2011-2015 Piaggio MP3 300 Yourban I.E RL, NRL Service & Repair Manual

SERVICE STATION MANUAL 677229 ÷ 677236 MP3 300 YOURBAN i.e. RL - NRL

SERVICE STATION MANUAL MP3 300 YOURBAN i.e. RL - NRL 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 300 YOURBAN i.e. RL - NRL This workshop 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 mounting techniques and procedures. Any important changes made to the vehicles or to specific mounting operations will be promptly reported 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 relating to special tools, along with the special tool catalogue. N.B. Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment. Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE-DELIVERY PRE DE

INDEX OF TOPICS CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. - Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections. MP3 300 YOURBAN i.e. RL - NRL Characteristics CHAR - 7

Vehicle identification The chassis prefix is stamped on the chassis un- der the cover «A» inside the helmet compartment. The engine prefix «B» is stamped near the rear left shock absorber lower support. VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix M64102 Engine prefix M634M Dimensions and mass VEHICLE TECHNICAL DATA Specification Desc./Quantity Chassis Tubular and sheet steel Front suspension The roll system is composed of an articulated parallelogram suspension with die-cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system. Rear suspension Two double-acting shock absorbers, adjustable to four positions at preloading. Characteristics MP3 300 YOURBAN i.e. RL - NRL CHAR - 8

Specification Desc./Quantity Front brake Ø 240-mm double disc brake with hydraulic control operated by the handlebar right-hand lever. Rear brake Ø 240-mm disc brake with hydraulic control operated by the handlebar left-hand lever. Wheel rim type Light alloy wheel rims. Front wheel rim 13" x 3.00" Rear wheel rim 14" x 3.75" Front tyre Without inner tube 110/70 13" 48P Rear tyre Without inner tube: 140/60-14" 64P Front tyre pressure 1.7 bar Rear tyre pressure 2.2 bar (2.6 bar with passenger) Kerb weight 212 kg (200 kg for version NRL without front suspension block and parking brake locking) Maximum weight allowed 405 kg Battery 12 V-12Ah SEALED BATTERY Engine DATA Specification Desc./Quantity Type single-cylinder, four-stroke and four liquid-cooled valves Engine capacity 278 cm³ Bore x stroke 75 X 63 mm Compression ratio 11 ± 0.5: 1 Engine idle speed 1,700 ± 100 rpm MAX. torque 23.2 Nm at 6,500 rpm Max. power 16.6 kW at 7,500 rpm Timing system single overhead camshaft, chain-driven, on the left-hand side, three-arm rocking levers set up with threaded set screw valve clearance intake: 0.10 mm - exhaust: 0.15 mm Starting system electric starter motor with freewheel Lubrication with lobe pump (inside the crankcase) chain-driven and double filter: mesh and paper Fuel system ELDOR KUBO03 electronic injection with 32 mm diam. throttle body and electric fuel pump. Fuel Unleaded petrol (95 RON) Air filter sponge, impregnated with mixture (50% petrol and 50% oil) Silencer Absorption-type exhaust muffler with catalytic converter and lambda probe. Max. speed 125 km/h Emissions compliance EURO 3 Transmission TRANSMISSION Specification Desc./Quantity Transmission 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 Desc./Quantity Engine oil Capacity: 1.3 l (dry); 1.2 l (when changing oil and filter) Transmission oil 250 cm³ Cooling system fluid ~ 2 l Fuel tank 11 ± 0.5 l MP3 300 YOURBAN i.e. RL - NRL Characteristics CHAR - 9

Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Ignition/advance Electronic, with inductive discharge and variable advance with three-dimensional mapping Spark plug NGK CR8EKB Battery 12V-12Ah Generator alternating current Frame and suspensions CHASSIS AND SUSPENSION Specification Desc./Quantity Chassis Tubular and steel sheets. Rear suspension Single arm with two double-acting hydraulic shock absorbers and preloading adjustment in 4 positions. Front suspension The roll system is composed of an articulated parallelogram suspension with die-cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system. Brakes BRAKES Specification Desc./Quantity Front brake Ø 240-mm double disc brake with hydraulic control operated by the handlebar right-hand lever. Rear brake Ø 240-mm disc brake with hydraulic control operated by the handlebar left-side lever. Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front wheel rim 13" x 3.00" Rear wheel rim 14" x 3.75" Front tyre Without inner tube 110/70 13" 48P Rear tyre Without inner tube: 140/60-14" 64P TYRE INFLATION PRESSURE Specification Desc./Quantity Front tyre pressure 1.7 bar Rear tyre pressure 2.2 bar (2.6 bar with passenger) N.B. CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU- LATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES Characteristics MP3 300 YOURBAN i.e. RL - NRL CHAR - 10

2011-2015 Piaggio MP3 300 Yourban I.E RL, NRL Service & Repair Manual

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