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Piaggio MP3 300 ie IBRIDO LT Shop Manual 2010 – 2015 – PDF DOWNLOAD
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Piaggio MP3 300 ie IBRIDO LT Shop Manual 2010 – 2015
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Description
Piaggio MP3 300 ie IBRIDO LT Shop Manual 2010 – 2015
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:412
DOWNLOADABLE:YES
FILE TYPE:PDF
PIAGGIO MP3 300 IE IBRIDO LT SHOP MANUAL 2010 – 2015 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Piaggio MP3 300 ie IBRIDO LT Shop Manual 2010 – 2015
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle mounting techniques and procedures. Any important changes made to the vehicles or to specific mounting operations will be promptly reported 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.
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.
- 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 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.
TABLE OF CONTENTS:
Piaggio MP3 300 ie IBRIDO LT Shop Manual 2010 – 2015
Man: MP3 300 IBRIDO LT (2010).................................. 5 Cap:Characteristics........................................ 6 Sez:Rules.............................................. 7 Sez:Safety rules....................................... 7 Sez:Maintenance rules.................................. 7 Sez:Vehicle identification............................. 7 Sez:Dimensions and mass................................ 8 Sez:Engine............................................. 9 Sez:Transmission....................................... 9 Sez:Capacities......................................... 9 Sez:Electrical system.................................. 10 Sez:Frame and suspensions.............................. 10 Sez:Brakes............................................. 10 Sez:Wheels and tyres................................... 10 Sez:Tightening Torques................................. 10 Sez:Overhaul data...................................... 13 Sez:Assembly clearances................................ 13 Sez:Cylinder - piston assy............................. 13 Sez:Crankcase - crankshaft - connecting rod............ 15 Sez:Cylinder Head...................................... 21 Sez:Slot packing system................................ 27 Sez:Products........................................... 28 Cap:Tooling................................................ 29 Cap:Maintenance............................................ 41 Sez:Maintenance chart.................................. 45 Sez:Spark plug......................................... 45 Sez:Hub oil............................................ 46 Sez:Check.............................................. 46 Sez:Replacement........................................ 47 Sez:Air filter......................................... 47 Sez:CVT filter removal................................. 48 Sez:CVT filter cleaning................................ 48 Sez:Engine oil......................................... 48 Sez:Replacement........................................ 49 Sez:Check.............................................. 50 Sez:Engine oil filter.................................. 50 Sez:Oil pressure warning light......................... 51 Sez:Cooling system..................................... 51 Sez:Braking system..................................... 51 Sez:Level check........................................ 51 Sez:Top-up............................................. 52 Sez:Headlight adjustment............................... 53 Cap:Troubleshooting........................................ 54 Sez:Engine............................................. 55 Sez:Excessive oil consumption/Exhaust smoke............ 55 Sez:Insufficient lubrication pressure.................. 55 Sez:Transmission and brakes............................ 55 Sez:Clutch grabbing or performing inadequately......... 55 Sez:Insufficient braking............................... 55 Sez:Brakes overheating................................. 56 Sez:Steering and suspensions........................... 56 Sez:Heavy steering..................................... 56 Sez:Excessive steering play............................ 56 Sez:Noisy suspension................................... 56 Sez:Suspension oil leakage............................. 56 Cap:Electrical system...................................... 0 Sez:Components arrangement............................. 62 Sez:Ground points...................................... 68 Sez:Electric traction system........................... 69 Sez:Operating principle diagram........................ 70 Sez:Traction battery................................... 72 Sez:Inverter........................................... 77 Sez:Inverter cooling fan............................... 78 Sez:Microswitch........................................ 82 Sez:Electric motor and temperature sensor.............. 85 Sez:Speed/phase sensor................................. 88 Sez:Charge indicator and buzzer........................ 90 Sez:CAN line........................................... 92 Sez:state of charge indicator.......................... 92 Sez:Electrical system installation..................... 94 Sez:Front side......................................... 94 Sez:Back side..........................................106 Sez:Conceptual diagrams................................119 Sez:Ignition...........................................119 Sez:Battery recharge and starting......................121 Sez:Level indicators and enable signals section........122 Sez:Devices and accessories............................123 Sez:Lights and turn indicators.........................125 Sez:Checks and inspections.............................126 Sez:Immobiliser........................................126 Sez:Virgin circuit.....................................128 Sez:Diagnostic codes...................................129 Sez:Diagnostic code - 1 flash..........................130 Sez:Diagnostic code - 2 flashes........................130 Sez:Diagnostic code - 3 flashes........................131 Sez:No spark plug......................................131 Sez:Battery recharge circuit...........................132 Sez:Remote controls check..............................132 Sez:Switches check.....................................132 Sez:Stator check.......................................135 Sez:Recharge system voltage check......................135 Sez:Starter motor......................................136 Sez:Horn control.......................................137 Sez:Turn signals system check..........................138 Sez:level indicators...................................139 Sez:Lights list........................................140 Sez:Fuses..............................................143 Sez:Dashboard..........................................144 Sez:Sealed battery.....................................145 Sez:Battery installation...............................145 Sez:Connectors.........................................149 Sez:Strumento di diagnosi..............................157 Cap:Engine from vehicle.................................... 0 Sez:Exhaust assy. Removal..............................161 Sez:Removal of the engine from the vehicle.............162 Cap:Engine.................................................168 Sez:Automatic transmission.............................169 Sez:Transmission cover.................................169 Sez:Air duct...........................................171 Sez:Removing the driven pulley shaft bearing...........172 Sez:Refitting the driven pulley shaft bearing..........172 Sez:Removing the driven pulley.........................173 Sez:Inspecting the clutch drum.........................173 Sez:Removing the clutch................................174 Sez:Inspecting the clutch..............................175 Sez:Pin retaining collar...............................175 Sez:Removing the driven half-pulley bearing............175 Sez:Inspecting the driven fixed half-pulley............176 Sez:Inspecting the driven sliding half-pulley..........177 Sez:Refitting the driven half-pulley bearing...........177 Sez:Refitting the driven pulley........................178 Sez:Inspecting the clutch spring.......................179 Sez:Refitting the clutch...............................179 Sez:Refitting the driven pulley........................180 Sez:Drive-belt.........................................181 Sez:Removing the driving pulley........................181 Sez:Inspecting the rollers case........................182 Sez:Refitting the driving pulley.......................184 Sez:Refitting the transmission cover...................185 Sez:Electric motor.....................................185 Sez:Electric motor removing and refitting..............186 Sez:Speed/phase sensor removing and refitting motor....187 Sez:End gear...........................................188 Sez:Removing the hub cover.............................188 Sez:Removing the wheel axle............................188 Sez:Removing the hub bearings..........................189 Sez:Removing the wheel axle bearings...................189 Sez:Removing the driven pulley shaft bearing...........190 Sez:Inspecting the hub shaft...........................191 Sez:Inspecting the hub cover...........................192 Sez:Refitting the wheel axle bearing...................192 Sez:Refitting the hub cover bearings...................193 Sez:Refitting the hub bearings.........................194 Sez:Refitting the ub cover.............................194 Sez:Flywheel cover.....................................195 Sez:Removing the hub cover.............................195 Sez:Removing the stator................................196 Sez:Refitting the stator...............................196 Sez:Refitting the flywheel cover.......................196 Sez:Flywheel and starting..............................198 Sez:Removing the starter motor.........................198 Sez:Removing the flywheel magneto......................198 Sez:Inspecting the flywheel components.................200 Sez:Starter gear rim...................................200 Sez:Intermediate gear..................................200 Sez:Refitting the free wheel...........................200 Sez:Refitting the flywheel magneto.....................201 Sez:Refitting the starter motor........................202 Sez:Cylinder assy. and timing system...................202 Sez:Removing the intake manifold.......................202 Sez:Removing the rocker-arms cover.....................202 Sez:Removing the timing system drive...................203 Sez:Removing the cam shaft.............................204 Sez:Removing the cylinder head.........................205 Sez:Removing the valves................................205 Sez:Removing the cylinder - piston assy................206 Sez:Inspecting the small end...........................207 Sez:Inspecting the wrist pin...........................207 Sez:Inspecting the piston..............................207 Sez:Inspecting the piston rings........................207 Sez:Removing the piston................................207 Sez:Choosing the gasket................................208 Sez:Refitting the piston rings.........................209 Sez:Refitting the cylinder.............................210 Sez:Inspecting the cylinder head.......................210 Sez:Inspecting the timing system components............211 Sez:Inspecting the valve sealings......................211 Sez:Inspecting the valves..............................211 Sez:Inspecting the springs and half-cones..............211 Sez:Refitting the valves...............................212 Sez:Inspecting the cam shaft...........................212 Sez:Refitting the head and timing system components....213 Sez:Refitting the rocker-arms cover....................215 Sez:Refitting the intake manifold......................215 Sez:Crankcase - crankshaft.............................215 Sez:Splitting the crankcase halves.....................215 Sez:Inspecting the crankshaft components...............217 Sez:Inspecting the crankshaft alignment................217 Sez:Inspecting the crankcase halves....................217 Sez:Inspecting the crankshaft plain bearings...........219 Sez:Coupling chart.....................................219 Sez:Refitting the crankcase halves.....................219 Sez:Studs..............................................221 Sez:Lubrication........................................222 Sez:Conceptual diagrams................................222 Sez:Oil pressure check.................................222 Sez:Crankshaft oil seals...............................223 Sez:Removal............................................223 Sez:Refitting..........................................224 Sez:Oil pump...........................................225 Sez:Removal............................................225 Sez:Inspection.........................................226 Sez:Refitting..........................................227 Sez:Removing the oil sump..............................228 Sez:Inspecting the by-pass valve.......................228 Sez:Refitting the oil sump.............................229 Cap:Injection..............................................230 Sez:Precautions........................................232 Sez:EMS circuit diagram................................234 Sez:Troubleshooting procedure..........................235 Sez:Engine does not start..............................235 Sez:Starting difficulties..............................235 Sez:Engine stops at idle...............................236 Sez:Engine does not rev down...........................236 Sez:Exhaust backfires in deceleration..................237 Sez:Engine revs irregularly............................237 Sez:Poor performance at full throttle..................238 Sez:Engine knocking....................................238 Sez:Fuel supply system.................................238 Sez:Removing the butterfly valve.......................239 Sez:Refitting the butterfly valve......................241 Sez:Pump supply circuit................................241 Sez:Circuit leak test..................................246 Sez:Fuel filter check..................................246 Sez:Inspecting the injector circuit....................248 Sez:Inspecting the injector hydraulics.................253 Sez:Tachometer.........................................254 Sez:HT coil............................................255 Sez:Coolant temperature sensor.........................260 Sez:Lambda probe.......................................261 Cap:Suspensions............................................264 Sez:Front..............................................265 Sez:Removing the front wheel...........................265 Sez:Front wheel hub overhaul...........................265 Sez:Handlebar..........................................267 Sez:Removal............................................267 Sez:Refitting..........................................267 Sez:The tilt mechanism.................................267 Sez:Hydraulic system layout............................267 Sez:Steering tubes.....................................269 Sez:Parallelogram device...............................275 Sez:Geared motor and Suspension locking system.........279 Sez:Electrical devices test............................294 Sez:Wheel alignment....................................307 Sez:Rear...............................................312 Sez:Removing the rear wheel............................312 Sez:Refitting the rear wheel...........................313 Sez:Swing-arm..........................................313 Sez:Removal............................................313 Sez:Overhaul...........................................314 Sez:Refitting..........................................318 Sez:Shock absorbers....................................320 Sez:Removal............................................320 Sez:Refitting..........................................320 Sez:Centre-stand.......................................321 Cap:Braking system......................................... 0 Sez:Interventions rules................................324 Sez:Brake system fitting...............................325 Sez:Rear brake calliper................................330 Sez:Removal............................................330 Sez:Front brake calliper...............................330 Sez:Removal............................................330 Sez:Front brake disc...................................331 Sez:Removal............................................331 Sez:Front brake pads...................................332 Sez:Removal............................................332 Sez:Fill...............................................333 Sez:Rear - combined....................................333 Sez:Front..............................................333 Sez:Brake pipes........................................333 Sez:Parking brake......................................334 Cap:Cooling system......................................... 0 Sez:Circuit diagram....................................338 Sez:Electric fan check.................................339 Sez:System bleed.......................................340 Sez:Thermostat.........................................341 Sez:Removal............................................341 Sez:Check..............................................341 Sez:Refitting..........................................342 Cap:Chassis................................................343 Sez:Seat...............................................344 Sez:Front handlebar cover..............................344 Sez:Headlight assy.....................................345 Sez:Frame central cover................................346 Sez:Legshield..........................................346 Sez:Knee-guard.........................................347 Sez:Taillight assy.....................................349 Sez:Footrest...........................................350 Sez:Side fairings......................................351 Sez:License plate holder...............................351 Sez:Vano portabatterie - inverter......................352 Sez:spoiler............................................353 Sez:Fuel tank..........................................354 Sez:Top-case...........................................354 Sez:Rear...............................................355 Sez:Handles and top side fairings......................355 Sez:Radiator cover.....................................356 Cap:Pre-delivery........................................... 0 Sez:Aesthetic inspection...............................360 Sez:Tightening torques inspection......................360 Sez:Electrical system..................................361 Sez:Levels check.......................................362 Sez:Road test..........................................362 Sez:Static test........................................362 Sez:Functional inspection..............................363 Cap:Time...................................................364 Sez:Engine.............................................365 Sez:Crankcase..........................................365 Sez:Crankshaft.........................................366 Sez:Cylinder assy......................................366 Sez:Cylinder head assy.................................367 Sez:Rocker arms support assy...........................368 Sez:Cylinder head cover................................369 Sez:Flywheel cover.....................................370 Sez:Driven pulley......................................371 Sez:Oil pump...........................................372 Sez:Final gear assy....................................372 Sez:Driving pulley.....................................373 Sez:Transmission cover.................................374 Sez:Water pump.........................................375 Sez:Starter motor......................................375 Sez:Flywheel magneto...................................376 Sez:Butterfly valve....................................377 Sez:Exhaust pipe.......................................378 Sez:Air cleaner........................................379 Sez:Frame..............................................380 Sez:Centre-stand.......................................381 Sez:Legshield spoiler..................................382 Sez:Side fairings......................................383 Sez:Rear cover.........................................384 Sez:Central cover......................................385 Sez:Mudguard...........................................386 Sez:Fuel tank..........................................387 Sez:Rear shock-absorber................................388 Sez:Handlebar covers...................................389 Sez:Handlebar components...............................390 Sez:Swing-arm..........................................391 Sez:Seat...............................................392 Sez:Instrument panel...................................393 Sez:Locks..............................................394 Sez:Turn signal lights.................................395 Sez:Front wheel........................................397 Sez:Rear wheel.........................................398 Sez:Electric devices...................................399 Sez:Electronic controls................................401 Sez:Transmissions......................................402 Sez:Helmet bay.........................................403 Sez:Rear side fairings.................................404 Sez:Front suspension...................................404 Sez:Cooling system.....................................405 Sez:Braking system.....................................406 Sez:Windscreen.........................................408 Sez:Stickers...........................................408 Sez:The tilt mechanism.................................409 Sez:Geared motor.......................................409
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