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Piaggio MP3 300 Yourban I.E RL, NRL 2011-2015 Service Repair Manual – PDF Download
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Description
Piaggio MP3 300 Yourban I.E RL, NRL 2011-2015 Service Repair Manual
FILE DETAILS:
Piaggio MP3 300 Yourban I.E RL, NRL 2011-2015 Service Repair Manual
LANGUAGE:ENGLISH
PAGES:332
DOWNLOADABLE:YES
FILE TYPE:PDF
PIAGGIO MP3 300 YOURBAN I.E RL, NRL 2011-2015 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Piaggio MP3 300 Yourban I.E RL, NRL 2011-2015 Service Repair Manual
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.
TABLE OF CONTENTS:
Piaggio MP3 300 Yourban I.E RL, NRL 2011-2015 Service Repair Manual
Man: MP3 300 YOURBAN i.e. RL - NRL............................. 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.................................. 47 Sez:Spark plug......................................... 48 Sez:Hub oil............................................ 49 Sez:Check.............................................. 49 Sez:Replacement........................................ 50 Sez:Air filter......................................... 50 Sez:Engine oil......................................... 51 Sez:Replacement........................................ 51 Sez:Check.............................................. 52 Sez:Engine oil filter.................................. 53 Sez:Oil pressure warning light......................... 53 Sez:Cooling system..................................... 54 Sez:Braking system..................................... 55 Sez:Level check........................................ 55 Sez:Top-up............................................. 56 Sez:Headlight adjustment............................... 56 Cap:Troubleshooting........................................ 58 Sez:Engine............................................. 59 Sez:Excessive oil consumption/Exhaust smoke............ 59 Sez:Insufficient lubrication pressure.................. 59 Sez:Transmission and brakes............................ 59 Sez:Clutch grabbing or performing inadequately......... 59 Sez:Insufficient braking............................... 59 Sez:Brakes overheating................................. 60 Sez:Steering and suspensions........................... 60 Sez:Heavy steering..................................... 60 Sez:Excessive steering play............................ 60 Sez:Noisy suspension................................... 60 Sez:Suspension oil leakage............................. 60 Cap:Electrical system...................................... 0 Sez:Components arrangement............................. 65 Sez:Ground points...................................... 71 Sez:Electrical system installation..................... 71 Sez:Front side......................................... 74 Sez:Back side.......................................... 82 Sez:Conceptual diagrams................................ 87 Sez:Ignition........................................... 87 Sez:Battery recharge and starting...................... 88 Sez:Level indicators and enable signals section........ 89 Sez:Devices and accessories............................ 90 Sez:Lights and turn indicators......................... 92 Sez:Checks and inspections............................. 94 Sez:Immobiliser........................................ 94 Sez:Virgin circuit..................................... 97 Sez:Diagnostic codes................................... 97 Sez:Diagnostic code - 1 flash.......................... 99 Sez:Diagnostic code - 2 flashes........................ 99 Sez:Diagnostic code - 3 flashes........................ 99 Sez:Ignition circuit................................... 99 Sez:No spark plug......................................100 Sez:Battery recharge circuit...........................100 Sez:Remote controls check..............................100 Sez:Switches check.....................................101 Sez:Stator check.......................................103 Sez:Recharge system voltage check......................104 Sez:Starter motor......................................104 Sez:Horn control.......................................106 Sez:Turn signals system check..........................106 Sez:level indicators...................................108 Sez:Lights list........................................109 Sez:Fuses..............................................111 Sez:Dashboard..........................................112 Sez:Battery installation...............................113 Sez:Connectors.........................................117 Cap:Engine from vehicle.................................... 0 Sez:Exhaust assy. Removal..............................124 Sez:Removal of the engine from the vehicle.............124 Cap:Engine.................................................130 Sez:Automatic transmission.............................131 Sez:Transmission cover.................................131 Sez:Air duct...........................................131 Sez:Removing the driven pulley shaft bearing...........132 Sez:Refitting the driven pulley shaft bearing..........132 Sez:Removing the driven pulley.........................133 Sez:Inspecting the clutch drum.........................133 Sez:Removing the clutch................................134 Sez:Inspecting the clutch..............................135 Sez:Pin retaining collar...............................135 Sez:Removing the driven half-pulley bearing............135 Sez:Inspecting the driven fixed half-pulley............136 Sez:Inspecting the driven sliding half-pulley..........137 Sez:Refitting the driven half-pulley bearing...........137 Sez:Refitting the driven pulley........................138 Sez:Inspecting the clutch spring.......................139 Sez:Refitting the clutch...............................139 Sez:Refitting the driven pulley........................140 Sez:Drive-belt.........................................141 Sez:Removing the driving pulley........................141 Sez:Inspecting the rollers case........................143 Sez:Refitting the driving pulley.......................144 Sez:Refitting the transmission cover...................145 Sez:End gear...........................................145 Sez:Removing the hub cover.............................145 Sez:Removing the wheel axle............................146 Sez:Removing the hub bearings..........................146 Sez:Removing the wheel axle bearings...................147 Sez:Removing the driven pulley shaft bearing...........147 Sez:Inspecting the hub shaft...........................148 Sez:Inspecting the hub cover...........................149 Sez:Refitting the wheel axle bearing...................149 Sez:Refitting the hub cover bearings...................150 Sez:Refitting the hub bearings.........................151 Sez:Refitting the ub cover.............................152 Sez:Flywheel cover.....................................152 Sez:Removing the hub cover.............................152 Sez:Removing the stator................................153 Sez:Refitting the stator...............................154 Sez:Refitting the flywheel cover.......................154 Sez:Flywheel and starting..............................155 Sez:Removing the starter motor.........................155 Sez:Removing the flywheel magneto......................156 Sez:Inspecting the flywheel components.................157 Sez:Starter gear rim...................................157 Sez:Intermediate gear..................................157 Sez:Refitting the free wheel...........................158 Sez:Refitting the flywheel magneto.....................158 Sez:Refitting the starter motor........................159 Sez:Cylinder assy. and timing system...................159 Sez:Removing the intake manifold.......................160 Sez:Removing the rocker-arms cover.....................160 Sez:Removing the timing system drive...................160 Sez:Removing the cam shaft.............................161 Sez:Removing the cylinder head.........................162 Sez:Removing the valves................................163 Sez:Removing the cylinder - piston assy................163 Sez:Inspecting the small end...........................164 Sez:Inspecting the wrist pin...........................164 Sez:Inspecting the piston..............................165 Sez:Inspecting the piston rings........................165 Sez:Removing the piston................................165 Sez:Choosing the gasket................................166 Sez:Refitting the piston rings.........................167 Sez:Refitting the cylinder.............................167 Sez:Inspecting the cylinder head.......................168 Sez:Inspecting the timing system components............168 Sez:Inspecting the valve sealings......................169 Sez:Inspecting the valves..............................169 Sez:Inspecting the springs and half-cones..............169 Sez:Refitting the valves...............................169 Sez:Inspecting the cam shaft...........................170 Sez:Refitting the head and timing system components....170 Sez:Refitting the rocker-arms cover....................172 Sez:Refitting the intake manifold......................173 Sez:Crankcase - crankshaft.............................173 Sez:Splitting the crankcase halves.....................173 Sez:Inspecting the crankshaft components...............175 Sez:Inspecting the crankshaft alignment................175 Sez:Inspecting the crankcase halves....................175 Sez:Inspecting the crankshaft plain bearings...........177 Sez:Coupling chart.....................................177 Sez:Refitting the crankcase halves.....................177 Sez:Studs..............................................179 Sez:Lubrication........................................180 Sez:Conceptual diagrams................................180 Sez:Oil pressure check.................................180 Sez:Crankshaft oil seals...............................181 Sez:Removal............................................181 Sez:Refitting..........................................182 Sez:Oil pump...........................................183 Sez:Removal............................................183 Sez:Inspection.........................................184 Sez:Refitting..........................................185 Sez:Removing the oil sump..............................186 Sez:Inspecting the by-pass valve.......................186 Sez:Refitting the oil sump.............................187 Cap:Injection..............................................188 Sez:Precautions........................................190 Sez:EMS circuit diagram................................191 Sez:Troubleshooting procedure..........................193 Sez:Engine does not start..............................193 Sez:Starting difficulties..............................193 Sez:Engine stops at idle...............................194 Sez:Engine does not rev down...........................194 Sez:Exhaust backfires in deceleration..................195 Sez:Engine revs irregularly............................195 Sez:Poor performance at full throttle..................195 Sez:Engine knocking....................................196 Sez:Fuel supply system.................................196 Sez:Removing the butterfly valve.......................197 Sez:Refitting the butterfly valve......................199 Sez:Pump supply circuit................................199 Sez:Circuit leak test..................................201 Sez:Fuel filter check..................................202 Sez:Inspecting the injector circuit....................203 Sez:Inspecting the injector hydraulics.................205 Sez:Tachometer.........................................206 Sez:HT coil............................................207 Sez:Coolant temperature sensor.........................210 Sez:Lambda probe.......................................211 Cap:Suspensions............................................214 Sez:Front..............................................215 Sez:Removing the front wheel...........................215 Sez:Front wheel hub overhaul...........................215 Sez:Refitting the front wheel..........................217 Sez:Handlebar..........................................217 Sez:Removal............................................217 Sez:Refitting..........................................218 Sez:The tilt mechanism.................................218 Sez:Hydraulic system layout............................218 Sez:Steering tubes.....................................219 Sez:Parallelogram device...............................225 Sez:Geared motor and Suspension locking system.........230 Sez:Electrical devices test............................257 Sez:Wheel alignment....................................270 Sez:Rear...............................................275 Sez:Removing the rear wheel............................275 Sez:Refitting the rear wheel...........................276 Sez:Swing-arm..........................................276 Sez:Removal............................................276 Sez:Overhaul...........................................277 Sez:Refitting..........................................281 Sez:Shock absorbers....................................282 Sez:Removal............................................282 Sez:Refitting..........................................283 Sez:Centre-stand.......................................283 Cap:Braking system......................................... 0 Sez:Interventions rules................................286 Sez:Brake system fitting...............................286 Sez:Rear brake calliper................................289 Sez:Removal............................................289 Sez:Refitting..........................................289 Sez:Front brake calliper...............................289 Sez:Removal............................................289 Sez:Refitting..........................................290 Sez:Removal............................................290 Sez:Refitting..........................................291 Sez:Disc Inspection....................................291 Sez:Front brake disc...................................292 Sez:Removal............................................292 Sez:Refitting..........................................293 Sez:Disc Inspection....................................293 Sez:Front brake pads...................................294 Sez:Refitting..........................................294 Sez:Removal............................................294 Sez:Fill...............................................295 Sez:Rear - combined....................................295 Sez:Front..............................................295 Sez:Brake pipes........................................295 Sez:Parking brake......................................296 Cap:Cooling system......................................... 0 Sez:Circuit diagram....................................300 Sez:Electric fan check.................................301 Sez:System bleed.......................................302 Sez:Thermostat.........................................303 Sez:Removal............................................303 Sez:Check..............................................304 Sez:Refitting..........................................304 Cap:Chassis................................................306 Sez:Seat...............................................307 Sez:Front handlebar cover..............................307 Sez:Headlight assy.....................................309 Sez:Frame central cover................................310 Sez:Legshield..........................................311 Sez:Knee-guard.........................................313 Sez:Taillight assy.....................................314 Sez:Footrest...........................................316 Sez:Side fairings......................................318 Sez:License plate holder...............................319 Sez:Helmet bay.........................................319 Sez:spoiler............................................321 Sez:Fuel tank..........................................322 Sez:Handles and top side fairings......................323 Sez:Flyscreen..........................................324 Sez:Radiator cover.....................................325 Cap:Pre-delivery........................................... 0 Sez:Aesthetic inspection...............................328 Sez:Tightening torques inspection......................328 Sez:Electrical system..................................328 Sez:Levels check.......................................329 Sez:Road test..........................................329 Sez:Static test........................................330 Sez:Functional inspection..............................330
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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