PIAGGIO 633823 Guide

SERVICE STATION MANUAL
633823
MP3 250 i.e.

SERVICE STATION
MANUAL
MP3 250 i.e.
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA 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 shown in this publication are available in all Countries. The availability of single versions
should be checked at the official Piaggio sales network.
"©Copyright2007-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL
MP3 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. 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 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 Sectionsmarked with this symbol indicatethe 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
TIME TIME

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 open 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 solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.
- 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 scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.
Characteristics MP3 250 i.e.
CHAR - 2

Vehicle identification
Chassis prefix (FULL OPTIONAL): M47201
Chassis prefix (BASE): M47200
Engine prefix: M472M
Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Kerb weight 224 ± 5 Kg
Wheelbase 1490 mm
Height 1245 mm
Width (handlebar) 745 mm
Overall length 2130 mm
Track 420 mm
Engine
DATA
Specification Desc./Quantity
Type single-cylinder, four-stroke and four liquid-cooled
valves
MP3 250 i.e. Characteristics
CHAR - 3

Specification Desc./Quantity
Timing system single overhead camshaft chain driven on the left-
hand side, three-arm rocking levers set up with
threaded set screw
Bore 72 mm
Stroke 60 mm
Cubic capacity 249.29 mm
Compression ratio 10.5 ÷ 11.5
Air filter sponge,impregnatedwithmixture(50%petroland
50% oil)
Starting system electric starter motor with freewheel
Lubrication with lobe pump (inside the crankcase) chain-driv-
en and double filter: mesh and paper
Fuel supply by electronic injection with electric fuel pump
valve clearance intake: 0.10 mm - discharge: 0.15 mm
Engine idle speed approx. 1600 ÷ 1800 rpm
Max. speed 125 km/h
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque
server,Vbelt,automaticclutch,gearreductionunit
and transmission housing with forced air circula-
tion cooling
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil approx. 1300 cc (recommended oil Selenia HI
Scooter 4 Tech)
Rear hub 250 cc ( recommended oil TUTELA MATRIX)
Fuel tank capacity Tank capacity: ~12 l (approximate value)
Fuel reserve approx. 2.5 litres (indicative value)
Cooling circuit Capacity: ~ 2.0 l
Electrical system
ELECTRICAL COMPONENTS
Specification Desc./Quantity
Ignition/advance Electronic, with inductive discharge and variable
advance with three-dimensional mapping
Spark plug CHAMPION RG 4 PHP
Battery 12V-12Ah
Generator alternating current
Characteristics MP3 250 i.e.
CHAR - 4

Frame and suspensions
FRAME AND SUSPENSIONS
Specification Desc./Quantity
Chassis Tubular and sheet steel.
Rear suspension Single arm with two double-acting hydraulic shock
absorbers and preloading adjustable to 4 posi-
tions.
Front suspension The tilt mechanism 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 disk with hydraulic control acti-
vated by the handlebar right-hand lever.
Rear brake Ø 240 mm disc brake with hydraulic control acti-
vated by the handlebar left-side lever.
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Front wheel Alloy rims: 12" x 3.00"
Rear wheel alloy rim: 12"x3,00
Front tyre 120/70-12", without inner tube
Rear tyre Without inner tube: 130/70-12" 62P
TYRE PRESSURE
Specification Desc./Quantity
Front tyre pressure (rider) Front tyre pressure (rider): 1.6 bar
Front tyre pressure (rider and passenger) Front tyre pressure (rider and passenger): 1.8 bar
Rear tyre pressure (rider) Rear tyre pressure (rider): 2 bar
Rear wheel pressure (rider and passenger): Rear tyre pressure (rider and passenger): 2.4 bar
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
Tightening Torques
STEERING
Name Torque in Nm
Steering lower ring nut (central headstock) 22 ÷ 27 loosen by 90°
Steering upper ring nut (central headstock) 27 ÷ 33
Handlebar fixing screw 50 ÷ 55
Fixing screws for handlebar control assembly U-
bolts 7 ÷ 10
MP3 250 i.e. Characteristics
CHAR - 5

FRAME
Name Torque in Nm
Engine arm bolt - frame arm 33 ÷ 41
Swinging arm buffer nut 64 - 72
Engine-swinging arm bolt 55 ÷ 61
Frame-swinging arm bolt 55 ÷ 61
Centre stand bolt 31 ÷ 39
FRONT SUSPENSION
Name Torque in Nm
Shock absorber lower clamp 19 ÷ 26
Upper shock absorber clamp 19 ÷ 29
Front wheel fixing screws 19 ÷ 24
Steering arm bolt nut 20 ÷ 25
Tilt calliper fixing screws 20 ÷ 25
Front wheel shaft 74 ÷ 88
Arm coupling screws 45 ÷ 50
Screws fixing arms to side headstocks 45 ÷ 50
Screws fixing arms to central headstock 45 ÷ 50
Screws fixing the half-arm coupling flange 20 ÷ 25
Fixing screws for tilt locking disc section 20 ÷ 25
Side headstock upper ring nut 20 - 24
Side headstock lower ring nut 12 ÷ 15
Screw fixing sliding stem to shock absorber 45 ÷ 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 ÷ 10
Electric motor to anti-tilting device clamp 11 ÷ 13
Clamp fixing pump bolt to anti-tilting device 11 ÷ 13
Pump to anti-tilting device clamp 11 ÷ 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 ÷ 25
Lower fitting for shock absorber sliding locking
clamp pipes 20 ÷ 25
Upper fitting for shock absorber sliding locking
clamp pipes 20 ÷ 25
REAR SUSPENSION
Name Torque in Nm
Upper shock absorber clamp 33 ÷ 41
Shock absorber lower clamp 33 ÷ 41
Shock absorber-crankcase attachment bracket 20 ÷ 25
Rear wheel axle 104 ÷ 126
Muffler arm clamping screws 27 ÷ 30
FRONT BRAKE
Name Torque in Nm
Oil bleed screw 8÷12
Disc tightening screw (°) 5 - 6
Brake fluid pump - hose fitting 16 ÷ 20
Brake fluid pipe-calliper fitting 20 ÷ 25
Characteristics MP3 250 i.e.
CHAR - 6

Name Torque in Nm
Screw tightening calliper to the support 20 ÷ 25
Calliper upper pipe fitting 20 ÷ 25
REAR BRAKE
Name Torque in Nm
Rear brake disc screws(°) 5 ÷ 6.5
Rear brake calliper-pipe fitting 20 ÷ 25
Rigid / flexible pipe fitting 13 ÷ 18
Rear brake pump-pipe fitting 16 ÷ 20
Rear brake calliper fixing screws 20 ÷ 25
REAR BRAKE
Product Description Specifications
(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-
strength threadlock
MUFFLER
Name Torque in Nm
Muffler heat guard fixing screw 4 ÷ 5
Screw for fixing muffler to the support arm 20 ÷ 25
Lambda probe clamp on exhaust manifold 40 ÷ 50
Exhaust manifold-muffler joint clamp 12 ÷ 13
Manifold - muffler diaphragm tightening clamp 16 ÷ 18
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 ÷ 17
Oil filter on crankcase fitting 27 ÷ 33
Engine oil drainage plug/mesh filter 24 ÷ 30
Oil filter 4 ÷ 6
Oil pump cover screws 7 ÷ 9
Screws fixing oil pump to the crankcase 5 - 6
Oil pump control crown screw 10 ÷ 14
Oil pump cover plate screws 4 ÷ 6
Oil sump screws 10 ÷ 14
Minimum oil pressure sensor 12 ÷ 14
CYLINDER HEAD
Name Torque in Nm
Spark plug 12 ÷ 14
Head cover screws 6 ÷ 7
Nuts fixing head to cylinder 7±1 + 10±1 + 270°
Head fixing side screws 11 ÷ 12 Nm
Starter ground screw 7 ÷ 8.5
Tappet set screw lock nut 6 ÷ 8
Inlet manifold screws 11 ÷ 13
Timing chain tensioner slider screw 10 ÷ 14
Starter ground support screw 11 ÷ 15
Timing chain tensioner support screw 11 ÷ 13
Timing chain tensioner central screw 5 - 6
Camshaft retention plate screw 4 ÷ 6
MP3 250 i.e. Characteristics
CHAR - 7

TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 ÷ 13
Clutch unit nut on driven pulley 45 ÷ 50
Drive pulley nut 75 ÷ 83
Transmission cover screws 11 ÷ 13
Driven pulley shaft nut 54 ÷ 60
Rear hub cap screws 24 ÷ 27
FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 ÷ 13
Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength
threadlock)
Flywheel nut 94 - 102 Nm
Pick-Up clamping screws 3 ÷ 4
Screw fixing freewheel to flywheel 13 ÷ 15
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 ÷ 6
Engine-crankcase coupling screws 11 ÷ 13
Starter motor screws 11 ÷ 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength
threadlock)
COOLING
Name Torque in Nm
Water pump rotor cover 3 ÷ 4
Thermostat cover screws 3 ÷ 4
Bleed screw: 3
Overhaul data
Assembly clearances
Characteristics MP3 250 i.e.
CHAR - 8

Cylinder - piston assy.
ENGINE COUPLING CATEGORY
Name Initials Cylinder Piston Play on fitting
Cylinder M 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064
Cylinder N 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064
Piston O 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 - 0.064
Piston P 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 - 0.064
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000
car.) Indirizzo Immagine
Crankshaft Crankshaftto crankcase
axial clearance
Crankshaft to crankcase axial clearance
MP3 250 i.e. Characteristics
CHAR - 9

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE
Name Description Dimensions Initials Quantity
Half-shaft, trans-
mission side 16.6 +0-0.05 A D = 0.20 - 0.50
Flywheel-side half-
shaft 16.6 +0-0.05 B D = 0.20 - 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50
Spacer tool 51.4 +0.05 E D = 0.20 - 0.50
Slot packing system
Characteristic
Compression ratio
10.5 ÷ 11.5 : 1
Characteristics MP3 250 i.e.
CHAR - 10

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 CRANK-
CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON
A GROUND PLANE
ENGINE 250 SHIMMING
Name Measure A Thickness
shimming 3.70 - 3.60 0.4 ± 0.05
shimming 3.60 - 3.40 0.6 ± 0.05
shimming 3.40 - 3.30 0.8 ± 0.05
MP3 250 i.e. Characteristics
CHAR - 11

Products
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE80W/90Oilthatexceedsthe
requirements of API GL3 specifi-
cations
AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-
sions (throttle control) Oil for 4-stroke engines
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives
for increased adhesiveness
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-
based spray grease with NLGI 2;
ISO-L-XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,
JASO MA Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid
SPECIAL AGIP PERMANENT
fluid coolant Monoethylene glycol-based anti- freeze fluid, CUNA NC 956-16
Characteristics MP3 250 i.e.
CHAR - 12

INDEX OF TOPICS
TOOLING TOOL

APPROPRIATE TOOL
Stores code Description
001330Y Tool for fitting steering seats
001467Y014 Pliers to extract ø 15-mm bear-
ings
005095Y Engine support
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seat
on steering tube
020004Y Punch for removing fifth wheels
from headstock
020055Y Wrench for steering tube ring nut
Tooling MP3 250 i.e.
TOOL - 2