Malaguti Password 250 Workshop Manual

PASSWORD 250

B

ELECTRICAL SYSTEM

DIAGNOSTICS

WORKSHOP MANUAL

B

0505 3

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INDEX

CHAPTER

EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 1

B - DIAGNOSTICS

Index

Sect. Page

INTRODUCTION 1 5

Publication update 1 5

Consultation notes 1 6

Configuration of the pages 1 6

Pages modified 1 6

Pages added 1 6

Symbols used 1 6

Abbreviations used 1 8

DIAGNOSTICS 2 9

Electrical components 2 9

General wiring diagram 2 11

Instrument panel connector configuration 2 11

Controlling the switches 2 13

Control procedures 2 13

Connection of switches illustrated in this manual 2 13

Controlling the fuses 2 14

Position of switches and connectors connection 2 15

Ignition system 2 16

Ignition system circuit 2 16

Failure diagnosis 2 17

Charging system 2 21

Charging system circuit 2 21

Failure diagnosis 2 22

Electric starting system 2 24

Electric starting system circuit 2 24

Failure diagnosis 2 25

Checking the starter motor 2 29

Lights system 2 33

Lights system circuit 2 33

Failure diagnosis 2 34

Signalling system 2 41

Signalling system circuit 2 41

Failure diagnosis 2 42

Cooling system 2 54

Cooling system circuit 2 54

Failure diagnosis 2 55

Automatic cold start system 2 57

Automatic cold start system circuit 2 57

Failure diagnosis 2 58

Fuel pump system 2 60

Fuel pump system circuit 2 60

Failure diagnosis 2 61

B

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INTRODUCTION

CHAPTER

EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 1

B - DIAGNOSTICS

• Malaguti reserves the right to make any type of alteration to its motorcycles at any time without it being

compulsory to give immediate notice.

• The reproduction or disclosure, even partial, of the matters dealt with and the illustrations in the Manuals,

object of this publication, are absolutely forbidden. All rights are reserved to Malaguti who must be asked for

(written) authorisation,specifying the use of any such reproduction or disclosure.

INTRODUCTION

• In this publication you will find all the procedures necessary for the failure diagnosis of the electrical system

(and of the Electronic Injection System) and what to do to solve problems, giving the technicians in this

sector (Authorised Assistance Centres) the main information so they will work in perfect harmony with the

modern concepts of “good workmanship” and “safety at the work place”.

• Other information can be gleaned from the “Cyclists” Workshop Manual, the “Engine” Workshop Manual

and the Spare Parts Catalogue.

• Skilled and experienced technicians are expected to do the jobs described herein.

• You will find the procedures for removing bodywork parts and electrical/mechanical parts, so the wiring or electrical

components on which you have to work can be accessed, detailed in the “Cyclists” Workshop Manual.

• All the instructions in this manual must be strictly abided by.

• For any other information please contact the Malaguti S.p.a. Technical Assistance Service.

• It is of utmost importance to follow the instructions given. If any of the jobs are done superficially or simply not

done at all it is quite possible that the buyer could be injured or the motorcycle damaged or, at the very least,

there could be unpleasant complaints as a result.

PUBLICATION UPDATE

• Any subsequent updates of this manual will be sent within a reasonable period of time.

• The Index will be updated if the alterations and changes to the pages of the manual fail to guarantee its rational

consultation.

• IMPORTANT! The Manual for finding electrical system failures must be considered as a real work tool and can

only maintain its “

value

” over time if kept constantly updated.

FIRST EDITION: 06/05

B

6 06.05

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INTRODUCTION

CHAPTER

PAGE EDITION

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 1

B - DIAGNOSTICS

W

Z

Y

X

PAGES MODIFIED

• The page that has been altered will bear the same number as the page of the previous edition followed by an M

with the new date of the edition in the relative box.

• The implementation of figures is possible on the modified pages in which case the figure (or figures) added will

bear the same number as the previous figure followed by a letter.

PAGES ADDED

• If any pages are added they will bear the last number of their section followed by an A and the new date of the

edition.

SYMBOLS USED

• For quicker and more rational reading symbols have been used (page 6) indicating situations of maximum

attention, practical tips or just information.

• These symbols can be by the side of a text (meaning they refer to that text alone), by the side of a figure

(they refer to whatever is illustrated in the figure and the corresponding text), or at the top of the page (they refer

to all the matters dealt with on that page).

Note:

Pay attention to the meaning of the symbols as their function is so that technical concepts or safety indications

do not have to be repeated. They are therefore to be considered real “memorandums”. Consult this page whenever

there are doubts as to their meanings.

Y Chapter

X Section title

W Page No.

Z Edition date

(RH PAGE)

PAGE CONFIGURATION

CONSULTATION NOTES

B

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INTRODUCTION

CHAPTER

EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 1

B - DIAGNOSTICS

R

M

L

H

F

A

B

D

C

I

G

E

A) ATTENTION! Precautionary tips and information about the

motorcyclist’s safety (the person using the motorcycle)

and for protecting the integrity of the motorcycle itself.

B) CAUTION! Descriptions of jobs that can be dangerous for

the maintenance engineer/repairer, for other workshop

people or people from outside, for the environment, for the

motorcycle and equipment.

C) FIRE HAZARD

Operations that could start a fire.

D) EXPLOSION HAZARD Operations that could lead to an

explosion.

E) TOXIC EXHALATIONS

Warning of the danger of intoxication or inflammation of

the respiratory system.

F) MECHANIC Work requiring the skill of an expert

motorcycle/mechanic.

G) ELECTRICIAN

Work requiring the skill of an expert electronic/electrician.

H) NO! Operations to be avoided.

I) ENGINE WORKSHOP MANUAL Information that can be

gleaned from this manual.

L) SPARE PARTS CATALOGUE

Information that can be gleaned from this documentation.

B

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INTRODUCTION

CHAPTER

PAGE EDITION

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 1

B - DIAGNOSTICS

A

ABBREVIATIONS USED

Note:

often in the illustrations securing or adjustment screws are referred to by the letter V. The number that follows this

letter indicates the quantity of identical screws in the unit or component subject of the description and relative

illustration. The letter without a number means quantity 1. In the case of different screws referred to in the

same figure, V will be followed by the number and by a small letter, i.e.: (V4a).

Reassembly of the units and components is normally done in the opposite order to how they were removed

(unless specified otherwise).

Make certain the motorcycle is perfectly stable before doing any work on it.

The front wheel must be anchored, preferably, on the part that is one with the lifting platform.

F Figure

Cs Tightening torque

P Page

Pr Paragraph

S Section

Sc Diagram

T Table

V Screw

B

06.05 9

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CHAPTER

EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Electrical Components

B - DIAGNOSTICS

14

10

12

9

8765

4

3

2

1

2

4

3

5

67

9

10

8

11

13

12

14

15 16

16 1315

11

2

ELECTRICAL COMPONENTS

1) HORN

2) RADIATOR

3) STARTER COMMAND HEAT PROBE

4) SOLENOID VALVE COMMAND HEAT PROBE

5) MAIN SWITCH

6) START RELAY

7) FLASHER RELAY

8) PETROL PROBE

9) START INTERRUPTION RELAY (WHITE)

10) PETROL PUMP COMMAND RELAY (BLACK)

11) HV COIL

12) SIDE STAND SWITCH

13) BATTERY

14) PETROL PUMP

15) “C.D.I.”

16) VOLTAGE REGULATOR

B

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FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

General Wiring Diagram

B - DIAGNOSTICS

15 A

5A

15 A

+

-

N

12V

.

12V

.

7.5 A

30 A

7.5 A

5A

0FF

ON

0FF

30 A

1

2

3

4

5

6

7

8

9

10

11

12

24

23

22

21 20

19

18

17

16

15

14

13

ON

0FF

ON

0FF

LO

HI

LUCI

HORN

PASSING

R

L

TURN

R

16

W

16

W

35 w

5

W

10

W

5

W

10

5

W

10

W

5

W

10

W

R

5

W

8

7

6

5

4

3

2

1

A

B

C

A

B

C

8

7

6

5

4

3

2

1

BL-R

BL

OFF

ON

BL-N

VR-N

N

BL

GL-B

BL-R

VR-N

BL-N

N

GL-B

R

M

A.T

BL

R

BL

R-VR

GL-N

RS

B-R

N

GL-B

GL-N

RS

BL

B-R

N

GL-BL

GL-V

GL-BL

B-BL

R

GL-N

RS

BL

B-R

N

GL-BL

GL-B

B-BL

R

BL

AZ-B

GL-N

B-N

VR

VL

M

AR

N

AZ-B

GL-N

B-N

VR

VL

M-N

AR

BL-N

B-GR

BL

R

AR

R

B-GR

M-N

VL

VR

M

MN

AZ-GR

M

AZ-GR

GL-V

A1

A4

A5

A6

A7

B3

B6

B8

C8

GL-R

GL-B

M-B

GL-N

B-BL

BL-N

B-N

AR

N

R

B-GR

B-N

BL-R

GL-VL

AZ-B

RS

N

B-R

GL-B

R-N

N

GL-B

N

AR

GL-VL

BL-R

GL

M-B

N

M-B

AR-R

B-VR

N

VR

GR

GL-BL

B

BL-N

N

VR

GL-N

B-N

BL-N

N

GL

B-BL

AR

GL

VR-N

AR-R

AR

BL

B-N

AZ-B

GL-N

B-N

M

VL

VR

AR

N

GL-B

BL-R

GL-BL

BL

R-N

RS

AZ-B

VR

GL-R

B-VR

GR

N

VL

B-N

R

B

B-N

AZ-B

RS

AZ-B AZ-B

B-N

RS

N

VL

R

RS

N

VR

VL

R

RS

N

VR

RS

N

RS

N

R

BL-R

N

VL

VR

N

VR

N

VL

85 85

86

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

N

R

86

DIODO 2 A

DIODO 2A

< RPM

<

RPM

>+12

<

PK+

<-12

>-12

PK-

>-12

>+12

1

2

3

4

5

7

6

8

9

11

10

12

13 14 15

16

17 20

18

19

21

22

23

24

N

25

26

27

28

29

30

31

323334

35

36

37

START

MODE

LIGHTS

ENGINE STOP

38

39

40

41

42

B

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FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

General Wiring Diagram

B - DIAGNOSTICS

1

23

4

567

8

9

10 11 12

13

14

15 16

17

18 19

20

21 22 23 24

GENERAL WIRING DIAGRAM

COLOUR KEY

N-R BLACK/RED B-VL WHITE/MAUVE

R RED B-BL WHITE/BLUE

R-VR RED/GREEN B-GR WHITE/GREY

RS PINK BL BLUE

RS-N PINK/BLACK BL-N BLUE/BLACK

VL MAUVE BL-R BLUE/RED

VL-N MAUVE/BLACK BL-VR BLUE/GREEN

VR-N GREEN/BLACK GL YELLOW

VR GREEN GL-B YELLOW/WHITE

AR ORANGE GL-N YELLOW/BLACK

AR-B ORANGE/WHITE GL-V YELLOW/GREEN

AR-VR ORANGE/GREEN GL-R YELLOW/RED

AR-BL ORANGE/BLUE GL-BL YELLOW/BLUE

AZ AZURE GR GREY

AZ-B AZURE/WHITE GR-R GREY/RED

AZ-GR AZURE/GREY M BROWN

B WHITE M-B BROWN/WHITE

B-VR WHITE/GREEN M-N BROWN/BLACK

B-N WHITE/BLACK N BLACK

B-R WHITE/RED

INSTRUMENT PANEL CONNECTOR CONFIGURATION

1)RPM 9) BATTERY POSITIVE 17)NEGATIVE

2)RIGHT INDICATOR 10)- 18)FUEL PROBE

3)LOW BEAM LIGHTS 11) - 19)TEMPERATURE PROBE

4)PARKING LIGHTS 12)ENGINE STOP 20)-

5)EXTERNAL TEMPERATURE 13)HALL SENSOR INPUT 21)-

6)KEY IN IGN.TURNED ONCE TO

MAKE CONTACT 14)MODE PUSH BUTTON 22)-

7)HALL VDC SENSOR 15)HIGH BEAM LIGHTS 23)-

8)- 16)LEFT INDICATOR 24)-

INSTRUMENT PANEL CONNECTOR

24 PIN

B

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FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

General Wiring Diagram

B - DIAGNOSTICS

GENERAL WIRING DIAGRAM LEGEND

1) FLYWHEEL

2) MAIN SWITCH

3) HORN

4) BATTERY

5) 15 A FUSE

6) 7.5 A FUSE

7) 5 A FUSE

8) 15 A FUSE

9) 30 A FUSE

10) 5 A FUSE

11) 7.5 A FUSE

12) 30 A FUSE

13) START RELAY

14) START INTERRUPTION RELAY (WHITE)

15) PETROL PUMP RELAY (BLACK)

16) STARTER MOTOR

17) TAILLIGHT UNIT

18) NUMBER PLATE LIGHT

19) RECHARGE POINT

20) RADIATOR FAN

21) SIDE STAND SWITCH

22) c/Km SENSOR

23) FUEL LEVEL SENSOR

24) WATER TEMPERATURE SENSOR

25) ELECTRIC STARTER

26) THERMAL SWITCH (ELECTRIC STARTER)

27) FAN THERMAL SWITCH

28) COIL

29) PETROL PUMP

30) “C.D.I.”

31) FRONT STOP SWITCH

32) RIGHT-HAND SWITCH

33) INSTRUMENT PANEL

34) EXTERNAL TEMPERATURE PROBE

35) RIGHT INDICATOR

36) HEADLIGHT

37) LEFT INDICATOR

38) LEFT SWITCH

39) REAR STOP SWITCH

40) FLASHER RELAY

41) REGULATOR

42) ANTI-THEFT PREDISPOSITION

B

06.05 13

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EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Controlling the Switches

B - DIAGNOSTICS

CONTROLLING THE SWITCHES

CONTROL PROCEDURES

Check the switches with a Multimeter (Code 08609500),

verifying continuity between their terminals to determine

whether or not they are connected correctly.

Change the switch even if only one of the possible

combinations fails to give a correct readout.

NOTE: Shift the switch several times from “ON” to

“OFF” and select



.

Set the Multimeter on the correct “0” position

before checking the switches.

CONNECTION OF THE SWITCHES ILLUSTRATED IN THIS MANUAL

- You will find diagrams in this Manual - like the one here on the right - showing

switch terminal connections (main switch, brake switch, “Mode” push button

etc...).

- The different positions of the switch are given in the first column on the left

while the colours of the wires connected to the switch terminals are given on

the top most line.

- The “ ” symbol indicates terminals where there is continuity, that is, a

closed circuit in a given position of the switch.

- In this diagram:

“BL/B” and “R” have continuity when the switch is in the “ON” position.

B

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PAGE EDITION

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Controlling the Switches

B - DIAGNOSTICS

CONTROLLING THE FUSES

ATTENTION: the main switch must always be put in the “OFF”

position whenever you are checking or changing fuses or if

there is a short circuit risk.

Control procedure:

- Connect the Multimeter (Code 08609500) to the fuse and check

its continuity.

NOTE: Put the Multimeter selector on “



” (sound function)





- If the Multimeter gives “I” and there is no sound, change the fuse.

How to change the fuse:

- Put the key in the “OFF” position.

- Fit a new fuse with the correct amperage.

- Put the key in the “ON” position

- Turn all the switches on to verify that all the relative electrical systems are working properly.

- If the fuse blows again check the relative circuit.

CAUTION: never use a fuse with an amperage different to that specified. Do not use other materials in

place of the fuse.

An unsuitable fuse can cause extensive damage to the electrical system, failures to ignition and lighting

and could even cause a fire.

B

06.05 15

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CHAPTER

EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Controlling the Switches

B - DIAGNOSTICS

9

10

11

3

2

1

6

7

8

1

4

32

5

6 7

8

9

10

11

12

13

B-GR

R

ON

0FF

LO

HI

AZ-B

GL-N

B-N

AR

N

B-GR

R

0FF

ON

0FF

GL-N

RS

BL

B-R

N

GL-BL

GL-B

B-BL

R

OFF

ON

BL-N

VR-N

N

BL

GL-B

BL-R

13

12

N

5

4

ON

0FF

R

L

BL

B-N

M

VL

VR

POSITION OF THE SWITCHES AND CONNECTORS CONNECTIONS

1) Rear stop switch 8) Engine start switch

2) Horn command 9) Engine stop switch

3) Lights switch 10) Mode

4) Passing 11) Main switch

5) Indicators switch 12) Side stand switch

6) Front stop switch 13) Fuses plate

7) Main lights switch

NOTE: The start switch is closed when the “START” push button is pressed.

The switch of the side stand is closed when the stand is up.

The “STOP” switch is closed when the brake lever is operated.

B

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CHAPTER

PAGE EDITION

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Ignition System

B - DIAGNOSTICS

15 A

5A

15 A

+

-

N

12V

.

12V

.

7.5 A

30 A

7.5 A

5A

0FF

ON

0FF

30 A

1

2

3

4

5

6

7

8

9

10

11

12

24

23

22

21 20

19

18

17

16

15

14

13

ON

0FF

ON

0FF

LO

HI

LUCI

HORN

PASSING

R

L

TURN

R

16

W

16

W

35 w

5

W

10

W

5

W

10

5

W

10

W

5

W

10

W

R

5

W

8

7

6

5

4

3

2

1

A

B

C

A

B

C

8

7

6

5

4

3

2

1

BL-R

BL

OFF

ON

BL-N

VR-N

N

BL

GL-B

BL-R

VR-N

BL-N

N

GL-B

R

M

A.T

BL

R

BL

R-VR

GL-N

RS

B-R

N

GL-B

GL-N

RS

BL

B-R

N

GL-BL

GL-V

GL-BL

B-BL

R

GL-N

RS

BL

B-R

N

GL-BL

GL-B

B-BL

R

BL

AZ-B

GL-N

B-N

VR

VL

M

AR

N

AZ-B

GL-N

B-N

VR

VL

M-N

AR

BL-N

B-GR

BL

R

AR

R

B-GR

M-N

VL

VR

M

MN

AZ-GR

M

AZ-GR

GL-V

A1

A4

A5

A6

A7

B3

B6

B8

C8

GL-R

GL-B

M-B

GL-N

B-BL

BL-N

B-N

AR

N

R

B-GR

B-N

BL-R

GL-VL

AZ-B

RS

N

B-R

GL-B

R-N

N

GL-B

N

AR

GL-VL

BL-R

GL

M-B

N

M-B

AR-R

B-VR

N

VR

GR

GL-BL

B

BL-N

N

VR

GL-N

B-N

BL-N

N

GL

B-BL

AR

GL

VR-N

AR-R

AR

BL

B-N

AZ-B

GL-N

B-N

M

VL

VR

AR

N

GL-B

BL-R

GL-BL

BL

R-N

RS

AZ-B

VR

GL-R

B-VR

GR

N

VL

B-N

R

B

B-N

AZ-B

RS

AZ-B AZ-B

B-N

RS

N

VL

R

RS

N

VR

VL

R

RS

N

VR

RS

N

RS

N

R

BL-R

N

VL

VR

N

VR

N

VL

85 85

86

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

N

R

86

DIODO 2 A

DIODO 2A

< RPM

<

RPM

>+12

<

PK+

<-12

>-12

PK-

>-12

>+12

1

2

3

4

5

7

6

8

9

11

10

12

13 14 15

16

17 20

18

19

21

22

23

24

N

25

26

27

28

29

30

31

323334

35

36

37

START

MODE

LIGHTS

ENGINE STOP

38

39

40

41

42

IGNITION SYSTEM CIRCUIT

B

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EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Ignition System

B - DIAGNOSTICS

ELECTRICAL COMPONENTS:

1) MAGNETIC FLYWHEEL

2) MAIN SWITCH

7) 5 A FUSE (No.3)

8) 15 A FUSE (No.4)

9) 30 A FUSE (No.5)

21) SIDE STAND SWITCH

28) IGNITION COIL

30) “C.D.I.”

32) RIGHT-HAND SWITCH (ENGINE STOP)

FAILURE DIAGNOSIS

If the ignition system stops working check:

1. The main 30A fuse, the 15A fuse and the 5A fuse

2. The battery

3. The spark plug

4. Plug cap resistance

5. Ignition coil

6. Pick-up resistance

7. Main switch

8. Engine stop switch

9. Side stand switch

10. Wiring connections

1. Fuses (30 A, 15 A, 5 A)

- Remove the relative fuse.

- Connect the Multimeter (



) to the fuse.

- Check fuse continuity.

- Fuse faulty: replace.

NO CONTINUITY

CONTINUITY

2. Battery

- Check battery conditions:

- a minimum voltage of 12.4 V

- density of the electrolytic solution: 1280 g/dm

3

NOT CONFORMING

- Clean the terminals.

- Top up with distilled water.

- Recharge or change the battery.

CONFORMING

B

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CHAPTER

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FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Ignition System

B - DIAGNOSTICS

4. Plug cap resistance

- Take the cap off.

NOTE: Do not pull when removing it.

- Removing Turn counter clockwise.

- Connection Turn clockwise.

- Check the HV cable before connecting the plug cap,

cutting it to about 5 mm.

- Connect the Multimeter (K



) to the spark plug cap as

follows:

- (+) Multimeter terminal Plug side (1).

- (-) Multimeter terminal H.V. cable side (2).

Plug cap resistance: 10 K



 at 20°C.

OUT OF SPEC

- Replace the plug

CORRECT VALUE

5. Ignition coil resistance

- Disconnect the cables and remove the plug cap from the

coil.

- Connect the Multimeter (



) to the coil as follows (see

figure):

- (+) Multimeter terminal Black terminal (1).

- (-) Multimeter terminal Green terminal (2).

- Check primary winding resistance.

- Primary winding resistance: 0.5÷0.7



 at 20°C.

NOTE: When reconnecting the cables be particularly

careful not to reverse them:

- Orange cable Black terminal (1).

- Black cable Green terminal (2).

1

2

1

2

- Faulty spark plug: replace.

CONFORMING

3. Spark plug

- Check plug conditions.

- Verify the type of plug.

- Check the distance between the electrode: 0.6÷0.7 mm.

NOT CONFORMING

0,6÷0,7 mm

B

06.05 19

ENGLISH

CHAPTER

EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Ignition System

B - DIAGNOSTICS

TO

SPEC

- Connect the Multimeter (K



) to the coil as follows (see

figure):

- (+) Multimeter terminal Spark plug cable (1).

- (-) Multimeter terminal Green terminal (2).

- Check secondary winding resistance.

- Secondary winding resistance: 2.1÷2.5 K



 at 20°C.

OUT OF SPEC

- Replace the ignition coil.

BOTH TO

SPEC

6. Pick-up resistance

- Disconnect the two-way connector on the magnetic

flywheel (3).

- Connect the Multimeter (



) to the magnetic flywheel

connector as follows:

- (+) Multimeter terminal Red cable (1).

- (-) Multimeter terminal Brown cable (2).

- Check pick-up coil resistance.

- Pick up resistance: 105÷110



 at 20°C.

OUT OF SPEC

- Replace the stator.

TO

SPEC

7. Main switch

- Disconnect the six-way switch connector (7) and connect

the Multimeter (



) as follows:

A

- (+) Multimeter terminal Black cable (1).

- (-) Multimeter terminal Yellow/white cable (2).

- Switch “ON” No continuity.

- Switch “OFF” Continuity.

B

- (+) Multimeter terminal Green/black cable (3).

- (-) Multimeter terminal Blue/black cable (4).

- Switch “ON” Continuity.

- Switch “OFF” No continuity.

C

- (+) Multimeter terminal Blue cable (5).

- (-) Multimeter terminal Blue/red cable (6).

- Switch “ON” Continuity.

- Switch “OFF” No continuity.

OUT OF SPEC

- Replace the main switch.

1

2

R

M

2

1

3

BL-R

BL

OFF

ON

BL-N

VR-N

N

BL

GL-B

BL-R

VR-N

BL-N

N

GL-B

62

1

5

4

3

7

B

20 06.05

ENGLISH

CHAPTER

PAGE EDITION

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Ignition System

B - DIAGNOSTICS

8. Engine stop switch

- Disconnect the six-way and two-way connectors of the

right-hand switch (3).

- Position the “Engine Stop” push button on the symbol

- Connect the Multimeter (



) as follows:

- (+) Multimeter terminal Yellow/blue cable (1).

- (-) Multimeter terminal Blue/white cable -

yellow/blue cable(2).

NO CONTINUITY

- Replace the right-hand switch.

CONTINUITY

9. Side stand switch

- Disconnect the two-way connector of the stand switch.

- Connect the Multimeter (



) as follows:

- (+) Multimeter terminal Terminal (1).

- (-) Multimeter terminal Terminal (2).

A) Stand on No continuity.

B) Stand off Continuity.

NOT CONFORMING

- Replace the side stand switch.

CONFORMING

10. Wiring connections

- Check the connections of the whole ignition system

- See “Circuit Diagram”.

FAULTY CONNECTIONS

- Repair wiring, consulting the “Circuit

Diagram”.

OK

- Replace the “C.D.I.”

0FF

ON

0FF

B-R

GL-N

RS

BL

N

GL-BL

B-BL

R

GL-N

RS

BL

B-R

N

GL-BL

GL-B

B-BL

R

START

MODE

LIGHTS

ENGINE STOP

3

1

2

N

2

1

B

06.05 21

ENGLISH

CHAPTER

EDITION PAGE

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Charging System

B - DIAGNOSTICS

15 A

5A

15 A

+

-

N

12V

.

12V

.

7.5 A

30 A

7.5 A

5A

0FF

ON

0FF

30 A

1

2

3

4

5

6

7

8

9

10

11

12

24

23

22

21 20

19

18

17

16

15

14

13

ON

0FF

ON

0FF

LO

HI

LUCI

HORN

PASSING

R

L

TURN

R

16

W

16

W

35 w

5

W

10

W

5

W

10

5

W

10

W

5

W

10

W

R

5

W

8

7

6

5

4

3

2

1

A

B

C

A

B

C

8

7

6

5

4

3

2

1

BL-R

BL

OFF

ON

BL-N

VR-N

N

BL

GL-B

BL-R

VR-N

BL-N

N

GL-B

R

M

A.T

BL

R

BL

R-VR

GL-N

RS

B-R

N

GL-B

GL-N

RS

BL

B-R

N

GL-BL

GL-V

GL-BL

B-BL

R

GL-N

RS

BL

B-R

N

GL-BL

GL-B

B-BL

R

BL

AZ-B

GL-N

B-N

VR

VL

M

AR

N

AZ-B

GL-N

B-N

VR

VL

M-N

AR

BL-N

B-GR

BL

R

AR

R

B-GR

M-N

VL

VR

M

MN

AZ-GR

M

AZ-GR

GL-V

A1

A4

A5

A6

A7

B3

B6

B8

C8

GL-R

GL-B

M-B

GL-N

B-BL

BL-N

B-N

AR

N

R

B-GR

B-N

BL-R

GL-VL

AZ-B

RS

N

B-R

GL-B

R-N

N

GL-B

N

AR

GL-VL

BL-R

GL

M-B

N

M-B

AR-R

B-VR

N

VR

GR

GL-BL

B

BL-N

N

VR

GL-N

B-N

BL-N

N

GL

B-BL

AR

GL

VR-N

AR-R

AR

BL

B-N

AZ-B

GL-N

B-N

M

VL

VR

AR

N

GL-B

BL-R

GL-BL

BL

R-N

RS

AZ-B

VR

GL-R

B-VR

GR

N

VL

B-N

R

B

B-N

AZ-B

RS

AZ-B AZ-B

B-N

RS

N

VL

R

RS

N

VR

VL

R

RS

N

VR

RS

N

RS

N

R

BL-R

N

VL

VR

N

VR

N

VL

85 85

86

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

N

R

86

DIODO 2 A

DIODO 2A

< RPM

<

RPM

>+12

<

PK+

<-12

>-12

PK-

>-12

>+12

1

2

3

4

5

7

6

8

9

11

10

12

13 14 15

16

17 20

18

19

21

22

23

24

N

25

26

27

28

29

30

31

323334

35

36

37

START

MODE

LIGHTS

ENGINE STOP

38

39

40

41

42

CHARGING SYSTEM CIRCUIT

B

22 06.05

ENGLISH

CHAPTER

PAGE EDITION

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

SECTION 2

Charging System

B - DIAGNOSTICS

ELECTRICAL COMPONENTS:

1) MAGNETIC FLYWHEEL

4) BATTERY

12) 30 A FUSE (No. 8)

41) VOLTAGE REGULATOR

FAILURE DIAGNOSIS

If the battery fails to recharge, check the:

1. Fuse (30 A)

2. Battery

3. Charging voltage

4. Stator coil resistance

5. Charging system wiring

1. Fuse (30 A)

- See paragraph “Controlling the switches (page 13).

2. Battery

- Remove the battery and connect the Multimeter (20 Vdc) as follows:

- (+) Multimeter terminal Battery (+) pole.

- (-) Multimeter terminal Battery (-) pole.

- If voltage is below 12.4 V recharging is necessary, utilising a suitable battery charger.

- Once the battery is charged leave it inactive for about 30 minutes and then measure voltage again.

- 12.8 V or more Charge completed.

- 12.5 V Still needs recharging.

- 12.0 V Replace the battery.

BATTERY OK

3. Verify charging voltage (use a charged battery)

- Connect the Multimeter (20 Vdc) to the battery as

follows:

- (+) Multimeter terminal Battery (+) pole.

- (-) Multimeter terminal Battery (-) pole.

- Start the engine at 5000 rpm.

- The resulting voltage should be: 13.40÷14.10 Volt.

TO SPEC

- The recharging circuit is efficient.

OUT OF SPEC

+

-

N

12V

.

12V

.

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Malaguti Password 250 Workshop Manual

Malaguti Password 250 Workshop Manual

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