PIAGGIO 500 cc Service Manual Download Page 1

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SERVICE

STATION

MANUAL

Piaggio & C. S.p.A.

Pontedera

After Sales Service

Dis. 594766 - 04/01

Grafica e Stampa:

C.L.D. - Pontedera (PI)

Data are subject to modification without notice.

We decline all liability for the use of non-original spare parts or accessories that have not been tested and/or approved.

• Engine 500 cc

Summary of Contents for 500 cc

Page 1: ...01 Grafica e Stampa C L D Pontedera PI Copyright 2001 PIAGGIO C S p A Pontedera All rights reserved Data are subject to modification without notice We decline all liability for the use of non original...

Page 2: ...pecific repair operations will be divulged by means of updates to this manual Satisfactory repair or service cannot be achieved without the necessary equipment and tools Refer to the pages of this man...

Page 3: ...MAINTENANCE SPECIFIC TOOLS AUTOMATIC TRANSMISSION FINAL REDUCTION FLYWHEEL AND STARTING SYSTEM THERMAL UNIT AND TIMING SYSTEM CRANKCASE AND DRIVING SHAFT INJECTION LUBRICATION FLYWHEEL COVER 10 9 8 7...

Page 4: ...TABLE OF CONTENTS GENERAL INFORMATION AND MAINTENANCE 1...

Page 5: ...he jet away from you to avoid inhaling the dust Although the brake linings are asbetos free inhala tion of the resulting dust is harmful Maintenance regulations Use only genuine PIAGGIO spare parts an...

Page 6: ...c fuel pump throttle body 38mm and single injector Max power at crankshaft 29 kW 39 CV bei 7250 rpm Max torque at crankshaft 40 N m 4 Kgm bei 5500 rpm General information and Maintenance Cooling syste...

Page 7: ...ove replace it with a plug of the recom mended type Insert the plug into the hole with the proper inclina tion screw it in fully by hand and then tighten it with the specially designed spanner Tighten...

Page 8: ...eeding 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 igni...

Page 9: ...lubricating the O ring Turninuntilthegasketmakescontactandthenscrew it with the prescribed torque Reinstall the silencer Add engine oil as previously described Tightening torque Oil filter 12 16 N m...

Page 10: ...steps Put the vehicle on the central stand on level ground Remove the expansion tank cap and top up if the coolantisbeloworneartheMINlevelintheexpansion tank The level of the fluid should always be b...

Page 11: ...xhaust respectively do not correspond with those indicated below adjust them by loosening the check nut and acting on the register with a screwdriver as shown in the figure Intake 0 20 mm cold engine...

Page 12: ...TABLE OF CONTENTS SPECIFIC TOOLING 2...

Page 13: ...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...

Page 14: ...l pressure gauge unio 020434Y 17 mm guide countershaft bearings 020439Y Driven half pulley spring compressor 020444Y 46 55 mm spanner 020444Y009 24 mm adaptor 020456Y Steering tube lower bearing extra...

Page 15: ...TABLE OF CONTENTS AUTOMATIC TRANSMISSION 3...

Page 16: ...RICATE WITH OIL APPLY PRODUCT LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE WARNING HANDLE WITH CARE REFERENCE A B C D E F G H I L M N O P Q QUANTITY 1 4 1 1 1 7 TORQUE N m 90 92 23 26 17 20 16...

Page 17: ...elt antiflapping roller Check that the roller is in good condition and that it turns freely Unloose the fixing screw with a 13 mm wrench Remove the roller and relevant bearing N B If the roller does n...

Page 18: ...ulley with its bush and rear washer taking care not to let the rollers come out Driven pulley axle support To be able to fit the specific tool for removal of the driven pulley shaft nut unloose the 2...

Page 19: ...andthewasher Remove the spacer below 05_014 Clutch housing Remove the clutch housing 05_016 05_015 Check that the clutch housing shows no signs of wear or damage Measure the clutch housing I D Standar...

Page 20: ...he ventilation holes Bring the rear stop screw in contact with the fixed driven pulley as shown in the figure Put the tool in a vice firmly Do not overtighten the rear screw to avoid buckling the tool...

Page 21: ...Remove the roller bearing by means of the specific tool supporting the fixed half pulley with the bell Specific tools Handle 020376Y 28x30 mm adapter 020375Y 25 mm guide 020364Y Bell 001467Y002 05_02...

Page 22: ...eans of the specific tool Specific tools Handle 020376Y 37 mm adapter 020477Y 20 mm guide 020363Y Fit the stop snap ring 05_029 05_028 Driven pulley assembly Fit the new oil seals Fit the new O rings...

Page 23: ...ter use 120 mm 05_030 Check the thickness of the clutch weights friction material Minimum allowed thickness 1 mm The weights must show no traces of grease If neces sary check the seals of the driven p...

Page 24: ...n on both half pulleys 05_036 05_033 Compress the spring and insert the clutch on the driven pulley bush N B Take care not to damage the sheath or the bush threaded end Screw the ring nut manually and...

Page 25: ...ed side must rest on the internal thrust side of the roller housing Rollers housing assembly Fit the spacer with the internal beveling facing the insertion side Assemble the half pulley with the rolle...

Page 26: ...fitted in the crankcase 05_047 05_045 Driven pulley unit assembly Fit the driven pulley unit and relevant belt Housing assembly Fit the housing and the spacer 05_046 05_037 Driven pulley axle support...

Page 27: ...020376Y 28x30 mm adapter 020375Y 17 mm guide 020439Y Driven pulley axle support bearing assembly Heat the driven pulley axle support with the thermal gun Specific tool Air heater 020151Y 05_039 Fit th...

Page 28: ...pulley axle support Specific tool Clutch housing lock tool 020473Y 05_050 Tightenthehousingfixingnuttotheprescribedtorque Tightening torque Driven pulley shaft nut 90 92 N m 05_051 Remove the specific...

Page 29: ...he fixed driving half pulley making sure it is in contact with the spacer and with the sliding bush of the mobile driving pulley 05_054 Fit the plain washer and the cup washer as shown in the figure 0...

Page 30: ...c tool Tightening torque Driving pulley nut 157 172 N m 05_010 Belt antiflapping roller assembly Fit the belt antiflapping roller with the belt contain ment edge to the engine crankcase side Tighten t...

Page 31: ..._006 External transmission cover N B Make sure that the air intake and the three air outlets are completely free Fit the plastic external transmission cover Tighten the 5 fixing screws to the prescrib...

Page 32: ...TABLE OF CONTENTS FINAL REDUCTION 4...

Page 33: ...INAL REDUCTION LUBRICATE WITH OIL APPLY PRODUCT LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE WARNING HANDLE WITH CARE REFERENCE A B C D E F G H I L M N O P Q QUANTITY 6 1 TORQUE N m 24 27 15 1...

Page 34: ...TABLE OF CONTENTS FLYWHEEL COVER 5...

Page 35: ...DUCT LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE WARNING HANDLE WITH CARE REFERENCE A B C D E F G H I L M N O P Q QUANTITY 6 14 1 1 6 3 1 1 2 2 1 TORQUE N m 3 4 11 13 4 5 24 30 3 4 8 10 1 5 2...

Page 36: ...bereplaced Removetheclamps by opening them with a screwdriver or by cutting them Take care not to damage the plastic unions 05_082 05_081 Remove the cooling tube bracket from the manifold fixing Therm...

Page 37: ...N B If necessary disassemble the pump cover com plete with thermostat and sleeves 05_086 05_085 Flywheel cover disassembly Drain the engine oil by removing the drain plug Collect the oil in a suitable...

Page 38: ...ny interferences between the stator and rotor while removing the cover Do not drop the bypass valve and rel evant spring 05_089 Flywheel cover components disassembly Remove the bypass and relevant spr...

Page 39: ...lve and relevant seal gasket Unloose the fixing screw and remove the gas outlet pipe and relevant O ring 05_094 05_095 Remove the water pump rotor by unscrewing it from its shaft N B The threading goe...

Page 40: ...haft and relevant stop washer 05_097 Remove the O ring 05_098 Remove the ceramic ring and relevant gasket 05_099 Remove the O ring for the pump shaft lubrication by means of a properly shaped tool 05_...

Page 41: ...of wear or deformation Check that the bypass valve seat torque limiter support and water pump shaft support show no signs of wear Bypass housing hole diameter 13 9 mm Diameter of starting gear shaft s...

Page 42: ...are noticed remember to carefully check the harness as this is realized with 2 types of cables stiff cables near the stator and soft cables near the connector 05_106 Check that the winding does not in...

Page 43: ...or worn Water pump rotor Check that the rotor is not deformed or cracked Check that the plastic rotor is perfectly integral with the metal part 05_109 05_110 Checking the water pump cover Check that t...

Page 44: ...heel cover components Make sure that all the components are well clean before reassembling them Carefully check all the cover case lubrication ducts in particular The 3 bypass channels 05_113 05_114 O...

Page 45: ...gate and tighten the screws to the prescribed torque Tightening torque Support screws 0 3 0 4 N m 05_119 05_093 Fit a new pump shaft O ring by means of the specific tool Fit the oil minimum pressure s...

Page 46: ...g the seat on the flywheel cover Fit the mechanical seal on the shaft aligning it with the rotor stop surface N B The depth of the final fitting depends on the rotor 05_120 05_121 Screw the rotor and...

Page 47: ...ipstick Fit the blow by recovery duct with a new O ring Tighten the screw to the prescribed torque Tightening torque Blow by recovery duct fixing screws 3 4 N m 05_123 05_122 Fit the spring and the by...

Page 48: ...stand stop Tighten the 14 fixing screws of the cover to the prescribed torque N B The screws come supplied in three different lengths the 5 shorter screws are located in the position shown in the figu...

Page 49: ...hermostat cover fixing screws 1 5 2 N m 05_088 05_083 Fit a new oil filter lubricate the seal tighten to the prescribed torque Tightening torque Oil filter 12 16 N m Assemble the two cooling system sl...

Page 50: ...and the engine oil drain plug Tighten it to the prescribed torque Refill the engine with oil of the recommended type Tightening torque Oil drain plug 24 30 N m Recommended oil Selenia HI Scooter 4 Te...

Page 51: ...TABLE OF CONTENTS FLYWHEEL AND STARTING SYSTEM 6...

Page 52: ...ING SYSTEM LUBRICATE WITH OIL APPLY PRODUCT LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE WARNING HANDLE WITH CARE REFERENCE A B C D E F G H I L M N O P Q QUANTITY 6 3 2 1 TORQUE N m 13 15 3 4...

Page 53: ...se the two fixing screws and remove the engine earth cable Remove the starting motor assembly Magneto flywheel disassembly N B To disassemble the magneto flywheel first re move the chain guide shoe st...

Page 54: ...shown in the figure making sure that the pins perfectly fit in the holes previously aligned and that it is almost in contact with the flywheel Specific tool Flywheel lock tool 020472Y Unloose the mag...

Page 55: ...t breaking of the magnetos 05_136 05_135 Fit the extractor Use a 27mm wrench and a 19mm bush to unlock the magneto flywheel Specific tool Flywheel extractor 020467Y Remove the extractor Remove the nut...

Page 56: ...5_140 05_139 The freewheel is precisely coupled with the flywheel if disassembly becomes difficult use 2 screws as holding points and as extractors Remove the idler gear provided with a torque limiter...

Page 57: ...If only the brass is damaged it is sufficient to replace the starting ring gear assembly In this case also check the diameter and surface of the driving shaft support Replace the driving shaft if nec...

Page 58: ...on the toothed disks it is recommendable to replace the assembly Freewheel assembly on magneto flywheel Check the freewheel contact surfaces condition Carefully clean the freewheel to remove any trac...

Page 59: ...ring gear hub surface Fit the starting ring gear on the flywheel and turn it clockwise at the same time 05_149 05_138 Idler gear with torque limiter assembly Grease the gear housing on the engine cran...

Page 60: ...ear Insert the washer and the nut on the driving shaft 05_151 05_152 Fully screw the flywheel lock tool guide bush and unscrew it by 1 4 of a turn N B Failure to observe the above procedure will cause...

Page 61: ...05_153 Assemble the chain guide shoe stop plate and tighten the 3 screws to the prescribed torque Tightening torque Chain guide shoe plate fixing screws 3 4 N m 05_128 05_129 Starting motor assembly...

Page 62: ...e the housing of the idler gear with torque limiter located on the flywheel cover Align the water pump drive with a reference mark and fit the flywheel cover as described in Chapter 5 Flywheel cover 0...

Page 63: ...TABLE OF CONTENTS THERMAL UNIT AND TIMING SYSTEM 7...

Page 64: ...CATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE WARNING HANDLE WITH CARE REFERENCE A B C D E F G H I L M N O P Q QUANTITY 3 1 2 1 4 4 4 4 1 1 2 3 3 1 1 TORQUE N m 4 6 30 35 11 13 5 6 38 42 44 46 11 13...

Page 65: ...dler gear with torque limiter as described in Chapter 5 FlywheelCover andinChapter6 FlywheelandStart ing system Intake manifold disassembly Unloose the 3 fixing screws one of which locks the supportin...

Page 66: ...ve the central screw and the valve lifter weight stop bell by means of the specific tool Specific tool Compass wrench 020565Y Remove the return spring and the valve lifter weight with the relevant sto...

Page 67: ...e 2 fixing screws and remove the tightener and relevant gasket Remove the internal hexagonal head screw and the counterweight as shown in the figure Remove the timing chain gear from the camshaft Remo...

Page 68: ...ction Camshaft and equalizers disassembly Unloose the 3 fixing screws and remove the camshaft stop bracket N B Removing the fixing screws may turn out to be difficult Make sure not to damage the inter...

Page 69: ...screws Remove the coolant temperature sensor N B The sensor controls both the injection and the analogue instrument on the dashboard Check this component according to the procedure described in Chapte...

Page 70: ...ontainer when the head is disassembled Warning Valves disassembly Disassemble the cotters caps springs and valves by means of the specific tool provided with an adapter Specific tool Valves disassembl...

Page 71: ...he cylinder To avoid damaging the piston hold it while disassembling the cylinder Warning Remove the 2 stop rings of the piston gudgeon pin through the specific openings Remove the gudgeon pin and the...

Page 72: ...y means of a micrometer Standard diameter 22 0 mm Calculate the connecting rod small end gudgeon pin allowance Standard clearance 0 015 0 029 mm Measure the piston support diameter Standard diameter 2...

Page 73: ...s higher than those indicated in the table are measured replace the piston N B Measure the play by inserting the feeler gauge blade on the 2nd gas ring side 05_186 05_187 Gas rings Insert alternately...

Page 74: ...eon pin stop ring in the specific tool with the opening in the position marked on the tool S left D right Fit the stop ring by means of the punch 05_190 05_191 Piston assembly Assemble the piston and...

Page 75: ...feeler pin is sliding perfectly Assemble the tool on the cylinder without changing the dial gauge position Lock the tool using the head fixing original nuts Move the driving shaft up to the TDC dial...

Page 76: ...itable tool be used to fit the rings N B The point of contact of the 2 sealing rings with the cylinder has a conical shape allowing for a better bedding Offset the ring openings by 120 as shown in the...

Page 77: ...that the head cover surface shows no signs of wear Check that the coolant sealing pad shows no signs of oxidation Checking the valve sealing surfaces Visually check the valves sealing surfaces Do not...

Page 78: ...f Prussian blue Measure the inside diameter of each valve guide Perform the measurement according to the thrust direction of the equalizer at three different heights Standard value 1 1 3 mm Limit allo...

Page 79: ...mm Exhaust 94 2 0 3 mm Check the valve head concentricity by placing a dial gauge at right angle to the valve head and turning the valve head on a V surface Limit allowed 0 03 mm Valve guide play chec...

Page 80: ...t on turning the valve when the lapping com pound is finished Carefully wash the head and the valves with a product suitable for the type of lapping compound used N B Do not change the valves assembly...

Page 81: ...fic tools Valve assembly tool 020382Y Adapter 020382Y012 N B Do not change the valves assembly position Assemble the valve springs according to the reference colour cotters side large coil spring 05_2...

Page 82: ...by means of a gauge Standard height Intake 33 988 mm Exhaust 33 417 mm Limits allowed Intake 33 740 mm Exhaust 33 170 mm Standard end play 0 0 22 mm Maximum allowed end play 0 3 mm Replace the defecti...

Page 83: ...iming system parts Check that the guide shoe and the tension pad are not excessively worn Check that the camshaft control timing gear and driving shaft pinion assembly show no signs of wear Replace th...

Page 84: ...ng torque Coolant temperature sensor 10 12 N m Warning Make sure the head lubrication duct is well clean If necessary clean with a jet of compressed air Assemble the head Oil the studs and the 4 fixin...

Page 85: ...ring sealing Assemble the union with the larger diameter facing the transmission side Tighten the 2 fixing screws to the prescribed torque Assemble the spark plug and tighten it to the pre scribed tor...

Page 86: ...3 4 N m Remove any LOCTITE residuals from the camshaft stop bracket fixing screws by means of a brush Apply LOCTITE 242 to the fixing screws after clean ing them from any residual of thread locking c...

Page 87: ...magneto support and the one on the flywheel cover are aligned Assemble the idler gear with torque limiter flywheel and flywheel cover as described in Chapter 6 Fly wheel and Starting System and in Ch...

Page 88: ...turn Fit the chain on the camshaft timing gear Fit the timing gear on the camshaft aligning the reference marks N B Duringthetimingcheck keepthechaintensioned by pressing from the tightener compartme...

Page 89: ...l fixing screws 30 35 N m 05_232 Position the engine with the valve play adjustment timing reference marks aligned with the head Check the valve equalizer play by means of a thick ness gauge Prescribe...

Page 90: ...Tightener fixing screws 11 13 N m Fit the spring with the central screw and washer Tighten the central screw to the prescribed torque Tightening torque Tightener screw 5 6 N m Tappets cover assembly C...

Page 91: ...nChapter5 Flywheel cover Intake manifold parts disassembly Injector disassembly N B Remove the injector from the manifold only if it is faulty Check the injector operation with the injector assembled...

Page 92: ...Absolutely avoid tampering with the valve beat register as the register has been suitably sealed For any troubles related with the slow running see Chapter 9 Injection N B Thethrottlebodycanberemovedw...

Page 93: ...Assemble the intake manifold on the engine Insert the 3 fixing screws and tighten them to the prescribed torque One of the screws is provided with a clamp supporting the cooling system sleeve Tighten...

Page 94: ...TABLE OF CONTENTS CRANKCASE AND DRIVING SHAFT 8...

Page 95: ...SHAFT LUBRICATE WITH OIL APPLY PRODUCT LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE WARNING HANDLE WITH CARE REFERENCE A B C D E F G H I L M N O P Q QUANTITY 1 2 2 14 4 TORQUE N m 25 29 5 6 8...

Page 96: ...edinChapter3 Automatic transmission Remove the flywheel cover with the cooling system sleeves as described in chapter 5 Flywheel cover Remove the magneto flywheel with the starting con trol as describ...

Page 97: ...er use 0 60 mm If the play exceeds the indicated values it means that the supporting surfaces of the crankcase driving shaft are worn To correctly measure the play completely restore the play in both...

Page 98: ...so allows for the driving shaft removal Remove the driving shaft with the shim washer flywheel side While separating the crankcase and removing the driving shaft take care that the shaft threaded ends...

Page 99: ...ific tool Countershaft lock wrench 020479Y Remove the fixing nut and relevant washer Removethespecifictoolandwithdrawthecountershaft complete with control gear Driving shaft crankcase 05_258 Oil pump...

Page 100: ...s Check the bearings out for anomalous noise or play Replace if necessary Half crankcase flywheel side Remove the snap ring situated on the inner side Driving shaft crankcase 05_262 Overturn the half...

Page 101: ...tool Put the half crankcase on a wooden base Specific tool Heater 020151Y Fit a new bearing on the specific tool after having greased the fitting slot Assemble the new bearing on the half crankcase by...

Page 102: ...r having greased the fitting slot Assemble a new bearing on the engine crankcase by means of the specific tool N B If a bearing with a plastic cage is used position the balls so that they face the cra...

Page 103: ...width conforms to the standard values and the surfaces show no signs of scoring Shim Check the total dimension of the driving shaft shoul der gear assembly Standard thickness 71 804 72 000 mm Make su...

Page 104: ...nts shown in the figure Specific tool Support for driving shaft control 020074Y 05_270_2 05_270_1 Driving shaft crankcase Max out of line allowed A 0 15 mm B 0 01 mm C 0 01 mm D 0 10 mm Check the cond...

Page 105: ...ine half crankcase check Before checking the crankcases carefully clean all the surfaces and lubrication ducts For the half crankcase transmission side act on the main bearing brass cooling jet transm...

Page 106: ...promising the lubrication pressure to the main bearing brasses and connecting rod Check that the driving shaft end play containment surfaces show no signs of wear Check the dimen sions according to th...

Page 107: ...ass 1 with crankcase FC1 or class 2 with crankcase FC2 A spare crankcase cannot be used with a mixed class driving shaft The shaft for the spare parts is provided with half shafts of the same class Dr...

Page 108: ...mbly Check the gasket correct position N B The gasket tooth must be positioned in the relevant seat 05_260 05_259 Assemble the oil pump complete with the gear Fit the 2 fixing screws through the slots...

Page 109: ...essary N B If the countershaft control gear and the oil pump are to be replaced also replace the countershaft gear Before assembling the gear on the driving shaft carefullycleanthetwocouplingsurfacesb...

Page 110: ...leting the assembly fit the oil pump gear with the control gear Complete the assembly and remove the specific tool N B While assembling the shaft on the half crank case take care not to damage the mai...

Page 111: ...taking care not to damage the half crankcase brass transmission side with the driving shaft threaded tang Insert without locking it the engine mount setscrew on the half crankcase flywheel side Fit t...

Page 112: ...control as described in Chapter 6 Flywheel and Starting system Assemble the flywheel cover with the cooling system sleeves as described in Chapter 5 Flywheel cover 05_245 Assemble the driving pulley a...

Page 113: ...TABLE OF CONTENTS FUEL INJECTION 9...

Page 114: ...INK CIRCUIT 9 34 FUEL INJECTION INDICATOR CIRCUIT 9 36 SELF DIAGNOSIS SYSTEM 9 38 FUEL SUPPLY SYSTEM 9 39 General details 9 39 Pump feed circuit 9 40 Circuit control 9 41 Hydraulics control and system...

Page 115: ...injector opening time Fuel supply pressure is kept constant on the basis of ambient pressure The feed circuit is composed of Fuel pump Fuel filter Injector Pressure regulator The pump filter and regul...

Page 116: ...diagnosis tester is also indispensible for idling carburation regulation The EMS igntion injection system carries out the func tion of revolution counter control and electrical fan control for coolin...

Page 117: ...ersed in the petrol 7 When washing the vehicle do not place pressure on the electrical components and cables 8 When ignition irregularities are revealed begin controls by checking the battery and fuel...

Page 118: ...sor incorrect 2 AnomaliesintheEMSsystemmayderivefromlooseconnectors Ensurethereforethatallconnectionsarecarried out correctly Check the connectors paying attention to the following points 1 check that...

Page 119: ...L DECODER 12 ELECTRICAL FAN 13 FUEL INJECTION INDICATOR 14 IMMOBILIZER LED 15 ELECTROMAGNETICSWITCHWITHFUSE 30A 16 ELECTROMAGNETIC SWITCH ENGINE STOP 17 DEVIATION STAND 18 OFF RUN SWITCH 19 CONTROLUNI...

Page 120: ...ETIC SWITCH 18 AIR TEMPERATURE SENSOR 6 ENGINE REVOLUTIONS SENSOR 19 85 ELECTROMAGNETIC SWITCH PUMP INJECTOR H V COIL 7 EMS DIAGNOSIS CONNECTOR 20 H V COIL NEGATIVE CONTROL 8 21 STEPPER MOTOR 9 EMS DI...

Page 121: ...etic switch 2 Electrical fan 3 Electromagnetic switch 4 H V coil 5 Fuel pump 6 Digital instrument 7 Injector 8 Liquid temp sensor 9 Air temp sensor 10 Throttle potentiometer 11 Stepper motor 12 EMS co...

Page 122: ...pressure Parameter reliability System uncodified System inefficient repair according to self diagnosis indications see page 9 20 Pump relay see page 9 41 H V coil see page 9 68 Injector see page 9 62...

Page 123: ...rol pressure low Injector capacity low Injector stability poor Presence of anomalies revealed through injection self diagnosis Pump relay see page 9 41 H V coil see page 9 68 Injector see page 9 62 Ph...

Page 124: ...e valve position sensor Stepper Coolant temperature sensor Air intake temperature sensor Air filter Choke tube and throttle valve Supplementary air duct and stepper head intake manifold Throttle body...

Page 125: ...ter Injector capacity Trimmer value adjustment CO adjustment Presence of anomalies revealed through injection self diagnosis Pump relay see page 9 41 H V coil see page 9 68 Injector see page 9 62 Phas...

Page 126: ...take temperature signal Spark lead Trimmer value adjustment CO adjustment Intake system seal infiltrations Intake manifold head Throttle body manifold Air intake hose Filter box Fuel supply pressure l...

Page 127: ...liability Fuel supply Spark plug Shielded cap H V cable H V coil Air filter Box filter seal Air intake hose seal Throttle valve position signal Coolant temperature signal Air intake temperature signal...

Page 128: ...der aerial master key red service key black diagnostic and deterrent LED 1 30A MAIN FUSE 10 DIODE 2 7 5A FUSE 11 7 5A FUSE 3 3A FUSE 12 DIGITAL INSTRUMENT 4 5A FUSE 13 IMMOBILIZ LED 5 STAND SWITCH 14...

Page 129: ...he spark plug inspection door and pull out the EMS diagnosis socket Remove the protection cap and connect the tester terminals Feed the diagnosis tester by connecting the clamps to thebatterypolesorth...

Page 130: ...changing from one key to the next is 10 seconds Up to 7 service keys black are accepted in the same memorization process The correct timing of the procedure is indispensable if incorrect repeat all fr...

Page 131: ...ndicates how many keys have been entered in the programming including the master key 2 Blinking deterrent light By setting from ON to OFF when the system is programmed the LED gives an intermittent li...

Page 132: ...s and the original master key It is also possible to request a duplicate by using the code of the vehicle CODE CARD Carry out the new programming using the master key and all the service keys See page...

Page 133: ...icates a system in which the decoder does not perceive the transponder signal Starting inhibited Fuel injection indicator fixed light In this case proceed as follows Control whether the code is repeat...

Page 134: ...ndicates a system in which the decoder perceives a transponder not foreseen in the program ming Starting inhibited Fuel injection indicator fixed light on Check whether the code persists if the master...

Page 135: ...STER key Led spento Led acceso ON 0 5 2 2 0 5 0 5 0 5 0 5 2 0 5 0 5 Diagnostics guide of anomalies not revealed through decoder self diagnosis Immobilizer LED fails to light up Control whether the fue...

Page 136: ...ystem and the fuel injection system Reset or replace the fuel injection harness Earth the connector yellow grey wire vehicle system side connector with control button Check if the LED lights up YES Ch...

Page 137: ...y positive tension on PIN 5 12 of the 12 way digital instrument Reset or replace the harness Check continuity of the digital instrument between PIN 6 12 yellow grey 4 8 light blue 0 continuity YES Che...

Page 138: ...Fuel injection 9 26 The blinking deterrent light is missing Disuse for more than 48 hours OK Check the decoder programming Replace the decoder and reprogramme Programme YES YES NO NO YES...

Page 139: ...d problem diagnosis tester n 020460Y gives the information THE CONTROL UNIT DOES NOT RESPOND To carry out controls proceed as follows Check if the immobilizer system LED signals that it is set to ON a...

Page 140: ...e fuse Check for a possible short circuit of the decoder or control unit Replace if necessary NO NO Interpose the special tool n 020481Y between the control unit and the fuel injection system See page...

Page 141: ...battery PIN 23 negative battery NO NO Reset the harness YES NO If lack of the battery positive is revealed disconnect the connection between the fuel injection system and the vehicle system The vehicl...

Page 142: ...OES NOT RESPOND 2 Control of the feed circuit deriving from the key switch To control the circuit proceed as follows Check if the immobilizer system LED signals the setting to ON Raise the side stand...

Page 143: ...9 8 Eliminate any short circuit replace the fuse If necessary check the decoder and control unit Disconnect the main decoder connector and check the following conditions Commutator set to ON switch se...

Page 144: ...in only one component check the connector concerned If the anomaly concerns both the decoder and the control unit disconnect the connector linking the vehicle system and the fuel injection system Whi...

Page 145: ...witch connector and deviation of the side stand NOTE the functioning of this circuit can be revealed also via signalling of impossibility to start the engine functioning of the ignition control Check...

Page 146: ...he same information is repeated proceed as follows Check the diagnosis tester connections YES NO Check the basic and under panel feeds of the control unit see page 9 8 Reset CIRCUIT DIAGRAM 9 2 3 1 23...

Page 147: ...system Repeat controls in the two system sections YES NO Repair any interruptions or short circuits Check the control unit Check the following conditions diagnosis socket 10 control unit continuity d...

Page 148: ...econds The diagnosis tester 020460Y is not programmed for the control of this circuit Proceed as follows Commutator ON under conditions of Side stand raised Emergency switch set to OFF The fuel inject...

Page 149: ...ector connector PIN15 control unit The fuel injection control unit therefore manages the indicator negative The indicator should turn itself off after the initial check The indicator lights up again a...

Page 150: ...age cooling Disconnection of the battery does not cancel the memorization The pages of the tester show a list of the errors that may be revealed during self diagnosis Errors revealed through self diag...

Page 151: ...with O ring and injector stop bracket The tubes are crossed and fixed to the air intake manifold so as not to provoke wear and tear on the quick connectionsconnectedtotheinjectorT ringjoint NOTE befo...

Page 152: ...vehicle parked with the engine warm In these conditions fuel altered by overheating will be mixed with that in the tank During use the pump function will be subordinated by the engine revolutions CIR...

Page 153: ...e engine revolution matches that of the pump The pump does not turn or turns continuously The electrical feed of the pump is conformant YES NO Connect diagnosis tester 020460Y to the vehicle system Se...

Page 154: ...481Y between the control unit and fuel injection system see page 9 8 Check and reset the earthing isolation of wires 19 85 of the electromag netic switch Check the two sections separately vehicle syst...

Page 155: ...jection side Check continuity of the vehicle harness and continuity of the relay coil Relay control 85 86 100 50 Check the efficiency of 10 A fuse n 2 YES NO Disconnect the vehicle system fuel injecti...

Page 156: ...n black pump continuity Disconnect the connectors to fuel pump HV coil injector Reset and repeat controls from the beginning NO YES Check the earthing isolation of the harness 87 pump electromagnetic...

Page 157: ...is tester 020460Y Select the fuel pump simulation function Activate the function with under panel feed inserted and engine stopped NO The tester asks the control unit to activate the pump for 30 secon...

Page 158: ...urn it The system is created in such a way that if traction is increased the terminal blocks further To disconnect the male terminals pump side it is necessary to push the coaxial tube rings towards t...

Page 159: ...tube to the return duct left side NOTE before mounting check that the tool ducts are clean Pressure regulator control Connect the diagnosis tester 020460Y see page 9 17 Select the function menu ACTIV...

Page 160: ...the current tube does not allow this operation fuel pressure greater than 300 KPa 3 BAR Pressure too high Check that the return duct is not clogged or compressed NO Replace the pressure regulator See...

Page 161: ...9 17 Connect the fuel pressure control kit 020480Y see page 9 46 Select the ACTIVE DIAGNOSIS function menu on the diagnosis tester Select the function PUMP DIAGNOSIS The pump activates for 30 seconds...

Page 162: ...essure is lower Carefully check the tension with the pump under pressure If tension is greater than 12 V replace the pump see page 9 54 overhaul of the pump support System seal is good Repeat the test...

Page 163: ...Check if pressure reduces much more slowly NO YES Rate variations are not evaluated Repeat the test by squeezing the tube of the special tool 020480Y in the tract be tween the derivation and the inje...

Page 164: ...ing container Using the diagnosis tester 020460Y activate the fuel pump for 10 seconds Ensure that feed tension is greater than 12 V Measure the quantity of fuel distributed Free flow capacity of the...

Page 165: ...djusting pressure cleanliness of the delivery filter To carry out a control of the current absorbed proceed as follows disconnect the pump command electromagnetic switch connector with the ignition ke...

Page 166: ...overhaul To remove the pump support from the tank proceed as follows Disconnect the electrical connection Start the engine and wait for it to stop spontaneously Clean the tank and the pump support if...

Page 167: ...control can also be carried out before disman tling from the support Measure resistance between the two wires of the indicator level Moving the arm with float check that the resistance is subjectedto...

Page 168: ...red pos 4 negative black NOTE the pump connections are not interchangeable Disconnect the feed wires Cut the hose clamp from the delivery pipe on the support Remove the fixing washer from the pump Rem...

Page 169: ...led with the pump support For replacement of the support it is necessary to trans fer the level indicator the pressure regulator and the pump from the old to the new support For these operations the i...

Page 170: ...tion and rotation Reconnect the electrical connection Reload the system with at least 4 5 timings key switch OFF ON NOTE do not activate the pump without fuel in the tank Failure to respect this regul...

Page 171: ...and await the tester result 4 injector openings are revealed The fuel injection tester responds test completed successfully No injector openings are revealed The fuel injection tester responds test f...

Page 172: ...electromagnetic switch Feed to the fuel pump is regular see pump feed circuit page 9 40 Install the special tool 020481Y between the control unit and fuel injection system see page 9 8 Arrange the mu...

Page 173: ...wire on the connector fuel injection system side 13 black green 14 5 5 injector resistance NO YES There is no continuity Disconnect the connector and repeat resistance controls directly on the injecto...

Page 174: ...ssary For these operations see Chapter 7 THERMAL UNIT AND TIMING SYSTEM Connect the diagnosis tester 020460Y see page 9 17 Use the socket in the saddle compartment Install the special tool 020480Y fro...

Page 175: ...er quantities proceed with replacement of the injector see Chapter 7 THERMAL UNIT AND TIMING SYSTEM Repeat the test If the anomaly persists replace the injector see Chapter 7 THERMAL UNIT AND TIMING S...

Page 176: ...ssimilated to a alternate tension generator which feeds the control unit The signal frequency is interrupted by the vacuum generated by two cogs lacking on the phonic wheel The sensor signal is fundam...

Page 177: ...proceed as follows YES NO Select the parameters function from the menu Check the number of Synchronizations lost 1 cog Synchronizations lost 1 cog NO The engine does not start Select the errors functi...

Page 178: ...ontrol unit Disconnect the connection between the phase revolutions sensor and the fuel injection system Measure the resistance of the sensor connecting the multimeter between the terminals marked and...

Page 179: ...Check the earthing isolation again 7 23 infinity 1M YES NO NO Measure the alternate tension between pins 7 and 12 with the engine in starting speed 7 12 0 8 4 5 V eff Revolutions speed 300 400 rpm YE...

Page 180: ...gine idling it is optimized to achieve speed stability at 1450 50 rpm Magnetization time The magnetization time of the coil is controlled via the control unit The ignition power is increased during th...

Page 181: ...olution 2 sec If an increased time available for the test is desired activate the relay pump diagnosis function 30 seconds The coil primary control circuit is efficient Check the connections with the...

Page 182: ...ween the vehicle System and fuel injection system Check continuity of the pink black wire in the two systems Pink black coil connector system connector Continuity Pink black system connector 20 Contin...

Page 183: ...e the harness concerned Repeat control using active diagnosis from the menu for HV coil command simulation Cancel the errors present in memory Check continuity of the HV coil primary See diagram Resis...

Page 184: ...fsubstantiallydifferentvaluesareobtained 1 20K proceed with replacement NOTE The lack of shielding on the cap or spark plug may lead to problems in the fuel injection system For full information conce...

Page 185: ...that truly activated on the engine Proceed as follows Remove the transmission box cover See chapter 3 AUTOMATIC TRANSMISSION Remove the plug for inspection of the TDC reference made between the flywhe...

Page 186: ...tween the revolutions values and actual spark advance and those stated by the diagnosis tester If the values do not correspond check valve gear timing phase revolutions sensor fuel injection control u...

Page 187: ...See page 9 17 Select the errors function from the menu Check if anomalies concerning the coolant temperature sensor have been registered NO The EMS system has not received temperature indications tha...

Page 188: ...ATURE 9 6K 10 C 5 975K 0 3 81K 10 C 2 5K 20 C 1 68K 30 C 0 3K 80 C Connect the sensor connection and repeat resistance control on terminals 4 and 22 4 22 Resistance equal to the value provided to the...

Page 189: ...e air temperature lines and throttle valve position Connect the special tool 020481Y to the control unit Set ignition to ON with switch on RUN and side stand raised NO TENSION TEMPERATURE X V 10 C X V...

Page 190: ...more in depth control of the sensor remove it from theengineandcheckthecontrolledtemperatureresist ance Using a suitable container immerse the metal part of the sensor in water heat gradually and rea...

Page 191: ...ERRORS function from the menu Check if any anomalies concerning the air intake temperature sensor have been registered The EMS system has not received temperature indications not included in the fiel...

Page 192: ...10 C 3 74 K 20 C 2 41 K 30 C Proceed with sensor replacement Connect the sensor connector and repeat resistance control on terminals 18 and 22 18 22 Resistance equal to the value given directly to the...

Page 193: ...ition to ON with switch on RUN and side stand raised NO NO YES Measured value 5 0 2V Repeat continuity controls of the sensor and harness Measured value 0 V Repeat control of earthing isolation of the...

Page 194: ...he diagnosis tester 020460Y See page 9 17 Select the errors function from the menu Check if anomalies concerning the pressure sensor have been registered YES NO Proceed with replacement of the fuel in...

Page 195: ...light up and activation of protection Under these conditions the engine can function even if not on optimum always safeguarding the integrity of catalyctic converter The TPS is particularly important...

Page 196: ...tle valve to maximum NO Check regulation of the throttle command flexible transmissions NO Reset or replace YES YES Gradually open the throttle valve check that mV indication Increases gradually in pr...

Page 197: ...llow 1 0 continuity Orange light blue 11 0 continuity Reset or replace the fuel injection harness NO YES Check the earthing isolation of the three circuit wires 22 23 infinity 1M 1 23 infinity 1M 11 2...

Page 198: ...cial tool 1 22 5 0 2 V Replace the throttle body complete with sensors and stepper see Chapter 7 THERMAL UNIT AND TIMING SYSTEM NO YES Measure the tension between terminals 11 and 22 Gradually open th...

Page 199: ...der no circumstances be tampered with The fuel injection system will complete the idling management via the stepper and the spark advance variation The throttle body after precalibration has the valve...

Page 200: ...on on the diagnosis tester Check that the throttle command is supported by the setscrews Ensuring that this position is maintained confirm the TPS reset procedure Select the parameters function and ch...

Page 201: ...itate the ignition procedure and correct the cold engine air feed When the engine reaches normal running temperature the stepper is partly closed To avoid anomalous wear on the adjusting piston the sp...

Page 202: ...60Y See page 9 17 Set ignition to ON with switch in position RUN and side stand raised Lift the vehicle with the central stand Select the errors function from the menu Check if the control unit has re...

Page 203: ...nse of the diagnosis tester Test completed successfully Revolutions variations perceived YES Stepper and related circuit are efficient Test failed No revolutions variation NO Test completed successful...

Page 204: ...ody See Chapter 7 THERMAL UNIT AND TIMING SYSTEM YES Connect the special tool 020481Y See page 9 8 For these controls do not connect the special tool to the control unit Check continuity of the 4 feed...

Page 205: ...ntrol unit connector Set ignition to position ON with switch on RUN and side stand raised Repeating the communications ON OFF ON check the presence of tension pulses on the command wires of the steppe...

Page 206: ...9 94 Fuel injection The stepper circuit is efficient Check the control unit connection If necessary replace la control unit NO YES...

Page 207: ...k reset of the exhaust gas analyzer 494929 Remove the plug of the exhaust manifold and connect the extension with the intake for the analyser tube Minimum carburation regulation must be carried out on...

Page 208: ...ons are reached coolant temperature more than 70 C air intake temperature 25 30 C On revealing non conformant CO values adjust fuel injection timing to minimum Select the CO PRECALIBRATION function fr...

Page 209: ...CO to adjust itself When regulation is shown to be correct press OK to memorize the value in the control unit NOTE When the CO percentage is correct and the CO2 value does not fall within the preset...

Page 210: ...maximum allowed limit check spark plug valves play timing phase exhaust valve seal If it proves necessary to replace the control unit it is important to carry out TPS reset and preventively preset the...

Page 211: ...ld occur before proceeding with electrical system controls check accurately level of the expansion tank drain from the tube leading to the engine drain on outlet from the cylinder head thermostat effi...

Page 212: ...IVE DIAGNOSIS function from the menu Activate the electrical fan diagnosis function Check acoustically the electrical fan rotation Await the results from the diagnosis tester Test completed successful...

Page 213: ...electromagnetic switch NO Connect the special tool 020481Y between the control unit and the fuel injection system see page 9 8 Do not connect to the control unit YES Check the presence of battery pos...

Page 214: ...tor and 5 of the control unit 86 Green White 5 0 continuity NO Disconnect the connector between the vehicle system and fuel injection system Check the connector and repeat continuity controls 86 Green...

Page 215: ...ence of tension between terminals 5 and 23 with the key switch set to ON 5 23 battery tension with panel set to ON Repeat the control with the control unit connected and the engine cold 5 23 battery t...

Page 216: ...d related circuit proceed as follows REVOLUTIONS COUNTER CONTROL CIRCUIT Terminals Conditions Standard Ignition set to ON Switch set to RUN Side stand raised Engine stopped 3 23 9 10 Volt While pressi...

Page 217: ...9 17 Set ignition to ON with switch in position RUN and side stand raised Select Active diagnosis on the menu Activate diagnosis of the revolutions counter Check that revolutions counter instrument ri...

Page 218: ...instrument Yellow terminal 4 12 3 0 continuity NO Disconnect the connection between the vehicle system and the fuel injection system Repeat continuity control of the two wires Terminal 4 12 yellow 0...

Page 219: ...sure the tension between pins 3 and 23 with engine stopped 3 23 9 10 V Using the diagnosis tester carry out a revolutions counter control Measure tension again 3 23 less than 1V for a few seconds YES...

Page 220: ...TABLE OF CONTENTS LUBRICATION 10...

Page 221: ...y pass Type piston Piston diameter 13 9 0 039 mm Free length of spring 62 5 mm Calibration pressure 4 bar Pre filter Type plastic mesh Oil filter Type paper with overpressure by pass and antidraining...

Page 222: ...is provided with a oil seal and related exhaust tube Leading from the housing on the flywheel side is the timing feed tube the delivery at the head is controlled by the special jet screwed into the e...

Page 223: ...nimum oil pressure indicator with a warm engine Remove the electrical connector of the minimum pressure switch Check that the indicator lamp turns off Control the actual oil pressure Check and reset t...

Page 224: ...ter 5 FLYWHEEL COVER Proceed with engine overhaul chapter 8 CRANKCASE AND DRIVING SHAFT MOTOR YES NO Open the engine crankcase and proceedwith with removal of the oil pump as described in chapter 8 CR...

Page 225: ...d rotate it with the opening on the opposite side of the shaft facing Check any anomalous plays between the shaft and pump casing Remove the internal rotor retaining ring turning it so that the openin...

Page 226: ...end play using a ground bar as a reference plane as shown in the figure Value limit allowed 0 1 mm Oil pump assembly Lubricate the internal rotors Check that the pump cover does not show signs of wear...

Page 227: ...ity A greater viscosity leads to an increase in system pressure On discovering oil consumption greater than 250 gr 1000 km in a run in engine proceed as described below Check the presence of oil in th...

Page 228: ...TABLE OF CONTENTS COOLING SYSTEM 11...

Page 229: ...11 2 Cooling 05_491 Expansion tank Radiator Drainage 2 3 way thermostat integrated into the pump cover Cylinder Head Drainage 1...

Page 230: ...9 bar THERMOSTAT Type wax with switch Initial opening 75 2 C Opening stroke at 90 C 4 mm ELECTROVENTILATION Type injection operated Initial electroventilation 106 C End electroventilation 98 C WATER P...

Page 231: ...e radiator with the ducts on two levels the delivery high up in the air and the fluid backflow low down in the fluid The system composed in this way is a 2 way type The first way is the internal engin...

Page 232: ...at the head Activation of the fan cannot be considered an indication of completed discharge The discharge can be considered complete when a temperature increase is noted in the expansion tank Warning...

Page 233: ...e of the multimeter near to the thermostat Heat the container with a heat gun Check the temperature at initial opening of the ther mostat Initial opening temperature 75 C Specific tools Multimeter 020...

Page 234: ...conformant values proceed with replacement of the fuel injection control box see Chapter 9 FUEL INJECTION If the temperature indication on the analogic instru ment is close to the red area but the ind...

Page 235: ...ulation causes permanent deformation of the gasket seals Diagnostics guide Eccessive system pressure Check condition of the expansion tank plug N B The plug has an overpressure valve calibrated to 0 9...

Page 236: ...TABLE OF CONTENCTS STARTING 12...

Page 237: ...nition kinematism in case of incorrect engine ignition manoevre with subsequent voltage build up of inverse revolution The free wheel allows a suitably silent starting Command of the starting excitati...

Page 238: ...e and if necessary replace the battery NO YES Check correct connection of the negative terminals battery negative and starting motor negative between themselves and the chassis Reset the connections N...

Page 239: ...otor rotation NO Low running speed High electrical absorption Check the engine revolution e g possible fusion of the brasses and if no anomalies are revealed replace the starting motor NO Low running...

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PIAGGIO 500 cc, Service Manual

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Summary of Contents for 500 cc

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