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April 1, 2022 NHTSA CAMPAIGN NUMBER: 22V217000
Brakes that do not perform as expected, and require the driver to apply more force to the brake levers or pedals, increase the risk of a crash.
NHTSA Campaign Number: 22V217
Manufacturer Piaggio Group Americas, Inc.
Components SERVICE BRAKES, HYDRAULIC
Potential Number of Units Affected 27
Summary
Piaggio Group Americas, Inc. (Piaggio) is recalling certain 2020-2021 MP3 500 HPE scooters. The brake hose terminal fittings zinc plating may contaminate the brake fluid, decreasing brake performance.
Remedy
Dealers will perform a complete brake system flush, free of charge. Owner notification letters were mailed April 18, 2022. Owners may contact Piaggio customer service at 1-212-380-4400.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Date: April 19, 2022
Contact: Technical Services
Subject: NHTSA Recall 22V217 – Brake bleeding campaign
Recall Communication: Campaign Code: PP2ZZQ2201
Affected Models: A specific range of:
- Piaggio MP3 500
- Piaggio MP3 500
Concern: Piaggio Group Americas (PGA) has identified the possibility of non-conformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever. This situation can cause reduced braking or stopping ability and can lead to a loss of control or a crash, increasing the risk of injury.
Cause: A non-conforming zinc plating process on the brake hose fittings causes hydrogen gas to escape into the brake fluid, leading to a loss of braking ability.
Correction: A brake system fluid replacement with comprehensive bleed (if necessary) must be performed based on the results of an initial test described in this bulletin. Two different claiming coupons are available based on the test results. If a vehicle passes the test, only a limited bleed procedure to replace the brake fluid is required (Coupon 1). If a vehicle fails the test, then a comprehensive bleed procedure and fluid replacement is required (Coupon 2)
Please prioritize the repair following the guidelines below:
Customer vehicles: Perform recall at first available opportunity
Vehicles in stock: Perform recall at the PDI stage before sale to customer
Please note that after the initial test is performed and the repair made under either Coupon 1 or Coupon 2, the vehicle must be left alone for 24 hours and the test repeated to verify results and document with final photos. Six photos are required when finishing each claim; ( 3 “before” photos taken during the initial test and 3 “after” photos taken during the final test after repairs are made)
All affected vehicles are blocked from warranty registration until the campaign has been completed in the PWM warranty system.
Note: It is imperative to perform this recall before the vehicle is sold and/or leaves the dealership. Using the PWM warranty system, click on “Campaigns”, then “Campaign Reports” to view ALL VINS in your inventory that require a technical update or recall. This list can be filtered by searching for a specific Campaign Description, a Frame number, the Campaign start date or Coupon state. This recall has the description, “Brake Fluid Replacement and brake system bleeding”. Customers can also check for themselves if their vehicle is subject to this recall by using this site: https://static.piaggio.com/recall/formpiaggio_en.html
Owner Notification: Each owner of a vehicle included in this recall will be notified by first class mail. In this letter PGA will describe the details of the concern, the cause, and the correction addressed by this recall. In addition, PGA asks that each owner contact their respective Piaggio/Vespa dealer to arrange for an appointment to have the parts and labor required of this recall completed.
Please make every effort to accommodate your recall customers within your existing service schedule. In addition, PGA has provided each recall customer with details of the TREAD Act Reimbursement program. In short, this program provides a plan to reimburse a customer who has already paid for the same repair or update as described in the recall documents. A copy of the Owner Notification and the TREAD Act Reimbursement letters are included at the end of this bulletin.
Important Note: Under the National Traffic and Safety Act of 1966 as amended, if there has been a recall campaign, dealers must assure that all new vehicles and new items of replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety Standards at the time of delivery to the customer. This means that dealers may not deliver new motor vehicles or new items of replacement equipment to consumers unless the safety defect or noncompliance has been remedied before delivery.
Chronology :
Details about chronology of principal events are listed here below:
05/25/2021 – Warranty analysis monitoring started
10/25/2021 – Piaggio & C. SpA After sales informs Product Quality about n°1 case relevant to safety ZAPTA210000009345
07/12/2021 – Gas analysis in SEA MARCONI (on dealer vehicle stock) Air extracted from brake lines and gas dissolved in brake fluid (H2 found)
12/15/2021 – Testing Hot Extraction (metodo Letomec) for hydrogen release analysis (from dealer stock) from the banjo (Piaggio Internal Laboratory), H2 not found, probably already released in brake fluid.
02/14/2022 – Gas analysis c/o SEA MARCONI (on vehicle ZAPTA210000009345) Air analysis from brake system and gas dissolved in the brake fluid analysis (H2 found)
03/11/2022 – Notification date to J.Juan (supplier) about the issue – Piaggio & C. S.p.A. notified supplier of the need to start a safety recall on network
03/29 /2022: P&C Spa notified network of start of Safety Recall
Warranty monitoring; from 05/25/2021 there have been new warranties about to excessive play in the brake levers/pedal after the vehicle has been sitting for an extended period. 1268 warranty claims Worldwide between 05/08/2020 and 11/30/2020. 12,462 units affected Worldwide.
4 claims were entered in the USA. There were no reported cases of injury or death.
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
PIAGGIO | MP3 500 | 2020-2021 |
11 Associated Documents
Defect Notice 573 Report
RCLRPT-22V217-6957.PDF 215.762KB
Recall 573 Report-Amendment 1 04/05/2022
RCLRPT-22V217-8636.PDF 215.77KB
Recall Acknowledgement
RCAK-22V217-9198.pdf 689.565KB
Remedy Instructions and TSB
RCRIT-22V217-5898.pdf 3251.17KB
Owner Notification Letter(Part 577)
RCONL-22V217-2633.pdf 2424.653KB
Manufacturer Reimbursement Plan – 04/16/2022
RMRP-22V217-3835.pdf 114.922KB
Recall 573 Report-Amendment 2 – 05/16/2022
RCLRPT-22V217-1860.PDF 218.243KB
Recall 573 Report-Amendment 3 – 06/02/2022
RCLRPT-22V217-8048.PDF 218.288KB
Recall 573 Report-Amendment 2 – 05/16/2022
RCLRPT-22V217-7522.PDF 218.242KB
Recall Quarterly Report #2, 2022-3
RCLQRT-22V217-7174.PDF 211.237KB
Recall Quarterly Report #3, 2022-4
RCLQRT-22V217-0635.PDF 211.322KB
Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V217&docType=RCL
- Provides an extra margin of safety in extreme braking conditions
- Mix of polyglycol ethers ensures hot brake-system operation will not create dangerous vapor
- Excellent for ABS, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy pedal
- Both wet and dry boiling points exceed the minimum government standards
- High quality blend of polyethylene glycol ethers and additives
- Compatible with all brake system rubber components and other brake fluids
- Prevents seal hardening or softening
- Protects against rust and corrosion
- Provides excellent lubricity
- High compatibility. Use with or direct replacement for DOT 3, DOT 4, and DOT 5. 1
- Extended Service Interval (ESI): Lasts 100% longer than DOT 3, 50% longer than DOT 4, and 10% longer than DOT 5. 1
- Exceeds all DOT 3, DOT 4, and DOT 5. 1 standards
- Wet boiling point ~ 365 DegreeF/Viscosity at -40 DegreeC ~ 685mm2/s
- Standard brake fluid has a recommended change interval of 2 years. The recommended change interval for Bosch ESI6 is 3 years.
- Premium DOT 3 Brake Fluid has a minimum boiling point of 450°F
- Meets and exceeds DOT 3 and all other Federal and SAE specifications and standards for motor vehicle brake fluids
- Mixes with all DOT 3 approved brake fluids
- Designed for use in disc, drum and ABS brake systems
- Synthetic quality brake fluid
- Contains special ingredients to guard against vapor lock and moisture absorption
- Exceeds requirements for both DOT 3 and DOT 4 brake fluids
- Specially formulated for DOT 4 brake fluid applications
- Designed for use in disc, drum and ABS brake systems
- Premium brake and hydraulic clutch fluid that protects internal components from corrosion under normal use
- High boiling point to minimize brake fluid boiling and vapor lock
- Excellent low temperature capability and stability when used where lower cold viscosities are required
- Excellent low temperature capability and stability when used where lower cold viscosities are required
- The 336⁰F wet boil point and 521⁰F dry boil point exceeds common characteristics for DOT 4 brake fluids
- Provides corrosion protection in brake components
- Matches needs of all DOT 4 manufacturer recommendations
- Compatible with all DOT 3 and DOT 4 applications
- Minimal decrease of boiling point due to excellent water locking properties
- Non-foaming when filling and bleeding the brake system
- Excellent corrosion protection due to selected additives
- High safety tolerance against steam bubbles
- Makes brake fluid changing intervals of up to 3 years possible
- 2 Pack
- Dry boiling point 594 degrees F
- Motul 600 brake fluid is 100 percent synthetic and has an extremely high boiling poin
- Helping to prevent vapor lock and brake fade during hard use
- This brake fluid exceeds both DOT 3 and DOT 4 specifications
Last update on 2024-04-12 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.
SEOCONTENT-START
04/16/2022 TREAD ACT CUSTOMER REIMBURSEMENT PLAN Customer Reimbursement for Safety Related Recall Repairs Effective with Safety related recalls initiated as of January 15, 2003, Piaggio Group Americas is initiating a safety related recall for a select range of models that includes your VIN number. If you have previously paid to have the repair or update as described in the recall documentation completed, you are entitled to be reimbursed for that expense. You are encouraged to request reimbursement from your respective Piaggio/Vespa dealer. Alternatively, you may submit the request for reimbursement to the following address: Customer Care Piaggio Group Americas 860 Washington Street, 9th Floor New York, NY 10014 In every case: • Repair expenses pertaining to the subject of the safety recall are reimbursable, not consequential expenses such as towing, rental, accommodations, damage repairs, etc. • Expenses from repair facilities outside of the Piaggio Group Americas authorized dealer network will be considered; however, the repair procedure must meet Piaggio Group Americas standards. • When reimbursing for parts, the Manufacturers Suggested Retail Price (MSRP) will be considered as the guideline for reasonable charges. • Expenses for repairs performed more than 10 days after the date of the last customer notification letter sent by Piaggio Group Americas are not eligible for reimbursement. • Taxes and hazardous waste disposal, where previously paid, are eligible for reimbursement. The authorized Piaggio/Vespa dealer will request a copy of the customer notification letter, as well as a copy of the owner’s previously paid invoice, and then inspect the vehicle (if still in the possession of the invoice holder) to determine the scope and quality of the previous repair. Claims will be processed within 60 days of receipt.
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Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 1 Date: April 19, 2022 Contact: Technical Services Subject: NHTSA Recall 22V217 – Brake bleeding campaign Recall Communication: Campaign Code: PP2ZZQ2201 Affected Models: A specific range of: 2020 Piaggio MP3 500 2021 Piaggio MP3 500 Concern: Piaggio Group Americas (PGA) has identified the possibility of non-conformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever. This situation can cause reduced braking or stopping ability and can lead to a loss of control or a crash, increasing the risk of injury. Cause: A non-conforming zinc plating process on the brake hose fittings causes hydrogen gas to escape into the brake fluid, leading to a loss of braking ability. Correction: A brake system fluid replacement with comprehensive bleed (if necessary) must be performed based on the results of an initial test described in this bulletin. Two different claiming coupons are available based on the test results. If a vehicle passes the test, only a limited bleed procedure to replace the brake fluid is required (Coupon 1). If a vehicle fails the test, then a comprehensive bleed procedure and fluid replacement is required (Coupon 2) Please prioritize the repair following the guidelines below: Customer vehicles: Perform recall at first available opportunity Vehicles in stock: Perform recall at the PDI stage before sale to customer Please note that after the initial test is performed and the repair made under either Coupon 1 or Coupon 2, the vehicle must be left alone for 24 hours and the test repeated to verify results and document with final photos. Six photos are required when finishing each claim; ( 3 “before” photos taken during the initial test and 3 “after” photos taken during the final test, after repairs are made) All affected vehicles are blocked from warranty registration until the campaign has been completed in the PWM warranty system. Note: It is imperative to perform this recall before the vehicle is sold and/or leaves the dealership. Using the PWM warranty system, click on “Campaigns”, then “Campaign Reports” to view ALL VINS in your inventory that require a technical update or recall. This list can be filtered by searching for a specific Campaign Description, a Frame number, the Campaign start date or Coupon state. This recall has the description, “Brake Fluid Replacement and brake system bleeding”. Customers can also check for themselves if their vehicle is subject to this recall by using this site: http://static.piaggio.com/recall/formpiaggio_ en.html Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 2 Checking your entire inventory for campaigns: Owner Notification: Each owner of a vehicle included in this recall will be notified by first class mail. In this letter PGA will describe the details of the concern, the cause, and the correction addressed by this recall. In addition, PGA asks that each owner contact their respective Piaggio/Vespa dealer to arrange for an appointment to have the parts and labor required of this recall completed. Please make every effort to accommodate your recall customers within your existing service schedule. In addition, PGA has provided each recall customer with details of the TREAD Act Reimbursement program. In short, this program provides a plan to reimburse a customer who has already paid for the same repair or update as described in the recall documents. A copy of the Owner Notification and the TREAD Act Reimbursement letters are included at the end of this bulletin. Important Note: Under the National Traffic and Safety Act of 1966 as amended, if there has been a recall campaign, dealers must assure that all new vehicles and new items of replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety Standards at the time of delivery to the customer. This means that dealers may not deliver new motor vehicles or new items of replacement equipment to consumers unless the safety defect or noncompliance has been remedied before delivery. VIN Identification (For individual VINS): 1. Go to the Dealer Portal https://dealerportal.piaggiogroup.com/ and enter your Username and Password. From the left hand menu, click on “Piaggio Business Service” 2. From the Piaggio Business Service page, choose the tab “Piaggio Warranty Management” 3. Select “Other functions” in left-hand main menu, then “Vehicle History” in the sub-menu. 4. Enter the VIN number next to “Frame number” and click “Retrieve Data” 5. Click the box next to “Active Campaigns” to view any recalls or technical updates that apply to the VIN. This recall has the description, “Brake fluid replacement and brake system bleeding”. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 3 6. The status of the campaign can be determined from the status column. Status examples are shown below: TO DO: a claim for the campaign has not be entered SUSPENDED: a dealer in the network has entered a claim for the campaign, but has not “carried out” the claim. Please contact the warranty administrator- Patricia.Pena@us.piaggio.com PERFORMED: a claim for the campaign has been entered and carried out by a dealer Warranty Claiming: 1. From the PWM warranty system menu, click on “Campaigns”. Under the heading “Enter Campaigns” enter the VIN next to “Frame number” and click “Search”. 2. Under “Campaign Code”, click on the underlined ID code for this campaign. ➢ Brake fluid replacement and brake system bleeding Please choose either Coupon 1 or 2 based on test results on page 5 of this bulletin 3. Under “Serv. Coup. Data”, enter the KM/Mi. of the vehicle. 4. Click the “SAVE” icon at the top of the claim. Important note: In order to begin the payment process, Campaign submission must be followed by “Carrying-Out” the recall or technical update campaign. This is the last step in the claim process, confirming that the work was actually performed by your dealer. “Carrying-out” recalls or updates is done under the function “State Management” in PWM. On claims found under State Management, you must click on the Wrench icon under the column “Perform work” for the respective claim. All types of claims (Normal warranty claims/ Technical update claims /Recall claims) are carried out under State Management. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 4 Labor reimbursement and necessary parts: Coupon 1 Brake fluid replacement (Passes initial test) service coupon for replacement of the brake fluid, (reimbursement of brake fluid, the O-Ring and the labor required) • Minutes of labor: 110 minutes • Reimbursement for brake fluid and O-Ring: $OIL150* Pages 8-23 refers to bodywork removal and Replacing brake fluid for all three masters (front, rear, pedal) Coupon 2 Replacing brake fluid and Bleeding brake system (Fails initial test) service coupon for the replacement of the brake fluid and comprehensive bleeding of the brake system, (reimbursement of the brake fluid, the O-Ring and the labor required) • Minutes of labor: 335 minutes • Reimbursement for brake fluid and O-Ring: $OIL150* Pages 23-44 -Bodywork removal and foot pedal pushrod check/adjustment Pages 45-56-Component removal and Rear brake bleeding Pages 56-63 -Component removal and Front brake bleeding Pages 63-66- Activation of ABS valves via PADS with manual bleed afterwards. Pages 67-69- Pedal circuit – bleeding through front servo valve Pages 69-70 – Total Brake fluid replacement (front left caliper, front right caliper, rear caliper) * Piaggio has included a flat rate of $7.50 in the service coupon, identified by the code $OIL150, to cover the cost for the purchase of approximately 500 cc of brake fluid and O-Ring. We also remind you that the O-Rings to carry out the tests (one per vehicle) will be sent to the dealer by P&C. IMPORTANT The service coupons must include a number of photos included as attachments. Instructions for each photo are given in the procedure. 6 photos are required when finalizing each claim in STATE MANAGEMENT ( 3 “Before” and 3 “After” photos). Photos are not entered when the claim is first submitted, only when finishing the claim to declare the work is complete. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 5 TEST PROCEDURE Below is an operational diagram to aid workshop operations y Test OK Immediately carry out the bleeding*** and brake fluid replacement operation as per the operating procedure, if necessary, manage the customer with a courtesy vehicle. NOT OK * The dealer will be responsible for analysing the outcome of the test. ** If the customer cannot leave the vehicle immediately in the workshop, schedule the intervention within a maximum of 6 days; illustrating to the customer, as also reported in the online use and maintenance booklet (https://dealerportal.piaggiogroup.com), that the efficiency of the braking system must be checked before each use. *** The bleeding procedure must only be performed on the part of the system that did not pass the Test; e.g.: 1. Left-hand lever + Right-hand lever + Pedal-> NOT OK -> perform the complete bleeding procedure + complete replacement of fluid 2. Left-hand lever -> NOT OK -> Bleeding of rear brake + complete replacement of fluid 3. Right-hand lever -> NOT OK -> Bleeding of front brake + complete replacement of fluid 4. Pedal -> NOT OK -> Bleeding of combined braking system + complete replacement of fluid Warning: for points 2 and 3 (one of the two levers NOT OK ) the control must always be performed on the pedal after having restored the manual circuit. Perform immediately** brake fluid replacement as per the operating procedure (Including Test). Test OK -> The three checks must be met 1. Distance measured to the right-hand lever ≥ 95 mm 2. Distance measured to the left-hand lever ≥ 95 mm 3. Brake pedal consistent Tests NOT OK -> Any of the three measures fail The vehicle arrives in the workshop Enter Coupon No. 1 as VALID (confirming that the test has been successfully* passed). Enter Coupon No. 2 as VALID (confirming that the test has NOT been passed*). Wait 24 hours and repeat the test: Test OK -> Return the vehicle (set the Coupon as COMPLETED by inserting the photographic attachments) Test NOT OK – > Contact HDS Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 6 MP3 500 OPERATING PROCEDURE LEVER TESTS – Preliminary checks. Pull the rear brake lever (left lever) and hold in position by fitting the O-ring, p/n 006731, onto the lever and handgrip as shown in the photo. Hold the fixed jaw of the vernier calliper against the handgrip as shown in the photo. N.B: To show the position of the vernier calliper more clearly, this photo has been taken with the counterweight removed. Measure the distance between the outer edge of the handgrip and the end of the brake lever. Minimum permissible distance: 95 mm N.B: The measurement must be made with the vernier calliper perfectly aligned with the direction of movement of the lever. NOTE: Take a photo of the position of the left hand lever when pulled completely before the procedure, and attach to the service coupon. Photo 1 Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 7 Repeat the procedure for the front brake lever (right lever) to measure the distance between the outer edge of the handgrip and the end of the lever when the lever is pulled completely. Minimum permissible distance: 95 mm NOTE: Take a photo of the position of the right-hand lever when pulled completely before the procedure, and attach to the service coupon. Photo 2 If possible, pull the two levers of the manual brake master cylinders forcefully at the same time. While holding the levers, check the travel of the combined braking system pedal. N.B: To ensure accurate test results, the pressure in the combined braking system circuit must not exceed the pressure values in the manual braking circuits to the levers. With an efficient pedal, the perceived actuation stroke will essentially be that relating to the recovery of mechanical play and a very short stroke of the piston. This means that the hydraulic compression of the pedal will be barely noticeable. NOTE: Take a photo of the position of the combined braking system pedal when pressed completely before the procedure, and attach to the service coupon. The photos for the preliminary checks described above were taken on a vehicle in proper working order. Photo 3 Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 8 Brake fluid replacement- Coupon 1 Remove the windscreen, removing the 4 fastener screws with the relative spacers. Remove the 4 fastener screws and the protective grille of the radiator. Remove the Y-shaped cover, detach the respective fastener lugs. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 9 Remove the 2 fastener screws and the lower cover of the windscreen mount. Open the glove box and unscrew the 2 fastener screws indicated. Remove the 2 front fastener screws of the windscreen mount complete with the relative washers. Remove the windscreen mount, removing the remaining 4 fastener screws with the relative shaped spacers. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 10 Remove the fastener screw and remove the right hand centre access panel. Remove the silencer guard, unscrewing and removing the 2 fastener screws with the relative metal flange rings. Loosen the screw of the metal clamp fastening the silencer to the exhaust pipe. Loosen the check nut of the silencer fastener system. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 11 Remove the fastener screw of the bracket. Remove the pin and remove the retainer bracket. Remove the mounting screw of the silencer with the relative washers, and detach and remove the silencer from the exhaust pipe. Remove the split pin and the relative cap. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 12 Engage the parking brake and remove the nut with the spacer. Remove the lower fastener bolt of the shock absorber. Remove the upper fastener bolt of the shock absorber. Remove the right hand shock absorber with the 4 spacers. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 13 Remove the screw with the washer. Remove the plastic guard panel, unscrewing the remaining 2 upper screws. Remove the speed sensor, unscrewing the 2 fastener screws. Remove the second fastener screw of the stand. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 14 Remove the 2 fastener nuts of the carrier arm. Lift the mudguard and detach and remove the carrier arm. Remove the rear wheel, unscrewing and removing the 5 fastener screws with the relative washers. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 15 Rear brake fluid replacement Connect the container for collecting fluid to the rear calliper bleed nipple. Remove the 2 screws and the lid of the left front reservoir complete with gasket. Operate the rear brake lever repeatedly. Keep the master cylinder under pressure. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 16 Open the bleed nipple of the rear calliper, discharging the fluid under pressure. Tighten the bleed nipple. Operate the master cylinder and repeat the bleeding sequence, draining the original brake fluid. Keep an eye on the brake fluid level in the reservoir to avoid the intake of air. Continue filling the rear brake circuit until approximately 120 cc has been drained into the collector container. Fill the rear master cylinder reservoir to the max. level. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 17 Fit the cover of the rear reservoir. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 18 Front brake fluid replacement Open the reservoir of the front master cylinder (right side reservoir) Change the brake fluid in the left front caliper circuit. Refill the right master cylinder reservoir, draining the used fluid under pressure from the bleed nipple of the left front calliper. N.B: Do not operate the lever of the master cylinder repeatedly while the bleed nipple is open. Continue filling the left front brake circuit until approximately 120 cc has been drained into the collector container. N.B: The photo illustrates the position of the steering where the reservoir of the front master cylinder offers the best filling conditions. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 19 Change the brake fluid in the right front caliper circuit. Refill the right master cylinder reservoir, draining the used fluid under pressure from the bleed nipple of the right hand front calliper. N.B: Do not operate the lever of the master cylinder repeatedly while the bleed nipple is open. Continue filling the right hand front brake circuit until approximately 120 cc has been drained into the collector container. N.B: The photo illustrates the position of the steering where the reservoir of the front master cylinder offers the best filling conditions. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 20 Combined/Pedal braking system fluid replacement Remove the fastener screw of the combined braking system master cylinder reservoir and top up to the max. level. Pull the two brake levers forcefully and hold to pressurise the manual brake master cylinders. At the same time, press the combined braking system master cylinder pedal. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 21 Then, bleed the front servo pump. Replace the brake fluid. Fill the combined braking system master cylinder reservoir, adding 4 times the volume of new fluid necessary to fill the reservoir system to flush the system, draining the fluid contained in the circuit under pressure from the bleed nipple of the front brake servo pump. N.B: Do not operate the pedal repeatedly while the bleed nipple is open. Refit the rear wheel with the 5 screws and the relative washers. Tighten the screws to a torque of 20-25 Nm. Continue with the reassembly of the carrier arm, paying attention to the correct application of all the tightening torques. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 22 Pay attention to the correct positioning of the gasket and to the correct fastening of the slip joint clamp screw. Tightening torque 16÷18 Nm. N.B: Lack of torque leads to sealing problems. Excessive torque blocks the joint with abnormal stresses on the exhaust system. Refit the remaining bodywork components. Once the operations are completed, the vehicle must be kept in the workshop for 24 hours without moving it or operating the brake levers or pedals. At the end of the 24 hours, the checks (Tests) already performed at the beginning of this procedure must be repeated, in order to document the outcome of the test and then attach the photos to the check coupon: TEST – Final checks 1. Take a photo illustrating the travel measured for the RH lever with the vernier calliper (minimum permissible value 95 mm), and attach to the service coupon. 2. Take a photo illustrating the travel measured for the LH lever with the vernier calliper (minimum permissible value 95 mm), and attach to the service coupon. 3. Carry out the pedal firmness test, taking a photo of the values measured and attaching it the service coupon. If the required values of not attained, technical support must be contacted to determine the cause of the problem. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 23 Brake fluid bleeding and complete fluid replacement – Coupon 2 Remove the windscreen, removing the 4 fastener screws with the relative spacers. Remove the 4 fastener screws and the protective grille of the radiator. Remove the front fastener screw of the 2 mudguard. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 24 Remove the 2 fastener screws of the front cover, situated inside the wheel housings. Remove the 2 upper screws fastening the front cover. Remove the front cover, unscrewing the 2 Torx screws. Remove the 2 upper screws fastening the bodywork mount. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 25 Remove the bodywork mount, unscrewing the remaining 2 Torx screws. Remove the rear fastener screw of both mudguards. Remove the upper fastener screw of both mudguards. Remove both front mudguards, pushing towards the front of the vehicle to detach all the fastener lugs. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 26 Remove the Y-shaped cover, detach the respective fastener lugs. Remove the 2 fastener screws and the lower cover of the windscreen mount. Open the glove box and unscrew the 2 fastener screws indicated. Remove the 2 front fastener screws of the windscreen mount complete with the relative washers. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 27 Remove the windscreen mount, removing the remaining 4 fastener screws with the relative shaped spacers. Remove the 2 mounting brackets, unscrewing the 4 fastener screws and removing the screws together with the relative washers. Disconnect the headlamp unit connector, releasing the safety lock clip. Remove the front headlamp unit, unscrewing the 4 fastener screws. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 28 Disconnect the 2 connectors of the front turn indicators. Remove the 2 lower fastener screws of the front leg shield. Remove the 2 upper fastener screws of the leg shield. Remove the front leg shield, unscrewing the remaining 4 fastener screws. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 29 Remove the rear view mirrors, unscrewing and removing the fastener nuts with the relative washers. Remove the centre cover panel of the handlebar carefully, lifting it up from the rear. Remove the fastener screws and disconnect and remove the handlebar switchgear sets. Remove the fastener screws of the handlebar cover, situated in the space under the handlebar switchgear sets Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 30 Remove the 3 fastener screws of the handlebar cover, situated in the space under the centre cover panel Remove the upper handlebar cover, disengaging the 4 fastener tabs. Disconnect the connector of the ambient temperature sensor. Remove the lower handlebar cover, loosening the 4 fastener screws. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 31 Remove the dashboard trim panel, unscrewing the 2 fastener screws. Remove the 2 fastener screws of the button panel. Release the 2 clips and disconnect the button panel, disconnecting the 4 electrical connectors. Remove the cover of the bag holder hook, unscrewing the 2 fastener screws. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 32 Remove the centre fastener screw of the cover panel. Remove the cover panel with the knee pads, unscrewing the 4 screws situated inside the suspension compartment. Remove the fastener screw of the expansion tank cap access cover. Unscrew the expansion tank cap. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 33 Remove and remove the fastener screw of the expansion tank with the relative washers. Release the fastener clip of the reverse switch cable. Remove the 2 rear fastener screws of the dashboard. Using a pair of circlip pliers, turn the bezel of the ignition switch anticlockwise to align the word ‘ON’ with the key slot. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 34 Remove the bezel of the ignition switch complete with metal ring. Release the lock tab and disconnect the power connector of the USB port. Release the lock tab and disconnect the flying lead connector of the dashboard connector. Release the lock tab and disconnect the dashboard connector. Remove the complete dashboard, turning it towards the right hand side of the vehicle. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 35 Remove the 3 fastener screws and the battery compartment cover. Remove the 2 screws fastening the saddle support system. Remove the fastener screw and the cover of the internal saddle sensor. Disconnect the sensor connector. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 36 Remove the seat, undoing the 2 fixing screws. Remove the grab handle cover, unscrewing and removing the 4 fastener screws with the relative washers. Use a screwdriver to prise out the 2 blanking plugs of the holes for the 2 front fastener screws of the grab handle. Remove the rear grab handle, undoing and removing the 5 screws with the relative washers. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 37 Remove the 2 screws fastening the rear cover. Remove the rear cover, detaching the 2 spring clips. Remove the lower screws of both side covers. Remove the upper screws of both side covers. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 38 Remove the central screws of the side covers. Remove the rear screws of both flanks. On both flanks, remove the 2 screws near the passenger footpegs. Remove the 2 screws fastening the centre cover, near the saddle. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 39 Remove the side covers, detaching the 5 clips. Disconnect the electrical connector of each rear light unit. Remove the fastener screw and remove the right hand centre access panel. Remove the 2 fastener screws of the right hand centre cover. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 40 Remove the fastener screw and remove the left hand centre access panel. Remove the 2 fastener screws of the left hand centre cover. Remove the fuel cap. Remove the centre cover, detaching the cable for internal saddle sensor and the fuel filler cover release cable. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 41 Remove the fastener plate of the right hand floor mat, unscrewing the 3 fastener screws. Remove the right hand floor mat with the 6 spacers for the fastener plate screws. Remove the front fastener screw of the right hand footboard. Remove the lower fastener screw of the right hand footboard. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 42 Remove the rear M6 fastener screw of the right hand footboard. Remove the upper M6 fastener screw of the right hand footboard with the relative washer. Remove the right hand rear footrest platform, unscrewing the clamp screw and unscrewing and removing the 2 Torx screws complete with the relative washers. Remove the 4 screws connecting the underside of the footboard to the footboard. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 43 Lift up the gaiter and remove the upper part of the combined braking system pedal, unscrewing the 2 fastener screws. Separate the two parts of the footboard and remove from the vehicle. Check that the combined braking system pedal is against the retainer bracket of the brake light switch when the pedal itself in the rest position. Press the pedal to release the brake light switch and reveal the clearance created between the pedal arm and the actuator pin of the brake light switch This photo illustrates an incorrectly adjusted pedal with excessive clearance between the pedal arm and brake light switch( pushrod too short) It is more serious, however, if there is no clearance between pedal arm and brake light switch when the pedal is in the rest position. (pushrod too long) Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 44 This is extremely dangerous as it may cause the rear brake circuit to remain under pressure even when the pedal is released In case of an incorrectly adjusted combined braking system pedal, move the gaiter out of the way, loosen the check nut and adjust the length of the master cylinder actuator link with pliers. Adjust the length of the pushrod so that the brake light actuator pin has no remaining clearance with the pedal arm at a distance of approximately 0.40 mm from the end stop rest. ( adjust pushrod so pedal arm just touches the end of the switch pin , with the .40mm gauge installed between the switch retainer bracket and pedal arm) Remove the silencer guard, unscrewing and removing the 2 fastener screws with the relative metal flange rings. Loosen the screw of the metal clamp fastening the silencer to the exhaust pipe. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 45 Loosen the check nut of the silencer fastener system. Remove the fastener screw of the bracket. Remove the pin and remove the retainer bracket. Remove the mounting screw of the silencer with the relative washers, and detach and remove the silencer from the exhaust pipe. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 46 Remove the split pin and the relative cap. Engage the parking brake and remove the nut with the spacer. Remove the lower fastener bolt of the shock absorber. Remove the upper fastener bolt of the shock absorber. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 47 Remove the right hand shock absorber with the 4 spacers. Remove the screw with the washer. Remove the plastic guard panel, unscrewing the remaining 2 upper screws. Remove the speed sensor, unscrewing the 2 fastener screws. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 48 Remove the second fastener screw of the stand. Remove the 2 fastener nuts of the carrier arm. Lift the mudguard and detach and remove the carrier arm. Remove the rear wheel, unscrewing and removing the 5 fastener screws with the relative washers. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 49 Remove the fastener screw of the air filter box, situated inside the vehicle. Remove the 2 remaining fastener screws of the air filter box. Lift the air filter box and support it adequately in a position allowing easier access to the fasteners of the brake calliper mounting bracket. Use a screwdriver to straighten the anti-rotation tabs of the fastener screws of the calliper mounting bracket. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 50 Remove the 2 fastener screws complete with antirotation devices. Remove the fastener screw of the pipe retainer bracket. Detach the callipers from the disc and place them in the position shown in the photo. Pull the rear brake lever repeatedly to bring the brake pads into contact with each other. N.B: This procedure cannot be carried out with very worn pads. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 51 Rear system bleeding Connect the container for collecting fluid to the rear calliper bleed nipple. Cut the cable tie fastening the wiring harness in the zone next to left hand master cylinder handlebar clamp. Loosen the left hand master cylinder handlebar clamp and adjust provisionally to bring the brake fluid reservoir as close as possible to the horizontal position. Remove the 2 screws and the lid of the reservoir complete with gasket. Top up the brake fluid level in the reservoir if necessary. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 52 Pull the rear brake lever repeatedly to generate pressure in the circuit. Stop pulling the brake lever once the master cylinder is pressurised or if the lever reaches the handgrip. Open the bleed nipple of the rear calliper and check the escaping fluid for air bubbles. Tighten the bleed nipple. N.B: Hold the calliper in the position shown to keep the bleed nipple at the top and expel air trapped air correctly. Pull the lever to operate the master cylinder and repeat the bleed sequence while observing the fluid drained from the calliper bleed nipple to check for air bubbles. Keep an eye of the fluid level in the reservoir and top up whenever necessary so that it does not drop below the minimum level. Once the fluid drained contains no more air bubbles, separate the pads with a circlip pliers (Beta 1458) or an equivalent tool. N.B: Make sure that there is enough space in the reservoir to receive the volume of fluid sent back from the calliper. For the best results, separate the pads in one quick movement. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 53 Operate the rear brake master cylinder slowly to bring the pads back into contact with each other. Separate the pads again in one, quick and firm movement. Provisionally fit the callipers onto the rear disc. Operate the rear master cylinder to set take up the clearance between the pads and the disc. Fill the rear master cylinder reservoir to the max. level. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 54 Fit the lid of the rear master cylinder reservoir, wiping off any spilt brake fluid. N.B: This procedure ensures that the reservoir is filled to the optimum level. Disconnect the connectors of the brake switch. Remove the 2 screws and the handlebar clamp Ubolt. Hold the rear brake master cylinder in a vertical position. Pull the brake lever repeatedly while tilting the master cylinder slightly away from the vertical in all directions. Continue until there is the available travel of the lever reduces perceptibly. N.B: Pull the lever completely, starting each time from the rest position. Refit the rear master cylinder onto the handlebar, making sure that the handlebar clamp U-bolt is fitted the right way around and that the clamp itself is adjusted correctly. The handlebar clamp U-bolt can only fit in one position onto the upper part of the clamp, and the adjustment of the respective fastener screws affects the inclination of the master cylinder unit and the lever relative to the handlebar. The mount of the master cylinder must be parallel with the handlebar clamp U-bolt. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 55 Manually check the effective travel of the rear brake lever. Connect the wires to the brake light switch. Pull the rear brake lever and hold in position by fitting the O-ring, p/n 006731, onto the lever and handgrip as shown in the photo. Hold the fixed jaw of the vernier calliper against the handgrip as shown in the photo. N.B: To show the position of the vernier calliper more clearly, this photo has been taken with the counterweight removed. Measure the distance between the outer edge of the handgrip and the end of the brake lever. The brake is adjusted correctly if the value measured is equal to or over 95 mm. N.B: The measurement must be made with the vernier calliper perfectly aligned with the direction of movement of the lever. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 56 Front system bleeding Support the vehicle adequately and remove both front wheels, removing the 10 fastener screws and the relative washers. Cut the cable tie fastening the wiring harness in the zone next to front brake master cylinder handlebar clamp (right front master). Adjust the fastener screws of the handlebar clamp U-bolt to bring the brake fluid reservoir as close as possible to the horizontal position. Open the lid of the reservoir and top up the fluid level if necessary. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 57 Connect the brake fluid collector container to the front bleed nipple for the left hand circuit. Pump the lever a few times and check for air bubbles in the drained fluid. Top up the reservoir and bleed using the bottom nipple for the right hand circuit. Remove the upper fasteners of both front callipers and restrain the callipers temporarily in a vertical position. N.B: Move the brake disc as necessary to attain this position. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 58 Connect the brake fluid collector container to left hand calliper. Pump the lever a few times and check for air bubbles in the drained fluid. Repeat the procedure for the right hand calliper. Remove the fastener screw of the left hand calliper pipe retainer clamp. Remove the lower fastener screw of the left hand calliper and separate the pads, pushing the pistons to their respective end stops. Secure the pads using the shim specific tool 005127Y (alternatively a spacer of 7 mm). Hold the left hand calliper in a vertical position and pressurise the master cylinder. While maintaining the pressure, bleed the calliper while holding it in the position shown. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 59 Refit the left hand calliper, tightening the 2 screws to a torque of 22 – 27 Nm. Fit the pipe retainer clamp and fasten with the relative screw. Remove the fastener screw of the right hand calliper pipe retainer clamp. Remove the lower fastener screw of the right hand calliper and separate the pads, pushing the pistons to their respective end stops. Secure the pads using the shim specific tool 005127Y (alternatively a spacer of 7 mm). Hold the right hand calliper in a vertical position and pressurise the master cylinder. While maintaining the pressure, bleed the calliper while holding it in the position shown. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 60 Refit the right hand calliper, tightening the 2 screws to a torque of 22 – 27 Nm. Fit the pipe retainer clamp and fasten with the relative screw. For greater safety, repeat the step to check if the fluid drained from the upper bleed nipple of the left hand circuit contains air bubbles. Repeat the step to check if the fluid drained from the upper bleed nipple of the right hand circuit contains air bubbles. Top the fluid in the right hand reservoir up to the max. level. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 61 Close the lid of the reservoir, wiping off any spilt fluid. N.B: This procedure ensures that the reservoir is filled to the optimum level. Disconnect the connectors of the brake light switch and loosen the fastener nut of the throttle cable sheath. Remove the 2 screws and the handlebar clamp Ubolt of the right hand master cylinder. Rotate the right hand master cylinder into a vertical position. Pull the brake lever repeatedly while tilting the master cylinder slightly away from the vertical in all directions. Continue until there is the available travel of the lever reduces perceptibly. N.B: Pull the lever completely, starting each time from the rest position. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 62 Refit the front master cylinder onto the handlebar, making sure that the handlebar clamp U-bolt is fitted the right way around and that the clamp itself is adjusted correctly. The handlebar clamp U-bolt can only fit in one position onto the upper part of the clamp, and the adjustment of the respective fastener screws affects the inclination of the master cylinder unit and the lever relative to the handlebar. The mount of the master cylinder must be parallel with the handlebar clamp U-bolt. Manually check the effective travel of the front brake lever. Pull the front brake lever and hold in position by fitting the O-ring, p/n 006731, onto the lever and handgrip as shown in the photo. Hold the fixed jaw of the vernier calliper against the handgrip as shown in the photo. N.B: To show the position of the vernier calliper more clearly, this photo has been taken with the counterweight removed. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 63 Measure the distance between the outer edge of the handgrip and the end of the brake lever. The brake is adjusted correctly if the value measured is equal to or over 95 mm. N.B: The measurement must be made with the vernier calliper perfectly aligned with the direction of movement of the lever. Connect the brake light switch and tighten the fastener nut of the throttle cable. Connect PADS to the vehicle’s diagnostic socket. Select ABS diagnosis. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 64 Select adjustments. ABS Rear circuit bleeding • Select Rear bleeding Before accessing the activation of the modulator, the message intended to prevent any unaware use of the modulator bleeding phase is displayed. The modulator activities must be linked to the brake lever command activations. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 65 Command the activation of the valves of the rear channel. When the electric pump is activated and the brake control is soft, perform complete activations of the master cylinder control lever. When the valves block the delivery of the manual pump, keep the system under pressure. When the pressure of the electric pump prevails over the manual pump, maintain the pressure by reducing the stroke of the lever as necessary. At the end of the test, the electric pump stops and when everything is efficient, the manual pump control returns to normal operation. For added safety, repeat the bleeding procedure a few times. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 66 If the ABS modulator had had air inside, this would have been transferred into the lines between the ABS pump and the caliper. In this case, if necessary, repeat the bleeding of the rear line starting from the removal of the rear calliper from the disc, up to the bleeding of the vertical axis master cylinder. ABS – front circuit bleeding The front brake master cylinder feeds the ABS modulator which in turn feeds the front left and right callipers via dedicated lines. Activate the valves of each front channel (left and right channels) using PADS The behavior of the brake lever during the activation of the front channels is similar to the rear channel, but with less evident effects. If the ABS modulator had air inside, this would have transferred into the lines between the ABS unit and the front callipers, restore them by bleeding from the fittings of the upper branches. Remove the right hand footboard, unscrewing the 4 fastener screws. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 67 Pedal circuit bleeding Remove the connector of the brake light switch and the 3 fastener screws of the combined braking system master cylinder bracket. Hold the combined braking system master cylinder in a vertical position so that the pedal can be operated manually. Connect the fluid collector container to the bleed nipple of the front brake servo pump and pump the pedal a few times while checking for air bubbles in the drained fluid. Refit the bracket of the combined braking system master cylinder, tightening the 3 screws to a torque of 20 Nm. Connect the wires to the brake light switch. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 68 Remove the fastener screw of the combined braking system master cylinder reservoir and top up to the max. level. Pull the two brake levers forcefully and hold to pressurise the manual brake master cylinders. Press the combined braking system master cylinder pedal. Bleed the front brake servo pump until the fluid drained contains no more air bubbles. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 69 Once the pedal circuit has been bled completely, carry out the procedure to Replace all the brake fluid. Fill the combined braking system master cylinder reservoir, adding 4 times the volume of new fluid necessary to fill the reservoir system to flush the system, draining the fluid contained in the circuit under pressure from the bleed nipple of the front brake servo pump. N.B: Do not operate the pedal repeatedly while the bleed nipple is open. Replacing the brake fluid in the Rear caliper circuit. Refill the left hand master cylinder reservoir, draining the used fluid under pressure from the bleed nipple of the rear calliper. N.B: Do not operate the lever of the master cylinder repeatedly while the bleed nipple is open. Continue filling the rear brake circuit until approximately 120 cc has been drained into the collector container. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 70 Replacing the brake fluid in the left front caliper circuit. Refill the right hand master cylinder reservoir, draining the used fluid under pressure from the bleed nipple of the left hand front calliper. N.B: Do not operate the lever of the master cylinder repeatedly while the bleed nipple is open. Continue filling the front brake circuit until approximately 120 cc has been drained from the left front caliper into the collector container. Replacing the brake fluid in the right front caliper circuit. Refill the right hand master cylinder reservoir, draining the used fluid under pressure from the bleed nipple of the right hand front calliper. N.B: Do not operate the lever of the master cylinder repeatedly while the bleed nipple is open. Continue filling the right front brake circuit until approximately 120 cc has been drained from the right front caliper into the collector container. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 71 After bleeding the braking circuits and changing the brake fluid, reassemble the parts removed from the vehicle by following the steps for removal in reverse order. After reassembly, the vehicle must be kept in the service centre without moving it or operating the brake levers or pedals for 24 hours. At the end of the 24 hours, the lever checks already performed at the beginning of this procedure must be repeated, in order to document the outcome of the test and then attach the photos to the check coupon: TEST – Final checks 4. Take a photo illustrating the travel measured for the RH lever with the vernier calliper (minimum permissible value 95 mm), and attach to the service coupon. 5. Take a photo illustrating the travel measured for the LH lever with the vernier calliper (minimum permissible value 95 mm), and attach to the service coupon. 6. Carry out the pedal firmness test, taking a photo of the values measured and attaching it the service coupon. If the required values of not attained, technical support must be contacted to determine the cause of the problem. Note that six (6) photos in total must be attached to the service coupon relative to the recall campaign: specifically, photos of the measurements of the two levers and of the measurement to determine pedal firmness taken before the procedure and at the end of the procedure after the 24 hour wait period Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 72 Copy of Customer Letter and Tread Act information Dear Valued Customer: IMPORTANT SAFETY RECALL Regarding your: 2020 or 2021 MP3 500 THIS NOTICE APPLIES TO YOUR VEHICLE VIN:__________________________________ This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. The NHTSA identification number of this recall is 22V-217 REASON FOR THIS RECALL Piaggio Group Americas (PGA) has decided that a defect, which relates to motor vehicle safety, exists in a specific range of Vespa scooters as noted below • Select 2020 MP3 500 • Select 2021 MP3 500 In the affected range, PGA has identified the possibility of a non-conformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever/pedal. This situation can cause reduced braking and stopping ability and can lead to a loss of control or a crash, increasing the risk of injury. According to vehicle registration records; you are the owner of a vehicle that falls within this affected VIN range. WHAT WE WILL DO To address this situation, Piaggio Group Americas will conduct a recall of the aforementioned models within the affected VIN range. Piaggio Group Americas, through the qualified dealer network will perform a complete brake system flush. This repair campaign will eliminate any potential safety risk. The work required by this recall may be completed by your qualified Piaggio/Vespa dealer at no charge to you for the required parts and labor. WHAT YOU SHOULD DO With the receipt of this letter, please contact your authorized Piaggio/Vespa dealership as soon as possible to schedule an appointment to have the recall completed. Instructions for this recall have been sent to your dealer. Your dealer is best equipped to provide service to ensure that your vehicle is corrected as promptly as possible. Please ensure that these instructions are followed by anyone that uses your vehicle. Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 73 If you take your vehicle to your dealer on the agreed service date and they do not remedy this condition on that date or within three (3) days, we recommend you contact our Customer Care helpline at: 212- 380-4400. After contacting your dealer and the above number, if you are still not able to have the safety defect remedied without charge and within a reasonable time, you may wish to write to: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Our Customer Care helpline (212-380-4400) is available to provide you with further information and any support you may need. Should the vehicle not be in your possession or available to you, please provide the name and address of the purchaser by contacting our Customer Care department or by filling out the form on the following page. This form can be faxed to 212-380-4459. If you previously had the work required of this recall completed at your own expense, please refer to the attached letter (Tread Act Customer Reimbursement Plan) describing the criteria and procedure to request reimbursement. Federal law requires any lessor who receives a notification of a determination of a safety-related defect or noncompliance pertaining to any leased motor vehicle shall send the notice to the lessee within 10 days. We are sorry to cause this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products. Thank you for your prompt attention to this important matter. Very truly yours, Piaggio Group Americas Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 74 2020 MP3 500 & 2021 MP3 500—Brake bleeding campaign VIN # (Full 17 digits): _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ New Owner Details (if not in your possession) First Name: _______________________ Last Name: ________________________________ Street Address: _______________________________________________________________ City: _____________________________ State: __________________ Zip: _____________ Date of transfer: _____________________ Vehicle not available for the following reasons: Scrapped: ______ Stolen: ______ Vehicle not available for other reasons: (Please specify) __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ Print Name: ______________________________________ Signature: ________________________________________Date: _____________________________ Piaggio Group Americas- 860 Washington St. 9th Floor, New York, NY 10014 Ph: 212-380-4400 Fax: 212-380-4459 Page | 75 TREAD ACT CUSTOMER REIMBURSEMENT PLAN Customer Reimbursement for Safety Related Recall Repairs Effective with Safety related recalls initiated as of January 15, 2003 Piaggio Group Americas (PGA) is initiating a safety related recall for a select range of 2020 MP3 500 and 2021 MP3 500 models that includes your VIN number. If you have previously paid to have the repair or update as described in the recall documentation completed, you are entitled to be reimbursed for that expense. You are encouraged to request reimbursement from your respective Piaggio/Vespa dealer. Alternatively, you may submit the request for reimbursement to the following address: Customer Care Piaggio Group Americas 860 Washington St, 9th Floor New York, NY 10014 In every case: • Repair expenses pertaining to the subject of the safety recall are reimbursable, not consequential expenses such as towing, rental, accommodations, damage repairs, etc. • Expenses from repair facilities outside of the PGA authorized dealer network will be considered; however, the repair procedure must meet PGA’s standards. • When reimbursing for parts, the Manufacturers Suggested Retail Price (MSRP) will be considered as the guideline for reasonable charges. • Expenses for repairs performed more than 10 days after the date of the last customer notification letter sent by PGA are not eligible for reimbursement. • Taxes and hazardous waste disposal, where previously paid, are eligible for reimbursement. The authorized Piaggio/Vespa dealer will request a copy of the customer notification letter, as well as a copy of the owner’s previously paid invoice, and then inspect the vehicle (if still in the possession of the invoice holder) to determine the scope and quality of the previous repair. Claims will be processed within 60 days of receipt. Best regards, Piaggio Group Americas
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PIAGGIO GROUP AMERICAS Date: April 21, 2022 Dear IMPORTANT SAFETY RECALL NHTSA Number: 22V-217 Regarding your: 2020 2021 MP3 500 THIS NOTICE APPLIES TO YOUR VEHICLE, VIN: ZAPTA This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. REASON FOR THIS RECALL Piaggio Group Americas has decided that a defect, which relates to motor vehicle safety, exists in certain Piaggio scooters as noted below • 2020 MP3 500 • 2021 MP3 500 In the affected range, the zinc plating surface treatment on the brake hose terminal fittings can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever/pedal. This situation can cause reduced braking and stopping ability and can lead to a loss of control or a crash, increasing the risk of injury. According to vehicle registration records, you are the owner of a vehicle that falls within this affected VIN range. WHAT WE WILL DO Piaggio Group Americas, through the qualified dealer network, will perform a complete brake system flush. The work required by this recall may be completed by your qualified PiaggioNespa dealer at no charge to you for the required parts and labor. Pllgglo GroupAmertc:aa A Piogglo Group Company 860 Washington Street, 9th Floor New Yori<, NY 10014 T:212.380.4400 F: 212.380.4459 ® PIAGGIO’ MO-T-O-GUZZr PIAGGIO GROUP AMERICAS TREAD ACT CUSTOMER REIMBURSEMENT PLAN Customer Reimbursement for Safety Related Recall Repairs Effective with Safety related recalls initiated as of January 15, 2003 Piaggio Group Americas is initiating a safety related recall for a select range of 2020 MP3 500 and 2021 MP3 500 models that includes your VIN number. If you have previously paid to have the repair or update as described in the recall documentation completed, you are entitled to be reimbursed for that expense. You are encouraged to request reimbursement from your respective PiaggioNespa dealer. Alternatively, you may submit the request for reimbursement to the following address: Customer Care Piaggio Group Americas 860 Washington Street, 9th Floor New York, NY 10014 In every case: • Repair expenses pertaining to the subject of the safety recall are reimbursable, not consequential expenses such as towing, rental, accommodations, damage repairs, etc. • Expenses from repair facilities outside of the Piaggio Group Americas authorized dealer network will be considered; however, the repair procedure must meet Piaggio Group Americas ‘s standards. • When reimbursing for parts, the Manufacturers Suggested Retail Price (MSRP) will be considered as the guideline for reasonable charges. • Expenses for repairs performed more than 10 days after the date of the last customer notification letter sent by Piaggio Group Americas are not eligible for reimbursement. • Taxes and hazardous waste disposal, where previously paid, are eligible for reimbursement. The authorized PiaggioNespa dealer will request a copy of the customer notification letter, as well as a copy of the owner’s previously paid invoice, and then inspect the vehicle (if still in the possession of the invoice holder) to determine the scope and quality of the previous repair. Claims will be processed within 60 days of receipt. Plagglo Group America• A Plagglo Group Company 860 Woshlngton Street, 9th Floor New Yori<, NY 10014 T:212.380.4400 f: 212.380.4459 @J PIAGGIO’ apria’ MO-T-O-G-UZZr I PIAGGIO GROUP AMERICAS 2020 MP3 500 & 2021MP3500-Brake bleeding campaign VIN# (Fu/117 digits): ___ __ _ _ _ _ _ ______ _ New Owner Details {if not in your possession) First Name: ——— Last Name: ————- Street Address: — —- —— — ——– City: ———– State: _ ____ __ Zip: ____ _ Date of transfer: – – – —– Vehicle not available for the following reasons: Scrapped: _ _ Stolen: Vehicle not available for other reasons: (Please specify) Print Name: _____________ _ Signature: ____ _ __________ Date: ____ ___ _ __ _ PIIOolo o~p M\tfleaa A Plaggio Group Company 860 Washington Street, 9th Floor New Yoric, NY 10014 T:212.380.4400 F: 212.380.44S9 @) ..,._.. NOTOGUllr PIAGGIO’ I PIAGGIO GROUP AMERICAS WHAT YOU SHOULD DO With the receipt of this letter, please contact your authorized PiaggioNespa dealership as soon as possible to schedule an appointment to have the recall completed. Instructions for this recall have been sent to your dealer. Your dealer is best equipped to provide service to ensure that your vehicle is corrected as promptly as possible. Please ensure that these instructions are followed by anyone that uses your vehicle. If you take your vehicle to your dealer on the agreed service date and they do not remedy this condition on that date or within three (3) days, we recommend you contact our Customer Care helpline at: 212-380-4400. After contacting your dealer and the above number, if you are still not able to have the safety defect remedied without charge and within a reasonable time, you may wish to write to: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1- 800-424-9153); or go to http://www.safercar.gov. Our Customer Care helpline (212-380-4400) is available to provide you with further infonnation and any support you may need. Should the vehicle not be in your possession or available to you, please provide the name and address of the purchaser by contacting our Customer Care department or by filling out the form on the following page. This form can be faxed to 212-380- 4459. If you previously had the work required of this recall completed at your own expense, please refer to the attached letter (Tread Act Customer Reimbursement Plan) describing the criteria and procedure to request reimbursement. Federal law requires any lessor who receives a notification of a determination of a safety-related defect or noncompliance pertaining to any leased motor vehicle shall send the notice to the lessee within 1 o days. We are sorry to cause this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products. Thank you for your prompt attention to this important matter. Very truly yours, Piaggio Group Americas Plagglo Group AmtnCII A Plagglo Group Company 860 Washington Street, 9th Floor New York, NY 10014 T:212 .380 . ◄◄ 00 F: 2 1 2 . 380 .◄459 @) PIAGGIO’ apria’ -,,ttOTOOUZZr
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-217 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Piaggio Group Americas, Inc. Submission Date : APR 05, 2022 NHTSA Recall No. : 22V-217 Manufacturer Recall No. : PP2ZZQ2201 Manufacturer Information : Manufacturer Name : Piaggio Group Americas, Inc. Address : 257 Park Avenue South 4th Floor New York NY 10010 Company phone : 949-645-0030 Population : Number of potentially involved : 27 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Piaggio MP3 500 HPE Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of non-use. We have received warranty claims from our dealer network that the front and in some cases rear brake levers have extended play after a prolonged period of inactivity. Excessive play on brake levers can cause reduced braking efficiency consequently. Introduction of dehydrogenation (DH) treatment on mass production, also confirmed from the absence of warranties in the field. The vehicles that are not affected have brake pipes with DH treatment. Production Dates : JUL 10, 2020 – DEC 18, 2020 VIN Range 1 : Begin : ZAPTA10X5L5000143 End : ZAPTA10XXM5000172 ✔ Not sequential Description of Defect : Description of the Defect : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of stop. FMVSS 1 : 105 – Hydraulic and electric brake systems FMVSS 2 : 106 – Brake hoses Description of the Safety Risk : An increase in the brake lever/pedal travel required to decelerate the vehicle can cause reduced braking efficiency that could potentially cause loss of control or a crash. Description of the Cause : Non-conformity of the zinc plating surface treatment on the brake hose terminals. The hydrogen presents in the hose terminals is released as a bubble causing an Part 573 Safety Recall Report 22V-217 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 inefficiency on the brake system. Identification of Any Warning that can Occur : Excessive stroke in the brake levers/pedal with low pressure could be found after long periods of inactivity. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : J.JUAN S.A Address : Poligono Industrial Camí Ral Gava Foreign States 8850 Country : Spain Chronology : Warranty monitoring; from 05/25/2021 there have been new warranties about to excessive play in the brake levers/pedal after the vehicle has been sitting for an extended period. Part 573 Safety Recall Report 22V-217 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : REASON FOR THIS RECALL Piaggio has decided that a defect, which relates to motor vehicle safety, exists in a specific range of Piaggio scooters as noted below • 2020 MP3 500 HPE models • 2021 MP3 500 HPE models In the affected range, Piaggio has identified the possibility of a nonconformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever and pedal. This situation can cause limited braking and stopping ability and can lead to a loss of control or a crash. According to vehicle registration records, you are the owner of a vehicle that falls within this affected VIN range. WHAT WE WILL DO To address this situation, Piaggio will conduct a recall of the models within the affected VIN range. Piaggio, through the qualified dealer network will perform a complete brake system flush. This repair campaign will eliminate any potential safety risk. The work required by this recall may be completed by your qualified Piaggio/Vespa dealer at no charge to you for the required parts and labor. How Remedy Component Differs from Recalled Component : DH treatment on brake pipes. Identify How/When Recall Condition was Corrected in Production : Internal definite solution: DH treatment on brake pipes (from Jan-21) Recall Schedule : Description of Recall Schedule : We will post the technical bulletin for our dealers no later than 04/11/2022 and we will send the customer letters before or by 04/18/2022. Planned Dealer Notification Date : APR 11, 2022 – APR 11, 2022 Planned Owner Notification Date : APR 18, 2022 – APR 18, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-217 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Piaggio Group Americas, Inc. Submission Date : JUN 02, 2022 NHTSA Recall No. : 22V-217 Manufacturer Recall No. : PP2ZZQ2201 Manufacturer Information : Manufacturer Name : Piaggio Group Americas, Inc. Address : 257 Park Avenue South 4th Floor New York NY 10010 Company phone : 949-645-0030 Population : Number of potentially involved : 27 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Piaggio MP3 500 HPE Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of non-use. We have received warranty claims from our dealer network that the front and in some cases rear brake levers have extended play after a prolonged period of inactivity. Excessive play on brake levers can cause reduced braking efficiency consequently. Introduction of dehydrogenation (DH) treatment on mass production, also confirmed from the absence of warranties in the field. The vehicles that are not affected have brake pipes with DH treatment. Production Dates : JUL 10, 2020 – DEC 18, 2020 VIN Range 1 : Begin : ZAPTA10X5L5000143 End : ZAPTA10XXM5000172 ✔ Not sequential Description of Defect : Description of the Defect : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of stop. FMVSS 1 : 105 – Hydraulic and electric brake systems FMVSS 2 : 106 – Brake hoses Description of the Safety Risk : An increase in the brake lever/pedal travel required to decelerate the vehicle can cause reduced braking efficiency that could potentially cause loss of control or a crash. Description of the Cause : Non-conformity of the zinc plating surface treatment on the brake hose terminals. The hydrogen presents in the hose terminals is released as a bubble causing an Part 573 Safety Recall Report 22V-217 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 inefficiency on the brake system. Identification of Any Warning that can Occur : Excessive stroke in the brake levers/pedal with low pressure could be found after long periods of inactivity. Involved Components : Component Name 1 : Brake Pipe LH (rigid brake line) Component Description : Brake Pipe LH (rigid brake line) Component Part Number : 1C005727R Component Name 2 : Brake Pipe RH (rigid brake line) Component Description : Brake Pipe RH (rigid brake line) Component Part Number : 1C005728R Component Name 3 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005541 Component Name 4 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005538 Component Name 5 : Brake Pipe rear valve/ABS HECU Component Description : Brake Pipe rear valve/ABS HECU Component Part Number : 1C005729R Component Name 6 : Brake Pipe front valve/ABS HECU Component Description : Brake Pipe front valve/ABS HECU Component Part Number : 1C005730R Part 573 Safety Recall Report 22V-217 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 7 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005965 Component Name 8 : Bake Pipe Component Description : Bake Pipe Component Part Number : 1C005539 Component Name 9 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005731R Component Name 10 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005546 Component Name 11 : Brake Pipe (Pump RH/front valve) Component Description : Brake Pipe (Pump RH/front valve) Component Part Number : 1C005540 Component Name 12 : Brake Pipe (Pump LH/front valve) Component Description : Brake Pipe (Pump LH/front valve) Component Part Number : 1C005537 Supplier Identification : Component Manufacturer Name : J.JUAN S.A Address : Poligono Industrial Camí Ral Gava Foreign States 8850 Part 573 Safety Recall Report 22V-217 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Country : Spain Chronology : Details about chronology of principal events are listed here below: 05/25/2021 – Warranty analysis monitoring started 10/25/2021 – Piaggio & C. SpA After sales informs Product Quality about n°1 case relevant to safety ZAPTA210000009345 07/12/2021 – Gas analysis in SEA MARCONI (on dealer vehicle stock) Air extracted from brake lines and gas dissolved in brake fluid (H2 found) 12/15/2021 – Testing Hot Extraction (metodo Letomec) for hydrogen release analysis (from dealer stock) from the banjo (Piaggio Internal Laboratory), H2 not found, probably already released in brake fluid. 02/14/2022 – Gas analysis c/o SEA MARCONI (on vehicle ZAPTA210000009345) Air analysis from brake system and gas dissolved in the brake fluid analysis (H2 found) 03/11/2022 – Notification date to J.Juan (supplier) about the issue – Piaggio & C. S.p.A. notified supplier of the need to start a safety recall on network 03/29 /2022: P&C Spa notified network of start of Safety Recall Warranty monitoring; from 05/25/2021 there have been new warranties about to excessive play in the brake levers/pedal after the vehicle has been sitting for an extended period. 1268 warranty claims Worldwide between 05/08/2020 and 11/30/2020. 12,462 units affected Worldwide. 4 claims were entered in the USA. There were no reported cases of injury or death. Description of Remedy : Description of Remedy Program : REASON FOR THIS RECALL Piaggio has decided that a defect, which relates to motor vehicle safety, exists in a specific range of Piaggio scooters as noted below • 2020 MP3 500 HPE models • 2021 MP3 500 HPE models In the affected range, Piaggio has identified the possibility of a nonconformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever and pedal. This situation can cause limited braking and stopping ability and can lead to a loss of control or a crash. According to vehicle registration records, you are the owner of a vehicle that falls within this affected VIN range. WHAT WE WILL DO To address this situation, Piaggio will conduct a recall of the models within the affected VIN range. Piaggio, through the qualified dealer network will perform a complete brake system flush. This repair campaign will eliminate any potential safety risk. The work required by this recall may be completed by your qualified Piaggio/Vespa dealer at no charge to you for the required parts and labor. All vehicles affected by this recall were under warrantee so no refund will be provided. Part 573 Safety Recall Report 22V-217 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : DH treatment on brake pipes. Identify How/When Recall Condition was Corrected in Production : Internal definite solution: DH treatment on brake pipes (from Jan-21) Recall Schedule : Description of Recall Schedule : We will post the technical bulletin for our dealers no later than 04/11/2022 and we will send the customer letters before or by 04/18/2022. Planned Dealer Notification Date : APR 11, 2022 – APR 11, 2022 Planned Owner Notification Date : APR 18, 2022 – APR 18, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-217 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Piaggio Group Americas, Inc. Submission Date : MAY 16, 2022 NHTSA Recall No. : 22V-217 Manufacturer Recall No. : PP2ZZQ2201 Manufacturer Information : Manufacturer Name : Piaggio Group Americas, Inc. Address : 257 Park Avenue South 4th Floor New York NY 10010 Company phone : 949-645-0030 Population : Number of potentially involved : 27 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Piaggio MP3 500 HPE Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of non-use. We have received warranty claims from our dealer network that the front and in some cases rear brake levers have extended play after a prolonged period of inactivity. Excessive play on brake levers can cause reduced braking efficiency consequently. Introduction of dehydrogenation (DH) treatment on mass production, also confirmed from the absence of warranties in the field. The vehicles that are not affected have brake pipes with DH treatment. Production Dates : JUL 10, 2020 – DEC 18, 2020 VIN Range 1 : Begin : ZAPTA10X5L5000143 End : ZAPTA10XXM5000172 ✔ Not sequential Description of Defect : Description of the Defect : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of stop. FMVSS 1 : 105 – Hydraulic and electric brake systems FMVSS 2 : 106 – Brake hoses Description of the Safety Risk : An increase in the brake lever/pedal travel required to decelerate the vehicle can cause reduced braking efficiency that could potentially cause loss of control or a crash. Description of the Cause : Non-conformity of the zinc plating surface treatment on the brake hose terminals. The hydrogen presents in the hose terminals is released as a bubble causing an Part 573 Safety Recall Report 22V-217 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 inefficiency on the brake system. Identification of Any Warning that can Occur : Excessive stroke in the brake levers/pedal with low pressure could be found after long periods of inactivity. Involved Components : Component Name 1 : Brake Pipe LH (rigid brake line) Component Description : Brake Pipe LH (rigid brake line) Component Part Number : 1C005727R Component Name 2 : Brake Pipe RH (rigid brake line) Component Description : Brake Pipe RH (rigid brake line) Component Part Number : 1C005728R Component Name 3 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005541 Component Name 4 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005538 Component Name 5 : Brake Pipe rear valve/ABS HECU Component Description : Brake Pipe rear valve/ABS HECU Component Part Number : 1C005729R Component Name 6 : Brake Pipe front valve/ABS HECU Component Description : Brake Pipe front valve/ABS HECU Component Part Number : 1C005730R Part 573 Safety Recall Report 22V-217 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 7 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005965 Component Name 8 : Bake Pipe Component Description : Bake Pipe Component Part Number : 1C005539 Component Name 9 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005731R Component Name 10 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005546 Component Name 11 : Brake Pipe (Pump RH/front valve) Component Description : Brake Pipe (Pump RH/front valve) Component Part Number : 1C005540 Component Name 12 : Brake Pipe (Pump LH/front valve) Component Description : Brake Pipe (Pump LH/front valve) Component Part Number : 1C005537 Supplier Identification : Component Manufacturer Name : J.JUAN S.A Address : Poligono Industrial Camí Ral Gava Foreign States 8850 Part 573 Safety Recall Report 22V-217 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Country : Spain Chronology : Details about chronology of principal events are listed here below: 05/25/2021 – Warranty analysis monitoring started 10/25/2021 – Piaggio & C. SpA After sales informs Product Quality about n°1 case relevant to safety ZAPTA210000009345 07/12/2021 – Gas analysis in SEA MARCONI (on dealer vehicle stock) Air extracted from brake lines and gas dissolved in brake fluid (H2 found) 12/15/2021 – Testing Hot Extraction (metodo Letomec) for hydrogen release analysis (from dealer stock) from the banjo (Piaggio Internal Laboratory), H2 not found, probably already released in brake fluid. 02/14/2022 – Gas analysis c/o SEA MARCONI (on vehicle ZAPTA210000009345) Air analysis from brake system and gas dissolved in the brake fluid analysis (H2 found) 03/11/2022 – Notification date to J.Juan (supplier) about the issue – Piaggio & C. S.p.A. notified supplier of the need to start a safety recall on network 03/29 /2022: P&C Spa notified network of start of Safety Recall Warranty monitoring; from 05/25/2021 there have been new warranties about to excessive play in the brake levers/pedal after the vehicle has been sitting for an extended period. 1268 warranty claims Worldwide between 05/08/2020 and 11/30/2020. 12,462 units affected Worldwide. 4 claims were entered in the USA. There were no reported cases of injury or death. Description of Remedy : Description of Remedy Program : REASON FOR THIS RECALL Piaggio has decided that a defect, which relates to motor vehicle safety, exists in a specific range of Piaggio scooters as noted below • 2020 MP3 500 HPE models • 2021 MP3 500 HPE models In the affected range, Piaggio has identified the possibility of a nonconformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever and pedal. This situation can cause limited braking and stopping ability and can lead to a loss of control or a crash. According to vehicle registration records, you are the owner of a vehicle that falls within this affected VIN range. WHAT WE WILL DO To address this situation, Piaggio will conduct a recall of the models within the affected VIN range. Piaggio, through the qualified dealer network will perform a complete brake system flush. This repair campaign will eliminate any potential safety risk. The work required by this recall may be completed by your qualified Piaggio/Vespa dealer at no charge to you for the required parts and labor. Part 573 Safety Recall Report 22V-217 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : DH treatment on brake pipes. Identify How/When Recall Condition was Corrected in Production : Internal definite solution: DH treatment on brake pipes (from Jan-21) Recall Schedule : Description of Recall Schedule : We will post the technical bulletin for our dealers no later than 04/11/2022 and we will send the customer letters before or by 04/18/2022. Planned Dealer Notification Date : APR 11, 2022 – APR 11, 2022 Planned Owner Notification Date : APR 18, 2022 – APR 18, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-217 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Piaggio Group Americas, Inc. Submission Date : APR 01, 2022 NHTSA Recall No. : 22V-217 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Piaggio Group Americas, Inc. Address : 257 Park Avenue South 4th Floor New York NY 10010 Company phone : 949-645-0030 Population : Number of potentially involved : 27 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Piaggio MP3 500 HPE Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of stop. We have received warranty claims from our dealer network that the front and in some cases rear brake levers have extended play after a prolonged period of inactivity. Excessive play on brake levers can cause reduced braking efficiency consequently. Introduction of dehydrogenation (DH) treatment on mass production, also confirmed from the absence of warranties in the field. The vehicles that are not affected have brake pipes with DH treatment. Production Dates : JUL 10, 2020 – DEC 18, 2020 VIN Range 1 : Begin : ZAPTA10X5L5000143 End : ZAPTA10XXM5000172 ✔ Not sequential Description of Defect : Description of the Defect : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of stop. FMVSS 1 : 105 – Hydraulic and electric brake systems FMVSS 2 : 106 – Brake hoses Description of the Safety Risk : An increase in the brake lever/pedal travel required to decelerate the vehicle can cause reduced braking efficiency that could potentially cause loss of control or a crash. Description of the Cause : Non-conformity of the zinc plating surface treatment on the brake hose terminals. The hydrogen presents in the hose terminals is released as a bubble causing an Part 573 Safety Recall Report 22V-217 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 inefficiency on the brake system. Identification of Any Warning that can Occur : Excessive stroke in the brake levers/pedal with low pressure could be found after long periods of inactivity. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : J.JUAN S.A Address : Poligono Industrial Camí Ral Gava Foreign States 8850 Country : Spain Chronology : Warranty monitoring; from 05/25/2021 there have been new warranties about to excessive play in the brake levers/pedal after the vehicle has been sitting for an extended period. Part 573 Safety Recall Report 22V-217 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : REASON FOR THIS RECALL Piaggio has decided that a defect, which relates to motor vehicle safety, exists in a specific range of Piaggio scooters as noted below • 2020 MP3 500 HPE models • 2021 MP3 500 HPE models In the affected range, Piaggio has identified the possibility of a nonconformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever and pedal. This situation can cause limited braking and stopping ability and can lead to a loss of control or a crash. According to vehicle registration records, you are the owner of a vehicle that falls within this affected VIN range. WHAT WE WILL DO To address this situation, Piaggio will conduct a recall of the models within the affected VIN range. Piaggio, through the qualified dealer network will perform a complete brake system flush. This repair campaign will eliminate any potential safety risk. The work required by this recall may be completed by your qualified Piaggio/Vespa dealer at no charge to you for the required parts and labor. How Remedy Component Differs from Recalled Component : DH treatment on brake pipes. Identify How/When Recall Condition was Corrected in Production : Internal definite solution: DH treatment on brake pipes (from Jan-21) Recall Schedule : Description of Recall Schedule : We will post the technical bulletin for our dealers no later than 04/11/2022 and we will send the customer letters before or by 04/18/2022. Planned Dealer Notification Date : APR 11, 2022 – APR 11, 2022 Planned Owner Notification Date : APR 18, 2022 – APR 18, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-217 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Piaggio Group Americas, Inc. Submission Date : MAY 16, 2022 NHTSA Recall No. : 22V-217 Manufacturer Recall No. : PP2ZZQ2201 Manufacturer Information : Manufacturer Name : Piaggio Group Americas, Inc. Address : 257 Park Avenue South 4th Floor New York NY 10010 Company phone : 949-645-0030 Population : Number of potentially involved : 27 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Piaggio MP3 500 HPE Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of non-use. We have received warranty claims from our dealer network that the front and in some cases rear brake levers have extended play after a prolonged period of inactivity. Excessive play on brake levers can cause reduced braking efficiency consequently. Introduction of dehydrogenation (DH) treatment on mass production, also confirmed from the absence of warranties in the field. The vehicles that are not affected have brake pipes with DH treatment. Production Dates : JUL 10, 2020 – DEC 18, 2020 VIN Range 1 : Begin : ZAPTA10X5L5000143 End : ZAPTA10XXM5000172 ✔ Not sequential Description of Defect : Description of the Defect : Brake system inefficiency: the inefficiency is a consequence of an excessive stroke on brake levers/pedal, and it occurs after an extended period of stop. FMVSS 1 : 105 – Hydraulic and electric brake systems FMVSS 2 : 106 – Brake hoses Description of the Safety Risk : An increase in the brake lever/pedal travel required to decelerate the vehicle can cause reduced braking efficiency that could potentially cause loss of control or a crash. Description of the Cause : Non-conformity of the zinc plating surface treatment on the brake hose terminals. The hydrogen presents in the hose terminals is released as a bubble causing an Part 573 Safety Recall Report 22V-217 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 inefficiency on the brake system. Identification of Any Warning that can Occur : Excessive stroke in the brake levers/pedal with low pressure could be found after long periods of inactivity. Involved Components : Component Name 1 : Brake Pipe LH (rigid brake line) Component Description : Brake Pipe LH (rigid brake line) Component Part Number : 1C005727R Component Name 2 : Brake Pipe RH (rigid brake line) Component Description : Brake Pipe RH (rigid brake line) Component Part Number : 1C005728R Component Name 3 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005541 Component Name 4 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005538 Component Name 5 : Brake Pipe rear valve/ABS HECU Component Description : Brake Pipe rear valve/ABS HECU Component Part Number : 1C005729R Component Name 6 : Brake Pipe front valve/ABS HECU Component Description : Brake Pipe front valve/ABS HECU Component Part Number : 1C005730R Part 573 Safety Recall Report 22V-217 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 7 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005965 Component Name 8 : Bake Pipe Component Description : Bake Pipe Component Part Number : 1C005539 Component Name 9 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005731R Component Name 10 : Brake Pipe Component Description : Brake Pipe Component Part Number : 1C005546 Component Name 11 : Brake Pipe (Pump RH/front valve) Component Description : Brake Pipe (Pump RH/front valve) Component Part Number : 1C005540 Component Name 12 : Brake Pipe (Pump LH/front valve) Component Description : Brake Pipe (Pump LH/front valve) Component Part Number : 1C005537 Supplier Identification : Component Manufacturer Name : J.JUAN S.A Address : Poligono Industrial Camí Ral Gava Foreign States 8850 Part 573 Safety Recall Report 22V-217 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Country : Spain Chronology : Details about chronology of principal events are listed here below: 05/25/2021 – Warranty analysis monitoring started 10/25/2021 – Piaggio & C. SpA After sales informs Product Quality about n°1 case relevant to safety ZAPTA210000009345 07/12/2021 – Gas analysis in SEA MARCONI (on dealer vehicle stock) Air extracted from brake lines and gas dissolved in brake fluid (H2 found) 12/15/2021 – Testing Hot Extraction (metodo Letomec) for hydrogen release analysis (from dealer stock) from the banjo (Piaggio Internal Laboratory), H2 not found, probably already released in brake fluid. 02/14/2022 – Gas analysis c/o SEA MARCONI (on vehicle ZAPTA210000009345) Air analysis from brake system and gas dissolved in the brake fluid analysis (H2 found) 03/11/2022 – Notification date to J.Juan (supplier) about the issue – Piaggio & C. S.p.A. notified supplier of the need to start a safety recall on network 03/29 /2022: P&C Spa notified network of start of Safety Recall Warranty monitoring; from 05/25/2021 there have been new warranties about to excessive play in the brake levers/pedal after the vehicle has been sitting for an extended period. 1268 warranty claims Worldwide between 05/08/2020 and 11/30/2020. 12,462 units affected Worldwide. 4 claims were entered in the USA. There were no reported cases of injury or death. Description of Remedy : Description of Remedy Program : REASON FOR THIS RECALL Piaggio has decided that a defect, which relates to motor vehicle safety, exists in a specific range of Piaggio scooters as noted below • 2020 MP3 500 HPE models • 2021 MP3 500 HPE models In the affected range, Piaggio has identified the possibility of a nonconformity in the zinc plating surface treatment on the brake hose terminal fittings. This can cause a chemical reaction with the brake fluid itself and result in excessive travel from the front or rear brake lever and pedal. This situation can cause limited braking and stopping ability and can lead to a loss of control or a crash. According to vehicle registration records, you are the owner of a vehicle that falls within this affected VIN range. WHAT WE WILL DO To address this situation, Piaggio will conduct a recall of the models within the affected VIN range. Piaggio, through the qualified dealer network will perform a complete brake system flush. This repair campaign will eliminate any potential safety risk. The work required by this recall may be completed by your qualified Piaggio/Vespa dealer at no charge to you for the required parts and labor. Part 573 Safety Recall Report 22V-217 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : DH treatment on brake pipes. Identify How/When Recall Condition was Corrected in Production : Internal definite solution: DH treatment on brake pipes (from Jan-21) Recall Schedule : Description of Recall Schedule : We will post the technical bulletin for our dealers no later than 04/11/2022 and we will send the customer letters before or by 04/18/2022. Planned Dealer Notification Date : APR 11, 2022 – APR 11, 2022 Planned Owner Notification Date : APR 18, 2022 – APR 18, 2022 * NR – Not Reported
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