2015-2016 Piaggio MP3 500 i.e. Sport Business LT ABS Service & Repair Manual

SERVICE STATION MANUAL 1Q000267 EN MP3 500 i.e. SPORT Business_LT_ ABS- ASR_EU_USA (2015)

SERVICE STATION MANUAL MP3 500 i.e. SPORT Business_LT_ ABS- ASR_EU_USA (2015) 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 2015 - 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 500 i.e. SPORT Business_LT_ ABS- ASR_EU_USA (2015) This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue. N.B. Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment 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. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections. MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics CHAR - 7

Vehicle identification The identification registration numbers consist of a prefix stamped on the chassis and engine "B" respectively, followed by a number. These numbers must always be indicated on spare parts re- quests. To read the chassis number, remove the relevant port "A" in the helmet compartment. We recommend checking that the chassis registration number stamped on the vehicle corresponds with that on the vehicle documentation. CAUTION PLEASE REMIND THAT ALTERING IDENTIFICATION REG- ISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.). VEHICLE IDENTIFICATION Specification Desc./Quantity Frame prefix (VERSION EQUIPPED WITH ABS - ASR SYS- TEM) ZAPM86100 Frame prefix (VERSION NOT EQUIPPED WITH ABS - ASR SYSTEM) ZAPM86101 Frame prefix USA/CND ZAPM860X Engine prefix M861M Engine prefix USA/CND M863M Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) CHAR - 8

Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Length 2205 mm (86.8 in) Width 775 mm (30.5 in) Maximum height 1460 mm (57.5 in) Wheelbase 1540 mm (60.6 in) Track 465 mm (18.3 in) Kerb weight 266 kg (586 lb) Maximum weight limit 460 kg (1014 lb) Engine ENGINE TECHNICAL DATA Specification Desc./Quantity Type Single-cylinder, 4-stroke Engine capacity 493 cm³ Bore x Stroke 94 x 71 mm Compression ratio 10.5 ± 0.5 : 1 Engine idle speed 1,600 ± 100 rpm Timing system Four valves, single overhead camshaft, chain-driven. Valve clearance Inlet: 0.15 mm Outlet: 0.15 mm MAX. power 29.5 kW at 7,250 rpm MAX. torque 45.5 Nm at 5,250 rpm Transmission CVT expandable pulley variator with torque server, V-belt, self- ventilating dry automatic centrifugal clutch and transmission housing with forced-circulation air cooling. Final reduction with gear reduction unit in oil bath. Lubrication Engine lubrication with lobe pump (inside crankcase), chain- driven, with double filter: mesh and paper. MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) Characteristics CHAR - 9

Specification Desc./Quantity Cooling Forced coolant circulation system. Electric Electric starter Ignition Highly efficient electronic inductive ignition, integrated with the injection system, with variable advance, separate HV coil and double spark plug. Ignition advance Three-dimensional map managed by control unit Spark plug NGK CR7EKB Electrode gap 0.7 ÷ 0.9 mm Fuel system By electronic injection with electric fuel pump. Fuel Unleaded petrol (95 RON) Exhaust silencer Absorption-type exhaust muffler with catalytic converter and lambda probe. Emissions compliance EURO 2 Transmission T RANSMISSION Specification Desc./Quantity TRANSMISSION Automatic expandable pulley variator with torque server, V- belt, automatic clutch. Final reduction with gear reduction unit in oil bath. Capacities CAPACITY Specification Desc./Quantity Engine oil 0.44 gal (1.7 l) Transmission oil 15.3 in³ (250 cm³) Cooling system fluid ~ 0.47 gal (~ 1.8 l) Fuel tank 3.2 gal ± 0.1 (12.0 ± 0.5 l) Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Electric Electric starter Ignition Electronic, inductive, high efficiency, integrated with the injection system, with variable advance separate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug NGK CR7EKB Alternative spark plug - Battery 12V-12Ah Alternator alternating current Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity Chassis Tubular and sheet steel Front suspension The roll system is composed of an articulated parallelogram suspension with die-cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system Front suspension travel 85 mm Rear suspension Two double-acting shock absorbers, adjustable to four posi- tions at preloading. Characteristics MP3 500 i.e. SPORT Business_LT_ ABS-ASR_EU_USA (2015) CHAR - 10

2015-2016 Piaggio MP3 500 i.e. Sport Business LT ABS Service & Repair Manual

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