PIAGGIO MP3 400 hpe E5 2021 User manual

MANUALE STAZIONE DI SERVIZIO
1Q000906
MP3 400 hpe E5

MANUALE
STAZIONE DI
SERVIZIO
MP3 400 hpe E5
The descriptions and images in this publication are given for illustrative purposes only. While the basic
features as described and illustrated in this manual 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 accessory supplies which it deems necessary to improve the product, or which
are required for manufacturing or commercial reasons.
Not all the versions shown in this publication are available in every country. Availability of the individual
versions must be verified with the official PIAGGIO sales network.
© Copyright 2021 - 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 400 hpe E5
Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle
officine dei concessionari e sub-agenzie Piaggio. 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 Sectionsmarkedwiththis 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
GENERAL MANDATORY REQUIREMENTS NORM
PRE-DELIVERY PRE DE
TECHNICAL DATA DT
TOOLING TOOL
MAINTENANCE MAIN
ENGINE ENG

INDEX OF TOPICS
GENERAL MANDATORY REQUIREMENTS NORM

General information
This section contains general information regarding the vehicle and the use of the manual, as well as
important notes regarding safety.
IMPORTANT WARNINGS AND NOTES
Each symbol has a precise meaning, as illustrated below.
•WARNING: - This symbol indicates risks for the health of the operator and of the nearby
persons if the described procedures are performed incorrectly.
•CAUTION:- This symbol indicates that the component on which works are being performed
may be damaged if the described procedures are performed incorrectly.
•NOTE: - This paragraph provides additional instructions for the ongoing procedure, so that
the operation may be performed in an efficient manner.
REACH REGULATION WARNINGS :
To protect the health and safety of the PROFESSIONAL CLIENT, as provided by the:
•(EC) Regulation No. 1907/2006 (REACh);
•2000/53/EC (END of LIFE VEHICLES);
•SCIP Database Directive (art.9, par.1 lett.i) of the framework directive regarding waste, as
modified by the Directive 2018/851
The technical personnel operating during the ordinary and special maintenance activities has the obli-
gation to always wear the personal protection equipment:
1. chemical protection gloves if the specific type is not explicitly indicated, or, if required, special
gloves according to the substance used;
2. mask, possibly a chemically active one, if specifically required;
3. protective goggles.
The above indications represent an alternative for the prescriptions of other regulations and of the
legislation in force in the specific countries. Regarding the use of other PPE, governed by the laws
regarding the safety at work, the relevant legislation in force apply.
MP3 400 hpe E5 General mandatory requirements
NORM - 7

GENERAL SAFETY WARNINGS :
1. Always wear protective goggles and proper clothing.
2. Always use a safety support to operate under the vehicle.
3. Check that the ignition switch is always OFF, unless the procedure indicates otherwise.
4. Pull the hand brake (if applicable) before starting working on the vehicle.
5. Start the engine only in well ventilated places, to avoid the risks related to the carbon oxide.
6. Keep a safe distance from the mobile parts during the operation of the engine, especially from
the fans and belts.
7. To avoid burns, avoid contact with the hot metallic parts, such as the radiator, exhaust manifold,
exhaust pipe, catalytic converter and silencer.
8. Do not smoke during maintenance operations.
9. To avoid any injuries, do not wear rings, watches, jewellery and loose clothing before starting to
work on the vehicle.
10.Keep your hands and other objects away from the blades of the radiator's fan (if present)!
11.The cooling fan (if present) is fitted on the radiator and may start any time due to a temperature
increase of the cooling fluid. It is important to check that the cooling fan's starter motor is discon-
nected from the wiring harness before starting the works.
The measurement units used in the manual are imperial UNITS of measurement. (International
system for UNITS). Example: 24.5-34.3 Nm
General mandatory requirements MP3 400 hpe E5
NORM - 8

INDEX OF TOPICS
PRE-DELIVERY PRE DE

Carry out the listed tests before delivering the vehicle.
Warning - Handle fuel with care.
Fit the plastic cover supplied on the joint on the
steering tube as shown in the figure.
Proceed as follows if the customer requests in-
stallation of splash guards on the vehicle:
•Fit the flap inside the mudguard shown
in the figure, matching up the 4 anchor
holes.
•Fit the 4 washers and the 4 screws on
the outer side of the mudguard, then
tighten to the specified torque.
Locking torques (N*m)
splash guard fastener screws 2 to 3
ASR SYSTEM CALIBRATION PROCEDURE.
The calibration procedure of the system must be
carried out according to what is indicated below,
riding on a straight flat stretch of road. In order to
maintain the effectiveness of the ASR system, the
procedure must be carried out again after the re-
placement of one or more tyres:
• It is necessary that the diagnostic phase of the
ASR systems and ABS is complete: for this pur-
pose, after switching to «ON», ride a short dis-
tance above 5 km/h and wait for the flashing of the
two warning lights to stop.
• Allow the engine to idle for at least 5 seconds.
• Pull the brake lever and press the ASR on/off
button «1» simultaneously for at least 3 seconds.
The activation process will be confirmed by the
Pre-delivery MP3 400 hpe E5
PRE DE - 10

ASR warning light «2» turning on with slow flash-
ing.
• Accelerate to a constant speed of 30 to 40 km/h
and maintain it for at least to 8 seconds. The con-
tinuity of the vehicle speed in the correct field to
completetheprocedurewillbeconfirmedbyavery
fast flashing of the ASR warning light «2».
• The end of the procedure will be indicated by the
steady lighting ASR warning light «2». The ASR
system is not active.
• Once the procedure is complete it is necessary
toswitchto«OFF»andwaitforatleast60seconds
before being able to switch again to «ON».
•Incaseoffailuretocompletetheprocedurewithin
5 minutes the ASR warning light «2» will stay on
steady and the ASR will remain off until switching
to «OFF».
• To switch again to «ON» it is necessary to reac-
tivate the ASR. It is however necessary to repeat
the process until it succeeds.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Safety locks check
- Safety fasteners
- Fastening screws
Safety fasteners:
•Rear shock absorber upper fixing
•Rear shock absorber lower fixing
•Front shock absorber upper fixing
MP3 400 hpe E5 Pre-delivery
PRE DE - 11

•Front shock absorber lower fixing
•Sliding shafts fixing
•Brake calliper fixing
•Front wheels fastening screws
•Front wheels axle nut
•Rear wheel axle nut
•Engine - frame oscillating arm fastening
•Handlebar lock nut
•Lateral steering tube lower ring nut
•Lateral steering tube upper ring nut
•Central steering tube lower ring nut
•Central steering tubes upper ring nut
•Constant-velocity universal joints
Electrical system
• Battery
• Main switch
• Lights: high beam lights, low beam lights, taillights (front and rear) and relevant warning lights
- Headlight adjustment according to the regulations currently in force
• Front and rear stop light buttons and bulb
• Turn indicators and their warning lights
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electric starter
• Engine stopping with emergency stop switch
• Electric opening of saddle with solenoid
• Tilting system locking - unlocking button
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATELY CHARGING THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS
USED FOR THE FIRST TIME WITH SHORTEN THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
Pre-delivery MP3 400 hpe E5
PRE DE - 12

BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO-
TECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE
OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Levels check
Level check:
- Hydraulic brake system liquid level.
- Roll lock system fluid level
- Rear hub oil level
- Engine coolant level
- Engine oil level
Road test
Test ride:
- Cold start
- Instrument operations
- Response to the gas command
- Stability on acceleration and braking
- Front and rear brake efficiency
- Parking brake efficiency
- Front and rear suspension efficiency
- Abnormal noise
- Tilting system locking - unlocking efficiency
Static test
Static control after the test drive:
• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY
BURST.
MP3 400 hpe E5 Pre-delivery
PRE DE - 13

Functional inspection
Functional Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting,
lock check, tyre pressure check, rear-view mirror and any accessory fitting
Specific operations for the vehicle
TOOLKIT
The toolkit comprises:
- a shock absorber pre-load adjusting wrench;
- One fuse puller.
The tools are stored in the helmet compartment.
WINDSHIELD
The vehicle has a windshield that cannot be ad-
justed with hand guards.
Fitting
Insert the spacers inside the windshield sheet, at
the four holes.
Pre-delivery MP3 400 hpe E5
PRE DE - 14

Rest and keep it resting with a light pressure (so
that it does not fall) the windshield on the top fair-
ing, aligning the holes and making sure that the
spacers are in place.
Insert the bushing.
Put in place the cover cap.
Insert the screw and tighten by hand.
MP3 400 hpe E5 Pre-delivery
PRE DE - 15

Repeat the operation for the other three fasten-
ings.
Tighten all four fastenings using an Allen wrench.
LICENCE PLATE HOLDER
CAUTION
N.B.
ONLY FIT THE LICENCE PLATE HOLDER SUPPLIED AS
STANDARD WITH THE VEHICLE, SINCE IT HAS TYPE-AP-
PROVED AND OBLIGATORY SIDE REFLECTORS.
If the reflectors need to be removed and replaced,
use the inside of the plate holder at the indicated
points.
Pre-delivery MP3 400 hpe E5
PRE DE - 16

INDEX OF TOPICS
TECHNICAL DATA DT

This section describes the general specifications of the vehicle.
Vehicle identification
The frame prefix «A» is stamped near the fuel
tank.
Theengineprefix «B»isstampedneartherearleft
shock absorber lower support.
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Frame prefix ZAPTD1200
Engine prefix TD13M
Vehicle data
VEHICLE DATA
Specification Desc./Quantity
Frame In tubes and steel sheet metal
Front suspension Rolling system composed of a universal joint composed of alu-
minium rods and of two side tubes and shock absorbers with a
hydraulic lock system
Rear suspension Two double-acting shock absorbers, adjustable to four posi-
tions at pre-loading.
Front brake Dual 258 mm hydraulically operated disc brakes controlled
from RH handlebar lever; braking assisted by ABS system
(where available).
Rear brake Ø240mmhydraulicallyoperateddisc brake controlled from LH
handlebar lever; braking assisted by ABS system (where avail-
able).
Integral braking system A hydraulic system allowing the rider to operate all three brake
discs simultaneously from the pedal on the foot board; braking
assisted by ABS system (where available).
Wheel rims type Light alloy.
Front wheel rims 13" x 3.00
Rear rim 14'' x 4.00
Front tyres Tubeless 110/70 - 13" 48S
Technical Data MP3 400 hpe E5
DT - 18

Specification Desc./Quantity
Rear tire Tubeless 140/70 - 14" 68S
Front tyre pressure 2 bar
Rear tire pressure (with passenger) 2.4 (2.6) bar
Kerb weight 257 kg
Maximum weight limit 460 kg
Battery 12V - 12Ah
Engine Data
ENGINE SPECIFICATIONS
Specification Desc./Quantity
Type Single cylinder 4-stroke
Engine capacity 399 cc
Bore per stroke 84,0 x 72,0 mm
Compression ratio 11,5 ± 0,5 :1
Idle speed 1600 ± 100 rpm
Timing system Four valves, single overhead camshaft, chain-driven.
Valve clearance Intake: 0.10 mm
Exhaust: 0.15 mm
Maximum power 26.0 kW at 7000 rpm
Maximum torque 37.7 Nm at 5500 rpm
Transmission With the expandable pulley continuously variable transmission
with torque server, trapezoid belt, automatic clutch oil bath
centrifuge.
Final drive reduction gear Gear reduction unit in oil bath.
Lubrication Engine lubrication with trochoidal pump (inside the crankcase),
oil filter and pressure adjustment by-pass.
Cooling Forced coolant circulation system.
Starting Electric
Ignition Electronic,inductive,highefficiencyignition,integratedwiththe
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Power supply Indirect electronic injection.
Spark plug NGK / MR7BI-8
Fuel Unleaded gasoline E10 (95 R.O.N.)
Silencer Absorption-type exhaust silencer with a three-way catalytic
converter and lambda probe to the exhaust.
Emissions compliance EURO 5
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil 1.40 l
Transmission oil 500 cm³
Cooling system liquid - replacement ~ 1.8 l
Fuel tank 13.2 ± 0.5 l
MP3 400 hpe E5 Technical Data
DT - 19

INDEX OF TOPICS
TOOLING TOOL