Malaguti X3Motard Workshop Manual

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

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

3

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.

•

4

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.

•

X

SECTION TITLE

W

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).

•

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

•

8

4

3

2

1

41 40 33353739 34 32 29 2728

26

25

24

23

21191816159 131110

5

7

8

12 14 17 20

36

6

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

7

8

4

3

2

1

1 42 3

5

6

107 8 9

5

9

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

1

2

3

4

5

6

9

3

4

2

5

8

6

7

8

9

10

11

1

10

11

7

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

14

131415

21

12

13

17

18

19

20

16

15

161718

19

21

22

2012

22

14

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

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

•

16

C H E C K I N G S W I T C H E S

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”.

•

17

F. 1

F. 2

C H E C K I N G F U S E S

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.

•

18

NO

OK

NO

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.

•

Eliminate short-circuit.

Replace fuse.

•

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

3

.

•

Clean terminals.

Top up with distilled water.

Recharge or replace battery.

•

19

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.

•

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.

•

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.

•

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).

•

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).

•

Replace ignition coil.

6. Key switch

Disconnect key switch from system.

Turn key “ON”.

•

Connect Tester () and check continuity of key switch as follows:

Terminal (+) of Tester Orange cable (5).

Terminal (-) of Tester Green cable (6).

•

Replace key switch.

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