PIAGGIO X9 500 User Manual

• X9 500 cc

SERVICE STATION

MANUAL

Piaggio & C. S.p.A.

Pontedera

After Sales Service

Dis. 594523 - 04/01

Grafica e Stampa:

Data subject to change without notice.

No responsibility is assumed for the use of non-genuine components and accessories other than those tested

and approved by the Manufacturer.

C.L.D. - Pontedera (PI)

SERVICE STATION

MANUAL

X9 500 cc

This manual has been designed by Piaggio for use in authorized dealers' and subdealers' workshops. It is assumed that those who use this publication for maintaining and repairing Piaggio vehicles are familiar with the principles of mechanics and with vehicle repairing procedures and techniques. Any significant changes to the characteristics of the vehicles or to specific repairing procedures will be covered in updates of this manual. Since satisfactory results cannot be obtained without the necessary equipment and tooling, we recommend referring to the pages of this manual concerning the specific equipment required and to the catalogue of specific tools.

Pieces of particularly important information are identified as follows:

Note: Provides important information intended to simplify and clarify a procedure.

Warning

Caution

NOTE - For any intervention to the engine, refer to the “Service Station Manual” for 500 cc Engines.

- Denotes specific procedures to be used to avoid damaging the vehicle.

- Identifies specific procedures to be followed to avoid injury to repairing personnel.

TABLE OF CONTENTS

VEHICLE SPECIFICATIONS AND OVERHAUL DATA

SPECIFIC TOOLING

MAINTENANCE AND TROUBLESHOOTING

ELECTRICAL EQUIPMENT

ENGINE

FRONT AND REAR SUSPENSIONS

BRAKING SYSTEM

BODYWORK

PREDELIVERY OPERATIONS

TABLE OF WORKING TIMES

Assembly plays

Vehicle overhaul data

(Values in mm)

DIAMETER MEASURING HEIGHT

A 43.2

B 43

01_004

Mating between piston and cylinder

(Values in mm)

PART DIMENSIONS MATING CLASSES ASSEMBLY

CODE CYLINDER PISTON CLEARANCE

Cylinder 92

Ø C B 91.997 - 92.004 91.954 - 91.961

Piston 91.961

- 0.010 + 0.018

+ 0.014

- 0.014

A 91.990 - 91.997 91.947 - 91.954

C 92.004 - 92.011 91.961 - 91.968

0.036

0.050

Ø P D 92.011 - 92.018 91.968 - 91.975

The piston must be fitted so that the arrow faces the exhaust side. The piston rings must be fitted so that the marks face upwards.

Piston rings

Ring opening

Arrange for the piston rings opening as shown

Assemble the rings 2 and 3 with the “Top” writing facing upwards.

in the figure

“A” value of the ring inside the cylinder

(Values in mm)

PART DIMENSIONS CLEARANCE SEAT CLEARANCE

CODE CLEARANCE AFTER USE

1st Compression ring 92 x 1.5 A 0.15 - 0.35 0.5

2nd Compression ring 92 x 1.25 A 0.25 - 0.50 0.65

Scraper ring 92 x 2.5 A 0.25 - 0.50 0.65

01_005

1 - 7

Vehicle overhaul data

SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO: CR = 10.5 : 1

“A” MEASUREMENT

(WITH PISTON AT TDC)

N.B.: The “A” measurement is referred to the piston projection or recess value; it indicates the type of gasket to be fitted on the cylinder to restore the compression ratio. Therefore the more the surface formed by the piston crown sticks out of the surface formed by the cylinder top, the thicker the gasket will be. Vice versa, the more the piston crown is hollow to the cylinder top, the less thick the gasket will be.

FIT THE GASKETS SHOWN IN THE TABLE ACCORDING TO THE “A” MEASUREMENT

NOTE: THE “A” MEASUREMENT MUST BE TAKEN WITH NO GASKET FITTED BETWEEN CRANKCASE AND CYLINDER

“A” MEASUREMENT THICKNESS OF BASE GASKET

- 0.185 - - 0.10 0.4 ± 0.05

- 0.10 - + 0.10 0.6 ± 0.05

+ 0.10 - + 0.185 0.8 ± 0.05

Crankshaft/crankcase axial clearance 0.1 - 0.5 mm (cold engine)

01_006

1 - 8

01_010

Crankshaft/connecting rod axial clearance

PART DIMENSIONS CLEARANCE

Web, transmission side A =0.8

Shaft section, transmission side B =19.6

Connecting rod C =22

Shaft section, flywheel side E =19.6

Web, flywheel side F =13

Crankshaft assembly G =63.5

± 0.025

+ 0.05

- 0.10

- 0.15

+ 0.05

± 0.025

+ 0.1

- 0.05

Vehicle overhaul data

01_007

D = 0.20 - 0.40

Crankshaft alignment and diameters

- Measure the housings on both axes x and y.

Standard diameter

Class 1 40.010 - 40.016

Class 2 40.016 - 40.022

Max. allowable runout: A = 0.15 mm

B = 0.01 mm C = 0.010 mm D = 0.10 mm

01_008

01_009

1 - 9

TABLE OF CONTENTS

SPECIFIC TOOLING

Specific Tooling

Specific tools for Piaggio X9 500 cc 4-stroke 4-valve

RECOMMENDED TOOLS

TOOL NAME PART NO.

Circlip pliers 002465Y Steering thrust ring removing drift 020004Y Crankshaft aligning tool 020074Y Support for “METABO HG 1500/2” air heater 020150Y “METABO HG 1500/2” air heater 020151Y Mityvac-type vacuum pump 020329Y Stroboscopic gun for two- and four-stroke engines 020330Y Digital multimeter 020331Y Single battery charger 020333Y Multiple battery charger 020334Y Magnetic stand and dial gauge 020335Y Engine support connection 020482Y Engine mount base 020527Y Engine mount revolving base 020604Y11

= New tools

2 - 2

Specific Tooling

NECESSARY TOOLS

TOOL NAME PART NO.

STEERING SEAT FITTING TOOL, to be fitted with parts 9 - Lower 001330Y bearing adaptor, 10 - Upper bearing adaptor Bell Ø 80 mm 001467Y002 20 mm pliers 001467Y006 Bell Ø 63 mm 001467Y007 18 mm pliers 001467Y008 Bell Ø 45 mm 001467Y017 Bell Ø 60 mm 001467Y031 15 mm pliers 001467Y034 Hub bearing extraction bell 001467Y035 Steering tube ring spanner 020055Y Oil pressure gauge 020193Y Valve seal rings assembly tool 020306Y 37x40 mm adaptor 020358Y 42x47 mm adaptor 020359Y 52x55 mm adaptor 020360Y 20 mm guide (Driven pulley bearings) 020363Y 25 mm guide (Driven pulley bearings) 020364Y Ø 28x30 mm adaptor 020375Y Adapter sleeve 020376Y Bushing (valve removing tool) 020382Y012 15 mm guide 020412Y Valve oil seal extractor 020431Y Oil pressure gauge unio 020434Y 17 mm guide (countershaft bearings) 020439Y Driven half pulley spring compressor 020444Y 46-55 mm spanner 020444Y009 Ø 24 mm adaptor 020456Y Steering tube lower bearing extractor 020458Y Drift for fitting bearing on steering tube 020459Y Injection tester kit 020460Y Flywheel extractor 020467Y Piston fitting band 020468Y Injection tester reprogramming kit 020469Y Piston pin retainer fitting tool 020470Y Countershaft timing peg 020471Y Flywheel retaining tool 020472Y Clutch bell housing retaining tool 020473Y Drive pulley stop spanner 020474Y Piston position comparator support 020475Y Pillar kit 020476Y Ø 37 mm adaptor 020477Y Driven pulley needle roller drift 020478Y Countershaft stop spanner 020479Y Fuel pressure measuring kit 020480Y Control unit interface wiring harness 020481Y 30 mm guide 020483Y Piston stop fork 020512Y Compass wrench (valve lifter bell stop) 020565Y Exhaust gas analyser 494929

2 - 3

Spark plug

Check and replacement

Maintenance

Warning

is cold. Replace the spark plug every 12,000 km. The use of unsuitable ignition control units and spark plugs other than those specified can seriously damage the engine.

Recommended spark plug: CHAMPION RG 6 YC

- Put the vehicle on the central stand.

- Open the door on the left side of the vehicle by levering in the recess in the lower part of the door after removing the screw.

- Disconnect the spark plug HV cable cap.

- Unscrew the spark plug with the spanner provided.

- Check the spark plug to see if the insulator is cracked, the electrodes are worn out or excessively sooty. Also check the condition of the seal washer and measure the spark gap with a suitable thickness gauge.

Spark gap: 0,7 - 0,8 mm

- If necessary adjust the spark gap by carefully bending the side electrode. If the spark plug has any of the defects mentioned above, replace it with a plug of the recommended type.

- Insert the plug into the hole with the proper inclination, screw it in fully by hand and then tighten it with the specially designed spanner.

Tightening torque: 10 N·m (1 Kg·m)

- Push the spark plug cap all the way down onto the spark plug and then proceed to the reassembly.

- Remove the spark plug when the engine

NGK CR 7 EKB

03_001

03_002

Air filter

- Remove the left-hand lower side panel as described in Chapter 8-Bodywork.

- Remove the cleaner cap after loosening the eight fixing screws, including one screw of the knob type.

- Pull out the filter element.

- Replace the air filter with a new one.

Note: Check and if necessary blow the air filter every 6,000 km. Direct the air jet from the inside to the outside of the filter (i.e. in the opposite direction to the air flow during normal engine operation).

Warning

roads, the air filter needs to be cleaned and replaced at shorter intervals than indicated in the Maintenance Schedule.

Warning

in place as this would result in excessive wear of the cylinder and piston as well as in damage to the throttle body.

- If the vehicle is mostly used on dusty

- Do not run the engine if the air filter is not

03_003

03_004

3 - 3

Maintenance

Engine oil level

In four-stroke engines oil is used to lubricate the valve gear components, the crankshaft bearings and the power plant. A lack of engine oil can cause serious damage to the engine. In all four-stroke engines, oil deterioration and consumption are, to some extent, normal, especially during running-in. Consumption partly depends on the riding style (for example, constantly riding at full throttle increases oil consumption).

Checking the oil level

Perform this operation when the engine cold, as described below:

1) Put the vehicle on its central stand on a flat surface.

2) Unscrew dipstick «A», dry it with a clean cloth and refit by screwing it completely.

3) Remove the dipstick again and check that the oil level is between the MAX and MIN marks on the dipstick; top up if necessary.

The MAX level mark indicates an amount of about 1700 cc of engine oil. The level will be lower if checked after using the vehicle (i.e. when the engine is hot). To obtain a correct indication of the oil level, wait for at least 10 minutes after switching off the engine.

Since a certain amount of oil remains in the circuit, the replenishment must be made by adding approximately 1,500 cc of fresh oil through cap «A». Subsequently start the engine, let it idle for a few minutes and then switch it off. After about 5 minutes, check the level and if necessary top up without exceeding the MAX level. The filter cartridge must be replaced every time the oil is changed. For top-ups and renewals use fresh oil of the Selenia HI Scooter 4 Tech type.

Note: Renew the oil when the engine is hot.

MAX MIN

03_005

Topping up

If the oil level is too low, top up by adding fresh oil

without exceeding the MAX level.

Approximately 400 cc of oil are needed to restore the level between the MIN and MAX marks.

Oil pressure warning light

A warning light on the instrument panel comes on when the ignition key is turned to the “ON” position. The light must go out after the engine has started.

Should the warning light come on while braking, idling or cornering, check the oil level and the lubrication system as soon as possible.

Renewing the oil and the filter

The oil and the filter must be renewed every 6,000 km. Drain all the oil from the engine by removing gauze strainer drain plug «B» on the transmission side. To facilitate the outflow, also remove cap/dipstick «A». Once the oil has drained completely through the drain hole, unscrew oil filter cartridge «C» and remove it as described below.

03_006

03_007

3 - 4

Replacing the filter

Maintenance

Warning

ment. Carry out the disposal of the oil, the gasket and the filter in accordance with the law.

Caution

hot engine parts.

- Remove the silencer.

- Remove filler plug «A».

- Remove and clean the drain plug gauze strainer with compressed air.

- Using a strap wrench for filters, remove cartridge filter «C».

- Ensure that the O-rings on the prefilter and the drain plug are in good condition.

- Lubricate the O-rings and then refit the gauze strainer and the oil drain plug. Tighten the drain plug with the prescribed torque.

- Fit a new cartridge filter after lubricating the O-ring. Turn in until the gasket makes contact and then tighten it with the prescribed torque.

- Reinstall the silencer.

- Add engine oil as previously described.

Tightening torque: Tappo scarico olio motore Engine oil drain plug: 24 - 30 N·m Oil filter: 12 - 16 N·m

Oil type: Selenia HI Scooter 4 Tech

- Do not dispose of the oil in the environ-

- To avoid burns, take care not to touch

Checking the hub oil level

- Put the vehicle on the central stand on level ground.

- Unscrew oil dipstick «A», wipe it with a clean cloth, reinsert it and then screw it in fully.

- Pull out the dipstick again and check that the oil level is between the MIN and MAX marks (see figure); if the level is below the MIN mark, top up with oil.

- Reinsert the dipstick and screw it tight.

Renewing the hub oil

- Remove oil filler plug «A».

- Unscrew oil drain plug «B» and drain all the oil.

- Retighten the oil drain plug and then fill the hub with fresh oil.

MAX

MIN

03_008

Recommended oil: TUTELA ZC 90 Hub oil capacity: ~ 250 cc

03_009

3 - 5

Maintenance

Engine cooling Adding coolant and bleeding air from the system

The level of the fluid must be checked every 6,000 km when the engine is cold. Follow these steps:

- Put the vehicle on the central stand on level ground.

- Remove the expansion tank cap and top up if the coolant is below or near the MIN level in the expansion tank. The level of the fluid should always be between the MIN and MAX marks.

- To have an indication of the coolant level, refer to the groove in the plastic strip that can be seen through the coolant filler hole. The upper and lower parts of the groove correspond to the MAX and MIN levels respectively.

- The coolant consists of a 50 percent mixture of demineralized water and antifreeze solution with a base of ethylene glycol and corrosion inhibitors. Total coolant capacity: ~ 1,8 lt

- To check the presence of air in the circuit follow the procedure described in Chapter 11-Cooling, in the manual of Engine 500 cc.

- Switch off the engine and allow it to cool down. After a few minutes, remove the expansion tank cap and check the level of the fluid.

- If necessary, top up by pouring fresh coolant into the expansion tank up to the correct level.

03_010

Warning

- To prevent the coolant from leaking out of the expansion tank during use, be sure to never exceed the MAX level when refilling.

Water pump

If the water pump becomes noisy or liquid leaks through the pump drain hole, check the water pump as described in Chapter 5-Flywheel cover of the manuale Engine 500 cc. Perform the following preliminary operations:

- Put the vehicle on the central stand on level ground.

- Remove the lower right-hand side panel and the

right-hand footboard as described in Chapter 8Bodywork.

- Remove the silencer to gain access to the flywheel

cover as described in Chapter 5-Engine;

- Remove the sleeves from the water pump cover and

the filler cap from the expansion tank and empty the cooling circuit.

Warning

- Perform the operation when the engine is cold.

03_011

- As described in the manual Engine 500cc, partially drain the system and overhaul the pump.

- After solving the problem and refitting all components, fill and bleed the cooling circuit again.

N.B.: Change the coolant as described in Chapter 11Cooling of the Manual Engine 500 cc

- Remove the water pump cover shown in the figure after loosening the six fixing screws.

- Cooling circuit capacity: ~ 1,8 lt.

3 - 6

03_013

Adjusting the play of the valves - Checking the valve gear timing

To adjust the play of the valves and to check the valve gear timing as described in Chapter 7-Thermal Unit and Timing system of the Engine manual, follow these preliminary steps:

- Put the vehicle on the central stand;

- Remove the relevant body sections to gain access to the pivot fixing the engine to the swingarm (refer to Chapter 8-Bodywork);

- Support the bottom of the engine, e.g. with a jack;

- Remove the engine from the frame as described in Chapter 5-Engine;

- Shift the engine backwards to make room for the removal of the cylinder head cover (until the swingarm cross member touches the starter motor).

- After adjusting the play of the valves, refit the components by following the reverse procedure to the removal.

Maintenance

03_012

Warning

prevent it from touching the stop push button of the electrohydraulic stand.

Note: The checking areas are shown in the two figures at the right.

Play of valves: Intake 0,20 mm cold engine

0.15

Exhaust 0,20 mm cold engine

0.15

Checking the level

To gain access to the front and rear brake fluid reservoirs, remove the covers on the handlebar cover.

Follow these steps:

- Put the vehicle on the central stand and turn the handlebar to the central position.

- Remove cap «A» after loosening fixing screw «B».

- Check the level of the fluid through the sight.

A certain decrease in the level of the fluid occurs as a result of pad wear.

Restoring the brake fluid level

- Do not lower the engine too much to

03_012_4

03_012_1

Warning

Brake fluid type: TUTELA TOP 4 Use the following procedure: Remove the «A», covers and the tank cap by unscrewing the two screws, remove the gasket and restore the brake fluid level with liquid of the recommended type, without exceeding the max. level.

- Only use brake fluid classified as DOT 4.

03_012_2

3 - 7

Maintenance

Warning

- Keep the brake fluid away from the skin, the eyes and clothing. In case of contact, rinse generously with water.

Warning

- The brake fluid is highly corrosive. Take care not to spill it on the paintwork.

Warning

- The brake fluid is hygroscopic, i.e. it absorbs humidity from the air. If the humidity contained in the fluid exceeds a given concentration, the braking action becomes insufficient. Never draw the fluid from open or partly empty containers.

Under normal climatic conditions the fluid should be renewed every 20,000 km, or in any case every two years.

N.B.: Change the brake fluid and bleed the system as described in Chapter 7-Braking system.

03_012_3

Steering lock

Disassembly with lock turned to “OFF”

- Remove the rear shield as described in Chapter 8-

Bodywork.

- Remove the immobilizer aerial shown in the figure.

- Disconnect the wiring.

- Pull out the retaining spring shown in the figure and

remove the ignition switch.

03_014

3 - 8

03_015

- Push the bolt lightly and extract the retainer from the

70÷73 cm

10 m

milled part shown in the figure.

- Extract the bolt assembly from the lock body.

- To refit, follow the reverse procedure.

Maintenance

03_016

Removal with lock in LOCK position

The bolt retaining spring is not accessible in the LOCK position. It is then necessary to drill the bolt as show in the figure to eject it.

Note: To refit the bolt from this position, first disengage the steering lock by putting the lock body (inner and outer part) in the OFF position. Proceed as described in the previous paragraph.

Adjusting the headlight

- Place the unloaded vehicle on a level surface, 10 metres from a half-lit white screen, with the tyres inflated to the prescribed pressure. Ensure that the axis of the vehicle is perpendicular to the screen.

- Draw a horizontal line on the screen 70-73 cm above the ground.

- Switch on the headlight, turn on the low beam and check that the horizontal line that divides the dark area from the lighted area is not above the line previously drawn on the screen. To shift the headlight, use the specially designed screw in the front shield (see figure).

03_017

03_018

3 - 9

TABLE OF CONTENTS

ELECTRICAL EQUIPMENT

SIDESTAND SWITCH

VOLTAGE REGULATOR

STAND CONTROL UNIT

ELECTRONIC CONTROL UNIT RELAY SWITCH

ENGINE STOP RELAY SWITCH

SERVICES ELECTROMAGNETIC SWITCH

FUSE BOX (3 X 7.5A, 1 X 15A)

NO. 2 SOLENOID STARTERS

375W FLYWHEEL MAGNETO

2 X STAND BUTTON

STAND PUMP MOTOR

PUMP ASSEMBLY WITH LEVEL INDICATOR

STARTER MOTOR

HELMET COMPARTMENT LAMP BUTTON

HELMET COMPARTMENT LAMP

12V SOCKET

2 X REAR FUSE BOX FOR CONTROL UNIT (1 X 3A, 1 X 5A,

1 X 10A, 1 X 3A) DIODE BOX (2 X 6 A AND 2 A DIODE)

FUSE BOX (2 X 7.5A, 1 X 15A AND 5A)

FUSE BOX WITH STRIP FOR STAND PUMP

ELECTROMAGNETIC SWITCH (NO. 1 OF 70A) DIGITAL INSTRUMENT SET (11 WARNING LIGHTS AND LEDS)

ANALOG INSTRUMENT SET (5 LAMPS)

HEADLIGHT, 2 X PARKING LIGHT BULB, HIGH/LOW BEAM

55/55W BULB LH FRONT TURN INDICATOR WITH 10W BULB

REAR BRAKE LIGHT BUTTON

LIGHTS SWITCH WITH HEADLIGHT FLASH

TURN INDICATOR SWITCH

HORN BUTTON

HAZARD WARNING LIGHT BUTTON

RESET BUTTON

TRUMPET HORN

LH REAR LIGHT WITH 5W PARKING LIGHT BULB AND 10W TURN INDICATOR BULB

REAR BRAKE LIGHT, 5 X 2.3W BULB

NUMBER-PLATE LIGHT 12V-5W

RH REAR LIGHT WITH 5W PARKING LIGHT BULB AND 10W TURN INDICATOR BULB

12V-14Ah BATTERY

FRONT BRAKE LIGHT BUTTON

ENGINE STOP SWITCH

WHEEL REVOLUTION SENSOR

RH FRONT TURN INDICATOR, 10W BULB

MAIN RELAY SWITCH

LIGHTS SELECTOR SWITCH

START BUTTON

STAND BUTTON

IGNITION SWITCH

RADIO DISPLAY

ELECTRIC FAN RELAY SWITCH

30A FUSE WITH SOLENOID STARTER

RADIO CONROL UNIT/INTERCOM/SPEAKERPHONE

No. 2 PUMP ELECTROMAGNETIC SWITCHES

RELAY SIGNALER GLUED

No. 2 HEADLIGHT ELECTROMAGNETIC SWITCHES

4 - 2

Electrical equipment devices

1. Digital instrument panel (11 LED indicators).

2. Analog instrument panel (5 bulbs).

3. Headlight (2 parking light bulbs, 55/55W low/high

beam bulbs).

4. LH front turn indicators (10W bulb).

5. Rear brake light button.

6. Lights selector switch with headlight flash.

7. Turn indicator switch.

8. Horn button.

9. Hazard warning light button.

10. Reset button.

11. Trumpet horn.

12. Sidestand switch.

13. Voltage regulator.

14. Stand control unit.

15. Engine stop relay switch.

16. Electronic control unit relay switch.

17. Stand pump relay switches.

18. LH rear light (5W parking light bulb, 10W turn

indicator bulb).

19. Rear brake light (5 x 2.3W bulbs).

20. Number-plate light with bulb.

21. RH rear light (5W parking light bulb, 10W turn

indicator bulb).

22. 12V-14Ah battery.

23. Fuse box (3 x 7.5A fuse, 1 x 15A fuse).

24. Starting relay switch.

25. Flywheel magneto (375W).

26. Engine oil pressure sensor.

27. Coolant temperature sensor.

28. Engine rpm sensor.

29. Air temperature sensor.

30. Idle speed adjusting motor.

31. Throttle potentiometer.

32. Petrol injector.

33. 2 stand switches.

34. Stand pump motor.

35. Injection electronic control unit.

36. Decoder.

37. Front brake light button.

38. Engine stop switch.

39. Wheel revolution sensor.

40. RH front turn indicator (10W bulb).

Electrical equipment diagram

41. Relay switch.

42. Lights switch.

43. Start button.

44. Stand button.

45. Immobilizer aerial.

46. Ignition switch.

47. Electric fan.

48. Electric fan relay switch.

49. Main relay switch.

50. HV coil.

51. Fuel gauge with pump.

52. Starter motor.

53. Helmet compartment lamp button.

54. Helmet compartment lamp.

55. 12V socket.

56. 2 rear fuse boxes for control unit (1 x 3A fuse, 1 x 5A

fuse, 1 x 10A fuse, 1 x 3A fuse).

57. Radio display.

58. Relay switch.

59. Outside temperature sensor.

60. Diode box (2 x 6A/2A diodes).

61. Fuse box (2 x 7.5A fuse, 1 x 15A fuse, 1 x 5A fuse).

62. Fuse box with base for stand pump (1 x 70A fuse).

63. Intercom/radio control unit.

64. Intercom connectors.

65. Relay signaler glued.

ELECTRICAL CABLES COLOUR: 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=White- Black - BBl=White-Blue - GV=Yellow-Green - Ar=Orange - Az=Azure - GrBl=Grey-Blue - GrN=Grey-

Black.

Warning

ment, take special care to ensure that the leads that link up to the electronic control device are properly connected by observing the polarity and colour coding of the connectors.

- When working on the electrical equip-

4 - 5

Schematic wiring diagrams

Ignition section

DOWN

OFF RUN

IMMOBILIZER DECODER

IGNITION SWITCH CONTACTS

VOLTAGE REGULATOR

FLYWHEEL MAGNETO

INJECTION ELECTRONIC POWER UNIT

HV COIL

SPARK PLUG

DIGITAL INSTRUMENT SET

5A FUSE

3A FUSE

4 - 6

IMMOBILIZER AERIAL

ENGINE STOP RELAY SWITCH

MAIN RELAY SWITCH

12V-14Ah BATTERY

30A FUSE

ENGINE STOP SWITCH

10A FUSE

ELECTRONIC POWER UNIT ELECTROMAGNETIC SWITCH

SIDE STAND SWITCH

2A DIODE

04_002

Lights section

Schematic wiring diagrams

12V-55W LOW BEAM BULB

12V-55W HIGH BEAM BULB

LOW BEAM RELAY SWITCH

HIGH BEAM RELAY SWITCH

DIGITAL INSTRUMENT SET

LIGHTS SWITCH

2 x 12V-5W FRONT PARKING LIGHT BULB, 2 x 12V-5W REAR

PARKING LIGHT BULB, 1 x 12V-5W NUMBER-PLATE LIGHT BULB

IGNITION SWITCH CONTACTS

MAIN RELAY SWITCH

FLYWHEEL MAGNETO

VOLTAGE REGULATOR

7.5 A FUSE

15 A FUSE

7.5 A FUSE

30 A FUSE

12V-14Ah BATTERY

HELMET COMPARTMENT LAMP BUTTON

12V-5W HELMET COMPARTMENT LAMP BULB

12V-180W SOCKET

15A FUSE

LIGHTS SELECTOR SWITCH

2A DIODE

04_003

4 - 7

+ 48 hidden pages