piaggio mp3 500 ie sport business rl my 2011 (en)

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This Service Manual describes the technical features and servicing procedures for the Piaggio MP3 500 Ie SPORT Business RL Made Year 2011

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MANUALE STAZIONE DI SERVIZIOxxxxxx(IT)-xxxxxx(EN)-xxxxxx(FR)-xxxxxx(DE)xxxxxx(ES)-xxxxxx(PT)-xxxxxx(NL)-xxxxxx(EL)

MP3 500 ie SPORT Business RL (2011)

MANUALE STAZIONE DI SERVIZIO

MP3 500 ie SPORT Business RL (2011)

The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet 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 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 2011 - 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 SERVIZIOMP3 500 ie SPORT Business RL (2011)Questo manuale per stazioni di servizio 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 pu comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed 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 Sections marked with this 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

CHARACTERISTICS TOOLING MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE INJECTION SUSPENSIONS BRAKING SYSTEM COOLING SYSTEM CHASSIS PRE-DELIVERY TIME

CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG INJEC SUSP BRAK SYS COOL SYS CHAS PRE DE TIME

INDEX OF TOPICS

CHARACTERISTICS

CHAR

MP3 500 ie SPORT Business RL (2011)

Characteristics

This section describes the general specifications of the vehicle.

RulesThis 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. - 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.

CHAR - 7

Characteristics

MP3 500 ie SPORT Business RL (2011)

Vehicle identificationThe identification registration numbers consist of a prefix stamped on the chassis and engine "B" respectively, 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

BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).

Dimensions and mass

CHAR - 8

MP3 500 ie SPORT Business RL (2011)

Characteristics

WEIGHTS AND DIMENSIONSSpecification Kerb weight Maximum weight allowed Width Maximum height Wheelbase Length Track Desc./Quantity 262 5 kg 445 kg 760 mm 1440 mm 1,550 mm 2,180 mm 425 mm

EngineENGINESpecification Type Engine capacity Bore x Stroke Compression ratio Engine idle speed Timing system Valve clearance Max. power MAX. torque Lubrication Lubrication pressure Minimum lubrication pressure (100 C) Fuel system Cooling Fuel Desc./Quantity Single-cylinder, 4-stroke with double spark plug 493 cm 94 x 71 mm 10.5: 1 1,500 100 rpm Four valves, single overhead camshaft, chain-driven. Intake: 0.15 mm Exhaust: 0.15 mm 29 kW at 7,500 rpm 44 Nm at 5,200 rpm Engine lubrication with lobe pump (inside crankcase), chaindriven, with double filter: mesh and paper. 3.5 4 bar 0.8 bar Electronic injection with electric fuel pump. Forced coolant circulation system. Unleaded petrol (95 RON)

TransmissionTRANSMISSIONSpecification TRANSMISSION Final reduction gear Desc./Quantity Automatic expandable pulley variator with torque server, Vbelt, automatic clutch. Gear reduction unit in oil bath.

CapacitiesCAPACITYSpecification Engine oil Transmission oil Cooling system fluid Fuel tank (reserve) Desc./Quantity 1.7 l 250 cm ~ 1.8 l approx. 12 l (approx. 2 l)

Electrical systemELECTRICAL SYSTEMSpecification Starter Desc./Quantity Electric

CHAR - 9

Characteristics

MP3 500 ie SPORT Business RL (2011)

Specification Ignition Ignition advance Spark plug Alternative spark plug Battery Alternator

Desc./Quantity Electronic, inductive, high efficiency ignition, integrated with the injection system, with variable advance and separate HV coil. Three-dimensional map managed by control unit NGK CR7EKB 12V-12Ah alternating current

Frame and suspensionsCHASSIS AND SUSPENSIONSSpecification Chassis Front suspension Desc./Quantity Tubular and sheet steel The roll system is composed of an articulated parallelogram suspension with die-cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system. 85 mm Two double-acting shock absorbers, adjustable to four positions at preloading. 110 mm

Front suspension travel Rear suspension Rear suspension travel

BrakesBRAKESSpecification Front brake Rear brake Desc./Quantity 240-mm double disc brake with hydraulic control operated by the handlebar right-hand lever. 240-mm disc brake with hydraulic control operated by the handlebar left-hand lever.

Wheels and tyresWHEELS AND TYRESSpecification Wheel rim type Front rim Rear wheel rim Front tyre Rear tyre Front tyre pressure Rear tyre pressure Desc./Quantity Light alloy wheel rims. 12'' x 3.00 14'' x 4.50 Tubeless, 120/70-12" 51S or 51P Tubeless, 140/70 -14" 68S or 68P 1.6 bar 2.5 bar

Tightening TorquesSTEERINGName Steering lower ring nut (central headstock) Steering upper ring nut (central headstock) Handlebar fixing screw Fixing screws for the handlebar control unit U-bolts Torque in Nm 10 to 12 22.5 to 25 50 55 7 to 10

CHAR - 10

MP3 500 ie SPORT Business RL (2011)

Characteristics

CHASSISName Swinging arm set screw bushing Engine arm bolt - frame arm Swinging arm set screw bushing nut Engine-swinging arm bolt Frame-swinging arm bolt Centre stand bolt Torque in Nm 57 32.5 40 54 60 98 118 54 60 31 - 39

FRONT SUSPENSIONName Shock absorber lower clamping Shock absorber upper clamp Front wheel fixing screws Steering arm bolt nut Tilt gripper fixing screws Front wheel axle Arm coupling screws Screws fixing arms to side headstocks Screws fixing arms to central headstock Screws fixing the

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