PIAGGIO MP3 500 ie SPORT Business LT (2011) User Manual

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MANUALE STAZIONE DI SERVIZIO

xxx(IT)-xxx(EN)-xxx(FR)-xxx(DE)-xxx(ES)-xxx(PT)-

xxx(NL)-xxx(EL)

MP3 500 ie SPORT Business LT (2011)

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MANUALE

STAZIONE DI

SERVIZIO

MP3 500 ie SPORT Business LT (2011)

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

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MANUALE STAZIONE DI

SERVIZIO

MP3 500 ie SPORT Business LT

(2011)

Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.

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Vehicle identification

Chassis prefix (A)

ZAPM642001

Engine prefix (B):

M474M

The identification registration numbers consist of a prefix stamped on the chassis and engine "B" respectively, followed by a number. These numbers must always be indicated on spare parts requests. To read the chassis number, remove the relevant port "A" in the helmet compartment. We recommend checking that the chassis registration number stamped on the vehicle corresponds with that on the vehicle documentation.

CAUTION

BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).

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Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification

Desc./Quantity

Kerb weight 253 ± 8 kg

Maximum weight allowed 445 kg

Maximum height 1440 mm

Width 760 mm

Wheelbase 1550 mm

Length 2210 mm

Track 465 mm

Engine

ENGINE

Specification

Desc./Quantity

Type Single-cylinder, 4-stroke with double spark plug

Engine capacity 493 cm³

Bore x Stroke 94 x 71 mm Compression ratio 10.5: 1 Engine idle speed 1,500 ± 100 rpm

Timing system Four valves, single overhead camshaft, chain-driven.

Valve clearance Intake: 0.15 mm

Exhaust: 0.15 mm

Max. power 29 kW at 7,500 rpm

MAX. torque 44 Nm at 5,200 rpm

Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.

Lubrication pressure 3.5 ÷ 4 bar

Minimum lubrication pressure (100° C) 0.8 bar

Fuel system Electronic injection with electric fuel pump.

Cooling Forced coolant circulation system.

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Specification Desc./Quantity

Fuel Unleaded petrol (95 RON)

Transmission

TRANSMISSION

Specification Desc./Quantity

TRANSMISSION Automatic expandable pulley variator with torque server, V-

belt, automatic clutch.

Final reduction gear Gear reduction unit in oil bath.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1.7 l

Transmission oil 250 cm³

Cooling system fluid ~ 1.8 l

Fuel tank (reserve) approx. 12 l (approx. 2 l)

Electrical system

ELECTRICAL SYSTEM

Specification

Desc./Quantity

Starter Electric

Ignition Electronic, inductive, high efficiency ignition, integrated with the

injection system, with variable advance and separate HV coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EKB

Alternative spark plug -

Battery 12V/14 Ah, sealed battery

Generator alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification

Desc./Quantity

Chassis Tubular and sheet steel

Front suspension The roll system is composed of an articulated parallelogram

suspension with die-cast aluminium control arms and two side

headstocks plus shock absorbers with hydraulic locking sys-

tem.

Front suspension travel 85 mm

Rear suspension Two double-acting shock absorbers, adjustable to four posi-

tions at preloading.

Rear suspension travel 110 mm

Brakes

BRAKES

Specification

Desc./Quantity

Front brake Ø 240-mm double disc brake with hydraulic control operated

by the handlebar right-hand lever.

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Specification Desc./Quantity

Rear brake Ø 240-mm disc brake with hydraulic control operated by the

handlebar left-hand lever.

Integral braking system The system operates all three discs simultaneously and is con-

trolled hydraulically via the pedal on the footrest.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rim type Light alloy wheel rims.

Front rim 12'' x 3.00

Rear wheel rim 14'' x 4.50

Front tyre Tubeless, 120/70-12" 51S or 51P

Rear tyre Tubeless, 140/70 -14" 68S or 68P Front tyre pressure 1.6 bar Rear tyre pressure 2.5 bar

Tightening Torques

STEERING

Name

Torque in Nm

Steering lower ring nut (central headstock) 10 to 12 Steering upper ring nut (central headstock) 22.5 to 25

Handlebar fixing screw 50 ÷ 55

Fixing screws for the handlebar control unit U-bolts 7 to 10

CHASSIS

Name

Torque in Nm

Swinging arm set screw bushing 5 ÷ 7

Engine arm bolt - frame arm 32.5 ÷ 40

Swinging arm set screw bushing nut 54 ÷ 60

Engine-swinging arm bolt 98 ÷ 118 Frame-swinging arm bolt 54 ÷ 60

Centre stand bolt 31 - 39

FRONT SUSPENSION

Name

Torque in Nm

Shock absorber lower clamping 19 - 26

Shock absorber upper clamp 19 - 29

Front wheel fixing screws 19 ÷ 24

Steering arm bolt nut 20 to 25

Tilt gripper fixing screws 20 to 25

Front wheel axle 74 - 88

Arm coupling screws 45 to 50

Screws fixing arms to side headstocks 45 to 50

Screws fixing arms to central headstock 45 to 50

Screws fixing the half-arm coupling flange 20 to 25

Screws fixing roll lock disc section 20 to 25

Side headstock upper ring nut 20 - 24

Side headstock lower ring nut 12 ÷ 15

Screw fixing sliding stem to shock absorber 45 to 50

Clamp for sliding stem locking device 6.5 - 10.5

Fixing nuts for constant-velocity universal joints 18 - 20

Potentiometer to anti-tilting device clamp 8 to 10 Electric motor to anti-tilting device clamp 11 to 13

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

Pump to anti-tilting device clamp 11 to 13

Pressure switch to distribution frame 18 - 20

Sensor to tilt gripper clamp 2.5 - 2.9

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Name Torque in Nm

Pipe terminals to fifth wheel check spring 7 - 11

Joint to anti-tilting device pump 20 to 25 Lower fitting for shock absorber sliding locking clamp pipes 20 to 25 Upper fitting for shock absorber sliding locking clamp pipes 20 to 25

REAR SUSPENSION

Name Torque in Nm

Shock absorber upper clamp 33 to 41

Shock absorber lower clamping 33 to 41

Shock absorber-crankcase attachment bracket 20 to 25

Rear wheel axle 104 to 126

Silencer arm clamping screws 27 - 30

FRONT BRAKE

Name Torque in Nm

Calliper coupling screw 22 ÷ 27

Oil bleed screw 8 - 12

Brake disc screws 8 to 10

Brake fluid pump-hose fitting 16 - 20

Brake fluid pipe-calliper fitting 20 to 25

Screw tightening calliper to support 20 to 25

Calliper upper pipe fitting 20 to 25

REAR BRAKE

Name

Torque in Nm

Oil bleed screw 12÷16

Brake disc screws 8 to 10

Rear brake calliper-pipe fitting 20 to 25

Rigid / flexible pipe fitting 13 - 18

Rear brake pump-pipe fitting 16 - 20

Rear brake calliper fixing screws 20 to 25

pad fastening pin screws 20 ÷ 25

REAR BRAKE

Product

Description Specifications

(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-strength

threadlock

SILENCER

Name

Torque in Nm

Silencer heat guard fixing screw 4 to 5

Screw for fixing silencer to supporting arm 20 to 25

Lambda probe tightening on exhaust manifold 40 to 50

Exhaust manifold-silencer joint tightening 12÷13

Manifold - silencer diaphragm tightening clamp 16 to 18

LUBRICATION

Name

Torque in Nm

Oil pump cover screws 0.7 - 0.9

Screws fixing oil pump to the crankcase 5 to 6

THERMAL GROUP AND TIMING SYSTEM

Name

Torque in Nm

Spark plug 12 ÷ 14

Head fixing stud bolts ***

Head fixing nuts 10 - 12

Exhaust / intake head fixing nuts 10 - 12

Head lubrication control jet 5 - 7

Coolant temperature sensor: 10 - 12

Lambda probe on exhaust manifold 10 - 12

injector fixing screw 3 ÷ 4

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Name Torque in Nm

Counterweight screw 7 to 8.5

Tensioner sliding block fixing screw 10 - 14

Rpm timing sensor fixing screw 3 - 4

Valve lifter mass stop bell fixing screws 30 - 35

Intake manifold screws 11 to 13 Tappet cover fixing screws 7 - 9 Throttle body fixing screws 11 ÷ 13

Head fixing screws 10 - 12

Camshaft retaining bracket screws: 4 ÷ 6

Tightener screw: 5 to 6

Tightener fastening screws: 11 to 13

*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90° in a crossed sequence. - tighten again by 90° in a criss-crossed sequence.

TRANSMISSION COVER

Name Torque in Nm

Driven pulley nut 92 - 100

Drive pulley nut 160 - 175

Anti-vibration roller screw 16.7 ÷ 19.6

M8 retainers for transmission cover 23 ÷ 26

M6 retainer 11 ÷ 13

Anti-vibration roller retainer 17 - 19

Clutch ring nut 65 - 75

Air conveyor screws 11 ÷ 12

Water pump cover screws 3 ÷ 4

External transmission cover screws 7 ÷ 9

Flywheel cover screws 11 - 13

FLYWHEEL COVER

Name

Torque in Nm

Chain guide sliding block retain plate fastening screws 3 ÷ 4

Flywheel fixing nut 115 - 125

Stator retainers 8 - 10

Blow-by recovery duct fixing screws 3 - 4

Screw fixing freewheel to flywheel 13 - 15

Stator cable harness guide bracket screws 3 - 4

Supporting screws with bulkhead 0.3 - 0.4

Minimum oil pressure sensor 12 to 14

Water pump impeller 4 ÷ 5

CRANKCASE AND CRANKSHAFT

Name

Torque in Nm

Countershaft fixing nut 25 ÷ 29

Engine oil filter 12 - 16

Engine oil drainage plug 24 to 30

Engine-crankcase coupling screws 11 to 13

Oil pump screws 5 to 6

Gear mounting on crankshaft screws 10 -12

Bulkhead screws for oil pump housing cover 8 - 10

COOLING

Name

Torque in Nm

Water pump impeller 4 ÷ 5

Water pump cover screws 3 ÷ 4

Thermostat cover screws 3 to 4

Bleed screw 3

Overhaul data

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Assembly clearances

Cylinder - piston assy.

HEIGHT TO MEASURE THE PISTON

Specification

Desc./Quantity

A 10 mm B 43 mm

CYLINDER - PISTON

Specification

Desc./Quantity

Cylinder diameter C 94 +0.018-0.01mm

Piston diameter P 93.968 - ±0.014 mm

COUPLING CATEGORIES

Name

Initials Cylinder Piston Play on fitting

Cylinder- Piston A 93.990÷93.997 93.954÷93.961 0.029÷0.043 Cylinder- Piston B 93.997÷93.004 93.961÷93.968 0.029÷0.043 Cylinder- Piston C 94.004÷94.011 93.968÷93.975 0.029÷0.043 Cylinder- Piston D 94.011÷94.018 93.975÷93.982 0.029÷0.043

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

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Piston rings

*Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the port of the rings as shown here. *** Value «A» of seal ring inside the cylinder.

Check the size of the sealing ring opening: Compression ring: 0.15 - 0.35 mm. Max. value 0.5 mm Oil scraper ring: 0.25 - 0.50 mm. Max. value 0.65 mm Oil scraper ring: 0.25 - 0.50 mm. Max. value 0.65 mm

Rings/housing coupling clearances:

Carefully clean the sealing ring housings. Place a feeler gauge between the ring and the housing as shown in the drawing and check the coupling clearances.

Top ring Standard coupling clearance:

0.01-0.06 mm Maximum clearances allowed after use: 0.10 mm

Intermediate ring Standard coupling clearance:0.02-0.07 mm Maximum clearances allowed after use: 0.10

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Oil scraper ring Standard coupling clearance:

0.01-0.06 mm Maximum clearances allowed after use: 0.10 mm Replace the piston if clearances exceed the maximum limits specified in the table.

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name

Description Dimensions Initials Quantity

Transmission-side

shoulder

1 ± 0.025 A D = 0.20 ÷ 0.50

Half-shaft, transmission

side

20.9 - 0.05 B D = 0.20 ÷ 0.50

Connecting rod 22 0.10 - 0.15 C D = 0.20 ÷ 0.50

Flywheel-side shoulder 1.8 ± 0.025 F D = 0.20 ÷ 0.50

Flywheel side half-shaft 19.6 + 0.05 E D = 0.20 ÷ 0.50

Complete crankshaft 65.5 +0.1 -0.05 G D = 0.20 ÷ 0.50

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Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

CRANKSHAFT

Specification Desc./Quantity

Cat. 1 Standard diameter: 40.010 ÷ 40.016 Cat. 2 Standard diameter: 40.016 ÷ 40.022

Crankshaft alignment

Specific tooling

020335Y Magnetic mounting for dial gauge

MAX. ADMISSIBLE DISPLACEMENT

Specification

Desc./Quantity

A = 0.15 mm B = 0.010 mm C = 0.010 mm D = 0.10 mm

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Characteristic

Crankshaft-crankcase axial clearance (H)

0.1 ÷ 0.405 mm (when cold)

Compression ratio

10.5: 1

Slot packing system

Shimming system to control compression ratio

DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE. DISTANCE «A» HELPS DETERMINE THE THICKNESS OF GASKET «B» THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE COMPRESSION RATIO. BASE GASKET «B» MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON CROWN PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND, THE MORE THE PISTON CROWN IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER THE GASKET THICKNESS.

Characteristic

Compression ratio

10.5: 1

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BASE GASKET THICKNESS

Name Measure A Thickness

«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05 «A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05 «A» MEASURE TAKEN + 0.10 - + 0.185 0.8 ± 0.05

N.B.

VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE.

N.B.

DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»

Products

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Rear hub oil

Capacity approximately 250 cc

Air filter

Proceed as follows: Unscrew the nine fixing screws «A» and remove the air filter cover.

- Wash the sponge with water and mild soap.

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- Dry it with a clean cloth and short blasts of compressed air.

- Soak it in a mixture of 50% petrol and 50% specified oil.

- Gently squeeze the filtering element with your hands but do not wring it; allow it to drip dry and then

refit.

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil

In four stroke engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Change oil and replace filter as indicated in the scheduled maintenance table. Empty the engine by draining the oil through drainage plug «B».

To facilitate oil drainage, loosen the cap/dipstick «A».

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Once all the oil has drained through the drainage hole, unscrew and remove the oil cartridge filter «C ».

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, engine oil must be added through plug «A». Then start the vehicle, leave it running for a few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Locking torques (N*m)

Engine oil filter 12 - 16 Engine oil drainage plug

24 to 30

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Check

This operation must be carried out with the engine cold and following the procedure below:

- Place the vehicle on its centre stand and on flat ground.

- Unscrew the cap/dipstick «A», dry it with a clean cloth and reinsert it, screwing it all the way down.

- Remove the cap/dipstick again and check that the level is between the min and max reference marks; top-up, if required. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level.

Oil top up

The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoring the level from the MIN to the MAX marks requires approx. 400 m³ of oil.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

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Oil pressure warning light

The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been started.

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

Checking the ignition timing

- Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark «T» on

the rotor matches the reference mark on the flywheel cover as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference is opposite the indicator on the head, turn the crankshaft once more. For the use of this reference mark, remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a calliper spanner applied to the camshaft command pulley casing.

Cooling system

Adding engine coolant.

Check coolant level when the engine is cold as indicated in the scheduled maintenance table, following the steps below: Place the vehicle on its centre stand and on flat ground.

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- Undo the screw shown in the figure and remove the expansion tank cap on RHS.

- Top up if the fluid level is near or below the MIN level edge. The liquid level must always be between the MIN and MAX level.

-The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised waterantifreeze solution mix.

CAUTION DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS

TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE VEHICLE IS IN USE.

Recommended products

AGIP PERMANENT SPEZIAL Coolant

Monoethylene glycol based antifreeze solution, CUNA NC 956-16

Braking system

Level check

FRONT AND REAR BRAKING SYSTEM LEVEL CHECK

The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows:

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

- Check the fluid level through the sight glass «C». A drop in the brake fluid level may be caused by pad wear.

INTEGRAL BRAKING SYSTEM LEVEL CHECK

- Rest the vehicle on its centre stand on level ground.

- Remove the inspection cover and check that the brake fluid inside the reservoir is not below the recommended level.

- A drop in the brake fluid level may be caused by pad wear.

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Top-up

FRONT AND REAR BRAKING SYSTEM TOPPING UP

Proceed as follows: Loosen the screw «B» and lift the plastic cover «A» in order to access the brake fluid reservoir. Loosen the two fixing screws and remove the reservoir cover; top-up with the recommended fluid without exceeding the 'MAX.' mark. This procedure applies to the rear brake pump topup operation; follow the same procedure for the front brake pump. Under standard climatic conditions, replace fluid as indicated in the scheduled maintenance table.

WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. BRAKING CIRCUIT FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT4 Synthetic fluid

INTEGRAL BRAKING SYSTEM LEVEL TOPPING UP

- Remove the inspection cover, unscrew the cap

indicated and top up using the recommended product.

- If there is air in the circuit, bleed the system as

described in the «Braking system/filling - bleeding the rear - integral braking system»

CAUTION

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AIR INSIDE THE INTEGRAL CIRCUIT IS SPECIALLY DANGEROUS: THIS SPECIFIC BRAKING SYSTEM CAN PUMP AIR INTO THE REAR AND/OR FRONT CIRCUITS THUS COMPROMISING THE CORRECT OPERATION OF EACH SYSTEM WHEN USED INDIVIDUALLY.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

See also

Rear - combined

Headlight adjustment

Proceed as follows:

- Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen; make sure the scooter axis is perpendicular to the screen;

- Remove the headlight assembly central cover.

- Turn on the headlight and check that the border of the projected light beam on the screen is not higher than 9/10 or lower than 7/10 f the height from the ground to the centre of vehicle headlamp;

- Otherwise, adjust the headlight with the screws « A» indicated in the figure

N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 49

This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given.

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valves

Misshapen/worn valve seats Replace the head unit

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

Worn or broken piston rings or piston rings that have not been

fitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil seal Replace the valve oil seal Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the

By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump components

Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause

Operation

Faulty clutch Check that there is no grease on the masses. Check that the

clutch mass faying surface with the bell is mainly in the centre with equivalent characteristics on the three masses. Check that

the clutch casing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause

Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are

not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

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Possible Cause Operation

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift

of the disc with a dial gauge and with wheel mounted on the

vehicle.

Brakes overheating

BRAKE OVERHEAT

Possible Cause Operation

Defective plunger sliding Check calliper and replace any damaged part.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

a wheel mounted on the vehicle to measure the axial shift of

the disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or stuck rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause

Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause

Operation

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

Noisy suspension

NOISY SUSPENSION

Possible Cause

Operation

Faults in the suspension system If the front suspension is noisy, check: the efficiency of the front

shock absorber; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers; and the movement

bushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disc in the

attachment to the hub and the steering tube.

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Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of the

steering covers and the adjustments.

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 53

KEY

1.BATTERY

2.STARTER SOLENOID

3. STARTER MOTOR

4. FUSE 01 - 15 A

5. FUSE 02 - 20 A

6. FUSE 03 - 20 A

7.FUSE 04 - 15 A

8. FUSE 05 - 15 A

9.FUSE 06 - 7.5 A

10.IGNITION KEY CONTACTS

11. FUSE 07 - 7,5 A

12. FUSE 08 - 10 A

13. FUSE 09 - 7.5 A

14. FUSE 10 - 7.5 A

15. FUSE 11 - 7.5 A

16. FUSE 12 - 7.5 A

17. FUSE 13 - 30 A

18.VOLTAGE REGULATOR

19. FLYWHEEL

20.HAZARD BUTTON

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21. TURN INDICATOR CONTROL DEVICE AND HAZARD

22. TURN INDICATOR SWITCH

23. STOP BUTTONS

24. 12V - 10W RIGHT BULBS

25. LEFT BULBS 12V-10W

26. PRE-INSTALLATION FOR SADDLE OPENING RECEIVER

27. PRE-INSTALLATION FOR ANTI-THEFT DEVICE

28.LICENSE PLATE LAMP

29.FRONT DAYLIGHT RUNNING LIGHT

30. LEFT REAR TAIL LIGHT BULB

31. RIGHT REAR TAIL LIGHT BULB

32. IMMOBILIZER AERIAL

33. HORN RELAY

34. FUEL GAUGE

35.INSTRUMENT PANEL

36.SWITCH FOR SADDLE OPENING

37.AMBIENT TEMPERATURE SENSOR

38.MODE BUTTON

39.OIL PRESSURE SENSOR

40.CASE OPENING SWITCH

41.SADDLE OPENING ACTUATOR

42. BOOT ACTUATOR

43. STARTER BUTTON

44. PARKING CONTROL ECU

45. DIAGNOSTICS SOCKET

46. LEFT SPEED SENSOR

47.RIGHT SPEED SENSOR

48. RIDER DETECTION SENSOR

49. HAND BRAKE

50. LOCK SWITCH

51. UNLOCK SWITCH

52. POTENTIOMETER

53. BRAKE CALLIPER SENSOR

54. GEAR MOTOR

55. ELECTRIC FAN

56. ELECTRIC FAN RELAY

57. FUEL INJECTOR

58.HV COIL

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59. INJECTION LOAD RELAY KEY

60.C.D.I.

61. ENGINE SPEED SENSOR

62.LAMBDA PROBE

63. LOCK/UNLOCK PRESSURE SENSOR

64.FUEL PUMP

65. ENGINE TEMPERATURE SENSOR

66.12V - 10W STOP LIGHT BULBS

67. ENGINE STOP

68. BOOT LIGHT SWITCH

69.SADDLE LIGHT SWITCH

70.START-UP ENABLING REMOTE CONTROL SWITCH

71.HEADLIGHT WITH 12V-55W TWIN-FILAMENT BULB

72. HEADLIGHT RELAY

73. Light switch

74. HORN

75.Horn button

76. BOOT/SADDLE LIGHT BULB

77.SOCKET 12V

78. C.D.I. GROUND NODE

79. BRAKE PEDAL BUTTON Colours of the electrical cables: B = White Bl = Blue G = Yellow Mr = Brown N = Black BV = White-Green GN = Yellow-Black Gr = Grey Rs = Pink R = Red Vi = Violet V = Green VN = Green-Black BN = Black-White BBl = White-Blue

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GV = Yellow-Green Ar = Orange Az = Sky blue GrBl = Grey-Blue GrN = Grey-Black RBl = Red-Blue GR =Yellow-Red BlN = Blue-Black

Components arrangement

1. Immobilizer Aerial

Remove the shield back plate to reach it.

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2. Geared motor

Remove the legshield to reach it.

3. Remote control switches

Remove the legshield to reach it.

4. Auxiliary fuses

Remove the flap of the right-side footrest to reach these fuses.

5. Horn

Remove the shield back plate lower side to reach it.

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6. Fuel level transmitter

7. HV coil

Remove the central chassis cover to reach it.

8. Lambda probe

The lambda probe is mounted on the exhaust manifold.

9. Oil pressure sensor

Remove the exhaust end to reach it.

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10. Turn indicator control device

Remove the left side fairing to reach it.

11. Voltage regulator

Remove the right side fairing to reach it.

12. Diagnosis connector

13. Main fuses

These components are found in the battery compartment.

14. Electronic control unit

15. Start-up remote control switch

16. Start-up enabling remote control switch

Remove the lid of the helmet compartment to reach it.

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17. Rider presence sensor

Open the saddle and remove the cover to reach the rider presence sensor.

18. Parking control ECU

Remove the shield back plate to reach it.

Conceptual diagrams

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Ignition

KEY

1.BATTERY

5. FUSE 02 - 20 A

7.FUSE 04 - 15 A

10.IGNITION KEY CONTACTS

14. FUSE 10 - 7.5 A

32. IMMOBILIZER AERIAL

35.INSTRUMENT PANEL

44. PARKING CONTROL ECU

45. DIAGNOSTICS SOCKET

57. FUEL INJECTOR

58.HV COIL

59. INJECTION LOAD RELAY

60.C.D.I.

61. ENGINE SPEED SENSOR

64.FUEL PUMP

65. ENGINE TEMPERATURE SENSOR

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Battery recharge and starting

KEY

1.BATTERY

2.STARTER SOLENOID

3. STARTER MOTOR

5. FUSE 02 - 20 A

10.IGNITION KEY CONTACTS

12. FUSE 08 - 10 A

17. FUSE 13 - 30 A

18.VOLTAGE REGULATOR

19. FLYWHEEL

23. STOP BUTTONS

35.INSTRUMENT PANEL

43. STARTER BUTTON

60.C.D.I.

66.12V - 10W STOP LIGHT BULBS

67. ENGINE STOP

70.START-UP ENABLING REMOTE CONTROL SWITCH

79.BRAKE PEDAL BUTTON

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Level indicators and enable signals section

KEY

1.BATTERY

5. FUSE 02 - 20 A

7.FUSE 04 - 15 A

10.IGNITION KEY CONTACTS

14. FUSE 10 - 7.5 A

32. IMMOBILIZER AERIAL

34. FUEL GAUGE

35.INSTRUMENT PANEL

39.OIL PRESSURE SENSOR

57. FUEL INJECTOR

59. INJECTION LOAD RELAY

60.C.D.I.

62.LAMBDA PROBE

65. ENGINE TEMPERATURE SENSOR

67. ENGINE STOP

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Devices and accessories

KEY

1.BATTERY

4. FUSE 01 - 15 A

5. FUSE 02 - 20 A

6. FUSE 03 - 20 A

7.FUSE 04 - 15 A

10.IGNITION KEY CONTACTS

13. FUSE 09 - 7.5 A

15. FUSE 11 - 7.5 A

16. FUSE 12 - 7.5 A

24. 12V - 10W RIGHT BULBS

25. LEFT BULBS 12V-10W

26. PRE-INSTALLATION FOR SADDLE OPENING RECEIVER

27. PRE-INSTALLATION FOR ANTI-THEFT DEVICE

33. HORN RELAY

35.INSTRUMENT PANEL

36.SWITCH FOR SADDLE OPENING

37.AMBIENT TEMPERATURE SENSOR

38.MODE BUTTON

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40.CASE OPENING SWITCH

41.SADDLE OPENING ACTUATOR

42. BOOT ACTUATOR

44. PARKING CONTROL ECU

46. LEFT SPEED SENSOR

47.RIGHT SPEED SENSOR

48. RIDER DETECTION SENSOR

49. HAND BRAKE

50. LOCK SWITCH

51. UNLOCK SWITCH

52. POTENTIOMETER

53. BRAKE CALLIPER SENSOR

54. GEAR MOTOR

63. LOCK/UNLOCK PRESSURE SENSOR

68. BOOT LIGHT SWITCH

69.SADDLE LIGHT SWITCH

72. HEADLIGHT RELAY

74. HORN

75. Horn button

76. BOOT/SADDLE LIGHT BULB

77.SOCKET 12V

78.C.D.I. GROUND NODE

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Lights and turn indicators

KEY

1.BATTERY

5. FUSE 02 - 20 A

7.FUSE 04 - 15 A

10.IGNITION KEY CONTACTS

12. FUSE 08 - 10 A

13. FUSE 09 - 7.5 A

15. FUSE 11 - 7.5 A

16. FUSE 12 - 7.5 A

20.HAZARD BUTTON

21. TURN INDICATOR CONTROL DEVICE AND HAZARD

22. TURN INDICATOR SWITCH

23. STOP BUTTONS

24. 12V - 10W RIGHT BULBS

25. LEFT BULBS 12V-10W

28.LICENSE PLATE LAMP

29.FRONT DAYLIGHT RUNNING LIGHT

30. LEFT REAR TAIL LIGHT BULB

31. RIGHT REAR TAIL LIGHT BULB

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35.INSTRUMENT PANEL

44. PARKING CONTROL ECU

66.12V - 10W STOP LIGHT BULBS

71.HEADLIGHT WITH 12V-55W TWIN-FILAMENT BULB

72. HEADLIGHT RELAY

73. Light switch

79. BRAKE PEDAL BUTTON

Checks and inspections

This section is dedicated to the checks on the electrical system components.

Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobilizer system consists of the following components:

- an electronic control unit

- immobilizer aerial

- Master key with incorporated transponder (red key)

- service key with incorporated transponder (black key)

- HV coil

- diagnosis LED The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to the "ON" position, the theft-de-

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terrent blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignitionkey switch and/or the instrument panel is not initiated, check if:

•

there is battery voltage

•

fuses 1,7,10 are in working order

•

there is power to the control unit as specified below:

Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions:

With the key switch set to OFF:

•

if there is battery voltage between terminals 6-26 and terminal 6-chassis ground (fixed power supply). If there is no voltage check that fuse 1 and its cable are in working order.

With the key switch in the OFF position:

•

there is battery voltage between terminals 5-26 and terminal 5-frame earth (fixed power supply). If there is no voltage, check the key switch contacts, that fuse no. 10 and its cable are in working order.

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•

There is continuity between terminals 12-18 with the emergency cut-off switch in the RUN position. If there is no continuity check the contacts of the switch.

If no faults are found, replace the electronic control unit.

After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture.

Remove the protective base from the connector.

With the ignition key at ON check there is battery voltage between the Red-White and Black cables

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With MIU connector disconnected, check the continuity between the Orange-White cable and pin 7 of the interface wiring.

Specific tooling

020481Y Control unit interface wiring 020331Y Digital multimeter

Virgin circuit

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly. The data storage procedure for a previously not programmed control unit provides for the recognition of the master as the first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys. The master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3 seconds).

- Insert the service key and turn it to «ON» for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- Insert the MASTER key again and turn it to «ON» for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, the master key transponder is strictly matched with the control unit. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any case it is advisable to use resistive spark plugs.

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Characteristic

MASTER key:

RED KEY

SERVICE key.

BLACK KEY

Diagnostic codes

The Immobilizer system is tested each time the ignition key is turned from «OFF» to «ON». During this diagnosis phase a number of control unit statuses can be identified and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the LED remains off permanently, the ignition is enabled. If, however, the LED remains on permanently, it means the ignition is inhibited:

1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after

which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs.

2. Previously unused control unit - transponder absent or cannot be used: the LED is on

permanently. In this condition no operations are possible including the start up of the vehicle.

3. Programmed control unit - the service key in (normal condition of use): a single 0.7-second

flash is displayed, after which the LED remains off steadily. The engine can be started.

4. Programmed control unit - Master key in: a

0.7-sec flash is displayed followed by the LED remaining off for 2 sec and then by short 0.46-sec flashes, the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been completed, the

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LED remains permanently OFF. The engine can be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are:

•

1-flash code

•

2-flash code

•

3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessary.

Diagnostic code - 2 flashes

A two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. If this is not the case, replace the defective key and/or reprogram the control unit. Replace the control unit if the problem continues.

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Diagnostic code - 3 flashes

A three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit. If this is not the case, reprogram the decoder.

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel. The generator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. The three-phase alternator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability.

Remote controls check

To check the operation of a solenoid:

1) Check that, given regular conditions, there is no continuity between terminals 87 and 30.

2) Apply a 12V voltage to power terminals 86 and 85 of the solenoid.

3) With the solenoid fed, check that there is continuity between terminals 87 and 30.

4) If these conditions are not met, the solenoid is surely damaged and, therefore, it should be replaced.

Stator check

Checking the stator windings

WARNING

THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Remove the right side panel.

2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the picture.

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3) Measure the resistance between each of the yellow terminals and the other two.

Electric characteristic

Resistance:

0.2 - 1 Ω

4) Check that there is insulation between the each yellow cable and the ground.

5) If values are incorrect, replace the stator.

Recharge system voltage check

Look for any leakage

1) Access the battery by removing its cover under the saddle.

2) Check that the battery does not show signs of losing fluid before checking the output voltage.

3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery.

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

Charging current check

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals..

3) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm. Maximum current output check.

- With the engine off and the panel at «ON» with the lights on, allow the battery voltage to stop at 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Start the engine and rev it up to a high engine speed while reading the value on the pincer. With an efficient battery a value must be detected: > 20A

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VOLTAGE REGULATOR/RECTIFIER

Specification Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 to 15V at 5000 rpm with lights off

Starter motor

KEY

1. Battery

2. Fuse No. 5

3. Start-up remote control switch

4. Starter motor

5. Key switch contacts

6. Fuse No. 8

7. Start-up enabling remote control switch

8. Stop buttons

9. Starter button

10. Injection ECU

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check fuses No. 5 and 8, the key switch contacts, the stop buttons and the starter button.

2) Check the start-up enabling remote control switch and the start-up remote control switch.

3) Check the following wiring for continuity:

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- Red-Black cable between fuse-box (fuse No. 5) and key switch.

- Orange cable between key switch and fuse-box (fuse No. 8).

- Red cable between fuse-box (fuse No. 8), stop buttons and start-up enabling remote control switch.

- White-Black cable between stop buttons and starter button and OrangeWhite cable between starter button and start-up enabling remote control switch.

- Orange-Blue cable between start-up enabling remote control switch and ECU (pin 24).

- Green-Blue cable between start-up enabling remote control switch and start-up remote control switch.

- Red cable between battery and start-up remote control switch and between the latter and the starter motor.

4) Check the ground connections for the start-up remote control switch and the starter motor (Black cables).

Horn control

KEY

1. Battery

2. Fuse No. 5

3. Key switch contacts

4. Fuse No. 9

5. Horn button

6. Horn

WARNING

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ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check fuses No. 5 and 9, the key switch contacts and the horn button.

2) Check the following wiring for continuity:

- Red-Black cable between fuse-box (fuse No. 5) and key switch.

- Orange cable between key switch and fuse-box (fuse No. 9).

- Blue cable between fuse-box (fuse No. 9) and horn button.

- Yellow-Pink cable between horn button and the horn itself.

3) Check the horn ground connection (Black cable).

Turn signals system check

KEY

1. Battery

2. Fuse No. 3

3. Key switch contacts

4. Fuse No. 12

5. Turn indicator switch

6. Hazard button

7. Turn indicator control device with Hazard

8. Rear right turn indicator bulb

9. Front right turn indicator bulb

10. Front left turn indicator bulb

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11. Rear left turn indicator bulb

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check that bulbs operate properly.

2) Check fuses No. 3 and 12.

3) Check the contacts of the key switch, the turn indicator switch and the Hazard button.

4)With the key switch set to «ON», check if there is battery voltage:

- in the White-Pink cable between turn indicator control device and the ground lead, with the turn indicator switch pressed to the left.

- in the Blue-Black cable between turn indicator control device and the ground lead, with the turn indicator switch pressed to the right.

- in the Brown cable between turn indicator control device and the ground lead, with the Hazard button pressed.

5) If there is no voltage, check that there is continuity in the relevant cable harness.

6) Check that the turn indicator control device is powered by make sure there is voltage:

- between the Blue and Black cables.

- between the Yellow-Black cable and the Black cable, with the key switch set to «ON».

7) Check that the cable harnesses are not interrupted wherever no voltage is detected.

8) Check that the cable harness connecting the bulbs to the turn indicator control device (White-Blue

and Pink cables) are not interrupted.

9) Check the bulbs ground connection.

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Lights list

KEY

1. Battery

2. Fuse No. 5

3. Key switch contacts

4. Fuse No. 3

5. Fuse No. 9

6. Fuse No. 11

7. Headlight remote control

8. Key switch contacts

9. Fuse No. 12

10. Tail light bulbs

11. License plate bulbs

12. Front tail light bulb

13. Parking control ECU

14. Headlight with twin-filament bulb

15. Light switch

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

TAIL LIGHT LINE CHECK

1) Check that bulbs operate properly.

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2) Check fuses No. 3 and 12.

3) Check key switch contacts.

4) Check there is voltage between the Yellow-Black of fuse No. 12 and the ground lead. Otherwise,

check the continuity of cable harnesses.

5) Check the continuity of the bulb cable harnesses using fuse No. 12 (Yellow-Black cables).

6) Check the bulbs ground connection. HIGH-/ LOW-BEAM LIGHTS LINE - CHECK

1) Check that bulbs operate properly.

2) Check fuses No. 3, 5, 9 and 11.

3) Check key switch contacts.

4) Check there is voltage:

- in the Blue cable between the headlight remote control and the ground lead.

- in the Yellow-Red cable between the headlight remote control and the ground lead, with the key switch set to «ON».

- in the Blue cable between the light switch and the ground lead, with the key switch set to «ON».

5) Check that the relevant cable harnesses are not interrupted wherever no voltage is detected.

6) Check the headlight remote control and the light switch contacts.

7) Check continuity in:

- the White-Black cable between the parking control ECU (pin 6A) and the headlight remote control.

- the Grey-Red cable between the headlight remote control and the light switch.

- the cable harnesses between the headlight and the light switch (Brown and Purple cables).

8) Check the bulbs ground connection.

LIGHT BULBS TABLE

Specification

Desc./Quantity

1 Low beam bulb Type: HALOGEN (H1)

Power: 12V - 55W

Quantity: 1

2 High beam light bulb Type: HALOGEN (H1)

Power: 12V - 55W

Quantity: 1

3 Helmet compartment light bulb Type: FESTOON BULB

Power: 12V - 5W

Quantity: 1

4 Rear turn indicator light bulb Type: Incandescent (BAU 15s)

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

5 Rear tail light bulb Type: Incandescent (W2.1 x 9.5D)

Power: 12V - 5W

Quantity: 1 RHS + 1 LHS

6 Stop light bulb Type: Incandescent (BAU 15s)

Power: 12V - 10W

Quantity: 2

7 License plate bulb Type: Incandescent

Power:12V - 5W

Quantity:2

8 Front turn indicator light bulb Type: Incandescent (BAU 15s)

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

9 Front side light bulb Type: Incandescent (W2.1x9.5d)

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Specification Desc./Quantity

Power: 12V - 5W

Quantity: 1

10 Instrument panel bulb Type: Incandescent

Power:12V - 2W

Quantity:4

Fuses

The electrical system has twelve fuses divided into two fuse boxes to protect the different installation circuits. One of them is inside the battery compartment «A» and the other is at the internal side of the right footrest «B».To have access, loosen the screw «C» and remove the plastic cover. The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

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FUSE TABLE

Specification Desc./Quantity

1 Fuse No. 1 Capacity: 7.5 A

Protected circuits:Injection ECU battery power

2 Fuse No. 2 Capacity: 15 A

Protected circuits:Battery-powered injection loads,

electrical fan

3 Fuse No. 3 Capacity: 15 A

Protected circuits:Saddle opening receiver battery

power supply, glove box lighting, headlight, turn indicator

command device, pre-installation for anti-theft device.

Live fuse No.12, saddle opening and boot.

4 Fuse No. 4 Capacity: 20A

Protected circuits:battery-powered ECU for parking

control

5 Fuse No. 5 Capacity: 20A

Protected circuits:battery-powered fuse No. 7, live

fuses No. 8 - 9 - 10 - 11

6 Fuse No. 6 Capacity: 15 A

Protected circuits:L.V. socket.

7 Fuse No. 7 Capacity: 7.5 A

Protected circuits:Battery-powered instrument panel

8 Fuse No. 8 Capacity: 10A

Protected circuits:Live stop, start-up and start-up ena-

bling lights.

9 Fuse No. 9 Capacity: 7.5 A

Protected circuits:live passing and horn

10 Fuse No. 10 Capacity: 7.5A

Protected circuits:Live injection ECU, immobilizer aer-

ial, electric fan remote control, injection load remote

control

11 Fuse No. 11 Capacity: 7.5A

Protected circuits:Live parking control ECU, pre-instal-

lation for anti-theft device, instrument panel, headlight

remote control, horn remote control

12 Fuse No. 12 Capacity: 7.5A

Protected circuits:Live turn indicator control, saddle

opening switch, tail lights, panel lighting

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Dashboard

A = Led immobilizer / anti-theft device B= Speedometer with twin scale (km/h and mph) C = CLOCK switch D = Digital display E = Front suspension locking system warning light (if available) F = SET switch G = Rpm indicator H = Fuel gauge I = Warning light for helmet compartment courtesy light on L = Engine control telltale light and injection system failure warning light M = Low fuel warning light N = Engine stop warning light O= Turn indicator warning light P = Low oil pressure warning light Q = Front suspension locking system failure warning light (if available) R = Warning light for parking brake engaged S = High-beam warning light

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A = Total odometer gauge B = «BELT» maintenance icon C = «SERVICE» maintenance icon D = Engine coolant temperature indicator E = Trip odometer (A-B) and ambient temperature

gauge (selected with the MODE button)

F = TIME-DATE indicator G = Low fuel warning light H = Trip odometer gauge (B) I = Trip odometer gauge (A) L = Kilometre - mile indicator

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every six months.

INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check up

Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 to 14.70V

- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity

- Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: Maximum 5 h

Battery installation

VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

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WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN

1) Battery preparation

Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.

2) Electrolyte preparation.

Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulphuric acid.

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery.

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5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point.

6) Battery closing.

Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery.

7) Recharging the new battery

With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged.

If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle.

The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between

12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).

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d - Press the red button, as shown in figure.

e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.

f - Check the ignition of the green LED indicated with a red arrow in figure.

g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place

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h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

Connectors

INJECTION ELECTRONIC CONTROL UNIT CONNECTOR

1. Injection telltale light LED (Brown-Black)

2. Rpm indicator on instrument panel (Yellow)

3. CAN "L" Line (White-Blue)

4. Lambda probe (-) (White-Green)

5. Live supply (Red-White)

6. Battery-powered (Orange-Black)

7. Immobilizer aerial (Orange-White)

8. Electric fan remote control (Blue-Yellow)

9. Coolant temperature sensor (Sky blue-Green)

10. CAN "H" Line (Pink-White)

11. Lambda probe (+) (Sky blue-Black)

12. Engine stop switch (Green-Black)

13. Engine rpm sensor positive (Red)

14. Fuel injector (Red-Yellow)

15. Engine rpm sensor negative (Brown)

16. Diagnosis (Purple-White)

17. Immobilizer LED (Red-Green)

18. Engine stop switch, coolant temperature sen-

sor (Grey-Green)

19. Not connected

20. Injection load remote control (Black-Purple)

21. Not connected

22. HV coil (Pink-Black)

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23. Not connected

24. Start-up enabling switch (Orange-Blue)

25. Not connected

26. Ground lead (Black) PICK-UP CONNECTOR

1. Injection ECU (Red)

2. Injection ECU (Brown)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red-Black)

2. Ground lead (Black)

3. Battery positive (Red-Black)

4. Ground lead (Black)

TURN INDICATOR CONTROL DEVICE CONNECTOR

1. Hazard switch (Brown)

2. LHS Switch (White-Pink)

3. RHS Switch (Blue-Black)

4. LHS Turn indicators (Pink)

5. RHS Turn indicators (White-Blue)

6. Battery powered (Blue)

7. Not connected

8. Key-on power (Yellow-Black)

9. Ground lead (Black)

10. Not connected

11. Not connected

12. Not connected

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HV COIL CONNECTOR

1. Injection load remote control (Black-Green)

2. Injection ECU (Pink-Black)

ANTI-THEFT DEVICE PRE-INSTALLATION CONNECTOR

1. Left turn indicators (Pink)

2. Right turn indicators (White-Blue)

3. Ground lead (Black)

4. Battery-powered (Blue)

5. Live supply (Yellow-Red)

6. Helmet compartment lighting (Blue-Black)

7. Channels 1/3 selector (Green-Blue)

8. Alarm code (Orange-Black) FUEL PUMP CONNECTOR

1. Injection load remote control (Black-Green)

2. Not connected

3. Not connected

4. Ground lead (Black)

5. Not connected

INSTRUMENT PANEL CONNECTOR "A"

1. Not connected

2. Not connected

3. Not connected

4. Not connected

5. Instrument panel lighting (Yellow-Black)

6. Battery-powered (Red-Blue)

7. Not connected

8. Not connected

9. Not connected

10. Not connected

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11. Ground lead (Black)

12. Live supply (Yellow-Red) INSTRUMENT PANEL CONNECTOR "B"

1. Scooter speed signal (Sky blue)

2. Fuel level indicator (White-Green)

3. Water temperature sensor (Sky blue-Black)

4. Water temperature sensor ground lead (Brown-

White)

5. «MODE» remote button (Green)

6. Oil pressure sensor (Pink-White)

7. Left turn indicator warning light (Pink)

8. Right turn indicator warning light (White-Blue)

9. High-beam warning light (Purple)

10. Boot open warning light (Blue-Black)

11. Rpm sensor (-)

12. Ambient temperature sensor (Yellow-Blue)

13. Ambient temperature sensor ground (White-

Yellow)

14. Engine disabled warning light (Orange-Blue)

15. Immobilizer warning light (Red-Green)

16. Engine check warning light (Brown-Black)

17. Parking brake warning light (Yellow-Grey)

18. Tilt locking activated warning light (Pink-Black)

19. Tilt locking system failure warning light (Grey-

Black)

20. Live supply from the parking control ECU (Yellow-Green)

PARKING CONTROL ECU CONNECTOR 1A. Potentiometer power supply (Orange-Blue) 2A. CAN "L" Line (White-Blue) 3A. Warning light power supply (Yellow-Green) 4A. Tilt locking activated warning light (Pink-

White) 5A. Tilt locking system failure warning light (GreyBlack)

6A. Headlight remote control (White-Black)

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7A. Potentiometer ground lead, rpm sensor, rider presence sensor (Yellow)

8A. Ground lead (Black) 1B. Live supply (Yellow-Red) 2B. CAN "H" Line (Pink-White) 3B. Left wheel turning sensor (Green) 4B. Right wheel turning sensor (Red) 5B. Potentiometer signal (Green-Blue) 6B. Locking/unlocking switch (Green-Grey) 7B. Horn remote control for alarms (White) 8B. Geared motor (White-Red) 1C. Battery powered (Blue-Red) 2C. Diagnosis (Purple-White) 3C. Locking/unlocking switch (Yellow-Blue) 4C. Calliper sensor (Brown) 5C. Locking/unlocking switch (Purple-Black) 6C. Rider presence sensor (Purple) 7C. Scooter speed signal (Sky blue) 8C. Geared motor (Blue)

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 94

Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.

Exhaust assy. Removal

- Remove the side fairings.

- Remove the central frame cover.

- Remove the exhaust end.

- Disconnect the lambda probe connector.

- Unscrew the probe.

- Working from both sides, release the two clamps securing the exhaust manifold to the head.

- Detach the exhaust manifold making it pass through the swinging arm.

CAUTION SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUF-

FLER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

To fit, follow the removal steps but in reverse order; be careful to tighten to the correct locking torques once the muffler silencer has been refitted.

Removal of the engine from the vehicle

- Use a jack to support the vehicle properly.

- Disconnect the battery.

- Remove the engine cover inside the helmet compartment.

- Remove the side fairings.

- Remove the footrests. Remove the full muffler unit.

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CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Remove the rear wheel.

- Remove the bracket supporting the rear brake callipers and the callipers as well.

- After removing the air filter from the crankcase, undo the screws fixing the bracket that secures the rear brake pipes.

- Remove the pipe that feeds coolant into the pump as shown in the photograph and then empty the system.

- Remove the engine coolant outlet pipe as indicated.

- Disconnect the fuel delivery pipe from the injector by removing the screw locking the retainer clamp.

- Disconnect the injector wiring and the throttle body control unit wiring.

- Remove the coolant outlet pipe from the engine as indicated.

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- Remove the spark plug caps.

- Remove the coolant temperature sensor connector indicated in the photograph.

- Remove the throttle cables from the throttle body by undoing the nuts indicated in the photograph.

- Remove the negative terminal cable from the starter motor.

- Remove the positive terminal cable from the starter motor as shown in the photograph.

- Remove the engine ground lead.

- Disconnect the connectors from the flywheel wiring as shown in the photo.

- Remove the cable from the retaining clip on the flywheel cover.

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Remove the lower screw of the left-hand shock absorber.

- Remove the engine-swinging arm fixing pin by undoing the nut and operating on the head of the pin as shown in the photograph.

- The engine is now free.

When refitting the engine onto the vehicle, carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter.

- Check the engine oil level and if necessary, top it up with the recommended type.

- Fill and bleed the cooling circuit.

- Check accelerator and electric devices for correct functioning.

CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.

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INDEX OF TOPICS

ENGINE ENG

Page 99

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- Loosen the 4 fastening screws

- Extract the outside plastic transmission cover.

- Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap.

- Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush.

- Remove the nut and the two washers.

N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-

ENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

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- Remove the six M6 screws.

- Remove the four M8 screws.

- Remove the transmission cover.

- Check that the bearing rotates freely, otherwise replace it.

Air duct

- Remove the transmission cover.

- Unscrew the two screws shown in the figure to remove the air conveyor.

Locking torques (N*m)

Air conveyor screws 11 ÷ 12

- Remove the external transmission cover.

- Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor.

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