Malaguti X3Mnourd Workshop Manual

Malaguti
Brand
Malaguti
Model
X3Mnourd
Category
Signal cables
Type
Workshop Manual

This manual is also suitable for

2
T A B L E O F C O N T E N T S
TABLE OF CONTENTS
Page
Introduction 3
Manual updates 3
Notes for easy consultation 4
Page layout 4
Modifi ed pages 4
Additional pages 4
Editing symbols 4
Abbreviations 6
Technical term dictionary 7
General wiring diagram 8
Key to general wiring diagram 9
Colour key 10
Instrument board connector confi guration 11
Continuity of contacts 12
Location of electrical components 13
Checking connectors 15
Checking switches 16
Connection of switches described in this manual 16
Checking fuses 17
Checking fuses 17
Ignition system 18
Faulty ignition 18
Page
Electrical starting system 22
Faulty electrical starting system 22
Recharging system 27
Battery cannot be charged 27
Lighting system 30
The entire lighting system does not work 30
The low beam light, high beam light and relative indicator lights do not come on
33
Rear light does not come on 35
Signalling system 36
Horn is not working 36
Stop light does not work 38
Turn indicators and relative indicator lights do not work 40
Right/left turn indicators do not work 42
Neutral indicator light does not come on 43
Display functions cannot be changed 44
Rev counter is not working 46
Reserve warning light does not come on 47
Heat sensor circuit system 49
General matters 49
Checking “PTC” heater circuit and heat sensor 49
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I N T R O D U C T I O N
INTRODUCTION
Malaguti reserves the right to make any and all changes to its vehicles as it deems fi t and appropriate at any time without prior notice.
No part of this publication, whether text or illustrations, may be reproduced or circulated either totally or partially. Malaguti reserves all rights over this publication.
Reasons must be given for any request for permission (written) thereto.
FIRST EDITION: 04/08
INTRODUCTION
This publication describes all necessary steps for troubleshooting concerning the electrical system (Electronic Injection System) and of the possible service operations,
which are necessary for their solution. It supplies the trade technicians (Authorised Service Centres) with the necessary information for operating in compliance with the
modern concepts of “good practice” and “safety at work”.
Further information can be derived from the “Chassis” workshop manual, from the “Engine” workshop manual and from the Spare Parts catalogue.
All described operations must be performed by technicians with the necessary skill and experience.
The steps for the removal of body parts and of electric and mechanical components, to allow access to wiring or electric components to service, can be taken from the
“Chassis” Workshop Manual.
We recommend you follow the information given in this publication with care.
For any further information you may need, refer to the Malaguti S.p.A. Technical Department.
It is essential to follow the instructions with great care. Work carried out carelessly or, worse still, work that has not been accomplished, can cause injuries and damage or,
in the less serious cases, tiresome complaints.
MANUAL UPDATES
Any subsequent updates applying to this Manual will be sent in a reasonable time.
The table of contents will be duly updated in the event that new pages are inserted, which render the consultation of the manual diffi cult.
The Electrical System Troubleshooting Manual is to be considered as an essential tool to be properly kept up-to-date so as to maintain its “validity”
over time.
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NUMERO DI PAGINA
T I T O L O S E Z I O N E
TITOLO SEZIONE
X
W
I N T R O D U C T I O N
INTRODUCTION
NOTES FOR EASY CONSULTATION
PAGE LAYOUT
MODIFIED PAGES
Modifi ed pages shall bear the same number as those in the previous edition, followed by the letter M, with the new date of issue appearing in the appropriate box.
Modifi ed pages may contain new illustrations; in this case, the added illustration (or illustrations) will bear the number of the illustration on the former page, followed by a
letter.
ADDITIONAL PAGES
Any additional pages shall bear the last number of the section to which they belong, followed by the letter A and the new date of issue.
EDITING SYMBOLS
Symbols have been provided for quick and easy reference (P. 5), identifying situations requiring utmost attention or providing practical suggestions or simple
information.
These symbols may appear next to a text (in which case they refer solely to the text itself), next to a fi gure (in which case they refer to the topic illustrated in the fi gure
and to the relative text), or at the top of the page (in which case they refer to all the topics dealt with in the page).
The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations. They
are therefore to be considered as veritable “memory tags”. In case of any doubt as to their meaning, consult the Page in which they are fully described.
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SECTION TITLE
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PAGE NUMBER
5
I N T R O D U C T I O N
INTRODUCTION
NOTE
Recommendations and precautions regarding rider safety and motor vehicle integrity.
CAUTION!
Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment,
vehicle or equipment.
FIRE HAZARD
Indicates operations which may constitute a fi re hazard.
DANGER OF EXPLOSION
Indicates operations which may constitute a risk of explosion.
TOXIC FUMES
Indicates a possibility of intoxication or infl ammation of the upper respiratory tract.
MECHANICAL MAINTENANCE
Operations to be performed only by an expert mechanic.
ELECTRICAL MAINTENANCE
Operations be performed only by an expert electrical/electronic technician.
NO!
Operations to be absolutely avoided.
M
ENGINE WORKSHOP MANUAL
Indicates information which may be obtained by referring to said document.
R
SPARE PARTS CATALOGUE
Indicates information which may be obtained by referring to said document.
6
A
I N T R O D U C T I O N
INTRODUCTION
ABBREVIATIONS
F Figure
Cs Tightening torque
P Page
Pr Paragraph
S Section
Sc Diagram
T Table
V Screw
The letter V in the illustrations refers to retaining or adjusting screws.
The number following this letter refers to the number of the same type
of screw in the unit or component described and illustrated. Letters not
followed by a number indicate a single screw. In case of different
screws being referred to in the illustration, the letter V is followed by a
number and a small letter, for instance: (V4a).
Unless otherwise specifi ed, units and components are reassembled by
proceeding in the reverse order of removal.
Before any servicing, make sure that the vehicle is perfectly
stable.
The front wheel should preferably be anchored to the equipment
integral with the lifting board (A).
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7
I N T R O D U C T I O N
INTRODUCTION
TECHNICAL TERM DICTIONARY
V = (DC) : direct current (supply from battery)
V ~ (AC) : alternating current (supply from fl ywheel)
A: Ampere: the unit of electric current
W: Watt: the unit of electric power
(result of Volts by Amps A x V = W)
: OHM: the unit of electrical resistance
Infi nite OHM: tester prods disconnected or cable interrupted
OHM = 0: continuity with tester prods connected and cable not interrupted
PIN: connector terminal
Line: cable between two PINS
< : less than
<: less than or equal to
> : greater than
> : greater than or equal to
KPa (or bar): the unit of pressure (100 KPa = 1 bar)
÷ : from - to
~ : approximately
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1
41 40 33353739 34 32 29 2728
26
25
24
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21191816159 131110
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7
8
12 14 17 20
36
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38 30
31
22
G E N E R A L W I R I N G D I A G R A M
GENERAL WIRING DIAGRAM
9
G E N E R A L W I R I N G D I A G R A M
GENERAL WIRING DIAGRAM
KEY TO GENERAL WIRING DIAGRAM
1) BATTERY
2) “CDI” CONTROL UNIT
3) FLYWHEEL MAGNETO
4) HORN
5) CHASSIS GROUND CONNECTION
6) REGULATOR GROUND CONNECTION
7) FLASHLIGHT
8) CLUTCH SWITCH
9) LEFT HAND CONTROL UNIT
10) “MODE” BUTTON
11) LIGHT CONTROL
12) TURN INDICATOR CONTROL
13) HORN CONTROL
14) FRONT LEFT TURN INDICATOR
15) LOW BEAM / HIGH BEAM LIGHT
16) PARKING LIGHT
17) FRONT RIGHT TURN INDICATOR
18) INSTRUMENT BOARD
19) KEY SWITCH
20) RIGHT HAND CONTROL UNIT
21) START BUTTON
22) “ENGINE STOP” BUTTON
23) FRONT STOP SWITCH
24) SPEEDOMETER SENSOR
25) REGULATOR
26) HEAT SENSOR
27) “PTC” FUEL HEATER
28) COIL
29) FUEL RESERVE SENSOR
30) LIGHT RELAY
31) DIODE BRIDGE
32) REAR RIGHT TURN INDICATOR
33) NUMBER PLATE LIGHT
34) TAIL AND STOP LIGHT
35) REAR LEFT TURN INDICATOR
36) REAR STOP SWITCH
37) STARTER MOTOR
38) DIODE SET
39) SIDE STAND SWITCH
40) STARTER RELAY
41) FUSE, 15 A
10
G E N E R A L W I R I N G D I A G R A M
GENERAL WIRING DIAGRAM
COLOUR KEY
AR ORANGE
AZ LIGHT BLUE
AZ-B LIGHT BLUE - WHITE
AZ-GR LIGHT - BLUE GREY
B WHITE
B-N WHITE - BLACK
B-VR WHITE - GREEN
B-M WHITE - BROWN
B-R WHITE - RED
B-VL WHITE - PURPLE
BL BLUE
BL-B BLUE - WHITE
BL-GL BLUE - YELLOW
BL-N BLUE - BLACK
BL-R BLUE - RED
GL YELLOW
GL-B YELLOW - WHITE
GL-N YELLOW - BLACK
GL-VR YELLOW - GREEN
GL-R YELLOW - RED
GR GREY
GR-R GREY - RED
M BROWN
M-N BROWN - BLACK
N BLACK
R RED
RS PINK
VL PURPLE
VR GREEN
VR-GL PURPLE - YELLOW
VR-N GREEN - BLACK
R-N RED - BLACK
RS-N PINK - BLACK
11
G E N E R A L W I R I N G D I A G R A M
GENERAL WIRING DIAGRAM
INSTRUMENT BOARD CONNECTOR CONFIGURATION
PIN CABLE COLOUR FUNCTION PIN CABLE COLOUR FUNCTION
1N NEGATIVE (-) 10 - -
2VRRIGHT HAND TURN INDICATOR 11 B-N HIGH BEAM LIGHT
3VLLEFT HAND TURN INDICATOR 12 - -
4 GL-R HALL SENSOR INPUT 13 - -
5R MODE BUTTON SIGNAL 14 BL + 12 V WITH KEY ON
6GR FUEL WARNING LIGHT 15 R-N NEUTRAL WARNING LIGHT
7- - 16 BL-R +12 V WITH KEY OFF
8 B-VR RPM 17 GL-VR HALL SENSOR CDD
9RS PARKING LIGHTS 18 BL-N HALL SENSOR VDC
12
6
10
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8
4
3
2
1
1 42 3
5
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107 8 9
5
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11
11
CLOSE
OPEN
C H E C K I N G S W I T C H E S
CHECKING SWITCHES
CONTINUITY OF CONTACTS
POS. SWITCHES
1 MODE BUTTON
2 LIGHT SWITCH
3 TURN INDICATOR SWITCH
4 HORN CONTROL
5 CLUTCH SWITCH
6 FRONT STOP SWITCH
7 ENGINE START SWITCH
8 ENGINE STOP SWITCH
9 KEY SWITCH
10 REAR STOP SWITCH
11 SIDE STAND SWITCH
13
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L O C A T I O N O F E L E C T R I C A L C O M P O N E N T S
LOCATION OF ELECTRICAL COMPONENTS
1 Thermal switch
2 Horn
3 “PTC” fuel heater
4 Neutral switch
5 Side stand switch
6 HV coil
7 Starter relay
8 Fuse 15 A
9 Flashlight
10 Regulator
11 Fuel probe
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131415
21
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17
18
19
20
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161718
19
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2012
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L O C A T I O N O F E L E C T R I C A L C O M P O N E N T S
LOCATION OF ELECTRICAL COMPONENTS
12 Digital instrument board
13 Key switch
14 Clutch switch
15 Battery
16 Diode set
17 Light relay
18 CDI control unit
19 Diode bridge
20 Front stop switch
21 Rear stop switch
22 Stator connectors
15
C H E C K I N G C O N N E C T O R S
CHECKING CONNECTORS
CHECKING CONNECTORS
Check connectors for corrosion and damp.
Disconnect connectors.
Dry terminals with compressed air.
Connect and disconnect connector two or three times.
Pull connector to make sure it is correctly plugged in.
If terminal is disconnected, bend stop (A) and refi t terminal in connector.
The “click” sound means that all connector parts are correctly
assembled.
Plug in connectors.
Check continuity (Tester ).
If there is no continuity, clean terminals.
As a temporary solution, use a contact cleaner.
Follow the instructions provided above to check the electrical
equipment.
Use Tester as shown in the illustration
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C H E C K I N G S W I T C H E S
CHECKING SWITCHES
CHECKING SWITCHES
CHECKING PROCEDURES
Using a tester (Code n°08611200), check the switches by making sure that there is
continuity between terminals and that they are correctly connected.
Replace the switch, even if only one of the possible combinations does not give the
requested result.
Select “Ω” (ohm) function of tester; sound-emitting function.
Using the tester in “” mode, you can also check integrity of the lamps.
CONNECTION OF THE SWITCHES DESCRIBED IN THIS MANUAL
This manual contains connection diagrams, like the one illustrated hereby, which
illustrate how switch terminals should be connected (key switch, brake switch,
MODE button, etc.).
The fi rst column from the left indicates the different positions of the switches; the
top line indicates the colour of the wires connected to the switch terminals.
The “ ” symbol identifi es terminals in which there is a condition of continuity, i.e.
a closed circuit, in a certain position of the switch.
In this diagram:
“BL-B” and “R”: there is continuous contact when the switch is “ON”.
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F. 1
F. 2
C H E C K I N G F U S E S
CHECKING FUSES
CHECKING FUSES
When checking or replacing fuses, always turn the main switch
“OFF” or short-circuits may occur.
Checking procedure:
Connect Tester (code n°08611200) to fuse and check continuity.
Put the Tester on “Ω” (sound-emitting function).
If the tester is showing “I” and no sound is given, replace the fuse.
Replacing procedure:
Turn key “OFF”.
Fit a new fuse with a correct amperage rating.
Turn key “ON”
Turn all switches on to check operation of the relative electrical systems.
If the fuse blows again, check the relative circuit.
Never use fuses with an amperage rating differing from that
indicated. Use only fuses and never other materials. An unsuitable
fuse can cause extensive damage to the electrical system,
malfunctioning of the ignition and light systems and even fi res
to break out.
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18
NO
OK
OK
NO
2
2
1
Tester ()
F. 3
F. 4
1
I G N I T I O N S Y S T E M
IGNITION SYSTEM
FAULTY IGNITION
Check:
1. Fuse, 15 A
2. Battery
3. Spark plug
4. Spark plug cap resistance
5. HV coil resistance
6. Key switch
7. Pick-up resistance
8. Ignition system connections
1. Fuse 15 A
Remove relative fuse.
Connect Tester () to fuse.
Check continuity of fuse.
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Eliminate short-circuit.
Replace fuse.
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2. Battery
Check condition of battery:
Terminal (+) of Tester Battery (+) pole (1).
Terminal (-) of Tester Battery (-) pole (2).
If voltage level is lower than 12.4 V, recharge using a suitable battery charger.
After charging the battery, do not use it for approximately 30 minutes; now measure voltage level again.
12.8 V or more Battery is charged.
12,5 V Battery needs to be recharged.
12,0 V or less Replace battery.
Density of electrolytic solution: 1280 g/dm
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Clean terminals.
Top up with distilled water.
Recharge or replace battery.
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NO
OK
NO
OK
Tester ()
2
1
OK
F. 5
I G N I T I O N S Y S T E M
IGNITION SYSTEM
3. Spark plug
Check condition of spark plug.
Check type of spark plug.
Check gap between electrodes.
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Gap between electrodes: 0.7 mm.•
Replace spark plug:
NGK CR7HSA or DENSO U22 FSR-U.
4. Spark plug cap resistance
Remove spark plug cap.
To remove, turn anti-clockwise.
To connect, turn clockwise.
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Connect tester ().
Terminal (+) of Tester Spark plug cable side (1).
Terminal (-) of Tester Spark plug side (2).
When connecting, check spark plug cable and if necessary replace it with a new one.
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Spark plug cap resistance: 5k ± 20% at 20°C.•
Replace spark plug cap.
20
NO
OK
NO
OK
5
6
Tester ()
OK
Tester ()
1
2
Tester k
1
3
Tester
F. 6
F. 7
F. 8
I G N I T I O N S Y S T E M
IGNITION SYSTEM
5. HV coil resistance
Disconnect orange cable.
Connect Tester () to HV coil.
Check resistance of coil’s primary winding: 0.9 ± 10% at 20°C.
Terminal (+) of Tester Terminal (1).
Terminal (-) of Tester Ground (2).
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Check resistance of coil’s secondary winding: 7.30 K ± 10% at 20°C.
Terminal (+) of Tester Terminal (1).
Terminal (-) of Tester Spark plug cable (3).
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Replace ignition coil.
6. Key switch
Disconnect key switch from system.
Turn key “ON”.
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Connect Tester () and check continuity of key switch as follows:
Terminal (+) of Tester Orange cable (5).
Terminal (-) of Tester Green cable (6).
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Replace key switch.
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Malaguti X3Mnourd Workshop Manual

Malaguti
Brand
Malaguti
Model
X3Mnourd
Category
Signal cables
Type
Workshop Manual
This manual is also suitable for
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