PIAGGIO MP3 500 ie SPORT Business LT 2011 User manual

MANUALE STAZIONE DI SERVIZIO
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MP3 500 ie SPORT Business LT (2011)

MANUALE
STAZIONE DI
SERVIZIO
MP3 500 ie SPORT Business LT (2011)
Thedescriptionsandimagesinthispublicationaregivenforillustrativepurposesonlyandarenotbinding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C.S.p.A.reservestheright,atanytimeandwithoutbeingrequiredtoupdatethispublicationbeforehand,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of each
model should be checked at the official PIAGGIO sales network.
© Copyright 2013 - 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

MANUALE STAZIONE DI
SERVIZIO
MP3 500 ie SPORT Business LT
(2011)
Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle
officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa
pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei
principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni
importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno
comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro
completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per
questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il
catalogo degli attrezzi specifici.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked with this symbol indicate the correct use of thevehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

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

INDEX OF TOPICS
CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
MP3 500 ie SPORT Business LT (2011) Characteristics
CHAR - 7

Vehicle identification
The identification registration numbers consist of a prefix stamped on the chassis and engine "B" re-
spectively, followed by a number. These numbers must always be indicated on spare parts requests.
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 REGISTRATION NUMBERS CAN LEAD TO
SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).
Chassis prefix (A)
ZAPM642001
Engine prefix (B):
M474M
THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION.
The identification registration numbers consist of a prefix stamped on the chassis and engine "B" re-
spectively, followed by a number. These numbers must always be indicated on spare parts requests.
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 REGISTRATION NUMBERS CAN LEAD TO
SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).
Characteristics MP3 500 ie SPORT Business LT (2011)
CHAR - 8

Chassis prefix (A)
ZAPM643001
Engine prefix (B):
M611M
Dimensions and mass
MP3 500 ie SPORT Business LT (2011) Characteristics
CHAR - 9

WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Kerb weight 253 ± 8 kg
Maximum weight allowed 445 kg
Maximum height 1440 mm
Width 760 mm
Wheelbase 1550 mm
Length 2210 mm
Track 465 mm
Engine
ENGINE
Specification Desc./Quantity
Type Single-cylinder, 4-stroke with double spark plug
Engine capacity 493 cm³
Bore x Stroke 94 x 71 mm
Compression ratio 10.5 ± 0.5: 1
Engine idle speed 1,500 ± 100 rpm
Timing system Four valves, single overhead camshaft, chain-driven.
Valve clearance (cold engine) Intake: 0.15 mm
Exhaust: 0.15 mm
Max. power 29.5 kW at 7,250 rpm
MAX power depotentiated version 25 kW
MAX. torque 46.5 Nm at 5,250 rpm
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Lubrication pressure 3.5 to 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel system Electronic injection with electric fuel pump.
Cooling Forced coolant circulation system.
Fuel Unleaded petrol (95 RON)
Transmission
TRANSMISSION
Specification Desc./Quantity
TRANSMISSION Automatic expandable pulley variator with torque server, V-
belt, automatic clutch.
Final reduction gear Gear reduction unit in oil bath.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil 1.7 l
Transmission oil 250 cm³
Cooling system fluid ~ 1.8 l
Fuel tank (reserve) approx. 12 l (approx. 2 l)
Characteristics MP3 500 ie SPORT Business LT (2011)
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Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Starter Electric starter
Ignition Electronic,inductive,highefficiencyignition,integratedwiththe
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug NGK CR7EKB
Alternative spark plug -
Battery 12V-12Ah
Alternator alternating current
THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION.
ELECTRICAL SYSTEM
Specification Desc./Quantity
Starter Electric starter
Ignition Electronic,inductive,highefficiencyignition,integratedwiththe
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug NGK CR7EKB
Battery 12V/14 Ah, sealed battery
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 sys-
tem.
Front suspension travel 85 mm
rear suspension Two double-acting shock absorbers, adjustable to four posi-
tions at preloading.
Rear suspension travel 110 mm
Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 240-mm double disc brake with hydraulic control operated
by the handlebar right-hand lever.
Rear drum Ø 240-mm disc brake with hydraulic control operated by the
handlebar left-hand lever.
Integral braking system The system operates all three discs simultaneously and is con-
trolled hydraulically via the pedal on the footrest.
MP3 500 ie SPORT Business LT (2011) Characteristics
CHAR - 11

Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rim type Light alloy wheel rims.
Front wheel rim 12'' x 3.00
Rear wheel rim 14'' x 4.50
Front tyre Tubeless, 120/70-12" 51S or 51P
Rear tyre Tubeless, 140/70 -14" 68S or 68P
Front tyre pressure 1.6 bar
Rear tyre pressure 2.5 bar
THE FOLLOWING INSTRUCTIONS REFER TO THE MY2013 VERSION.
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rim type Light alloy wheel rims.
Front wheel rim 12'' x 3.00
Rear wheel rim 14'' x 4.50
Front tyre Tubeless 120/70 - 12" 51S
Rear tyre Tubeless 140/70 - 14" 68S
Front tyre pressure 1.7 bar
Rear tyre pressure 2.8 bar
Tightening Torques
STEERING
Name Torque in Nm
Steering lower ring nut (central headstock) 10 to 12
Steering upper ring nut (central headstock) 22.5 to 25
Handlebar fixing screw 50 - 55
Fixing screws for the handlebar control unit U-bolts 7 - 10
CHASSIS
Name Torque in Nm
Swinging arm set screw bushing 5 ÷ 7
Engine arm bolt - frame arm 32.5 ÷ 40
Swinging arm set screw bushing nut 54 ÷ 60
Engine-swinging arm bolt 98 ÷ 118
Frame-swinging arm bolt 54 ÷ 60
Centre stand bolt 31 - 39
FRONT SUSPENSION
Name Torque in Nm
Shock absorber lower clamping 19 - 26
Shock absorber upper clamp 19 - 29
Front wheel fixing screws 19 ÷ 24
Steering arm bolt nut 20 to 25
Tilt gripper fixing screws 20 to 25
Front wheel axle 74 - 88
Arm coupling screws 45 to 50
Screws fixing arms to side headstocks 45 to 50
Screws fixing arms to central headstock 45 to 50
Screws fixing the half-arm coupling flange 20 to 25
Screws fixing roll lock disc section 20 to 25
Side headstock upper ring nut 20 - 24
Side headstock lower ring nut 12 ÷ 15
Characteristics MP3 500 ie SPORT Business LT (2011)
CHAR - 12

Name Torque in Nm
Screw fixing sliding stem to shock absorber 45 to 50
Clamp for sliding stem locking device 6.5 - 10.5
Fixing nuts for constant-velocity universal joints 18 - 20
Potentiometer to anti-tilting device clamp 8 to 10
Electric motor to anti-tilting device clamp 11 to 13
Clamp fixing pump bolt to anti-tilting device 11 to 13
Pump to anti-tilting device clamp 11 to 13
Pressure switch to distribution frame 18 - 20
Sensor to tilt gripper clamp 2.5 - 2.9
Pipe terminals to fifth wheel check spring 7 - 11
Joint to anti-tilting device pump 20 to 25
Lower fitting for shock absorber sliding locking clamp pipes 20 to 25
Upper fitting for shock absorber sliding locking clamp pipes 20 to 25
REAR SUSPENSION
Name Torque in Nm
Upper shock absorber retainer 33 - 41
Lower shock absorber clamp 33 - 41
Shock absorber-crankcase attachment bracket 20 to 25
Rear wheel axle 104 - 126
Silencer arm clamping screws 27 - 30
FRONT BRAKE
Name Torque in Nm
Calliper coupling screw 22 ÷ 27
Oil bleed screw 8 - 12
Brake disc screws 8 to 10
Brake fluid pump-hose fitting 16 - 20
Brake fluid pipe-calliper fitting 20 - 25
Screw tightening calliper to support 20 to 25
Calliper upper pipe fitting 20 to 25
REAR BRAKE
Name Torque in Nm
Oil bleed screw 12÷16
Brake disc screws 8 to 10
Rear brake calliper-pipe fitting 20 to 25
Rigid / flexible pipe fitting 13 - 18
Rear brake pump-pipe fitting 16 - 20
Rear brake calliper fixing screws 20 to 25
pad fastening pin screws 20 ÷ 25
REAR BRAKE
Product Description Specifications
(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-strength
threadlock
SILENCER
Name Torque in Nm
Silencer heat guard fixing screw 4 to 5
Screw for fixing silencer to supporting arm 20 ÷ 25
Lambda probe tightening on exhaust manifold 40 - 50
Exhaust manifold-silencer joint tightening 12 to 13
Manifold - silencer diaphragm tightening clamp 16 to 18
LUBRICATION
Name Torque in Nm
Oil pump cover screws 0.7 - 0.9
Screws fixing oil pump to the crankcase 5 - 6
MP3 500 ie SPORT Business LT (2011) Characteristics
CHAR - 13

THERMAL GROUP AND TIMING SYSTEM
Name Torque in Nm
Spark plug 12 ÷ 14
Head fixing stud bolts ***
Head fixing nuts 10 - 12
Exhaust / intake head fixing nuts 10 - 12
Head lubrication control jet 5 - 7
Coolant temperature sensor: 10 - 12
Lambda probe on exhaust manifold 10 - 12
injector fixing screw 3 ÷ 4
Counterweight screw 7 to 8.5
Tensioner pad fixing screw 10 - 14
Rpm timing sensor fixing screw 3 - 4
Valve lifter mass stop bell fixing screws 30 - 35
Intake manifold screws 11 to 13
Tappet cover fixing screws 7 - 9
Throttle body fixing screws 11 ÷ 13
Head fixing screws 10 - 12
Camshaft retaining bracket screws: 4 ÷ 6
Tightener screw: 5 to 6
Tightener fastening screws: 11 to 13
*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90° in a crossed sequence. - tighten again by 90° in
a criss-crossed sequence.
TRANSMISSION COVER
Name Torque in Nm
Driven pulley nut 92 - 100
Drive pulley nut 160 - 175
Anti-vibration roller screw 16.7 ÷ 19.6
M8 retainers for transmission cover 23 ÷ 26
M6 retainer 11 ÷ 13
Anti-vibration roller retainer 17 - 19
Clutch ring nut 65 - 75
Air conveyor screws 11 ÷ 12
Water pump cover screws 3 - 4
External transmission cover screws 7 to 9
Flywheel cover screws 11 - 13
FLYWHEEL COVER
Name Torque in Nm
Chain guide sliding block retain plate fastening screws 3 ÷ 4
Flywheel fixing nut 115 - 125
Stator clamps 8 - 10
Blow-by recovery duct fixing screws 3 - 4
Screw fixing freewheel to flywheel 13 - 15
Stator cable harness guide bracket screws 3 - 4
Supporting screws with bulkhead 0.3 - 0.4
Minimum oil pressure sensor 12 - 14
Water pump rotor 4 to 5
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Countershaft fixing nut 25 ÷ 29
Engine oil filter 12 - 16
Engine oil drainage plug 24 to 30
Engine-crankcase coupling screws 11 - 13
Oil pump screws 5 ÷ 6
Gear mounting on crankshaft screws 10 -12
Oil pump compartment cover bulkhead screws 8 - 10
COOLING
Name Torque in Nm
Water pump rotor 4 to 5
Characteristics MP3 500 ie SPORT Business LT (2011)
CHAR - 14

Name Torque in Nm
Water pump cover screws 3 - 4
Thermostat cover screws 3 ÷ 4
Bleed screw 3
Overhaul data
Assembly clearances
Cylinder - piston assy.
HEIGHT TO MEASURE THE PISTON
Specification Desc./Quantity
A 10 mm
B 43 mm
CYLINDER - PISTON
Specification Desc./Quantity
Cylinder diameter C 94 +0.018-0.01mm
Piston diameter P 93.968 - ±0.014 mm
COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder- Piston A 93.990÷93.997 93.954÷93.961 0.029÷0.043
Cylinder- Piston B 93.997÷93.004 93.961÷93.968 0.029÷0.043
MP3 500 ie SPORT Business LT (2011) Characteristics
CHAR - 15

Name Initials Cylinder Piston Play on fitting
Cylinder- Piston C 94.004÷94.011 93.968÷93.975 0.029÷0.043
Cylinder- Piston D 94.011÷94.018 93.975÷93.982 0.029÷0.043
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
Piston rings
*Fit piston rings «2» and «3» with the mark «TOP» facing up.
** Position the port of the rings as shown here.
*** Value «A» of seal ring inside the cylinder.
Check the size of the sealing ring opening:
Compression ring: 0.15 - 0.35 mm. Max. value 0.5 mm
Oil scraper ring: 0.25 - 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 - 0.50 mm. Max. value 0.65 mm
Characteristics MP3 500 ie SPORT Business LT (2011)
CHAR - 16

Rings/slots coupling clearances:
Carefully clean the sealing rings housings.
Place a feeler gauge between the ring and the
housing as shown in the drawing and check the
coupling clearances.
Top ring Standard coupling clearance:
0.01-0.06 mm
Maximum clearances allowed after use: 0.10
mm
Intermediate ring Standard coupling clear-
ance:0.02-0.07 mm
Maximum clearances allowed after use: 0.10
mm
Oil scraper ring Standard coupling clearance:
0.01-0.06 mm
Maximum clearances allowed after use: 0.10
mm
If clearances measured exceed the maximum val-
ues specified in the table, the piston should be
replaced by a new one.
MP3 500 ie SPORT Business LT (2011) Characteristics
CHAR - 17

Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Description Dimensions Initials Quantity
Transmission-side
shoulder 1 ± 0.025 A D = 0.20 ÷ 0.50
Half-shaft, transmission
side 20.9 - 0.05 B D = 0.20 ÷ 0.50
Connecting rod 22 0.10 - 0.15 C D = 0.20 ÷ 0.50
Flywheel-side shoulder 1.8 ± 0.025 F D = 0.20 ÷ 0.50
Flywheel side half-shaft 19.6 + 0.05 E D = 0.20 ÷ 0.50
Complete crankshaft 65.5 +0.1 -0.05 G D = 0.20 ÷ 0.50
Diameter of crankshaft bearings.
Measure the bearings on both axes x-y.
Characteristics MP3 500 ie SPORT Business LT (2011)
CHAR - 18

CRANKSHAFT
Specification Desc./Quantity
Cat. 1 Standard diameter: 40.010 ÷ 40.016
Cat. 2 Standard diameter: 40.016 ÷ 40.022
Crankshaft alignment
Specific tooling
020335Y Magnetic mounting for dial gauge
MAX. ADMISSIBLE DISPLACEMENT
Specification Desc./Quantity
A = 0.15 mm
B = 0.010 mm
C = 0.010 mm
D = 0.10 mm
Characteristic
Crankshaft-crankcase axial clearance (H)
MP3 500 ie SPORT Business LT (2011) Characteristics
CHAR - 19

0.1 ÷ 0.405 mm (when cold)
Compression ratio
10.5: 1
Slot packing system
Shimming system to control compression ratio
DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF
THE PISTON CROWN WITH RESPECT TO THE CYLINDER
PLANE.
DISTANCE «A» HELPS DETERMINE THE THICKNESS OF
GASKET«B» THAT HASTOBE FITTED TO THECYLINDER
HEAD IN ORDER TO RESTORE COMPRESSION RATIO.
BASE GASKET «B» MUST BE THICKER THE MORE THE
PLANE FORMED BY THE PISTON CROWN PROTRUDES
FROMTHEPLANE FORMED BY THECYLINDERHEAD.ON
THE OTHER HAND, THE MORE THE PISTON CROWN IS
RECESSED INTO THE CYLINDER TOP PLANE, THE
SMALLER THE GASKET THICKNESS.
Characteristic
Compression ratio
10.5: 1
BASE GASKET THICKNESS
Name Measure A Thickness
MEASURE TAKEN «A» - 0.185 to - 0.10 0.4 ± 0.05
MEASURE TAKEN «A» - 0.10 to + 0.10 0.6 ± 0.05
MEASURE TAKEN «A» + 0.10 to + 0.185 0.8 ± 0.05
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE
CYLINDER PLANE.
N.B.
DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»
Products
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis-
sions. API GL-4
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per-
formance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3
agip filter oil Special product for the treatment of foam
filters. -
AGIP GP 330 Water repellent stringy calcium spray
grease. R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 - I.A.T.A. 2 - I.M.D.G. class 2 UN 1950
Page 9022 EM 25-89
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116
- DOT 3/4 - ISO 4925 - CUNA NC 956
DOT 4
AGIP PERMANENT SPEZIAL Ethylene glycol-based antifreeze fluid
with organic inhibition additives. Red,
ready to use.
ASTM D 3306 - ASTM D 4656 - ASTM D
4985 - CUNA NC 956-16
Characteristics MP3 500 ie SPORT Business LT (2011)
CHAR - 20