braking system fluid, open the pump reservoir cap.

Loosen the two screws indicated in the figure and remove the calliper from the support. When refitting, tighten the two calliper retainers to the prescribed torque.

Locking torques (N*m)

Screw tightening calliper to support 24 to 27

Removal
Remove the cotter pin. Use new split pins when refitting.

Undo the wheel hub nut. - Upon refitting, secure to the specified torque.

Locking torques (N*m)

Wheel axle nut 74 - 88

BRAK SYS - 264

MP3 LT 250 i.e.

Braking system

Remove the Seeger ring, after that, remove the hub with the help of a rubber mallet slightly hitting on the brake disc side, turning the wheel hub at the same time.

Loosen the 6 screws indicated in the figure and remove the brake disc from the wheel hub. - Upon refitting, secure to the specified torque.

Recommended products
Loctite 242 product description Apply LOCTITE medium type 242 threadlock

Removal
Rest the vehicle on its centre stand and use the corresponding jack to lift the two front wheels; unscrew the five Allen screws indicated in the figure

Remove the pad upper closing cap.

BRAK SYS - 265

Braking system

MP3 LT 250 i.e.

Remove the pad pin lock with a screwdriver, paying attention not to spoil the calliper surface treatment. Use a corresponding measuring punch to extract the pad pin, if necessary move the brake pipes manually to release the pin. Then, remove the spring and the pads. Fit a new pad kit following the procedure but in reverse order.

Locking torques (N*m)

Wheel fixing screw 20 to 25

Fill Rear - combined

For the procedure in question see Highlighted operations section.

Front
For the procedure in question see Highlighted operations section.

Brake pipes
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.

BRAK SYS - 266

MP3 LT 250 i.e.

Braking system

Front brake pipes removal Unscrew the braking splitter screw. Disconnect the brake pipes removing the two metallic 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.

Parking brake
Remove the silencer loosening the 3 screws and the strap on the exhaust tube indicated in the picture. When refitting, place the parking brake flexible transmission retaining strap correctly.

BRAK SYS - 267

Braking system

MP3 LT 250 i.e.

Loosen the transmission set screw and release the cable from the calliper.

Remove the two fixing screws of the mechanic calliper and remove the calliper. To check calliper components, refer to the chapter on the roll lock calliper. When refitting, tighten to the specified torque.

Locking torques (N*m)

Screw tightening calliper to support 20 to 25

After removing the leg shield back plate, remove the engaging cable for the safety mechanism removing 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.

BRAK SYS - 268

MP3 LT 250 i.e.

Braking system

Remove the parking brake cable from the lever by operating the set screw indicated in the picture.

BRAK SYS - 269

INDEX OF TOPICS

COOLING SYSTEM

COOL SYS

MP3 LT 250 i.e.

Cooling system

System bleed
- Start up the engine until the operating temperature is reached. - Remove the rubber hood over the bleed valve - Obtain a rubber tube that is of the right length to connect the valve to the expansion tank - Place one end of the pipe on the bleed valve and the other in the expansion tank - Loosen the screw by two turns until the communication hole is revealed with the head as shown in the picture - Wait until only coolant comes out of the rubber pipe so as to eliminate any air bubbles inside the circuit. - Tighten the bleed valve respecting the maximum torque. - Bring the coolant up to the correct level inside the expansion tank

Locking torques (N*m)

Bleed screw 3

COOL SYS - 271

INDEX OF TOPICS

CHASSIS

CHAS

MP3 LT 250 i.e.

Chassis

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

Seat
Lift the saddle and disconnect the rider detection sensor. Remove the three fixing screws.

Front handlebar cover

Remove the upper cap by operating on the Allen screw indicated in the figure.

Remove the two brake pump caps.

CHAS - 273

Chassis

MP3 LT 250 i.e.

Remove the two screws under the brake pump caps previously removed.

Unscrew the two pairs of screws in the lower part of the half-handlebar.

After removing the front part of the handlebar cover, access the two screws fixing the rear part to the handlebar, as indicated in the picture.

Headlight assy.
Remove the radiator cover. Remove the two wheelhouses with the turn indicator. Unscrew the two screws fixing the wheelhouse to the shield. Disconnect the cable grommet; after that, turn the wheelhouse anticlockwise (inwards) to release it from the shield supports.

CHAS - 274

MP3 LT 250 i.e.

Chassis

To remove the shield central finishing, remove the PIAGGIO clip-on badge paying attention not to spoil the paint, unscrew the screw underneath and remove the finish carefully.

Remove the four screws "A" and disconnect the wiring.

See 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 Knee-guard Handles and top side fairings

CHAS - 275

Chassis

MP3 LT 250 i.e.

Legshield
Remove the headlight assembly. Remove the spoiler. Remove the two front screws and the two screws under the wheelhouse.

Remove the four screws on the leg shield back plate.

See also
spoiler Headlight assy.

Knee-guard
- Remove the legshield. - Remove the spoiler. - Remove the two central screws and the coolant cap cover screw.

CHAS - 276

MP3 LT 250 i.e.

Chassis

- Remove the expansion tank fixing screw and the frame from the instrument panel and manually release the unions with the leg shield back plate. - Unhook the instrument panel wiring.

- Remove the six screws and the cable grommet strap in the front part of the leg shield back plate.

CHAS - 277

Chassis

MP3 LT 250 i.e.

- Remove the ignition switch plastic ring and the two plastic covers near the footrest.

- Remove the five screws on the leg shield back plate rear part.

- Remove the two leg shield back plate front screws, see figure.

- Remove the two leg shield back plate lower screws. - Remove the external temperature sensor connection.

See also
Legshield spoiler

CHAS - 278

MP3 LT 250 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-footrest. Follow the same procedure for both half-footrests. Release the fuse-box

See also
CHAS - 279

Chassis

MP3 LT 250 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 release license plate support from the chassis.

CHAS - 280

MP3 LT 250 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 upper screws, the two saddle closing screws and the case light wiring.

CHAS - 281

Chassis

MP3 LT 250 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 opening switch on the other. Remove the six upper screws. Release the case latch. Remove the case light front and rear switch connections, 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 - 282

MP3 LT 250 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 - 283

Chassis

MP3 LT 250 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 figure. Remove the case light bulb indicated in the picture and remove the internal screw indicated in the picture. Remove the backrest cushion

CHAS - 284

MP3 LT 250 i.e.

Chassis

Remove the six screws indicated in the figure.

Radiator cover
- Remove the two front screws indicated in the picture

Remove the two lower retainers with the bushing

- Remove the two rear retainers and then, the two wheelhouse front retainers.

CHAS - 285

Chassis

MP3 LT 250 i.e.

- Remove the two screws fixing the radiator lower protection to the leg shield back plate. - After that, press up and pull the protection front part so as to release it from the radiator frame.

CHAS - 286

INDEX OF TOPICS

PRE-DELIVERY

PRE DE

Pre-delivery

MP3 LT 250 i.e.

Carry out the listed tests before delivering the vehicle. Warning - Handle fuel with care. Fit the plastic cover supplied on the joint on the steering tube as shown in the figure.

Proceed as follows if the customer requests installation of splash guards on the vehicle: Fit the flap inside the mudguard shown in the figure, matching up the 4 anchor holes. Fit the 4 washers and the 4 screws on the outer side of the mudguard, then tighten to the specified torque.

Locking torques (N*m)

splash guard fastener screws 2 - 3 WHEN SENT TO THE DEALERS, SOME VERSIONS DO NOT HAVE TURNING INDICATORS ALREADY FITTED BUT THE SPECIFIC KIT TO FIT THEM IS SUPPLIED INSIDE THE HELMET COMPARTMENT. Rear turning indicators -Fitting kit

PRE DE - 288

MP3 LT 250 i.e.

Pre-delivery

Vehicle cable harness for rear turning indicators electrical connection

Fit the small cup to support the turning indicator as indicated in the picture

Connect the two connectors to the turning indicator reflector being careful to properly insert the fixing bracket of the reflector in the correct guide as indicated in the picture.

Fit the bulb to the light reflector

PRE DE - 289

Pre-delivery

MP3 LT 250 i.e.

Fit the sight glass and fasten it with the screw from the back of the turning indicator as indicated in the picture.

Aesthetic inspection
Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt

Tightening torques inspection

Lock check - Safety fasteners - Fixing screws Safety fasteners: Rear shock absorber upper fixing Rear shock absorber lower fixing Front shock absorber upper fixing Front shock absorber lower fixing Sliding stems fixing Break callipers fixing Front wheels fixing screws

PRE DE - 290

MP3 LT 250 i.e.

Pre-delivery

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 Electric starter Engine stopping with emergency stop switch Electric opening of saddle with solenoid 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 NEGATIVE ONE.
WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. 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 PRE DE - 291

Pre-delivery

MP3 LT 250 i.e.

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. - Roll lock system fluid level - Rear hub oil level - Engine coolant level - Engine oil level

Road test
Test ride - Cold start - Instrument operations - Response to the gas command - Stability on acceleration and braking - Rear and front brake efficiency - Parking brake efficiency - Rear and front suspension efficiency - Abnormal noise - Tilting system locking - unlocking efficiency

Static test
Static control after the test ride: Hot engine restart Minimum seal (turning the handlebar) Uniform steering rotation Possible losses electric radiator fan operation
CAUTION

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 PRE DE - 292

MP3 LT 250 i.e.

Pre-delivery

Clutch: proper functioning check Engine: proper general functioning and no abnormal noise check Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting, lock check, tyre pressure check, rear-view mirror and any accessory fitting

PRE DE - 293

INDEX OF TOPICS

TIME

TIME

MP3 LT 250 i.e.

Time

This section is dedicated to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified.

Engine

ENGINE
1 2 3 Code 001001 001127 003064 Action Engine from chassis - Removal and refit. Engine - Complete service Engine oil - change Duration

TIME - 295

Time

MP3 LT 250 i.e.

Crankcase

CRANKCASE
1 2 3 4 5 Code 001133 001099 001100 001124 001153 Action Engine crankcase - Replacement Flywheel-side oil seal - Replacement Clutch-side oil seal - Replacement Lubrication by pass - Replacement Crankcase halves gasket - Replacement Duration

TIME - 296

MP3 LT 250 i.e.

Time

Crankshaft

CRANKSHAFT
1 Code 001117 Action Crankshaft - Replacement Duration

TIME - 297

Time

MP3 LT 250 i.e.

Cylinder assy.

CYLINDER ASSEMBLY
1 2 3 4 Code 001002 001154 001176 000212 Action Cylinder / Piston - Replacement Pistonsrings-pin assembly - Service Rings / Pin - Replacement Cylinder gasket - Repl. Duration

TIME - 298

MP3 LT 250 i.e.

Time

Cylinder head assy.

HEAD ASSEMBLY
1 2 3 4 5 6 Code 001057 007012 000235 001056 001045 001049 Action Thermostat - Replacement Coolant bleed valve - Replacement Coolant temperature sensor - Repl. Head gasket - change Valves - Replacement Valves - adjust Duration

TIME - 299

Time

MP3 LT 250 i.e.

Rocker arms support assy.

ROCKERS MOUNTING UNIT

1 2 3 4 Code 001148 001126 001044 001169 Action Rockers valves - Replacement Head - Replacement Camshaft - Replacement Pressure reducer - Replacement Duration

TIME - 300

MP3 LT 250 i.e.

Time

Cylinder head cover

HEAD COVER
1 2 3 4 5 Code 001089 001093 001088 001074 001159 Action Head cover - Replacement Spark plug - Replacement Head cover gasket - Replacement Oil vapour recovery pipe - Replacement Oil vapour recovery tank - Service Duration

TIME - 301

Time

MP3 LT 250 i.e.

Oil filter

OIL FILTER
1 2 3 4 5 Code 001150 001160 001123 001102 001113 Action Flywheel cover gasket - change Oil pressure sensor - change Oil filter -Replacement Net oil filter - change / Cleaning Water pump / Pump rotor - Replacement Duration

TIME - 302

MP3 LT 250 i.e.

Time

Flywheel cover

FLYWHEEL COVER
1 Code 007009 Action Head-pump by-pass rubber sleeve Replacement Duration

TIME - 303

Time

MP3 LT 250 i.e.

Driven pulley

DRIVEN PULLEY
1 2 3 4 Code 001012 001022 001110 001155 Action Driven pulley - overhaul Clutch - Replacement Driven pulley- Replacement Clutch housing - Replacement Duration

TIME - 304

MP3 LT 250 i.e.

Time

Oil pump

OIL PUMP
1 2 3 4 5 6 7 8 Code 001129 001125 001122 001172 001130 001042 001112 001051 Action Chain tensioner - Service and Replacement Chain guide pads - Replacement Oil pump chain - Replacement Chain cover flap - change Oil sump - change Oil pump - overhaul Oil pump - change Belt/Timing chain - Change Duration

TIME - 305

Time

MP3 LT 250 i.e.

Final gear assy.

FINAL REDUCTION GEAR

1 2 3 4 5 6 Code 002031 003065 004180 004125 001179 001156 Action Rear wheel hub bearings - Replacement Gear box oil - Replacement Reduction gear pipe - replace Rear wheel axle - Replacement Hub drive shaft - replacement Gear reduction unit cover - Replacement Duration

TIME - 306

MP3 LT 250 i.e.

Time

Driving pulley

DRIVING PULLEY
1 2 3 4 5 6 Code 001177 001141 001086 001011 001066 001006 Action CVT rollers / sliders - Replacement Belt anti-flapping roller - Replacement Driving half-pulley - Replacement Drive belt - Replacement Driving pulley - Removal and refitting Driving pulley - Service Duration

TIME - 307

Time

MP3 LT 250 i.e.

Transmission cover

TRANSMISSION COVER
1 2 3 4 5 Code 001135 001096 001131 001170 001132 Action Transmission cover bearing - Replacement Transmission crankcase cover - Replacement Transmission air intake - Replacement Air deflector - Replacement Transmission air intake pipe - Replacement Duration

TIME - 308

MP3 LT 250 i.e.

Time

Starter motor

ELECTRIC STARTER
1 2 3 4 Code 001020 005045 001151 001104 Action Starter motor - Replacement Starter motor cable assembly - Replacement Starter driven gearing - Replacement Start-up freewheel - Replacement Duration

TIME - 309

Time

MP3 LT 250 i.e.

Flywheel magneto

MAGNETO FLYWHEEL
1 2 3 4 Code 001173 001058 001067 001087 Action Rotor - Replacement Complete flywheel - change Stator - Removal and Refitting Flywheel cover - Replacement Duration

TIME - 310

MP3 LT 250 i.e.

Time

Butterfly valve

THROTTLE BODY
1 2 3 Code 001047 001023 001013 Action Injector - Replacement Control unit - Replacement Intake manifold - change Duration

Exhaust pipe

TIME - 311

Time

MP3 LT 250 i.e.

SILENCER
1 2 3 4 Code 001095 005138 001092 001009 Action Silencer heatshield - Replacement Lambda probe - Replacement Exhaust manifold - Replacement Silencer - Replacement Duration

Air cleaner

AIR CLEANER
1 2 3 Code 004122 001014 001015 Action Air cleaner carburettor fitting - Replacement Air filter - Replacement / cleaning Air filter box - Replacement Duration

TIME - 312

MP3 LT 250 i.e.

Time

Frame

CHASSIS
1 2 3 4 5 Code 004146 004116 004001 004147 004143 Action Front chassis - Replacement Rear frame - Replacement Chassis - Replacement footrest support bracket one side Replacement Footrest support - Replacement Duration

TIME - 313

Time

MP3 LT 250 i.e.

Centre-stand

STAND
1 2 3 Code 001053 004179 004004 Action Stand pin - Replacement Stand bumper - Replacement Stand - Replacement Duration

TIME - 314

MP3 LT 250 i.e.

Time

Legshield spoiler

LEGSHIELD
1 2 3 4 5 6 Code 004020 004064 004055 004149 004022 004167 Action Headlight frame - Replacement Legshield - Replacement Turning indicator frame - Replacement Shield central cover - Replacement Shield lower section - Replacement Grille / radiator cover - Replacement Duration

TIME - 315

Time

MP3 LT 250 i.e.

Side fairings

SIDE COVERS

1 2 3 4 5

Code 004036 004129 004085 004068 004037

Action Lower chassis cover - Replacement Rear fairing - Replacement Fairing (1) - Replacement Passenger handgrip - Replacement Side aprons-Replacement

Duration

TIME - 316

MP3 LT 250 i.e.

Time

Rear cover

REAR SHIELD
1 Code 004065 Action Legshield, rear part - Removal and refitting Duration

TIME - 317

Time

MP3 LT 250 i.e.

Central cover

CENTRAL COVER
1 2 3 4 5 6 Code 004059 004135 004011 004012 004015 004075 Action Spark plug inspection flap - Replacement Fuel tank port - Replacement Central chassis cover - Replacement Rear fairings - Removal and refitting Footrest - Removal and Refitting Front mat - Replacement Duration

TIME - 318

MP3 LT 250 i.e.

Time

Mudguard

MUDGUARDS
1 2 3 4 5 Code 007015 004009 004181 004184 004002 Action Radiator air duct - Replacement Rear mudguard - Replacement Lower cover - Replacement Front mudguard support - replacement Front mudguard - change Duration

TIME - 319

Time

MP3 LT 250 i.e.

Fuel tank

FUEL TANK
1 2 3 4 5 6 Code 004137 005010 004109 004168 004005 004073 Action Injector pump pipe - Replacement Tank float - Replacement Fuel tank breather - change Fuel tank cap - Replacement Fuel tank - Replacement Fuel pump - Replacement Duration

TIME - 320

MP3 LT 250 i.e.

Time

Rear shock-absorber

REAR SHOCK ABSORBERS

1 2 3 Code 003007 003035 003077 Action Rear shock absorber - Removal and Refitting Shock absorber mounting and brake calliper - Replacement silencer/rear shock absorber support arm - Service Duration

TIME - 321

Time

MP3 LT 250 i.e.

Handlebar covers

HANDLEBAR COVERS
1 2 3 4 Code 000307 004019 004026 004018 Action RIGHT OR LEFT CONTROL ASSEMBLY REPLACEMENT Rear handlebar covers - Replacement Handlebar cover - Replacement Front handlebar covers - Replacement Duration

TIME - 322

MP3 LT 250 i.e.

Time

Handlebar components

HANDLEBAR COMPONENTS
1 2 3 4 5 6 7 8 9 10 11 12 13 Code 002059 002060 002063 003001 002071 003059 002037 002048 002067 002080 004162 002024 002047 Action Right-hand knob - Replacement Complete throttle control - Replacement Complete throttle transmission - Replacement Handlebar - Replacement Left knob - Replacement Counterweight - Replacement Brake lever - Replacement Rear brake calliper - Replacement Rear brake pump - Replacement Rear brake oil bleed system Change Mirror mounting and/or brake pump fitting U-bolt - Replacement Front brake pump - Replacement Front brake fluid and air bleed system - Replacement Duration

TIME - 323

Time

MP3 LT 250 i.e.

Swing-arm

SWINGING ARM
1 2 3 4 Code 004058 003081 001072 003080 Action Silent block - Replacement Swinging arm support flange - Replacement Engine-chassis connection swinging arm - Replacement Swinging arm on frame - Replacement Duration

TIME - 324

MP3 LT 250 i.e.

Time

Seat

SADDLE
1 Code 004003 Action Saddle - Replacement Duration

TIME - 325

Time

MP3 LT 250 i.e.

Instrument panel

INSTRUMENT PANEL
1 2 3 4 Code 004021 005014 004099 004035 Action Shield upper section - Replacement Odometer - Replacement Odometer housing - Replacement Instrument panel - Replacement Duration

TIME - 326

MP3 LT 250 i.e.

Time

Locks

LOCKS
1 2 3 4 Code 004172 005099 004054 005072 Action Rear case lock catch - Replacement Saddle opening electric-actuator Replacement Saddle lock catch - Replacement Immobilizer aerial - Replacement Duration

Turn signal lights

Rear lights

TIME - 327

Time

MP3 LT 250 i.e.

REAR TURNING INDICATOR LIGHTS

1 2 3 4 5 6 7 Code 005005 005022 005031 005032 005131 005066 005068 Action Taillight - change Rear turning indicators - Replacement number plate light bulb - Replacement number plate light glass - Replacement number plate light support - Replacement Rear light bulbs - Replacement Rear turning indicator bulb - Replacement Duration

Front lights

TIME - 328

MP3 LT 250 i.e.

Time

FRONT TURNING INDICATOR LIGHTS

1 2 3 4 Code 005067 005012 005002 005008 Action Front turning indicator bulb - replacement Front turning indicators - Replacement Front light - replacement Headlight bulbs - Replacement Duration

TIME - 329

Time

MP3 LT 250 i.e.

Front wheel

FRONT WHEELS
1 2 3 4 5 6 Code 003047 003033 003037 005089 002041 004123 Action Front tyre - Replacement Front wheel hub- Replacement Front wheel rim - Replacement Tone wheel - Replacement Front brake disc - Replacement Front wheel - Replacement Duration

TIME - 330

MP3 LT 250 i.e.

Time

Rear wheel

REAR WHEEL
1 2 3 4 Code 002070 001016 001071 004126 Action Rear brake disc - Replacement Rear wheel - Replacement Front wheel rim - Removal and Refitting Rear wheel tyre - Replacement Duration

TIME - 331

Time

MP3 LT 250 i.e.

Electric devices

ELECTRICAL DEVICES

1 2 3 4 5

Code 005075 005035 005011 005007 005003

Action Stop solenoid - Replacement Headlight solenoid - Replacement Starter relay - Replacement Battery - change Horn - Replacement

Duration

TIME - 332

MP3 LT 250 i.e.

Time

CABLE HARNESS
1 Code 005001 Action Electrical system - Replacement Duration

Electronic controls

TIME - 333

Time

MP3 LT 250 i.e.

HANDLEBAR CONTROLS
1 2 3 4 5 6 7 8 9 10 11 12 Code 005017 005077 005041 004010 005040 005006 005039 005143 005142 005084 888126 005149 Action Stop switch - Replacement Emergency stop switch - Replacement Starter button - Replacement Anti-theft lock - Replacement Horn button - Replacement Light or turning indicator switch - Replacement Lights switch - Replacement Mode button - Replacement Unlocking switch - Replacement Emergency light switch - Replacement Helmet compartment light switch - replacement Brake pedal switch - Repl. Duration

Transmissions

LOCKS TRANSMISSIONS
1 2 3 4 5 Code 003094 002082 002083 002093 002026 Action Roll lock calliper control cable - replacement Fuel tank door opening drive - Replacement Saddle opening transmission - Replacement Case opening transmission - Replacement Parking brake transmission - replacement Duration

TIME - 334

MP3 LT 250 i.e.

Time

Helmet bay

HELMET COMPARTMENT
1 2 3 4 Code 005046 005026 005027 004016 Action Battery cover - change Helmet compartment bulb - Replacement Helmet compartment bulb support Replacement Helmet compartment - Replacement Duration

TIME - 335

Time

MP3 LT 250 i.e.

Rear side fairings

REAR COVERS
1 2 3 4 Code 004081 004174 005048 004082 Action Case lid - Replacement Case leverage number plate holder - Replacement Case gasket - Replacement Duration

TIME - 336

MP3 LT 250 i.e.

Time

Front suspension

FRONT SUSPENSION
1 2 3 4 5 6 Code 003010 003111 003038 003040 003107 003113 Action Front suspension - Service Side steering tube - replacement Front wheel axle - Remov. and refitt. Front wheel bearings - Replacement Sliding stems - replacement Front shock absorber - replacement Duration

TIME - 337

Time

MP3 LT 250 i.e.

Cooling system

COOLING SYSTEM
1 2 3 4 5 6 7 Code 007013 001052 007001 007024 007003 007016 007002 Action Radiator expansion tank connection pipe - change Coolant and air bleed - Replacement Expansion tank - Replacement Expansion tank cap - Replacement Coolant delivery and return pipe change Fan with support - Replacement Water radiator - replacement Duration

TIME - 338

MP3 LT 250 i.e.

Time

Braking system

INTEGRAL BRAKE PEDAL

1 2 3 4 5 Code 002014 002088 002084 002089 002090 Action Brake pedal - Removal and Refitting Integral brake pump - Replacement Integral brake pump pipe, device Replacement Integral braking device - Replacement Integral brake fluid and system bleeding - Change Duration

TIME - 339

Time

MP3 LT 250 i.e.

BRAKING SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Code 002025 003096 003100 003108 003109 002002 002020 002081 003118 003103 003102 003088 002021 002007 002039 Action Brake piping - Replacement Roll lock calliper- replacement Roll lock calliper pads - replacement Parking brake flexible transmission replacement Parking brake mechanical calliper replacement Shoes - Rear brake pads - Replacement Rear brake pipes - Removal and refitting Rear brake disc piping - Replacement Roll lock disc section - replacement Splitter for suspension locking system pipes- replacement Pipes for the splitter-calliper suspension locking system - replacement Roll lock hydraulic pump - replacement Front brake piping - Replacement Front brake pads - Replacement Front brake calliper - Replacement Duration

TIME - 340

MP3 LT 250 i.e.

Time

16 17 18 19 20 21

Code 003104 003119 003105 003106 003121 003122

Action Suspension system locking calliperreplacement Pipes for the pump-splitter suspension locking system - replacement Suspension locking system brake fluid - repl. Suspension locking system pressure sensor - Replacement Parking brake lever - replacement Parking brake lever micro-switch - replacement

Duration

Windscreen

WINDSCREEN
1 Code 004101 Action Windscreen - Replacement Duration

TIME - 341

Time

MP3 LT 250 i.e.

Stickers

TRANSFERS
1 2 Code 004066 004159 Action Driving mirror - Replacement Plates / Stickers - Replacement Duration

TIME - 342

MP3 LT 250 i.e.

Time

The tilt mechanism

ROLL SYSTEM
1 2 3 4 5 6 7 8 Code 003073 003112 003002 003115 003114 003116 003117 003110 Action Steering clearance - Adjustment Central steering tube - replacement Steering bearing - Replacement Parallelogram arms - replacement Parallelogram bearings - replacement Steering rod - replacement Constant-velocity universal joint - replacement Side headstock fifth wheels - Repl. Duration

TIME - 343

Time

MP3 LT 250 i.e.

Geared motor

GEARED MOTOR
1 2 3 4 5 6 7 8 9 10 11 12 Code 003101 005009 003095 001069 001094 003120 003093 003090 003092 003091 003089 003097 Action Roll lock calliper control lever - replacement Voltage regulator - Replacement Roll lock calliper support bracket - replacement HV coil - Replacement Spark plug cap - Replacement Roll lock control unit - replacement Geared motor crankcase - replacement Gear electric motor - replacement Geared motor bearings - replacement Geared motor pinion - replacement Geared motor potentiometer - replacement Roll lock calliper micro-switch - replacement Duration

TIME - 344

A
Air filter: 40

B
Battery: 60, 70, 74 Brake: 258, 263, 266, 267

C
Checks: 64 Coolant: 188

E
Electric: 332 Engine oil: 40

F
Fuel: 163, 172, 283, 320 Fuses: 72

H
Headlight: 45, 274, 276, 283 Hub oil: 39

I
Identification: 8 Instrument panel: 326

M
Maintenance: 7, 31, 34

O
Oil filter: 42, 302

R
Recommended products:

S
Saddle: Shock absorbers: 254 Spark plug: 38 Stand: Suspension: 48, 49, 213, 337

T
Tank: 283, 320

Transmission: 9, 47, 89, 103, 308 Turn indicators: 63 Tyre pressure: Tyres: 10

V
Vehicle: 8, 83, 84