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)
CHAR - 10