iTechnical 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 questionsI 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 anyconfusion.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
ii
Technical / After sales contacts:
For any After Sales problems or questions, your first contact should be yourRegional After Sales Manager.
Benjy Straw - Technical Services Manager020 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 Management020 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 Manager020 7401 4329. [email protected]
Technical department Fax: 020 7401 4321
PLEASE MAKE SURE THAT YOU CONTACT THERIGHT PERSON
3Chapter 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 Fuses8. 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 connections20. 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 Notes9. 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 / Charging9. 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 lighting3. 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
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
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 / Charging
19. 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
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
Chapter 4
Electrical Systems
Two StrokeManual Engines
1. H@k / GSM Ignition / Charging
2. H@K / GSM Notes
3. H@K / GSM Wiring Diagram
4. 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
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
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
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 Gilera
10. Keys General
11. De-Restriction Notes
12. Chassis Number Location
13. Quick Reference Guide
14. Service Limit List
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
Chapter 9
Tech Tips
A collection of the
Tech Tips
previously published
on the Piaggio Portal
01
02
03
04
05
30/09/2005Piaggio Ltd. 5 pin regulator
50 / 80cc 2T Charging (early vehicles)
BATTERY12v
+
CHOKE UNIT
7.5 ampFUSE
IGNITIONSWITCH
YELLOW
BLUE
GREY / BLUE
RED
GREY
DC SERVICESBrake 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 regulatedDC 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 motorbut not the DC circuit or ignition circuit.
1
3
WH
ITE
BLA
CK
YE
LLO
W
GR
EY
/ B
LUE
RECTIFIER&
REGULATOR
B+GAA
REGULATOR
2
GR
EY
ACSERVICESHead lightTail light
Instruments
12v 4ah - 50cc12v 5ah - 80cc
1 - 1
OFF
ON
RED
30/12/2005Piaggio Ltd. 8 pin regulator
50 / 80cc 2T charging
BATTERY12v
+
CHOKE UNIT
7.5 ampFUSE
ACSERVICES
YELLOW
BLUE
GREY / BLUE
RED / WHITE
GREY
DC SERVICESBrake light
Horn
RED
BLUEWHITE
* 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 rpm4. 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
NOTUSED
see noteTO INDICATOR
SWITCH
Head lightTail light
Instruments
WH
ITE
BLUE / BLACKBLA
CK
YELLOW
4
GR
EY
/ BL
UE
4321 5 6 7 8
REGULATORRECTIFIER
®ULATOR
2
OILWARNING
LIGHT OIL TANKSENDER
1-2
IGNITION SWITCH
OFF
ON
OILLIGHTTIMER
GREY
DC SERVICESBrake light
Horn
TO INDICATORSWITCH
BLU
E /
RE
D
BLUE / BLACK
BLA
CK
YELLOW
GR
EY
/ BL
UE
CHOKE UNIT
ACSERVICESHead lightTail light
Instruments
RECTIFIER&
REGULATOR
4321 5 6 7 8
REGULATOR
TIMER
YE
LLO
W /
GR
EEN
WH
ITE
/ V
IOLE
T
BLUE / RED
30/09/2005Piaggio Ltd. 8 pin regulator
NRG (up to Mc3) & ZIP Cat. Charging & Guages
BATTERY12v
+
7.5 ampFUSE
IGNITIONSWITCH
YELLOW
BLUE
GREY / BLUE
RED / WHITERED
BLUE WHITE
OILWARNING
LIGHT
1 - 2 a
FUELWARNING
LIGHT
FUEL GUAGENRG only
FUELSENDER
UNIT
WH
ITE
/ V
IOLE
T
WH
ITE
YE
LLO
W /
GR
EEN
WH
ITE
/ G
RE
EN
The NRG (up to Mc3) / Zip Cat wiring is very similar to other 50 / 80 scooters.Refer to page 1-2 (50 / 80 Charging) and page 1-3 (50cc 2t Ignition) for other information.
TESTS1. 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 TANKSENDER
BR
OW
N
BLUE / REDWHITE
BR
OW
NW
HIT
E /
VIO
LET
5
5
FUEL
1-2b
- 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. Signal7 Yellow / Black GN Instrument lights8 Black / Orange NAr ?9 - - Not used10 Green V Rev counter signal. 100> volts AC
*11* Yellow / Red GR Coolant temperature. Signal out to gauge, gauge earth's12 White / Green BV Fuel gauge. 12v out to sender, sender earth's13 Purple Vi High beam14 White / Blue BBl Turn signal right. 12v in to bulb when right turn selected15 Pink R Turn signal left. 12v in to bulb when left turn selected16 White / Purple BVi Low two stoke oil warning light. Power in from sender17 Yellow / Green GV Low fuel light. Power out to gauge, gauge earth's18 - - Not used19 - - 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
25/08/05Piaggio Ltd Piaggio Ltd
50cc 2t Ignition
GREEN
GREEN
GREEN
IGNITION SWITCH
IGNITION PICK UP
Champion NR2CNGK BR9ES
RED
WHITE
TESTS1. UNPLUG STATOR and CDI. GREEN WIRE SHOULD BEEARTHED 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 EARTHFOR
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 / COILunit
CDI / COILunit
IgnitionCharging 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 theelectrical 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
1-3
11/09/2003Piaggio Ltd
125 & 180cc 2t charging / IgnitionTyphoon, Skipper, Hexagon, Runner
STATOR
BATTERY12v
+
CDIUnit
IGNITIONPICK UP
FUSE
CHARGEWARNING
LIGHT
RED
RED
RED
RED
YELLOW
YELLOW
GREEN
WHITEBROWN
PURPLE
GR
EY
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 flatTESTS1. 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.Hexagon (EXS1T & ZAPM05 / 06) 25 amp.Typhoon (ZAPM02) 15 amp.Skipper (CSM1T) 7.5 amp.
GGBL CA
ChokeControl
DCRectifier
RegulatorOut put only whencharging
RED
WH
ITE
BR
OW
N
GR
EY
YELL
OW
YELL
OW
COOLING FANON
WATER COOLEDMODELS
Choke Unit Carb. Heater
OFF
ON
IGNITION SWITCH
SUPPLYTO
SYSTEMS
1-4
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
11/09/2003Piaggio Ltd.Hexagon LX / LXTRunner FX / FXRSkipper & 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.
1-6
Purple - EarthHT Primary
HT lead - EarthHT Secondary
Meter between >To test >
Hexagon LX / LXTRunner FX / FXRSkipper / Typhoon 125
Red - BrownPick - up Coil90 - 140 ohm90 - 140 ohm90 - 140 ohm
White - GreenCharge Coil
50 - 100 ohm50 - 100 ohm100 - 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+
1-7Piaggio Ltd. May 2000
FUSE EXPLANATIONRunner 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 amp 1
7.5 amp 2
10 amp 3
+12v whenignition is ON
Permanent +12vvia 25 amp fuse
HeadlightRelay
LightingSwitch
Head LightFlash
High / LowSwitchLow Beam
High Beam1
4
3
From Fuse#
Rectifier /Regulator
11/06/02Piaggio Ltd. Derbi engine
DIESIS 100 Charging / Ignition
Red4
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.
NGKB9 ES
Yellow / Green
Yellow / Green
Yellow / Green
Green / Black
Orange
PinkWhite
Red / Blue
Yellow
Green / Black
Red
Red
Gre
en /
Blac
k
Yel
low
/ G
reen
AC Supply
DC Supply
LEFT
OFF
RIGHT
Indicators
Yellow / White
White / Red
Ignition SwitchLOCK
OFF
ON
GreenOrangeBlack Red / White
Black / Red
Carb. Heater
BATTERY12v4ah
+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.Ignition: HT coil secondary resistance = 5 - 6 K ohm. Unit un-plugged.
+ 5o C
Thermostat
Black
Black
1-8
IndicatorRelay
Rectifier&
RegulatorRegulator
Orange - Indicator switch
Yellow - AC circuit
Red / Blue - DC supply
White / Red - Stator
Red - Battery
Explanation of Rectifier / regulator wiring
02/09/2003Piaggio Ltd. GILERA RUNNER
PUREJET 50 IGNITION / CHARGE
OFF
ON
BATTERY12v
+
~ ~ ~ +
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
BLU
E
RED
BLAC
K / V
IOLE
T
OR
ANG
E
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 ChampionRG6YCA
BLUE
BLUE
BLU
E
BROWN
BRO
WN
To starterrelay
1-9
12/01/2004Piaggio Ltd. Runner
Purejet 50 Turn Signals & Oil check
BATTERY12v
+
ON
Yellow
White
Ora
nge
BESL
Black
White
Yellow
Black / Blue
Red
/ B
lue
Red
15 ampFuse's inBattery
Compartment
Yellow
7.5 amp Fuse'sin HornCompartment
Grey / Red
Blue
White / Red
Oil TankSender
Low OilWarning
Light
TurnIndicatorSwitch
Rig
ht T
urn
Indi
cato
rs
Pink
Pink White / Blue
White / Blue
Ignition Switch
Black / Blue
IndicatorControl 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.
Whi
te
1 - 10
Left
Turn
Indi
cato
rs
OFF
LEFT
RIGHT
LOW
13/12/2005Piaggio Ltd. 2 stroke engine
Fly 50 & Vespa LX 50 charging & carb heater
BATTERY12v 4ah
+
CHOKE UNIT
7.5 ampFUSE
IGNITIONSWITCH
YELLOW
BLUE
GREY / BLUE
RED / BLUE
YELLOW / BLACK
DC SERVICESBrake 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 strokesbut there are a few slight variations including the electric carb heater.TESTS.y Stator out put. Grey / Blue to earth = 25-30v AC stator un-plugged and engine at 2000rpm.y Stator out put. Yellow to Blue = 26-30v AC stator un-plugged and engine at 2000 rpm.y Ammeter between red wire and battery positive = 1.5-2 amp with fully charged battery and engine at 2000
rpmy Output to the indicator switch will be a 12v DC pulse with ignition on.NOTES.y 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).y The choke is AC powered as normal. It is not controlled by the Carb. heater controller.y 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
3
NOTUSED
TO INDICATORSWITCH
WH
ITE
/ R
ED
BLU
E /
BLA
CK
BLA
CK
YE
LLO
W
4
GREY / BLUE
2
OILWARNING
LIGHT
OIL TANKSENDER
1-11
OFF
ON
RE
D /
GR
EE
N
ORANGE
WH
ITE
RECTIFIER&
REGULATOR
4321 5 6 7 8
REGULATOR
OILLIGHTTIMER
GREY / BLUE
ACSERVICESHead lightTail light
Instruments
YELLOW / BLACK
YELLOW / BLACK
CARB. HEATER Lt. BLUE
ORANGE / BLACK
WHITEWHITE
Carburettorheatercontrol
AC
3 2 18 7 6 5 4
Rectifier /Regulatorp/n: 82501R
25/08/05Piaggio Ltd. With IMMOBILISER
B 125 / 200 ignition / charging
Red
White / Black
Yellow
IgnitionPick up
CDI / Immobiliser
IgnitionSwitch
HT Coil
White
Purple
Red / Black
Black
White
CoolingFan Fan
Switch
Red / Black
Green
White / Green or Light Blue
White
Red / Black
Lt. Blue
White /Green
G
Choke Unit White
White /OrangeWhite
Lt. Blue
Black / BlueIndicatorSwitch
Yellow / Blue
Red / Blue
Red / Black
Green
Orange
Emergency Stop
Green / Blue
OFF
1
2
Seat Lock Seat ReleasePush Button
Blue
White / BlueWhite
Blue
Green
Ignition Relay
4 amp
BATTERY12v
10ah
+
CR 9EB
Side StandSwitch
ImmobiliserLED
StandWarning
Blue / Black
CDI CONNECTIONS1. BLUE / BLACK - INDICATOR SWITCH SUPPLY2. GREEN - INPUT FROM IGNITION PICK UP3. PURPLE - TO HT COIL4. RED / BLACK - 12v PERMANENT LIVE5. WHITE / GREEN - SUPPLY FROM IGNITION SWITCH6. YELLOW / BLUE - IMMOBILISER LED7. WHITE / BLACK - CHOKE CONTROL8. BLACK - EARTH
STOP
RUN
Down
UP
2-1
15 4
Blu
e
Red
/ B
lack
Red
/ B
lue
15 15
White / Black
Yellow / Blue
White / Green
Red / Black
antenna
2-2
B 125 / 200 NOTES
The notes should be used in conjunction with Service Station Manual 594845 andthe 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 samefuse.
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. Immobiliser is 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 off
to operate an over run valve in the carburettor. Carburettor icing is controlled by a warm water feed from the cooling
system. Choke is the automatic (wax pellet) type used on all our automatics.
Remember that these units default to being ON and are turned offelectrically. They are more likely to cause running rich when hot than coldstarting problems.
5. Spark Plugs.Please note that the correct spark plugs are:125cc :- NGK CR8 EB p.n. 828866200cc :- Champion RG6 YC p.n. 828708 (or NGK CR7EB)
08/05/2003Piaggio Ltd. Piaggio Ltd.
B 125 FUSE EXPLANATION
FRONT FUSE BOX
2 4 amp
4 4 amp
3 7.5amp
1 4 ampWHITE
12v DC fromignition switch
GREYFrom light
switchYELLOW
Anologue, Inst. & side lights
RED / GREYHorn, Headlight flash
WHITE / REDBrake lights, start inhibit
WHITE / ORANGEEngine start, run, warning lights
REAR FUSE BOX
7
15a
5
4a
6
10a
8
15a
RED12v DC from battery
RED / BLUEDigital Panel, LED, Radio
RED / BLACKGeneral
YELLOWHeadlight via relay
BLUEUnder seat, Light, Socket, Lock
2-3
Rectifier /Regulatorp/n: 82501R
13/08/2003Piaggio Ltd. DNA 125 / 180
DNA Leader engine ignition / charging
GALTERNATORSTATOR
ToIndicatorswitch
Headlightvia relay
Red
Green
Green
White / Black
Yellow
IgnitionPick up
ECU
IgnitionSwitch
Blue /Black
15amp
Blue / Red
Green / Yellow
White/ Pink
Red
Power toLights, horninstruments
Black
3 2 18 7 6 5 4
BATTERY12v
12ah
+
Choke Unit
Red
Lt. Blue / Green
Yellow / RedRedWhite
Connector for Alarm
Orange
Orange
Yellow
7.5amp
7.5amp
FanSwitch
GreenCoolingFan
HT Coil
NGKCR 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.CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
OFF
ON
STOP
RUN
2-4
08/05/2003Piaggio Ltd. Refer to Service Station Manual594329 (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
PINKBLUE - BLACK
WHITE - BLUEWHITE
PURPLEBROWN
YELLOW - BLACKGREY - BLACK
BLACK
LEFT HANDSWITCHES
ITEM 8ON WIRING DIAGRAM
HORNINDICATORS MAIN / DIP
0
RUN
0
PUSH
OFF
SIDE
ALL
EMERGENCYSTOPSTARTLIGHTS
WHITEYELLOW - RED
GREEN - BLACKWHITE - BLACK
ORANGEBROWN
YELLOW
RIGHT HANDSWITCHES
ITEM 9ON WIRING DIAGRAM
2-5
Rectifier /Regulatorp/n: 82501R
30/09/2005Piaggio Ltd. With IMMOBILISER
ET4 Leader / LX 125 ignition / charging
GALTERNATORSTATOR
ToIndicatorswitch
Headlightvia relay
Red
Green
Green
White /Black
Red / Blue
RG4HCCR 9E
Carb. Heater
Choke Unit
Yellow
IgnitionPick up
ECU / Immobiliser
IgnitionSwitch
HT Coil
Blue /Black
15amp
Orange
Orange
White
Red /Blue
Purple
Grey
Red / Blue
Powerto
services
Red / Blue
Black
antennaYellow
LED oninstrument
pannel
Diagnosticsocket
6 1
8 3
4 5
7 2 GREEN
WHITE / BLACKORANGE
RED / BLUE
PURPLEBLACK
BLUE / BLACK
YELLOW
Layout of pinsin the ECU / immobiliser
Orange
7.5amp
BATTERY12v9ah
+
3 2 18 7 6 5 4
TESTS.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.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.
HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
OFF
ON
2-6
Rectifier /Regulatorp/n: 82501R
13/03/02Piaggio Ltd. With IMMOBILISER
Hexagon GTX 125 ignition / charging
GALTERNATORSTATOR
ToIndicatorswitch
Red
Green
Green
White/ Black
White
Yellow
IgnitionPick up
ECU / Immobiliser
IgnitionSwitch
HT Coil
Blue / Black15amp
Orange
Orange
Red
Purple
Red
Red
Black
antenna
Yellow
Red / Blue
LED oninstrumentpannel
Layout of pinsin the ECU / immobiliser
Yellow / Blue
BATTERY12v
12ah
+
Orange
RG4HCCR 9EB
CoolingFan
FanSwitch
RedGreen
Choke Unit
Lt. Blue
Orange
5amp
5amp 6
1 8
3 4
5 7
2 GREENWHITE / BLACKLt. BLUE
RED
PURPLEBLACK
BLUE / BLACK
YELLOW
Diagnosticsocket
3 2 18 7 6 5 4
TESTS.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.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.
HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
OFF
ON
STOP
RUN
2-7
antenna
Rectifier /Regulatorp/n: 82501R
19/07/02Piaggio Ltd. With IMMOBILISER
Runner VX / VXR ignition / charging
GALTERNATORSTATOR
ToIndicatorswitch
Headlightvia relay
Red
Green
Green
White /Black
Red / Blue
Choke Unit
Yellow
IgnitionPick up
ECU / Immobiliser
IgnitionSwitch
HT Coil
Blue / Black
15amp
Red / Blue
Orange
Red
Purple
Grey/ Red
Red
Power toservices
Red
Black
Yellow
Red / Blue
NGKCR 8EB
CoolingFanFan
Switch
Red
Green5
amp
6 1
8 3
4 5
7 2 GREEN
WHITE / BLACKRED / BLUE
RED
PURPLEBLACK
BLUE / BLACK
YELLOW
Diagnosticsocket
Red
LED oninstrumentpannel
Yellow / Red
Layout of pinsin the ECU / immobiliser
3 2 18 7 6 5 4
TESTS.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.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.
HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
BATTERY12v
10ah
+
OFF
ON
2-8
27/02/2004Piaggio Ltd SSM page 4-8
X9 125 indicator wiring
10 amp
7.5 amp
7.5
amp
BATTERY12v
+
Instruments panel
OFF
ON
LEFT
CANCEL
RIGHT
+ G G G
FUSES IN UNDER SEATCOMPARTMENT
RECTIFIER / REGULATOR
INDICATOR SWITCH
LEFT INDICATORS
FUSES IN FRONTSTORAGE
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. B
LUE
/ BLA
CK
. To
switc
h. R
IGH
T tu
rn
6. P
INK
/ B
LAC
K. T
o sw
itch.
LEF
T tu
rn
7. R
ED /
GR
EY. 1
2v+
from
igni
tion
switc
h
8. 22.
21.
20.
19.
18.
17.
24.
31.
32.
32.
33.
34.
35.
23.
12v+
from
bat
tery
. RED
/ W
HIT
E 1. 2.
3.
To R
IGH
T in
dica
tor b
ulbs
. WH
ITE
/ BLU
E 4. 14
.
GR
EY /
BLU
E. C
ance
l 13.
To L
EFT
indi
cato
r bul
bs. P
INK
12.11
.
10.
9.
16.
25.
26.
27.
28.
29.
30.
15.
2-9a
Rectifier /Regulatorp/n: 82501R
15/10/2004Piaggio Ltd. With IMMOBILISER
X9 125 / 180 & 250 Evo ignition / charging
GALTERNATORSTATOR
Red
Green
Green
White / Black
Yellow
IgnitionPick up
ECU / Immobiliser
IgnitionSwitch
15amp
Orange
Orange
Red / Black
Yellow
Layout of pinsin the ECU / immobiliser
Yellow / Grey
BATTERY12v
12ah
+
CoolingFan
Fan Switch
Red / Black
Green
Choke Unit
EmergencyStop
Lt. Blue
Orange
5amp
Diagnosticsocket
2 GREEN
7 WHITE / BLACK
5 Lt. BLUE
4 RED / BLACK
3 PURPLE8 BLACK
6 YELLOW
Red / Black
Yellow / BlueYellow / Green
Grey/ Black
Lt. Blue
TESTS.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.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.
HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
3 2 18 7 6 5 4
RG4HCCR 9EB
HT Coil
Purple
Black
SideStandSwitch
Red / White
STOP
RUN
STOP
RUN
UP
DOWN
2-9
ImmobiliserLED
StandWarning
Power toServices
antenna NOTE.Indicators are powered bythe digital instrument panel.
Rectifier /Regulatorp/n: 82501R
13/08/2003Piaggio Ltd. NO Immobiliser
ZIP 125 Leader engine ignition / charging
GALTERNATORSTATOR
ToIndicatorswitch
Red
Green
Green
White /Black
Choke Unit
Yellow
IgnitionPick up Ignition
Switch
Blue / Black15amp
Orange
Orange
Purple
Red / Blue
Powerto
services
Black
ECU CONNECTIONS1. BLUE / BLACK - INDICATOR SWITCH SUPPLY2. GREEN - INPUT FROM IGNITION PICK UP3. PURPLE - TO HT COIL4.5. ORANGE - SUPPLY FROM IGNITION SWITCH6.7. WHITE / BLACK - CHOKE CONTROL8. BLACK - EARTH
TESTS.Yellow - Yellow. Charging coils. 0.7 - 0.9 ohmYellow - Earth. No continuityGreen - Earth. Ignition pick up coil. 105 - 124 ohm.Purple - Earth. Coil primary winding. 0.4 - 0.5 ohmHT - Earth. Coil secondary winding. 3000 ohm
LOCK
OFF
ON
Carb. Heater
Layout of pinsin the ECU
3 2 18 7 6 5 4
ECU
6 1
8 3
4 5
7 2 GREEN
WHITE / BLACKORANGE
PURPLEBLACK
BLUE / BLACK
RG6YCCR 7EB
HT Coil
BATTERY12v9ah
+
2-10
2-111 of 2
Piaggio Ltd February 2004
LEADER ENGINEIgnition, charging & immobiliser
Use these notes in conjunction with the SERVICE STATION MANUAL
The electrical system on the new Leader engine is very different to previous two stroke andfour 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, VespaGT 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 / IMMOBILISERNote 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 aroundthe 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 isprogrammed and working correctly the LED should be flashing steadily with the ignitionturned off to confirm that the immobiliser system is functioning. The immobiliser earths theLED (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
2-112 of 2
Piaggio 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 lightsoff.
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 theignition 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 tooperate 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 theECU. The unit will not function until the engine is running when the CDI will complete thecircuit 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 issupplied 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 thefan. So if the fan is faulty it could be the cause of a flat battery.
Piaggio, Gilera & Vespa
Immobilisersystems
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 enginedvehicles because this is by far the most common.
Much of the operation of other systems is the same as the Leadersystem.
Systems covered:
LeaderPre Leader
QuasarMaster
Published January 20061st edition
Piaggio and other after market alarms and immobilisersare not covered here.
Copies of this and other Piaggio technical information can be obtainedfrom the Piaggio UK dealer portal web site
or from Piaggio Ltd.
Immobiliser SystemsINDEX
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 12 - Explanation of operation & Fault codes
Page 13 - Pre Leader ET4 wiring explanation
QUASAR
Page 14 - Explanation of operation & Fault codes
Page 15 - Notes on fault codes and diagnostic tester
Page 16 - Programming
MASTER
Page 17 - Explanation of operation & Fault codes
Page 18 - Notes on fault codes
Page 19 - Programming
Possible LED Flashing Fault Codes
TUR
N IG
NIT
ION
ON
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 programmed2. Transponder is detected3. Engine will run to 2000rpm
1. Immobiliser is programmed2. Transponder is not detected3. Ignition is not possible
LED OFF
LED ON1. Immobiliser not programmed2. Transponder is not detected3. Engine will run to 2000rpm
2 sec.
3 x 0.5 sec.0.7 sec.
LED OFF
LED ON1. Immobiliser is programmed2. Transponder is not recognised3. Ignition is not possible
0.7 sec.
LED OFF
LED ON1. Immobiliser is programmed2. Transponder is detected3. Engine can run normally
page 2
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.
19/01/2006PAGE 3 NEW KEYS
Leader Immobiliser
FAULT: I need new keys.
I have theMaster key
You must changeThe lock set and
The CDI / Immobiliser
I have theservice key
Take the key to anautomotive lock smith.
They will be able to clone it.
Obtain a blank service key,get it cut and program theimmobiliser to recognise it
See: PAGE 9
YES
NO
NO
It is not possible to program in anew key without the master key.Fortunately automotive locksmiths can create a clone that willnot need programming.
It is not possible to buy an extramaster key or have one made.
It is not possible to by pass theimmobiliser.The code card does not containany electronic data and is onlyused to cut the key by number.
See PAGE 4 & 5
Tell your customer to onlyuse the service key and keep
the master key in a safeplace at home
OR
YES
Gilera Runner service keysThe 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 atransponder
page 3
page 4
19/01/2006PAGE 4 NEW LOCKS
Leader Immobiliser
FAULT: I need to fit new locks.
Is the originalmaster keyavailable?
1. Fit the new lock set2. Remove the chip from the original master key and fit it to the new master key.3. The immobiliser will not know anything has changed4. Program the the new service key to the immobiliser. See PAGE 9
You must fit a new lock set and a newCDI / Immobiliser unit
It is not possible to bypass theimmobiliser.
See PAGES 4 & 5
The lock set is supplied with one(brown) master key and one service key.
YESNO
19/01/2006PAGE 5 NEW CDI
Leader Immobiliser
FAULT: I need to fit a new CDI / Immobiliser.
I have themaster & service
keyYES
I only havethe master key
I only havethe service key
NO The replacement CDI / immobilisermust be new and unused.
Fit the new CDI and use the servicekey to check the engine starts andruns (only 2000 rpm)
Program the immobiliser.See: PAGE 9
Fit the new CDI and use the masterkey with the chip "out" to check theengine starts and runs(only 2000rpm)
You must replace the lock set
NO YES
Obtain a new service key
Tell your customer to only use theservice key and keep the masterkey in a safe place at home
3 2 18 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 ConnectionsPlease refer to individual wiring diagrams andService Station Manuals for a full explanationand 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.
page 5
GREEN
BLACK
19/01/2006PAGE 6 Fault Finding
Leader Immobiliser
Ignitionturned off
PowerSupply
Problem7
One short flashGoes outStays out
TurnIgnition On
One long flashGoes outStays out
LEDFlashing?
Immobiliseris workingcorrectly
8
Immobiliserneeds
programming9
NO YES
One long flashTwo short flashes
Goes outStays out
One short flashTwo short flashes
Comes onStays on
One short flashThree short flashes
Comes onStays on
Fault is not with theimmobiliser
Immobiliserneeds
programming9
Transpondernot
detected10
Transpondernot
recognised11
Fault is not with theimmobiliser
Fault is not with theimmobiliser
Transpondernot
detected10
FAULT: Engines turns over but there is no spark when tested with a strobe light
For an explanation of each faultgo to the relevant numbered NOTES page
YES
YES
YES
YES
YES
NO
NO
NO
NO
page 6
19/01/2006PAGE 7 NO LED
Leader Immobiliser
3 2 18 7 6 5 4
CDI / Immobiliser
PERMANENT LIVE
SWITCHED LIVE
LED
EARTH
FAULT: With Ignition turned off the LED light is not flashing
Refer
to in
dividu
al mo
dels
wiring
diag
ram to
iden
tify w
ire
colou
rs
ChargedBattery
?
Ensure afully charged
battery is connected
LEDFunctioning
?
Un-plug the CDIConnect LED wire to earth
LED should light up
PermanentLive toCDI ?
1. Check Fuse.2. Check continuity of wire to instruments.3. Check continuity of wire from instruments to CDI.
YES
NO
DON'TKNOW
NO
YES
SwitchedLive toCDI ?
GoodEarth
?
YES
YES
1. Check Fuse.2. Check continuity of wire from fuse to CDI.
1. Check Fuse.2. Check continuity of wire from fuse to ignition switch.3. Check continuity of wire from ignition switch to CDI.
Check continuity from CDIconnector to battery negative
NO
NO
NO
Returnto
Page 6
page 7
Note. With an all new / virgin system the LED may not be flashing but thecheck function flashes should occur when the ignition is turned on.
19/01/2006PAGE 8 Immobiliser OK
Leader Immobiliser
Ignitionturned off
One short flashGoes outStays out
TurnIgnition On
LEDFlashing?
Immobiliseris workingcorrectly
8
YES
Fault is not with theimmobiliser
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 ignoredand 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.
page 8
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 electricalinterference 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 programmedThe engine should start but will not rev above 2000 rpm until the immobiliser isprogrammed.
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* Insert the brown master 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.
page 9
Possible LED Flashing Codes
TUR
N IG
NIT
ION
ON
LED OFF
LED ON
Phase 1 Phase 2 Phase 3
1. Immobiliser not programmed2. Transponder is detected3. Engine will run to 2000rpm
2 sec.
0.7 sec.
LED OFF
LED ON1. Immobiliser is programmed2. Transponder is detected3. Engine can run normally
19/01/2006PAGE 10 NOT DETECTED
Leader Immobiliser
FAULT: Transponder not detected.
Possible LED Flashing Codes
TUR
N IG
NIT
ION
ON LED OFF
LED ON2 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 programmed2. Transponder is not detected3. Ignition is possible
1. Immobiliser is programmed2. Transponder is not detected3. Ignition is not possible
The immobiliser knows the ignition has been turned on but it has not been able to detect thetransponder 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.
page 10
19/01/2006PAGE 11 NOT RECOGNISED
Leader Immobiliser
Possible LED Flashing Codes
TUR
N IG
NIT
ION
ON
LED OFF
LED ON3 x 0.5 sec.
Phase 1 Phase 2 Phase 3
1. Immobiliser programmed2. Transponder is not detected3. Ignition is not possible
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 intactand 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 notrecognise the chip.
2. The key you are using has not been programmed into the immobiliser.See PAGE 9 for details of programming .
page 11
19/01/2006PAGE 12 EXPLANATION
Non Leader Immobiliser
The original Vespa ET4 (ZAPM04) was powered by an air-cooled four stroke engine that lookedsimilar 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 immobiliserImmobiliser 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.
page 12
Possible LED Flashing Fault Codes
TUR
N IG
NIT
ION
ON
LED OFF
LED ON
0.5 sec.0.7 sec.
Phase 1 Phase 2 Phase 3
1. CDI not programmed2. Transponder is detected3. Engine will run to 2000rpm
LED OFF
LED ON 1. Immobiliser is programmed2. Break in serial line (orange) or decoder earth (black)3. Ignition is not possible
2 sec.
2 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Transponder is not detected3. Ignition is not possible
3 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Transponder is not recognised3. Ignition is not possible
0.7 sec.
LED ON
LED OFF
1. Immobiliser is programmed2. Transponder is detected3. Engine can run normally
4 x 0.5 sec.0.7 sec.1. Immobiliser is programmed2. Virgin immobiliser, programmed CDI3. Ignition is not possible
LED ON
LED OFF
Immobiliseris workingcorrectly
19/01/2006PAGE 13 ZAPM 04 Later version
Vespa ET4 125 charge / ignition (non Leader)
VOLTAGESTABILISER
DECODER
3 5 8 6 4
CDI UNIT
3 2 1V G W B R
ORANGE
ANTENNA
(Serial Line)
DCSERVICES
ACSERVICES
GREEN
GREEN
WHITE
BROWN
RED
YELLOW
LIGHT BLUE
LIGHT BLUE
WHITE / RED
PINK
LIGHT BLUE
BLACK / BLUE
PIN
K
Lt. BLUE
BLUE
BLUE
WHITE
WHITE
PURPLE
GR
EY /
BLU
E
GREY
GR
EY
WH
ITE
YELL
OW
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.Charging. AC section. Un-plug regulator. Grey - Earth = 25v AC with engine at about 3000 rpm. DC section. Ammeter between Battery + and red wire = at least 1.8 amps, fully charged battery Disconnect battery. yellow - red = at least 15v AC @ 3000 rpm.
IMMOBILISER UNIT
RED / BLUE
21 3 4 5 6 7 8
RECTIFIER / REGULATOR
1. AC out2. AC in3. not used4. not used5. DC out6. Earth7. Indicators8. DC in
HT COIL
BATTERY12v
+
7.5 AMPFUSE
PINK
RED
DiagnosticTest Socket
OFFON
IGNITION SWITCH
To In
dica
tors
WHITE / RED
GREEN
BLU
E
WH
ITE
RED
GR
EEN
BLA
CK
page 13
19/01/2006PAGE 14 EXPLANATION
Quasar Immobiliser
page 14
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 Leaderengine.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 mustobtain 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.
Possible LED Flashing Codes
TUR
N IG
NIT
ION
ON
LED OFF
LED ON
0.5 sec.0.7 sec.
Phase 1 Phase 2 Phase 3
1. ECU not programmed2. Transponder is detected3. Engine will run to 2000rpm
LED OFF
LED ON 1. Immobiliser is programmed2. Break in serial line (ECU to aerial)3. Ignition is not possible
2 sec.
2 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Transponder is not detected3. Ignition is not possible
3 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Transponder is not recognised3. Ignition is not possible
0.7 sec.1. Immobiliser is programmed2. Transponder is detected3. Engine can run normally
LED ON
LED OFF
LED OFF
LED ON 1. ECU not programmed2. Transponder is not detected3. Ignition is not possible
AnyKey
AnyKey
ServiceKey
MasterKey
ServiceKey
ServiceKey
ServiceKey
2 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Two service keys are programmed3. Engine can run normally
Immobiliseris workingcorrectly
Could beany numberfrom 0 to 7
A
B
C
D
E
See Noteon the
Next Page
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 TesterIf 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 ECULED - 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 14 D)
Wrong Key code Yes / No Yes = Key transponder is seen but not recognisedLED - three flashes in phase two (page 14 E)
Commun timeout Yes / No Yes = No signal from active antenna to ECULED - one flash in phase two (page 14 C)
Stored key num Number of keys coded to the ECU (0 up to 7)
page 15
Programming.
Notes.
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 needre-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 electricalinterference 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 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 programmedThe engine should start but will not rev above 2000 rpm until the immobiliser isprogrammed.
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* (any extra service keys are included here)
- Insert the extra service key and turn on for two seconds* Insert the brown master 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
page 16
19/01/2006PAGE 17 EXPLANATION
Master Immobiliser
page 17
The 500 cc Master engine has separate immobiliser and ECU.Once the system is programmed the ECU and immobiliser are irrevocably linked to the brownmaster 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.
Possible LED Flashing Codes
TUR
N IG
NIT
ION
ON
0.5 sec.0.7 sec.
Phase 1 Phase 2 Phase 3
LED OFF
LED ON 1. Immobiliser is programmed2. Break in serial line3. Ignition is not possible
2 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Transponder is not detected3. Ignition is not possible
3 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Transponder is not recognised3. Ignition is not possible
0.7 sec.1. Immobiliser is programmed2. Transponder is detected3. Engine can run normally
LED ON
LED OFF
LED OFF
LED ON 1. Immobiliser not programmed2. ECU is programmed3. Ignition is not possible
2 sec.
AnyKey
ServiceKey
MasterKey
ServiceKey
ServiceKey
ServiceKey
2 x 0.5 sec.0.7 sec.
LED OFF
LED ON 1. Immobiliser is programmed2. Two service keys are programmed3. Engine can run normally
Immobiliseris workingcorrectly
Could beany numberfrom 0 to 7
A
B
C
D
See Noteon the
Next Page
E
2 sec.1. System not programmed2. Transponder is detected3. Engine runs only to 2000 rpm.
LED ON
LED OFF
AnyKey
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.
page 18
Programming.
Notes.
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 needre-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 electricalinterference from a faulty HT circuit could upset the immobiliser.Plug cap must be at least 5000 ohms. Change the cap and lead if suspect.Also 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 programmedThe engine should start but will not rev above 2000 rpm until the immobiliser isprogrammed.
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* (any extra service keys are included here)
- Insert the extra service key and turn on for two seconds* Insert the brown master 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 19 PROGRAMMING
Master Immobiliser
page 19
30/09/2005Piaggio Ltd. With IMMOBILISER
Vespa GT 125 / 200 ignition / charging
2 -13
Rectifier / Regulatorp/n: 82501R
GALTERNATORSTATOR
ToIndicatorswitch
Red
Green
Green
White / Black
Yellow
IgnitionPick up
ECU / Immobiliser
HT Coil
Main15amp
Orange
Orange
PurpleRed / Black
Red / Black
Black
Yellow
Red / BlueLED on
instrumentpannel
Layout of pinsin the ECU / immobiliser
BATTERY12v
12ah
+
RG4HCCR 9EB
CoolingFan
FanSwitch
Green
Choke Unit
Lt. Blue
Orange
GREEN
WHITE / BLACKLt. BLUE
RED / BLACK
PURPLEBLACK
BLUE / BLACK
YELLOW
3 2 18 7 6 5 4
Note that the ECU fitted to the 125 and 200 have different characteristics.They are NOT interchangeable.
TESTS.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.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.
HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
STOP
RUN
6 1
8 3
4 5
7 2
antenna
Fuses inglove box
Red / Black
IgnitionSwitch
OFF
ON
LOCK
Seat releasepush button
Seat lock
Grey
Grey / BlueGrey / Black
WHITE / RED
YELLOW / BLACK
YELLOW / REDWHITE
RED / BLUE
GREY
RED / BLACK12v DC from battery
ORANGESwitched 12v
ORANGESwitched 12v
BLUE
BLUE
RED / BLACK12v DC from battery
19/08/2003Piaggio Ltd.
Vespa GT Fuses
3
7.5a
1
10a
2
7.5a
4
7.5a
5
5a
6
5a
The wire colours shown here are different to those "on line" and in the owners handbook.The colours and fuse functions here are correct, they were checked on GT200ZAPM312 * 2550.
FUSE:1. 10 amp. Electric seat release. Headlights. Main beam warning light.2. 7.5 amp. Intercom. Alarm. Immobiliser LED.3. 7.5 amp. Intercom. Alarm. Water temp. Fuel warning & guage. Oil pressure warning.4. 7.5 amp. Horn.5. 5 amp. Stop light. start switch.6. 5 amp. Side lights. Number plate light. Instrument panel lights.
MAIN FUSE.A 15 amp fuse is located at the front of the under seat compartment.
2-14
Rectifier /Regulatorp/n: 82501R
30/09/05Piaggio Ltd. With IMMOBILISER
Skipper ST ignition / charging
GALTERNATORSTATOR
ToIndicatorswitch
Headlightvia relay
Red
Green
Green
White /Black
Red / Blue
RG4HCCR 9E
Carb. Heater
Choke Unit
Yellow
IgnitionPick up
ECU / Immobiliser
IgnitionSwitch
HT Coil
Blue /Black
15amp
Ora
nge
Orange
Red
/Blu
e
Purple
Grey
Red / Blue
Powerto
services
Red / Blue
Black
antenna
Yellow
LED oninstrument
pannel
6 1
8 3
4 5
7 2 GREEN
WHITE / BLACKORANGE
RED / BLUE
PURPLEBLACK
BLUE / BLACK
YELLOW
Layout of pinsin the ECU / immobiliser
BATTERY12v9ah
+
3 2 18 7 6 5 4
TESTS.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.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.
HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
OFF
ON
2-15
RED / BLUE
ORANGE
RED / BLUE
RED / BLUERED
06/01/2004Piaggio Ltd. Leader Engine
SKIPPER ST 125 FUSE EXPLANATION
RED12 V DC from battery
3
5a
1
7.5a
2
5a
4
5a
RED / WHITEClock & Interphone Socket
RED / BLACKTo Light Switch
GREY / REDTo Main / Dip Switch
WHITEGeneral
2 15 amp
1 15 ampGREYTo Head Light Relay
OFF
ON
IGNITION SWITCH
2-16
The early Skipper ST did not have an immobiliser. The speedo unit for this vehicle581308 (or 581307) is no longer available.It must be replaced with 583271, this is the speedo fitted to later Skipper ST withimmobiliser.To fit this new speedo you must make some modifications to the wiring at the plugswhich connect to the speedo unit.Below are diagrams that show the plugs on the wiring loom as they appear on the vehicleand also how they must appear to enable the new speedo to be used.1. Confirm that the wiring on your vehicle is as shown on the "Original Loom" diagram2. Remove the white / green and yellow / green wires from the large plug complete withtheir connectors.3. Remove the white and the brown wires from the small plug complete with theirconnectors.4. Re-fit these wires in the positions shown on the "Modified Loom" diagram.It is possible to remove the connectors by carefully inserting a small screwdriver orsimilar and pressing the retaining tag in.
View of the two plugs that connect to the speedometer
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13/12/2005Piaggio Ltd. With IMMOBILISER
Replacing Skipper ST speedometer
ORIGINALLOOM
WHITE / BLUE
VIOLET
BLACKYELLOW / BLACK
WHITE / GREEN