231991663-piaggio-service kopie.pdf

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


50 / 80cc 2T charging

BATTERY12v

+

CHOKE UNIT

7.5 ampFUSE

ACSERVICES

YELLOW

BLUE

GREY / BLUE

RED / WHITE

GREY


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

&REGULATOR

2

OILWARNING

LIGHT OIL TANKSENDER

1-2

IGNITION SWITCH

OFF

ON

OILLIGHTTIMER

GREY


Horn

TO INDICATORSWITCH

BLU

E /

RE

D

BLUE / BLACK

BLA

CK

YELLOW

GR

EY

/ BL

UE

CHOKE UNIT


Instruments

RECTIFIER&

REGULATOR

4321 5 6 7 8

REGULATOR

TIMER

YE

LLO

W /

GR

EEN

WH

ITE

/ V

IOLE

T

BLUE / RED


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


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


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


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



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



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


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






OFF

ON

STOP

RUN

2-7

antenna



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


3 2 18 7 6 5 4






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


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



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


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






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.


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 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

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

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



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?


8

YES


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


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.


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


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


TUR

N IG

NIT

ION

ON

LED OFF

LED ON3 x 0.5 sec.


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


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.


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


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


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


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.


TUR

N IG

NIT

ION

ON

LED OFF

LED ON

0.5 sec.0.7 sec.


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


3 x 0.5 sec.0.7 sec.

LED OFF


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


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)


* 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.


Quasar Immobiliser

page 16


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.


TUR

N IG

NIT

ION

ON

0.5 sec.0.7 sec.


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


3 x 0.5 sec.0.7 sec.

LED OFF


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


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)


* 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.


Master Immobiliser

page 19


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


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.






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



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


BATTERY12v9ah

+

3 2 18 7 6 5 4






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

2-17


Replacing Skipper ST speedometer

ORIGINALLOOM

WHITE / BLUE

VIOLET

BLACKYELLOW / BLACK

WHITE / GREEN

231991663-piaggio-service kopie.pdf

Documents

expandon technical information

sales manager

technical services piaggio

cc charging ignition5

sales problems

sales contacts

sales training07881

cc ignition7