Technical Notes and Workshop Reference. - …

1 ITechnical Notes and Workshop reference file has been built up over the last twelve years at Piaggio Ltd,To help with fault finding, assembly understanding and to clarify and expandon Technical information contained in Service Station Manuals and partscatalogues supplied from of these pages have been created to help answer often asked questionsI hope you find it must ask you to consider this information as classified and therefore donot pass it on to anyone for any reason. I will be very disappointed if anythinghere turns up in the press or is quoted by customers. This information iscontinually being updated so please check the Piaggio Web site occasionallyto see if there are new or updated pages you find an amended page please destroy the original to avoid you find any mistakes or you feel that the information could be betterpresented or improved please contact me at Piaggio Ltd, after information supplied here is accurate to the best of my knowledge but no guarantee isgiven as to the accuracy or suitability of this information.

2 This information should always beused in conjunction with the relevant Piaggio Ltd, reserves the right to amend or withdraw any information contained herewithout prior Ltd, its employees and agents can not be held responsible for any inaccuracies oromissions in this information. Nor can they be held liable for any consequence of using ChampionPiaggio Services Piaggio Ltd 1995 - 2006iiTechnical / After sales contacts:For any After Sales problems or questions, your first contact should be yourRegional After Sales Straw - Technical Services Manager020 7401 4323. Dalzell - Regional after sales manager, Midlands and North07050 263036. Balsillie - Regional after sales manager, Southern07050 263039. Edwards - Warranty Management020 7401 for warranty authorisation: 020 7401 4321 David Champion - Technical information and advice020 7401 4325.

3 Roylance - Technical & After Sales Training07881 786478. Umman - Spare Parts and Accessories Manager020 7401 4329. department Fax: 020 7401 4321 PLEASE MAKE SURE THAT YOU CONTACT THERIGHT PERSON3 Chapter 12 Stroke Auto engines1. 50 / 80cc Charging early type2. 50 / 80cc Charging later type2a. NRG Charging & Gauges2b. NRG Power Instrument connection3. 50cc 2t Ignition4. 125 & 180cc Charging / Ignition5. 125 & 180cc Indicator circuit6. 125 / 180cc Ignition7. Runner 125 / 180cc 2t Fuses8. Diesis 100 Ignition / Charging9. Purejet 50 Charging / Ignition10. Purejet 50 Indicators / Oil Check11. Fly 50 Charging / Carb heaterChapter 2 Leader / Quasar B125 / 200 Ignition / Charging2. B125 Notes3. B125 Fuse explanation4. DNA 125 / 180 Ign. / Charging5. DNA 125 / 180 Switch Wiring6. ET4 125 Ignition / Charging7. Hexagon GTX Ignition / Charging8.

4 Runner VX / VXR X9 125 / 180 Ignition / Charging9a. X9 125 Indicator Wiring10. Zip 125 Ignition / Charging11. General notes12. Immobiliser System explanation13. Vespa GT 125 / 200 Ignition / Charging14. Vespa GT Fuses15. Skipper ST Ignition / Charging16. Skipper ST Fuses17. Skipper ST replacement instrument panel18. X9 250 Evo Ignition / Charging19. Fly 125 Ignition / Charging19a Fly 125 Instrument panel connections20. X8 125 / 200 Ignition / Charging21. X8 Seat & Trunk Release22. X8 125 / 200 Fuse ExplanationChapter 34 Stroke (Non Leader) engines1. Coguar 125 Ignition / Charging2. ET4 (ZAPM04) Early Charging3. ET4 (ZAPM04) Late Charging4. ET4 (ZAPM04) Immobiliser Notes5. Hexagon GTX 250 Charging6. Liberty 125(non Leader) Charging7. X9 250 Ignition / Charging8. X9 250 Notes9. X9 250 Fuse Explanation10. 50cc 4 stroke Ignition / Charging11.

5 50cc 4 stroke Restriction NotesChapter 42 Stroke Manual H@k / GSM Ignition / Charging2. H@K / GSM Notes3. H@K / GSM Wiring Diagram4. Vespa PX Ignition / Charging5. Vespa PX Start Permissive Circuit6. Vespa PX Indicator Circuit7. Vespa T5 Horn circuit8. Gilera RCR 50 Ignition / Charging9. Gilera RCR NotesChapter 5 Electrical General1. X9 Range General Notes2. X9 Range. Under the front Panel3. Stator Coil Values - Quick Auto Choke Operation5. Fuel Gauge Circuit6. Digital Instrument Display Notes7. Remote Seat Release8. Setting the 2 button Digital ClockChapter 6 Fuel Systems1. Typhoon 80 / 125 Fuel System2. DNA Fuel Systems3. Hexagon (EXS1T) Fuel System4. Pumped Fuel Systems5. Vespa PX Fuel TapChapter 7 Mechanical1. Fitting Main Bearings. All 2t Vespa PX Clutch Piston & Small End Sizes4. Up Side Down Forks5.

6 Spark Plug List6. Oil List7. Tyres / Wheels Piaggio7a. Tyres / Wheels Vespa8. Tyres / Wheels Gilera9. Keys Gilera10. Keys General11. De-Restriction Notes12. Chassis Number Location13. Quick reference Guide14. Service Limit ListChapter 8 Injected Vehicles1. X9 500 ignition2. X9 500 lighting3. X9 500 Centre Stand wiring4. Nexus 500 Instrument panel connectionsChapter 9 Tech Tips Collection1. Tech Tips 012. Tech Tips 023. Tech Tips 034. Tech Tips 045. Tech Tips 05 Chapter 1 Electrical systemsTwo Stroke Auto engines1. 50 & 80cc Charging, early type2. 50 & 80cc Charging, later type2a. NRG / Zip Cat Charging & Gauges2b. NRG Power instruments3. 50 & 80cc Ignition4. 125 & 180cc Charging / Ignition5. 125 & 180cc Indicator circuits6. 125 & 180cc Ignition7. Runner 125 / 180 2t Fuses8. Diesis 100 Ignition / Charging9. Purejet 50 Charging / Ignition10.

7 Purejet 50 Indicators / Oil check11. Fly 50 Charging / Carb heaterChapter 2 Electrical SystemsLEADER / QUASAR Engines1. B125 / 200 Ignition / Charging2. B125 Notes3. B125 Fuse Explanation4. DNA 125 / 180 Ign. / Charging5. DNA 125 / 180 Switch Wiring6. ET4 125 Ignition / Charging7. Hexagon GTX Ign. / Charging8. Runner VX / VXR Ign. / Charging9. X9 125 / 180 Ignition / Charging9a. X9 125 Indicator Wiring10. Zip 125 Ignition / Charging11. Leader General Notes12. Immobiliser Notes13. Vespa GT 125 / 200 Ignition / Charging14. Vespa GT 125 / 200 Fuses15. Skipper ST Ignition / Charging16. Skipper ST Fuses17. Skipper ST replacement instrument panel18. X9 250 Evo Ignition / Charging19. Fly 125 Ignition / Charging19a. Fly 125 Instrument X8 125 / 200 Ignition / Charging21. X8 Seat & Trunk release22. X8 125 Fuse explanationChapter 3 Electrical SystemsFour Stroke (Non Leader)1.

8 Coguar 125 Ignition / Charging2. ET4 (ZAPM04) Early Charging3. ET4 (ZAPM04) Late Charging4. ET4 (ZAPM04) Immobiliser Notes5. Hexagon GTX 250 Charging6. Liberty 125 (non Leader) Charging7. X9 250 Ignition / Charging8. X9 250 Notes9. X9 250 Fuse Explanation10. 50cc 4 stroke Ignition / Charging11. 50cc 4 stroke Restriction NotesChapter 4 Electrical SystemsTwo StrokeManual Engines1. H@k / GSM Ignition / Charging2. H@K / GSM Notes3. H@K / GSM Wiring Diagram4. Vespa PX Ignition / Charging5. Vespa PX Start Permissive Circuit6. Vespa PX Indicator Circuit7. Vespa T5 Horn circuit8. Gilera RCR 50 Ignition / Charging9. Gilera RCR 50 NotesChapter 5 Electrical SystemsGeneral1. X9 Range General Notes2. X9 Range. Under the front Panel3. Stator Coil Values - Quick Auto Choke Operation5. Fuel Gauge Circuit6. Digital Instrument Display Notes7. Remote Seat ReleaseChapter 6 Fuel Systems1.

9 Typhoon 80 / 125 Fuel System2. DNA Fuel Systems3. Hexagon (EXS1T) Fuel System4. Pumped Fuel Systems5. Vespa PX Fuel TapChapter 7 Mechanical Systems1. Fitting Main Bearings. All 2t Vespa PX Clutch Piston & Small End Sizes4. Up Side Down Forks5. Spark Plug List6. Oil List7. Tyres / Wheels Piaggio7a. Tyres / Wheels Vespa8. Tyres / Wheels Gilera9. Keys Gilera10. Keys General11. De-Restriction Notes12. Chassis Number Location13. Quick reference Guide14. Service Limit ListChapter 8 Injected Vehicles1. X9 500 Charging wiring2. X9 500 Ignition Wiring3. X9 500 Centre Stand Wiring4. Nexus 500 Instruments WiringChapter 9 Tech TipsA collection of theTech Tipspreviously publishedon the Piaggio Portal010203040530/09/2005 Piaggio pin regulator50 / 80cc 2T Charging (early vehicles)BATTERY12v+CHOKE ampFUSEIGNITIONSWITCHYELLOWBLUEGREY / BLUEREDGREYDC SERVICESB rake lightHornREDBLUEWHITE* This diagram shows the early 50cc and 80cc two stroke wiring using a five pin connector on the rectifier / regulator.

10 Refer to the separate diagram for later circuit using an eight pin rectifier / regulator.* RECOGNISE THIS CIRCUIT: If the oil warning light comes on when the starter button is pressed.* Two completely separate circuits for AC & is full wave and regulatedDC is half wave rectified and regulated* If voltage at the B+ terminal falls below 8v (approx) the DC rectifier / regulator will not function so there will be no output from the alternator on the DC circuit.* Separate indicator relay.* The choke is supplied with 12v AC when the engine is running . Grey / Blue to earth = 25-30v AC stator un-plugged and engine at Yellow to Blue = 26-30v AC stator and battery disconnected and engine at 2000 Ammeter between red wire and battery positive = amp with fully charged battery and engine at 2000 must be earthed to the chassis / battery. Lack of this connection will affect the AC circuit and starter motorbut not the DC circuit or ignition / BLUERECTIFIER&REGULATORB+GAAREGULATOR2 GREYACSERVICESHead lightTail lightInstruments12v 4ah - 50cc12v 5ah - 80cc1 - 1 OFFONRED30/12/2005 Piaggio pin regulator50 / 80cc 2T chargingBATTERY12v+CHOKE ampFUSEACSERVICESYELLOWBLUEGREY / BLUERED / WHITEGREYDC SERVICESB rake lightHornREDBLUEWHITE* This diagram shows the later 50cc and 80cc two stroke wiring using an eight pin connector on the rectifier / regulator.