MP3 400 i.e.

Suspensions

Check the ball bearings on the parallelogram

arms. Replace them in case of signs of abnormal
wear.

Check the inside tracks of the parallelogram bear-

ings on the chassis.

For refitting, follow the operations for removal but

in reverse order, lubricating the locking pins on the
parallelogram half-arms and observing the pre-
scribed torques.

PARALLELOGRAM DEVICE
Name Torque in Nm
Arm coupling screws 45 ÷ 50
Screws fixing arms to side headstocks 45 ÷ 50
Screws fixing arms to central headstock 45 ÷ 50
Screws fixing the half-arm coupling flange 20 ÷ 25

SUSP - 15
Suspensions MP3 400 i.e.

Name Torque in Nm
Fixing screws for tilt locking disc section 20 ÷ 25

Geared motor and Suspension locking system

Select the SYSTEM RESET option from the main
menu

Turn the key switch to ON

Select the LOWER STOP SEARCH option from
the SYSTEM RESET menu
WAIT
PROCEDURE IN PROGRESS

SUSP - 16
MP3 400 i.e. Suspensions

The hand-held computer indicates the outcome of

the stop search operation:
POSSIBLE LIMIT STOP VALUES. TO EXIT,
PRESS A KEY AND TURN OFF AND ON. SE-
LECT PARAMETERS TO ADJUST AT 12°.
Check the geared motor if the hand-held computer
does not indicate this.

Select the PARAMETERS option from the main

menu

The hand-held computer displays the option: REL-

ATIVE POTENTIOMETER ANGLE
This function is active coming from the LOWER
STOP SEARCH procedure.
NOTE: a slight oscillation of the angle value be-
tween 0.00° and 0.50° is considered normal

Remove the protection cap of the geared motor set

screw
Use a plain slot screwdriver to turn the set screw
anticlockwise until replicating the 12° condition on
the hand-held computer
RELATIVE POTENTIOMETER ANGLE 12° (a
slight value oscillation is considered normal)
Refit the protection cap

SUSP - 17
Suspensions MP3 400 i.e.

Remove the protection cap, align the pump control

and lock the screw to the prescribed torque

Locking torques (N*m)

Clamp fixing pump bolt to anti-tilting device 11
÷ 13

Select the SYSTEM RESET option from the MAIN

menu

SUSP - 18
MP3 400 i.e. Suspensions

Select the POTENTIOMETER RESET option from

the SYSTEM RESET menu and press OK.
WAIT....
PROCEDURE IN PROGRESS

The hand-held computer displays the words:

CHECK THAT THE CONTROL IS SET AT 12°
FROM THE LOWER STOP. PRESS OK TO CON-
TINUE
Press OK
The hand-held computer displays the words: POS-
SIBLE LIMIT STOP VALUES. PRESS A KEY AND
SHIFT OFF AND ON
If this is not successful, the tilt locking mechanism
remains locked for safety.

Adjust the flexible transmission so that a small

clearance is left to guarantee switch activation on
the tilt locking calliper

Remove the two bracket screws after releasing the

spring and freeing the flexible transmission adjust-
ment.
CAUTION: A FIRST PRODUCTION BATCH WILL
BE EQUIPPED WITH DOUBLE COAXIAL
SPRING.
It is very important to remove the flexible trans-
mission from its fitting only for replacement.

SUSP - 19
Suspensions MP3 400 i.e.

When refitting, tighten the two bracket screws and

the flexible transmission lever nut to the prescribed
torque.

Locking torques (N*m)

Bracket tightening screws 8 ÷ 12

Unscrew the Allen screw and remove the switch.

When refitting, place the switch with the button ori-
ented to the stop indicated on the calliper lever;
observing the reference indicated on the switch
supporting bracket.
After refitting, check in detail that the switch is reg-
ularly activated by the stop on the lever.

SUSP - 20
MP3 400 i.e. Suspensions

Unscrew the two pad pin screws, remove the pads

with the spring.
When refitting, tighten the two screws to the pre-
scribed torque and use Threadlock.
When refitting, adjust the cable properly so that the
switch is pushed when the system is unlocked.

Refit the spring/toothed sector unit, hold the crank-

case in a perfectly horizontal and stable position,
place the spring/toothed sector unit keeping it per-
fectly perpendicular to the bearing already fitted on
the crankcase; if necessary, slightly hit the unit
shaft end with a mallet and protect the thread by
screwing in a nut.

SUSP - 21
Suspensions MP3 400 i.e.

Fit the pinion and align the reference on the pinion

teeth with the reference indicated on the second
slot of the toothed sector.
Grease the pinion and the toothed sector with spe-
cific grease.
Refit the toothed sector spacer.

Recommended products
MONTBLANC MOLYBDENUM GREASE MON-
TBLANC MOLYBDENUM GREASE
Molybdenum disulphide grease

Lubricate the interference areas, match the crank-

case halves with slight hits of a mallet to get them
into contact.
Place the flexible transmission supporting bracket,
refit the four screws, screw them to the prescribed
torque.

Locking torques (N*m)

Geared motor crankcase halves coupling
screws 11 ÷ 13
Refit the electric motor; check the position is cor-
rect by means of the reference indicated during
removal.
The motor should be so positioned that it does not
protrude from the reduction unit mould, see figure.
Tighten the screws to the prescribed torque.

Locking torques (N*m)

Electric motor coupling screws 11 ÷ 13

SUSP - 22
MP3 400 i.e. Suspensions

Place the moulded washer of the flexible trans-

mission control lever shaft and the tongue.
Refit the flexible transmission control lever as
shown in the figure.

Refit the potentiometer (not forcing in the D-type

connector ensures a sole position) with the con-
nector directed to the opposite side of the hydraulic
pump.

Refit the hydraulic pump on the geared motor body

and tighten the screws to the prescribed torque.
Fit but not tighten the pump stem coupling screw
and refit the plastic protection cap.
The synchronisation procedure should be com-
plete when the installation is finished.

Locking torques (N*m)

Geared motor hydraulic pump tightening
screws 11 ÷ 13

Remove the retaining seeger ring of the bearing of

the flexible transmission lever control shaft bear-
ing.
Remove the bearing with the specific tool.

Specific tooling
020376Y Adaptor handle
020441Y 26 x 28 mm adaptor
020362Y 12 mm guide

SUSP - 23
Suspensions MP3 400 i.e.

Extract the electric motor bearing with the specific

tool.

Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide

Hold the crankcase in a perfectly horizontal posi-

tion, heat it with a heat gun at a temperature of
about 120 °C, use the specific tool to fit the bearing
of the flexible transmission lever control shaft. Hit
slightly with a mallet if necessary.
Refit the bearing check seeger ring.

Specific tooling
020151Y Air heater
020376Y Adaptor handle
020362Y 12 mm guide
020357Y 32 x 35 mm adaptor
Hold the crankcase in a perfectly horizontal posi-
tion, heat it with a heat gun at a temperature of
about 120 °C, use the specific tool to fit the bearing
of the electric motor. Hit slightly with a mallet if
necessary.

Specific tooling
020363Y 20 mm guide
020358Y 37x40-mm adaptor
020151Y Air heater

SUSP - 24
MP3 400 i.e. Suspensions

020376Y Adaptor handle

Remove the spring/toothed sector unit from its fit-
ting, slightly hit with a mallet if necessary to release
the unit.

Extract the bearing of the spring/toothed sector

unit with the specific tool.

Specific tooling
001467Y002 Driver for OD 73 mm bearing

Extract the bearing of the electric motor with the

specific tool.

Hold the crankcase in a perfectly horizontal posi-

tion, heat it with a heat gun at a temperature of
about 120 °C, use the specific tool to fit the bearing
of the spring/toothed sector unit. Hit slightly with a
mallet if necessary.

Specific tooling
020360Y Adaptor 52 x 55 mm
020151Y Air heater
020376Y Adaptor handle

SUSP - 25
Suspensions MP3 400 i.e.

Hold the crankcase in a perfectly horizontal posi-

tion, heat it with a specific heat gun at a tempera-
ture of about 120 °C, use the specific tool to fit the
bearing of the electric motor. Hit slightly with a
mallet if necessary.

Specific tooling
020363Y 20 mm guide
020151Y Air heater
020376Y Adaptor handle
020477Y Adaptor 37 mm

Before removing the geared motor:

Disable the suspension lock.
- Remove the front shield.
With the set nut indicated in the photograph, re-
move the tensioning cable of the suspension lock-
ing mechanical calliper.

Remove the electrical connection of the geared

motor position potentiometer.

Remove the electrical connection of the geared

motor electric motor.

SUSP - 26
MP3 400 i.e. Suspensions

Disconnect the hydraulic pipes between the pump

and the sliding stem locking clamps. Empty the
system and use a container to collect the brake
fluid.
CAUTION
ELIMINATE ANY REMAINING BRAKE FLUID
SPILLS.

WARNING: BRAKE FLUID IS HIGHLY POISON-

OUS. DO NOT INGEST OR SWALLOW. IF AC-
CIDENTALLY SWALLOWED, DRINK LARGE
QUANTITIES OF MILK OR WATER AND SEEK
MEDICAL ADVICE IMMEDIATELY. BRAKE
FLUID DESTROYS SKIN AND OCULAR TIS-
SUE. IF YOU ACCIDENTALLY SPILL BRAKE
FLUID ON YOURSELF, TAKE OFF YOUR
CLOTHES, WASH WITH HOT WATER AND
SOAP AND SEEK MEDICAL ADVICE IMMEDI-
ATELY. IF BRAKE LIQUID GETS ACCIDEN-
TALLY IN CONTACT WITH YOUR EYES, RINSE
WITH ABUNDANT FRESH WATER AND SEEK
MEDICAL ADVICE IMMEDIATELY. KEEP
BRAKE FLUID OUT OF THE REACH OF CHIL-
DREN.
Remove the 3 fixing screws indicated and remove
the whole geared motor.

Use a screwdriver to remove the plastic access

cover to the pump joint/geared motor
Unscrew the pump joint screw.
Unscrew the two geared motor pump locking
screws.

SUSP - 27
Suspensions MP3 400 i.e.

Unscrew the two potentiometer screws.

When refitting, plug the potentiometer in D-type
connector, afterwards place it with its electric con-
nection directed to the opposite side of the pump.

Remove the nut indicated in the figure, if neces-

sary lock the lever with a vice making sure not to
spoil the surface.
In case of difficulties when removing the lever, use
the specific tool.
Remove the tongue and then, the moulded wash-
er.

Specific tooling
020234y extractor

SUSP - 28
MP3 400 i.e. Suspensions

Remove the three fixing screws of the electric mo-

tor.
It is important to mark the direction of the electric
motor position in order to refit it correctly.

Remove the four screws indicated in the figure,

remove the flexible transmission supporting brack-
et, separate the two crankcase halves, if neces-
sary, use a rubber mallet to hit the flexible
transmission lever in order to separate the two
crankcases.

Electrical devices test

PRINCIPLE DIAGRAM FOR TILT LOCKING ELECTRICAL SYSTEM

KEY
1. Geared motor

SUSP - 29
Suspensions MP3 400 i.e.

2. Brake calliper sensor

3. Tilt unlocking-locking control switch
4. Potentiometer
5. Rider presence sensor
6.Left speed sensor
7.Right speed sensor
8. Diagnostic tester serial line
9. Engine electronic control unit
10. Direct +Battery
11. Live +Battery
12. To light switch
13. 20A Fuse No. 4
14. Light remote control
15. Pressure switch
16. Horn remote control
17. Instrument panel
18. Tilt locking system control unit

GEARED MOTOR

SUSP - 30
MP3 400 i.e. Suspensions

1: GEARED MOTOR

With the interface wiring disconnected from the

control unit, check the continuity between pin 28
and the white-red cable, between pin 38 and the
blue cable on the geared motor connector

With the interface wiring disconnected from the

control unit, check the continuity of the geared mo-
tor winding placing the multimeter probes on pins
28 and 38 as indicated in the figure.

TILT LOCKING-UNLOCKING SWITCH

SUSP - 31
Suspensions MP3 400 i.e.

0: REST POSITION
1: LOCKING POSITION
2: UNLOCKING POSITION
3: TILT LOCKING-UNLOCKING SWITCH

With interface wiring disconnected from the control

unit, check the continuity of the electrical lines be-
tween the interface wiring and the tilt locking-un-
locking switch:
Pin 26 and green - grey cable
Pin 35 and violet - black cable
Pin 33 and yellow - blue cable
Also check that the above indicated electrical lines
are insulated from the earth.

SUSP - 32
MP3 400 i.e. Suspensions

Check the continuity between the black cable on

the connector and an earth point on the chassis.

With a multimeter, check the operation of the tilt

locking-unlocking switch referring to the diagram
indicated in the figure.
KEY
1. GROUND
2. LOCKING
3. REST
4. UNLOCKING

POTENTIOMETER

1: POTENTIOMETER

SUSP - 33
Suspensions MP3 400 i.e.

With interface wiring connected to the control unit,

secure the vehicle on its centre stand and switch
to "ON". Select the reading scale on 20 V. Insert
the multimeter probes on pins 17 and 25. Check
that the voltage in the activated locking condition
is 4V and 1V in the locking to rest condition.

With the interface wiring disconnected from the

control unit, check the continuity between pin 17
and the yellow cable of the potentiometer connec-
tor, between pin 25 and the green-blue cable,
between pin 11 and the orange-blue cable. Also
check that these lines are insulated from each oth-
er and earth.

RIDER PRESENCE SENSOR

SUSP - 34