21959150 piaggio vespa gilera technical notes and workshop reference

7/22/2019 21959150 Piaggio Vespa Gilera Technical Notes and Workshop Reference

1/150i

Technical Notes and Workshop Reference.

This reference file has been built up over the last twelve years at Piaggio Ltd,To help with fault finding, assembly understanding and to clarify and expandon technical information contained in Service Station Manuals and partscatalogues supplied from Italy.

Most of these pages have been created to help answer often asked questions

I hope you find it useful.

We must ask you to consider this information as classified and therefore donot pass it on to anyone for any reason. I will be very disappointed if anythinghere turns up in the press or is quoted by customers. This information iscontinually being updated so please check the Piaggio Web site occasionallyto see if there are new or updated pages available.

If you find an amended page please destroy the original to avoid any

confusion.If you find any mistakes or you feel that the information could be betterpresented or improved please contact me at Piaggio Ltd, after sales.

DISCLAIMER.The information supplied here is accurate to the best of my knowledge but no guarantee isgiven as to the accuracy or suitability of this information. This information should always beused in conjunction with the relevant Piaggio manuals.Piaggio Ltd, reserves the right to amend or withdraw any information contained herewithout prior notification.

Piaggio Ltd, its employees and agents can not be held responsible for any inaccuracies oromissions in this information. Nor can they be held liable for any consequence of using thisinformation.

David ChampionPiaggio Ltd.

Technical Services Piaggio Ltd 1995 - 2006


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Technical / After sales contacts:

For any After Sales problems or questions, your first contact should be yourRegional After Sales Manager.

Benjy Straw - Technical Services Manager

020 7401 4323. [email protected]

Gene Dalzell - Regional after sales manager, Midlands and North07050 263036. [email protected]

Paul Balsillie - Regional after sales manager, Southern07050 263039. [email protected]

Mike Edwards - Warranty Management

020 7401 [email protected] for warranty authorisation: 020 7401 4321

David Champion - Technical information and advice020 7401 4325. [email protected]

Adam Roylance - Technical & After Sales Training07881 786478. [email protected]

Sebnem Umman - Spare Parts and Accessories Manager

020 7401 4329. [email protected]

Technical department Fax: 020 7401 4321

PLEASE MAKE SURE THAT YOU CONTACT THERIGHT PERSON


3/1503

Chapter 12 Stroke Auto engines

1. 50 / 80cc Charging early type2. 50 / 80cc Charging later type2a. NRG Charging & Gauges2b. NRG Power Instrument connection3. 50cc 2t Ignition4. 125 & 180cc Charging / Ignition5. 125 & 180cc Indicator circuit6. 125 / 180cc Ignition7. Runner 125 / 180cc 2t Fuses

8. Diesis 100 Ignition / Charging9. Purejet 50 Charging / Ignition10. Purejet 50 Indicators / Oil Check11. Fly 50 Charging / Carb heaterChapter 2

Leader / Quasar engines.1. B125 / 200 Ignition / Charging2. B125 Notes3. B125 Fuse explanation4. DNA 125 / 180 Ign. / Charging5. DNA 125 / 180 Switch Wiring6. ET4 125 Ignition / Charging7. Hexagon GTX Ignition / Charging8. Runner VX / VXR Ign./Charging9. X9 125 / 180 Ignition / Charging9a. X9 125 Indicator Wiring10. Zip 125 Ignition / Charging11. General notes12. Immobiliser System explanation13. Vespa GT 125 / 200 Ignition / Charging14. Vespa GT Fuses15. Skipper ST Ignition / Charging16. Skipper ST Fuses17. Skipper ST replacement instrument panel18. X9 250 Evo Ignition / Charging19. Fly 125 Ignition / Charging19a Fly 125 Instrument panel connections

20. X8 125 / 200 Ignition / Charging21. X8 Seat & Trunk Release22. X8 125 / 200 Fuse ExplanationChapter 3

4 Stroke (Non Leader) engines1. Coguar 125 Ignition / Charging2. ET4 (ZAPM04) Early Charging3. ET4 (ZAPM04) Late Charging4. ET4 (ZAPM04) Immobiliser Notes5. Hexagon GTX 250 Ign./ Charging6. Liberty 125(non Leader) Charging7. X9 250 Ignition / Charging8. X9 250 Notes

9. X9 250 Fuse Explanation10. 50cc 4 stroke Ignition / Charging11. 50cc 4 stroke Restriction NotesChapter 4

2 Stroke Manual engines.1. H@k / GSM Ignition / Charging2. H@K / GSM Notes3. H@K / GSM Wiring Diagram4. Vespa PX Ignition / Charging5. Vespa PX Start Permissive Circuit6. Vespa PX Indicator Circuit7. Vespa T5 Horn circuit8. Gilera RCR 50 Ignition / Charging

9. Gilera RCR Notes

Chapter 5Electrical General

1. X9 Range General Notes2. X9 Range. Under the front Panel3. Stator Coil Values - Quick Ref.4. Auto Choke Operation5. Fuel Gauge Circuit6. Digital Instrument Display Notes7. Remote Seat Release8. Setting the 2 button Digital ClockChapter 6

Fuel Systems1. Typhoon 80 / 125 Fuel System2. DNA Fuel Systems3. Hexagon (EXS1T) Fuel System4. Pumped Fuel Systems5. Vespa PX Fuel TapChapter 7

Mechanical1. Fitting Main Bearings. All 2t autos.2. Vespa PX Clutch assy.3. Piston & Small End Sizes4. Up Side Down Forks5. Spark Plug List6. Oil List7. Tyres / Wheels Piaggio7a. Tyres / Wheels Vespa8. Tyres / Wheels Gilera9. Keys Gilera10. Keys General11. De-Restriction Notes12. Chassis Number Location13. Quick Reference Guide14. Service Limit ListChapter 8

Injected Vehicles1. X9 500 ignition2. X9 500 lighting

3. X9 500 Centre Stand wiring4. Nexus 500 Instrument panel connectionsChapter 9

Tech Tips Collection1. Tech Tips 012. Tech Tips 023. Tech Tips 034. Tech Tips 045. Tech Tips 05


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Chapter 1

Electrical systems

Two Stroke Auto engines

1. 50 & 80cc Charging, early type

2. 50 & 80cc Charging, later type

2a. NRG / Zip Cat Charging & Gauges

2b. NRG Power instruments

3. 50 & 80cc Ignition

4. 125 & 180cc Charging / Ignition

5. 125 & 180cc Indicator circuits

6. 125 & 180cc Ignition

7. Runner 125 / 180 2t Fuses

8. Diesis 100 Ignition / Charging

9. Purejet 50 Charging / Ignition

10. Purejet 50 Indicators / Oil check

11. Fly 50 Charging / Carb heater


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Chapter 2

Electrical Systems

LEADER / QUASAR Engines

1. B125 / 200 Ignition / Charging

2. B125 Notes

3. B125 Fuse Explanation

4. DNA 125 / 180 Ign. / Charging

5. DNA 125 / 180 Switch Wiring

6. ET4 125 Ignition / Charging

7. Hexagon GTX Ign. / Charging

8. Runner VX / VXR Ign. / Charging

9. X9 125 / 180 Ignition / Charging

9a. X9 125 Indicator Wiring

10. Zip 125 Ignition / Charging

11. Leader General Notes

12. Immobiliser Notes

13. Vespa GT 125 / 200 Ignition / Charging

14. Vespa GT 125 / 200 Fuses

15. Skipper ST Ignition / Charging

16. Skipper ST Fuses

17. Skipper ST replacement instrument panel

18. X9 250 Evo Ignition / Charging19. Fly 125 Ignition / Charging

19a. Fly 125 Instrument connections.

20. X8 125 / 200 Ignition / Charging

21. X8 Seat & Trunk release

22. X8 125 Fuse explanation


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Chapter 3

Electrical Systems

Four Stroke (Non Leader)

1. Coguar 125 Ignition / Charging

2. ET4 (ZAPM04) Early Charging

3. ET4 (ZAPM04) Late Charging

4. ET4 (ZAPM04) Immobiliser Notes

5. Hexagon GTX 250 Ign./ Charging

6. Liberty 125 (non Leader) Charging

7. X9 250 Ignition / Charging

8. X9 250 Notes

9. X9 250 Fuse Explanation

10. 50cc 4 stroke Ignition / Charging

11. 50cc 4 stroke Restriction Notes


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Chapter 4

Electrical Systems

Two StrokeManual Engines

1. H@k / GSM Ignition / Charging

2. H@K / GSM Notes

3. H@K / GSM Wiring Diagram4. Vespa PX Ignition / Charging

5. Vespa PX Start Permissive Circuit

6. Vespa PX Indicator Circuit

7. Vespa T5 Horn circuit

8. Gilera RCR 50 Ignition / Charging

9. Gilera RCR 50 Notes


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Chapter 5

Electrical Systems

General

1. X9 Range General Notes

2. X9 Range. Under the front Panel

3. Stator Coil Values - Quick Ref.

4. Auto Choke Operation

5. Fuel Gauge Circuit

6. Digital Instrument Display Notes

7. Remote Seat Release


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Chapter 6

Fuel Systems

1. Typhoon 80 / 125 Fuel System

2. DNA Fuel Systems

3. Hexagon (EXS1T) Fuel System

4. Pumped Fuel Systems

5. Vespa PX Fuel Tap


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Chapter 7

Mechanical Systems

1. Fitting Main Bearings. All 2t autos.

2. Vespa PX Clutch assy.

3. Piston & Small End Sizes

4. Up Side Down Forks

5. Spark Plug List

6. Oil List

7. Tyres / Wheels Piaggio

7a. Tyres / Wheels Vespa

8. Tyres / Wheels Gilera

9. Keys Gilera10. Keys General

11. De-Restriction Notes

12. Chassis Number Location

13. Quick Reference Guide

14. Service Limit List


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Chapter 8

Injected Vehicles

1. X9 500 Charging wiring

2. X9 500 Ignition Wiring

3. X9 500 Centre Stand Wiring

4. Nexus 500 Instruments Wiring


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Chapter 9

Tech Tips

A collection of the

Tech Tips

previously published

on the Piaggio Portal

01

02

03

04

05


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30/09/2005Piaggio Ltd. 5 pin regulator

50 / 80cc 2T Charging (early vehicles)

BATTERY

12v

+

CHOKE UNIT

7.5 amp

FUSE

IGNITION

SWITCH

YELLOW

BLUE

GREY / BLUE

RED

GREY

DC SERVICES

Brake light

Horn

RED

BLUE

WHITE

* This diagram shows the early 50cc and 80cc two stroke wiring using a five pin connector on the rectifier /

regulator. Refer to the separate diagram for later circuit using an eight pin rectifier / regulator.* RECOGNISE THIS CIRCUIT: If the oil warning light comes on when the starter button is pressed.

* Two completely separate circuits for AC & DC.

AC is full wave and regulated

DC is half wave rectified and regulated

* If voltage at the B+terminal falls below 8v (approx) the DC rectifier / regulator will not function so there will be no

output from the alternator on the DC circuit.

* Separate indicator relay.

* The choke is supplied with 12v AC when the engine is running .

TESTS.

1. Grey / Blue to earth = 25-30v AC stator un-plugged and engine at 2000rpm.

2. Yellow to Blue = 26-30v AC stator and battery disconnected and engine at 2000 rpm.

3. Ammeter between red wire and battery positive = 1.5-2 amp with fully charged battery and engine at 2000 rpmNOTES.

Engine must be earthed to the chassis / battery. Lack of this connection will affect the AC circuit and starter motor

b t t th DC i it i iti i it

1

3

WHITE

BLACK

YELLOW

GREY/BLUE

RECTIFIER

&

REGULATOR

B+GAA

REGULATOR

2

GREY

AC

SERVICES

Head light

Tail light

Instruments

12v 4ah - 50cc

12v 5ah - 80cc

OFF

ON

RED


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50 / 80cc 2T charging

BATTERY

12v

+

CHOKE UNIT

7.5 amp

FUSE

AC

SERVICES

YELLOW

BLUE

GREY / BLUE

RED / WHITE

GREY

DC SERVICES

Brake light

Horn

RED

BLUE

WHITE

* This diagram shows the later 50cc and 80cc two stroke wiring using an eight pin connector on the rectifier /

regulator. Refer to the separate diagram for earlier circuit using a five pin rectifier / regulator.

* RECOGNISE THIS CIRCUIT: If the oil warning light comes on for 15 seconds when ignition is turned on.

* Two completely separate circuits for AC & DC.

* Eight pin rectifier / regulator incorporates the indicator relay and oil light check function.

* The choke is supplied with 12v AC when the engine is running .

TESTS.

1. Grey / Blue to earth = 25-30v AC stator un-plugged and engine at 2000rpm.

2. Yellow to Blue = 26-30v AC stator and battery disconnected and engine at 2000 rpm.

3. Ammeter between red wire and battery positive = 1.5-2 amp with fully charged battery and engine at 2000 rpm

4. Output to the indicator switch will be a 12v DC pulse with ignition on.

NOTES.

* Engine must be earthed to the chassis / battery. Lack of this connection will affect the AC circuit and starter motor but not the DC circuit or ignition circuit.

* Rectifier regulator pin 3 & 4 are both out puts from the timer so the wire could be connected to either pin

1

3

NOT

USED

see note

TO INDICATOR

SWITCH

Head light

Tail light

Instruments

WHITE

BLUE / BLACKBLACK

YELLOW

4

GREY/BLUE

4321 5 6 7 8

REGULATORRECTIFIER

&

REGULATOR

2

OIL

WARNING

LIGHT OIL TANKSENDER

IGNITION SWITCH

OFF

ON

OIL

LIGHT

TIMER


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GREY

DC SERVICES

Brake light

Horn

TO INDICATOR

SWITCH

BLUE/RED

BLUE / BLACK

BLACK

YELLOW

GR

EY/BLUE

CHOKE UNIT

AC

SERVICES

Head light

Tail light

Instruments

RECTIFIER

&

REGULATOR

4321 5 6 7 8

REGULATOR

TIMER

YELL

OW/

GREEN

WHITE/VIOLET

BLUE / RED


NRG (up to Mc3) & ZIP Cat. Charging & Guages

BATTERY

12v

+

7.5 amp

FUSE

IGNITION

SWITCH

YELLOW

BLUE

GREY / BLUE

RED / WHITE

RED

BLUE WHITE

OIL

WARNING

LIGHT

FUEL

WARNING

LIGHT

FUEL GUAGENRG only

FUELSENDER

UNITWH

ITE/VIOLET

WHITE

YELLOW/

GREEN

WHITE/GREEN

TESTS

1. Grey / Blue to earth = 25-30v AC

stator un-plugged and engine at 2000rpm.

2. Yellow to Blue = 26-30v AC

stator and battery disconnected and engine at

2000 rpm.

3. Ammeter between red wire and battery positive

= 1.5-2 amp with fully charged battery and

engine at 2000 rpm.

4. Output to the indicator switch will be a 12v DC

pulse with ignition on.

5. 12v DC for 15 seconds after ignition is turned on

With sender unplugged.

NOTES.

* Wires at terminals 3 & 4 could be reversed.

* Engine must be earthed to the chassis / battery. Lack of this connection will affect the AC circuit and

starter motor but not the DC circuit or ignition circuit.

1

4

32

OIL TANK

SENDER

BROWN

BLUE / REDWHITE

BROWN

WH

ITE/VIOLET

5

5

FUEL


16/1501-2b

- NRG POWER Digital Instrument Panel Connector-

Multi pin connector on rear of instrument panel

PIN WIRE COLOUR CONNECTION1 Blue / Red BlR Battery Positive. Permanent Live +

2 White B Ignition Switch. Switched Live +

3 Black N Earth -

4 Grey / Black GrN Wheel Speed Sender. Earth -

5 Red Rs Wheel Speed Sender. Power +

6 Light Blue Az Wheel Speed Sender. Signal

7 Yellow / Black GN Instrument lights

8 Black / Orange NAr ?

9 - - Not used

10 Green V Rev counter signal. 100> volts AC

*11* Yellow / Red GR Coolant temperature. Signal out to gauge, gauge earth's

12 White / Green BV Fuel gauge. 12v out to sender, sender earth's

13 Purple Vi High beam

14 White / Blue BBl Turn signal right. 12v in to bulb when right turn selected

15 Pink R Turn signal left. 12v in to bulb when left turn selected

16 White / Purple BVi Low two stoke oil warning light. Power in from sender

17 Yellow / Green GV Low fuel light. Power out to gauge, gauge earth's

18 - - Not used

19 - - Not used20 - - Not used

* Pin 11 is only used on the liquid cooled engine *.

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20


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25/08/05Piaggio Ltd Piaggio Ltd

50cc 2t Ignition

GREEN

GREEN

GREEN

IGNITION SWITCH

IGNITION PICK UP

Champion NR2C

NGK BR9ES

RED

WHITE

TESTS

1. UNPLUG STATOR and CDI. GREEN WIRE SHOULD BE

EARTHED WHEN IGNITION IS "OFF"

2. CHECK CHARGING COIL.

GREEN TO WHITE = 980 50 ohms.

3. CHECK TRIGGER COIL. RED TO WHITE = 88 5 ohms.

4. SPARK PLUG

NRG's are now supplied with Champion N1C plugs

The NGK equlivilent is B10ES.

This plug is very cold running and may not suit all riders.

If you find that a machine is fouling plugs try fitting an

NGK B9ES.

COMMON EARTH

FOR

INSTRUMENT PANNEL

1

REV COUNTER

STATOR

This circuit could apply to any twist & go 50cc two stroke with or without a rev counter

OFF

ON

CDI / COIL

unit

CDI / COIL

unit

Ignition

Charging Coil

NOTES

White wire is a common, dedicated earth for the ignition system.

If the engine earth strap was missing the engine would run but you may have problems with the CDI unit failing because the

electrical system may try to use the white wire as its earth connection.

Green wire will have 150-200v AC when engine is running.

Ignition timing ix fixed, i.e. there is no automatic advance / retard.

GREEN

WHITE

RED


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11/09/2003Piaggio Ltd

125 & 180cc 2t charging / IgnitionTyphoon, Skipper, Hexagon, Runner

STATOR

BATTERY

12v

+

CDI

Unit

IGNITION

PICK UP

FUSE

CHARGE

WARNING

LIGHT

RED

RED

RED

RED

YELLOW

YELLOW

GREEN

WHITE

BROWN

PURPLE

GREY

WHITE

GREEN

NOTES

* Choke and Carb' heater will have a supply with ignition turned on but the

rectifier / regulator will only complete the circuit to earth when it detects a

charge. I.e. the engine is running.

* The Charge warning light goes out when the engine is charging because +12v D.C. is applied to both sides of the bulb, not because the circuit is broken.

* On water cooled engines the cooling fan is always live, the thermostat switch is

on the earth side. So a battery going flat could be caused by a faulty fan or fan

switch.

* The starter solenoid is always live so is a possible cause of a battery going flat

TESTS

1. Stator Output.

Yellow to Yellow 27 - 31 v A.C.@ 2000 rpm. Unplug regulator.

Green - White 50 -150 ohm. Runner & Hexagon.(Stator un-plugged)

100 -160 ohm. Skipper & Typhoon.(Stator un-plugged)

Red - Brown 90 -140 ohm. All models. (Stator un-plugged)

2. Charging.

Between Red & Battery positive: >< 8.5 amps@ 2000 rpm with a fully

charged battery (13.5v)

3. Battery voltage must be present at terminal "C" with ignition on or the output

from terminal B will be unregulated. Battery will boil, bulbs will blow etc.MAIN FUSE:

Runner (ZAPM07 / 08) 25 amp.

GGBL CA

Choke

Control

DC

Rectifier

RegulatorOut put only when

RED

WHITE

BROWN

GREY

YELLOW

YELLOW

COOLING FAN

ON

WATER COOLED

MODELS

Choke Unit Carb. Heater

OFF

ON

IGNITION SWITCH

SUPPLY

TO

SYSTEMS


19/150

INDICATOR SWITCH

ABOVE. Vehicles 1999> Cirduit with oil check light that comes on when ignition is switched on.

Refer to the Service Station Manual. Also Technical Notes 2/99 and 3/99.

BELOW. Vehicles


20/150

11/09/2003Piaggio Ltd.Hexagon LX / LXT

Runner FX / FXR

Skipper & Typhoon 125

125 / 180 2T Ignition

R B W G V

CDI UNIT

OFF

ON

STATOR

RED

BROWN

WHITE

GREEN BLACK

GREEN

PURPLE

IGNITION SWITCH

IGNITION TIMING IS CDI CONTROLLED Not adjustable

Skipper and Typhoon:

Ignition is fixed at 19 degrees.

Hexagon and Runner:

Two position ignition (not progressive).9 deg @ 1500+ rpm. Then 22 deg @ 7500+

* The ignition circuit is a separate self-contained circuit with no fuses and no connection to the other electrical circuits on the vehicle. It has a separate charging coil in the stator (Green & White wires).

* The ignition switch contacts are OPEN when the engine is RUNNING. Contacts are CLOSED when

switch is turned OFF, this allows the system to discharge to earth. When fault finding, if there is no spark

then check the "green" and "purple" wires to see if there is a "leak" to earth. Unplug stator & CDI, check

green to earth: Ignition on = no continuity. Ignition off = continuity.

* A "Resistor" type spark plug and a resistor plug cap should always be fitted.

* This circuit does not require the engine to chassis earth. But if that earth lead is missing it is possible that

trying to use the starter motor could force excess current through the CDI and damage it.

Always prove you have a good engine to chassis earth connection.

NOTES.

Purple - Earth

HT Primary

HT lead - Earth

HT Secondary

Meter between >

To test >

Hexagon LX / LXT

Runner FX / FXR

Skipper / Typhoon 125

Red - Brown

Pick - up Coil

90 - 140 ohm

90 - 140 ohm

90 - 140 ohm

White - Green

Charge Coil

50 - 100 ohm

50 - 100 ohm

100 - 160 ohm

STATOR TEST VALUES. Stator un-plugged

0.5 0.025 ohm+

0.5 0.025 ohm+

0.5 0.025 ohm+

4.8 0.25 k ohm+

4.8 0.25 k ohm+

4.8 0.25 k ohm+


21/1501-7

Piaggio Ltd. May 2000

FUSE EXPLANATION

Runner FX 125 & FXR 180

Circuits protected by each fuse.

1. Head light flash (passing light).2. Indicators. Brake light. Oil indicator. Electric start relay. Temp gauge. Fuel gauge. Horn.

Choke.

3. Headlight relay. Town light. Rear light (lighting switch)4. Both headlights (power)Notes.

Ignition circuit is completely separate and self powered. It does not have any fuses. The cooling fan is permanently live and is protected by the main 25 amp fuse. The starter motor supply is not fused.Relation between lighting and the fuses.

WHITE

WHITE

WHITE

WHITE / RED

GREY / BLACK

GREY RED

RED / BLACK

10 amp 4

7.5 am 1

7.5 amp 2

10 am 3

+12v when

ignition is ON

Permanent +12vvia 25 am fuse

Headlight

Relay

Lighting

Switch

Head Light

Flash

High / Low

SwitchLow Beam

High Beam1

4

3

From Fuse

#


22/150

Rectifier /

Regulator

11/06/02Piaggio Ltd. Derbi engine

DIESIS 100 Charging / Ignition

Red

4

amp

White / Red

Yellow

Earth wires are - Yellow / green.

Yellow wire is AC supply.

Red / Blue wire is DC supply.

Engine earth is very important.

Carb heater is driven by AC power via a thermostat.

No separate Ignition pick up, CDI is triggered by the AC wave.

Ignition is earthed to stop the engine.

NGK

B9 ES

Yellow / Green

Yellow / Green

Yellow / Green

Green / Black

Orange

PinkWhite

Red / Blue

Yellow

Green / Black

Red

Red

Gre

en/Black

Yellow/

Green

AC Supply

DC Supply

LEFT

OFF

RIGHT

Indicators

Yellow / White

White / Red

Ignition Switch

LOCK

OFF

ON

Green

Orange

Black Red / White

Black / Red

Carb. Heater

BATTERY

12v

4ah

+

Red

Tostarter

solenoid

TESTS.

Stator: Yellow - Earth = min 25 v AC. White / Red - Earth = min 30 v AC. Engine at mid rpm.

Yellow - Earth = 0.9 ohm+0.2. White / Red - Earth = 1.1ohm +0.2. Stator un-plugged.

Black / Red - Earth = 238 ohm +10%. Stator un-plugged.

Regulator: Yellow Earth 13 5 + 0 5 v AC White / Red Earth 13 5 + 1 0 v DC Engine at mid rpm

+ 5oC

Thermostat

Black

Black

Indicator

Relay

Rectifier

&

Regulator

Regulator

Orange - Indicator switch

Yellow - AC circuit

Red / Blue - DC supply

White / Red - Stator

Red - Battery

Explanation of Rectifier / regulator wiring


23/150

02/09/2003Piaggio Ltd. GILERA RUNNER

PUREJET 50 IGNITION / CHARGE

OFF

ON

BATTERY

12v

+

~ ~ ~ +

YELLOW

YELLOWYELLOW

BLUE

BLUE

RED

RED

ORANGERED / BLUE

BLACK / VIOLET

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

ECU

BLUE

RED

BLACK/VIOLET

ORANGE

SYSTEM NOTES.

* 3 Phase AC.

* Permanent live battery feed to Rectifier, ECU, HT Coil (blue wire). Any of these could drain the battery if they were faulty.

* HT Coil is trigered by the BLACK / VIOLET wire being earthed via the ECU.

TESTS:

Stator: Disconected. Any yellow to any yellow = 0.7 - 0.9 ohm. Any yellow to earth = No continuity

Pick Up coil value is not quoted.

Rectifier / Regulator: With a charged battery the possible voltage must not exceed 15.2 volts.

HT COIL

IGNITION SWITCH

RECTIFIER / REGULATOR

STATOR

PICK UP

FUSE

15 amp

15 amp Champion

RG6YCA

BLUE

BLUE

BLUE

BROWN

BROWN

To starter

relay


24/150

12/01/2004Piaggio Ltd. Runner

Purejet 50 Turn Signals & Oil check

BATTERY

12v

+

ON

Yellow

White

Orange

B

E

S

L

Black

White

Yellow

Black / Blue

Red/Blue

Red

15 ampFuse's in

Battery

Compartment

Yellow

7.5 amp Fuse's

in Horn

Compartment

Grey / Red

Blue

White / Red

Oil Tank

Sender

Low Oil

Warning

Light

Turn

Indicator

Switch

RightTurnIn

dicators

Pink

Pink White / Blue

White / Blue

Ignition Switch

Black / Blue

Indicator

Control Unit

* The low oil warning light check function is controlled by the indicator relay.

* The oil check light should come on for 15 seconds when the ignition is first turned on.

* If the system fails: first check the 7.5 amp fuse located under the front grill (horn) panel.

White

LeftTurnIndicators

OFF

LEFT

RIGHT

LOW


25/150

13/12/2005Piaggio Ltd. 2 stroke engine

Fly 50 & Vespa LX 50 charging & carb heater

BATTERY

12v 4ah

+

CHOKE UNIT

7.5 amp

FUSE

IGNITION

SWITCH

YELLOW

BLUE

GREY / BLUE

RED / BLUE

YELLOW / BLACK

DC SERVICES

Brake light

Horn

RED

BLUE

WHITE

This diagram shows the Fly 50 & Vespa LX 50 two stroke wiring, it is basically the same as other 50 two strokes

but there are a few slight variations including the electric carb heater.

TESTS.

Stator out put. Grey / Blue to earth = 25-30v AC stator un-plugged and engine at 2000rpm.

Stator out put. Yellow to Blue = 26-30v AC stator un-plugged and engine at 2000 rpm.

Ammeter between red wire and battery positive = 1.5-2 amp with fully charged battery and engine at 2000

rpm

Output to the indicator switch will be a 12v DC pulse with ignition on.

NOTES.

The carburettor heater is DC powered but the controller is activated by AC so it will only turn the heater on

when the engine is running (AC output is detected).

The choke is AC powered as normal. It is not controlled by the Carb. heater controller.

Engine must be earthed to the chassis / battery. Lack of this connection will affect the AC circuit and starter

t b t t th DC i it i iti i it

1

3

NOT

USED

TO INDICATOR

SWITCH

WH

ITE/RED

BLU

E/BLACK

BLACK

YE

LLOW

4

GREY / BLUE

2

OIL

WARNING

LIGHT

OIL TANK

SENDER

OFF

ON

RED/GREEN

ORANGE

WHITE

RECTIFIER

&

REGULATOR

4321 5 6 7 8

REGULATOR

OIL

LIGHT

TIMER

GREY / BLUE

AC

SERVICES

Head light

Tail light

Instruments

YELLOW / BLACK

YELLOW / BLACK

CARB. HEATERLt. BLUE

ORANGE / BLACK

WHITEWHITE

Carburettor

heater

control

AC


26/150

3 2 1

8 7 6 5 4

Rectifier /

Regulatorp/n: 82501R

25/08/05Piaggio Ltd. With IMMOBILISER

B 125 / 200 ignition / charging

Red

White / Black

Yellow

Ignition

Pick up

CDI / Immobiliser

Ignition

Switch

HT Coil

White

Purple

Red / Black

Black

White

Cooling

Fan Fan

Switch

Red / Black

Green

White / Green or Light Blue

White

Red / Black

Lt. Blue

White /

Green

G

Choke Unit White

White /Orange

White

Lt. Blue

Black / BlueIndicatorSwitch

Yellow / Blue

Red / Blue

Red / Black

Green

Orange

Emergency

StopGreen / Blue

OFF

1

2

Seat Lock Seat Release

Push Button

Blue

White / Blue

White

Blue

Green

Ignition Relay

4 amp

BATTERY

12v10ah

+

CR 9EB

Side Stand

Switch

Immobiliser

LED

Stand

Warning

Blue / Black

CDI CONNECTIONS

1. BLUE / BLACK - INDICATOR SWITCH SUPPLY

2. GREEN - INPUT FROM IGNITION PICK UP

3. PURPLE - TO HT COIL

4. RED / BLACK - 12v PERMANENT LIVE

5. WHITE / GREEN - SUPPLY FROM IGNITION SWITCH

6. YELLOW / BLUE - IMMOBILISER LED

STOP

RUN

Down

UP

154

Blue

Red/Black

Red/Blue

15 15

Yellow / Blue

White / Green

Red / Black

antenna


27/1502-2

B 125 / 200 NOTES

The notes should be used in conjunction with Service Station Manual 594845 and

the notes B 125 ignition / charging and B 125 Fuse Explanation

1. Seat has electric release. Only works when ignition switch is in the offposition.

If seat lock fails to operate: Check fuse 7 in rear fuse box. 4 amp red wire in & blue wire out. Check for power on Blue wire at ignition switch Check for power on White / Blue wire at ignition switch with ignition off. Check the push button, Blue / Black should earth when button is pressed.Seat lock, power socket and under seat light are all controlled by the same

fuse.

2. Wires from The engine. Three Yellow wires: Three phases of generator, all feed directly to the

rectifier / regulator.

Green wire: Ignition pick up. Goes to ECU unit. Brown wire: From oil pressure switch, goes to indicator light on instrument

panel.

3. Immobiliseris like other Leader engines. There are separate notes to explainthe immobiliser system.

4. Fuel system. (similar to the DNA 125 / 180 four strokes) Fuel is pumped from the tank and supplied to the carburettor under

pressure.

Fuel pump is on the bottom of the tank and is driven by manifold vacuum. The feed pipe from pump to carburettor has a non-return valve and an

inline filter.

200cc engine may (early vehicles) have a vacuum pipe that branches offto operate an over run valve in the carburettor.

Carburettor icing is controlled by a warm water feed from the coolingsystem.

Choke is the automatic (wax pellet) type used on all our automatics.Remember that these units default to being ON and are turned off

electrically. They are more likely to cause running rich when hot than cold

starting problems.

5. Spark Plugs.

Please note that the correct spark plugs are:

125cc :- NGK CR8 EB p.n. 828866

200cc :- Champion RG6 YC p.n. 828708 (or NGK CR7EB)


28/150

08/05/2003Piaggio Ltd. Piaggio Ltd.

B 125 FUSE EXPLANATION

FRONT FUSE BOX

2 4 amp

4 4 amp

3 7.5amp

1 4 amp

WHITE

12v DC from

ignition switch

GREY

From light

switch

YELLOW

Anologue, Inst. & side lights

RED / GREY

Horn, Headlight flash

WHITE / RED

Brake lights, start inhibit

WHITE / ORANGE

Engine start, run, warning lights

REAR FUSE BOX

7

15a

5

4a

6

10a

8

15a

RED

12v DC from battery

RED / BLUE

Digital Panel, LED, Radio

RED / BLACK

General

YELLOWHeadlight via relay BLUEUnder seat, Light, Socket, Lock


29/150

Rectifier /


13/08/2003Piaggio Ltd. DNA 125 / 180

DNA Leader engine ignition / charging

GALTERNATOR

STATOR

To

Indicator

switch

Headlight

via relay

Red

Green

Green

White / Black

Yellow

Ignition

Pick up

ECU

Ignition

Switch

Blue /

Black

15

amp

Blue / Red

Green / Yellow

White

/ Pink

Red

Power to

Lights, horn

instruments

Black

3 2 1

8 7 6 5 4

BATTERY

12v

12ah

+

Choke Unit

Red

Lt. Blue / Green

Yellow / RedRedWhite

Connector for Alarm

Orange

Orange

Yellow

7.5

amp

7.5

amp

Fan

Switch

Green

Cooling

Fan

HT Coil

NGK

CR 8EB

White / Black

Blue / Red

Blue / Red

STATOR: ANY YELLOW TO ANY YELLOW = 0.7 - 0.9 ohm. YELLOW TO EARTH = NO CONTINUITY

GREEN TO BLACK (EARTH) = 105 - 124 ohm

REGULATOR: VOLTAGE ACROSS A FULLY CHARGED BATTERY, LIGHTS OFF, HIGH REVS = 14 - 15.2 V.

OFF

ON

STOP

RUN


30/150

08/05/2003Piaggio Ltd.Refer to Service Station Manual

594329 (02/01) page 4-23>

DNA 125 / 180 Switch Wiring

FEED FROM LIGHT SWITCH. WHEN LIGHTS ARE TURNED ON

SUPPLY TO REAR LIGHTS AND FRONT PILOT LIGHT

MAIN SUPPLY TO IGNITION SYSTEM, LIGHTS ETC.

MAIN FEED FROM BATTERY

OFF

PARK

LOCK

ON

3 4 6521

IGNITION SWITCHITEM 6 ON WIRING DIAGRAM

BROWN

GREEN

BLACK

RED

YELLOW - BLACK

WHITE

ORANGE

OFF

LEFT

RIGHT

LOW

HIGH

FLASH

0

PUSH

PINK

BLUE - BLACK

WHITE - BLUE

WHITE

PURPLE

BROWN

YELLOW - BLACK

GREY - BLACK

BLACK

LEFT HAND

SWITCHESITEM 8

ON WIRING DIAGRAM

HORNINDICATORS MAIN / DIP

0

RUN

0

PUSH

OFF

SIDE

ALL

EMERGENCY

STOPSTARTLIGHTS

WHITE

YELLOW - RED

GREEN - BLACK

WHITE - BLACK

ORANGE

BROWN

YELLOW

RIGHT HAND

SWITCHESITEM 9

ON WIRING DIAGRAM


31/150

Rectifier /



ET4 Leader / LX 125 ignition / charging

GALTERNATOR

STATOR

To

Indicator

switch

Headlight

via relay

Red

Green

Green

White /

Black

Red / Blue

RG4HC

CR 9E

Carb. Heater

Choke Unit

Yellow

Ignition

Pick up

ECU / Immobiliser

Ignition

Switch

HT Coil

Blue /

Black

15

amp

Orange

Orange

White

Red /

Blue

Purple

Grey

Red / Blue

Powerto

services

Red / Blue

Black

antennaYellow

LED on

instrument

pannel

Diagnostic

socket

6

1

8

3

4

5

7

2GREEN

WHITE / BLACK

ORANGE

RED / BLUE

PURPLE

BLACK

BLUE / BLACK

YELLOW

Layout of pins

in the ECU / immobiliser

Orange

7.5

amp

BATTERY

12v

9ah

+

3 2 1

8 7 6 5 4

TESTS.

STATOR: ANY YELLOW TO ANY YELLOW = 0.7 - 0.9 ohm.

YELLOW TO EARTH = NO CONTINUITY



CHARGING: AMMETER IN RED WIRE = > 8 AMPS

WITH LIGHTS ON AND HIGH REVS

OFF

ON


32/150

Rectifier /



Hexagon GTX 125 ignition / charging

GALTERNATOR

STATOR

To

Indicator

switch

Red

Green

Green

White

/ Black

White

Yellow

Ignition

Pick up

ECU / Immobiliser

Ignition

Switch

HT Coil

Blue / Black15

amp

Orange

Orange

Red

Purple

Red

Red

Black

antenna

Yellow

Red / Blue

LED on

instrument

pannel

Layout of pins

in the ECU / immobiliserYellow / Blue

BATTERY

12v

12ah

+

Orange

RG4HC

CR 9EB

Cooling

Fan

Fan

Switch

RedGreen

Choke Unit

Lt. Blue

Orange

5

amp

5

amp6

1

8

3

4

5

7

2GREEN

WHITE / BLACK

Lt. BLUE

RED

PURPLE

BLACK

BLUE / BLACK

YELLOW

Diagnostic

socket

3 2 1

8 7 6 5 4

TESTS.







OFF

ON

STOP

RUN


33/150

antenna

Rectifier /



Runner VX / VXR ignition / charging

GALTERNATOR

STATOR

To

Indicator

switch

Headlight

via relay

Red

Green

Green

White /

Black

Red / Blue

Choke Unit

Yellow

Ignition

Pick up

ECU / Immobiliser

Ignition

Switch

HT Coil

Blue / Black

15

amp

Red / Blue

Orange

Red

Purple

Grey

/ Red

Red

Power toservices

Red

Black

Yellow

Red / Blue

NGK

CR 8EB

Cooling

FanFanSwitch

Red

Green5

amp

6

1

8

3

4

5

7

2GREEN

WHITE / BLACK

RED / BLUE

RED

PURPLE

BLACK

BLUE / BLACK

YELLOW

Diagnosticsocket

Red

LED on

instrument

pannel

Yellow / Red

Layout of pins


3 2 1

8 7 6 5 4

TESTS.




REGULATOR: VOLTAGE ACROSS A FULLY CHARGED BATTERY,

LIGHTS OFF, HIGH REVS = 14 - 15.2 V.


BATTERY

12v

10ah

+

OFF

ON


34/150

27/02/2004Piaggio Ltd SSM page 4-8

X9 125 indicator wiring

10 amp

7.5 amp

7.5amp

BATTERY

12v

+

Instruments panel

OFF

ON

LEFT

CANCEL

RIGHT

+ G G G

FUSES IN UNDER SEAT

COMPARTMENT


INDICATOR SWITCH

LEFT INDICATORS

FUSES IN FRONT

STORAGE

COMPARTMENT

IGNITION SWITCH

RIGHT INDICATORS

RED

RED / BLACK

RED / BLACK

RED / BLACKRED / WHITE

ORANGE

RED / GREY

RED / WHITE

BLUE / BLACK

GREY / BLUE

PINK / BLACK

WHITE / BLUE

PINK

LAYOUT OF INSTRUMENT PANEL MULTI PIN CONNECTOR

1 7 5 13 6 4 12

5.BL

UE/BLACK.Toswitch.RIGHTturn

6.PIN

K/BLACK.Toswitch.LEFTturn

7.RE

D/GREY.12v+fromignitionswitch

8.

22.

21.

20.

19.

18.

17.

24.

31.

32.

32.

33.

34.

35.

23.

12v+frombattery.RED/WHITE1. 2

.3.

ToRIGHTindicatorbulbs.WHITE/BLUE4.

14.

GREY/BLUE.Cancel13.

ToLEFTindicatorbulbs.PINK12.

11.

10.9

.16.

25.

26.

27.

28.

29.

30.

15.


35/150

Rectifier /



X9 125 / 180 & 250 Evo ignition / charging

GALTERNATOR

STATOR

Red

Green

Green

White / Black

Yellow

Ignition

Pick up

ECU / Immobiliser

Ignition

Switch

15

amp

Orange

Orange

Red / Black

Yellow

Layout of pins


Yellow / Grey

BATTERY

12v

12ah

+

Cooling

Fan

Fan Switch

Red / Black

Green

Choke Unit

Emergency

Stop

Lt. Blue

Orange

5

amp

Diagnostic

socket

2 GREEN

7 WHITE / BLACK

5 Lt. BLUE

4 RED / BLACK

3 PURPLE

8 BLACK

6 YELLOW

Red / Black

Yellow / Blue

Yellow / Green

Grey

/ BlackLt. Blue

TESTS.







3 2 1

8 7 6 5 4

RG4HC

CR 9EB

HT Coil

Purple

Black

Side

Stand

Switch

Red / White

STOP

RUN

STOP

RUN

UP

DOWN

Immobiliser

LED

Stand

Warning

Power to

Services

antennaNOTE.

Indicators are powered by

the digital instrument panel.


36/150

Rectifier /


13/08/2003Piaggio Ltd. NO Immobiliser

ZIP 125 Leader engine ignition / charging

GALTERNATOR

STATOR

To

Indicator

switch

Red

Green

Green

White /

Black

Choke Unit

Yellow

Ignition

Pick up

Ignition

Switch

Blue / Black15

amp

Orange

Orange

Purple

Red / Blue

Powerto

services

Black

ECU CONNECTIONS1. BLUE / BLACK - INDICATOR SWITCH SUPPLY

2. GREEN - INPUT FROM IGNITION PICK UP

3. PURPLE - TO HT COIL

4.

5. ORANGE - SUPPLY FROM IGNITION SWITCH

6.

7. WHITE / BLACK - CHOKE CONTROL

8. BLACK - EARTH

TESTS.

Yellow - Yellow. Charging coils. 0.7 - 0.9 ohmYellow - Earth. No continuity

Green - Earth. Ignition pick up coil. 105 - 124 ohm.

Purple - Earth. Coil primary winding. 0.4 - 0.5 ohm

LOCK

OFF

ON

Carb. Heater

Layout of pins

in the ECU

3 2 1

8 7 6 5 4

ECU

6

1

8

3

4

5

7

2GREEN

WHITE / BLACK

ORANGE

PURPLE

BLACK

BLUE / BLACK

RG6YC

CR 7EB

HT Coil

BATTERY

12v

9ah

+


37/150

2-11

1 of 2Piaggio Ltd February 2004

LEADER ENGINE

Ignition, charging & immobiliserUse these notes in conjunction with the SERVICE STATION MANUAL

The electrical system on the new Leader engine is very different to previous two stroke and

four stroke Piaggio engines. The ignition, charging & immobiliser circuits do not function inthe same way and do not share common components with previous versions.

Ignition is now using the battery circuit. Everything shares one common supply. Alternator has three phase (all yellow wires) and ignition pick up coil (green wire) outputs

only.

Rectifier / Regulator is very simple. Three phase (yellow) inputs and one output. ECU unit has become more complicated. The one unit is responsible for: ignition,

immobiliser, indicators & choke unit. Much of the circuit is the same on ET4 Leader, Fly 125, Super Hexagon GTX 125,

Liberty 125 Leader, B 125, Skipper ST, Runner VX / VXR and DNA 125 / 180, Vespa

GT 125 / 200 X8 125, X9 125 and Zip 125 but be careful because there are differences.Early Skipper ST did not have an immobiliser, the later version does have it.

IGNITION.When the ignition is turned on power is supplied to the CDI (terminal 5).

Ignition pick up is via green wire (terminal 2).

Output to the HT coil is via purple wire (terminal 3).The unit is earthed via black wire (terminal 8).

CDI / IMMOBILISER

Note the ECU units have different part numbers for different models and engines size.

Refer to the diagram for each specific model. The wiring and wire colours may vary.

It is important that the correct part number is used as the ignition characteristics vary andalthough the units look the same they are different!

On vehicles with an immobiliser;The wires connected to the unmarked terminals are from the antenna that is mounted around

the ignition lock barrel.

Check antenna for continuity, unplugged resistance = 7 - 9 .The red or red / blue wire (terminal 4) supplies battery voltage even with ignition off.

Yellow wire (terminal 6) is from the LED on the instrument panel. If the system is

programmed and working correctly the LED should be flashing steadily with the ignitionturned off to confirm that the immobiliser system is functioning. The immobiliser earths the

LED (or not) to make it turn on or off.

See pages 3-4 below for more details on using the LED for immobiliser fault finding.

HT COIL. 82597R = Common to most Leader engines. 82582R = Skipper ST & X9 125

Purple to Black - primary winding = 0.4 - 0.5 HT to Black - secondary winding = 3000 300 Plugged in with engine cranking the peak voltage Purple to Earth = 100 vdc


38/150

2-11

2 of 2Piaggio Ltd February 2004

IGNITION PICK UP COIL.

Un plug, check resistance, Green to Black = 105 - 124 Un-plugged with engine cranking the peak voltage Green to Black = 2 vdc

STATOR.

Any yellow to yellow should give continuity. Un-plugged, yellow to yellow = 0.7 - 0.9

Yellow to earth should not give continuity.

RECTIFIER / REGULATOR.p/n 82501R common to leader engines. Regulated voltage. With a fully charged battery check charging rate by putting volt meter

across the battery terminals. Peak voltage = 14 - 15.2 vdc. Engine at high speed and lights

off. Charge current. Connect ammeter to the red wire. Then Start engine. Charge 10 amp.

With the head light turned on.

INDICATORS (Not X9 125).

There is no separate indicator relay. The relay function is contained within the ECU unit,

Power to the indicator switch is via the blue / black wire (terminal 1).

If the indicators fail first check that you are getting voltage at terminal 1 (blue/black)To check the switch and wiring. Unplug the CDI and link red/blue wire to blue/black wire,

when the turn switch is operated the appropriate lights should come on. (you will not need the

ignition to be turned on).

INDICATORS X9 125.

X9 has indicators driven by the digital instrument panel.

Three wires go to the switch from the panel. The switch earths the appropriate wire to

operate the indicators. Output to the indicators comes from the panel. See the explanationdiagram 2-9a.

CHOKE UNIT.The choke is now controlled by the CDI. (not the regulator).

Power is supplied to the choke via the main switched wire from the ignition switch to the

ECU. The unit will not function until the engine is running when the CDI will complete the

circuit to earth (terminal 7). Un Plugged, resistance across the connections = >< 30 @ 20C Plunger extension. Measure how far the plunger protrudes from the body when it is cold,

this should be 12.5 - 13.0 mm. Now connect the choke unit to a 12v battery. The plungershould have extended to 18.5 - 19.0 mm within 5 minutes.

Supply. Orange or Red / Blue to earth = Battery volts with ignition on. Orange or Red / Blue to White/Black = 13-14.5v dc (system volts) with engine running.

CARB. HEATER. Fitted to air-cooled engines.

The carburettor heater will start working as soon as the ignition is turned on. Power is

supplied via the switched wire that goes to the CDI.Water cooled engines use a warm water connection from the cooling system.

COOLING FAN. On water-cooled engines.The live feed from battery to fan is permanently connected. The switch is in the earth from the

fan. So if the fan is faulty it could be the cause of a flat battery.


39/150

Piaggio, Gilera & VespaImmobiliser

systems

The following pages are an explanation of the original fitmentimmobiliser systems fitted to vehicles beginning in the

1990's with the original (pre Leader) Vespa ET4.

Most space is devoted to the system fitted to Leader engined

vehicles because this is by far the most common.

Much of the operation of other systems is the same as the Leader

system.

Systems covered:

Leader

Pre Leader

Quasar

Master

Published January 20061st edition

Piaggio and other after market alarms and immobilisers

are not covered here.

Copies of this and other Piaggio technical information can be obtained

from the Piaggio UK dealer portal web site

or from Piaggio Ltd.


40/150

Immobiliser Systems

INDEX

LEADER

Page 2 - Explanation of operation & Fault codes

Page 3 - I need new keys

Page 4 - I need new locks

Page 5 - I need to fit a new CDI / Immobiliser unit

Page 6 - No Spark - Fault Finding Flow Chart

Page 7 - LED Not Flashing - Power supply problem

Page 8 - Immobiliser functioning correctly

Page 9 - Programming a CDI / Immobiliser

Page 10 - Transponder not detected

Page 11 - Transponder not recognised

PRE LEADER


Page 13 - Pre Leader ET4 wiring explanation

QUASAR


Page 15 - Notes on fault codes and diagnostic tester

Page 16 - Programming

MASTER


Page 18 - Notes on fault codes

Page 19 - Programming


41/150

Possible LED Flashing Fault Codes

TURNIGNITIONON

LED OFF

LED ON

2 x 0.5 sec.

2 x 0.5 sec.0.7 sec.

2 sec.

LED OFF

LED ON

Phase 1 Phase 2 Phase 3

1. Immobiliser not programmed

2. Transponder is detected

3. Engine will run to 2000rpm

1. Immobiliser is programmed

2. Transponder is not detected

3. Ignition is not possible

LED OFF

LED ON




2 sec.

3 x 0.5 sec.0.7 sec.

LED OFF

LED ON


2. Transponder is not recognised


0.7 sec.

LED OFF

LED ON



3. Engine can run normally

19/01/2006PAGE 2 EXPLANATION

Leader Immobiliser

1. The immobiliser system fitted to all Piaggio, Gilera & Vespa "Leader" engined vehicles operates in

exactly the same way.

2. Although the principle is the same the wiring differs on different models.

Refer to the wiring diagram and Service Station Manual for your specific model.3. CDI and immobiliser are combined in one unit.

4. The CDI / immobiliser units may look the same but:

They have different characteristics on different models.

Ensure you fit the correct unit. Always order by part number .

5. The flashing LED on the instrument panel is the key to understanding how the immobiliser is

behaving. The list below shows what the LED can tell you.

Note that the LED should flash steadily all the time the ignition is off and the battery is connected.

If not, go to PAGE 7 for fault finding information.

6. If you have no spark you must first prove that it is not due to the immobiliser.

7. Keys should not be on a metal key ring or with other keys. Sometimes this can upset the system.


42/150

19/01/2006PAGE 3 NEW KEYS

Leader Immobiliser

FAULT:I need new keys.

I have the

Master key

You must change

The lock set and

The CDI / Immobiliser

I have the

service key

Take the key to an

automotive lock smith.

They will be able to clone it.

Obtain a blank service key,

get it cut and program the

immobiliser to recognise it

See: PAGE 9

YES

NO

NO

It is not possible to program in a

new key without the master key.

Fortunately automotive lock

smiths can create a clone that will

not need programming.

It is not possible to buy an extra

master key or have one made.

It is not possible to by pass the

immobiliser.

The code card does not contain

any electronic data and is only

used to cut the key by number.

See PAGE 4 & 5

Tell your customer to only

use the service key and keep

the master key in a safe

place at home

OR

YES

Gilera Runner service keys

The red service key for Runner two strokes and Runner four strokes now look the same.

The four stroke key has a transponder chip in it and the two stroke key does not.

You can recognise the keys which contain a transponder by a symbol that is engraved on the key

This key contains a

transponder


43/150

19/01/2006PAGE 4 NEW LOCKS

Leader Immobiliser

FAULT:I need to fit new locks.

Is the original

master key

available?

1. Fit the new lock set

2. Remove the chip from the original

master key and fit it to the new

master key.

3. The immobiliser will not know anything has changed

4. Program the the new service key to

the immobiliser. See PAGE 9

You must fit a new lock set and a new

CDI / Immobiliser unit

It is not possible to bypass the

immobiliser.

See PAGES 4 & 5

The lock set is supplied with one

(brown) master key and one service key.

YESNO


44/150

19/01/2006PAGE 5 NEW CDI

Leader Immobiliser

FAULT: I need to fit a new CDI / Immobiliser.

I have the

master & service

keyYES

I only have

the master key

I only have

the service key

NOThe replacement CDI / immobiliser

must be new and unused.

Fit the new CDI and use the service

key to check the engine starts and

runs (only 2000 rpm)

Program the immobiliser.

See: PAGE 9

Fit the new CDI and use the master

key with the chip "out" to check the

engine starts and runs

(only 2000rpm)

You must replace the lock set

NO YES

Obtain a new service key

Tell your customer to only use the

service key and keep the master

key in a safe place at home

3 2 1

8 7 6 5 4

antenna

Output to indicators

Ignition pick up

HT Coil

Earth

Choke unit

LED

Switched Live

Permanent Live

Battery

+12v

FUSES

CDI / Immobiliser Connections

Please refer to individual wiring diagrams and

Service Station Manuals for a full explanation

and wiring colours.

1. Choke has a switched live,

CDI earths it to complete the circuit and

turn it off.

2. LED has a permanent live,

CDI earths it to complete the circuit and

make it come on.

3. X9 does not use the indicator

function. Indicators are driven by

the digital panel.

GREEN

BLACK


45/150

19/01/2006PAGE 6 Fault Finding

Leader Immobiliser

Ignition

turned off

Power

Supply

Problem

7

One short flash

Goes out

Stays out

Turn

Ignition On

One long flash

Goes out

Stays out

LED

Flashing?

Immobiliser

is working

correctly

8

Immobiliser

needs

programming

9

NO YES

One long flash

Two short flashes

Goes out

Stays out

One short flash

Two short flashes

Comes on

Stays on

One short flashThree short flashes

Comes on

Stays on

Fault is not with the

immobiliser

Immobiliser

needs

programming

9

Transponder

not

detected

10

Transponder

not

recognised

11


immobiliser


immobiliser

Transponder

not

detected

10

FAULT: Engines turns over but there is no spark when tested with a strobe light

For an explanation of each fault

go to the rele ant n mbered NOTES page

YES

YES

YES

YES

YES

NO

NO

NO

NO


46/150

19/01/2006PAGE 7 NO LED

Leader Immobiliser

3 2 1

8 7 6 5 4

CDI / Immobiliser

SWITCHED LIVE

LED

EARTH

FAULT: With Ignition turned off the LED light is not flashing

Refer

toindi

vidu

almod

els

gdiag

ramto

identif

ywire

Charged

Battery

?

Ensure a

fully charged

battery is connected

LED

Functioning

?

Un-plug the CDI

Connect LED wire to earth

LED should light up

Permanent

Live to

CDI ?

1. Check Fuse.

2. Check continuity of wire

to instruments.


from instruments to CDI.

YES

NO

DON'T

KNOW

NO

YES

Switched

Live to

CDI ?

Good

Earth

?

YES

YES

1. Check Fuse.


from fuse to CDI.

1. Check Fuse.


from fuse to ignition switch.


from ignition switch to CDI.

Check continuity from CDI

connector to battery negative

NO

NO

NO

Return

to

Page 6

Note. With an all new / virgin system the LED may not be flashing but the

check function flashes should occur when the ignition is turned on.


47/150

19/01/2006PAGE 8 Immobiliser OK

Leader Immobiliser

Ignition

turned off

One short flash

Goes out

Stays out

Turn

Ignition On

LED

Flashing?

Immobiliseris working

correctly

8

YES


immobiliser

FAULT: Engines turns over but there is no spark when tested with a strobe light

YES

We know that the immobiliser is working correctly so the immobiliser system can now be ignored

and normal fault finding can be continued.

1. Test the ignition pick up.

Un-plug the CDI. Green wire to earth = 105 - 124 ohms.

2. Test the HT coil (unplugged).Primary: Purple to Earth = 0.4 - 0.5 ohm.

Secondary: HT to Earth = 3000 ohms (3k ohm).

A 5000 ohms (5K ohm) resistor plug cap should be fitted.

3. Test earth continuity.

Un-plug the CDI. Check continuity between black wire and battery negative.

If no fault has been found you should suspect the CDI unit.

* Fit a new CDI (not from another bike)

* Use the service key (not the brown master key)

* Check that the spark is restored. engine should start but it will not rev beyond 2000 rpm.

If the fault is cured you must program the CDI unit.

GO TO PAGE 9 for programming information.


48/150

19/01/2006PAGE 9 PROGRAMMING

Leader Immobiliser

FAULT: I need to program the immobiliser unitNotes.

1. It is not possible to re-program an immobiliser unit to a new master key.

Once it has been programmed it is irrevocably linked to that master key.2. It is not normally possible for an immobiliser to loose it's program and then need

re-programming.

If it was programmed and working but now it is saying that it is not programmed,

First, check the HT lead and plug cap, It is possible that extreme electrical

interference from a faulty HT circuit could upset the immobiliser.

Plug cap must be at least 5000 ohms. Change the cap and lead if suspect.

A resistor plug must be used on all Leader engines.

Then try re-programming the immobiliser.

If it will not re-program then it is faulty.

Programming a new immobiliser.

1. Do not attempt to program a new immobiliser until you know that the fault is cured.

Attach the new immobiliser, use the service key (not the brown master key)LED will give one long flash then go out and stay out. System is working correctly,

Immobiliser is not programmed

The engine should start but will not rev above 2000 rpm until the immobiliser is

programmed.

2. To program a new immobiliser

* Insert the brown master key and turn on for two seconds

* Insert the service key and turn on for two seconds

* (extra service keys are included here)

- Insert the extra service key and turn on for two seconds


* The timing of the two seconds can be critical so use a watch to time it,

you may need to do the sequence several times before it is accepted.

* Changing from one key to the next should be done within ten seconds.

* An extra service key is not just added,

you must go through re-programming all the keys as above.

You are not re-programming the master key, the master key is giving permission for the

service keys to be added.

* You do not need to start the engine just to check if the programming has been successful,

Just turn on the ignition and watch the LED.

One short flash (half second) means the programming was successful.

One long flash (two seconds) means the system is still not programmed.

Possible LED Flashing Codes

T

URNIGNITIONON

LED OFF

LED ON





2 sec.

0.7 sec.

LED OFF

LED ON


2. Transponder is detected3. Engine can run normally


49/150

19/01/2006PAGE 10 NOT DETECTED

Leader Immobiliser

FAULT: Transponder not detected.


TURNIG

NITIONON LED OFF

LED ON2 x 0.5 sec.

2 x 0.5 sec.0.7 sec.

2 sec.

LED OFF

LED ON




3. Ignition is possible




The immobiliser knows the ignition has been turned on but it has not been able to detect the

transponder chip in the key.

Possible reason for transponder chip not being detected.

1. The transponder chip is damaged or missing from the key.

* Try another key.

2. The aerial is damaged, un-plugged or not correctly positioned

* Un-plug the aerial from the CDI and check the aerial for continuity.

Aerial resistance = 7 to 9 ohms. If resistance is wrong replace the aerial.

* Check that the black plastic aerial housing is securely clipped into position around

the ignition switch.

* Inspect the pins in the plug and socket for signs of damage or corrosion.


50/150

19/01/2006PAGE 11 NOT RECOGNISED

Leader Immobiliser


TURNIGNITIONON

LED OFF

LED ON3 x 0.5 sec.


1. Immobiliser programmed



0.7 sec.

FAULT: Transponder is not recognised.

The immobiliser has seen the transponder chip so you know that the chip in the key is intact

and the aerial is working correctly.

Possible reasons for the transponder not being recognised.

1. The wrong key is being used.

It is possible for two keys to have the same cut profile on different vehicles

(there are limited number of profiles).

If the keys were mixed up you could turn on the ignition but the immobiliser would not

recognise the chip.2. The key you are using has not been programmed into the immobiliser.

See PAGE 9 for details of programming .


51/150


Non Leader Immobiliser

The original Vespa ET4 (ZAPM04) was powered by an air-cooled four stroke engine that looked

similar but was very different to the Leader engine.

On the next page there is an explanation of the wiring for this engine.

Immobiliser operation once the system is programmed and working correctly:

CDI is irrevocably linked to the immobiliser

Immobiliser is irrevocably linked to the red master key.

It is possible to fit a new CDI alone.

It is not possible to fit a new immobiliser alone, you must also change the CDI.

It is not possible to change the red key alone.

Fault finding:

* Fault finding is done either with the diagnostic tester or a 12 volt LED.

* The tester is explained in the service station manual. Using an LED is explained here.

* The vehicle is not fitted with an LED in the instrument panel.

* You must connect a 12 volt LED to the test socket.* The test socket is a grey two pin plug with nothing plugged into it located in a

large rubber sheath on the right side of the engine bay.

* Remove the helmet storage to access the socket.

Note. Keys should not be on a metal key ring or with other keys.

Sometimes this can upset the system.

Possible LED Flashing Fault Codes

TURNIGNITION

ON

LED OFF

LED ON

0.5 sec.0.7 sec.


1. CDI not programmed



LED OFF

LED ON1. Immobiliser is programmed

2. Break in serial line (orange) or decoder earth (black)


2 sec.

2 x 0.5 sec.0.7 sec.

LED OFF




3 x 0.5 sec.0.7 sec.

LED OFF




0.7 sec.

LED ON

LED OFF


2. Transponder is detected3. Engine can run normally

4 x 0.5 sec.0.7 sec.


2. Virgin immobiliser, programmed CDI


LED ON

LED OFF

Immobiliser

is workingcorrectly


52/150

19/01/2006PAGE 13 ZAPM 04 Later version

Vespa ET4 125 charge / ignition (non Leader)

VOLTAGE

STABILISER

DECODER

3 5 8 6 4

CDI UNIT

3 2 1V G W B R

ORANGE

ANTENNA

(Serial Line)

DC

SERVICESAC

SERVICES

GREEN

GREEN

WHITE

BROWN

RED

YELLOW

LIGHT BLUE

LIGHT BLUE

WHITE / RED

PINK

LIGHT BLUE

BLACK / BLUE

PINK

Lt. BLUE

BLUE

BLUE

WHITE

WHITE

PURPLE

GREY/BLUE

GREY

GREY

WHITE

YELLOW

NOTES.

* This Diagram shows the non "Leader" ET4 125 with the later type 8 pin rectifier / regulator.

* This charging and ignition system is very similar to Piaggio 50cc 2 strokes and totally different to the

later "Leader" engined ET4 125.

* Three separate systems. DC, AC and ignition.

* Ignition is self generating. The green wire (charging coil) is shorted to earth to stop the engine.

Immobiliser. See separate notes for a full explanation of the immobiliser system.* PINK wire is non switched live (battery voltage) feed to the immobiliser.

* WHITE / RED is voltage stabilised power for immobiliser and CDI.

* When ignition switch is turned on the immobiliser and CDI are energised via the LIGHT BLUE wire.

The immobiliser uses the antenna to look for a recognised unique code from the key being used.

If the immobiliser recognises the key they it sends another unique code to the CDI via the ORANGE

wire (serial line). If the CDI does not receive that code it will not operate. It is this code that makes it

impossible to bypass the immobiliser box.

* The diagnostic test socket will be found when the helmet compartment is removed.

Look on the right side for a large rubber shroud protecting several plugs and sockets.

The diagnostic socket is a grey two pin socket with nothing plugged into it.

You can connect a 12v LED or the diagnostic tester to this socket.

Test box use is well covered in the Service Station Manual.

Testing using 12v LED is covered in these notes.

Tests. See the service station manual for a full explanation of testing the system.

Ignition. Stator (un-plugged) Green-White = 300 - 400 ohms. Red-Brown = 90 -140 ohms.

Loom. Unplug stator and CDI. Green wire should give continuity to earth with ignition OFF and no

continuity with ignition ON.

IMMOBILISER UNIT

RED / BLUE

21 3 4 5 6 7 8


1. AC out

2. AC in

3. not used

4. not used

5. DC out

6. Earth

7. Indicators

8. DC in

HT COIL

BATTERY

12v

+

7.5 AMP

FUSE

PINK

RED

Diagnostic

Test Socket

OFF

ONIGNITION SWITCH

ToIndicators

WHITE / RED

GREEN

BLUE

WHITE

RED

GREEN

BLACK


53/150


Quasar Immobiliser

The 250 cc Quasar engine is available with a CV carburettor or semi closed loop fuel injection.

The Quasar engine with a carburettor has exactly the same immobiliser function as a Leader

engine.

The Injected engine is detailed below.

This is only a quick reference guide for basic fault finding of the immobiliser system.

For a full explanation please see the Service Station manual.

The Quasar has an ECU with a separate immobiliser which is built into the aerial, so the ECU must

obtain authority from the aerial (active antenna).

Keys should not be on a metal key ring or with other keys. Sometimes this can upset the system.


TURNIGNITIONON

LED OFF

LED ON

0.5 sec.0.7 sec.


1. ECU not programmed



LED OFF

LED ON 1. Immobiliser is programmed

2. Break in serial line (ECU to aerial)


2 sec.

2 x 0.5 sec.0.7 sec.

LED OFF




3 x 0.5 sec.0.7 sec.

LED OFF

LED ON

1. Immobiliser is programmed2. Transponder is not recognised


0.7 sec.




LED ON

LED OFF

LED OFF

LED ON1. ECU not programmed



Any

Key

Any

Key

Service

Key

Master

Key

Service

Key

Service

Key

ServiceKey

2 x 0.5 sec.0.7 sec.

LED OFF


2. Two service keys are programmed3. Engine can run normally

Immobiliser

is working

correctly

Could be

any number

A

B

C

D

E

See Note

on the

Next Page


54/150

19/01/2006PAGE 15 NOTES

Quasar Immobiliser

LED flashing code notes.

A.ECU is not programmed.The LED gives a single two second flash. The Engine management light will be on.

You should get this code when you have fitted a new ECU.

The immobiliser system is working correctly and only needs programming.

B.ECU is not programmed. Transponder is not detected.The LED gives a single two second flash, then two short flashes, then comes back on..

The ECU is not programmed (as above) but also the chip in the key has not been detected.

You must resolve the transponder problem before trying to program the ECU.

The master key will give this fault if the chip is hinged out.

If you have another key try that, if it is still not detected it is probably the aerial.

Verify that the aerial is correctly located and secure in it's mounting around the ignition lock.

C.Break in the Serial line.A single short flash, pause, then a second short flash, LED then comes back on.

There is a break in the wire between the ECU and the aerial (active antenna).

The Orange / White wire on pin 7. is the link.

D.Transponder is not detected.A single short flash, then two short flashes, then comes back on.

The chip in the key has not been seen.

Either there is a fault with the key or the aerial.

If you have another key try that, if it is still not detected it is probably the aerial.

Verify that the aerial is correctly located and secure in it's mounting around the ignition lock.

E.Transponder is not recognised.A single short flash, then three short flashes, then comes back on.

The chip in the key is seen be is not recognised.

The key is not programmed into the immobiliser memory.

You are using the wrong key or it needs to be programmed into the immobiliser memory.

Diagnostic Tester

If you use the hand held diagnostic tester you can check the immobiliser.

Select the "Errors" menu to see detailed fault information.

DISPLAY NOTES

Uncoded ECU Yes / No Yes = Virgin ECU

LED - one 2 sec flash in phase one (page 14 A)

Imm start inhib Yes / No Yes = Ignition is not possible (no spark).

LED remaining on in phase three (page 14 B,C,D,E)

Universal code Yes / No For production assembly line use only. Yes = Virgin ECU

Key failure Yes / No Yes = Key transponder is not seen.

LED - two flashes in phase two (page 14D)

Wrong Key code Yes / No Yes = Key transponder is seen but not recognised

LED - three flashes in phase two (page 14 E)

Commun timeout Yes / No Yes = No signal from active antenna to ECU

LED - one flash in phase two (page 14 C)


55/150

Programming.

Notes.


Once it has been programmed it is irrevocably linked to that master key.

2. It is not normally possible for an immobiliser to loose it's program and then need

re-programming.




Plug cap must be at least 5000 ohms. Change the cap and lead if suspect.

A resistor spark plug must be used.

Then try re-programming the immobiliser.

If it will not re-program then it is faulty.

Programming a new immobiliser.

1. Do not attempt to program a new immobiliser until you know that the fault is cured.

Connect the new immobiliser, use the service key (not the brown master key)

LED will give one long flash then go out and stay out. System is working correctly,

Immobiliser is not programmed

The engine should start but will not rev above 2000 rpm until the immobiliser is

programmed.

2. To program a new immobiliser


* Insert the service key and turn on for two seconds* (any extra service keys are included here)

- Insert the extra service key and turn on for two seconds


* The timing of the two seconds can be critical so use a watch to time it,

you may need to do the sequence several times before it is accepted.

* Changing from one key to the next should be done within ten seconds.

* An extra service key is not just added,

you must go through re-programming all the keys as above.

You are not re-programming the master key, the master key is giving permission for the

service keys to be added.

* It is not the keys that are programmed.

The immobiliser is being programmed to recognise the keys.* You do not need to start the engine just to check if the programming has been successful,

Just turn on the ignition and watch the LED.

One short flash (half second) means the programming was successful.

One long flash (two seconds) means the system is still not programmed.

19/01/2006PAGE 16 PROGRAMMING

Quasar Immobiliser


56/150


Master Immobiliser

The 500 cc Master engine has separate immobiliser and ECU.

Once the system is programmed the ECU and immobiliser are irrevocably linked to the brown

master key.

Keys should not be on a metal key ring or with other keys. Sometimes this can upset the system.

For a full explanation of fault finding please see the Service Station manual.


TURNIGNITIONON

0.5 sec.0.7 sec.


LED OFF


2. Break in serial line3. Ignition is not possible

2 x 0.5 sec.0.7 sec.

LED OFF




3 x 0.5 sec.0.7 sec.

LED OFF




0.7 sec.




LED ON

LED OFF

LED OFF

LED ON1. Immobiliser not programmed

2. ECU is programmed


2 sec.

Any

Key

Service

Key

Master

Key

Service

Key

Service

Key

Service

Key

2 x 0.5 sec.0.7 sec.

LED OFF


2. Two service keys are programmed


Immobiliser

is working

correctly

Could be

any number

from 0 to 7

A

B

C

D

See Note

on the

Next Page

E

2 sec.

1. System not programmed2. Transponder is detected

3. Engine runs only to 2000 rpm.

LED ON

LED OFF

AnyKey


57/150

19/01/2006PAGE 18 NOTES

Master Immobiliser

LED flashing code notes.

A.System is not programmed.The LED gives a single two second flash. The Engine management light will be on.

You should get this code when you have fitted a new immobiliser and ECU.

The immobiliser system is working correctly and only needs programming.

B.Immobiliser is not programmed, ECU is programmed.The LED gives one long flash, then four short flashes, LED then comes back on.

Programming the immobiliser is only possible if the original master key is used.

If the original master key (chip) is not available then you must change the ECU as well.

C.Break in the Serial line.A single short flash, pause, then a second short flash, LED then comes back on.

Either there is a break in the orange / white wire between the immobiliser and ECU

(serial line) or if the vehicle has a "fall over cut out" fitted it could be that.

If the cut out is active it shorts the serial line to earth.

The fall over sensor is located behind the fuel tank (Nexus) in a rubber mounting.

The fall over sensor

must be mounted

THIS WAY UP

D.Transponder is not detected.A single short flash, then two short flashes, then comes back on.

The chip in the key has not been seen.

Either there is a fault with the key or the aerial.

If you have another key try that, if it is still not detected it is probably the aerial or it's wires.

Un-plug the aerial from the immobiliser and check for continuity.

Check that the aerial is correctly located and secure in it's mounting.

E.Transponder is not recognised.A single short flash, then three short flashes, then comes back on.

The chip is seen be is not recognised. The key is not programmed into the immobiliser.

You are using the wrong key or it needs to be programmed into the immobiliser memory.


58/150

Programming.

Notes.


Once it has been programmed it is irrevocably linked to that master key.

2. It is not normally possible for an immobiliser to loose it's program and then need

re-programming.




Plug cap must be at least 5000 o

21959150 piaggio vespa gilera technical notes and workshop reference

Documents