WORKSHOP MANUAL Evolution... · 2019. 6. 5. · WORKSHOP MANUAL X9 Evolution 500 ABS This workshop...

WORKSHOP MANUAL633196

X9 Evolution 500 ABS

WORKSHOPMANUAL

X9 Evolution 500 ABS

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

any time and without being required to update this publication beforehand, to make any changes tocomponents, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.Not all versions shown in this publication are available in all countries. The availability of single models

should be checked at the official Piaggio sales network."© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."PIAGGIO & C. S.p.A. - After-Sales

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

WORKSHOP MANUALX9 Evolution 500 ABS

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have abasic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any importantchanges made to the vehicles or to specific fixing operations will be promptly reported by updates to thismanual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools areunavailable. It is therefore advisable to read the sections of this manual relating to specific tools, alongwith the specific tool catalogue.

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

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

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

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

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

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

ELECTRICAL SYSTEM ELE SYS

BRAKING SYSTEM BRAK SYS

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Vehicle identification

FRAMESpecification Desc./QuantityFrame prefix M27000 > 6.000.001

ENGINESpecification Desc./QuantityEngine prefix M27*M ÷ 1001

Capacities

CAPACITYSpecification Desc./Quantity

Cooling system approx. 1.8 litresFuel tank (including a ~ 2.5 l reserve) ~ 14.5 l

Rear hub oil 250 ccEngine oil (empty) 1.7 lt.

Engine oil (at oil and filter change) 1.5 lt.Fork oil (quantity for single rod) 268 ± 2 cc

Brakes

BRAKESSpecification Desc./QuantityFront brake Ø 260mm disc with brake booster and ABS

X9 Evolution 500 ABS Characteristics

CHAR - 7

Specification Desc./QuantityCombined brake Two Ø 260 mm discs on the front wheel with brake booster and

ABS and one Ø 240 mm on the rear wheel with traditional hy-draulic linkage.

Emergency brake In the event of a fault with the ABS system, the vehicle pre-serves all the characteristics of traditional system:

• Front brake controlled by the RHS lever• Rear brake controlled by the LHS lever

Products

TABLE OF RECOMMENDED PRODUCTSProduct Description Specifications

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-quirements of API GL3 specifications

AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed therequirements of API SL, ACEA A3, JASO

MA specificationsAGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based

spray grease with NLGI 2; ISO-L-XBCIB2AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions

(throttle control)Oil for 4-stroke engines

SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreezefluid, CUNA NC 956-16

MONTBLANC MOLYBDENUMGREASE

Grease for driven pulley shaft adjustingring and movable driven pulley housing

Grease with Molybdenum disulphide

AGIP FORK 7.5 W Oil for front fork Hydraulic fluid SAE 7.5 WAGIP GREASE PV2 Grease for steering bearings and spindle

seatsSoap-based lithium and zinc oxidegrease containing NLGI 2; ISO-L-

XBCIB2 of the swinging armAGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

PIAGGIO CODE 602683M Muffler cleaning paste Specific product for cleaning and polish-ing stainless steel muffler

Characteristics X9 Evolution 500 ABS

CHAR - 8

INDEX OF TOPICS

TOOLING TOOL

TOOLINGStores code Description

020630Y Software for ABS diagnosis

Tooling X9 Evolution 500 ABS

TOOL - 10

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

DISTINTA SCHEMA ELETTRICO X9 500 EVOLUTION ABSSpecification Desc./Quantity

1 Sensore temperatura esterna2 Stop button on rear brake3 Light switch4 Indicators switch5 Horn button6 Emergency flashing switch7 Front fuse holder box8 Fuse no. 11 7,5 A9 Fuse no. 9 15 A10 10 fuses 10 A11 Horn12 Side stand switch13 connettori per interfono14 Gruppo cavetti pompa cavalletto15 Voltage regulator16 Side stand control unit17 Engine stop remote control switch18 Control unit remote control switch19 teleruttore pompa cavalletto elettroidraulico20 Fusibile cavalletto elettroidraulico 70 A21 Scatola portafusibile con basetta per fusibile cavalletto

elettroidraulico22 Lampada indicatore di direzione posteriore SX23 Lampada luce posizione posteriore SX24 Fusibile n°1 7,5 A25 Fuse no. 2 10 A26 Fuse no. 4 5 A27 Fusibile n°3 3 A28 Fuse holder box29 Tilting sensor30 Lampada luce posizione posteriore DX31 Saddle opening actuator

Electrical system X9 Evolution 500 ABS

ELE SYS - 12

Specification Desc./Quantity32 Brake light33 License plate light bulb 12V - 5W34 Lampada indicatore di direzione posteriore DX35 Remote starter switch36 Fusibile n°7 7,5 A37 Battery 12V - 14 Ah38 Box helmet illumination push button39 Roof lamp for box helmet illumination with lamp40 Socket for users 12V - 180W max41 Fusibile n°6 7,5 A42 Starter motor43 Fuse no. 8 7,5 A44 Fuse no. 12 7,5 A45 HV coil46 ABS diagnosis socket47 EMS diagnostic socket48 Rear fuse box49 Fuse no. 5 15 A50 Magneto flywheel51 Engine oil pressure sensor52 Senalatopre relè incollato53 Cooling fluid temperature sensor for inj. circuit54 Cavetto bipolare schermato55 Engine rpm sensor56 Air temperature sensor57 Stepper motor58 Throttle potentiometer59 Fuel injector60 Lampada luce di posizione anteriore 12V - 5W61 Pulsante di consenso cavalletto elettroidraulico62 Pulsante di fine corsa cavalletto elettroidraulico63 Bulb for upper beams 12V - 55W64 Motorino pompa cavalletto elettroidraulico65 Electronic injection control unit66 nodo di massa anteriore67 Immobilizer decoder68 Stop light switch (front brake)69 Wheel RPM sensor70 Engine stop switch71 Actuators control device72 Start-up remote control relay73 "Reset" button74 Pulsante cavalletto elettroidraulico75 Anti-theft alarm fitting76 Key switch77 Immobilizer aerial78 Indicatore di livello e pompa carburante79 Saddle opening button80 nodo di massa anteriore81 Electric fan82 Main remote control switch83 Diode 1 A84 ABS relay switch85 Electric fan remote control switch86 Fitting for accessories87 Diode 6A88 Diode unit89 ABS cpu Built-in to modulator90 Lampada indicatore di direzione anteriore DX 12V - 10W91 Bulb for lowerbeams 12V - 55W92 Digital instrument unit93 Display radio / interfono94 Fanale posteriore destro95 Intercom control unit96 Analogue instrument unit97 Lampada indicatore di direzione anteriore SX 12V - 10W98 Start up button

X9 Evolution 500 ABS Electrical system

ELE SYS - 13

Specification Desc./Quantity99 Fanale posteriore sinistro100 Voltage maintenance device

Colori cavi eletrici:

B=Bianco - Bl=Blu - G=Giallo - M=Marrone - N=Nero - BV=Bianco-Verde - GN=Giallo-Nero - Gr=Grigio

- Rs=Rosa - R=Rosso - Vi=Viola - V=Verde - VN=Verde-Nero - BN=Bianco-Nero - BBl=Bianco-Blu -

GV=Giallo-Verde - Ar=Arancione - Az=Azzurro - GrBl=Grigio-Blu - GrN=Grigio-Nero - AzG=Azzurro-

giallo - BG=Bianco-giallo - ArN=Arancione-Nero - ArBl=Arancione-blu - VGr=Verde-Grigio -

RsN=Rosa-nero - BlGr=Blu-grigio - BlN=Blu-Nero - GRs=Grigio-rosa - GrR=Grigio-Rosso -

GN=Giallo-Nero - GrN=Grigio-Nero - BV=Bianco-Verde - NVl=Nero-Viola - RBl=Rosso-Blu -

Arb=Arancione-Bianco - GGr=Giallo-Grigio - BVl=Bianco-Viola - RN=Rosso-Nero - BRs=Bianco-Rosa

- NMr=Nero-Marrone - BBl=Bianco-Blu - RB=Rosso-Bianco - BMr-Bianco-Marrone - GB=Giallo-Blu -

RG=Rosso-Giallo - VR=Verde-rosso - AzV=Azzurro-Verde - GV=Giallo-Verde - ArAz=Azzurro-Verde

- AzR=Azzurro-Rosso - BGr=Bianco-Grigio - AzN= Azzurro-Nero - VN=Verde-Nero - MrG=Marrone-

GialloCAUTION

SHOULD ANY INTERVENTIONS TO THE ELECTRIC SYSTEM BE REQUIRED, MAKE SURE THATTHE LEADS TO THE ELECTRONIC IGNITION DEVICE ARE PROPERLY CONNECTED ACCORD-ING TO POLARITY AND TO THE LEAD COLOURS.


ELE SYS - 14

Components arrangement

COMPONENT LAYOUTSpecification Desc./Quantity

Front brake pumpRear brake pump - built-inFront brake lamp switch

Rear brake lamp switch built-inModulator

Delay valve Causes a delay in front braking action when the left control lev-er is activated

Front brake caliperPhonic wheelSpeed sensor

Rear brake caliperABS relay switch

Conceptual diagrams


ELE SYS - 15

ABS

ABSSpecification Desc./Quantity

1 ABS cpu Built-in to modulator2 Battery 12V - 14 Ah3 Fuse no. 13 30 A4 Stoplight switches5 Phonic wheel6 ABS diagnosis socket7 10 fuses 10 A8 ABS relay switch9 Stop light N° 5 bulbs 12V-2.3W10 Main remote control switch11 Starter motor contactor12 Start up button13 Digital instrument unit14 Side stand control unit15 Voltage maintenance device


ELE SYS - 16

Checks and inspections

Dashboard

Vehicle X9 has an instrument panel divided into 2 sections: the analogue section fitted in the fairing and

the digital section attached to the handlebars.

The analogue section includes:

- Double scale speedometer (mph-Km/h) control-

led by the phonic wheel vai the ABS cpu and digital

section;

- rpm counter controlled by the signal from the in-

jection cpu;

- Fuel level indicator controlled by a resistive sen-

sor (inside the tank);

- Coolant temperature indicator controlled by a re-

sistive sensor (on the head).

These instruments are electrical and managed

with a stepper motor.

The digital section include the lamps:

- Fuel warning lamp: yellow;

- Parking lights and dipped beams: green;

- High or flashing beams: blue;

- Left turn indicator: green;

- Right turn indicator: green;

- Emergency lights (four indicators): red;

- Engine not on: red;

- ABS fault: yellow;

- Oil pressure: red;

- Injection warning: yellow;

- ALARM (electrohydraulic stand): red.

The petrol reserve warning, turn indicators and

emergency lights are activated by the digital in-

strument panel. For example, the petrol reserve

warning lamp only goes on when the reserve indi-

cation from the tank lasts for at least 13.5 seconds.

This prevents the reserve lamp from going on and

off.


ELE SYS - 17

- Intermittent operation is incorporated in the in-

strument electronics: this makes operation of the

emergency lights possible with the switch in the

"OFF" position and control switch disabled. The

control switch is only enabled with the panel on.

In order to ensure safety when driving, the turn in-

dicator control" function is connected to the odom-

eter. If the driver forgets to turn off the turn

indicator, it is automatically disabled after 1 kilo-

metre of driving.

- The "engine not on" lamp is enabled by the lateral

stand switch and emergency switch located on the

right side of the handlebars.

- The LCD display has a 5 figure indication of the

total travel of the vehicle. This can be expressed

in kilometres or miles: naturally, this figure can

never be reset. To select the indication, with the

ley in the "OFF" position, press the "Trip" and "M"

buttons at the same time, and then turn the ley

switch to the "ON" position; by keeping these 2

buttons pressed for more than 3 seconds, first

"SET" will appear on the display, and then the

change from miles to kilometers and vice versa.

The digital section of the instrument panel is completed with a liquid crystal display and four control

buttons.

The display has 3 icons with the words:

- Oil;

- Service;

- Belt.

If the "Oil" icon flashes, the engine oil needs to be changed.

If the "Service" icon flashes, scheduled servicing indicated on the coupons needs to be effected.

If the "Belt" icon flashes, the drive belt needs to be changed.

Following servicing by an authorised centre, the warning of the icon or icons needs to be cancelled

using the "Reset" button located in the front part of the vehicle under the upper light cover. The "reset"

button is used to reset the mileage for "OIL" and "BELT" and the annual count for "Service". This count

remains enabled even if the battery is disconnected for a short period of time.

To reset one of the icons, go to the icon before the one to reset, press the "Reset" button for less than

1 second, then press the "Reset" button for at least 3 seconds so that the following is displayed:


ELE SYS - 18

- Selection of the desired icon with the lamp going on;

- Flashing of this icon and confirmation of resetting;

For example, to reset the "Service" icon go to "Oil" and press the "Reset" button for at least 3 seconds.

To reset "Oil", repeat the above procedure positioned on "Belt".

It is necessary to repeat this procedure since the icon selection and its resetting are simultaneous

operations (for this operation it is not possible to display the desired function and reset by pressing two

different buttons, because, if this procedure is followed, the following icon would be reset).

ABS LAMP

Each time the key is turned to "ON" the ABS lamp flashes for a few seconds and checks the servo

brakes and part of the ABS check.

The lamp stays on until the ABS and phonic wheel test is finished.

This test occurs when the vehicle exceeds the speed of 5 Km/h with consequent switching off of the

lamp.THE ABS SYSTEM CHECK TAKES PLACE WHENEVER THE KEY IS TURNED TO "ON" AND MAYBE CARRIED OUT AGAIN, ESPECIALLY AT LOW TEMPERATURES, ONCE THE ENGINE ISSTARTED; THIS IS DUE TO THE DROP IN THE BATTERY VOLTAGE CAUSED BY THE ENGINESTART-UP. REPETITION OF THE CHECK, DUE TO LOWERING OF THE BATTERY VOLTAGEDURING THE STARTING PHASE, CAUSES THE "ECU POWER" CODE FTE 5 ERROR, BUT DOESNOT CAUSE UPDATING OF THE "ABS ERROR" FIELD UNDER THE "PARAMETERS" MENU.

Phonic wheel

Checking the phonic wheel circuit

• Disconnect the phonic wheel connector.

• -Disconnect the ABS cpu connector.

• Check the continuity of the green wire between

PIN 12 of the cpu connector and the connector for

the phonic wheelN.B.To make the connection on the phonic wheel connectorside use a pin placing it gently on the connector terminal.Completely inserting the pin causes permanent deforma-tion of the terminal.It is advisable to use tester wires with clamps

• Check the continuity of the grey wire between

PIN 21 of the ABS cpu connector and the connec-

tor for the phonic wheel.

• Check the isolation towards the earth of the lines.


ELE SYS - 19

Electric characteristicPIN 12 ÷ PIN 24= OHM Infinitive


• Check the isolation from positive of the lines with the key switch in "ON" position

Electric characteristicPIN 12 ÷ PIN 24= 0 Volt

Electric characteristicPIN 21 ÷ PIN 24= 0 Volt

• Check the isolation between the two lines


ELE SYS - 20


If faults are found replace the wiring.

• Reconnect the ABS cpu connector.

• Keep the phonic wheel connector disconnected.

• Turn the key switch to "ON"

• Check that between PIN 12 (Green wire) and the

earth that battery voltage is present (a slight volt-

age drop of around 0.5V is allowed)

• Position the key switch to "ON"

• Connect the multimeter to the battery positive,

and check that the earth is present at PIN 21 (grey

wire).

• Keep the key switch in the "ON" position.

• Short PINs 12 and 21 with the ends of the multi-

meter in ammeter function.

• Make sure there is a current of around 20 mA.


ELE SYS - 21

• Keep the key switch in the "ON" position.

• Using the phonic wheel connector short PINs 12

and 21.

• Measure the positive voltage of the short using

the multimeter.

Standard value = battery value (a slight drop in

voltage of around 0.5 V is allowed)

• Check the voltage of the speed sensor indicated in the parameters menu

Speed sensor voltage

Electric characteristicSP. SEN VOL.around 2,8 V

If faults are found replace the wiring.

If voltage faults are found check the ABS cpu power circuit.

If no power faults are found check operation with a new modulator.

If the phonic wheel signal continues to be faulty and the voltmeter and ammeter checks do not reveal

any faults, replace the phonic wheel and repeat the operating test

Connectors


ELE SYS - 22

Dashboard

8 WAY CONNECTORSpecification Desc./Quantity

1 Earth for analogue circuit board2 Battery positive for analogue circuit board3 Analogue circuit board serial clock output4 Immobilizer LED output5 Analogue circuit board serial data output6 Lights on output7 Not connected8 Not connected


1 To the electrohydraulic stand cpu (PIN 4)2 Alarm lamp input3 ABS lamp input4 Right turn indicator output5 right turn indicator input6 left turn indicator input7 ABS lamp input8 Air temperature sensor input9 Engine cannot be started lamp input10 Oil pressure lamp input11 Not connected12 Left turn indicator output13 Turn indicator stop button input14 Service reset button input15 Water temperature sensor input16 Fuel level sensor input


1 Battery positive


ELE SYS - 23

Specification Desc./Quantity2 Not connected3 To the electrohydraulic stand cpu (PIN 4)4 Engine rpm sensor input5 Battery positive6 Immobilizer LED7 Live positive lead8 Wheel rpm sensor input9 to earth10 Air temperature sensor connection to chassis structure

negative11 Emergency light button input (Hazard)12 Lights on input

ABS Modulator

ABS CPU CONNECTORSpecification Desc./Quantity

1 Not connected2 Not connected3 Not connected4 Not connected5 Not connected6 Not connected7 Not connected8 Not connected9 Not connected10 Not connected11 Rear stop switch12 at + of wheel rpm sensor13 diagnosis output14 ABS relay switch excitation15 Stop light switch (front brake)16 + of main relay switch17 Brake light18 at PIN 3/16 of digital instrument unit19 at earth20 at earth21 at - of wheel rpm sensor22 Not connected23 at PIN 12 stand control cpu and PIN 8/12 digital instru-

ment unit


ELE SYS - 24

Specification Desc./Quantity24 to earth25 + of ABS relay switch

SYSTEM SIDE CONNECTOR

Voltage maintenance device


ELE SYS - 25

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

CAUTION

If the front wheel is to be disassembled, for example to change the tyre, be careful not to damage thephonic wheel.Visually inspect the phonic wheel for damage and carry out a road test, having a complete check bemade of the ABS system before delivering the vehicle to the customer.Damage of the phonic wheel causes the modulator pump to operate continuously even when the brakelever is not activated.

ABS

Operating diagram

OPERATING DIAGRAMSpecification Desc./Quantity

Front brake pumpFront brake caliper

Control valve Located inside modulatorFront brake lamp switch

Pilot valve Located inside modulatorSpeed sensor

Oil pump Located inside modulator and activated by motor "M" controlledby "ECU"

Low pressure oil hoseECU Located inside modulator

Rear brake lamp switch built-inABS alarm lamp

X9 Evolution 500 ABS Braking system

BRAK SYS - 27

Specification Desc./QuantityBrake light

Rear brake pump - built-inDelay valve Causes a delay in front braking action when the left control lev-

er is activatedRear brake caliper

ModulatorOil tank Located inside modulator

Palm-set menu description

This function is very useful for checking the conditions of the main system components and related

circuits

ENABLED DIAGNOSISSpecification Desc./Quantity

PUMP MOTOR Enables the modulator pump for around 20 seconds.BRAKE LIGHT Changes the status of the brake light for around 15 seconds.

E.g. in normal operating conditions the brake light goes on.In the event of brake light always on (error C2) the cpu turns

off the light.INSTRUMENT PANEL LAMP Changes the status of the ABS lamp. The lamp returns to the

initial status, when a key is pressed at the end of the test. Eg.In normal operating conditions the lamp goes on, if the lamp

stays on (error C6) the cpu turns it off.SPEEDOMETER TEST Controls the analogue speedometer needle up to a speed of 5

Km/h for around 5 seconds.

CANCELLING ERRORS This function is used to cancel faults and any codes recorded by the auto-

diagnosis of the ABS cpu.

This function does not reset the "ABS ERROR" and "BRAKE ERROR' in the "PARAMETERS" menu.

MEMORISED PARAMETERS This function is used to display previously memorised parameters.

As previously explained in the description of the parameters function, memorisation is effected by

pressing the "TAB" key at the desired time.

The diagnosis tester can only contain one memorisation.

This is automatically deleted when the tester power is turned off.

PIN INITIALISATION Enable PIN INITIALISATION to memorise the vehicle code (if compatible) on a

cpu based on the status of pins 19, 20 and 22.

All the parameters can be displayed by displaying the 3 pages.

If necessary, all the parameters can be memorised in the tester by pressing the "TAB" key when you

want.

The parameters stay memorised as long as the diagnosis tester power is on.

PARAMETERSSpecification Desc./Quantity

VEHICLE SPEED Indicates the vehicle speed in Km/h

Braking system X9 Evolution 500 ABS

BRAK SYS - 28

Specification Desc./QuantityRIGHT BRAKE SIGNAL Indicates the enable signal for activating the front brake leverLEFT BRAKE SIGNAL Indicates the enable signal for activating the combined brake

leverPUMP MOTOR

ABS VALVEFRONT SPEED SIGNAL Indicates the front wheel speed expressed in Hz

BATT. VOLT. Indicates the battery voltage expressed in voltsSPEED SENS. VOLT. Indicates the speed sensor voltage expressed in volts

It must be between 0.4-0.8V or 1.2-2V based on whether thespeed sensor is positioned on "no-load" or "full-load" on the

phonic wheel.POWER BRAKE TEST Indicates if the check has been carried out on the power brake

system.ABS TEST Indicates if the check has been carried out on the ABS system.

The check includes the speed sensor, which can only be testedif the speed is over 5 Km/h, with the vehicle stopped it is "Dis-

abled".CURRENT PIN* Indicates the vehicle code the cpu reads based on the status

of the 3 pins 19, 20 and 22. Code 6 identifies the X9 vehicleMEMORISED PIN* Indicates the first combination code between the cpu and ve-

hicle based on the pins 19, 20 and 22. Code 6 identifies the X9vehicle.

VEHICLE ON Indicates the amount of time the vehicle has been on.BRAKE ENABLED Indicates the amount of time the power brake has been ena-

bled.ABS ENABLED Indicates the activation time of the ABS expressed in seconds.BRAKE ERROR Indicates the minute of "VEHICLE ON" when a "BRAKE ER-

ROR" occurred."BRAKE ERROR" is generated in the event of a type A error

(excluding 128), B or 15.ABS ERROR Indicates the minute of "VEHICLE ON" when an "ABS ERROR"

occurred."ABS ERROR" is generated in the event of a type 128, 129 or

103 error.

ERRORS

TYPE OF ER-

ROR

REFER-

ENCE

FLOW

CHART

FTE

ERROR

CODE

ERROR DESCRIPTION POW-

ER

BRAKE

ABS LAMP ON

BRAKE ER-

ROR

A 1 HAZARD INTERRUPT NO NO YES

3 RAM ERROR

4 ROM ERROR

7 CYCLE TOO LONG

8 STACK ERROR

21 INTERNAL CONTROLLER

22 EEPROM ERROR

27 CALCULATION ERROR

28 EEPROM PARAMETERS

30 AD CONVERSION

B 2 MAIN RELAY

5 ECU POWER

6 ABS VALVE


BRAK SYS - 29

11 PUMP MOTOR

15 15 VEHICLE CODE

ERROR ABS A 128 VALVE CURRENT YES

129 129 WHEEL SLIPPAGE

130 130 SPEED SENSOR

--- C --- ERRORS NOT DETECTED BY AUTODIAGNO-

SIS

YES/

NO

YES/NO YES/NO

If the "ECU POWER" error is present in the error menu in memorised (M) status, the "BRAKE ERROR"

and "VEHICLE ON" parameters need to be checked.

If an error other than voltage decrease occurs when the engine is started, the lamp on the instrument

panel goes on and "BRAKE ERROR" will appear where the lamp goes on.

If this occurs follow the type "B" troubleshooting procedure.

If the "BRAKE ERROR" is not present in the "PARAMETERS" menu or if it is unreliable (e.g. occurred

a long time ago, probably due to a previous problem), the "POWER ERROR" is due to the natural

decrease in battery voltage when the engine is started.

This voltage decrease may cause the ABS system check to be repeated, for this reason the following

note appears on the vehicle use and maintenance handbook:

THE ABS SYSTEM CHECK TAKES PLACE WHENEVER THE KEY IS TURNED TO "ON" AND MAYBE CARRIED OUT AGAIN, ESPECIALLY AT LOW TEMPERATURES, ONCE THE ENGINE ISSTARTED; THIS IS DUE TO THE DROP IN THE BATTERY VOLTAGE CAUSED BY THE ENGINESTART-UP.

Indicates the information related to the vehicle and cpu software.

INFO ECUSpecification Desc./Quantity

HARDWARE VERSIONABS SOFTWARE VERSION Indicates the ABS software version

SW DATE Indicates the software version date in YYYYMMDD format.EEPROM VERSION Indicates the Eeprom version

MODULATOR Indicates the modulator versionFTE S.N. Indicates the progressive number of the ABS unit supplier

CHASSIS NO. Indicates the vehicle chassis number.

Guide to diagnosis

*A*FLOW CHART "A"

ble width="100%" border=1>

1. Procedures for cpu error code.

2. Internal error: replace the modulator.


BRAK SYS - 30

3. Proceed following the generic procedures.

BFLOW CHART "B"


1. Procedures for power error code.

2. Inspect battery. Faulty battery?

YES

point 3

NO

point 4

3. Change the battery.

YES

point 18

4. . Battery OK. Inspect battery terminals. Terminals OK?

YES

point 5

NO

point 6

5. Replace or repair battery terminals.

YES

point 18

6. Battery terminals OK. Inspect wiring. Faulty wiring?

YES

point 7

NO

point 8

7. Replace wiring.

YES

point 18

8. Wiring OK. Inspect main ECU connector.

9. Disconnect main ECU connector..

10. Access instrument pane.

11. Measure voltage at pin 25. Is the voltage equal to 0 V?

YES

point 12


BRAK SYS - 31

NO

point 16

12. Voltage =0 V. Earth pin 24.

13. Measure voltage on pin 25. Is the voltage equal to the bat-

tery voltage?

YES

point 14

NO

point 16

14. Pin 25 voltage equal to battery voltage. Turn off the instru-

ment panel.

15. Internal error: replace modulator.

YES

point 19

16. Turn off the instrument panel.

17. Replace the relay.

18. External error: do not replace the modulator.


CFLOW CHART "C7"

1. Procedure for error code C7

2. Inspect the level of the brake fluid in both reservoirs:

Too low fluid level point 3 Acceptable fluid level point

3. Fill the reservoir.

4. Check the brake connection tube from the right brake res-

ervoir to the modulator reservoir for leaks:

Leak point 5 No leak point 6

5. Replace the brake tube

6. Check the level of filling of the front and rear brake circuits:

Presence of air in the brake circuit point 7 Acceptable filling

level point 8

7. Manually bleed the brake circuit according to the instruction

related to the bleeding operation.

YES point 6


BRAK SYS - 32

8. Put the vehicle on a stand so that both of the wheels can be

turned freely by hand.

9. Turn on the instrument panel.

10. Activate each of the two brake levers once with the front

wheel moved manually at more than 5 km/h.

11. Make sure the pump starts (detectable by a sound):

YES point 12 NO error P0

12. Initialise connection with ECU with safety access.

13. Interrupt the main cycle with the diagnostic device.

14. Disable the electrohydraulic pump with the diagnostic de-

vice.

15. Activate the right brake lever with a constant force equal to

around 100 N - Front brake passive -

16. See if the lever moves as time passes. YES/NO.

17. See if the braking torque increases on the front wheel. YES/

NO.

18. Enable the electrohydraulic pump with the diagnostic de-

vice.

19. Activate the right brake lever with a constant force equal to

around 100 N - Front brake active -

20. See if the lever moves as time passes. YES/NO.

21. See if the braking torque increases on the front wheel. YES/

NO.

22. Establish the fault code based on the error code table.

23.

FLOW CHART "C2"




3. Turn off the brake lights with diagnostic device.

4. Turn on/off brake light. Is the light on?

YES

point 5

NO

point 14

5. Interrupt connection with the ECU.


BRAK SYS - 33


7. Disconnect the main connector from the ECU.

8. Turn on the instrument panel


YES

point 10

NO

point 18


11. Replace the wiring.



14. Inspect the condition of the brake switches. Brake levers

not enabled.

15. Right brake switch status:

CLOSE

point 16

OPEN

punto 20

16. Left brake switch status:

CLOSE

point 17

OPEN

punto 20



19. Internal error: replace modulator

YES

point 13.


21. Disconnect the faulty brake switch.

22. Measure the voltage on the wiring side pins of the faulty

switch. Read one of the two pins:

EQUAL TO KL 15

point 23

DIFFERENT THEN KL 15

point 10


BRAK SYS - 34

23. 23. Bypass the wire side brake switch pins.

24. 24. Turn on/off brake light. Is the light on?

YES

point 25

NO

point 32

25. Reconnect the brake switch.




29. Measure the voltage on the wiring side pin of the faulty

switch [right: pin 15/left: pin11]:

EQUAL TO KL 15

point 18

DIFFERENT THEN KL 15

point 30



YES

point 12


33. Replace the faulty brake switch.

YES

point 12

FLOW CHART "C3"


1. Procedure for speedometer error C3.

2. Disconnect the wiring from the speedometer.

3. Check speedometer operation:

Faulty speedometer

point 21

Operating speedometer

point 4



6. Interrupt the main cycle with the diagnostic device


BRAK SYS - 35

7. Set the speedometer output signal on LOW level with the

diagnostic device.

8. Output voltage on wire side speedometer connector.

Greater than 0.5V

point 23

Less than or equal to 0.5V

point 9

9. Set the speedometer output signal on LOW level with the

diagnostic device.

10. Output voltage on wire side speedometer connector.

Less than 4V

point 25

Greater than or equal to 4V

point 11



13. Inspect the sensor assembly and sensor bracket.

Correct assembly

point 14

Incorrect assembly

point 30

14. Check the sensor body and wire for mechanical damage.

No damage

point 15

Sensor body or cable damaged

point 34

15. Check the sensor bracket for mechanical damage.

No damage

point 16

Damaged bracket

point 31

16. Inspect the phonic wheel assembly.

Correct assembly

punto 17

Incorrect assembly

punto 32

17. Check the phonic wheel for mechanical damage.


BRAK SYS - 36

No damage

point 18

Damaged phonic wheel

point 33

18. Inspect the electrical connection between sensor and wir-

ing:

Wire side connection not valid

point 26

Modulator side connection not valid

point 19

Valid connection

point 34



21. Replace the speedometer.


YES

point 20

23. Interrupt the main cycle with the diagnostic device


25. Interrupt the connection with the ECU. Inspect the electrical

connection from the speedometer to the wiring.

Defective wire side connection

point 26

Defective speedometer side connection

point 21

Valid connection

point 27


YES

point 22

27. Check for mechanical damage on the wiring from the

speedometer to the modulator.

Damaged wiring

point 28

Valid wiring

point 29


BRAK SYS - 37


YES

point 22

29. Check the electrical connection from the wiring to the mod-

ulator.

Damaged wiring

point 28

Valid wiring

point 19

30. Correctly reassemble the sensor and sensor bracket.

YES

point 22

31. Replace the sensor bracket:

YES

point 22

32. Correctly reassemble the phonic wheel.

YES

point 22

33. Replace the phonic wheel.

YES

point 22

34. Replace the wheel speed sensor.

35. Faulty sensor: replace the wheel speed sensor.

YES

point 20

3

FLOW CHART "C5"


1. Procedure for error C5.



4. Turn on/off lamp. Is the lamp on?

YES

point 8

NO

point 5


BRAK SYS - 38

5. Lamp off. Turn off the instrument panel.

6. Check the lamp bulb. Is it working?

YES

point 7

NO

point 12

7. Lamp bulb working. Check the electrical connection from the

wiring to the modulator (pin 18). Is the wiring correct?

YES

point 8

NO

point 9


YES

point 11




12. Replace lamp bulb.

YES

point 10

FLOW CHART "C6"


1. Procedures for error C6 â lamp constantly on

2. Turn on the instrument panel

3. Brake levers not enabled.


YES

point 18

NO

point 5


6. Turn on the lamp with the diagnostic device.


YES

point 8


BRAK SYS - 39

NO

point 19




11. Earth pin 18 (lamp).



YES

point 14

NO

point 28





18. Turn off the instrument panel. Proceed with the procedure

for error C2



21. Inspect the sensor assembly and sensor bracket.

Correct assembly

point 22

Incorrect assembly

point 29

22. Check the sensor body and wire for mechanical damage.

No damage

point 23

Sensor body or cable damaged

point 30

23. Check the sensor bracket for mechanical damage.

No damage

point 24

Damaged bracket

point 32

24. Inspect the phonic wheel assembly.

Correct assembly


BRAK SYS - 40

point 25

Incorrect assembly

point 33

25. Check the phonic wheel for mechanical damage.

No damage

point 26

Damaged phonic wheel

point 34

26. Inspect the electrical connection from the sensor to the wir-

ing.

Sensor side connection not valid

point 35


point 36

Valid connection

point 37


YES

point 17


YES

point 27

29. Correctly reassemble the sensor and sensor bracket.

YES

point 16


31. Sensor error: replace the wheel speed sensor.

YES

point 17

32. Replace the sensor bracket.

YES

point 16

33. Correctly reassemble the phonic wheel.

YES

point 16

34. Replace the phonic wheel.

YES


BRAK SYS - 41

point 16


YES

point 31


YES

point 16

37. Inspect the electrical connection from the wiring to the mod-

ulator.

Valid wiring

point 27

Not valid wiring

point 36

FLOW CHART "C"


1. Procedures for diagnosis tester error code C

2. Brake light error.

Brake light always off: error C1

Brake light always on: error C2

3. Speedometer error: error C3.

4. No starter operation. Starter relay does not trip: error C4

5. Lamp error:

Lamp constantly off after instrument panel turned on: error C5

Lamp constantly on after instrument panel turned on and speed

> 5 km/h: error C6

5. Brake operation error:

Brake performance excessively poor: error C7

Excessive brake response or uncontrollable: error C8

FLOW CHART "C1"


error C1 â brake light error - brake light always off



4. Interrupt the main cycle with the diagnostic device.


BRAK SYS - 42

5. Turn on the brake light with diagnostic device.


YES

point 7

NO

point 28

7. Inspect the condition of the brake switches:

9.Brake lever not activated. Activate right brake lever. Check

the state of the right brake switch. Is it open?

YES

point 10

NO

point 14

10. Activate left brake lever. Check the state of the left brake

switch. Is it open?

YES

point 11

NO

point 14

11. Interrupt the connection with ECU.

YES

point 24



14. Disconnect the faulty brake switch.

15. Check the state of the faulty brake switch. Is it open?

YES

point 25

NO

point 16

16. Interrupt connection with the ECU




20. Measure the voltage on the wire side pin of the faulty switch

[right: pin 15/left: pin11]. Is the reading of the faulty pin equal

to KL15?


BRAK SYS - 43

YES

point 21

NO

point 24




YES

point 13


YES

point 12



27. Replace the faulty brake switch.

YES

point 23



30. Check the lamp and lamp holder. Is the lamp or lamp holder

faulty?

YES

point 31

NO

point 36


32. Connect pin 17 (brake light) and pin 16.

33. Turn on the instrument panel 18) Turn on/off brake light. Is

the lamp on?

YES

point 27

NO

point 34



YES

point 23


BRAK SYS - 44

36. Replace the lamp or lamp holder.

YES

point 23

FLOW CHART "C4"


1. Error C4.

2. Brake light operation:

YES

point 3

NO

point 5

3. Check the starter relay and wiring.



6. Error C1. Carry out the tests in the section dedicated to this

error.

15


1. Procedure per codice errore codifica veicolo.


3. Read the displayed codes:

- Current pin (memorised in RAM) - Memorised pin (memorised

in EEPROM)


Is the current pin the same as the memorised pin?

YES

point 5

NO

point 15

5. Current pin same as memorised pin. Turn off the instrument

panel.

6. Is the type of wiring specifically for the vehicle?

YES

point 7


BRAK SYS - 45

NO

point 17

7. Specific wiring. Disconnect the ECU.

8. Visually inspect the pins on the main ECU connector, wiring

side; particularly pins with code (19/20/22). Are the pins dam-

aged?

YES

point 14

NO

point 9

9. Pins not damaged. Turn on the instrument panel.

10. Make sure the pins with code (19/20/22) are correctly con-

nected to the wiring, by testing electrically. Are the connections

correct?

YES

point 11

NO

point 14







17. Specified vehicle code is partially from permitted codes.

YES

point 18 NO point 28

18. Standby code = 255 (new code upgrade).

YES

point 19 NO point

19. Initialise connection with ECU with safety access

20. Set standby code 255 (new code upgrade)



23. Turn off/on the instrument panel.


25. Read the error code: - xxx


BRAK SYS - 46

26. FTE error code.

YES

point 11

NO

point 27


YES point 16


29. Reset ECU fault


31. Note on diagnosis form: modulator not specific for vehicle

type!

YES

point 11

129


1. Procedures for speed signal error code

2. Make sure the front wheel is free to spin with the right brake

lever not activated (passive braking). Is the wheel free to spin?

YES

point 3

NO

point 26

3. Front wheel free. Activate the right brake lever once.

4. Make sure the front wheel is free to spin with the right brake

lever not activated (passive braking). Is the wheel free to spin?

YES

point 5

NO

point 26

5. Front wheel free. Turn on the instrument panel.

6. Enable the electrohydraulic pump with the diagnostic tester.

7. Make sure the front wheel is free to spin with both brake

levers activated (active braking). Is the wheel free to spin?

YES

point 8


BRAK SYS - 47

NO

point 27

8. Front wheel free. Disable the electrohydraulic pump with the

diagnostic tester.


10. Check the assembly of the sensor and sensor bracket. Is

the assembly correct?

YES

point 11

NO

point 19

11. Assembly OK. Make sure the sensor body and wire do not

show signs of mechanical damage. Is there any damage?

YES

point 12

NO

point 21

12. No sensor body and wire damage. Make sure the sensor

bracket is not mechanically damaged. Is there any damage?

YES

point 13

NO

point 20

13. No sensor bracket damage. Check the phonic wheel as-

sembly. Is the assembly correct?

YES

point 14

NO

point 22

14. Make sure the phonic wheel does not show signs of me-

chanical damage. Is there any damage?

YES

point 15

NO

point 23

15. No phonic wheel damage. Check the electrical connection

from the sensor to the wiring. Is the wiring correct?


BRAK SYS - 48

YES

point 16

NO

(Wire side connection not valid) point 31

NO

(Sensor side connection not valid) point 32

16. Wiring correct. Check the electrical connection from the

wiring to the modulator. Is the wiring correct?

YES

point 17

NO

(Wire side connection not valid) point 30

NO

(Modulator side connection not valid) point 32



19. Assembly OK. Correctly assemble the sensor and sensor

bracket.

YES

point 24

20. Sensor bracket damaged. Replace sensor bracket.

YES

point 24

21. Speed sensor damaged. Replace the wheel speed sensor.

YES

point 24

22. Phonic wheel assembly not correct. Correctly assemble the

phonic wheel.

YES

point 24

23. Phonic wheel damaged. Replace wheel.

YES

point 24

24. Measure the distance between the sensor and phonic

wheel, the value must be between 0.8 - 1 mm. Is the distance

within this tolerance?

YES


BRAK SYS - 49

point 17

NO

point 25

25. Adjust the distance using a calibrated washer.

YES

point 17

26. Replace the brake calliper or brake hose from the modula-

tor to the calliper.

YES

point 17

27. Disable the electrohydraulic pump with the diagnostic de-

vice

28. Turn off the instrument panel


YES

point 18


31. Sensor error. Replace the speed sensor

YES

point 18


YES

point 18

130FLOW CHART "130"


1. Procedure for speed sensor error (diagnosis tester no. 130).

2. Check the sensor body and wire for mechanical damage. Is

the sensor or wire damaged?

YES

point 3

NO

point 6


YES


BRAK SYS - 50

point 5

4. Internal error: replace the modulator


6. No damage. Check the electrical connection from the sensor

to the wiring.

Sensor side connection not valid

: point 3


: point 21

Valid connection

: point 7

7. . Check the electrical connection from the wiring to the mod-

ulator:

Modulator side connection not valid

: point 4


: point 21

Valid connection

: point 8

8. Install new wheel speed sensor.



11. Reset ECU fault


13. Turn off/on the instrument panel.

Interrupt connection with the ECU

15. Read the error code: Error code FTE



18. Read the FTE error code:

EQUAL TO 130

: point 19

DIFFERENT THEN 130

: point 23

19. Check the two sensor wires for electrical contact between

the sensor connector (CS) and main connector (CP). Pin 12


BRAK SYS - 51

(CP) to pin 2 (CS); Pin 21 (CP) to pin 1 (CS); and incorrect earth

contacts:

Defective sensor cables

: point 21

Good sensor cables

: point 20


YES

point 5



YES

point 5

23. Replace the wheel speed sensor (assembled spare part).

YES

point 5


BRAK SYS - 52

Modulator

MODULATORSpecification Desc./Quantity

ABS cpu connectorLow pressure oil coupling

Rear brake pump coupling - built-inRear brake pump bleed valve - built-in

Front brake pump bleed valveFront brake pump coupling

Front brake calliper couplingOil tank

Fill

Rear - combinedWARNINGAlways use a rubber tube with an adequate diameter to apply to the bleed screw


BRAK SYS - 53

N.B.

DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTOCONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THEBLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKEFLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKEPADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKINGAND EFFICIENCY OF THE BRAKING SYSTEMN.B.

IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUTAMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUTTHE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER ANDON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKEDISC.

Start the procedure by bleeding the brake calliper.

- Loosen the bleed screw shown in the photo and

activate the left brake lever until only brake fluid

comes out

- Close the bleed screw

- Activate the left lever several times

- Keeping the lever activated, loosen the bleed

screw and make sure only brake fluid comes out

- Top up the liquid in the reservoir

Proceed with bleeding of the check valve

- Remove the rubber cap shown in the photo

- Insert the spanner as shown in the photo


BRAK SYS - 54

- Apply the rubber tube as shown in the photo

- Loosen the bleed screw

- Activate the left brake lever until only brake fluid

comes out of the bleed screw

- Close the screw




Proceed with bleeding of the modulator- Apply the

rubber tube

- Loosen the shortest bleed screw on the modula-

tor shown in the photo



- Close the screw




FrontWARNING

Always use a rubber tube with an adequate diameter to apply to the bleed screwN.B.

DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTOCONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THEBLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKEFLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKEPADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKINGAND EFFICIENCY OF THE BRAKING SYSTEMN.B.

IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUTAMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUTTHE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER ANDON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKEDISC.


BRAK SYS - 55

Start the procedure with the modulator

- Loosen the longest bleed screw on the modulator

shown in the photo

- Activate the right brake lever until only brake fluid


- Close the bleed screw- Activate the right brake

lever several times

- Keeping the brake lever activated open the bleed



Proceed with bleeding of the brake calliper

- Loosen the bleed screw shown in the photo

- Activate the right brake lever until only brake fluid


- Close the bleed screw - Activate the right brake

lever several times

- Keeping the brake lever activated open the bleed



Proceed with internal bleeding of the modulator

- Remove the low pressure tube from the oil tank

cap on the modulator as shown in the photo and

plug the end of the tub with a tapered cap

- Remove the stop collar and the modulator tank

cap as shown in the photo

- Using the diagnosis tester, under enabled diag-

noses, activate the modulator internal pump. This

bleeds the inside of the modulator

- Top up the level of the modulator tank if needed


BRAK SYS - 56

After bleeding the modulator it is likely that part of

the air present in the circuit will get into the tube

between the pilot valve and brake calliper. Thus it

is necessary to proceed with bleeding of the tube.

- Get a transparent tube long enough to connect

the bleed valve on the calliper and the brake fluid

reservoir on the modulator.

- Apply one end of the tube to the bleed valve on

the calliper as shown in the photo

- Remove the filter inside the brake fluid reservoir

as shown in the photo

- Keep the other end of the tube on the outlet of

the modulator reservoir

- Loosen the bleed valve on the brake calliper

- Enable the pump using the diagnosis tester

- With the pump enabled, activate the right brake

lever in order to increase the pressure in the tube

to bleed

This will cause all the fluid in the tube to come out

and any air that got in when the modulator was

bled and then the brake fluid left in the circuit.

- Close the bleed valve on the brake calliper

- Refit the filter on the modulator reservoir

- Completely fill the modulator reservoir

- Refit the cap on the reservoir with the stop collar

- Refit the low pressure tube on the reservoir cap


BRAK SYS - 57

INDEX OF TOPICS

TIME TIME

Front wheel

FRONT WHEELCode Action Duration

1 003037 Front wheel rim - Replacement2 003047 Front tyre - Replacement3 004123 Front wheel - Replacement4 003040 Front wheel bearings - Replacement5 002041 Front brake disc - Replacement6 005089 Tone wheel - Replacement7 005134 Speed sensor - Replacement8 004175 Speed sensor bracket - Replace-

ment9 003038 Front wheel axle - Replacement

Braking systemCAUTION

If the front wheel is to be disassembled, for example to change the tyre, be careful not to damage thephonic wheel.Visually inspect the phonic wheel for damage and carry out a road test, having a complete check bemade of the ABS system before delivering the vehicle to the customer.Damage of the phonic wheel causes the modulator pump to operate continuously even when the brakelever is not activated.

X9 Evolution 500 ABS Time

TIME - 59

ABSCode Action Duration

1 002095 ABS modulator - Replace2 002097 Sound-proofing - Replace3 002096 Delay valve - Replace4 002039 Front brake caliper - Replacement5 002048 Rear calliper - Replacement6 002002 Rear brake pads - Replacement7 002007 Front brake pads - replace8 002021 Front brake piping - Replacement9 002100 Delay valve / Modulator tube - Re-

place10 002101 Pump / Delay valve tube - Replace11 002102 Pump / Modulator tube - Replace12 002098 Low pressure tube - Replace13 002081 Rear brake rigid pipes - Replacement14 002020 Rear brake disc piping - Replace-

ment15 002047 Bleed circuit and front brake oil - Re-

place16 002099 ABS circuit air bleed (front and rear)17 002090 Integral brake fluid and bleeding sys-

tem - Replacement18 005135 Voltage maintenance device - Re-

place

Time X9 Evolution 500 ABS

TIME - 60

AABS: 16, 24, 27

IIdentification: 7

MMaintenance: 25

Man: X9 Evolution 500 ABSCap:CharacteristicsSez:Vehicle identificationSez:CapacitiesSez:BrakesSez:Products

Cap:ToolingCap:Electrical systemSez:Components arrangementSez:Conceptual diagramsSez:ABSSez:Checks and inspectionsSez:DashboardSez:Phonic wheelSez:ConnectorsSez:DashboardSez:ABS ModulatorSez:Voltage maintenance device

Cap:Braking systemSez:ABSSez:Operating diagramSez:Palm-set menu descriptionSez:Guide to diagnosisSez:*A*Sez:BSez:CSez:15Sez:129Sez:130Sez:ModulatorSez:FillSez:Rear - combinedSez:Front

Cap:TimeSez:Front wheelSez:Braking system

WORKSHOP MANUAL Evolution... · 2019. 6. 5. · WORKSHOP MANUAL X9 Evolution 500 ABS This workshop...

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Transcript of WORKSHOP MANUAL Evolution... · 2019. 6. 5. · WORKSHOP MANUAL X9 Evolution 500 ABS This workshop...