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 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

GENERAL MANDATORY REQUIREMENTS

NORM

PRE-DELIVERY PRE DE

TECHNICAL DATA DT

TOOLING TOOL

MAINTENANCE MAIN

ENGINE ENG
INDEX OF TOPICS

GENERAL MANDATORY REQUIREMENTS NORM

MP3 400 hpe E5 General mandatory requirements

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.

NORM - 7
General mandatory requirements MP3 400 hpe E5

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

NORM - 8
INDEX OF TOPICS

PRE-DELIVERY PRE DE
Pre-delivery MP3 400 hpe E5

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 DE - 10
MP3 400 hpe E5 Pre-delivery

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
complete the procedure will be confirmed by a very
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
to switch to «OFF» and wait for at least 60 seconds
before being able to switch again to «ON».
• In case of failure to complete the procedure within
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

PRE DE - 11
Pre-delivery MP3 400 hpe E5

• 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 DE - 12
MP3 400 hpe E5 Pre-delivery

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.

PRE DE - 13
Pre-delivery MP3 400 hpe E5

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 DE - 14
MP3 400 hpe E5 Pre-delivery

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.

PRE DE - 15
Pre-delivery MP3 400 hpe E5

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 DE - 16
INDEX OF TOPICS

TECHNICAL DATA DT
Technical Data MP3 400 hpe E5

This section describes the general specifications of the vehicle.

Vehicle identification

The frame prefix «A» is stamped near the fuel

tank.

The engine prefix «B» is stamped near the rear left

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 Ø 240 mm hydraulically operated disc 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

DT - 18
MP3 400 hpe E5 Technical Data

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, high efficiency ignition, integrated with the
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

DT - 19
INDEX OF TOPICS

TOOLING TOOL
MP3 400 hpe E5 Tooling

ATTREZZATURA SPECIFICA - SPECIAL TOOLS

Stores code Description
001330Y Tool for fitting steering seats

001467Y Extractor for bearings for holes

001467Y002 Driver for OD 73 mm bearing

001467Y003 Nut

001467Y004 Lug / Taper pin

001467Y005 Screw

TOOL - 21
Tooling MP3 400 hpe E5

Stores code Description

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54-mm bearings

001467Y014 Calliper to extract ø 15-mm bearings

001467Y017 Bearing housing, external ø 36 mm

001467Y035 Bearing housing, external ø 47 mm

006029Y Punch for fitting steering bearing on the

steering tube

020004Y Punch for removing steering bearings

from headstock

TOOL - 22
MP3 400 hpe E5 Tooling

Stores code Description

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaft

alignment

020084Y punch ø 20

020115Y punch ø 18

020128Y Piston fitting ring

020151Y Air heater

TOOL - 23
Tooling MP3 400 hpe E5

Stores code Description

020163Y Crankcase splitting plate

020193Y Oil pressure gauge

020234y extractor
020244Y punch ø 15

020271Y Tool for removing-fitting silent bloc

020306Y Punch valve seal rings fitting

020329Y Mity-Vac vacuum pump

TOOL - 24
MP3 400 hpe E5 Tooling

Stores code Description

020331Y Digital multimeter

020332Y Digital rpm indicator

020335Y Magnetic mounting for dial gauge

020357Y 32 x 35-mm Adaptor

020358Y 37 x 40 mm Adaptor

TOOL - 25
Tooling MP3 400 hpe E5

Stores code Description

020359S 42 x 47 mm Adaptor

020360S 52 x 55 mm adaptor

020362Y 12 mm guide

020363Y 20-mm guide

020364Y 25-mm guide

020375Y 28 x 30 mm adaptor

TOOL - 26
MP3 400 hpe E5 Tooling

Stores code Description

020376Y Adaptor handle

020382Y Valve cotters equipped with part 012 re-

moval tool

020382Y011 adapter for valve removal tool

020382Y012 bush (valve removing tool)

020412Y 15-mm guide

020431Y Valve oil seal extractor

TOOL - 27
Tooling MP3 400 hpe E5

Stores code Description

020434Y Union for oil pressure measurement

020439Y 17-mm guide

020441S 26 x 28 mm adaptor

020442Y Pulley lock wrench

020444Y009 wrench 46 x 55

020454Y Tool for fitting the pin snap rings (200 -

250)

TOOL - 28
MP3 400 hpe E5 Tooling

Stores code Description

020456Y Ø 24 mm adaptor

020467Y Flywheel extractor

020477Y Adapter 37 mm

020480Y Fuel pressure measurement kit

020483Y 30-mm guide

020489Y Hub cover support stud bolt kit

TOOL - 29
Tooling MP3 400 hpe E5

Stores code Description

020627Y Flywheel lock tool

020648Y Single battery charger

020661Y Water pump overall seal replacement kit

020892y Steering side headstock ring nut key

020916Y Magneto flywheel blocking tool

020917Y Driven pulley stop

TOOL - 30
MP3 400 hpe E5 Tooling

Stores code Description

020918Y Clutch lock

020919Y Clutch discs disassembly tool

020921Y Piston position checking tool

020922Y Diagnosis Tool

020924Y Bluetooth for the PADS diagnostic tool

021017Y EOBD E5 diagnostics cable

TOOL - 31
INDEX OF TOPICS

MAINTENANCE MAIN
MP3 400 hpe E5 Maintenance

Maintenance chart

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Clean more frequently in cases of intensive use on gravel roads

km x 1,000 (mi x 1,000) 1 (0.6) 10 (6.2) 20 30 40 50 EVERY EVERY

(12.4) (18.6) (24.8) (31.0) 12 24
MONTH MONTH
S S
Safety blocks I I I I
Spark plug R R
Centre stand L L L L L L L
Roll lock calliper control cable A A A A A
Drive belt R R
Throttle control A A A A A A I I
Complete roller housing I I
Diagnosis by tool I I I I I I I I
Air filter * R R R R R
CVT Filter * C C C C C
Engine oil filter R R R R R R R R
Valve clearance A A
Electrical system and Battery I I I I I I
Braking system I I I I I I
Coolant I I I I I I I R
Brake Fluid I I I I I I I R
Engine oil R R R R R R R R
Hub oil R R R I I
Headlight direction adjustment I I I
Brake pads I I I I I I I I
Sliding shoes / CVT rollers R R
Tire pressure and wear I I I I I I I I
Test drive I I I I I I I I
Suspensions I I I I I I I
Centre and side steering A A A A A A I I
Transmission I I I I I I I
Labour time (minutes) 120 160 290 160 290 160 40 140
N.B.
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.
CAUTION
AFTER THE SCHEDULED MAINTENANCE PROGRAM IS FINISHED YOU ARE TOLD TO PRO-
CEED WITH THE MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE COUPON
OF 10,000 km (6,214 miles) OR 10 MONTHS.

Recommended products

Piaggio Group recommends the use of prod-

ucts from its Castrol official partner for the
scheduled maintenance of its vehicles.
Only use lubricants and fluids which meet or ex-
ceed the performance characteristics specified.
This also applies when topping up only.

MAIN - 33
Maintenance MP3 400 hpe E5

TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications
Engine oil 5W -40 Synthetic-based lubricant for four-stroke SAE 5W-40; JASO MA, MA2; API SL;
engines. ACEA A3
Transmission oil 80W-90 Lubricant for gearboxes and transmis- SAE 80W-90 API GL-4
sions.
Anti-freeze liquid, ready to use, colour red Ethylene glycol antifreeze liquid with or- ASTM D 3306 - ASTM D 4656 - ASTM D
ganic inhibition additives. Red, ready to 4985 - CUNA NC 956-16
use.
DOT 4 brake fluid Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4
Lubricant grease Lithium and medium fibre yellow brown ISO L-X-BCHA 3 - DIN 51 825 K3K -20
coloured grease suitable for various
uses.
Water repellent spray grease Water repellent pouring calcium spray White, soap base spray grease with NLGI
grease. 2 Calcium complex; ISO-L-XBCIB2

MEASUREMENT UNITS CONVERSION - FROM THE ANGLO-SAXON SYSTEM TO THE INTERNATION-

AL SYSTEM (I.S.).
Specification Desc./Quantity
1 Inch (in) 25.4 Millimetres (mm)
1 Foot (ft) 0.305 Metres (m)
1 Mile (mi) 1.609 Kilometres (km)
1 US gallon (gal US) 3.785 Litres (l)
1 Pound (lb) 0.454 Kilograms (Kg)
1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)
1 Pound per foot (lb ft) 1.356 Newton metres (N m)
1 Mile per hour (mi/h) 1.602 Kilometres per hour (km/h)
1 Pound per square foot (PSI) 0.069 (bar)
1 Fahrenheit (°F) 32+(9/5) Celsius (°C)

MAIN - 34
INDEX OF TOPICS

ENGINE ENG
Engine MP3 400 hpe E5

This section describes the operations to be carried out on the engine and the tools to be used.

N.B.

ENG - 36
MP3 400 hpe E5 Engine

THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS

OF THE DECIMAL METRIC SYSTEM. IN THE CASE OF VALUES EXPRESSED USING IMPERIAL
AND US CUSTOMARY MEASUREMENT UNITS, REFER TO THE CONVERSION TABLE IN CHAP.
«SPECIFICATIONS».

Automatic transmission

Transmission cover

- Insert the special tool.

- Rotate the engine until the driven pulley stops.

Specific tooling
020917Y Driven pulley stop

- Supporting the tool, undo the fixing screw.

- Unscrew and remove the external transmission

cover's fixing screws at the crankcase.

ENG - 37
Engine MP3 400 hpe E5

- Undo and remove the central screw from the

transmission cover.

- Remove the transmission cover.

Air duct

- Unscrew and remove the cooling cover fastening

screws.

Remove the cooling cover.

ENG - 38
MP3 400 hpe E5 Engine

Removing the driven pulley shaft bearing

- Remove the Seeger ring.

CAUTION
PLACE THE COVER ON A SURFACE, REMOVING OR EX-
CLUDING THE ALIGNMENT DOWELS.

- Using the housing to support the cover of the

transmission, interpose a few layers of heavy cloth
so as not to damage the outer surface of the cover.
- Using appropriate tools, remove the bearing.

Specific tooling
020376Y Adaptor handle
020358Y 37 x 40 mm Adaptor
020439Y 17-mm guide
001467Y002 Driver for OD 73 mm bearing

Refitting the driven pulley shaft bearing

- Use the heat gun to heat the inner part of the lid.
CAUTION
DO NOT HEAT EXCESSIVELY SO AS NOT TO DAMAGE
THE PAINTWORK.

Specific tooling
020151Y Air heater

Using the equipment, mount a new bearing, apply

grease on the adapter and on the guide in order to
maintain the position of the bearing during opera-
tion on the vertical axis.

Specific tooling
020376Y Adaptor handle
020358Y 37 x 40 mm Adaptor
020439Y 17-mm guide

ENG - 39
Engine MP3 400 hpe E5

- Insert the Seeger ring.

- Insert the alignment dowels if removed during
disassembly.

Removing the driven pulley

To remove the driven pulley, proceed as follows:

- Remove the drive pulley to release the drive belt.

- Remove the driven pulley together with the belt.

WARNING
AS A RESULT OF THE OPERATION THERE MAY BE A
LIGHT "HAMMERING" BETWEEN THE KNURLING OF THE
PULLEY AXLE. THIS CAN MAKE REMOVAL BY HAND DIF-
FICULT.
IN CASE OF NEED USE AN EXTRACTOR.

Inspecting the clutch drum

- To remove the housing from the driven pulley

shaft it is necessary to remove the complete clutch
assembly from the engine as described in section
«Disassembling the clutch».
- Remove the protection caulking.

ENG - 40
MP3 400 hpe E5 Engine

- Using the specific tool to maintain the clutch

housing in position, unscrew the nut to recover the
washer.

Specific tooling
020917Y Driven pulley stop

- Remove the housing from the shaft.

- To fit, follow the removal steps but in reverse order, being careful to tighten to the specified torque.
CAUTION
ALWAYS USE A NEW NUT FOR RETAINING THE CLUTCH OUTPUT SHAFT, THEN PROCEED TO
THE CAULKING.
Locking torques (N*m)
Clutch output shaft nut 120 to 130

ENG - 41
Engine MP3 400 hpe E5

Removing the clutch

- To remove the clutch assembly it is necessary to

remove the inlet pinion to the final reduction unit,
operating as described in the section «Dismount-
ing the hub cover».

- Working from the automatic transmission side,

remove the driven pulley.
- Unscrew the six fixing screws from the clutch
cover.

- By using two screwdrivers work on the appendi-

ces and remove the cover taking care not to drop
the clutch assembly.

- Remove the clutch assembly.

ENG - 42
MP3 400 hpe E5 Engine

Inspecting the clutch

COVER REVISION
- Adequately support the cover and using a screw-
driver remove the seal ring.

Specific tooling
001467Y007 Driver for OD 54-mm bearings

- Working from the opposite side, supporting the

cover, proceed to the removal of the bearing.

Specific tooling
001467Y007 Driver for OD 54-mm bearings
020376Y Adaptor handle
020358Y 37 x 40 mm Adaptor

- Heat the crankcase by means of specific tools

and then insert a new bearing.
- Using the equipment plant a new bearing, apply
grease on the adapter and guide in order to main-
tain the position of the bearing during operation on
the vertical axis.

Specific tooling
020151Y Air heater
020376Y Adaptor handle
020360S 52 x 55 mm adaptor
020364Y 25-mm guide
- Insert a new seal ring and grease the seal lips.

Specific tooling
020376Y Adaptor handle
020360S 52 x 55 mm adaptor

ENG - 43
Engine MP3 400 hpe E5

- Replace the outer O-ring and grease properly.

WARNING

IN ORDER TO PREVENT ABNORMAL FORMATIONS OF

DIRT DUE TO THE RELEASE OF GREASE, WE RECOM-
MEND FIRST LUBRICATING THE SEAL RING STOPS WITH
A BRUSH.

DISASSEMBLY
- Insert the clutch assembly in the special tool and
tighten the three wing nuts until you hear the end
of stroke.
- Prepare two aluminium protections in the vice
and tighten the shaft of the driven pulley.

Specific tooling
020919Y Clutch discs disassembly tool

ENG - 44
MP3 400 hpe E5 Engine

- Using pliers remove the lock circlips.

- Disengage the upper ring of the specific tool.

- Remove the outer ring with the seat for the Bel-
leville spring.
- Remove the Belleville spring.

- Remove the spring door upper disc.

ENG - 45
Engine MP3 400 hpe E5

- Remove the discs separation spring.

- Remove the semi-trimmed duct disc (trimmed on
one side).
- Remove a conductor disc.
- Remove the discs clearance recovery spring
- Remove a duct metallic disc.
- Remove a conductor disc (trimmed on both
sides).

ENG - 46
MP3 400 hpe E5 Engine

- Remove the discs clearance recovery spring

- Remove a non-trimmed duct metallic disc.
- Remove a conductor disc (trimmed on both
sides).
- Remove the discs clearance recovery spring
- Remove the semi-trimmed duct disc (trimmed on
one side).

ENG - 47
Engine MP3 400 hpe E5

CAUTION

THE CLEARANCE RECOVERY SPRING DISCS ARE FIT-

TED INDIVIDUALLY.
THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI-
TIONED TOWARDS THE INSIDE OF THE HOUSING, AS
SHOWN IN FIGURE.

- Remove the hub.

- Remove the shaft.

ENG - 48
MP3 400 hpe E5 Engine

- Remove the lower spring holder disc complete

with the six springs.

- Remove the rollers.

- Check that there is no abnormal wear on the roll-

ers, the support channels for rollers and those for
discs.

ENG - 49
Engine MP3 400 hpe E5

CLUTCH SPRING REVISION

Characteristic
Clutch springs
Free spring measurement 15.3 mm
Clutch spring wear limit
15,0 mm

CLEARANCE RECOVERY SPRING REVISION

Check for any deformation or abnormal wear.

Characteristic
Clearance recovery spring «A» standard di-
mensions
3.2±0.1 mm
Clearance recovery spring wear limit
2,8 mm

CLUTCH DISCS REVISION

Check the clutch discs for damage or signs of
wear: In this case, replace them all.
Measure the thickness of the discs in four posi-
tions, and if they do not meet specifications, re-
place them all.

Characteristic
Clutch discs thickness
Conductor disc thickness «B» = 3.00±0.08 mm

Trimmed duct disc thickness «C» = 1.95±0.05 mm

Duct disc thickness «D» = 1.400±0.035 mm

ENG - 50
MP3 400 hpe E5 Engine

DISCS WEAR LIMIT

If the discs exceed the following wear limits, replace them all.

Characteristic
Clutch discs wear limit
Conductor disc wear limit «B» = 2.6 mm

Trimmed duct wear limit «C» = 1.7 mm

CLUTCH DISCS REVISION: MAXIMUM DEFOR-

MATION
Measure the maximum deformation of the discs by
positioning them on a reference plane and check-
ing with a feeler gauge. If out of specification,
replace them all.

Characteristic
Clutch discs maximum deformation
Max. duct disc unevenness «D» 0.2 mm

ENG - 51
Engine MP3 400 hpe E5

REASSEMBLY
- Working in reverse order to the removal, insert
the components while taking care to follow the fol-
lowing guidelines:
- Place the rollers as shown in the photo, after ev-
ery two leave a clearance so that each pair has its
opposite for proper balance.

- Lubricate the parts of the clutch pack with the

recommended product.

Recommended products
Transmission oil 80W-90 Lubricant for gear-
boxes and transmissions.
SAE 80W-90 API GL-4

CAUTION

THE CLEARANCE RECOVERY SPRING DISCS ARE FIT-

TED INDIVIDUALLY.
THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI-
TIONED TOWARDS THE INSIDE OF THE HOUSING, AS
SHOWN IN FIGURE.

ENG - 52
MP3 400 hpe E5 Engine

- Insert the semi-trimmed disc with the trimmed

surface facing the lower support disc

- Respect the indicated position of the discs clear-

ance recovery spring.
CAUTION

THE CLEARANCE RECOVERY SPRING DISCS ARE FIT-

TED INDIVIDUALLY.
THE LAST IN THE ASSEMBLY PHASE MUST BE POSI-
TIONED TOWARDS THE INSIDE OF THE HOUSING, AS
SHOWN IN FIGURE.

- Insert the semi-trimmed disc with the trimmed

surface facing the upper support disc

- Insert the upper support disc in the spring.

ENG - 53
Engine MP3 400 hpe E5

- Insert the Belleville spring facing upwards, taking

care to insert it properly into the seat in the closure
ring.

- Fit the specific tool to compress the clutch pack

and place the retaining ring at the specified loca-
tion.

Specific tooling
020919Y Clutch discs disassembly tool

FINAL CHECK
Once the clutch is assembled, turn by hand the exit axis to the final reduction.
The rotation must be free.
If you feel resistance in the movement, or if you detect impediments, disassemble the clutch again and
check the correct installation.

ENG - 54
MP3 400 hpe E5 Engine

CLUTCH OUTPUT SHAFT ROLLER CASING IN-

SPECTION
- Using specific tools, remove the roller casing

Specific tooling
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54-mm bearings

- Insert a new roller casing and set it with specific

tools.

Specific tooling
020084Y punch ø 20

ENG - 55
Engine MP3 400 hpe E5

Pin retaining collar

- Use the tool equipped with medium length pins

in "C" position screwing them from the inside of the
tool.
- Install the driven pulley into the tool providing the
support of an appendix against a pin.
- Ensure the centring of the driven pulley by means
of the key inserted on the nut.

Specific tooling
020444Y Tool for installing/removing clutch
on/from driven pulley
020444Y009 wrench 46 x 55
- Turn the key to unscrew the nut.
- Adjust the specific tool command screw to re-
lease the torque server spring.

ENG - 56
MP3 400 hpe E5 Engine

- Remove the following components in this order:

• upper cap;
• spring;
• lower spring support;
• synthetic ring.

- Using two screwdrivers lift the locking sheath of

the torque server and remove it.

ENG - 57
Engine MP3 400 hpe E5

- Remove the two O-rings and replace them, mak-

ing sure to lubricate them during installation.

- Thoroughly clean the slots and pins.

- Check that the bushings on the pins and the slots
of the torque server are free from wear and rotate
freely.
- Then grease with recommended product using a
syringe, in order to inject the oil directly into the
holes in the bushing.
CAUTION

THE TORQUE SERVER PINS ARE SET ON THE BUSHING

WITH INTERFERENCE, AND ARE THEREFORE NOT RE-
MOVABLE. WHEN IT IS NECESSARY TO REPLACE THE
INTERNAL SEAL RINGS OR THE PULLEY SURFACES IF
THERE IS ABNORMAL WEAR, REPLACE THE DRIVEN
PULLEY UNIT.

Recommended products
MONTBLANC MOLYBDENUM GREASE MON-
TBLANC MOLYBDENUM GREASE
Molybdenum disulphide grease, ivory coloured;
Specification TL 9150 066, symbol NATO G 460
N.B.
GREASE USING THE CHANNELS IN THE PULLEY.

ENG - 58
MP3 400 hpe E5 Engine

- Insert the closure sheath of the torque server

taking care to respect the positioning of the ap-
pendices in their corresponding seats.

Refitting the driven pulley

- Insert the synthetic ring.

- Insert the lower spring support.

- Insert the spring, lubricating the ends.

ENG - 59
Engine MP3 400 hpe E5

- Insert the upper cap.

- Insert the belt paying attention to the direction of

rotation.

Specific tooling
020444Y Tool for installing/removing clutch
on/from driven pulley

- Turn the control screw of the specific tool and

spring preloading.
- Insert the fixing nut and using the specific
wrench, tighten to torque.

Specific tooling
020444Y009 wrench 46 x 55

Locking torques (N*m)

Driven pulley nut 50 ÷ 60

Inspecting the clutch spring

- Check the free length of the spring of the mobile

driven half-pulley.

Characteristic
Unloaded spring length
101.5 mm
Acceptable limit after use
98 mm

ENG - 60
MP3 400 hpe E5 Engine

Refitting the clutch

- Insert the complete clutch assembly.

- Insert the clutch cover and tighten the six screws

to the specified torque.
WARNING

IN ORDER TO PREVENT ABNORMAL FORMATIONS OF

DIRT DUE TO THE RELEASE OF GREASE, WE RECOM-
MEND FIRST LUBRICATING THE SEAL RING STOPS WITH
A BRUSH.
WARNING
THE OUTER O-RING MUST BE PROPERLY GREASED.
DUE TO THE HIGH STRENGTH OF THE O-RING IT IS REC-
OMMENDED TO TIGHTEN IN CROSSED SEQUENCE UN-
TIL COMPLETING THE INSERTION.

Locking torques (N*m)

Clutch cover retainer screws 11 to 13
- Working as described in section «Fitting the hub cover» proceed to the locking of the clutch assem-
bly.

Refitting the driven pulley

- Insert the driven pulley, complete with belt, on the

shaft.

Drive-belt

- Make sure the drive belt is not damaged and does not show abnormal wear.

ENG - 61
Engine MP3 400 hpe E5

- Replace according to the scheduled maintenance table.

Removing the driving pulley

- Using specific tools, lock the driving pulley and

loosen the flanged nut.

Specific tooling
020442Y Pulley lock wrench

- remove the flat washer and the cup washer.

- remove the stationary half-pulley and the washer.

- disengage the belt.

- remove the complete roller housing.

ENG - 62
MP3 400 hpe E5 Engine

Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter A.
- Measure outer diameter B of the pulley sliding
bushing shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the sliding shoes for the variator back-
plate are not worn.
- Check the wear of the roller housings and of the
belt facing surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic
movable driving half-pulley bushing: Standard
Diameter
30 mm (+0 +0.021)
movable driving half-pulley bushing: Maxi-
mum allowable diameter
Ø 26.12 mm
Sliding bushing: Standard Diameter
Ø 30 mm (-0.02 +0.041)
Sliding bushing: Minimum diameter permitted
Ø 25.95 mm
Roller: Standard diameter
Ø 25 mm±0.1

ENG - 63
Engine MP3 400 hpe E5

Refitting the driving pulley

- perform the operations in reverse order of disas-

sembly.
CAUTION
INSERT THE ROLLERS WITH THE LARGEST SUPPORT
SURFACE ACCORDING TO THE DIRECTION OF ROTA-
TION.

- Use the specific tool to lock the pulley, tightening

to the prescribed torque.

Specific tooling
020442Y Pulley lock wrench

Locking torques (N*m)

Nut M14x1.5 securing the driving pulley 120 ÷
130

CAUTION
DURING THE INSTALLATION PAY SPECIAL ATTENTION
TO THE ASSEMBLY OF THE SPRING WASHER, AS
SHOWN IN FIGURE.

Refitting the transmission cover

- Put the transmission cover.

ENG - 64
MP3 400 hpe E5 Engine

- Insert the transmission cover central screw and

tighten it to the prescribed torque.

Locking torques (N*m)

Transmission cover screws 11 ÷ 13

- Insert and tighten the external fixing screws of the

transmission cover to the crankcase to the pre-
scribed torque.

Locking torques (N*m)

Transmission cover screws 11 ÷ 13

- Insert the nut.

- Insert the special tool.
- Rotate the pulley axle until the pulley stops.

Specific tooling
020917Y Driven pulley stop

- Supporting the tool tighten the fixing screw to the

prescribed screw.

Locking torques (N*m)

Driven pulley M10x1.25 screw 74 ÷ 80

ENG - 65
Engine MP3 400 hpe E5

End gear

Removing the hub cover

- Use a container large enough to recover the final

reduction oil. Unscrew the indicated screw and re-
cover the aluminium seal.
- Unscrew the oil filler screw in order to facilitate
bleeding.

- Unscrew the seven hub cap fixing screws.

ENG - 66
MP3 400 hpe E5 Engine

- Using a suitable screwdriver use leverage on the

upper and lower appendices to detach the sealant.

- Remove the final reduction cap complete with the

wheel axle, being careful not to drop the inter-
mediate gear.

- Remove the final reduction cap.

- Turn the shaft of the driven pulley until aligning a
slot with the axis of the intermediate bearing and
insert the specific tool.

Specific tooling
020918Y Clutch lock

ENG - 67
Engine MP3 400 hpe E5

- Remove the nut and incorporated washer secur-

ing the pinion.

- The pinion is symmetrical: mark the outer surface

to avoid reversed reassembly.
- Remove the pinion and the specific tool.
CAUTION
CLEAN THE THREAD FROM ANY RESIDUAL THREAD-
LOCK.

Removing the wheel axle

- Remove the intermediate gear.

- Remove the wheel axle.

ENG - 68
MP3 400 hpe E5 Engine

Removing the hub bearings

REMOVAL
Removing the clutch shaft bearing
- Remove the screw and countersunk washer.
- Using the specific tools remove the bearing.

Specific tooling
020376Y Adaptor handle
020357Y 32 x 35-mm Adaptor
020363Y 20-mm guide

Wheel axle bearing removal

- Using the specific tools remove the bearing.

Specific tooling
020376Y Adaptor handle
020357Y 32 x 35-mm Adaptor
020363Y 20-mm guide

Removing the intermediate gear bearing

- Using the specific tools remove the bearing.

Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020412Y 15-mm guide

FITTING
- Heat the crankcase by means of the specific tool and then insert the bearings.

Specific tooling
020151Y Air heater

ENG - 69
Engine MP3 400 hpe E5

Fitting the Wheel axle bearing

- Using the equipment set a new bearing.

Specific tooling
020376Y Adaptor handle
020359S 42 x 47 mm Adaptor
020363Y 20-mm guide

Fitting the Clutch shaft bearing

- Using the equipment set a new bearing.

Specific tooling
020376Y Adaptor handle
020360S 52 x 55 mm adaptor
020363Y 20-mm guide

Fitting the Intermediate gear bearing

- Using the equipment set a new bearing.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-
ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.

Specific tooling
020376Y Adaptor handle
020359S 42 x 47 mm Adaptor
020412Y 15-mm guide
- After completing the insertions, tighten the lock
screw of the clutch shaft bearing, respecting the
direction of the washer and apply the recommen-
ded product.

Recommended products
Loctite 242 Medium strength thread-locking
sealant.
Blue

Locking torques (N*m)

Bearing lock screw 9 ÷ 11

ENG - 70
MP3 400 hpe E5 Engine

Inspecting the hub shaft

- Check the three shafts and the intermediate gear

for wear or distortion of the toothed surfaces, the
bearing housings, and the oil seal housings.
- In case of faults, replace the damaged parts.

Characteristic
Driven pulley shaft standard sizes
A: 25mm -0.01 -0.02

B: 19.6mm -0.20 -0.33

Clutch output shaft standard sizes
C: 20mm -0 -0.013

D: 20mm -0.01 -0.02

Wheel axle
E: 35mm -0 -0.013

F: 30mm -0.13 -0.26

Intermediate gear
G: 0.7874(-0.0004 -0.0008)in (20(-0.01 -0.02)mm)

H: 0.7874(-0.0004 -0.0008)in (20(-0.01 -0.02)mm)

ENG - 71
Engine MP3 400 hpe E5

Inspecting the hub cover

- Check that the fitting surface is not dented or dis-

torted.
- Check the bearing bearings.
- In case of faults, replace the damaged compo-
nents.
- Check the thorough cleaning of lubrication duct.

Refitting the hub cover bearings

REMOVAL
Wheel axle bearing removal
- Remove the Seeger ring.

- Using the specific tools, support the hub cover.

- Using the specific tools remove the bearing.
N.B.
TO FIT THE BEARING ON THE COVER, ADEQUATELY
SUPPORT THE COVER WITH THE STUD BOLT KIT.

Specific tooling
020489Y Hub cover support stud bolt kit
020376Y Adaptor handle
020357Y 32 x 35-mm Adaptor
020483Y 30-mm guide
- Remove the hub cover from the stud bolts and
using the specific tools pull out the oil seal.

Specific tooling
020376Y Adaptor handle
020359S 42 x 47 mm Adaptor

ENG - 72
MP3 400 hpe E5 Engine

Removing the intermediate gear bearing

- Take out the bearing using the specific tool.

Specific tooling
001467Y003 Nut
001467Y004 Lug / Taper pin
001467Y005 Screw
001467Y006 Pliers to extract 20 mm bearings
001467Y035 Bearing housing, external ø 47
mm
FITTING
Fitting the Intermediate gear bearing
- Heat the crankcase by means of the specific tool
and then insert the bearings.

Specific tooling
020151Y Air heater

- Using the equipment set a new bearing.

Specific tooling
020376Y Adaptor handle
020359S 42 x 47 mm Adaptor
020363Y 20-mm guide

Fitting the Wheel axle bearing

- Using the equipment plant a new bearing, apply
grease on the adapter and guide in order to main-
tain the position of the bearing during operation on
the vertical axis.

Specific tooling
020376Y Adaptor handle
020360S 52 x 55 mm adaptor
020483Y 30-mm guide

ENG - 73
Engine MP3 400 hpe E5

- Fit the seeger ring.

- Insert a new seal ring with the seal facing the in-
side of the hub by means of the appropriate tool.
- Grease the sealing lips.

Specific tooling
020376Y Adaptor handle
020360S 52 x 55 mm adaptor

Refitting the hub bearings

Insert the gears in the cover in order to prevent

abnormal movements during insertion into the en-
gine. - Insert the wheel axis.

- Insert the intermediate gear.

ENG - 74
MP3 400 hpe E5 Engine

Refitting the ub cover

- Working in reverse order to the removal and us-

ing the specific tool, insert the control pinion, use
the recommended product and tighten the torque.
CAUTION
FOR THE INSTALLATION, ALWAYS USE NEW NUTS AL-
READY PROVIDED WITH SCOTCH GRIP.

Specific tooling
020918Y Clutch lock

Locking torques (N*m)

M12x1.25 gear clutch shaft retainer nut 95 ÷ 105
- Pay attention to the correct positioning of the
alignment dowels.
- Thoroughly clean the surfaces of the engine
crankcase and reduction cover and seal, with the
recommended product, the matching surface
around the entire outer perimeter of the duct that
leads to the breather.
CAUTION

AN IMPROPER SEALING OF THE VENTILATION CIRCUIT

MEANS A LOSS OF OIL INTO THE AUTOMATIC TRANS-
MISSION HOUSING.

Recommended products
THREE BOND TB1207B Liquid sealant
Three Bond liquid gasket TB1207B

- Remove the gasket.

- Insert the gears of the reduction unit in the re-

duction cover and tighten the screws to the speci-
fied torque, tightening in crossed sequence.
- Check the correct the tightening drainage screw.

Locking torques (N*m)

Final reduction cover screws 24 ÷ 27 Reduction
unit oil drainage screw 15 ÷ 17

CAUTION

THE FOLLOWING OIL REDUCTION FILLING PROCEDURE MUST BE CARRIED OUT ONLY WITH
THE MOTOR FITTED ON THE VEHICLE, ON THE CENTRE STAND IN FLAT LAND.

ENG - 75
Engine MP3 400 hpe E5

- Restore the level of oil inside reduction unit with

the recommended product, acting on the filler
screw until touching.
- Tighten to the specified torque.

Recommended products
Transmission oil 80W-90 Lubricant for gear-
boxes and transmissions.
SAE 80W-90 API GL-4

Characteristic
Final reduction unit oil
about 500 cc

Locking torques (N*m)

Oil relief screw 15 ÷ 17

Flywheel cover

Removing the hub cover

- Perform the actions described in the section

«Removing the flywheel cover components».
- Unscrew the 13 fixing screws of the flywheel cov-
er.

- Remove the cover.

ENG - 76
MP3 400 hpe E5 Engine

- Remove the gasket.

Removing the flywheel cover components

- Disconnect the spark plug cap.

- Undo the two fixing screws of the coil.

- Loosen the two clamps and remove the coolant

internal recirculation pipe.

- Undo the four screws «A» and the fixing screw

«B» of the coolant pump cover.

ENG - 77
Engine MP3 400 hpe E5

- Remove the cover and the relative gasket.

- The flywheel cover can be removed without un-

screwing the impeller.
- Should it be necessary to remove the impeller,
loosen the moulded nut.
CAUTION
THE THREAD IS ANTICLOCKWISE.
CAUTION
IF THE EFFORT REQUIRED TO UNSCREW THE IMPELLER
IS HIGHER THAN THE NORMAL LOCKING TORQUE, REF-
ERENCE SHOULD BE MADE TO THE REMOVAL OF THE
DISMOUNTED FLYWHEEL COVER IMPELLER.
FAILURE TO FOLLOW THIS WARNING WILL CAUSE AB-
NORMAL AXIAL THRUST THAT CAN CAUSE DAMAGE TO
THE CERAMIC SEAL.

Removing the stator

- Remove the flywheel cover.

- Unscrew the three flywheel fixing screws and the
four pick-up fixing screws and cable harness re-
tainer screws.

- Remove the flywheel and the pick-up complete with wiring harness.

ENG - 78
MP3 400 hpe E5 Engine

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.
- Respect the operation of the pick-up.

Characteristic
Pick-up rotor measurement
0.4 to 0.75 mm

Locking torques (N*m)

Stator fixing screws 8 to 10 Pickup fixing
screws 3 - 4

Refitting the flywheel cover components

- Perform the procedure in reverse order of disassembly, taking care to tighten to specified torque.

Locking torques (N*m)

Pick-up screws 3 to 4 Coil fixing screw 11 to 13 Oil drain screw 20 to 24

Refitting the flywheel cover

- Fit the gasket and be careful with the two align-

ment dowels.

- Paying attention to the alignment of the coolant

pump shaft insert the crankcase with the com-
mand screw.
- Tighten the screws and tighten to the specified
torque.

Locking torques (N*m)

Flywheel cover retainer screws (2 screws) -
PRETIGHTENING 5 to 6 Flywheel cover retainer
screws (12 screws) - TIGHTENING 11 to 13 TCIC
M5x10 flywheel cover retainer screw 2.9 to 3.9

ENG - 79
Engine MP3 400 hpe E5

Flywheel and starting

Removing the starter motor

- Undo the two fixing screws and remove the start-

er motor.

Removing the flywheel magneto

- Undo the screw indicated and remove the plate.

- Install the support plate.

Specific tooling
020916Y Magneto flywheel blocking tool

ENG - 80
MP3 400 hpe E5 Engine

- Install the specific tool and unscrew the retainer

nut of the flywheel, recovering the washer.

Specific tooling
020627Y Flywheel lock tool

- Act on the extractor to remove the flywheel to-

gether with the starting sprocket.
- Remove the flywheel nut with its washer
- Do up the flywheel nut by three or four threads
so that the flywheel does not fall accidentally dur-
ing extraction
- Screw the extractor onto the flywheel and extract
it as shown in the picture
CAUTION

SCREWING UP THE NUT WITHOUT WASHER HELPS PRO-

TECT THE THREAD AGAINST THE STRAIN EXERTED BY
THE EXTRACTOR AND ALSO PREVENTS DROPPING THE
FLYWHEEL ACCIDENTALLY UPON EXTRACTING IT. PO-
TENTIAL DROPS MAY DAMAGE THE CERAMIC INSERTS.

Specific tooling
020467Y Flywheel extractor
- Remove the tool and unscrew the nut.
- Remove the complete flywheel paying attention
to recover the tongue.

Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pick-up control plate.

ENG - 81
Engine MP3 400 hpe E5

Intermediate gear

- Remove the flywheel.

- Remove the intermediate gear from its housing.

- Visually inspect the surfaces, if there is no abnormal wear, grease the housing thoroughly and insert
the intermediate gear.

Refitting the free wheel

- Make sure the freewheel contact surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.

Recommended products
Loctite 243 Medium strength thread-locking sealant.
Blue

- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-
wheel itself, i.e. with wheel Seeger ring visible.
- Lock the six clamping screws in criss-cross fash-
ion to the prescribed torque.

Locking torques (N*m)

Screw fixing freewheel to flywheel 13 - 15

- Oil the free wheel "rollers".

ENG - 82
MP3 400 hpe E5 Engine

Refitting the intermediate gear

- Lubricate the sliding surfaces and insert the in-

termediate gear in its seat.

Refitting the flywheel magneto

- Place the tab.

- Insert the magneto flywheel on the crankshaft.

- Insert the washer.

ENG - 83
Engine MP3 400 hpe E5

- Insert the flywheel fixing nut.

- Place the support plate.

Specific tooling
020916Y Magneto flywheel blocking tool

- Fit the specific tool.

- Tighten the flywheel fixing nut to the specified
torque.

Specific tooling
020627Y Flywheel lock tool

Locking torques (N*m)

Flywheel fixing nut 100 to 110

Refitting the starter motor

- Fit a new O-ring on the starter motor and lubricate

it.
- Fit the starter motor on the crankcase and lock
the 2 screws to the specified torque.

Locking torques (N*m)

Starter screws 11 to 13

Cylinder assy. and timing system

ENG - 84
MP3 400 hpe E5 Engine

Removing the intake manifold

- The intake manifold is housed in the big end,

loosen the clamps to remove the sleeve.

- Remove the sleeve connecting the throttle body.

Removing the rocker-arms cover

- Support the big end cover.

- Unscrew and remove the special cover fastening
screws.

- Remove the big end cover.

ENG - 85
Engine MP3 400 hpe E5

Removing the timing system drive

- Before working on the timing system it is recom-

mended to place the engine at TDC in compres-
sion, aligning the references as shown in the
figure.

- First loosen the tensioner and unscrew the fixing

screws.

- Remove the tensioner complete with gasket.

ENG - 86
MP3 400 hpe E5 Engine

- Undo the fixing screw and remove the washer.

- Remove the complete mass of the return spring.

- Loosen the screw

- Remove the counterweight fixing screw.

ENG - 87
Engine MP3 400 hpe E5

- Remove the counterweight.

- Disengage the chain from the sprocket and re-

move the camshaft control sprocket.

Removing the cam shaft

- Remove the big end cover.

- Remove the timing system control.

- Unscrew the two screws of the camshaft lock.

ENG - 88
MP3 400 hpe E5 Engine

- Remove the plate.

- Remove the camshaft.

- Remove the lock of the rockers to allow them to

slide on the pins to access the calibrated pads.

- Remove the calibrated pads

CAUTION
PROPERLY REPLACE THE PADS AND ROCKERS SO AS
TO PRESERVE THE COUPLINGS.
CAUTION

IF NECESSARY USE A TELESCOPIC MAGNET TO RE-

MOVE THE PADS, PAY PARTICULAR ATTENTION THAT
THEY DO NOT FALL IN THE TRANSMISSION HOUSING.

ENG - 89
Engine MP3 400 hpe E5

- Remove the pins and the rockers.

N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

Removing the cylinder head

- Undo the two external screws.

- Gradually loosen the four columns in crossed se-

quence, recovering the washers.

- Remove the cylinder head.

N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, PINS AND ROCKING LEVERS WITHOUT RE-
MOVING THE DRIVING PULLEY UNIT. REMEMBER TO
HOLD THE TIMING CHAIN WITH A PIECE OF METAL CA-
BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE-
FITTING.

ENG - 90
MP3 400 hpe E5 Engine

- Remove the gasket.

Removing the valves

- Use the specific tool to remove the cotters, cap

and spring.
CAUTION
PROPERLY REPLACE THE PADS AND ROCKERS SO AS
TO PRESERVE THE COUPLINGS.

Specific tooling
020382Y Tool to extract valve cotters
020382Y012 bush (valve removing tool)

ENG - 91
Engine MP3 400 hpe E5

- Use the specific tool to remove the valve oil seal.

Specific tooling
020431Y Valve oil seal extractor

- Slide off the valve and remove the lower support.

ENG - 92
MP3 400 hpe E5 Engine

Removing the cylinder - piston assy.

- Unscrew and remove the fastening screws of the

coil.

- Remove the coil.

- Unscrew and remove the lower cylinder fixing

screw.

- Remove the cylinder, paying attention to the cyl-

inder - head alignment dowels.
N.B.
IN ORDER NOT TO DAMAGE THE BASE GASKET WITH
THE PISTON LOCK FORK 020512Y DURING THE MOUNT-
ING PHASE, IT IS RECOMMENDED TO INSERT THE
ALIGNMENT DOWELS OF THE CYLINDER - CRANKCASE
UNDER THE CYLINDER DURING THE ASSEMBLY.
CAUTION
TO PREVENT DAMAGING THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.

ENG - 93
Engine MP3 400 hpe E5

- Remove the base gasket.

- Remove the retainer rings and remove the piston.

N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.

Inspecting the small end

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

Inspecting the wrist pin

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

Inspecting the piston

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

Inspecting the piston rings

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

ENG - 94
MP3 400 hpe E5 Engine

Removing the piston

- Insert the pin.

- Insert the retainer rings.
CAUTION

POSITION THE ARROW PRINTED ON THE PISTON

CROWN TOWARDS THE EXHAUST OPENING.
CAUTION

AT EVERY NEW MOUNTING USE RETAINER RING PINS.

Choosing the gasket

- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool.

Specific tooling
020921Y Piston position checking tool

- Using an abutment plane, reset the dial gauge

with a pre-load of a few millimetres.
- Finally fix the dial gauge.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the dial gauge position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inver-
sion point of the dial gauge rotation).
- Measure the deviation from the reset value.

- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to
be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-
sion ratio.
- Remove the special tool and the cylinder.

See also

ENG - 95
Engine MP3 400 hpe E5

Slot packing system

Refitting the piston rings

- Pistons (like cylinders) are supplied in 4 catego-

ries: M,N,O,P, must be mounted so that the refer-
ence arrow is pointing towards the exhaust duct.
The letter is found at the centre of the piston.
- Fit the sealing rings with the word TOP or the
identification letter facing upwards. In any case,
the step must be facing opposite the piston crown.
- Sealing rings are manufactured with a cylinder
contact conical cross-section and piston gaps
must be offset by 120° in order to obtain a better
bedding.
- Lubricate rings with engine oil when fitting them.
CAUTION
AT EVERY NEW MOUNTING USE RETAINER RING PINS.

ENG - 96
MP3 400 hpe E5 Engine

Refitting the cylinder

- Insert the cylinder base gasket.

- Fit the specific tool.

Specific tooling
020426Y Piston fitting fork

- Place the seal rings as indicated in the figure.

- Place the cylinder and the specific tool.

Specific tooling
020128Y Piston fitting ring

ENG - 97
Engine MP3 400 hpe E5

- Check the position of the dowels and insert the

gasket with the previously determined thickness.

Inspecting the cylinder head

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.
- Ensure that the camshaft control pulley chain as-
sembly and the sprocket wheel are not worn.
- If you detect wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn, replace
the whole unit
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
unit.

Inspecting the valve sealings

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

ENG - 98
MP3 400 hpe E5 Engine

Inspecting the valves

VALVE CLEARANCE CHECK

- Remove the cover.
- Position the engine to the TDC in compression.

- Using a feeler gauge check the valve clearance.

CAUTION
- USE THE FEELER GAUGE LATERALLY, IN LINE WITH
THE VALVES, IN ORDER TO PREVENT ACCIDENTAL
BENDING OF THE BLADE THAT MAY AFFECT THE MEAS-
UREMENTS.

Characteristic
Valve clearance (cold engine)
Intake: 0.10 mm Exhaust: 0.15 mm

- Detecting incorrect values, proceed with the re-

placement of the calibrated pad. To perform this
operation you must remove the rockers lock.
- Using pliers, remove the lock.

ENG - 99
Engine MP3 400 hpe E5

- Move the rocker and replace the interested pad,

correcting the clearance in the pre-set value.
N.B.
INSERT THE CALIBRATED PADS WITH THE WORDS SIDE
VALVE IN ORDER TO PRESERVE THE INDICATION OF
THICKNESS OVER TIME.
THE OUTLET ROCKER SLIDES ON THE AXIS ONLY AF-
TER THE INTAKE ROCKER HAS BEEN MOVED. MAKE
SURE THAT THE PADS DO NOT FALL INSIDE THE ENGINE
COMPARTMENT.

Characteristic
Valve clearance (cold engine)
Intake: 0.10 mm Exhaust: 0.15 mm

- Insert the rockers lock.

- Fit the valve cover.

ENG - 100
MP3 400 hpe E5 Engine

Inspecting the springs and half-cones

- Check that the upper and lower supporting spring

washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component
when worn.

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.
- Using the special punch, fit the four valve seal
rings.
- Fit the valves, the springs and the caps. Using
the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE
VALVE SPRINGS WITH THE REFERENCE COLOUR ON
COTTER SIDE (TURNS WITH GREATER PITCH).

Specific tooling
020306Y Punch valve seal rings fitting
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)

Inspecting the cam shaft

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

ENG - 101
Engine MP3 400 hpe E5

Refitting the head and timing system components

CAUTION
AT EACH REMOVAL OF THE CYLINDER HEAD IT IS NEC-
ESSARY TO REPLACE THE STUD BOLTS. FOR FITTING
QUOTA SEE THE SECTION "MOTOR/STUD BOLT SHAFT
CRANKCASE"

- Position the crankshaft to the TDC in compres-

sion.

- Insert the head gasket and check the correct op-

eration of the alignment dowels.
- Insert the chain guide slider.
- Insert the head.
- Lubricate the stud bolt threads with engine oil.

ENG - 102
MP3 400 hpe E5 Engine

- Tighten up the nuts to an initial pre-torque of 9-11

± 1 Nm.
- Tighten up the nuts by rotating 270.0±5.0° with
crossed sequence.
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.
CAUTION

ALWAYS USE A NEW HEAD GASKET UPON REFITTING.

Locking torques (N*m)

Screws fixing cylinder head to crankcase 20 ÷
24 Cylinder head nut (PRE-TIGHTENING) 6 ÷ 8
Cylinder head nut (TIGHTENING) 9 ÷ 11 (Tighten
to 9 ÷ 11 Nm then proceed for 270.0° ±5.0° of rotation)

Fit the pins and rocking levers.

- Lubricate the two rockers through the upper
holes.
- Lubricate the two housings and insert the cam-
shaft in the cylinder head with the cams opposing
the rockers.
- Insert the calibrated pads and block the sliding of
the rockers by inserting the lock.
- Insert the retention plate and tighten the three
screws locking them to the specified torque. Clean
any threadlock remains from the seats, do not use
threadlock, the new screws to use during mounting
have scotch-grip application.
CAUTION
FOR THE INSTALLATION, ALWAYS USE NEW NUTS AL-
READY PROVIDED WITH SCOTCH GRIP.

Locking torques (N*m)

Containing plate retainer screws 4.5 ÷ 5.5

ENG - 103
Engine MP3 400 hpe E5

- Working in reverse order, assemble the camshaft

command components, respecting the phase po-
sition.
- To tighten the decompressor, bring the mass
screw to a stop and, holding it tightly, tighten the
central locking screw of the starter crown.
- Then tighten the central screw.

Locking torques (N*m)

Pressure reducer counterweight retainer
screw 7 ÷ 8.5 Nm Timing system gear sprocket
fixing screw 11 ÷ 15
Set the tensioner cursor to the rest position.
- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the specified
torque.
- Insert the chain tensioning screw, together with the spring and washer, tightening it to the specified
torque.

Locking torques (N*m)

Mount the locking chain tensioner with 2 screws 11 ÷ 13 Locking the chain tensioner support
hood 5 ÷ 6

Refitting the rocker-arms cover

- Check the status of the tappet cover gasket and

of the special screws rubber blocks.
- Fit the tappet cover paying attention to the integ-
rity of the sealing rubber blocks and to the correct
positioning of the gasket.

ENG - 104
MP3 400 hpe E5 Engine

- Tighten the special screws to the specified tor-

que.

Locking torques (N*m)

Head cover screws 6 ÷ 7

Refitting the intake manifold

- Connect the rubber sleeve complete with throttle

body to the intake manifold.

- Place the clamps and tighten them to the speci-

fied torque.

Locking torques (N*m)

Throttle body clamp screws 1.3 ÷ 1.7

Crankcase - crankshaft

ENG - 105
Engine MP3 400 hpe E5

Splitting the crankcase halves

- Undo the twelve crankcase coupling screws.

- Separate the crankcase halves while keeping the
crankshaft in one of these two halves.
- Only after the halves have been separated, can
the crankshaft be checked.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE CRANKSHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
CAUTION

KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES

OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL
TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY
FALL.

- Remove the gasket and be careful with the align-

ment dowels.

- Remove the by-pass and the oil bulkhead.

ENG - 106
MP3 400 hpe E5 Engine

- After removing the oil bulkhead, blow and clean

thoroughly before fitting.

Inspecting the crankshaft components

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

Inspecting the crankshaft alignment

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.
- On the transmission-side crankcase half, take
particular care when handling the oil pump com-
partment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the trans-
mission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the piston, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.

ENG - 107
Engine MP3 400 hpe E5

- Inspect the coupling surfaces on the crankcase

halves for scratches or deformation, taking partic-
ular care with the cylinder/crankcase surfaces and
the crankcase halves surfaces.
- Defects in the crankcase coupling gasket be-
tween the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bushings and
connecting rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES PIS-
TON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-
ERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD.
N.B.
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET;: THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure
(3.2 bar) and a good oil flow rate; the bushings
must be correctly positioned so as not to obstruct
the oil supply channels.
- The main bushings are comprised of two half-
bearings, one with holes and channels for lubrica-
tion whereas the other is solid.

Characteristic
«A»

ENG - 108
MP3 400 hpe E5 Engine

AXIS CYLINDER

- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Coupling chart
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

Refitting the crankcase halves

- Insert the crankshaft on one of the two crankcase

halves.

- insert the oil shield.

ENG - 109
Engine MP3 400 hpe E5

- Insert the by-pass valve.

- Place a new crankcase gasket.

- Couple the crankcases, paying particular atten-

tion to avoid accidental movements during inser-
tion of the crankcase half which could cause
collision with the oil pump control toothing on the
crankshaft and, consequently, damage the bush-
ings.

- insert the crankcase fastening screws and tighten

it them to the specified torque.

Locking torques (N*m)

Engine-crankcase coupling screws 11 ÷ 13

ENG - 110
MP3 400 hpe E5 Engine

- Complete the coupling operations with the verifi-

cation of the crankshaft axial clearance.
- Using specific tools to support the dial gauge,
verify that the fitting clearance is within the limits.
- Higher clearances are signs of wear of the crank-
shaft - crankcase supporting surfaces.

Specific tooling
020163Y Crankcase splitting plate
020335Y Magnetic mounting for dial gauge

Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm

Studs

- Using two nuts, fitted as nut and lock nut type, remove and then drive from the seat.
- Proceed with a thorough cleaning of the threaded seat on the crankcase.
N.B.
THE STUD BOLTS MUST BE REPLACED AT EACH REMOVAL OF THE CYLINDER HEAD.
N.B.
NEW STUD BOLTS DO NOT NEED THREADLOCK, AS THEY COME EQUIPPED WITH SCOTCH-
GRIP.

Lubrication

ENG - 111
Engine MP3 400 hpe E5

Conceptual diagrams

The lobe pump «F» sucks the oil from the sump, through the mesh pre-filter «C», it pushes it into the
cartridge filter «E» where there is also a safety valve «D».
Through the suitable passages found in the crankcases, the oil enters the crank chamber «G» where
the main bearings are lubricated and the big end (with high pressure), the piston pin and connecting
rod small end via spray «H».
Afterwards, the oil, through a nozzle «M» whose function is to reduce the flow rate, reaches the timing
system where it lubricates the camshaft «A» and from there, the valves and rockers. The oil passes
through the timing chain duct and returns to the sump «B» by gravity.
In the system there is a minimal oil pressure sensor «I» and a spray that serves to lubricate the stator
«L».

Oil pressure check

- Remove the electrical minimum oil pressure

switch connection and remove the switch.
- Check that the oil pressure reading is between
0.5 and 1.2 bar with the engine idling at 1650 rpm
and the oil at the required temperature (wait for at
least one electric ventilation).

ENG - 112
MP3 400 hpe E5 Engine

- Check that the oil pressure is between 3.2 and

4.2 bar with the engine running at 6000 rpm and
the oil at the required temperature.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the specified torque
and fit the flywheel cover.
- If the oil pressure is not within the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER
CONDITION.

Characteristic
Oil pressure
Operating pressure

- At 1650 rpm: 0.5 - 1.2 bar

- At 6000 rpm: 3.2 - 4.2 bar

Locking torques (N*m)

Minimum oil pressure sensor 12 ÷ 14

Crankshaft oil seals

Removal

- Unscrew the three screws and remove them,

complete with the copper gaskets.

ENG - 113
Engine MP3 400 hpe E5

- Using pliers remove the door by acting on the

appendices.

- Remove the spacer and the O-ring.

ENG - 114
MP3 400 hpe E5 Engine

Refitting

- Insert the components making sure to thoroughly

grease the O-ring and the oil seal.
- Follow the steps in reverse order taking care to
tighten to torque.
WARNING

IN ORDER TO PREVENT ABNORMAL FORMATIONS OF

DIRT DUE TO THE RELEASE OF GREASE, WE RECOM-
MEND FIRST LUBRICATING THE SEAL RING STOPS WITH
A BRUSH.

Locking torques (N*m)

Crankcase timing cover screws 3.5 ÷ 4.5

Oil pump

Removal

- Remove the flywheel.

- Preventing rotation, unscrew the water pump
command screw and collect the washer.
CAUTION
THE THREAD IS ANTICLOCKWISE.

ENG - 115
Engine MP3 400 hpe E5

- Unscrew the two screws and remove the ten-

sioner pad

- Remove the oil pump command sprocket com-

plete with chain.

- Undo the fastening screws of the oil pump.

- Remove the oil pump and collect the gasket.

ENG - 116
MP3 400 hpe E5 Engine

- Remove the oil pump command sprocket com-

plete with chain.

- Unscrew the two screws and remove the oil

pump.

Inspection

- Remove the two screws and remove the oil pump

cover.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible.
- Using a feeler gauge, check the distance be-
tween the rotors in the position shown in the figure.
- Check the distance between the outer rotor and
pump body, see figure.
Check the axial clearance of the rotors using a
trued bar as shown in the figure.

Characteristic
Axial rotor clearance
Limit value admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors

ENG - 117
Engine MP3 400 hpe E5

Admissible limit clearance: 0.12 mm

Refitting

- - Insert the oil pump with the corresponding gas-

ket in the seat.

ENG - 118
MP3 400 hpe E5 Engine

- Insert and tighten the oil pump fastening screws

to the crankcase to the specified torque.

Recommended products
Loctite 243 Medium strength thread-locking
sealant.
Blue

Locking torques (N*m)

Screws fixing oil pump to the crankcase 5 ÷ 6

- Insert the oil pump driving sprocket and chain.

- fit the tensioner pad.

- place the spring washer and insert the water

pump control screw.
- Preventing rotation, tighten the water pump com-
mand screw.
CAUTION
THE THREAD IS ANTICLOCKWISE.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM
TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP
TURNS FREELY.

Locking torques (N*m)

Oil pump command sprocket screw 9 ÷ 11

ENG - 119
Engine MP3 400 hpe E5

Inspecting the by-pass valve

- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defec-
tive parts.

Characteristic
Standard length
52.4 mm
Piston standard diameter
12.861 + 12.843 mm

Water pump

Removal

- Before removing the flywheel cover, loosen the

impeller.
CAUTION
THE THREAD IS ANTICLOCKWISE.
CAUTION
IF THE LOCKING TORQUE IS EXCESSIVE, DO NOT INSIST
WITH THE OPERATION BUT CARRY IT OUT AFTER THE
REMOVAL OF THE FLYWHEEL COVER. AFTER REMOV-
ING THE FLYWHEEL COVER, LOCK THE IMPELLER
(DRIVE SIDE OF MOTORCYCLE) IN THE CLAMP AND,
ACTING FROM THE OPPOSITE SIDE, LOOSEN THE IM-
PELLER SHAFT (LEFT-HAND THREAD).

- Keeping the cover locked in a vice, unscrew the

impeller shaft drive. During removal, support the
flywheel crankcase. Remove the drive and the
shim washer underneath.
CAUTION
THE THREAD IS ANTICLOCKWISE.

ENG - 120
MP3 400 hpe E5 Engine

- Using the special tool and appropriate supports,

ensure a proper support surface. Using a hammer
and a plug (of diameter less than 8 mm and being
careful not to damage the shaft seat) remove the
shaft and ceramic seal.

Specific tooling
001467Y002 Driver for OD 73 mm bearing

- Supporting the ceramic seal properly, remove the

impeller shaft, acting from the mobile side of the
seal.

ENG - 121
Engine MP3 400 hpe E5

- Using a screwdriver, remove the seal ring from

the flywheel cover.
- Check that the shaft housing hole on the crank-
case does not show abnormal wear. Make sure the
ceramic seal seat does not show signs of scoring.
Check the cleaning of the drain and lubrication
holes.

Fitting

- Lubricate the new seal ring with grease and insert

it in the flywheel cover.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor

ENG - 122
MP3 400 hpe E5 Engine

- Grease the shaft and insert it in the seat. Insert

the shim washer and manually start-up the drive.

- Locking the drive in a vice, properly lock the shaft.

- Check that the shaft rotates freely (considering
the friction of the oil seal) and that the axial clear-
ance is noticeable but not excessive.

Locking torques (N*m)

Water pump impeller driving joint 13 ÷ 15

ENG - 123
Engine MP3 400 hpe E5

- Insert the new ceramic seal using the specific

tool.
- Start the tool.
- Insert the new ceramic seal.
- Insert the housing of the tool and tighten the nut
with a wrench while holding the central pin locked.
Screw until the seal stops on the crankcase.
- The special tool provides for processing that en-
sures the proper preloading of the ceramic seal.
- Remove the tool.

Specific tooling
020661Y Water pump overall seal replacement
kit

ENG - 124
MP3 400 hpe E5 Engine

- Insert and screw the impeller to the specified tor-

que.

Locking torques (N*m)

Impeller on the pump shaft 4 ÷ 6

ENG - 125
I
Identification: 18

M
Maintenance: 33

R
Recommended products: 33

T
Technical Data: 18
Transmission: 37, 64

V
Vehicle: 14, 18