WORKSHOP MANUAL

633196

X9 Evolution 500 ABS

WORKSHOP MANUAL

X9 Evolution 500 ABS

The descriptions and illustrations given in this publication are not binding. While the basic specifications as 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 to components, 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 MANUAL
X9 Evolution 500 ABS
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with 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 personal injury.

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

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

INDEX OF TOPICS

CHARACTERISTICS TOOLING ELECTRICAL SYSTEM BRAKING SYSTEM TIME

CHAR TOOL ELE SYS BRAK SYS TIME

INDEX OF TOPICS

CHARACTERISTICS

CHAR

X9 Evolution 500 ABS

Characteristics

Vehicle identification
FRAME
Specification Frame prefix Desc./Quantity M27000 > 6.000.001

ENGINE
Specification Engine prefix Desc./Quantity M27*M 1001

Capacities
CAPACITY
Specification Cooling system Fuel tank (including a ~ 2.5 l reserve) Rear hub oil Engine oil (empty) Engine oil (at oil and filter change) Fork oil (quantity for single rod) Desc./Quantity approx. 1.8 litres ~ 14.5 l 250 cc 1.7 lt. 1.5 lt. 268 2 cc

Brakes
BRAKES
Specification Front brake Desc./Quantity 260mm disc with brake booster and ABS

CHAR - 7

Characteristics

X9 Evolution 500 ABS

Specification Combined brake

Emergency brake

Desc./Quantity Two 260 mm discs on the front wheel with brake booster and ABS and one 240 mm on the rear wheel with traditional hydraulic linkage. In the event of a fault with the ABS system, the vehicle preserves all the characteristics of traditional system: Front brake controlled by the RHS lever Rear brake controlled by the LHS lever

Products
TABLE OF RECOMMENDED PRODUCTS
Product AGIP ROTRA 80W-90 AGIP CITY HI TEC 4T Description Rear hub oil Engine oil Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2 Oil for 4-stroke engines Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 Grease with Molybdenum disulphide Hydraulic fluid SAE 7.5 W Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-LXBCIB2 of the swinging arm FMVSS DOT 4 Synthetic fluid Specific product for cleaning and polishing stainless steel muffler

AGIP GP 330 AGIP CITY HI TEC 4T SPECIAL AGIP PERMANENT fluid MONTBLANC MOLYBDENUM GREASE AGIP FORK 7.5 W AGIP GREASE PV2

Grease for brake levers, throttle Oil to lubricate flexible transmissions (throttle control) coolant Grease for driven pulley shaft adjusting ring and movable driven pulley housing Oil for front fork Grease for steering bearings and spindle seats Brake fluid Muffler cleaning paste

AGIP BRAKE 4 PIAGGIO CODE 602683M

CHAR - 8

INDEX OF TOPICS

TOOLING

TOOL

Tooling

X9 Evolution 500 ABS

TOOLING
Stores code 020630Y Description Software for ABS diagnosis

TOOL - 10

INDEX OF TOPICS

ELECTRICAL SYSTEM

ELE SYS

Electrical system

X9 Evolution 500 ABS

DISTINTA SCHEMA ELETTRICO X9 500 EVOLUTION ABS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Specification Sensore temperatura esterna Stop button on rear brake Light switch Indicators switch Horn button Emergency flashing switch Front fuse holder box Fuse Fuse 10 fuses Horn Side stand switch connettori per interfono Gruppo cavetti pompa cavalletto Voltage regulator Side stand control unit Engine stop remote control switch Control unit remote control switch teleruttore pompa cavalletto elettroidraulico Fusibile cavalletto elettroidraulico Scatola portafusibile con basetta per fusibile cavalletto elettroidraulico Lampada indicatore di direzione posteriore SX Lampada luce posizione posteriore SX Fusibile n1 Fuse Fuse Fusibile Fuse holder box Tilting sensor Lampada luce posizione posteriore DX Saddle opening actuator Desc./Quantity

no. 11 7,5 A no. 9 15 A 10 A

70 A

7,5 A no. 2 10 A no. 4 5 A n3 3 A

ELE SYS - 12

X9 Evolution 500 ABS

Electrical system

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

Specification Brake light License plate light bulb Lampada indicatore di direzione posteriore DX Remote starter switch Fusibile n7 Battery Box helmet illumination push button Roof lamp for box helmet illumination with lamp Socket for users Fusibile n6 Starter motor Fuse Fuse HV coil ABS diagnosis socket EMS diagnostic socket Rear fuse box Fuse Magneto flywheel Engine oil pressure sensor Senalatopre rel incollato Cooling fluid temperature sensor for inj. circuit Cavetto bipolare schermato Engine rpm sensor Air temperature sensor Stepper motor Throttle potentiometer Fuel injector Lampada luce di posizione anteriore Pulsante di consenso cavalletto elettroidraulico Pulsante di fine corsa cavalletto elettroidraulico Bulb for upper beams Motorino pompa cavalletto elettroidraulico Electronic injection control unit nodo di massa anteriore Immobilizer decoder Stop light switch (front brake) Wheel RPM sensor Engine stop switch Actuators control device Start-up remote control relay "Reset" button Pulsante cavalletto elettroidraulico Anti-theft alarm fitting Key switch Immobilizer aerial Indicatore di livello e pompa carburante Saddle opening button nodo di massa anteriore Electric fan Main remote control switch Diode ABS relay switch Electric fan remote control switch Fitting for accessories Diode Diode unit ABS cpu Lampada indicatore di direzione anteriore DX Bulb for lowerbeams Digital instrument unit Display radio / interfono Fanale posteriore destro Intercom control unit Analogue instrument unit Lampada indicatore di direzione anteriore SX Start up button

Desc./Quantity 12V - 5W

7,5 A 12V - 14 Ah

12V - 180W max 7,5 A no. 8 7,5 A no. 12 7,5 A

no. 5 15 A

12V - 5W

12V - 55W

1A

6A Built-in to modulator 12V - 10W 12V - 55W

12V - 10W

ELE SYS - 13

Electrical system

X9 Evolution 500 ABS

99 100

Specification Fanale posteriore sinistro Voltage maintenance device

Desc./Quantity

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=Azzurrogiallo - 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=MarroneGiallo
CAUTION

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

ELE SYS - 14

X9 Evolution 500 ABS

Electrical system

Components arrangement

COMPONENT LAYOUT

Specification Front brake pump Rear brake pump - built-in Front brake lamp switch Rear brake lamp switch built-in Modulator Delay valve Front brake caliper Phonic wheel Speed sensor Rear brake caliper ABS relay switch

Desc./Quantity

Causes a delay in front braking action when the left control lever is activated

Conceptual diagrams

ELE SYS - 15

Electrical system

X9 Evolution 500 ABS

ABS

ABS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Specification ABS cpu Battery Fuse no. 13 Stoplight switches Phonic wheel ABS diagnosis socket 10 fuses ABS relay switch Stop light Main remote control switch Starter motor contactor Start up button Digital instrument unit Side stand control unit Voltage maintenance device Desc./Quantity Built-in to modulator 12V - 14 Ah 30 A

10 A N 5 bulbs 12V-2.3W

ELE SYS - 16

X9 Evolution 500 ABS

Electrical system

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) controlled by the phonic wheel vai the ABS cpu and digital section; - rpm counter controlled by the signal from the injection cpu; - Fuel level indicator controlled by a resistive sensor (inside the tank); - Coolant temperature indicator controlled by a resistive 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 instrument panel. For example, the petrol reserve warning lamp only goes on when the reserve indication from the tank lasts for at least 13.5 seconds. This prevents the reserve lamp from going on and off.

ELE SYS - 17

Electrical system

X9 Evolution 500 ABS

- Intermittent operation is incorporated in the instrument 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 indicator control" function is connected to the odometer. If the driver forgets to turn off the turn indicator, it is automatically disabled after 1 kilometre 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

X9 Evolution 500 ABS

Electrical system

- 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 MAY BE CARRIED OUT AGAIN, ESPECIALLY AT LOW TEMPERATURES, ONCE THE ENGINE IS STARTED; THIS IS DUE TO THE DROP IN THE BATTERY VOLTAGE CAUSED BY THE ENGINE START-UP. REPETITION OF THE CHECK, DUE TO LOWERING OF THE BATTERY VOLTAGE DURING THE STARTING PHASE, CAUSES THE "ECU POWER" CODE FTE 5 ERROR, BUT DOES NOT 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 wheel
N.B. To make the connection on the phonic wheel connector side use a pin placing it gently on the connector terminal. Completely inserting the pin causes permanent deformation 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 connector for the phonic wheel.

Check the isolation towards the earth of the lines. ELE SYS - 19

Electrical system

X9 Evolution 500 ABS

Electric characteristic
PIN 12 PIN 24 = OHM Infinitive

Electric characteristic
PIN 21 PIN 24 = OHM Infinitive

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

Electric characteristic
PIN 12 PIN 24 = 0 Volt

Electric characteristic
PIN 21 PIN 24 = 0 Volt

Check the isolation between the two lines

ELE SYS - 20

X9 Evolution 500 ABS

Electrical system

Electric characteristic
PIN 12 PIN 21 = OHM Infinitive

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 voltage 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 multimeter in ammeter function. Make sure there is a current of around 20 mA.

ELE SYS - 21

Electrical system

X9 Evolution 500 ABS

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 characteristic
SP. 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

X9 Evolution 500 ABS

Electrical system

Dashboard

8 WAY CONNECTOR
1 2 3 4 5 6 7 8 Specification Earth for analogue circuit board Battery positive for analogue circuit board Analogue circuit board serial clock output Immobilizer LED output Analogue circuit board serial data output Lights on output Not connected Not connected Desc./Quantity

16 WAY CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Specification To the electrohydraulic stand cpu (PIN 4) Alarm lamp input ABS lamp input Right turn indicator output right turn indicator input left turn indicator input ABS lamp input Air temperature sensor input Engine cannot be started lamp input Oil pressure lamp input Not connected Left turn indicator output Turn indicator stop button input Service reset button input Water temperature sensor input Fuel level sensor input Desc./Quantity

12 WAY CONNECTOR
1 Specification Battery positive Desc./Quantity

ELE SYS - 23

Electrical system

X9 Evolution 500 ABS

2 3 4 5 6 7 8 9 10 11 12

Specification Not connected To the electrohydraulic stand cpu (PIN 4) Engine rpm sensor input Battery positive Immobilizer LED Live positive lead Wheel rpm sensor input to earth Air temperature sensor connection to chassis structure negative Emergency light button input (Hazard) Lights on input

Desc./Quantity

ABS Modulator

ABS CPU CONNECTOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Specification Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Rear stop switch at + of wheel rpm sensor diagnosis output ABS relay switch excitation Stop light switch (front brake) + of main relay switch Brake light at PIN 3/16 of digital instrument unit at earth at earth at - of wheel rpm sensor Not connected at PIN 12 stand control cpu and PIN 8/12 digital instrument unit Desc./Quantity

ELE SYS - 24

X9 Evolution 500 ABS

Electrical system

24 25 SYSTEM SIDE CONNECTOR

Specification to earth + of ABS relay switch

Desc./Quantity

Voltage maintenance device

ELE SYS - 25

INDEX OF TOPICS

BRAKING SYSTEM

BRAK SYS

X9 Evolution 500 ABS

Braking system

CAUTION

If the front wheel is to be disassembled, for example to change the tyre, be careful not to damage the phonic wheel. Visually inspect the phonic wheel for damage and carry out a road test, having a complete check be made 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 brake lever is not activated.

ABS Operating diagram

OPERATING DIAGRAM

Specification Front brake pump Front brake caliper Control valve Front brake lamp switch Pilot valve Speed sensor Oil pump Low pressure oil hose ECU Rear brake lamp switch built-in ABS alarm lamp

Desc./Quantity

Located inside modulator Located inside modulator Located inside modulator and activated by motor "M" controlled by "ECU" Located inside modulator

BRAK SYS - 27

Braking system

X9 Evolution 500 ABS

Specification Brake light Rear brake pump - built-in Delay valve Rear brake caliper Modulator Oil tank

Desc./Quantity

Causes a delay in front braking action when the left control lever is activated

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 DIAGNOSIS
Specification PUMP MOTOR BRAKE LIGHT Desc./Quantity Enables the modulator pump for around 20 seconds. 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. 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. Controls the analogue speedometer needle up to a speed of 5 Km/h for around 5 seconds.

INSTRUMENT PANEL LAMP

SPEEDOMETER TEST

CANCELLING ERRORS This function is used to cancel faults and any codes recorded by the autodiagnosis 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.

PARAMETERS
Specification VEHICLE SPEED Desc./Quantity Indicates the vehicle speed in Km/h

BRAK SYS - 28

X9 Evolution 500 ABS

Braking system

Specification RIGHT BRAKE SIGNAL LEFT BRAKE SIGNAL PUMP MOTOR ABS VALVE FRONT SPEED SIGNAL BATT. VOLT. SPEED SENS. VOLT.

Desc./Quantity Indicates the enable signal for activating the front brake lever Indicates the enable signal for activating the combined brake lever

POWER BRAKE TEST ABS TEST

CURRENT PIN* MEMORISED PIN*

VEHICLE ON BRAKE ENABLED ABS ENABLED BRAKE ERROR

ABS ERROR

Indicates the front wheel speed expressed in Hz Indicates the battery voltage expressed in volts Indicates the speed sensor voltage expressed in volts It must be between 0.4-0.8V or 1.2-2V based on whether the speed sensor is positioned on "no-load" or "full-load" on the phonic wheel. Indicates if the check has been carried out on the power brake system. Indicates if the check has been carried out on the ABS system. The check includes the speed sensor, which can only be tested if the speed is over 5 Km/h, with the vehicle stopped it is "Disabled". Indicates the vehicle code the cpu reads based on the status of the 3 pins 19, 20 and 22. Code 6 identifies the X9 vehicle Indicates the first combination code between the cpu and vehicle based on the pins 19, 20 and 22. Code 6 identifies the X9 vehicle. Indicates the amount of time the vehicle has been on. Indicates the amount of time the power brake has been enabled. Indicates the activation time of the ABS expressed in seconds. Indicates the minute of "VEHICLE ON" when a "BRAKE ERROR" occurred. "BRAKE ERROR" is generated in the event of a type A error (excluding 128), B or 15. 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 ERROR REFERENCE FLOW CHART BRAKE ERROR A 1 3 4 7 8 21 22 27 28 30 B 2 5 6 HAZARD INTERRUPT RAM ERROR ROM ERROR CYCLE TOO LONG STACK ERROR INTERNAL CONTROLLER EEPROM ERROR CALCULATION ERROR EEPROM PARAMETERS AD CONVERSION MAIN RELAY ECU POWER ABS VALVE NO NO YES FTE ERROR CODE ERROR DESCRIPTION POWER BRAKE ABS LAMP ON

BRAK SYS - 29

Braking system

X9 Evolution 500 ABS

11 15 ERROR ABS A 129 130 --C 15 128 129 130 ---

PUMP MOTOR VEHICLE CODE VALVE CURRENT WHEEL SLIPPAGE SPEED SENSOR ERRORS NOT DETECTED BY AUTODIAGNOSIS YES/ NO YES/NO YES/NO YES

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 MAY BE CARRIED OUT AGAIN, ESPECIALLY AT LOW TEMPERATURES, ONCE THE ENGINE IS STARTED; THIS IS DUE TO THE DROP IN THE BATTERY VOLTAGE CAUSED BY THE ENGINE START-UP. Indicates the information related to the vehicle and cpu software.

INFO ECU
Specification HARDWARE VERSION ABS SOFTWARE VERSION SW DATE EEPROM VERSION MODULATOR FTE S.N. CHASSIS NO. Desc./Quantity Indicates the ABS software version Indicates the software version date in YYYYMMDD format. Indicates the Eeprom version Indicates the modulator version Indicates the progressive number of the ABS unit supplier 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

X9 Evolution 500 ABS

Braking system

3. Proceed following the generic procedures.

B
FLOW CHART "B" ble width="100%" border=1>
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

Braking system

X9 Evolution 500 ABS

NO point 16 12. Voltage =0 V. Earth pin 24. 13. Measure voltage on pin 25. Is the voltage equal to the battery voltage? YES point 14 NO point 16 14. Pin 25 voltage equal to battery voltage. Turn off the instrument 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. 19. Proceed following the generic procedures.

C
FLOW 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 reservoir 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

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Braking system

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 device. 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 device. 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" ble width="100%" border=1>

1. Turn on the instrument panel. 2. Initialise connection with ECU with safety access. 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

Braking system

X9 Evolution 500 ABS

6. Turn off the instrument panel. 7. Disconnect the main connector from the ECU. 8. Turn on the instrument panel 9. Turn on/off brake light. Is the light on? YES point 10 NO point 18 10. Turn off the instrument panel. 11. Replace the wiring. 12. External error: do not replace the modulator. 13. Proceed following the generic procedures. 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 17. Interrupt connection with the ECU. 18. Turn off the instrument panel. 19. Internal error: replace modulator YES point 13. 20. Interrupt connection with the ECU. 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

X9 Evolution 500 ABS

Braking system

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. 26. Turn off the instrument panel. 27. Disconnect the main connector from the ECU. 28. Turn on the instrument panel. 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 30. Turn off the instrument panel. 31. Replace the wiring. YES point 12 32. Turn off the instrument panel. 33. Replace the faulty brake switch. YES point 12

FLOW CHART "C3" ble width="100%" border=1>

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 4. Turn on the instrument panel. 5. Initialise connection with ECU with safety access. 6. Interrupt the main cycle with the diagnostic device

BRAK SYS - 35

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X9 Evolution 500 ABS

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 11. Interrupt connection with the ECU. 12. Turn off the instrument panel. 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

X9 Evolution 500 ABS

Braking system

No damage point 18 Damaged phonic wheel point 33 18. Inspect the electrical connection between sensor and wiring: Wire side connection not valid point 26 Modulator side connection not valid point 19 Valid connection point 34 19. Internal error: replace the modulator. 20. Proceed following the generic procedures. 21. Replace the speedometer. 22. External error: do not replace the modulator. YES point 20 23. Interrupt the main cycle with the diagnostic device 24. Turn off the instrument panel. 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 26. Replace the wiring. 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

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X9 Evolution 500 ABS

28. Replace the wiring. YES point 22 29. Check the electrical connection from the wiring to the modulator. 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" ble width="100%" border=1>

1. Procedure for error C5. 2. Disconnect the main connector from the ECU. 3. Turn on the instrument panel. 4. Turn on/off lamp. Is the lamp on? YES point 8 NO point 5

BRAK SYS - 38

X9 Evolution 500 ABS

Braking system

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 8. Internal error: replace the modulator. YES point 11 9. Replace the wiring. 10. External error: do not replace the modulator. 11. Proceed following the generic procedures. 12. Replace lamp bulb. YES point 10

FLOW CHART "C6" ble width="100%" border=1>

1. Procedures for error C6 lamp constantly on 2. Turn on the instrument panel 3. Brake levers not enabled. 4. Turn on/off brake light. Is the light on? YES point 18 NO point 5 5. Initialise connection with ECU with safety access. 6. Turn on the lamp with the diagnostic device. 7. Turn on/off lamp. Is the lamp on? YES point 8

BRAK SYS - 39

Braking system

X9 Evolution 500 ABS

NO point 19 8. Interrupt connection with the ECU. 9. Turn off the instrument panel. 10. Disconnect the main connector from the ECU. 11. Earth pin 18 (lamp). 12. Turn on the instrument panel. 13. Turn on/off lamp. Is the lamp on? YES point 14 NO point 28 14. Turn off the instrument panel. 15. Replace the wiring. 16. External error: do not replace the modulator. 17. Proceed following the generic procedures. 18. Turn off the instrument panel. Proceed with the procedure for error C2 19. Interrupt connection with the ECU. 20. Turn off the instrument panel. 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

X9 Evolution 500 ABS

Braking system

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 wiring. Sensor side connection not valid point 35 Wire side connection not valid point 36 Valid connection point 37 27. Internal error: replace the modulator. YES point 17 28. Turn off the instrument panel. YES point 27 29. Correctly reassemble the sensor and sensor bracket. YES point 16 30. Replace the wheel speed sensor. 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

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X9 Evolution 500 ABS

point 16 35. Replace the wheel speed sensor. YES point 31 36. Replace the wiring. YES point 16 37. Inspect the electrical connection from the wiring to the modulator. Valid wiring point 27 Not valid wiring point 36

FLOW CHART "C" ble width="100%" border=1>

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" ble width="100%" border=1>

error C1 brake light error - brake light always off 2. Turn on the instrument panel. 3. Initialise connection with ECU with safety access. 4. Interrupt the main cycle with the diagnostic device.

BRAK SYS - 42

X9 Evolution 500 ABS

Braking system

5. Turn on the brake light with diagnostic device. 6. Turn on/off brake light. Is the light on? 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 12. Internal error: replace the modulator. 13. Proceed following the generic procedures. 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 17. Turn off the instrument panel. 18. Disconnect the main connector from the ECU. 19. Turn on the instrument panel. 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

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X9 Evolution 500 ABS

YES point 21 NO point 24 21. Turn off the instrument panel. 22. Replace the wiring. 23. External error: do not replace the modulator. YES point 13 24. Turn off the instrument panel. YES point 12 25. Interrupt connection with the ECU. 26. Turn off the instrument panel. 27. Replace the faulty brake switch. YES point 23 28. Interrupt connection with the ECU 29. Turn off the instrument panel. 30. Check the lamp and lamp holder. Is the lamp or lamp holder faulty? YES point 31 NO point 36 31. Disconnect the main connector from the ECU. 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 34. Turn off the instrument panel. 35. Replace the wiring. YES point 23

BRAK SYS - 44

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Braking system

36. Replace the lamp or lamp holder. YES point 23

FLOW CHART "C4" ble width="100%" border=1>

1. Error C4. 2. Brake light operation: YES point 3 NO point 5 3. Check the starter relay and wiring. 4. External error: do not replace the modulator. 5. Proceed following the generic procedures. 6. Error C1. Carry out the tests in the section dedicated to this error.

15
ble width="100%" border=1>
1. Procedure per codice errore codifica veicolo. 2. Turn on the instrument panel. 3. Read the displayed codes: - Current pin (memorised in RAM) - Memorised pin (memorised in EEPROM) 4. Interrupt connection with the ECU. 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

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X9 Evolution 500 ABS

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 damaged? 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 connected to the wiring, by testing electrically. Are the connections correct? YES point 11 NO point 14 11. Turn off the instrument panel. 12. Internal error: replace the modulator. 13. Proceed following the generic procedures. 14. Turn off the instrument panel. 15. Replace the wiring. 16. External error: do not replace the modulator. 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) 21. Replace the wiring. 22. Interrupt connection with the ECU 23. Turn off/on the instrument panel. 24. Interrupt connection with the ECU 25. Read the error code: - xxx

BRAK SYS - 46

X9 Evolution 500 ABS

Braking system

26. FTE error code. YES point 11 NO point 27 27. Turn off the instrument panel. YES point 16 28. Initialise connection with ECU with safety access 29. Reset ECU fault 30. Interrupt connection with the ECU 31. Note on diagnosis form: modulator not specific for vehicle type! YES point 11

129
ble width="100%" border=1>
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

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X9 Evolution 500 ABS

NO point 27 8. Front wheel free. Disable the electrohydraulic pump with the diagnostic tester. 9. Turn on the instrument panel. 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 assembly. Is the assembly correct? YES point 14 NO point 22 14. Make sure the phonic wheel does not show signs of mechanical 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

X9 Evolution 500 ABS

Braking system

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 17. External error: do not replace the modulator. 18. Proceed following the generic procedures. 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

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X9 Evolution 500 ABS

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 modulator to the calliper. YES point 17 27. Disable the electrohydraulic pump with the diagnostic device 28. Turn off the instrument panel 29. Internal error: replace the modulator. YES point 18 30. Replace the wheel speed sensor. 31. Sensor error. Replace the speed sensor YES point 18 32. Replace the wiring. YES point 18

130
FLOW CHART "130" ble width="100%" border=1>
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 3. Replace the wheel speed sensor. YES

BRAK SYS - 50

X9 Evolution 500 ABS

Braking system

point 5 4. Internal error: replace the modulator 5. Proceed following the generic procedures. 6. No damage. Check the electrical connection from the sensor to the wiring. Sensor side connection not valid : point 3 Wire side connection not valid : point 21 Valid connection : point 7 7. . Check the electrical connection from the wiring to the modulator: Modulator side connection not valid : point 4 Wire side connection not valid : point 21 Valid connection : point 8 8. Install new wheel speed sensor. 9. Turn on the instrument panel. 10. Initialise connection with ECU with safety access 11. Reset ECU fault 12. Interrupt connection with the ECU 13. Turn off/on the instrument panel. Interrupt connection with the ECU 15. Read the error code: Error code FTE 16. Interrupt connection with the ECU 17. Turn off the instrument panel. 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

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X9 Evolution 500 ABS

(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 20. Internal error: replace the modulator. YES point 5 21. Replace the wiring. 22. External error: do not replace the modulator. YES point 5 23. Replace the wheel speed sensor (assembled spare part). YES point 5

BRAK SYS - 52

X9 Evolution 500 ABS

Braking system

Modulator

MODULATOR
Specification ABS cpu connector Low pressure oil coupling Rear brake pump coupling - built-in Rear brake pump bleed valve - built-in Front brake pump bleed valve Front brake pump coupling Front brake calliper coupling Oil tank Desc./Quantity

Fill Rear - combined

WARNING

Always use a rubber tube with an adequate diameter to apply to the bleed screw BRAK SYS - 53

Braking system

X9 Evolution 500 ABS

N.B.

DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM
N.B.

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

X9 Evolution 500 ABS

Braking system

- 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 - Activate the left brake lever until only brake fluid comes out of the bleed screw - Top up the liquid in the reservoir Proceed with bleeding of the modulator- Apply the rubber tube - Loosen the shortest bleed screw on the modulator shown in the photo - Activate the left brake lever until only brake fluid comes out of the bleed screw - Close the screw - Activate the left brake lever until only brake fluid comes out of the bleed screw - Top up the liquid in the reservoir

Front
WARNING

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

DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM
N.B.

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

BRAK SYS - 55

Braking system

X9 Evolution 500 ABS

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 comes out of the bleed screw - Close the bleed screw- Activate the right brake lever several times - Keeping the brake lever activated open the bleed screw and make sure only brake fluid comes out - Top up the liquid in the reservoir Proceed with bleeding of the brake calliper - Loosen the bleed screw shown in the photo - Activate the right brake lever until only brake fluid comes out of the bleed screw - Close the bleed screw - Activate the right brake lever several times - Keeping the brake lever activated open the bleed screw and make sure only brake fluid comes out - Top up the liquid in the reservoir 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 diagnoses, 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

X9 Evolution 500 ABS

Braking system

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

X9 Evolution 500 ABS

Time

Front wheel

FRONT WHEEL
1 2 3 4 5 6 7 8 9 Code 003037 003047 004123 003040 002041 005089 005134 004175 003038 Action Front wheel rim - Replacement Front tyre - Replacement Front wheel - Replacement Front wheel bearings - Replacement Front brake disc - Replacement Tone wheel - Replacement Speed sensor - Replacement Speed sensor bracket - Replacement Front wheel axle - Replacement Duration

Braking system
CAUTION

If the front wheel is to be disassembled, for example to change the tyre, be careful not to damage the phonic wheel. Visually inspect the phonic wheel for damage and carry out a road test, having a complete check be made 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 brake lever is not activated.

TIME - 59

Time

X9 Evolution 500 ABS

ABS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Code 002095 002097 002096 002039 002048 002002 002007 002021 002100 002101 002102 002098 002081 002020 002047 002099 002090 005135 Action ABS modulator - Replace Sound-proofing - Replace Delay valve - Replace Front brake caliper - Replacement Rear calliper - Replacement Rear brake pads - Replacement Front brake pads - replace Front brake piping - Replacement Delay valve / Modulator tube - Replace Pump / Delay valve tube - Replace Pump / Modulator tube - Replace Low pressure tube - Replace Rear brake rigid pipes - Replacement Rear brake disc piping - Replacement Bleed circuit and front brake oil - Replace ABS circuit air bleed (front and rear) Integral brake fluid and bleeding system - Replacement Voltage maintenance device - Replace Duration

TIME - 60

A
ABS: 16, 24, 27

I
Identification: 7

M
Maintenance: 25