Info Manual 2 PDF

B 125 / 200 ignition / charging
Piaggio Ltd. 25/08/05 With IMMOBILISER
Seat Lock Seat Release

Blue Push Button
Ignition 2
Red / Black Switch 1
OFF
Blue
G
Ignition
Pick up White / Blue Blue / Black
White
White
Cooling
Fan Fan
Green Switch
Yellow Green
Red / Black
White
Ignition Relay
White RUN
STOP
Red / Black White / Green / Blue Emergency

Green Stop
Lt. Blue
Immobiliser Stand Orange
Rectifier / LED Warning
UP
Regulator
Down
p/n: 82501R
Side Stand
Switch
Red / Blue
Lt. Blue
White /Orange 4 amp
CR 9EB White
Choke Unit White
White / Black
Red / Black
Red / Blue
Yellow / Blue
Blue
White / Green or Light Blue
15 15 4 Red / Black
15
Green Indicator
Black / Blue Switch
HT Coil
CDI / Immobiliser
Purple
3 21
Red Black 8 76 54
antenna
+ BATTERY CDI CONNECTIONS Red / Black

1. BLUE / BLACK - INDICATOR SWITCH SUPPLY
12v 2. GREEN
3. PURPLE
- INPUT FROM IGNITION PICK UP
- TO HT COIL White / Green
10ah 4. RED / BLACK - 12v PERMANENT LIVE
5. WHITE / GREEN - SUPPLY FROM IGNITION SWITCH
6. YELLOW / BLUE - IMMOBILISER LED Yellow / Blue
7. WHITE / BLACK - CHOKE CONTROL
8. BLACK - EARTH
White / Black
2-1
B 125 / 200 NOTES
The notes should be used in conjunction with Service Station Manual 594845 and
the notes “B 125 ignition / charging” and “B 125 Fuse Explanation”
1. Seat has electric release. Only works when ignition switch is in the “off”
position.
If seat lock fails to operate:
Check fuse “7” in rear fuse box. 4 amp red wire in & blue wire out.
Check for power on Blue wire at ignition switch
Check for power on White / Blue wire at ignition switch with ignition “off”.
Check the push button, Blue / Black should earth when button is pressed.
Seat lock, power socket and under seat light are all controlled by the same
fuse.
2. Wires from The engine.

Three Yellow wires: Three phases of generator, all feed directly to the
rectifier / regulator.
Green wire: Ignition pick up. Goes to ECU unit.
Brown wire: From oil pressure switch, goes to indicator light on instrument
panel.
3. Immobiliser is like other Leader engines. There are separate notes to explain
the immobiliser system.
4. Fuel system. (similar to the DNA 125 / 180 four strokes)

Fuel is pumped from the tank and supplied to the carburettor under
pressure.
Fuel pump is on the bottom of the tank and is driven by manifold vacuum.
The feed pipe from pump to carburettor has a non-return valve and an
inline filter.
200cc engine may (early vehicles) have a vacuum pipe that branches off
to operate an over run valve in the carburettor.
Carburettor icing is controlled by a warm water feed from the cooling
system.
Choke is the automatic (wax pellet) type used on all our automatics.
Remember that these units default to being “ON” and are turned off
electrically. They are more likely to cause running rich when hot than cold
starting problems.
5. Spark Plugs.
Please note that the correct spark plugs are:
125cc :- NGK CR8 EB p.n. 828866
200cc :- Champion RG6 YC p.n. 828708 (or NGK CR7EB)
2-2
B 125 FUSE EXPLANATION
Piaggio Ltd. 08/05/2003 Piaggio Ltd.
FRONT FUSE BOX
WHITE / ORANGE
1 4 amp Engine start, run, warning lights
WHITE
WHITE / RED
12v DC from 2 4 amp Brake lights, start inhibit
ignition switch
RED / GREY
3 7.5amp Horn, Headlight flash
GREY
YELLOW
From light 4 4 amp Anologue, Inst. & side lights
switch
REAR FUSE BOX
RED
12v DC from battery
5 6 7 8
4 10 15 15
a a a a
RED / BLUE RED / BLACK

Digital Panel, LED, Radio General
YELLOW BLUE
Headlight via relay Under seat, Light, Socket, Lock
2-3
DNA Leader engine ignition / charging
Piaggio Ltd. 13/08/2003 DNA 125 / 180
Ignition Ignition Green

ON RUN
Pick up Switch
OFF STOP
White
Red Yellow / Red
G
ALTERNATOR
STATOR
7.5 7.5
Green amp amp
Power to
Fan Cooling
Lights, horn
Switch Fan Orange
Yellow instruments
Connector for Alarm
Orange
Lt. Blue / Green

Yellow
Rectifier /
Regulator Red Blue / Red
p/n: 82501R
Red Blue / Red Choke Unit
Headlight White / Black

via relay
NGK
CR 8EB
White
To
/ Pink
Indicator
switch
15
amp
HT Coil Blue /
Red Black
Green / Yellow
+ BATTERY
3 21
12v ECU
8 76 54
12ah
Black Blue / Red
White / Black Green
STATOR: ANY YELLOW TO ANY YELLOW = 0.7 - 0.9 ohm. YELLOW TO EARTH = NO CONTINUITY
GREEN TO BLACK (EARTH) = 105 - 124 ohm
REGULATOR: VOLTAGE ACROSS A FULLY CHARGED BATTERY, LIGHTS OFF, HIGH REVS = 14 - 15.2 V.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS WITH LIGHTS ON AND HIGH REVS.
HT COIL: PRIMARY = 0.4 - 0.5 OHM. SECONDARY = 3K + 300 OHM.
2-4
DNA 125 / 180 Switch Wiring
Refer to Service Station Manual
Piaggio Ltd. 08/05/2003 594329 (02/01) page 4-23>
1 2 3 4 5 6
ON
OFF
IGNITION SWITCH
LOCK ITEM 6 ON WIRING DIAGRAM
PARK
BROWN FEED FROM LIGHT SWITCH. WHEN LIGHTS ARE TURNED ON
YELLOW - BLACK SUPPLY TO REAR LIGHTS AND FRONT PILOT LIGHT
WHITE MAIN SUPPLY TO IGNITION SYSTEM, LIGHTS ETC.
RED MAIN FEED FROM BATTERY
BLACK
GREEN
INDICATORS MAIN / DIP HORN

RIGHT FLASH PUSH LEFT HAND
LEFT
OFF
HIGH
LOW
0
SWITCHES
ITEM 8
ON WIRING DIAGRAM
BLACK
GREY - BLACK
YELLOW - BLACK
BROWN
PURPLE
WHITE ORANGE
WHITE - BLUE
BLUE - BLACK
PINK
EMERGENCY
LIGHTS START STOP
ALL PUSH RUN RIGHT HAND
SIDE 0 0
SWITCHES
OFF ITEM 9
ON WIRING DIAGRAM
WHITE
YELLOW - RED
GREEN - BLACK
WHITE - BLACK
ORANGE
BROWN
YELLOW
2-5
ET4 Leader / LX 125 ignition / charging
Ignition Green
ON Ignition
Pick up Switch Power
OFF
to
services
Orange
G
ALTERNATOR
STATOR Red / Blue Carb. Heater
RG4HC
CR 9E
Yellow
Orange
Choke Unit
Rectifier / HT Coil White /

Regulator Black
p/n: 82501R
Red / Blue Orange Green
Black
7.5 Red /
Headlight Blue GREEN
6 1 8 3 4 5 7 2
amp
via relay WHITE / BLACK
ORANGE
RED / BLUE
To Purple
Blue / PURPLE
Grey Indicator Black

BLACK
switch BLUE / BLACK

YELLOW
White
Diagnostic
15 socket
ECU / Immobiliser
amp
Red / Blue Yellow 3 21
LED on antenna 8 76 54
Red instrument
Layout of pins
pannel in the ECU / immobiliser
+ BATTERY TESTS.
STATOR: ANY YELLOW TO ANY YELLOW = 0.7 - 0.9 ohm.
12v YELLOW TO EARTH = NO CONTINUITY
9ah REGULATOR: VOLTAGE ACROSS A FULLY CHARGED BATTERY,
LIGHTS OFF, HIGH REVS = 14 - 15.2 V.
CHARGING: AMMETER IN RED WIRE = > 8 AMPS
WITH LIGHTS ON AND HIGH REVS.
2-6
Hexagon GTX 125 ignition / charging
Ignition Green
ON Ignition
Pick up
OFF Switch
Orange
G
ALTERNATOR Red
STATOR Red
Green
Fan Cooling
RG4HC
Switch Fan
CR 9EB
Yellow Orange
Choke Unit
RUN
STOP
Orange
Lt. Blue White
Rectifier / HT Coil / Black
Regulator
p/n: 82501R
Black Green
Red Red
GREEN
6 1 8 3 4 5 7 2
WHITE / BLACK
Orange Lt. BLUE

RED
Purple
PURPLE
To BLACK
15 5 Indicator BLUE / BLACK
switch Blue / Black YELLOW

amp amp
Diagnostic
White socket Yellow
ECU / Immobiliser
5 3 21
antenna
amp 8 76 54
Red Layout of pins Yellow / Blue LED on

in the ECU / immobiliser
instrument
Red / Blue pannel
+ BATTERY TESTS.
2-7
Runner VX / VXR ignition / charging
Green
Ignition Ignition ON
Pick up Power to
Switch OFF
services
Orange
G
ALTERNATOR
STATOR Red
Red
NGK 5
CR 8EB Green amp
Yellow Cooling
Fan Fan
Switch
Red / Blue
Choke Unit
White /
Rectifier / HT Coil Black
Regulator Green
p/n: 82501R
Black
Red Red
6 1 8 3 4 5 7 2 GREEN
WHITE / BLACK
RED / BLUE
Red / Blue
Purple RED
Headlight PURPLE
BLACK
via relay BLUE / BLACK
To YELLOW
Indicator Blue / Black
switch
Grey
/ Red Diagnostic
Yellow ECU / Immobiliser
Red / Blue socket
15
Yellow / Red antenna
amp
Red 3 2 1 LED on
8 7 6 5 4
Layout of pins
instrument
in the ECU / immobiliser Red pannel
+ BATTERY TESTS.
2-8
X9 125 indicator wiring
7. RED / GREY. 12v+ from ignition switch

5. BLUE / BLACK. To switch. RIGHT turn
6. PINK / BLACK. To switch. LEFT turn

Piaggio Ltd 27/02/2004 SSM page 4-8
LAYOUT OF INSTRUMENT PANEL MULTI PIN CONNECTOR
18.
17.
19.
20.
21.
22.
23.
24.
31.
32.
32.
33.
34.
35.
8.
To RIGHT indicator bulbs. WHITE / BLUE 4.
GREY / BLUE. Cancel 13.

12v+ from battery. RED / WHITE 1.
2.
3.
9.
10.
11.
To LEFT indicator bulbs. PINK 12.
14.
15.
16.
25.
26.
27.
28.
29.
30.
LEFT INDICATORS RIGHT INDICATORS
Instruments panel
1 7 5 13 6 4 12 INDICATOR SWITCH
RED / WHITE RIGHT
RED / GREY PINK CANCEL
LEFT
FUSES IN FRONT
WHITE / BLUE
7.5 amp
STORAGE
COMPARTMENT
PINK / BLACK
IGNITION SWITCH
GREY / BLUE
ON
OFF
BLUE / BLACK
ORANGE
RED / WHITE RED / BLACK RED / BLACK

7.5 amp
RED
BATTERY + 10 amp
RED / BLACK
+ G G G
12v FUSES IN UNDER SEAT RECTIFIER / REGULATOR

COMPARTMENT
2-9a
X9 125 / 180 & 250 Evo ignition / charging
Ignition RUN Ignition Green

Pick up STOP Switch
Red / Black
Orange Cooling
G
Fan
ALTERNATOR
Red / Black
STATOR Green
Fan Switch
Orange
Choke Unit
Yellow
Grey
/ Black
Lt. Blue Orange
RUN Emergency
STOP Stop
5
Side amp
UP
Stand
DOWN
Switch
Yellow / Green
Yellow / Blue
Rectifier / Red / White
Immobiliser Stand
Regulator LED Warning
p/n: 82501R
Red / Black
HT Coil White / Black
RG4HC Diagnostic Green

CR 9EB Yellow / Grey socket
Power to 2 GREEN
Services 7 WHITE / BLACK
Yellow 6 YELLOW
Lt. Blue
5 Lt. BLUE
Purple 4 RED / BLACK

3 PURPLE
8 BLACK
Black
15 3 21
amp 8 76 54
Layout of pins
ECU / Immobiliser
NOTE.
antenna
Indicators are powered by
+Red BATTERY
the digital instrument panel.
TESTS.
12v STATOR: ANY YELLOW TO ANY YELLOW = 0.7 - 0.9 ohm.
YELLOW TO EARTH = NO CONTINUITY
12ah GREEN TO BLACK (EARTH) = 105 - 124 ohm
REGULATOR: VOLTAGE ACROSS A FULLY CHARGED BATTERY,
2-9
ZIP 125 Leader engine ignition / charging
Piaggio Ltd. 13/08/2003 NO Immobiliser
Ignition Green
Pick up ON Ignition
Power
OFF
Switch
to
LOCK services
G
ALTERNATOR
Orange
STATOR
RG6YC Carb. Heater

CR 7EB
Yellow
Orange
Choke Unit

Regulator Black
p/n: 82501R
Red / Blue Green
Black
GREEN
6 1 8 3 4 5 7 2
WHITE / BLACK
ORANGE
Purple
PURPLE
To BLACK
Indicator BLUE / BLACK
switch Blue / Black

15
3 21
amp 8 76 54
Layout of pins
in the ECU
Red ECU
ECU CONNECTIONS
+ BATTERY
1. BLUE / BLACK - INDICATOR SWITCH SUPPLY
2. GREEN - INPUT FROM IGNITION PICK UP
3. PURPLE - TO HT COIL
12v 4.
9ah 5. ORANGE
6.
- SUPPLY FROM IGNITION SWITCH
7. WHITE / BLACK - CHOKE CONTROL

8. BLACK - EARTH
TESTS.
Yellow - Yellow. Charging coils. 0.7 - 0.9 ohm
Yellow - Earth. No continuity
Green - Earth. Ignition pick up coil. 105 - 124 ohm.
Purple - Earth. Coil primary winding. 0.4 - 0.5 ohm
HT - Earth. Coil secondary winding. 3000 ohm
2-10
LEADER ENGINE
Ignition, charging & immobiliser
Use these notes in conjunction with the SERVICE STATION MANUAL
The electrical system on the new Leader engine is very different to previous two stroke and
four stroke Piaggio engines. The ignition, charging & immobiliser circuits do not function in
the same way and do not share common components with previous versions.
Ignition is now using the battery circuit. Everything shares one common supply.
Alternator has three phase (all yellow wires) and ignition pick up coil (green wire) outputs
only.
Rectifier / Regulator is very simple. Three phase (yellow) inputs and one output.
ECU unit has become more complicated. The one unit is responsible for: ignition,
immobiliser, indicators & choke unit.
Much of the circuit is the same on ET4 Leader, Fly 125, Super Hexagon GTX 125,
Liberty 125 Leader, B 125, Skipper ST, Runner VX / VXR and DNA 125 / 180, Vespa
GT 125 / 200 X8 125, X9 125 and Zip 125 but be careful because there are differences.
Early Skipper ST did not have an immobiliser, the later version does have it.
IGNITION.
When the ignition is turned on power is supplied to the CDI (terminal 5).
Ignition pick up is via green wire (terminal 2).
Output to the HT coil is via purple wire (terminal 3).
The unit is earthed via black wire (terminal 8).
CDI / IMMOBILISER
Note the ECU units have different part numbers for different models and engines size.
Refer to the diagram for each specific model. The wiring and wire colours may vary.
It is important that the correct part number is used as the ignition characteristics vary and
although the units look the same they are different!
On vehicles with an immobiliser;

The wires connected to the unmarked terminals are from the antenna that is mounted around
the ignition lock barrel.
Check antenna for continuity, unplugged resistance = 7 - 9 Ω.
The red or red / blue wire (terminal 4) supplies battery voltage even with ignition off.
Yellow wire (terminal 6) is from the LED on the instrument panel. If the system is
programmed and working correctly the LED should be flashing steadily with the ignition
turned off to confirm that the immobiliser system is functioning. The immobiliser earths the
LED (or not) to make it turn on or off.
See pages 3-4 below for more details on using the LED for immobiliser fault finding.
HT COIL. 82597R = Common to most Leader engines. 82582R = Skipper ST & X9 125
Purple to Black - primary winding = 0.4 - 0.5 Ω
HT to Black - secondary winding = 3000 ± 300 Ω
Plugged in with engine cranking the peak voltage Purple to Earth = 100 vdc
2-11
1 of 2
Piaggio Ltd February 2004
IGNITION PICK UP COIL.
Un plug, check resistance, Green to Black = 105 - 124 Ω
Un-plugged with engine cranking the peak voltage Green to Black = 2 vdc
STATOR.
Any yellow to yellow should give continuity. Un-plugged, yellow to yellow = 0.7 - 0.9 Ω
Yellow to earth should not give continuity.
RECTIFIER / REGULATOR. p/n 82501R common to leader engines.

Regulated voltage. With a fully charged battery check charging rate by putting volt meter
across the battery terminals. Peak voltage = 14 - 15.2 vdc. Engine at high speed and lights
off.
Charge current. Connect ammeter to the red wire. Then Start engine. Charge ≥ 10 amp.
With the head light turned on.
INDICATORS (Not X9 125).

There is no separate indicator relay. The relay function is contained within the ECU unit,
Power to the indicator switch is via the blue / black wire (terminal 1).
If the indicators fail first check that you are getting voltage at terminal 1 (blue/black)
To check the switch and wiring. Unplug the CDI and link red/blue wire to blue/black wire,
when the turn switch is operated the appropriate lights should come on. (you will not need the
ignition to be turned on).
INDICATORS X9 125.
X9 has indicators driven by the digital instrument panel.
Three wires go to the switch from the panel. The switch earth’s the appropriate wire to
operate the indicators. Output to the indicators comes from the panel. See the explanation
diagram 2-9a.
CHOKE UNIT.
The choke is now controlled by the CDI. (not the regulator).
Power is supplied to the choke via the main switched wire from the ignition switch to the
ECU. The unit will not function until the engine is running when the CDI will complete the
circuit to earth (terminal 7).
Un Plugged, resistance across the connections = >< 30 Ω @ 20˚C
Plunger extension. Measure how far the plunger protrudes from the body when it is cold,
this should be 12.5 - 13.0 mm. Now connect the choke unit to a 12v battery. The plunger
should have extended to 18.5 - 19.0 mm within 5 minutes.
Supply. Orange or Red / Blue to earth = Battery volts with ignition on.
Orange or Red / Blue to White/Black = 13-14.5v dc (system volts) with engine running.
CARB. HEATER. Fitted to air-cooled engines.

The carburettor heater will start working as soon as the ignition is turned on. Power is
supplied via the switched wire that goes to the CDI.
Water cooled engines use a warm water connection from the cooling system.
COOLING FAN. On water-cooled engines.

The live feed from battery to fan is permanently connected. The switch is in the earth from the
fan. So if the fan is faulty it could be the cause of a flat battery.
2-11
2 of 2
Piaggio Ltd February 2004
Piaggio, Gilera & Vespa
Immobiliser
systems
The following pages are an explanation of the original fitment

immobiliser systems fitted to vehicles beginning in the
1990's with the original (pre Leader) Vespa ET4.
Most space is devoted to the system fitted to Leader engined

vehicles because this is by far the most common.
Much of the operation of other systems is the same as the Leader
system.
Systems covered:
Leader
Pre Leader
Quasar
Master
Published January 2006
1st edition
Piaggio and other after market alarms and immobilisers

are not covered here.
Copies of this and other Piaggio technical information can be obtained

from the Piaggio UK dealer portal web site
or from Piaggio Ltd.
Immobiliser Systems
INDEX
LEADER
Page 2 - Explanation of operation & Fault codes
Page 3 - I need new keys
Page 4 - I need new locks
Page 5 - I need to fit a new CDI / Immobiliser unit
Page 6 - No Spark - Fault Finding Flow Chart
Page 7 - LED Not Flashing - Power supply problem
Page 8 - Immobiliser functioning correctly
Page 9 - Programming a CDI / Immobiliser
Page 10 - Transponder not detected
Page 11 - Transponder not recognised
PRE LEADER
Page 13 - Pre Leader ET4 wiring explanation
QUASAR
Page 15 - Notes on fault codes and diagnostic tester
Page 16 - Programming
MASTER
Page 18 - Notes on fault codes
Page 19 - Programming
Leader Immobiliser
PAGE 2 19/01/2006 EXPLANATION
1. The immobiliser system fitted to all Piaggio, Gilera & Vespa "Leader" engined vehicles operates in
exactly the same way.
2. Although the principle is the same the wiring differs on different models.
Refer to the wiring diagram and Service Station Manual for your specific model.
3. CDI and immobiliser are combined in one unit.
4. The CDI / immobiliser units may look the same but:
They have different characteristics on different models.
Ensure you fit the correct unit. Always order by part number .
5. The flashing LED on the instrument panel is the key to understanding how the immobiliser is
behaving. The list below shows what the LED can tell you.
Note that the LED should flash steadily all the time the ignition is off and the battery is connected.
If not, go to PAGE 7 for fault finding information.
6. If you have no spark you must first prove that it is not due to the immobiliser.
7. Keys should not be on a metal key ring or with other keys. Sometimes this can upset the system.
Possible LED Flashing Fault Codes
Phase 1 Phase 2 Phase 3
2 sec.
LED ON
1. Immobiliser not programmed
2. Transponder is detected
3. Engine will run to 2000rpm
LED OFF
2 sec. 2 x 0.5 sec.

LED ON
2. Transponder is not detected
TURN IGNITION ON
LED OFF
0.7 sec. 2 x 0.5 sec.

LED ON
1. Immobiliser is programmed
3. Ignition is not possible
LED OFF
0.7 sec. 3 x 0.5 sec.

LED ON
2. Transponder is not recognised
LED OFF
0.7 sec.
LED ON
3. Engine can run normally
LED OFF
page 2
Leader Immobiliser
PAGE 3 19/01/2006 NEW KEYS
FAULT: I need new keys.
Obtain a blank service key,

get it cut and program the I have the It is not possible to buy an extra
immobiliser to recognise it
YES Master key master key or have one made.
See: PAGE 9
OR
NO
Take the key to an It is not possible to program in a

automotive lock smith. new key without the master key.
I have the
They will be able to clone it. YES service key
Fortunately automotive lock
smiths can create a clone that will
not need programming.
NO
It is not possible to by pass the

You must change immobiliser.
The lock set and The code card does not contain
The CDI / Immobiliser any electronic data and is only
used to cut the key by number.
See PAGE 4 & 5
Tell your customer to only

use the service key and keep
the master key in a safe
place at home
Gilera Runner service keys

The red service key for Runner two strokes and Runner four strokes now look the same.
The four stroke key has a transponder chip in it and the two stroke key does not.
You can recognise the keys which contain a transponder by a symbol that is engraved on the key
This key contains a

transponder
page 3
Leader Immobiliser
PAGE 4 19/01/2006 NEW LOCKS
FAULT: I need to fit new locks.
Is the original
NO master key YES
available?
1. Fit the new lock set

You must fit a new lock set and a new
2. Remove the chip from the original
CDI / Immobiliser unit
master key and fit it to the new
master key.
It is not possible to bypass the
3. The immobiliser will not know
immobiliser.
anything has changed
4. Program the the new service key to
See PAGES 4 & 5
the immobiliser. See PAGE 9
The lock set is supplied with one

(brown) master key and one service key.
page 4
Leader Immobiliser
PAGE 5 19/01/2006 NEW CDI
FAULT: I need to fit a new CDI / Immobiliser.
I have the
The replacement CDI / immobiliser
NO master & service YES must be new and unused.
key
Fit the new CDI and use the service

I only have
NO the master key YES key to check the engine starts and
runs (only 2000 rpm)
Fit the new CDI and use the master

I only have
key with the chip "out" to check the
the service key
engine starts and runs
(only 2000rpm)
Program the immobiliser.

You must replace the lock set Obtain a new service key
See: PAGE 9
Tell your customer to only use the

service key and keep the master
key in a safe place at home
CDI / Immobiliser Connections

Please refer to individual wiring diagrams and
Service Station Manuals for a full explanation Output to indicators
and wiring colours.
1. Choke has a switched live, Ignition pick up GREEN

CDI earths it to complete the circuit and
turn it off. HT Coil
2. LED has a permanent live,
CDI earths it to complete the circuit and 3 21
make it come on. 8 76 54
3. X9 does not use the indicator BLACK
function. Indicators are driven by Earth
the digital panel.
Choke unit antenna
LED
Battery FUSES
+12v Switched Live
Permanent Live
page 5
Leader Immobiliser
PAGE 6 19/01/2006 Fault Finding
FAULT: Engines turns over but there is no spark when tested with a strobe light
Ignition
turned off
Power
Supply
Problem LED Turn
NO Flashing?
YES Ignition On
7
Immobiliser
is working One short flash
correctly
YES Goes out
8 Stays out
Fault is not with the

immobiliser NO
Immobiliser
needs
One long flash
programming
YES Goes out
9 Stays out

immobiliser NO
Immobiliser Transponder
needs not One long flash
programming detected YES Two short flashes
9 10 Goes out
Stays out

immobiliser NO
Transponder
not One short flash
detected
YES Two short flashes
10 Comes on
Stays on
NO
Transponder
not One short flash
recognised
YES Three short flashes
For an explanation of each fault 11 Comes on
Stays on
go to the relevant numbered NOTES page
page 6
Leader Immobiliser
PAGE 7 19/01/2006 NO LED
FAULT: With Ignition turned off the LED light is not flashing
Note. With an all new / virgin system the LED may not be flashing but the
check function flashes should occur when the ignition is turned on.
Charged Ensure a
Battery NO fully charged
? battery is connected
YES
LED Un-plug the CDI

DON'T
YES Functioning Connect LED wire to earth
? KNOW LED should light up
NO
1. Check Fuse.
2. Check continuity of wire
to instruments.
3. Check continuity of wire
from instruments to CDI.
Permanent 1. Check Fuse.

Live to NO 2. Check continuity of wire
CDI ? from fuse to CDI.
YES
1. Check Fuse.
Switched 2. Check continuity of wire
Live to NO from fuse to ignition switch.
CDI ? 3. Check continuity of wire
from ignition switch to CDI.
YES
Good
Check continuity from CDI
Earth NO connector to battery negative
?
CDI / Immobiliser
Return
3 21
ire
to
tif ls
8 76 54
w
en e
Page 6
id o d
y
to l m
a
EARTH
am u
gr ivid
ur i a d
LED
lo g d i n
co rin r to
w e fe
SWITCHED LIVE
s
R
i
PERMANENT LIVE
page 7
Leader Immobiliser
PAGE 8 19/01/2006 Immobiliser OK
FAULT: Engines turns over but there is no spark when tested with a strobe light
Ignition
turned off
LED Turn
Flashing?
YES Ignition On
Immobiliser
is working One short flash
correctly
YES Goes out
8 Stays out

immobiliser
We know that the immobiliser is working correctly so the immobiliser system can now be ignored
and normal fault finding can be continued.
1. Test the ignition pick up.

Un-plug the CDI. Green wire to earth = 105 - 124 ohms.
2. Test the HT coil (unplugged).
Primary: Purple to Earth = 0.4 - 0.5 ohm.
Secondary: HT to Earth = 3000 ohms (3k ohm).
A 5000 ohms (5K ohm) resistor plug cap should be fitted.
3. Test earth continuity.
Un-plug the CDI. Check continuity between black wire and battery negative.
If no fault has been found you should suspect the CDI unit.
* Fit a new CDI (not from another bike)
* Use the service key (not the brown master key)
* Check that the spark is restored. engine should start but it will not rev beyond 2000 rpm.
If the fault is cured you must program the CDI unit.
GO TO PAGE 9 for programming information.
page 8
Leader Immobiliser
PAGE 9 19/01/2006 PROGRAMMING
FAULT: I need to program the immobiliser unit
Notes.
1. It is not possible to re-program an immobiliser unit to a new master key.
Once it has been programmed it is irrevocably linked to that master key.
2. It is not normally possible for an immobiliser to loose it's program and then need
re-programming.
If it was programmed and working but now it is saying that it is not programmed,
First, check the HT lead and plug cap, It is possible that extreme electrical
interference from a faulty HT circuit could upset the immobiliser.
Plug cap must be at least 5000 ohms. Change the cap and lead if suspect.
A resistor plug must be used on all Leader engines.
Then try re-programming the immobiliser.
If it will not re-program then it is faulty.
Programming a new immobiliser.
1. Do not attempt to program a new immobiliser until you know that the fault is cured.
Attach the new immobiliser, use the service key (not the brown master key)
LED will give one long flash then go out and stay out. System is working correctly,
Immobiliser is not programmed
The engine should start but will not rev above 2000 rpm until the immobiliser is
programmed.
2. To program a new immobiliser
* Insert the brown master key and turn on for two seconds
* Insert the service key and turn on for two seconds
* (extra service keys are included here)
- Insert the extra service key and turn on for two seconds
* The timing of the two seconds can be critical so use a watch to time it,
you may need to do the sequence several times before it is accepted.
* Changing from one key to the next should be done within ten seconds.
* An extra service key is not just added,
you must go through re-programming all the keys as above.
You are not re-programming the master key, the master key is giving permission for the
service keys to be added.
* You do not need to start the engine just to check if the programming has been successful,
Just turn on the ignition and watch the LED.
One short flash (half second) means the programming was successful.
One long flash (two seconds) means the system is still not programmed.
Possible LED Flashing Codes

2 sec.
LED ON
TURN IGNITION ON
LED OFF
0.7 sec.
LED ON
LED OFF
page 9
Leader Immobiliser
PAGE 10 19/01/2006 NOT DETECTED
FAULT: Transponder not detected.
2 sec. 2 x 0.5 sec.

LED ON
3. Ignition is possible
LED OFF
TURN IGNITION ON
0.7 sec. 2 x 0.5 sec.

LED ON
LED OFF
The immobiliser knows the ignition has been turned on but it has not been able to detect the
transponder chip in the key.
Possible reason for transponder chip not being detected.
1. The transponder chip is damaged or missing from the key.

* Try another key.
2. The aerial is damaged, un-plugged or not correctly positioned

* Un-plug the aerial from the CDI and check the aerial for continuity.
Aerial resistance = 7 to 9 ohms. If resistance is wrong replace the aerial.
* Check that the black plastic aerial housing is securely clipped into position around
the ignition switch.
* Inspect the pins in the plug and socket for signs of damage or corrosion.
page 10
Leader Immobiliser
PAGE 11 19/01/2006 NOT RECOGNISED
FAULT: Transponder is not recognised.

TURN IGNITION ON
0.7 sec. 3 x 0.5 sec.

LED ON
1. Immobiliser programmed
LED OFF
The immobiliser has seen the transponder chip so you know that the chip in the key is intact
and the aerial is working correctly.
Possible reasons for the transponder not being recognised.
1. The wrong key is being used.

It is possible for two keys to have the same cut profile on different vehicles
(there are limited number of profiles).
If the keys were mixed up you could turn on the ignition but the immobiliser would not
recognise the chip.
2. The key you are using has not been programmed into the immobiliser.
See PAGE 9 for details of programming .
page 11
Non Leader Immobiliser
The original Vespa ET4 (ZAPM04) was powered by an air-cooled four stroke engine that looked
similar but was very different to the Leader engine.
On the next page there is an explanation of the wiring for this engine.
Immobiliser operation once the system is programmed and working correctly:

CDI is irrevocably linked to the immobiliser
Immobiliser is irrevocably linked to the red master key.
It is possible to fit a new CDI alone.
It is not possible to fit a new immobiliser alone, you must also change the CDI.
It is not possible to change the red key alone.
Fault finding:
* Fault finding is done either with the diagnostic tester or a 12 volt LED.
* The tester is explained in the service station manual. Using an LED is explained here.
* The vehicle is not fitted with an LED in the instrument panel.
* You must connect a 12 volt LED to the test socket.
* The test socket is a grey two pin plug with nothing plugged into it located in a
large rubber sheath on the right side of the engine bay.
* Remove the helmet storage to access the socket.
Note. Keys should not be on a metal key ring or with other keys.
Sometimes this can upset the system.
Possible LED Flashing Fault Codes

2 sec.
LED ON
1. CDI not programmed
LED OFF
0.7 sec. 0.5 sec.

LED ON
2. Break in serial line (orange) or decoder earth (black)
LED OFF
0.7 sec. 2 x 0.5 sec.

LED ON
TURN IGNITION ON

LED OFF
0.7 sec. 3 x 0.5 sec.

LED ON
2. Transponder is not recognised
LED OFF
0.7 sec. 4 x 0.5 sec.

LED ON
2. Virgin immobiliser, programmed CDI
LED OFF
0.7 sec.
LED ON
1. Immobiliser is programmed Immobiliser
2. Transponder is detected is working
3. Engine can run normally correctly
LED OFF
page 12
Vespa ET4 125 charge / ignition (non Leader)
PAGE 13 19/01/2006 ZAPM 04 Later version
ANTENNA HT COIL RECTIFIER / REGULATOR
1 2 3 4 5 6 7 8
IMMOBILISER UNIT
WHITE
GREY / BLUE
YELLOW
GREY
1. AC out
DECODER 2. AC in
To Indicators
3. not used
4. not used
5. DC out
VOLTAGE 6. Earth
STABILISER 7. Indicators
CDI UNIT 8. DC in
3 5 8 6 4
V 3 2 1 G W B R
AC DC
SERVICES SERVICES
PURPLE
PINK
GREY WHITE
WHITE / RED ORANGE (Serial Line) YELLOW
LIGHT BLUE BLACK / BLUE

Diagnostic
Test Socket
LIGHT BLUE
LIGHT BLUE
ON
IGNITION SWITCH
OFF
RED
GREEN
BLACK
WHITE
BLUE
BROWN
PINK
RED
WHITE
GREEN BLUE
GREEN GREEN
WHITE
Lt. BLUE
NOTES.
WHITE / RED * This Diagram shows the non "Leader" ET4 125 with the later type 8 pin rectifier / regulator.
* This charging and ignition system is very similar to Piaggio 50cc 2 strokes and totally different to the
RED / BLUE later "Leader" engined ET4 125.
* Three separate systems. DC, AC and ignition.
BLUE * Ignition is self generating. The green wire (charging coil) is shorted to earth to stop the engine.
Immobiliser. See separate notes for a full explanation of the immobiliser system.
* PINK wire is non switched live (battery voltage) feed to the immobiliser.
7.5 AMP * WHITE / RED is voltage stabilised power for immobiliser and CDI.
FUSE * When ignition switch is turned on the immobiliser and CDI are energised via the LIGHT BLUE wire.
The immobiliser uses the antenna to look for a recognised unique code from the key being used.
If the immobiliser recognises the key they it sends another unique code to the CDI via the ORANGE
PINK
wire (serial line). If the CDI does not receive that code it will not operate. It is this code that makes it
impossible to bypass the immobiliser box.
RED
* The diagnostic test socket will be found when the helmet compartment is removed.
Look on the right side for a large rubber shroud protecting several plugs and sockets.
The diagnostic socket is a grey two pin socket with nothing plugged into it.
+BATTERY You can connect a 12v LED or the diagnostic tester to this socket.
Test box use is well covered in the Service Station Manual.
Testing using 12v LED is covered in these notes.
12v
Tests. See the service station manual for a full explanation of testing the system.
Ignition. Stator (un-plugged) Green-White = 300 - 400 ohms. Red-Brown = 90 -140 ohms.
Loom. Unplug stator and CDI. Green wire should give continuity to earth with ignition OFF and no
continuity with ignition ON.
Charging. AC section. Un-plug regulator. Grey - Earth = 25v AC with engine at about 3000 rpm.
DC section. Ammeter between Battery + and red wire = at least 1.8 amps, fully charged battery
Disconnect battery. yellow - red = at least 15v AC @ 3000 rpm.
page 13
Quasar Immobiliser
The 250 cc Quasar engine is available with a CV carburettor or semi closed loop fuel injection.
The Quasar engine with a carburettor has exactly the same immobiliser function as a Leader
engine.
The Injected engine is detailed below.
This is only a quick reference guide for basic fault finding of the immobiliser system.
For a full explanation please see the Service Station manual.
The Quasar has an ECU with a separate immobiliser which is built into the aerial, so the ECU must
obtain authority from the aerial (active antenna).
Keys should not be on a metal key ring or with other keys. Sometimes this can upset the system.
See Note
Possible LED Flashing Codes on the
Next Page
2 sec.
LED ON
1. ECU not programmed
Any
Key
2. Transponder is detected A
LED OFF
LED ON
1. ECU not programmed
Any
Key
2. Transponder is not detected B
LED OFF
0.7 sec. 0.5 sec.

LED ON
Service
C
TURN IGNITION ON
2. Break in serial line (ECU to aerial)

Key
LED OFF
0.7 sec. 2 x 0.5 sec.

LED ON
Service
Key
2. Transponder is not detected D
LED OFF
0.7 sec. 3 x 0.5 sec.

LED ON
Service
Key
2. Transponder is not recognised E
LED OFF
0.7 sec.
LED ON
Service
Key
LED OFF
Immobiliser
is working
correctly
0.7 sec. 2 x 0.5 sec.
LED ON
Master
2. Two service keys are programmed
Key
LED OFF
Could be
any number
from 0 to 7
page 14
Quasar Immobiliser
PAGE 15 19/01/2006 NOTES
LED flashing code notes.
A. ECU is not programmed.

The LED gives a single two second flash. The Engine management light will be on.
You should get this code when you have fitted a new ECU.
The immobiliser system is working correctly and only needs programming.
B. ECU is not programmed. Transponder is not detected.

The LED gives a single two second flash, then two short flashes, then comes back on..
The ECU is not programmed (as above) but also the chip in the key has not been detected.
You must resolve the transponder problem before trying to program the ECU.
The master key will give this fault if the chip is hinged out.
If you have another key try that, if it is still not detected it is probably the aerial.
Verify that the aerial is correctly located and secure in it's mounting around the ignition lock.
C. Break in the Serial line.

A single short flash, pause, then a second short flash, LED then comes back on.
There is a break in the wire between the ECU and the aerial (active antenna).
The Orange / White wire on pin 7. is the link.
D. Transponder is not detected.

A single short flash, then two short flashes, then comes back on.
The chip in the key has not been seen.
Either there is a fault with the key or the aerial.
If you have another key try that, if it is still not detected it is probably the aerial.
Verify that the aerial is correctly located and secure in it's mounting around the ignition lock.
E. Transponder is not recognised.

A single short flash, then three short flashes, then comes back on.
The chip in the key is seen be is not recognised.
The key is not programmed into the immobiliser memory.
You are using the wrong key or it needs to be programmed into the immobiliser memory.
Diagnostic Tester
If you use the hand held diagnostic tester you can check the immobiliser.
Select the "Errors" menu to see detailed fault information.
DISPLAY NOTES
Uncoded ECU Yes / No Yes = Virgin ECU

LED - one 2 sec flash in phase one (page 14 A)
Imm start inhib Yes / No Yes = Ignition is not possible (no spark).
LED remaining on in phase three (page 14 B,C,D,E)
Universal code Yes / No For production assembly line use only. Yes = Virgin ECU
Key failure Yes / No Yes = Key transponder is not seen.

LED - two flashes in phase two (page 14 D)
Wrong Key code Yes / No Yes = Key transponder is seen but not recognised
LED - three flashes in phase two (page 14 E)
Commun timeout Yes / No Yes = No signal from active antenna to ECU

LED - one flash in phase two (page 14 C)
Stored key num <value> Number of keys coded to the ECU (0 up to 7)

page 15
Quasar Immobiliser
Programming.
Notes.

re-programming.
A resistor spark plug must be used.
Connect the new immobiliser, use the service key (not the brown master key)
programmed.
* (any extra service keys are included here)
* It is not the keys that are programmed.
The immobiliser is being programmed to recognise the keys.
page 16
Master Immobiliser
The 500 cc Master engine has separate immobiliser and ECU.

Once the system is programmed the ECU and immobiliser are irrevocably linked to the brown
master key.
Keys should not be on a metal key ring or with other keys. Sometimes this can upset the system.
For a full explanation of fault finding please see the Service Station manual.
See Note
on the
Phase 1 Phase 2 Phase 3 Next Page
2 sec.
LED ON
1. System not programmed
Any
Key
2. Transponder is detected A
LED OFF
3. Engine runs only to 2000 rpm.
2 sec.
LED ON
Any
Key
2. ECU is programmed B
LED OFF
0.7 sec. 0.5 sec.

LED ON
Service
C
TURN IGNITION ON
2. Break in serial line

Key
LED OFF
0.7 sec. 2 x 0.5 sec.

LED ON
Service
Key
2. Transponder is not detected D
LED OFF
0.7 sec. 3 x 0.5 sec.

LED ON
Service
Key
2. Transponder is not recognised E
LED OFF
0.7 sec.
LED ON
Service
Key
LED OFF
Immobiliser
is working
correctly
0.7 sec. 2 x 0.5 sec.
LED ON
Master
2. Two service keys are programmed
Key
LED OFF
Could be
any number
from 0 to 7
page 17
Master Immobiliser
PAGE 18 19/01/2006 NOTES
LED flashing code notes.
A. System is not programmed.

The LED gives a single two second flash. The Engine management light will be on.
You should get this code when you have fitted a new immobiliser and ECU.
The immobiliser system is working correctly and only needs programming.
B. Immobiliser is not programmed, ECU is programmed.

The LED gives one long flash, then four short flashes, LED then comes back on.
Programming the immobiliser is only possible if the original master key is used.
If the original master key (chip) is not available then you must change the ECU as well.
C. Break in the Serial line.

A single short flash, pause, then a second short flash, LED then comes back on.
Either there is a break in the orange / white wire between the immobiliser and ECU
(serial line) or if the vehicle has a "fall over cut out" fitted it could be that.
If the cut out is active it shorts the serial line to earth.
The fall over sensor is located behind the fuel tank (Nexus) in a rubber mounting.
The fall over sensor

must be mounted
THIS WAY UP
D. Transponder is not detected.

A single short flash, then two short flashes, then comes back on.
The chip in the key has not been seen.
Either there is a fault with the key or the aerial.
If you have another key try that, if it is still not detected it is probably the aerial or it's wires.
Un-plug the aerial from the immobiliser and check for continuity.
Check that the aerial is correctly located and secure in it's mounting.
E. Transponder is not recognised.

A single short flash, then three short flashes, then comes back on.
The chip is seen be is not recognised. The key is not programmed into the immobiliser.
You are using the wrong key or it needs to be programmed into the immobiliser memory.
page 18
Master Immobiliser
Programming.
Notes.

re-programming.
Also a resistor spark plug must be used.
Connect the new immobiliser, use the service key (not the brown master key)
programmed.
* (any extra service keys are included here)
* It is not the keys that are programmed.
The immobiliser is being programmed to recognise the keys.
page 19
Vespa GT 125 / 200 ignition / charging
Ignition Seat release Seat lock Green

push button ON
Pick up Ignition
OFF
Switch
LOCK
Grey / Black Grey / Blue Orange
G
ALTERNATOR Grey
STATOR
Red / Black
Green
Fan Cooling
RG4HC
Switch Fan
CR 9EB
Yellow
Orange
Choke Unit
RUN
STOP
Orange
Lt. Blue
Rectifier / Regulator White / Black
p/n: 82501R HT Coil
Green
Purple
Red / Black
GREEN
6 1 8 3 4 5 7 2
Red / Black Black WHITE / BLACK

Lt. BLUE
RED / BLACK
PURPLE
To BLACK
Fuses in Indicator BLUE / BLACK
glove box switch Yellow

YELLOW
Main Red / Blue ECU / Immobiliser

15 LED on
instrument antenna 3 21
amp 8 76 54
pannel
Layout of pins
Red in the ECU / immobiliser
Note that the ECU fitted to the 125 and 200 have different characteristics.
They are NOT interchangeable.
+ BATTERY
TESTS.
12v GREEN TO BLACK (EARTH) = 105 - 124 ohm
2 -13
Vespa GT Fuses
Piaggio Ltd. 19/08/2003
WHITE YELLOW / RED
RED / BLUE WHITE / RED
GREY YELLOW / BLACK
1 2 3 4 5 6
10 7.5 7.5 7.5 5 5
a a a a a a
RED / BLACK
12v DC from battery
BLUE
RED / BLACK BLUE

12v DC from battery
ORANGE ORANGE
Switched 12v Switched 12v
The wire colours shown here are different to those "on line" and in the owners hand
book.
The colours and fuse functions here are correct, they were checked on GT200
ZAPM312 * 2550.
FUSE:
1. 10 amp. Electric seat release. Headlights. Main beam warning light.
2. 7.5 amp. Intercom. Alarm. Immobiliser LED.
3. 7.5 amp. Intercom. Alarm. Water temp. Fuel warning & guage. Oil pressure warning.
4. 7.5 amp. Horn.
5. 5 amp. Stop light. start switch.
6. 5 amp. Side lights. Number plate light. Instrument panel lights.
MAIN FUSE.
A 15 amp fuse is located at the front of the under seat compartment.
2-14
Skipper ST ignition / charging
Ignition Green
ON Ignition
Pick up Switch Power
OFF
to
services
Orange
G
ALTERNATOR
STATOR Red / Blue Carb. Heater
RG4HC
CR 9E
Yellow
Orange
Choke Unit

Regulator Black
p/n: 82501R
Red / Blue
Red /Blue
Green
Black
Headlight GREEN
6 1 8 3 4 5 7 2
via relay WHITE / BLACK

ORANGE
RED / BLUE
Purple
To Blue / PURPLE
Grey Indicator Black

BLACK
BLUE / BLACK
switch YELLOW
Yellow
Red / Blue
LED on
15 instrument
ECU / Immobiliser
amp pannel
3 21
8 76 54
antenna
Red Layout of pins
+ BATTERY TESTS.
2-15
SKIPPER ST 125 FUSE EXPLANATION
Piaggio Ltd. 06/01/2004 Leader Engine
RED
GREY 12 V DC from battery
To Head Light Relay 1 15 amp
RED
RED / BLUE
2 15 amp
IGNITION SWITCH
ON
OFF
RED / BLUE
ORANGE
RED / BLUE
1 2 3 4
7.5 5 5 5
a a a a
RED / WHITE RED / BLACK

Clock & Interphone Socket To Light Switch
GREY / RED WHITE

To Main / Dip Switch General
2-16
Replacing Skipper ST speedometer
The early Skipper ST did not have an immobiliser. The speedo unit for this vehicle
581308 (or 581307) is no longer available.
It must be replaced with 583271, this is the speedo fitted to later Skipper ST with
immobiliser.
To fit this new speedo you must make some modifications to the wiring at the plugs
which connect to the speedo unit.
Below are diagrams that show the plugs on the wiring loom as they appear on the vehicle
and also how they must appear to enable the new speedo to be used.
1. Confirm that the wiring on your vehicle is as shown on the "Original Loom" diagram
2. Remove the white / green and yellow / green wires from the large plug complete with
their connectors.
3. Remove the white and the brown wires from the small plug complete with their
connectors.
4. Re-fit these wires in the positions shown on the "Modified Loom" diagram.
It is possible to remove the connectors by carefully inserting a small screwdriver or
similar and pressing the retaining tag in.
View of the two plugs that connect to the speedometer
ORIGINAL MODIFIED
LOOM LOOM
YELLOW / GREEN WHITE / GREEN
WHITE / GREEN
YELLOW / BLACK YELLOW / BLACK

BLACK BLACK
BLACK BLACK
VIOLET VIOLET
WHITE / BLUE WHITE / BLUE
RED RED
WHITE
WHITE BROWN
BROWN YELLOW / GREEN
2-17
X9 250 Evo ignition / charging
Piaggio Ltd. 05/05/2004 QUASAR Engine

Pick up STOP Switch
Red / Black
Orange Cooling
G
Fan
ALTERNATOR
STATOR Red / Black
Green
Orange Fan Switch
Choke Unit
Main Relay
Yellow Lt. Blue Orange
Grey / Black
RUN Emergency
STOP Stop
UP Side
Stand
DOWN
Red / White Switch
Green
Yellow / Green
Yellow / Black
7.5 7.5
amp amp
Rectifier /
Regulator Yellow / Green
Black
Immobiliser Stand Yellow / Blue

Red / Black
LED Warning
HT Coil
White / Black
RG4HC Green
CR 9EB Diagnostic
Yellow / Grey socket
2 GREEN
Power to
7 WHITE / BLACK
Services
Yellow 6 YELLOW
Lt. Blue
5 Lt. BLUE
Purple 4 RED / BLACK

3 PURPLE
8 BLACK
15 Black
amp 3 21
8 76 54
Layout of pins
ECU / Immobiliser
antenna NOTE.
+Red
Indicators are powered by
BATTERY the digital instrument panel.
TESTS.
LIGHTS OFF (Remove front 10 A fuse) , HIGH REVS = 14 - 15.2 V.
2-18
Fly 125 Instrument connection
Piaggio Ltd 25/01/2006
You may find an incorrect wiring diagram, with wiring that does not match the vehicle.
This diagram should match the vehicle.
WHITE / GREEN 5
WHITE 4
YELLOW / GREEN 3
WHITE / BLUE 2
YELLOW / BLACK 1
BROWN
PINK
VIOLET
BLACK
Instrument
Illumination
Right turn
Earth
signal
Low fuel
High beam
warning
Switched Red / Blue Left turn

Live 12v + signal
Yellow / Red
Fuel gauge Oil Pressure
To CDI unit
Immobiliser LED.
The LED has a permanent live feed, the CDI earths it when it wants it to light.
If the battery is connected the LED should have a live feed on the Red / Blue wire
If you short the Yellow / Red wire to earth the LED should light.
Oil Pressure.
Live feed to switch. Switch shorts it to earth to light the bulb.
Fuel Gauge.
Live feed to unit in tank. The tank unit shorts it to earth via a variable resistor.
If the gauge is not working.
Un-plug the instruments put a meter between white / green and black.
Low resistance (3 ohms) = full tank. High resistance (100 ohms) = empty tank.
This has checked the wiring and tank unit.
Low Fuel Warning.
Live feed to unit in tank. The tank units shorts to earth to light the bulb.
2-19 A
Fly 125 ignition / charging
Ignition Green
ON Ignition
Pick up
OFF Switch Power
Orange to
services
G
ALTERNATOR
STATOR Orange To
Carb. Heater
headlight
switch
Yellow
Red / Blue
Orange
RG4HC
CR 9E Choke Unit
White / Black
Rectifier /
Regulator
p/n: 82501R HT Coil
Red / Blue
Orange
Green
Red / Blue
Black
GREEN
6 1 8 3 4 5 7 2
7.5 WHITE / BLACK

ORANGE
amp
Purple RED / BLUE
PURPLE
To BLACK
Indicator BLUE / BLACK

Blue / Black
switch Yellow
YELLOW
White Diagnostic
socket
ECU / Immobiliser
15 Red / Blue Yellow / Red
amp 3 21
LED on 8 76 54
Red instrument antenna Layout of pins
pannel in the ECU / immobiliser
+ BATTERY
TESTS.
12v GREEN TO BLACK (EARTH) = 105 - 124 ohm
2-19
X8 125 / 200 ignition / charging

Pick up STOP Switch
Red
Orange Cooling
G
Fan
ALTERNATOR
STATOR Red
Green
Fan Switch
Orange
Yellow Choke Unit
RUN Emergency
STOP Stop
Lt. Blue Power to
Red Services
Rear Fuse
Box
Immobiliser
Rectifier / LED
Regulator 15
Red / Blue To Indicator
10
Red / Black Switch
5
Yellow / Blue
White / Black
Red / Green
RG4HC HT Coil Green

CR 9EB
2 GREEN
7 WHITE / BLACK
1 BLACK / BLUE
Diagnostic Yellow 5 Lt. BLUE
socket 4 RED
6 YELLOW
Purple
3 PURPLE
8 BLACK
Black
Red / Black
3 21
8 76 54
Layout of pins
in the ECU / immobiliser ECU / Immobiliser
antenna
+Red BATTERY
TESTS.
2-20
X8 125 Seat & Trunk Release
ON
SEAT RELEASE
BUTTON IGNITION SWITCH OFF
LOCK
RED
ORANGE
RED / BLUE
RED / BLACK
GREEN
SEAT
SOLENOID
ANTENNA
TRUNK RELEASE
BUTTON
ET
IOL
V FRONT
WHITE FUSE BOX
RED / BLACK
BLACK
10 A
YELLOW
TRUNK
SOLENOID
GREEN
1
2
3 RED / BLUE RED / BLUE
4
6
7
10 REAR
11 FUSE BOX
12
10 A
VIOLET / BLUE
ORANGE / WHITE
YELLOW
ORANGE / BLACK
RED / BLACK
SOLENOID
CONTROL UNIT
15 A RED
+
BATTERY
12v
ORANGE / WHITE ORANGE / WHITE
RED / BLUE
SOCKET FOR ALARM
2-21
Coguar 125 Charging & Ignition
Piaggio Ltd. 04/02/2004 Honda XLR 125w Engine
RECTIFIER / REGULATOR
YELLOW YELLOW PICK

UP
YELLOW YELLOW
YELLOW YELLOW STATOR
RED RED
GREEN BLACK
RED
IGNITION ON RUN BLUE YELLOW / BLUE
SWITCH
OFF STOP
RED / BLACK GREEN

ORANGE
YELLOW / RED
STAND
WARNING
LIGHT UP
20 15 FUSES DOWN
1 X 20 AMP DPR8 EA9
STAND
1 X 15 AMP SWITCH
WHITE / GREEN
NEUTRAL
LIGHT
NEUTRAL
STARTER
IN GEAR
BUTTON
NEUTRAL
SWITCH
M
STARTER
RELAY WHITE / BLUE
IN
IGNITION
+
OUT
BLACK UNIT
BATTERY CLUTCH
BLUE (ECU)
SWITCH
12v
YELLOW / RED
WHITE / GREEN
NOTES
Three phase charging with inductive low voltage ignition.
The start & run permissive circuit is shown here in lighter detail.
For the engine to run the ECU must be earthed via the White / Green wire.
TESTS
Stator: Any yellow to any yellow = 0.8 ohm. Any yellow to earth should give NO continuity.
Regulated voltage: 14.0 - 14.8 volts with fully charged battery and lights on. Engine running at 5000 rpm.
3-1
Vespa ET4 (ZAPM04) charging
Up to ZAP04 * 51159 11/09/2003 5 pin regulator
BLUE BLUE RED

7.5 amp
IGNITION FUSE
SWITCH
ON
OFF
2
GREEN
RED
BLACK
WHITE
CHOKE CONTROL
GREEN
WHITE
CHOKE UNIT RELAY

GREEN BOX
UNDER THE SEAT
L B (-) E
WHITE / RED
GREEN / BLACK
YELLOW GREY
+12v DC from
start button
AC SERVICES DC SERVICES
GREY / BLUE
1
YELLOW
WHITE
GREY
BLACK
RED
A A G B+
3
RECTIFIER BATTERY +
REGULATOR &
REGULATOR 12v
* This diagram shows the early ET4 (non Leader) wiring using a five pin connector on the rectifier / regulator.
Refer to the separate diagram for later circuit using an eight pin rectifier / regulator.
* Three completely separate circuits for AC, DC & ignition.
AC is full wave and regulated
DC is half wave rectified and regulated
Ignition is the self powered CDI type typical on our two stroke scooters. Shorted to earth to stop.
* Engine must be earthed to the chassis / battery. Lack of this connection will affect the AC circuit and starter
motor but not the DC circuit or ignition circuit.
* 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 powered by the DC circuit but the relay to activate it is controled by the AC circuit.
Circuit will only be completed when both:
AC is present at relay terminal "B" and +12v DC is NOT present at the unmarked terminal.
TESTS.
1. Grey / Blue to earth = 25-30v AC stator un-plugged and engine at 2000rpm.
2. Yellow to Blue = 26-30v AC stator and battery disconnected and engine at 2000 rpm.
3. Ammeter between red wire and battery positive = 1.5-2 amp with fully charged battery and engine at 2000 rpm
3-2
Vespa ET4 (ZAPM04) charging circuit
From ZAPM04 * 51160 11/09/2003 8 pin regulator
YELLOW
2
7.5 amp 3
FUSE
BLUE RED
RED / WHITE
IGNITION + BATTERY
SWITCH
12v
WHITE
ON
BLUE
OFF
GREEN
GREEN
BLACK WHITE
1
DC SERVICES
GREY / BLUE Brake light
Horn
WHITE
AC
GREY / BLUE
CHOKE UNIT SERVICES 4

WHITE
BLACK
Head light
TO INDICATOR
Tail light
WHITE / RED BLUE / BLACK SWITCH
Instruments
3&4 YELLOW
GREY
NOT
USED
1 2 3 4 5 6 7 8
RECTIFIER
REGULATOR &
REGULATOR
GREY
* This diagram shows the later (non Leader) ET4 wiring using an eight pin connector on the rectifier /
regulator. Refer to the separate diagram for earlier circuit using a five pin rectifier / regulator.
* The charging system is basically the same as the 50cc & 80cc two stroke Sferoids.
* Two completely separate circuits for AC & DC.
* Eight pin rectifier / regulator incorporates the indicator relay.
* The choke is supplied with 12v DC when the ignition is turned on but the circuit to earth is only completed
when the engine is running and 12v AC is supplied to the choke control relay.
TESTS.
1. Grey / Blue to earth = 25-30v AC stator un-plugged and engine at 2000rpm.
2. Yellow to Blue = 26-30v AC stator and battery disconnected and engine at 2000 rpm.
3. Ammeter between red wire and battery positive = 1.5-2 amp with fully charged battery and engine at 2000 rpm
4. Output to the indicator switch will be a 12v DC pulse with ignition on.
NOTES.
* Engine must be earthed to the chassis / battery. Lack of this connection will affect the AC circuit and starter
motor but not the DC circuit or ignition circuit.
3-3
ET4 IGNITION IMMOBILISER.
Original, Non Leader
General description
The ignition key contains an electronic digital code; this code must be recognised by the system before
the ignition system will function.
Thus the scooter has two forms of security – the key must physically operate the lock (in the normal way),
and the electronic code must be recognised by the system. In this way the scooter is safe against having
the ignition switch forced, or being hot-wired.
Main components
Special keys, with built in transponders.

The red key is the “master” key, which is used for programming, with the transponder mounted in
a flip-out section.
The blue key(s) is for normal use.
Decoder, which uses the antenna to read the electronic code of the key transponder.
CDI unit, which latches to the ON position only if an appropriate signal is received from the decoder.
Other components
Antenna, located encircling the ignition switch.
7.5 amp fuse, which supplies +12V DC to the voltage stabiliser (located within the decoder box).
Voltage stabiliser (located within the decoder box), whose output (+12V DC) supplies power to the
decoder and the CDI unit via contacts in the ignition switch.
“Serial Line”, connects the decoder to the CDI unit, and conveys the authorising signal enabling the CDI
to latch to the “ON” position.
Diagnostic test socket under the helmet holding compartment.
Normal Operation
The key grip contains a passive electronic transponder – a device that contains a unique pre-set digital
code, which can be read without direct electrical contact (similar to those used in the Datatag system).
The keys do not need any power and they do not contain a battery.
When the ignition switch is turned on, the decoder interrogates the key’s transponder.
Only if the decoder recognises the transponder’s electronic digital code will it send a signal via the serial
line to the CDI unit, enabling the otherwise conventional ignition system (alternator with pick-up and
charger coil, CDI unit and HT coil) to function.
However, the CDI unit and the decoder are also programmed to operate together as a matched pair; if
they detect a mismatch the CDI unit will not allow ignition.
3-4
Piaggio Ltd.
page1 of 6
To check the correct operation of the system
IT IS IMPORTANT THAT ON PDI AND AFTER ANY WORK ON THE IMMOBILSER SYSTEM, THE
CORRECT OPERATION OF THE SYSTEM IS CHECKED.
• Insert the red key with the hinged transponder in the flipped out position (this takes it out of radio
range of the antenna, thus enabling the system to be tested without the antenna automatically picking
up a code).
• Turn the ignition on and try to start the engine. IT SHOULD NOT START.
• Insert the blue key and try to start the engine. IT SHOULD START AND RUN NORMALLY.
Fault finding points to note
Decoder and CDI units are initially manufactured as blank units. In this state (“Virgin”) and up to the time
they are programmed the immobiliser system will not offer any protection, and the ignition will function in
a conventional way. However, a “virgin” unit can be used as a substitute to aid in fault finding.
Programming functions can only be done with a red key. Once either the decoder or the CDI unit has
been programmed using a red key, they will only ever recognise that particular red key.
Therefore, it is vital that you USE ONLY THE BLUE KEY FOR ALL TESTING PURPOSES other than the
programming procedure itself.
Diagnostic test procedure
If there is any fault with the system, the Immobiliser Test Box should be plugged in to the diagnostic test
socket. The test box (Part no 020319Y, Current dealer price £53.99 + VAT) is an invaluable, time saving
tool, and one which without doubt should be owned by all dealers.
Proceed as follows-
• With ignition off, turn on and wait for ‘On’ and ‘Pronto’ LEDs to illuminate.
• Turn ignition on. The ‘Seriale’ LED will flash, showing the signal on the Serial line.
• After a few seconds the appropriate LED will indicate the result of the diagnostic tests.
If the “No Serial line” LED lights up, it may be for the following reasons-
Serial Line circuit is broken.
Decoder is faulty
CDI unit is faulty
However if no LEDs light up, it may be for the following reasons-

+12V DC power supply failure.
Decoder is faulty
CDI unit is faulty
Before re-testing, press the reset button.
3-4
Piaggio Ltd.
page2 of 6
Diagnostic points to note-
To check for +12V DC power supply failure, check 7.5 amp fuse, and that +12V DC is present on
decoder terminals 3,5 and 8, and CDI unit terminal 1.
The CDI unit does not have its own earth lead, but is earthed to the alternator stator back-plate via the
white wire from terminal W. However, note also that back-plate and the engine itself is only earthed via
the electric starter motor lead. The decoder has its own earth lead.
There are two different types of transponder/decoder system; each type is not compatible with the other.
However this problem should only show up when trying to program new blue keys. In this case most
automotive locksmiths will be able to “clone” a new blue key if they are provide with a functioning red key.
These “cloned” keys will be recognised by the system without the need for programming.
Component replacement procedure
Component to be replaced Action

Blue key Follow programming procedure (pages 4-14,4-15 in SSM)-
1. Turn the ignition ON using the red key. After 1 to 3
seconds turn OFF.
2. Within 10 seconds turn the ignition ON using a blue key.
After 1 to 3 seconds turn OFF.
3. If needed, repeat step 2 up to seven times to program
further spare keys.
4. Turn the ignition ON using the red key. After 1 to 3
seconds turn OFF.
Red key Red key alone cannot be replaced.

Follow appropriate replace lock set instructions
Lock set 1. Replace lock set.

(if old red key available) 2. Swap red transponder from old key into new key.
3. Check for correct operation of system.
4. Program new blue key using above procedure.
Lock set 1. Replace lock set, decoder and CDI unit.

(if old red key not available) 2. Check for correct operation of system.
3. Program system as per blue key procedure above.
Decoder 1. Replace decoder (CDI must also be replaced).

2. Check for correct operation of system. Note that with a
virgin decoder the engine will start, but won’t rev above
2,000rpm.
3. Program system as per blue key procedure above
CDI unit 1. Replace CDI unit (CDI can be replaced on its own).
2. Check for correct operation of system. Note that with a
virgin CDI unit the engine will start and run normally, but
the immobiliser system is inactive.
3. Program the CDI unit simply by turning on the ignition
switch using the red key
When programming keys do not have more than one transponder type key on the key ring, as the
decoder may pick-up both transponders.
3-4
Piaggio Ltd.
page3 of 6
VESPA ET4 IMMOBILIZER DIAGNOSTICS
When fault finding the ignition system on VESPA ET4, there is a very simple and quick check, which can
be done to give the Immobiliser the ‘all clear’. If you don’t have the effort-saving Immobiliser Tester (part
no. 020319Y) then insert a 12 Volt LED in the 2 pin socket (the blue/black lead is negative) located under
the helmet compartment and switch on the ignition whilst observing the LED. Note that the LED marked
Seriale on the Tester display shows this same signal.
It is advisable to get into the habit of using the blue key for all use and testing purposes other
than the programming procedure itself.
Normally-Functioning Immobiliser
The signal for a normally functioning Immobiliser system is a quick flash (0.7 seconds) and then the LED
remains off.
Immobilizer Fault-Finding
If the system is not functioning normally, it is recommended to obtain the Piaggio Immobiliser Tester. This
is by far the easiest way to diagnose faults. However, if for some reason this is not available, fault finding
can be done by observing the following.
Example Serial Line Signal

0.7 secs 0.5 secs
LED on
2 secs 2 secs
LED off
0.5 secs
The above diagram shows the trace of the diagnostic signal for Decoder and CDI Units both
programmed, using a key with an unknown transponder (Table 2, case 5), resulting in 3 FLASHES during
the second phase of the diagnostic signal (Phase 2).
Phase 1: 0.7 sec flash = NORMAL OPERATION (Cases 7-14 in Table 2)

2 sec flash = CDI Unit unprogrammed (Cases 1-6 in Table 2)
BOTH of the above flashes will be followed by a 2-second pause.
Phase 2: A series of 0-4 flashes (0.5 sec each with 0.5 sec pauses) which form diagnostic signal (refer to
Table 1).
Phase 3: LED remains OFF if no fault is detected or ON if a fault is detected in the Immobilizer system
(the Tester does not consider a non-programmed CDI Unit a fault).
If the led does not light up at all try the following:
Possible Fault Test

No power supply to Immobiliser circuitry in 12 V. should show on blue lead (pin 1 of the
CDI CDI unit).
Faulty Decoder unit Replace and test with BLUE KEY
Faulty CDI unit Replace and test with BLUE KEY
3-4
Piaggio Ltd.
page4 of 6
Table 1: Immobilizer Diagnosis Chart
Phase 2
LED Signal DIAGNOSIS
0 FLASHES NORMAL OPERATION
1 FLASH BREAK IN SERIAL LINE (ORANGE) OR DECODER EARTH (BLACK)
2 FLASHES NO TRANSPONDER DETECTED - FAULTY KEY OR IMMOB. ANTENNA
3 FLASHES TRANSPONDER DETECTED BUT NOT RECOGNISED BY IMMOB.
4 FLASHES VIRGIN DECODER AND PROGRAMMED CDI UNIT
Table 2: Immobilizer Component Combinations and Related Diagnostic Signal
Phase 1 Phase 2 CDI Key

Flash Signal Decoder Unit Transponder Antenna Spark Notes
1 2 sec 0 flashes V V PRESENT - ANY Y 9 Note 1
2 2 sec 2 flashes V V ABSENT or ANY N 9 Note 1
3 2 sec 0 flashes P V PRESENT - PROG. Y 9
4 2 sec 2 flashes P V ANY N
5 2 sec 3 flashes P V PRESENT - UNKNOWN Y
6 2 sec 2 flashes P V ABSENT Y or N
7 0.7 sec 4 flashes V P ANY Y 9 Notes 1,2
8 0.7 sec 2 flashes V P ANY N
9 0.7 sec 2 flashes V P ABSENT Y or N
10 0.7 sec 2 flashes P P ABSENT Y or N
11 0.7 sec 2 flashes P P ABSENT or UNKNOWN N
12 0.7 sec 3 flashes P P PRESENT - UNKNOWN Y
13 0.7 sec 2 flashes P P PRESENT - PROG. N
14 0.7 sec 0 flashes P P PRESENT - PROG. Y 9 Note 3
15 N/A 1 flash N/A N/A N/A N/A Note 4
KEY:
P = UNIT PROGRAMMED
V = VIRGIN i.e. UNPROGRAMMED
Y = ANTENNA FUNCTIONING
N = ANTENNA ABSENT or NOT FUNCTIONING
9 = IGNITION POSSIBLE
= IGNITION NOT POSSIBLE
PROG. = TRANSPONDER RECOGNISED THROUGH PROGRAMMING PROCEDURE
ANY = KEY WITH TRANSPONDER PRESENT BUT CODE DOESN’T MATTER
NOTES:
1. BLUE KEY - use for testing ignition after replacing Decoder and / or CDI Unit, otherwise you may
sacrifice perfectly good units; programs both Decoder and CDI Unit.
RED KEY - only use for programming operations and ONLY when you are sure the ignition system is
delivering a satisfactory spark.
The EXCEPTION to the above two points is when testing the Antenna with the RED KEY transponder
flipped out, as per the ET4 Service Station Manual.
2. LIMITED TO 2000 rpm
3. Normal operation with the either key
4. Break in the Serial line (orange lead) or Decoder not earthed properly (black lead)
3-4
Piaggio Ltd.
page5 of 6
3-4
Piaggio Ltd.
page6 of 6
HEXAGON 250
Charging & Ignition Circuit
STATOR
White
12 volt 12 ah.
CHOKE
HEATER
Ignition
Ignition Switch
Pick up
15 AMP
MAIN FUSE
Red Red
Yellow
Black Blue / Red
Green Black
SERVICES
RECTIFIER / REGULATOR
14 – 15v @ 5000 rrpm.
Black
Yellow / Black
White / Green
Blue / Yellow
Blue / Red
Red / Black
Green
Black
Spark Plug
IGNITION NGK. DPR6EA-9
SWITCH
See Note
Yellow / Black
White / Green
Green
Black
Green / Yellow
White / Black
Contacts are:
Open to
run.
Green
Closed to
Pink
?
stop.
Fuel Pump
CDI Ignition Unit
• Note that the wire colour sometimes changes from one side of a conector to the other.
• The choke supply is ><12 volts AC (only when the engine is running).
• The fuel pump senses the engine speed and varies the supply rate accordingly.
TESTING. Green – Black: No continuity with ignition switch and kill switch to Run.
Yellow - Yellow - Yellow: 0.1 – 1.0 Ώ. Stator winding.
Black/Red – Black: 50 – 350 Ώ. Ignition charging coil.
Green/White – Blue/Yellow: 50 – 170 Ώ. Ignition pick up coil
Yellow/Black – Black: 0.1 – 0.2 Ώ. HT coil primary winding.
HT – Black: 3.6 – 4.6 K Ώ. HT coil secondary winding.
3-5
Piaggio Ltd. March 1999
LIBERTY 125 Charging Circuit
RECTIFIER / REGULATOR WITH AN EIGHT PIN CONNECTOR
STATOR
Yellow
15 A FUSE
CHOKE
UNIT Blue
White
/ Red + Battery
12v 9ah
Grey
White IGNITION
SWITCH
DC SERVICES
AC SERVICES BRAKE LIGHT
Red / HORN
HEAD LIGHT 7.5 A
Black TAIL LIGHT ETC.
CHOKE Fuse
CONTROL INSTRUMENT LIGHTS
To Indicator
RELAY
switch
Blue /
Grey Grey / Blue White Black Black Yellow
1 2 3&4 5 6 7 8
Green / Not used
Black
DC RECTIFIER
AC &
12v DC REGULATOR REGULATOR
from
starter button
Rectifier / Regulator
P/N: 294878
THIS IS THE ORIGINAL ENGINE NOT THE LEADER
• The charging system is basically the same as the 50 / 80cc Sferoids.

1. Two completely separate circuits, AC & DC.
2. DC circuit is regulated on the negative side of the alternator.
• The eight pin rectifier / regulator combines the indicator relay.
• Choke unit is supplied with + 12v DC when ignition is switched on. But current can only flow
(via choke control relay contacts) when the engine is running so AC is present to pull the relay
“in”. A logic circuit in the relay will not allow the choke to begin to turn off while the starter
button is being pressed.
3-6
Piaggio Ltd. April 1999
X9 250 Charging & Ignition
Piaggio Ltd. 11/09/2003 Honda Engine
WHITE
RED / YELLOW HT COIL
MAIN POWER DPR7EA-9
FUSES IN
RELAY 15 7.5 7.5 10 FRONT
STORAGE 4
WHITE COMPARTMENT
WHITE / BLACK
RED /
IGNITION BLACK RED BLUE / YELLOW
SWITCH AUTO
2
CHOKE
BLACK
BLACK GREEN FUEL
DIGITAL
RED / RED / INSTRUMENTS THROTTLE PUMP
BLACK POSITION 5
BLACK
SENSOR
1 BLUE / YELLOW
7.5 10 10 20
FUSES IN RED / YELLOW
HELMET
COMPARTMENT
YELLOW / BLACK
RED
GREEN / BLACK
GREY / BLACK
YELLOW / WHITE
STARTER
STARTER MOTOR RADIATOR
RELAY 3 TEMP.
RED
RED / WHITE
BLACK RED
30 amp YELLOW / GREEN
START
RUN
PERMISSION
RELAY 9 ENGINE
RECTIFIER STOP
REGULATOR 10
RED /
GREEN /
BLACK
BLACK
WHITE / YELLOW
7 ORANGE / BLUE
STARTER YELLOW GREEN /

PUSH / BLACK WHITE
BUTTON UP
STAND
ORANGE SWITCH
WHITE / BLACK
YELLOW
6
+ BATTERY
12v
12 ah IGNITION
CONTROL
8 UNIT
YELLOW YELLOW
WHITE / YELLOW YELLOW / GREY
3-7
X9 250 (Honda engine)
* At PDI
Set the clock TIME and DATE.
Set the TRIP to MILES.
Reset all three SERVICE LIGHTS.
* To change km to miles.
Insert ignition key.
Press and hold down “Trip” and “M” buttons
Turn on the ignition.
The display should now have changed.
* To reset the service light.

1. Remove the central panel between the headlights, this is retained by 5 screws.
2. You will find a button above the headlight unit marked “RES”
3. Turn on the ignition. One of the three service lights will be flashing.
4. Briefly press the button. The light before the one you want to reset should light.
5. Press and hold the button. The light you want to reset will start flashing fast. While it is
flashing fast release the button. Now the light should have gone out.
6. Turn off the ignition and turn back on to prove the light has been cancelled.
* To test System.
With ignition off.
Press and hold down “clock” and “set” buttons
Turn on the ignition
All the systems will check them selves and all the lights should come on.
Any blown bulb or faulty system will be obvious.
* Stop lights.
There are a total of five stop light bulbs.
If two or more bulbs fail the warning light will come on.
* Hazard Lights.
Ignition on
Press hazard button, lights will start flashing.
Turn ignition off.
To stop the lights, first turn the ignition on then press the switch.
* Battery current drain.

Current drain with ignition off should be 1-1.5ma. This equates to a useful battery life of 40
days without any charging.
Test the drain by inserting your meter between battery and earth lead.
* If the battery is going flat check that the helmet compartment light is going out. Remove
the battery cover to see into the helmet compartment with seat closed.
* Battery charging.
Charging at idle (1500 rpm) with the main beam on should be 2 amps.
3-8
1 of 4
* Low fuel warning lamp.
The light will only come on when it has received a continuous signal from the sender for 13
seconds.
* Relays.
The vehicle has five relays.
Starter relay p/n 496403 has a 30 amp fuse and is in the battery compartment.
Start Permission relay p/n 292332 is in the battery compartment.
Two head light relays and the main power relay are all the same p/n 58002R they are all
under the front shield, headlights are central and the power relay is on the near side by the
indicator.
* Headlights.
The headlights are controlled by relays and each has it’s own relay so if the light fails and it
is not the bulb, check the relay.
* Choke unit.
Temperature sensor in the radiator can control the choke.
If the temperature drops to 0 degrees C then choke will come on (no voltage to the unit)
* Honda Foresight Engine.

There are two versions of the engine. The engine number will contain the letter “X” or
“UU” . Piaggio use the “UU” version. Specific parts for this engine are identified by the
colour blue (blue rollers etc.)
* Valve clearance.
Set Cold.
Engine at TDC.
Valve clearance is one division on the scale.
Correct level
* Gear Box Oil Level
Remove the level screw.
If no oil comes out top up until oil drips
then wait until oil stops before re-fitting
the bolt.
* Indicators
The indicator relay function is part of the digital display cluster. P/n. 581413. There is no
separate relay.
The wires involved are:
Blue / Black - right turn
Grey / Blue
Red / Black - left turn
Note that to operate the indicators the handlebar switch shorts the relevant wire to earth.
Hazard lights work by the switch earthing the brown wire from the digital cluster.
3-8
2 of 4
* Braking system
1. Three brake disks are all the same size. 200mm diameter.
2. Both master cylinders are the same size.
3. All brake pads are the same. p.n. 494966
4. L/H front and rear calliper are the same and have 22mm pistons
5. R/H front calliper has 24mm pistons.
6. L/H front and rear are linked together in the following way
When left hand lever is used
Up to 8 bar pressure the rear brake only is operated.
8 - 23 bar both brakes are applied.
Over 23 bar the amount of pressure to the front brakes begins to decrease relative to the rear.
7. The R/H front calliper is operated by the R/H brake lever and has no connection to the other
brakes.
* Rollers and Drive Belt

Roller kit p.n. 496293. Roller min dia. = 22.5mm. Rollers are coloured blue.
Drive Belt p.n. 496304 Min width = 22.3mm
3-8
3 of 4
X9 250 CHARGING & IGNITION
Refer to the X9 Charging & Ignition diagram.
* Note that sometimes the wires coming from a component change colour at the connector that joins
them to the wiring loom.
* See the separate sheet for an explanation of the fuses.
* Charging is three phase, fully rectified.
* Ignition is digitally mapped and can not be manually adjusted.
Spark advance will be affected by:
• Engine speed.
• Throttle position. See # 1
• Coolant temperature. See # 3
# 1. Throttle position sensor is on the carburettor.

Power supply is nominally 5v dc.
Resistance drops as throttle is opened.
# 2. Auto Choke. Normal wax pellet type. Defaults to “on” it is controlled by the ignition
control box and can be turned on by low coolant temperature (temperature sender in
radiator). If coolant temp is less than 0°c the choke will stay on.
Checks.
1. Remove the choke unit from the carb. Measure the length of the plunger extension.
Attach the choke to a 12 volt battery, after 4-5 minutes the plunger should have extended by
about 4.5 mm.
2. White/Black wire should have 12v when ignition is on.
Yellow /White wire should have continuity to earth when the engine is running.
# 3. Radiator temperature sender.
This is on the right hand side of the radiator. The fan switch is on the left.
# 4. HT Coil.
Primary. White/black to blue/yellow = 3Ω
Secondary. HT to blue/yellow = 15,000Ω (15k)
Plug cap. 5,000Ω (5k)
# 5. Fuel Pump is situated under the left foot board.
# 6. Stator.
Charging coils. yellow to yellow = 0.6Ω
yellow to earth should give continuity.
Ignition Pick up. White/yellow to yellow = 200Ω
# 7. Rectifier / Regulator. With a fully charged battery. To check the charging rate, place a
voltmeter across the battery terminals.
With lights off you should have 14-15 volts at 5,000 rpm.
# 8. Battery drain with ignition off should be 1-1.5 ma. This gives a useful battery life without
charging (or use) of about 40 days.
#9. Start Permission Relay.
Situated in the battery compartment. Contacts are normally closed. When green/black is
earthed by the stand switch the contacts will open to break the start circuit..
#10. Engine Stop Switch.
The yellow/green wire from the ECU must be earthed to allow the engine to run. When the
stop switch is “stop” the connection to earth is broken.
3-8
4 of 4
X9 250 FUSE EXPLANATION
FUSES IN HELMET COMPARTMENT
BLUE
1 20 amp Under seat light / Power socket
RED
WHITE / RED
12v direct from 2 10 amp Headlight relay
battery
RED / BLUE
3 10 amp Headlight relay
RED / BLACK
RED / BLACK
12v from battery 4 7.5 amp Digital Instruments
via start relay
FUSES IN FRONT STORAGE COMPARTMENT

RED / YELLOW WHITE
12v ign. on 12v from ign.
via power relay switch
1 2 3 4
15 7.5 7.5 10
a a a a
PURPLE WHITE / BLACK

Head Light (relay) Ignition
RED / GREY RED

Horn, Side lights, Instruments Brake lights, engine stop relay
3-9
50cc 4 stroke Charging / Ignition
STATOR
Test 2 Test 3
BLACK GREY / BLUE
BROWN
Test 1
PICK UP SUPPLY TO
INDICATORS
BROWN
GREY / BLUE
1 2 3 4
GREEN INDICATORS
SWITCH
CDI / COIL
BLUE / BLACK
UNIT IGNITION SWITCH
ON
OFF
LOCK
CHAMPION
RG4HC
GREY / BLUE
RECTIFIER
BROWN WHITE WHITE REGULATOR
TO START RED BLACK
RELAY
10A FUSE WHITE GREY
SUPPLY TO
DC SERVICES
Test 4
BLACK
+ BATTERY AC SUPPLY YELLOW / BLACK
TO LIGHTS
12v
CHOKE HEATER
7ah GREY
LIGHTS
ON / OFF
SWITCH
GREY
Only two wires come from the stator. The engine to earth connection is very important.
Battery voltage at idle = 13 v (Battery charged) max will be 14.5 volts at high revs. Meter between battery neg. & pos.
Battery charge at idle = 1.5 - 2 amps (lights off). max will be >5 amps at high revs with all lights on. Meter between red wire and battery pos.
Test 1: Brown - earth = ~170 ohm To test pick up coil. Stator un-pluged
Test 2: Black - earth = ~1 ohm To test charging coils. Stator un-pluged
Test 3: Blue / Grey - earth = 25 - 35 v ac @ 2000 rpm with regulator disconnected. To test charging coils.
Test 4: White - Black = ~8 M ohm. If the resistance is low it could cause the fuse to blow.
3-10
This information is intended only for authorised Piaggio dealers.
50cc Four Stroke Restriction
Piaggio do not advocate changing the restriction on any 50cc machine that may be used on public roads.
Remember that if a Piaggio, Gilera or Vespa 50cc moped is de-restricted it will be technically illegal. It will not conform to
Motorcycle legislation but it did conform to Moped legislation.
The restriction is the same on all 50cc four stroke models including the LX 50 4t, Fly 50 4t
and Zip 50 4t (China).
The main restriction on the 50 cc four stroke engine is electronic. There is no restriction in
the exhaust pipe.
AC6+0000
38 mm
Cut here
Cut 3 mm deep
at 45º 60 mm
1. Make a 3mm deep cut with a hacksaw in the position shown. Then fill the slot with silicon.
2. Remove the spacer washer between the front pulley halves.
3. Fit carburettor main jet size #78. Part number CM 142103
CUT
If you do not de-restrict. A moped should have a top speed of 45 km/h on the flat.
This engine will achieve that with an average size rider once it has run in for about 50 km.
Initial acceleration is brisk but changing the main jet for that mentioned above will help it
obtain top speed more easily.
3-11
Piaggio Ltd.

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B 125 / 200 ignition / charging

Piaggio Ltd. 25/08/05 With IMMOBILISER

Seat Lock Seat Release

Red / Black White / Green / Blue Emergency

White / Green or Light Blue

+ BATTERY CDI CONNECTIONS Red / Black

2. Wires from The engine.

4. Fuel system. (similar to the DNA 125 / 180 four strokes)

FRONT FUSE BOX

REAR FUSE BOX

RED / BLUE RED / BLACK

Ignition Ignition Green

Connector for Alarm

Lt. Blue / Green

Headlight White / Black

BROWN FEED FROM LIGHT SWITCH. WHEN LIGHTS ARE TURNED ON

YELLOW - BLACK SUPPLY TO REAR LIGHTS AND FRONT PILOT LIGHT

WHITE MAIN SUPPLY TO IGNITION SYSTEM, LIGHTS ETC.

RED MAIN FEED FROM BATTERY

INDICATORS MAIN / DIP HORN

Rectifier / HT Coil White /

Grey Indicator Black

switch BLUE / BLACK

Orange Lt. BLUE

15 5 Indicator BLUE / BLACK

switch Blue / Black YELLOW

Red Layout of pins Yellow / Blue LED on

7. RED / GREY. 12v+ from ignition switch

6. PINK / BLACK. To switch. LEFT turn

LAYOUT OF INSTRUMENT PANEL MULTI PIN CONNECTOR

GREY / BLUE. Cancel 13.

To LEFT indicator bulbs. PINK 12.

RED / GREY PINK CANCEL

RED / WHITE RED / BLACK RED / BLACK

12v FUSES IN UNDER SEAT RECTIFIER / REGULATOR

Ignition RUN Ignition Green

HT Coil White / Black

RG4HC Diagnostic Green

Services 7 WHITE / BLACK

Purple 4 RED / BLACK

RG6YC Carb. Heater

Rectifier / HT Coil White /

Indicator BLUE / BLACK

switch Blue / Black

7. WHITE / BLACK - CHOKE CONTROL

On vehicles with an immobiliser;

RECTIFIER / REGULATOR. p/n 82501R common to leader engines.

INDICATORS (Not X9 125).

CARB. HEATER. Fitted to air-cooled engines.

COOLING FAN. On water-cooled engines.

The following pages are an explanation of the original fitment

Most space is devoted to the system fitted to Leader engined

Piaggio and other after market alarms and immobilisers

Copies of this and other Piaggio technical information can be obtained

Page 2 - Explanation of operation & Fault codes

Page 3 - I need new keys

Page 4 - I need new locks

Page 5 - I need to fit a new CDI / Immobiliser unit

Page 6 - No Spark - Fault Finding Flow Chart