2
T A B L E O F C O N T E N T S
Pag.
Introduction 3
Manual updates 3
Notes for easy consultation 4
Page layout 4
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
Checking switches 11
Connection of switches described in this manual 11
Position of switches and continuity of contacts 12
Checking fuses 13
Location of electrical components 14
Ignition system 15
Faulty ignition 15
Electrical starting system 18
Faulty electrical starting system 18
Pag.
Recharging system 22
Battery cannot be charged 22
Lighting system 24
The entire lighting system does not work 24
Headlight does not work 27
Instrument board indicator light does not come on 28
Rear light does not come on 29
Signalling system 30
The entire signalling system does not work 30
Horn is not working 32
“Stop” light does work 34
Turn indicators and relative indicator light do not work 36
The mix oil signal does not work 38
Fuel reserve indicator light is not working 39
3
I N T R O D U C T I O N
Malaguti
No part of this publication, whether text or illustrations, may be reproducedMalaguti
FIRST EDITION: 06/08
INTRODUCTION
This publication describes all necessary steps for troubleshooting concerning the electrical system (Electronic Injection System) and of the possible service operations,
trade technicians (Authorised Service Centres) with the necessary information for operating in compliance with the
Further information can be derived from the “Chassis” workshop manual, from the “Engine” workshop manual and from the Spare Parts catalogue
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
For any further information you may need, refer to the Malaguti S.p.A.
MANUAL UPDATES
Any subsequent updates
The table of contents
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
X
W
I N T R O D U C T I O N
NOTES FOR EASY CONSULTATION
PAGE LAYOUT
MODIFIED PAGES
M, with the new date
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
EDITING SYMBOLS
Symbols have been provided for quick and easy reference
These symbols may appear next to a text (in which case they refer solely to the text itself), next to a gure
and to the relative text), or at the top of 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
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 re hazard.
DANGER OF EXPLOSION
Indicates operations which may constitute a risk of explosion.
TOXIC FUMES
Indicates a possibility of intoxication or inammation 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
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 specied, 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
TECHNICAL TERM DICTIONARY
V = (DC) : direct current (supply from battery)
V ~ (AC) : alternating current (supply from ywheel)
A: Ampere: the unit of electric current
W: Watt: the unit of electric power
(result of Volts by Amps A x V = W)
Ω: OHM: the unit of electrical resistance
Innite 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
ON
0FF
N
N
N
VL
VR
VL
AR
N
B-R
VR
VR
VL
VR
AR
HORN
R
L
TURN
BL
N
RELAIS
BA
TTERIA
BL
B-R
R
+
-
N
BL-R
N
N
M
R
BL
BL
R
BL
VL
VR
N
10
W
10
W
W
15
W
15
W
VL
AR
VL
RS
VR
VL
BL
M-N
M-N
N
AR
BL-R
BL-R
R
GL
R-VR
R-VR
N
BL
B
GR
N
B-AZ
M-
N
N
NN
N
VR
VL
R
RS
10 A
7.5
A
RS
RS
RS
N
N
VR
N
GL
+
M-N
AR
AZ
GR
M
AZ
12V
4 Ah
N
B-VR
N
GL-B B
GL-B
A.T
.
B
R/VR
N
B/VR
B
B/AZ
GL
B/VR
R/N
R/VR
B/AZ
N
GL
B
B-AZ
B-VR
AR
AR
N
N
>
>
<
>
R-VR
N
GL
BL-R
Tegolo
BL-R
N
ON
0FF
N
AZ
-B
AZ
GL
-R
ON
0FF
-R
G
L
AZ
GL
-N
G
AZ
-B
N
LIGHTS START
N
GL-B
N
BL
-R
B
BL
B-N
R
GR
M
LOCK
OFF
CHECK
ON
B
-
N
NN
R
M
GR
*
VLV
VRV
B
RSR
GR
R
N
58
54
10
N
W
10
VR
B
VL
GR
VRV
RSR
BL
N
GL
RS
R
-
N.c.
+
<
<
<
<
<
<
<
<
<
<
<
<
>
<
<
>
S
+
W
2
5
2
W
+
+
GL
R/VR
N
B/AZ
B/VR
B
071128
GL-VR
N.c.
21W
5W
ON
0FF
N
N
N
VL
VR
VL
AR
N
B-R
VR
VR
VL
VR
AR
HORN
R
L
TURN
BL
N
RELAIS
BA
TTERIA
BL
B-R
R
+
-
N
BL-R
N
N
M
R
BL
BL
R
BL
VL
VR
N
10
W
10
W
W
15
W
15
W
VL
AR
VL
RS
VR
VL
BL
M-N
M-N
N
AR
BL-R
BL-R
R
GL
R-VR
R-VR
N
BL
B
GR
N
B-AZ
M-
N
N
NN
N
VR
VL
R
RS
10 A
7.5
A
RS
RS
RS
N
N
VR
N
GL
+
M-N
AR
AZ
GR
M
AZ
12V
4 Ah
N
B-VR
N
GL-B B
GL-B
A.T
.
B
R/VR
N
B/VR
B
B/AZ
GL
B/VR
R/N
R/VR
B/AZ
N
GL
B
B-AZ
B-VR
AR
AR
N
N
>
>
<
>
R-VR
N
GL
BL-R
Tegolo
BL-R
N
ON
0FF
N
AZ
-B
AZ
GL
-R
ON
0FF
-R
G
L
AZ
GL
-N
G
AZ
-B
N
LIGHTS START
N
GL-B
N
BL
-R
B
BL
B-N
R
GR
M
LOCK
OFF
CHECK
ON
B
-
N
NN
R
M
GR
*
VLV
VRV
B
RSR
GR
R
N
58
54
10
N
W
10
VR
B
VL
GR
VRV
RSR
BL
N
GL
RS
R
-
N.c.
+
<
<
<
<
<
<
<
<
<
<
<
<
>
<
<
>
S
+
W
2
5
2
W
+
+
GL
R/VR
N
B/AZ
B/VR
B
071128
GL-VR
N.c.
21W
5W
4
2
1
19 18
16
15
14
12
9
7
5
6
13
3
8
10
11
17
202122232425262728
G E N E R A L W I R I N G D I A G R A M
9
G E N E R A L W I R I N G D I A G R A M
KEY TO GENERAL WIRING DIAGRAM
1) ELECTRICAL STARTER
2) FLYWHEEL MAGNETO
3) HORN WITH SHIELDING
5) STOP SWITCH
6) LEFT HAND SWITCH
7) FRONT LEFT TURN INDICATOR
8) DOUBLE HEADLIGHT
9) FRONT RIGHT TURN INDICATOR
10) INSTRUMENT BOARD
11) PROVISION FOR ALARM SYSTEM
12) KEY SWITCH
13) RIGHT HAND SWITCH
14) STOP SWITCH
15) CAPACITOR, 50 V - 2200 UF
16) CDI CONTROL UNIT
17) VOLTAGE REGULATOR
18) COIL
19) FUEL LEVEL SENSOR
20) OIL INDICATOR SWITCH
21) REAR RIGHT TURN INDICATOR
22) PARKING LIGHT, 5 W
23) REAR LEFT TURN INDICATOR
24) STARTER MOTOR
25) RELAY
26) FUSE, 10 A
28) 12 V BATTERY
10
G E N E R A L W I R I N G D I A G R A M
COLOUR KEY
AR ORANGE
AZ LIGHT BLUE
AZ-B LIGHT BLUE - WHITE
B WHITE
B-VR WHITE - GREEN
B-BL WHITE - BLUE
B-R WHITE - RED
B-VL WHITE - PURPLE
BL BLUE
BL-VR BLUE - GREEN
BL-R BLUE - RED
GL YELLOW
GL-B YELLOW - WHITE
GL-VR YELLOW - GREEN
GL-R YELLOW - RED
GR GREY
M BROWN
M-N BROWN - BLACK
M-B BROWN - WHITE
N BLACK
N-R BLACK - RED
R RED
R-VR RED - GREEN
RS PINK
VL PURPLE
VR GREEN
11
C H E C K I N G S W I T C H E S
CHECKING PROCEDURES
Using a Tester (Code n°08611200), check the switches by making sure that there is
Replace the switch, even if only one of the possible combinations does not give the
Select “Ω” (ohm) function of tester; sound-emitting function.
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,
The “
In this diagram:
“BL-B” and “R”: there is continuous contact when the switch is “ON”.
•
•
•
•
12
3
2
1
1 42 3
5
6
7
6
10
7
8
C H E C K I N G S W I T C H E S
POSITION OF SWITCHES AND CONTINUITY OF CONTACTS
POS. SWITCHES
1 REAR STOP SWITCH
2 TURN INDICATOR SWITCH
3 HORN CONTROL
4 FRONT STOP SWITCH
5 LIGHT SWITCH
6 “START” SWITCH
7 KEY SWITCH
NOTE
3
2
1
4
7
5
6
13
A B
C H E C K I N G F U S E S
When checking or replacing fuses, always turn the main switch
“OFF” or short-circuits may occur.
Checking procedure:
Put the Tester on “Ω” (sound-emitting function).
Replacing procedure:
Turn key “ON”
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 res
to break out.
•
•
•
•
•
•
•
•
•
14
5
9
1
2
3
4
76 8 10
11
12
13
1
2
3
4
5
6
7
11
13
10
12
8
9
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
9 Battery
10 Capacitor (50 V - 2200 UF)
11 Fuel level sensor
12 Connector for anti-theft system
13 Stator connector
1 Oil indicator switch
2 Horn
3 Flashlight
4 Voltage regulator
5 “CDI” control unit
6 Starting relay
7 Wire terminals for connection to ground
8 HV coil
15
NO
OK
OK
NO
Tester (KΩ)
1
2
I G N I T I O N S Y S T E M
FAULTY IGNITION
Check:
1. Condition of spark plug
•
•
2. Spark plug cap resistance
NOTE: when removing spark plug cap, avoid pulling it.
To remove
To connect turn clockwise
Terminal (+) of Tester Spark plug side (1)
Terminal (-) of Tester
•
•
•
•
•
•
•
•
•
16
NO
OK
NO
OK
OK
Tester (Ω)
Tester KΩ
Tester Ω
1
Tester (KΩ)
2
I G N I T I O N S Y S T E M
3. Coil H. V.
A) Primary winding resistance
Connect
Compliant: 0.6 ÷ 0.9 Ω at 20° C
•
•
B) Secondary winding resistance
Connect
Tester (KΩ)
Compliant: 3.30 ÷ 3.60 KΩ at 20° C
•
•
4. Resistance of stator pick-up•
•
Connect
Tester (KΩ).
Terminal (+) of Tester White/Green
Terminal (-) of Tester White/Light blue cable (2)
•
•
•
Pick-up resistance:
400 ÷ 460 Ω at 20°C•
17
NO
OK
NO
OK
OK
2
Tester (KΩ)
1
OK NO
I G N I T I O N S Y S T E M
5. Control unit power supply
Connect Tester (K Ω).
Terminal (+) of Tester Red/Black cable (1)
Terminal (-) of Tester Engine grounding (2)
Resistance: 790 ÷ 850 Ω at 20° C
•
•
•
•
•
6. Key switch•
Turn key “OFF” and then “ON
Tester (Ω)
•
•
•
7. Connections of ignition system
•
•
Replace “CDI” control unit (code n°: 02415700
18
NO
OK
NO
OK
E L E C T R I C A L S T A R T I N G S Y S T E M
FAULTY ELECTRICAL STARTING SYSTEM
Check:
1. Fuse, 10 A
Connect Tester (Ω)
•
•
•
•
2. Battery
Minimum voltage: 12.5 V
Density of electrolytic solution: 1280 g/dm
3
•
•
•
19
OK
NO
OK
NO
OK
2
1
3
1
4
E L E C T R I C A L S T A R T I N G S Y S T E M
3. Starter motor
Use a bridge cable (3) to connect the positive battery terminal (1) to the cable of the starter motor (2), as shown
•
•
To connect, use cables that are compatible with the power draw of the starter motor.
4. Starter relay
Connect the battery to the terminals of the starter relay (4) using bridge cables (1)
Pole (+) of battery Red
Pole (-) of battery White/Red
•
•
•
•
20
NO
OK
NO
OK
Tester (Ω)
OK
A
1
2
1) Leva freno
2) Leva freno
E L E C T R I C A L S T A R T I N G S Y S T E M
5. Key switch
Turn key “OFF” and then “ON
Tester (Ω)
•
•
•
6. Front/rear “Stop” switch
Disconnect cables of switch (A)
Connect Tester (Ω)
•
•
•
•
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
-
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
-
32
-
33
-
34
-
35
-
36
-
37
-
38
-
39
-
40
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
Related papers
-
Malaguti X3Mnourd Workshop Manual
-
-
-
-
-
-
-
-
-
Other documents
-
KYMCO 125 AGILITY CITY - User manual
-
Yamaha MAJESTY YP250 User manual
-
Arctic Cat DVX 300 2014 User manual
-
Yamaha T-50 User manual
-
-
Kawasaki 1993 KLX650 User manual
-
-
-
Suzuki DF15 User manual
-