Malaguti Password 250 Workshop Manual

ELECTRICAL SYSTEM

DIAGNOSTICS

B

PASSWORD 250

WORKSHOP MANUAL

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

INDEX

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

CHAPTER

B

ENGLISH

0505 3

EDITION PAGE

SECTION 1

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

INTRODUCTION

• 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.

FIRST EDITION: 06/05

CHAPTER

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.

B

• 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.

ENGLISH

06.05 5

EDITION PAGE

SECTION 1

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

B

CHAPTER

CONSULTATION NOTES

PAGE CONFIGURATION

B - DIAGNOSTICS

INTRODUCTION

ENGLISH

Y Chapter

X Section title

W Page No.

Z Edition date

(RH PAGE)

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.

X

Z

Y

W

• 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.

6 06.05

PAGE EDITION

SECTION 1

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

INTRODUCTION

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.

CHAPTER

A

B

C

B

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.

ENGLISH

D

E

F

G

H

I) ENGINE WORKSHOP MANUAL Information that can be

gleaned from this manual.

I

M

L) SPARE PARTS CATALOGUE

Information that can be gleaned from this documentation.

L

R

06.05 7

EDITION PAGE

SECTION 1

B

ENGLISH

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

ABBREVIATIONS USED

F Figure

Cs Tightening torque

P Page

Pr Paragraph

S Section

Sc Diagram

T Table
V Screw

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).

INTRODUCTION

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.

A

8 06.05

PAGE EDITION

SECTION 1

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

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 - DIAGNOSTICS

Electrical Components

CHAPTER

B

ENGLISH

16 1315

8

1

9

10

2

3

11

12

4

67

5

14

4

3

2

1

14

12

11

10

9

2

06.05 9

EDITION PAGE

13

15 16

8765

SECTION 2

B

+

-

N

12V

.

0FF

35 w

35 w

35 w

35 w

AZ-GR

GL-B

BL-N

BL-R

DIODO 2A

<

RPM

>+12

<-12

>-12

ENGINE STOP

CHAPTER

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

General Wiring Diagram

ENGLISH

GL

A.T

GL-B

GL-R

27

N

AR

GL

VR

N

>-12

PK-

>-12

<-12

PK+

<

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

GL-N

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

AZ-B

BL-R

MODE

ENGINE STOP

START

GL-R

GL-BL

GL-B

LIGHTS

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8

9

21 20
22

10

23

11

24

12

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

W

10

W

N

N

W

RS

RS

5

5

18

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

R-N

N

N

N

W

5

35 w

RS

35 w

B-N

36

B-N

RS

W

N

5

38

39

35 w

AZ-B AZ-B

35 w

N

N
AR

HORN

0FF

ON

VL

M

VR

TURN

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

R

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

BL-R

1

BL-R

BL

BL-R

GL-VL

N

BL

BL-N

VR-N

BL-R

GL-B

ON

OFF

GL-B

BL

VR-N

N

BL-N

2

BL

AR

3

GL

AZ-GR

R

BL-R

GL-V

AZ-GR

R-VR

BL

B-BL

GL-B

BL-N

GL-B

R

R

15
7

AR

AZ-GR

5

13

AZ-GR

GL-VL

11

3

BL

B-GR

9

1

4

AR

86

AR-R

B-R

85 85

86

B-R

R

B-R

R

8

30 A

16

7.5 A

11

14
6

30 A

9

4

12

5A

7

2

10

15 A

5

.

13 14 15

BL

12

5A

10

15 A

8

7.5 A

6

R

R

12V

10 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

General Wiring Diagram

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

CHAPTER

B

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

ENGLISH

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

1

234567

13

06.05 11

EDITION PAGE

14

15 16

17

18 19

24 PIN

8

9

10 11 12

21 22 23 24

20

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

B

CHAPTER

GENERAL WIRING DIAGRAM LEGEND

B - DIAGNOSTICS

General Wiring Diagram

ENGLISH

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

39) REAR STOP SWITCH

40) FLASHER RELAY

41) REGULATOR

42) ANTI-THEFT PREDISPOSITION

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

12 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Controlling the Switches

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.



.



CHAPTER

B

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.

ENGLISH

06.05 13

EDITION PAGE

SECTION 2

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

B

CHAPTER

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.

Controlling the Switches

ENGLISH

NOTE: Put the Multimeter selector on “

- 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.



” (sound function)









14 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Controlling the Switches

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

CHAPTER

B

0FF

ON

HI

LO

R

B-GR

B-N

AR

N

GL-N

1

3

AZ-B

1

6 7

8

9

10

11

13

ENGLISH

2

4325

12

5

M

VL

0FF

BL

B-N

4

VR

R

ON

L

6

GL-N

RS

RS

BL

7

B-R

8

N

GL-BL

9

GL-B

0FF

R

B-GR

B-BL

10

R

N

GL-B

BL-N

VR-N

BL

11

BL-R

0FF

OFF

ON

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.

06.05 15

EDITION PAGE

ON

ON

N

N

SECTION 2

12

N

13

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

N

12V

.

35 w

35 w

35 w

35 w

BL-N

BL-R

B-GR

AZ-GR

AZ-GR

AZ-GR

GL-B

BL-R

GL-BL

BL-N

BL-N

GL-R

DIODO 2A

<

RPM

ENGINE STOP

B

CHAPTER

IGNITION SYSTEM CIRCUIT

B - DIAGNOSTICS

Ignition System

ENGLISH

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

GL-R

AZ-B

BL-R

GL-B

35 w

35 w

TURN

MODE

ENGINE STOP

START

GL-BL

35 w

35 w

LIGHTS

N

B-N

B-N

N

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

R-N

N

N

W

RS

5

36

RS

W

N

5

AZ-B AZ-B

38

N
AR

HORN

0FF

ON

VL

M

VR

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

W

10

W

N

N

W

RS

RS

5

5

18

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

B-BL

GL-B

BL-N

GL-B

BL-R

BL

BL-R

GL-VL

N

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

1

BL

BL-N

VR-N

BL-R

GL-B

BL

AR

ON

OFF

GL-B

BL

BL-R

VR-N

N

BL-N

2

3

GL

AZ-GR

R

BL-R

GL-V

AZ-GR

R-VR

BL

R

R

15
7

AR

AZ-GR

5

13

AZ-GR

GL-VL

11

3

BL

B-GR

9

1

4

AR

86

AR-R

B-R

85 85

86

B-R

R

B-R

R

8

30 A

16

7.5 A

11

14

6

30 A

9

4

12

5A

7

2

10

15 A

5

.

13 14 15

BL

12

5A

10

15 A

8

7.5 A

6

R

R

12V

16 06.05

PAGE EDITION

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

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

B - DIAGNOSTICS

Ignition System

CHAPTER

B

ENGLISH

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

- Remove the relative fuse.

- Connect the Multimeter (

- Check fuse continuity.

2. Battery

- Check battery conditions:

- a minimum voltage of 12.4 V

- density of the electrolytic solution: 1280 g/dm



) to the fuse.



CONTINUITY

CONFORMING

NO CONTINUITY

- Fuse faulty: replace.

NOT CONFORMING

3

- Clean the terminals.

- Top up with distilled water.

- Recharge or change the battery.

06.05 17

EDITION PAGE

SECTION 2

B

CHAPTER

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Ignition System

ENGLISH

3. Spark plug

- Check plug conditions.

- Verify the type of plug.

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

CONFORMING

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
follows:

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

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

Plug cap resistance: 10 K



) to the spark plug cap as





 at 20°C.



0,6÷0,7 mm

NOT CONFORMING

- Faulty spark plug: replace.

2

1

OUT OF SPEC

CORRECT VALUE

5. Ignition coil resistance

- Disconnect the cables and remove the plug cap from the
coil.

- Connect the Multimeter (
figure):

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

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

- Check primary winding resistance.

- Primary winding resistance: 0.5÷0.7

NOTE: When reconnecting the cables be particularly
careful not to reverse them:

- Orange cable Black terminal (1).

- Black cable Green terminal (2).



) to the coil as follows (see





 at 20°C.



- Replace the plug

1

2

18 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Ignition System

CHAPTER

B

- 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.



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.



1

OUT OF SPEC

- Replace the ignition coil.

3

1

R

M

2

OUT OF SPEC

2

ENGLISH

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.

- Replace the stator.

BL-N

VR-N

BL

GL-B

BL-R

OFF

ON

N

7

GL-B

BL-R

VR-N

BL-N

3

4

62

BL

N

5

1

OUT OF SPEC

TO

SPEC

- Replace the main switch.

06.05 19

EDITION PAGE

SECTION 2

B

GL-N

ENGINE STOP

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

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

Ignition System

B-BL

R

GL-B

START

B-R

N

ENGINE STOP

GL-BL

0FF

ON

MODE

GL-N

BL

RS

RS

LIGHTS

0FF

ON

3

ENGLISH

- Connect the Multimeter (



) as follows:



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

- (-) Multimeter terminal Blue/white cable -

yellow/blue cable(2).

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.

RS

GL-N

NO CONTINUITY

- Replace the right-hand switch.

2

GL-BL

B-BL

N

B-R

BL

N

GL-BL

R

1

2

N

1

CONFORMING

10. Wiring connections

- Check the connections of the whole ignition system

- See “Circuit Diagram”.

OK

- Replace the “C.D.I.”

NOT CONFORMING

- Replace the side stand switch.

FAULTY CONNECTIONS

- Repair wiring, consulting the “Circuit
Diagram”.

20 06.05

PAGE EDITION

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

N

12V

.

35 w

35 w

35 w

35 w

GL-BL

B-GR

AZ-GR

AZ-GR

B-BL

B-R

B-R

GL-BL

GL-N

AR-R

DIODO 2A

<

RPM

ENGINE STOP

CHARGING SYSTEM CIRCUIT

B - DIAGNOSTICS

Charging System

CHAPTER

B

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

AZ-B

BL-R

MODE

ENGINE STOP

START

GL-R

GL-BL

GL-B

LIGHTS

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

N

N

W

RS

RS

5

W

10

W

5

18

ENGLISH

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

R-N

N

N

N

W

5

35 w

RS

35 w

B-N

36

B-N

RS

W

N

5

35 w

AZ-B AZ-B

35 w

N

38

N
AR

HORN

0FF

ON

VL

M

VR

TURN

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

BL-R

1

BL-R

BL

BL-R

GL-VL

N

BL

BL-N

VR-N

BL-R

GL-B

ON

OFF

GL-B

BL

VR-N

N

BL-N

2

BL

AR

3

GL

AZ-GR

R

BL-R

GL-V

AZ-GR

R-VR

BL

B-BL

GL-B

BL-N

GL-B

R

R

15
7

AR

AZ-GR

5

13

AZ-GR

GL-VL

11

3

BL

B-GR

9

1

4

AR

86

AR-R

B-R

85 85

86

B-R

R

B-R

R

8

30 A

16

7.5 A

11

14

6

30 A

9

4

12

5A

7

2

10

15 A

5

.

13 14 15

BL

12

5A

10

15 A

8

7.5 A

6

R

R

12V

06.05 21

EDITION PAGE

SECTION 2

B

+

-

N

12V

.

ENGLISH

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

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

Charging System

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.

OUT OF SPEC

TO SPEC

22 06.05

PAGE EDITION

SECTION 2

- The recharging circuit is efficient.

12V

.

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

4. Verify stator recharging resistance

- Remove the three-way connector of the magnetic
flywheel and connect the Multimeter (

- (+) Multimeter terminal Red cable.

- (-) Multimeter terminal Red cable.

- By interchanging the sequences of the cables, the resistance
value should not vary: from 0.6



 to 0.9





) as follows:





 at 20°C.



TO

SPEC

Charging System

OUT OF SPEC

CHAPTER

R
R
R

B

5. Verify wiring connections

- Check the connections of the whole charging system.

- See “Circuit Diagram”.

CONFORMING

- Replace the Voltage Regulator.

- Stator faulty: replace it.

NOT CONFORMING

- Restore wiring.

ENGLISH

06.05 23

EDITION PAGE

SECTION 2

B - DIAGNOSTICS

+

-

N

12V

.

35 w

35 w

35 w

35 w

GL-N

B-GR

AZ-GR

AZ-GR

AZ-GR

GL-V

B8

GL-B

GL-BL

BL-N

BL-N

DIODO 2A

<

RPM

ENGINE STOP

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

B

CHAPTER

ELECTRIC STARTING SYSTEM CIRCUIT

Electric Start System

ENGLISH

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

AZ-B

BL-R

MODE

ENGINE STOP

START

GL-R

GL-BL

GL-B

LIGHTS

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

W

10

W

N

N

W

RS

RS

5

5

18

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

R-N

N

N

N

W

5

35 w

RS

35 w

B-N

36

B-N

RS

W

N

5

35 w

AZ-B AZ-B

35 w

N

38

N
AR

HORN

0FF

ON

VL

M

VR

TURN

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

24 06.05

PAGE EDITION

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

BL-R

1

BL-R

BL

BL-R

GL-VL

N

BL

BL-N

VR-N

BL-R

GL-B

ON

OFF

GL-B

BL

VR-N

N

BL-N

2

BL

AR

3

GL

AZ-GR

R

BL-R

GL-V

AZ-GR

R-VR

BL

B-BL

GL-B

BL-N

GL-B

R

R

15
7

AR

AZ-GR

5

13

AZ-GR

GL-VL

11

3

BL

B-GR

9

1

4

AR

86

AR-R

B-R

85 85

86

B-R

R

B-R

R

BL

8

30 A

16

7.5 A

14

6

30 A

4

12

5A

2

10

15 A

.

12

11

5A

10

9

15 A

8

7

7.5 A

6

5

R

R

12V

13 14 15

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS:

2) MAIN SWITCH

4) BATTERY

7) 5 A FUSE (3)

8) 15 A FUSE (4)

9) 30 A FUSE (5)

13) START RELAY

14) START INTERRUPTION RELAY

16) STARTER MOTOR

21) SIDE STAND SWITCH

31) FRONT STOP SWITCH

32) RIGHT-HAND SWITCH (ENGINE STOP/START)

B - DIAGNOSTICS

Electric Start System

CHAPTER

B

FAILURE DIAGNOSIS

If the starter motor fails to work check the:

1. Main fuse 30 A (No. 5)

2. Fuse 5 A (No. 3)

3. Battery

4. Starter motor

5. Start relay

6. Starting circuit interruption relay

7. Main switch

8. Engine stop switch

9. Side stand switch

10. Start switch

11. Front/rear stop switch

12. Starting system wiring connection

1. Main fuse 30 A (No. 5)

- Remove the relative fuse.

- Connect the Multimeter (

- Verify fuse continuity.



) to the fuse.



ENGLISH

NO CONTINUITY

- Replace the fuse.

CONTINUITY

2. Fuse 5 A (No. 3)

- Remove the relative fuse.

- Connect the Multimeter (

- Verify fuse continuity.

06.05 25

EDITION PAGE



) to the fuse.



CONTINUITY

NO CONTINUITY

- Replace the fuse.

SECTION 2

B

+

-

N

12V

.

N

+

-

N

12V

.

CHAPTER

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Electric Start System

ENGLISH

3. Battery

- Check battery conditions.

- See page 22.

TO

SPEC

4. Check the starter motor

- Connect a 12 V battery to the starter motor with two
cables (see figure).

MOTOR

RUNNING

OUT OF SPEC

- Replace the battery.

.

12V

MOTOR NOT RUNNING

- Replace the starter motor.

5. Start relay

- Disconnect the relay connector.

- Connect the Multimeter (
terminals of the relay as follows:

- (+) battery pole Terminal (86).

- (-) battery pole Terminal (85).

Caution: do not reverse the battery connections on the
relay terminals.

- (+) Multimeter terminal Terminal (87).

- (-) Multimeter terminal Terminal (30).



) and a battery (12 V) to the



CONTINUITY

NO CONTINUITY

- Replace the relay.

87

12V

.

85

30

86

26 06.05

PAGE EDITION

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

N

12V

.

6. Starting circuit interruption relay

B - DIAGNOSTICS

Electric Start System

CHAPTER

B

- Disconnect the (white) relay connector.

- Connect the Multimeter (
relay terminals as follows.

- (+) battery pole

- (-) battery pole Terminal (85).

Caution: do not reverse the battery connections on
the relay terminals.

- (+) Multimeter terminal Terminal (87).

- (-) Multimeter terminal Terminal (30).

7. Main switch



) and a battery (12 V) to the



Terminal (86).

CONTINUITY

NO CONTINUITY

- Replace the relay.

NOT CONFORMING

86

12V

.

87

30

85

ENGLISH

- See controlling the main switch on page 19.

CONFORMING

8. Engine stop switch

- See controlling the engine stop switch on page 20.

CONFORMING

9. Side stand switch

- See controlling the side stand switch on page 20.

CONFORMING

- Replace the main switch.

NOT CONFORMING

- Replace the right-hand switch

NOT CONFORMING

- Replace the side stand switch.

06.05 27

EDITION PAGE

SECTION 2

B

ENGINE STOP

CHAPTER

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Electric Start System

ENGLISH

10. Start switch

- Disconnect the six-way right-hand switch connector (3)
and connect the Multimeter (



) as follows:



- (+) Multimeter terminal White/red cable (1).

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

- Press the “Start” button and verify continuity.

CONTINUITY

11. Front/rear stop switch

- Disconnect the red cable and the white/grey cable of the
stop switch (3).

- Connect the Multimeter (



) as follows:



- (+) Multimeter terminal Terminal (1).

- (-) Multimeter terminal Terminal (2).

- Operate the brake lever and verify continuity.

3

GL-N

B-R

BL

RS

RS

0FF

ON

START

LIGHTS

RS

GL-N

BL

NO CONTINUITY

- Replace the right-hand switch.

3

1

N

ENGINE STOP

B-R

N

GL-BL

GL-BL

GL-BL

1

B-BL

R

GL-B

0FF

ON

MODE

B-BL

R

2

2

CONTINUITY

12. Wiring connections

- Check connections of the whole starting system.

- See “Circuit Diagram”.

NO CONTINUITY

- Replace the stop switch.

NOT CONFORMING

- Restore wiring.

28 06.05

PAGE EDITION

SECTION 2

CHECKING THE STARTER MOTOR

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Electric Start System

7

CHAPTER

B

4

6

5

DISMANTLING THE STARTER MOTOR

Dismantle the parts in this order.

1) Front bracket

2) Ring

3) Spacers

4) Rear bracket

5) Ring

6) Spacers

7) Brush holder unit

8) Rotor

9) Stator

To assemble, work in the opposite order.

9

8

3

2

1

ENGLISH

1. INSPECTION AND REPAIRS

1.1 Switch

1

- If the switch is dirty clean with sand paper, No. 600.

- Measure switch diameter (1).

- Switch wear limit: 27 mm.

TO

SPEC

06.05 29

EDITION PAGE

OUT OF SPEC

- Replace the starter motor.

SECTION 2

B

ENGLISH

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

1.2 Mica

- Measure mica notch (1).

- Mica notch: 0.7 mm.

- NOTE: The switch’s mica insulation has to be scraped to
ensure the switch works properly.

Electric Start System

TO

SPEC

1

OUT OF SPEC

-Scrape the mica until you have the
right value (a saw blade can be
sharpened to give it the necessary
shape and dimensions).

1.3 Rotor

- Examine rotor winding resistance (insulation/continuity).

- Good conditions:
1 Continuity
2 No continuity

- Bad conditions:
1 Continuity
2 Continuity

1 No continuity
2 No continuity

1 No continuity
2 Continuity

GOOD

CONDITIONS

1.4 Brushes

2

2

BAD CONDITIONS

-Replace the rotor.

1

1

- Measure the length of the brushes (1).

- Brush length limit: 4.0 mm.

TO

SPEC

1

OUT OF SPEC

-Replace the brushes.

30 06.05

PAGE EDITION

SECTION 2

1.5 Brush spring

- Measure the brush spring load (1).

- Brush spring load: 570÷920 g.

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Electric Start System

COLLAPSED/OUT OF SPEC

TO

SPEC

CHAPTER

B

1.6 Bearing and oil seal

- Inspect bearing and oil seal.

2. ASSEMBLY

2.1 Install

- Brush holder (1).

- NOTE: Align the projecting part (2) with the brush housing
with the notch on the housing.

-Replace the whole unit.

ENGLISH

WORN/DAMAGED

-Replace.

2

1

2.2 Install

- Spacers (1).

- Rotor (2).

06.05 31

EDITION PAGE

SECTION 2

1

2

B

ENGLISH

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

2.3 Install

- A new ring (1).

- The stator unit (2).

- Spacers (3).

- The front bracket (4) .

- NOTE: Tighten the front bracket to 5 Nm (0.5 m*Kg).

2.4 Last operations

Electric Start System

1

2

3

4

- Put a thin layer of molybdenum grease on the starter
motor bearings.

- Align stator references with those of the brackets.

32 06.05

PAGE EDITION

SECTION 2

+

-

N

12V

.

7.5 A

35 w

35 w

35 w

35 w

GL-BL

B-GR

AZ-GR

AZ-GR

B-BL

B-R

B-R

GL-BL

GL-N

AR-R

DIODO 2A

<

RPM

ENGINE STOP

LIGHTING SYSTEM CIRCUIT

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Lighting System

CHAPTER

B

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

AZ-B

BL-R

MODE

ENGINE STOP

START

GL-R

GL-BL

GL-B

LIGHTS

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

N

N

W

RS

RS

5

W

10

W

5

18

ENGLISH

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

R-N

N

N

N

W

5

35 w

RS

35 w

B-N

36

B-N

RS

W

N

5

35 w

AZ-B AZ-B

35 w

N

38

N
AR

HORN

0FF

ON

VL

M

VR

TURN

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

06.05 33

EDITION PAGE

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

BL-R

1

BL-R

BL

BL-R

GL-VL

N

BL

BL-N

VR-N

BL-R

GL-B

ON

OFF

GL-B

BL

VR-N

N

BL-N

2

BL

AR

3

GL

AZ-GR

R

BL-R

GL-V

AZ-GR

R-VR

BL

B-BL

GL-B

86

85 85

BL-N

GL-B

86

B-R

R

BL

R

8

30 A

R

16

15

7.5 A

7

5

13

11

3

9

1

AR

GL-VL

AZ-GR

AZ-GR

BL

B-GR

11

14

5A

6

30 A

9

4

15 A

12

5A

7

2

10

15 A

5

.

12V

4

AR

AR-R

B-R

B-R

R

13 14 15

12

10

8

7.5 A

6

R

R

SECTION 2

B

CHAPTER

ELECTRICAL COMPONENTS:

2) MAIN SWITCH

4) BATTERY

5) 15 A FUSE (No. 1)

17) TAILLIGHT

19) NUMBER PLATE LIGHT

32) RIGHT-HAND SWITCH

33) INSTRUMENT PANEL

36) HEADLIGHT

38) LEFT-HAND SWITCH

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Lighting System

ENGLISH

FAILURE DIAGNOSIS

If the headlight, lights, low beam indicator, high beam indicator or front and rear parking lights fail
to come on, check the:

1. 15 A fuse (No.1)

2. Battery

3. Main switch

4. Lights switch

5. Lights switch and “passing” push button

6. Wiring connection of the whole lighting system

1. 15 A fuse (No. 1)

- Remove the fuse.

- Connect the Multimeter (

- Check fuse continuity.



) to the fuse.



CONTINUITY

NO CONTINUITY

- Replace the fuse.

2. Battery

- Check the conditions of the battery.

- See verification on page 22.

CONFORMING

3. Main switch

- Check the main switch.

- See verification on page 19.

CONFORMING

34 06.05

PAGE EDITION

SECTION 2

NOT CONFORMING

- Clean the battery terminals.

- Recharge or replace the fuse.

NOT CONFORMING

- Replace the main switch.

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Lighting System

CHAPTER

B

4. Lights switch (right-hand switch)

- See the “controlling the switches” section (page 13).

CONFORMING

5. Lights switch/“passing” push button
(left-hand switch)

- See the “controlling the switches” section (page 13).

CONFORMING

6. Wiring connections

- Check the connections of the whole lighting system.

- See “Circuit Diagram”.

NOT CONFORMING

- Replace the right -hand switch.

NOT CONFORMING

- Replace the right-hand switch.

ENGLISH

NOT CONFORMING

- Restore the lighting system.

06.05 35

EDITION PAGE

SECTION 2

B - DIAGNOSTICS

35 w

35 w

35 w

35 w

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

B

CHAPTER

CONTROLLING THE LIGHTING SYSTEM

1. THE HIGH BEAM LIGHT IS NOT TURNING ON

Lighting System

ENGLISH

1.1 Check the lamp and lamp holder

- See the “controlling the switches” section (page 13).

CONTINUITY

1.2 Check voltage

- Connect the Multimeter (20 Vdc) to the 4-way connector
as follows:

- (+) Multimeter terminal White/black cable (1).

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

- Put the key in the “ON” position.

- Put the lights switch on the ( ) symbol.

- Put the lights switch on the (HI) symbol.

- The resulting voltage must be 12 V.

TO

SPEC

NO CONTINUITY

- Replace the lamp and/or lamp
holder.

AZ-B

B-N

W

5

N

RS

35 w

35 w

N

B-N

RS

1

W

5

N

RS

AZ-B AZ-B

35 w

35 w

N

B-N

N

2

OUT OF SPEC

- The front headlight wiring is interrupted.

- Repair

- See “Circuit Diagram”.

2. THE HIGH BEAM INDICATOR IS NOT TURNING ON

2.1 Check voltage

- Connect the Multimeter (20 Vdc) to the instrument panel
connector as follows:

- (+) Multimeter terminal White/black cable (Pin 15) (1).

- (-) Multimeter terminal Black cable (Pin 17) (2).

- Put the key in the “ON” position.

- Put the lights switch on the ( ) symbol.

- Put the lights switch on the (HI) symbol.

- The resulting voltage must be 12 V.

- The white/black cable between the
left-hand switch and front headlight
connector is interrupted.

- Repair.

- See “Circuit Diagram”.

GR

N

B-VR

8

19

7

18

17

6

BL

GL-BL

5

16

4

R-N

24

232221 20

12

11

GL-B

9

10

BL-R

OUT OF SPEC

VL

15

RS

3

B-N

14

2

AZ-B

R

VR

1

2

B

13

1

GL-R

TO

SPEC

- The system is working okay.

- Replace the instrument panel.

36 06.05

PAGE EDITION

- The white/black cable between the left­hand switch, the front headlight and the
instrument panel connector is interrupted.

- Repair.

- See “Circuit Diagram”.

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

35 w

35 w

35 w

35 w

3. THE LOW BEAM LIGHT IS NOT TURNING ON

B - DIAGNOSTICS

Lighting System

CHAPTER

B

3.1 Check the lamp and lamp holder

- See the “controlling the switches” section (page 13).

CONTINUITY

3.2 Check voltage

- Connect the Multimeter (20 Vdc) to the 4-way wiring
connector as follows:

- (+) Multimeter terminal White/azure cable (1).

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

- Put the key in the “ON” position.

- Put the lights switch on the ( ) symbol.

- Put the lights switch on the (LO) symbol.

- The resulting voltage must be 12 V.

TO

SPEC

NO CONTINUITY

- Replace the lamp and/or lamp
holder.

AZ-B

B-N

1

W

5

N

RS

35 w

35 w

N

B-N

RS

W

5

N

RS

AZ-B AZ-B

35 w

35 w

N

B-N

N

2

OUT OF SPEC

ENGLISH

- The front headlight wiring is interrupted.

- Repair.

- See “Circuit Diagram”.

- The white/azure cable between the
left-hand switch and the front
headlight is interrupted.

- Repair.

- See “Circuit Diagram”.

06.05 37

EDITION PAGE

SECTION 2

B

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

4. THE LOW BEAM INDICATOR IS NOT TURNING ON

Lighting System

ENGLISH

4.1 Check voltage

- Connect the Multimeter (20 Vdc) to the instrument panel
connector as follows:

- (+) Multimeter terminal White/azure cable
(Pin 3) (1).

- (-) Multimeter terminal Black cable (Pin 17) (2).

- Put the key in the “ON” position.

- Put the lights switch on the ( ) symbol.

- Put the lights switch on the (LO) symbol.

- The resulting voltage must be 12 V.

TO

SPEC

- The system is working okay.

- Replace the instrument panel

2

VL

B-N

GR

N

R

24

232221 20

12

11

GL-B

B-VR

16

18

17

19

9

10

7

6

8

5

4

BL

GL-BL

R-N

BL-R

15

RS

3

AZ-B

B

14

13

1

2

VR

GL-R

1

OUT OF SPEC

-The white/azure cable between the left­hand switch, the front headlight and the
instrument panel connector is interrupted.

- Repair.

- See “Circuit Diagram”.

5. INSTRUMENT PANEL LIGHTING IS NOT WORKING

5.1 Check voltage

- Connect the Multimeter (20 Vdc) to the instrument

panel connector as follows:

- (+) Multimeter terminal Pink cable (Pin 4) (1).

- (-) Multimeter terminal Black cable (Pin 17) (2).

- Put the key in the “ON” position.

- Put the lights switch on the ( ) symbol.

- The resulting voltage must be 12 V.

TO

SPEC

- The system is working okay.

- Replace the instrument panel.

2

VL

B-N

GR

N

R

B

15

14

13

4

1

3

2

RS

VR

AZ-B

GL-R

24

232221 20

12

11

GL-B

B-VR

16

18

17

19

9

10

7

6

8

5

BL

GL-BL

R-N

BL-R

1

OUT OF SPEC

- The pink cable between the right-hand
switch, the front headlight and the instru­ment panel connector is interrupted.

- Repair.

- See “Circuit Diagram”.

38 06.05

PAGE EDITION

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

6. THE TAILLIGHT IS NOT TURNING ON

B - DIAGNOSTICS

Lighting System

CHAPTER

B

6.1 Check the lamp and lamp holder

- See the “controlling the switches” section (page13).

TO SPEC

6.2 Check voltage

- Connect the Multimeter (20 Vdc) to the six-way

connector of the taillight wiring as follows:

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

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

- Put the key in the “ON” position.

- Put the lights switch on the ( ) symbol.

- The resulting voltage must be 12 V.

TO

SPEC

OUT OF SPEC

- Replace the lamp and/or lamp
holder.

2

1

R

VR

VL

RS

N

5

W

10

W

10

W

OUT OF SPEC

ENGLISH

W

5

- Taillight wiring is faulty.

- Repair.

- See “Circuit Diagram”.

- The pink cable between the taillight and
the right-hand switch is interrupted.

- Repair.

- See “Circuit Diagram”.

06.05 39

EDITION PAGE

SECTION 2

B - DIAGNOSTICS

35 w

35 w

35 w

35 w

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

B

CHAPTER

7. THE FRONT PARKING LIGHT IS NOT TURNING ON

Lighting System

ENGLISH

7.1 Check lamp and lamp holder

- See the “controlling the switches” section (page13).

TO

SPEC

7.2 Check voltage

- Connect the Multimeter (20 Vdc) to the 4-way connector

of the headlight wiring as follows:

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

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

- Put the key in the “ON” position.

- Put the lights switch on the ( ) symbol.

- The resulting voltage must be 12 V.

TO

SPEC

OUT OF SPEC

- Replace the lamp and/or lamp
holder.

AZ-B

B-N

W

5

N

RS

35 w

35 w

B-N

N

RS

W

5

N

RS

AZ-B AZ-B

35 w

35 w

N

B-N

N

2 1

OUT OF SPEC

- Taillight wiring is faulty.

- Repair.

- See “Circuit Diagram”.

- The pink cable between the headli­ght and right-hand switch is interrup­ted.

- Repair.

- See “Circuit Diagram”.

40 06.05

PAGE EDITION

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

N

12V

.

35 w

35 w

35 w

35 w

GL-B

GL-BL

B-GR

AZ-GR

AZ-GR

B-BL

B-R

B-R

GL-B

GL-BL

GL-N

AR-R

DIODO 2A

<

RPM

ENGINE STOP

SIGNALLING SYSTEM CIRCUIT

B - DIAGNOSTICS

Signalling System

CHAPTER

B

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

AZ-B

BL-R

MODE

ENGINE STOP

START

GL-R

GL-BL

GL-B

LIGHTS

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

N

N

W

RS

RS

5

W

10

W

5

18

ENGLISH

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

R-N

N

N

N

W

5

35 w

RS

35 w

B-N

36

B-N

RS

W

N

5

35 w

AZ-B AZ-B

35 w

N

38

N
AR

HORN

0FF

ON

VL

M

VR

TURN

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

06.05 41

EDITION PAGE

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

BL-R

1

BL-R

BL

BL-R

GL-VL

N

BL

BL-N

VR-N

BL-R

GL-B

ON

OFF

GL-B

BL

VR-N

N

BL-N

2

BL

AR

3

GL

AZ-GR

R

BL-R

GL-V

AZ-GR

R-VR

BL

B-BL

GL-B

86

85 85

BL-N

GL-B

86

B-R

R

BL

R

8

30 A

R

16

15

7.5 A

7

5

13

11

3

9

1

AR

GL-VL

AZ-GR

AZ-GR

BL

B-GR

11

14

5A

6

30 A

9

4

15 A

12

5A

7

2

10

15 A

5

.

12V

4

SECTION 2

AR

AR-R

B-R

B-R

R

13 14 15

12

10

8

7.5 A

6

R

R

B

CHAPTER

ELECTRICAL COMPONENTS:

2) MAIN SWITCH

3) HORN

4) BATTERY

6) 7.5 A FUSE (No. 2)

9) 30 A FUSE (No. 5)

17) TAILLIGHT (STOP)

22) PICKOFF c/Km

23) FUEL PROBE

24) THERMISTOR

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Signalling System

ENGLISH

30) “C.D.I.”

31) FRONT STOP SWITCH

32) RIGHT-HAND SWITCH

33) INSTRUMENT PANEL

34) EXTERNAL TEMPERATURE PROBE

39) REAR STOP SWITCH

40) FLASHER RELAY

FAILURE DIAGNOSIS

1. THE STOP LIGHT IS NOT TURNING ON

1.1 Check the 7.5 A fuse (No. 2)

- See the “controlling the switches” section (page 13).

CONTINUITY

1.2 Lamp and lamp holder

NO CONTINUITY

- Replace the fuse.

NO CONTINUITY

- See the “controlling the switches” section (page 13).

- Replace the lamp and/or lamp

CONTINUITY

1.3 Stop switch (front/rear)

- See the “controlling the switches” section (page 13).

CONTINUITY

42 06.05

PAGE EDITION

SECTION 2

holder.

NO CONTINUITY

- Replace the stop switch.

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

1.4 Check voltage

- Connect the Multimeter (20 Vdc) to the six-way

connector of the taillight wiring as follows:

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

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

- Put the key in the “ON” position.

- Operate the brake lever.

- The resulting voltage must be 12 V.

B - DIAGNOSTICS

Signalling System

5

W

CHAPTER

B

2

1

R

VL

RS

N

10

W

3

VR

W

10

5

W

TO

SPEC

- Taillight wiring (3) is faulty.

- Repair.

- See “Circuit Diagram”.

2. THE DIRECTION INDICATORS ARE NOT FLASHING

2.1 Lamp and lamp holder

- See the “controlling the switches” section (page 13).

CONTINUITY

OUT OF SPEC

ENGLISH

- The red cable is interrupted.

- Repair.

- See “Circuit Diagram”.

NO CONTINUITY

- Replace the lamp and/or lamp
holder.

2.2 Direction indicators switch (Turn)

NO CONTINUITY

- See the “controlling the switches” section (page 13).

- Direction indicators switch faulty.

CONTINUITY

06.05 43

EDITION PAGE

- Replace the left-hand switch.

SECTION 2

B

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

2.3 Check voltage

- Connect the Multimeter (20 Vdc) to the flasher relay as

follows:

- (+) Multimeter terminal White/grey cable (1).

- (-) Multimeter terminal Chassis earth (2).

- Put the key in the “ON” position

- Flasher relay input voltage (white/grey cable) must be 12 V.

Signalling System

M-N

B-GR

1

2

ENGLISH

TO

SPEC

2.4 Check the flasher relay

- Connect the Multimeter (20 Vdc) to the flasher relay as

follows:

- (+) Multimeter terminal Brown/black cable (1).

- (-) Multimeter terminal Chassis earth (2).

- Put the key in the “ON” position.

- Flasher relay output voltage (brown/black cable) must be 12 V.

TO

SPEC

OUT OF SPEC

- The circuit between the fuse carrier
and flasher relay is faulty.

- Repair.

- See “Circuit Diagram”.

1

M-N

B-GR

2

OUT OF SPEC

- Flasher relay faulty.

- Replace it.

44 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

PASSING

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Signalling System

CHAPTER

B

2.5 Check the brown/black cable

- Connect the Multimeter (



) to the brown/black cable



as follows:

- (+) Multimeter terminal Black/brown cable (1)
flasher relay output.

- (-) Multimeter terminal Black/brown cable (2)
left-hand switch input

- Verify continuity.

CONTINUITY

2.6 Check voltage

M-N

B-GR

1

M

VL

0FF

ON

PASSING

BL

B-N

HI

LO

VR

AZ-B

B-N

GL-N

R

L

LUCI

B-N

BL

AZ-B

GL-N

R-VR

AZ-B

GL-N

B-N

AR

N

0FF

ON

HORN

TURN

VR

VL

M

AR

N

M-N

AR

VR

BL-N

VL

2

NO CONTINUITY

- The brown/black cable is interrupted

- Repair.

- See “Circuit Diagram”.

ENGLISH

- Connect the Multimeter (20 Vdc) to the 6-way connector

of the taillight wiring as follows:

- Check the left indicators:

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

- (-) Multimeter terminal Black cable (3).

- Check the right indicators:

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

- (-) Multimeter terminal Black cable (3).

- Put the key in the “ON” position.

- Move the “Turn” switch left and right.

- In both cases the voltage must be 12 V.

OUT OF SPEC

2.7 Wiring connections

- The circuit between the (Turn) switch and the front and/or

rear light wiring connector is faulty.

- Repair.

- See “Circuit Diagram”.

3

1

R

VR

VL

RS

N

10

W

5

W

10

W

10

5

W

W

10

W

2

3

R

VR

VL

RS

N

10

W

5

W

10

W

10

5

W

W

10

W

06.05 45

EDITION PAGE

SECTION 2

B

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

3. THE HORN IS NOT WORKING

Signalling System

ENGLISH

3.1 Horn switch

- See the “controlling the switches” section (page 13).

CONTINUITY

3.2 Verify earth

- Connect the Multimeter (



) to the left-hand switch



connector (3) as follows:

- (+) Multimeter terminal Blue/black cable (1).

- (-) Multimeter terminal Chassis earth (2).

CONTINUITY

NO CONTINUITY

- Replace the left-hand switch.

GL-N

BL

R-VR

AZ-B

AZ-B

AZ-B

GL-N

GL-N

B-N

B-N

VR

R

L

TURN

VR

VL

M

AR

M-N

VR

AR

VL

BL

B-N

0FF

ON

PASSING

B-N

HI

LO

LUCI

3

2

M

NO CONTINUITY

- The blue/black cable is interrupted.

- Repair.

- See “Circuit Diagram”.

VL

N

BL-N

0FF

ON

HORN

AR

N

1

3.3 Horn

- Disconnect the horn wires (3)

- Connect the Multimeter (DC 20 V) to the terminals as follows:

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

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

- Put the key in the “ON” position.

- Press the “Horn” push button.

- The resulting voltage must be 12 V.

CAUTION: do not reverse position of wires.

.

OUT OF SPEC

1

BL
AR

2

3

TO SPEC

- Replace the horn

46 06.05

PAGE EDITION

SECTION 2

3.4 Check voltage

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Signalling System

CHAPTER

B

- Connect the Multimeter (DC 20 V) to the horn (3) as

follows:

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

- (-) Multimeter terminal Chassis earth (2).

- Put the key in the “ON” position.

- The resulting voltage must be 12 V.

TO

SPEC

- The orange cable between the left-hand switch and the

horn is interrupted.

- Repair.

- See “Circuit Diagram”.

4. FUEL LEVEL INDICATOR IS NOT WORKING

1

BL
AR

3

2

OUT OF SPEC

ENGLISH

- The blue cable is interrupted.

- Repair.

- See “Circuit Diagram”.

4.1 Fuel probe

- Take the probe out of the fuel tank (see Workshop

Manual).

- Disconnect the probe connector.

- Connect the Multimeter (



) to the probe connector as



follows:

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

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

- Verify probe resistance

- Float up (3) Resistance 4÷10

- Float down (4) Resistance 90÷100



.





.



TO SPEC

3

4

OUT OF SPEC

- Fuel probe faulty.

- Replace.

1

2

VR

N

06.05 47

EDITION PAGE

SECTION 2

B

CHAPTER

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Signalling System

ENGLISH

4.2 Testing the earth

- Connect the Multimeter (



) to the fuel probe connector



as follows:

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

- (-) Multimeter terminal Chassis earth (2).

CONTINUITY

4.3 Testing grey cable continuity

- Connect the Multimeter (



) as follows:



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

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

- Verify the continuity of the grey cable between probe and

instrument panel.

CONTINUITY

N N

VR

GR

1

2

NO CONTINUITY

- Black cable interrupted.

- Repair, creating a bridge between
the black cable and chassis earth.

N N

VR

GR

1

GR

24

232221 20

12

11

GL-B

B-VR

18

19

9

10

7

6

8

BL

BL-R

GL-BL

2

VL

B-N

N

R

B

16

15

17

14

13

5

4

1

3

2

RS

VR

R-N

AZ-B

GL-R

- Replace the instrument panel.

NO CONTINUITY

- Grey cable interrupted between
probe and instrument panel (Pin 18).

- Repair.

- See “Circuit Diagram”.

48 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

GL-R

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Signalling System

CHAPTER

B

5. THE REVOLUTION COUNTER IS NOT WORKING

5.1 Continuity of the yellow/red cable

- Disconnect the “C.D.I.” connector (3) and the instrument
panel connector (4).

- Connect the Multimeter (



) as follows:



- (+) Multimeter terminal Pin A1 control unit (1).

- (-) Multim. terminal Pin 1 instrument panel (2).

- Test continuity of the yellow/red cable.

CONTINUITY

5.2 Test the “C.D.I.”

- Disconnect the instrument panel connector (3) and
connect the Multimeter (20 Vac) as follows:

- (+) Multim. terminal Red/Yellow Cable (Pin 1) (1).

- (-) Multimeter terminal Chassis earth (2).

- Start the engine at about 2500 rpm.

- The resulting voltage must be 5÷6 V~.

5

2

6

3

4

6

A6

GL-N

5

4

A7

B-BL

3

1

A

B

C

2

1

B3B6B8

B-N

BL-N

AR

7

A1

GL-R

A

B

C

A4

GL-B

8

7

8

A5

M-B

3

4

VL

GR

N

1

24

232221 20

12

11

GL-B

B-VR

16

18

17

19

9

10

7

6

8

5

4

RS

BL

R-N

BL-R

GL-BL

NO CONTINUITY

- The yellow/red cable between the C.D.I.
and instrument panel is interrupted.

- Repair.

- See “Circuit Diagram”.

3

GR

N

B-VR

24

232221 20

12

11

GL-B

9

10

BL-R

8

19

7

GL-BL

16

18

17

6

5

BL

R-N

2

C8

N

15

3

4

B-N

14

2

AZ-B

VL

15

3

RS

1

R

B

13

1

VR

GL-R

B-N

14

2

VR

AZ-B

R

2

ENGLISH

B

13

1

GL-R

- The instrument panel is faulty.

- Replace it.

TO

SPEC

OUT OF SPEC

- The C.D.I. is faulty.

- Replace it.

06.05 49

EDITION PAGE

SECTION 2

B

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

6. TEMPERATURE INDICATOR NOT WORKING

Signalling System

ENGLISH

6.1 Thermistor

- Drain the coolant liquid and remove the thermistor from
the thermal unit.

- Dip the thermistor (2) in the liquid (3) and heat

- Verify temperatures with a thermometer (1).

- Coolant temp. 80°C Resistance 60÷70

- Coolant temp. 100°C Resistance 35÷38

- Coolant temp. 120°C Resistance 21÷23


















WARNING: Do not let the thermistor touch the bottom
of the heated container.
NOTE: The red indicator light on the instrument panel
turns on at about 105°C (29



).



TO

SPEC

6.2 White/green cable continuity

- Disconnect the white/green cable from the thermistor and
connect the Multimeter (



) as follows:



- (+) Multimeter terminal White/green cable (1)

instrument panel (Pin 19).

- (-) Multimeter terminal White/green cable (2)

thermistor (3).

- Verify continuity of the white/green cable.

NO

CONTINUITY

1

3

2

OUT OF SPEC

- Replace the thermistor.

24

232221 20

12

11

10

GL-B

2

B-VR

CONTINUITY

9

BL-R

8

B-VR

19

7

GL-BL

1

VL

B-N

GR

18

6

BL

R

N

17

5

R-N

3

B

16

15

14

13

4

1

3

2

RS

VR

AZ-B

GL-R

- The white/green cable between the thermistor and Pin 19
instrument panel is interrupted.

- Instrument panel faulty.

- Replace.

- Repair.

- See “Circuit Diagram”.

50 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

ENGINE STOP

B-BL

ENGINE STOP

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Signalling System

7. INSTRUMENT PANEL NOT CHANGING FUNCTION

7.1 “Mode” push button

- Disconnect the 2-way connector of the right-hand switch
(3) and connect the Multimeter (

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

- (-) Multim. term Yellow/blue, blue/white cable (2).

- Press the “Mode” push button.

- Verify continuity of the “Mode” push button.



) as follows:



CONTINUITY

3

GL-N

LIGHTS

B-R

BL

RS

RS

0FF

ON

START

RS

GL-N

BL

2

NO CONTINUITY

- Replace the right-hand switch.

N

ENGINE STOP

N

B-R

GL-BL

GL-BL

GL-BL

CHAPTER

B-BL

R

GL-B

0FF

ON

MODE

B-BL

R

B

1

7.2 Check voltage

- Connect the Multimeter (20 Vdc) to the 2-way connector
of the right-hand switch (3) as follows:

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

- (-) Multimeter terminal Chassis earth (2).

- Put the key in the “ON” position.

- The resulting voltage must be 12 V.

TO

SPEC

GL-N

RS

3

RS

LIGHTS

2

OUT OF SPEC

- Blue cable interrupted.

- Repair.

- See “Circuit Diagram”.

ENGLISH

B-BL

R

GL-B

GL-BL

B-R

N

BL

0FF

ON

START

RS

GL-N

BL

ENGINE STOP

N

B-R

1

GL-BL

GL-BL

0FF

ON

MODE

B-BL

R

BL

R

BL

06.05 51

EDITION PAGE

SECTION 2

B

ENGINE STOP

ENGLISH

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

CHAPTER

7.3 Red cable continuity

- Connect the Multimeter (



) as follows:



- (+) Multimeter terminal

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

- Verify continuity of the red cable between the “Mode” push
button and instrument panel (Pin 14).

Signalling System

Red cable (1).

CONTINUITY

LIGHTS

24

232221 20

12

11

GL-B

GL-N

RS

0FF

ON

START

B-R

RS

GL-N

BL

ENGINE STOP

GL-BL

N

GL-BL

0FF

ON

BL

MODE

B-BL

R

1

B-BL

R

GL-B

GL-BL

B-R

N

BL

RS

2

R

BL

VL

B-N

GR

N

R

B-VR

18

17

19

9

10

7

6

8

BL

BL-R

GL-BL

B

16

15

14

13

5

4

1

3

2

RS

VR

R-N

AZ-B

GL-R

- Replace the instrument panel.

8. THE ODOMETER IS NOT INDICATING THE SPEED

8.1 Check voltage

- Disconnect the 3-way connector of the c/Km sensor and
connect the Multimeter (20 Vdc) as follows:

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

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

- Put the key in the “ON” position.

- “Engine stop” push button on start.

- The resulting voltage must be 5

±0,5 V=

.

NO CONTINUITY

- Red cable interrupted.

- Repair.

- See “Circuit Diagram”.

N

B

GL-BL

2

1

TO

SPEC

OUT OF SPEC

52 06.05

PAGE EDITION

- Replace the instrument panel.

SECTION 2

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Signalling System

8.2 Verify the instrument panel signal

- Connect the Multimeter (20 Vdc) to the instrument panel
connector (without disconnecting it) as follows (F.3):

- (+) Multi.term. Instr panel’s white cable (Pin 13) (1).

- (-) Mult.term. Instr panel’s black cable (Pin 17) (2).

- Put the key in the “ON” position.

- “Engine stop” push button on start.

- Turn the wheel in the direction of travel and check voltage
as follows:
F. 1

- Sensor (3) disc slot (5).

- Voltage 5
F. 2

- Sensor (3) disc body (4).

- Voltage 0.20

±0.5 V=

±0.15 V=

.

.

CHAPTER

B

3

5

F. 1

3

4

F. 2

ENGLISH

OUT OF SPEC

- Verify continuity of the white cable (Multimeter



)



between Pin 13 of the instrument panel and the terminal
inserted in the 3-way connector on the system side.

CONTINUITY

- Replace the c/Km sensor.

24

232221 20

12

11

GL-B

NO CONTINUITY

- White cable interrupted.

- Repair.

- See “Circuit Diagram”.

2

1

VL

B-N

GR

N

R

B-VR

18

17

19

9

10

7

6

8

5

BL

GL-BL

R-N

BL-R

B

16

15

14

13

4

1

3

2

RS

VR

AZ-B

GL-R

F. 3

06.05 53

EDITION PAGE

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

N

12V

.

35 w

35 w

35 w

35 w

B-GR

AZ-GR

AZ-GR

GL-B

BL-R

GL-BL

BL-N

BL-N

VR-N

GL-R

DIODO 2A

<

RPM

ENGINE STOP

B

CHAPTER

COOLING SYSTEM CIRCUIT

B - DIAGNOSTICS

Cooling System

ENGLISH

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

GL-R

AZ-B

BL-R

GL-B

35 w

35 w

TURN

MODE

ENGINE STOP

START

GL-BL

35 w

35 w

LIGHTS

N

B-N

B-N

N

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

R-N

N

N

W

RS

5

36

RS

W

N

5

AZ-B AZ-B

38

N
AR

HORN

0FF

ON

VL

M

VR

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

W

10

W

N

N

W

RS

RS

5

5

18

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

B-BL

GL-B

BL-N

GL-B

BL-R

BL

BL-R

GL-VL

N

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

1

BL

BL-N

VR-N

BL-R

GL-B

BL

AR

ON

OFF

GL-B

BL

BL-R

VR-N

N

BL-N

2

3

GL

AZ-GR

BL-R

R

GL-V

AZ-GR

R-VR

BL

R

R

15
7

AR

AZ-GR

5

13

AZ-GR

GL-VL

11

3

BL

B-GR

9

1

4

AR

86

AR-R

B-R

85 85

86

B-R

R

B-R

R

8

30 A

16

7.5 A

11

14

6

30 A

9

4

12

5A

7

2

10

15 A

5

.

13 14 15

BL

12

5A

10

15 A

8

7.5 A

6

R

R

12V

54 06.05

PAGE EDITION

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

12V

.

+

-

12V

.

ELECTRICAL COMPONENTS:

2) MAIN SWITCH

4) BATTERY

11) 7.5 A FUSE (No. 7)

20) FAN

27) THERMAL SWITCH

FAILURE DIAGNOSIS

THE FAN MOTOR IS NOT WORKING

B - DIAGNOSTICS

Cooling system

CHAPTER

B

1. 7.5 A FUSE (No. 7)

- See the “controlling the switches” section (page 13).

CONTINUITY

2. Fan motor (1st control)

- Disconnect the fan connector (3).

- Connect the battery (4) as illustrated in the figure:

- (+) battery cable Red cable (1).

- (-) battery cable Black cable (2).

- Verify fan motor operation.

WORKING

NO CONTINUITY

- Replace the fuse.

.

12V

4

NOT WORKING

- Replace the fan motor.

ENGLISH

3

2

N
R

1

3. Fan motor (2nd control)

1

GL

7.5 A

GL

N

N

R

GL

2

- Disconnect the two yellow cables from the thermal switch
(green) (1).

- Connect the two yellow cables with a bridge cable (2).

- Turn the key round to “ON”.- Verify fan motor operation.

WORKING

AZ-GR

.

12V

NOT WORKING

- The circuit feeding the fan motor is
faulty.

- The yellow cables between the fuse
carrier and thermal switch, thermal
switch and fan or black cable (earth)
are interrupted.

- Repair.

- See “Circuit Diagram”.

06.05 55

EDITION PAGE

SECTION 2

B

CHAPTER

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Cooling System

ENGLISH

4. Checking the thermal switch (P= green)

- Remove the thermal switch from the radiator.

- Dip the thermal switch (1) in a container holding some
cooling liquid (2).

- Connect the Multimeter (

- Verify continuity of the thermal switch

NOTE: Measure the temperature with a thermometer (3)
while the coolant liquid is heating up.

ATTENTION: Do not let the thermal switch touch the
bottom of the container.

- The thermal switch closes at 95°±3°C
Continuity.

- The thermal switch opens at 90°±3°C No
continuity.



) to the thermal switch terminals.



P

OUT OF SPEC

1

3

1

2

- Replace the thermal switch.

56 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

+

-

N

12V

.

7.5 A

35 w

35 w

35 w

35 w

GL-BL

B-GR

AZ-GR

AZ-GR

B-BL

B-R

B-R

GL-BL

GL-N

AR-R

DIODO 2A

<

RPM

ENGINE STOP

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Automatic Cold Start System

AUTOMATIC COLD START SYSTEM CIRCUIT

CHAPTER

B

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

AZ-B

BL-R

MODE

ENGINE STOP

START

GL-R

GL-BL

GL-B

LIGHTS

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

N

N

W

RS

RS

5

W

10

W

5

18

ENGLISH

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

R-N

N

N

N

W

5

35 w

RS

35 w

B-N

36

B-N

RS

W

N

5

35 w

AZ-B AZ-B

35 w

N

38

N
AR

HORN

0FF

ON

VL

M

VR

TURN

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

06.05 57

EDITION PAGE

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

BL-R

1

BL-R

BL

BL-R

GL-VL

N

BL

BL-N

VR-N

BL-R

GL-B

ON

OFF

GL-B

BL

VR-N

N

BL-N

2

BL

AR

3

GL

AZ-GR

BL-R

R

GL-V

AZ-GR

R-VR

BL

B-BL

GL-B

86

85 85

BL-N

GL-B

86

B-R

R

BL

R

8

30 A

R

16

15

7.5 A

7

5

13

11

3

9

1

AR

GL-VL

AZ-GR

AZ-GR

BL

B-GR

11

14

5A

6

30 A

9

4

15 A

12

5A

7

2

10

15 A

5

.

12V

4

AR

AR-R

B-R

B-R

R

13 14 15

12

10

8

7.5 A

6

R

R

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

B

CHAPTER

ELECTRICAL COMPONENTS

2) MAIN SWITCH

4) BATTERY

7) 5 A FUSE (No. 3)

9) 30 A FUSE (No. 5)

25) ELECTRIC STARTER

26) THERMAL SWITCH

30) C.D.I.

32) RIGHT-HAND SWITCH (ENGINE STOP)

FAILURE DIAGNOSIS

B - DIAGNOSTICS

Automatic Cold Start System

ENGLISH

THE AUTOMATIC COLD START SYSTEM DEVICE IS NOT WORKING

1. Thermal switch (P= brown)

- Remove the thermal switch from the radiator.

- Dip the thermal switch (1) in a container of cooling liquid (2).

- Connect the Multimeter (

- Verify continuity of the thermal switch.

NOTE: Measure the temperature with a thermometer (3)
while the coolant liquid is heating up.

ATTENTION: Do not let the thermal switch touch the
bottom of the container.

- The thermal switch closes at 50°±3°C
Continuity.

- The thermal switch opens at 40°±3°C

No continuity.



) to the thermal switch terminals.



TO

SPEC

P

OUT OF SPEC

1

3

1

2

- Replace the thermal switch

2. Check the electric starter

- Disconnect the electric starter connector.

- Connect the Multimeter (
connector as follows:

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

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

- Electric starter resistance: 26÷32

58 06.05

PAGE EDITION



) to the electric starter





 at 20°C.



TO SPEC

SECTION 2

OUT OF SPEC

- Replace the electric starter.

1

GL
VR-N

2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Automatic Cold Start System

3. Check voltage

- Disconnect the electric starter connector.

- Connect the Multimeter (20 Vdc) as follows:

- (+) multimeter terminal Yellow/white cable(1).

- (-) multimeter terminal Chassis earth (2).

- Put the key in the “ON” position.

- Put the “Engine stop” push button on the symbol.

- The resulting voltage must be 12 V.

B - DIAGNOSTICS

2

OUT OF SPEC

M-B

GL-B

CHAPTER

B

GL
VR-N

1

TO SPEC

4. Check the “C.D.I.”

- Disconnect the electric starter connector.

- Connect the Multimeter (



) to the connector on the



system side as follows:

- (+) multimeter terminal

Brown/white cable (1).

- (-) multimeter terminal Chassis earth (2).

- Start the engine at 5000 rpm.

- Wait 60 seconds and verify continuity of the brown/
white cable earth.

NO CONTINUITY

AFTER 60 SECONDS

5. Verify continuity of the brown/white cable

- Connect the Multimeter (



) and check continuity of the brown/



white cable between the C.D.I. and the electric starter.

- The yellow/white cable between the
“Engine Stop” button and electric
starter is interrupted.

- Repair.

- See “Wiring Diagram”.

5

5

GL-N

4

4

A7

B-BL

3

3

2

2

B3

BL-N

1

1

B6

B-N

A

B

C

B8

C8

AR

N

A1

GL-R

A

B

C

A4

8

8

GL-B

A5

7

7

M-B

6

6

A6

1

+12V

=

M-B

GL-B

NO CONTINUITY

ENGLISH

2

GL
VR-N

- The brown/white cable between the

CONTINUITY

C.D.I. and electric starter is interrupted.

- Repair.

- See “Circuit Diagram”.

- Replace the “C.D.I.”

06.05 59

EDITION PAGE

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

N

12V

.

35 w

35 w

35 w

35 w

GL-B

BL-R

B-GR

AZ-GR

AZ-GR

GL-B

BL-R

GL-BL

GL-N

BL-N

BL-N

AR-R

DIODO 2A

<

RPM

ENGINE STOP

B

CHAPTER

FUEL PUMP SYSTEM CIRCUIT

B - DIAGNOSTICS

Fuel Pump System

ENGLISH

GL

A.T

GL-N

GL-R

27

GL

N

VR

N

AR

>-12

PK-

>-12

<-12

PK+

<

GL-B

>+12

< RPM

M

BL-N

AR-R

>+12

28

N

N

N

C8

B8

AR

B6

B-N

B3

BL-N

B-BL

A7

A6

M-B

A5

A4

A1

29

30

B

A

C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

B

A

C

31

R

AZ-B

BL-R

MODE

ENGINE STOP

START

GL-R

GL-BL

GL-B

LIGHTS

B-GR

R

R

B-BL

GL-V

GL-BL

GL-B

GL-BL

N

N

B-R

B-R

R-VR

BL

RS

RS

GL-N

GL-N

323334

R

B-BL

ON

0FF

GL-B

GL-BL

N

B-R

ON

0FF

BL

RS

RS

GL-N

B

1

13

R

VR

2

14

B-N

3

15

VL

RS

4

16

N

R-N

5

17

GR

BL

6

18

B-VR

7

19

8
9

21 20
22

10

23

11

24

12

M-B

26

N

25

24

GL

VR-N

B-VR

M-B

GL-B

23

N

VR

N

GR

GL-BL

N

B

N

BL-N

N

BL-R

22

N

N

21

N

N

R

GL

19

W

10

W

N

N

W

RS

RS

5

5

18

W

VR

N

RS

R

VL

10

VR

N

RS

R

VL

17 20

W

10

W

5

W

10

16

R-N

N

N

N

W

5

35 w

RS

35 w

B-N

36

B-N

RS

W

N

5

35 w

AZ-B AZ-B

35 w

N

38

N
AR

HORN

0FF

ON

VL

M

VR

TURN

R

L

AZ-B

GL-N

B-N

LUCI

HI

LO

B-N

BL

PASSING

0FF

ON

39

60 06.05

PAGE EDITION

VR

W

35

N

16

VR

N

VL

RS

RS

B-N

B-N

AZ-B

AZ-B

N

N

N

W

37

VL

16

BL-N

N

AR

AR

M-N

M

VL

VL

VR

VR

B-N

B-N

GL-N

GL-N

AZ-B

AZ-B

R-VR

BL

B-GR

R

N

VR

VL

M

M

B-N

M

MN

M

M

42

DIODO 2 A

M-N

B-GR

40

R

41

GL-N

R

M

BL-R

1

BL-R

BL

BL-R

GL-VL

N

BL

BL-N

VR-N

BL-R

GL-B

ON

OFF

GL-B

BL

VR-N

N

BL-N

2

BL

AR

3

GL

AZ-GR

BL-R

R

GL-V

AZ-GR

R-VR

BL

B-BL

GL-B

BL-N

GL-B

R

R

15
7

AR

AZ-GR

5

13

AZ-GR

GL-VL

11

3

BL

B-GR

9

1

4

AR

86

AR-R

B-R

85 85

86

B-R

R

B-R

R

BL

8

30 A

16

7.5 A

14

6

30 A

4

12

5A

2

10

15 A

.

12

11

5A

10

9

15 A

8

7

7.5 A

6

5

R

R

12V

SECTION 2

13 14 15

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS:

2) MAIN SWITCH

4) BATTERY

7) 5 A FUSE (No. 3)

9) 30 A FUSE (No. 5)

10) 5 A FUSE (No. 6)

15) FUEL PUMP RELAY

29) FUEL PUMP

30) “C.D.I.”

32) ENGINE STOP SWITCH

OPERATION OF THE FUEL PUMP CIRCUIT

The “C.D.I.” controls the fuel pump.

B - DIAGNOSTICS

Fuel Pump System

CHAPTER

B

27

9

4

32

GL/B

10

B/BL

86

85

AR

ENGLISH

15

AR/R

29

N

A7

30

06.05 61

EDITION PAGE

SECTION 2

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

+

-

N

12V

.

B

CHAPTER

THE FUEL PUMP IS NOT WORKING.

B - DIAGNOSTICS

Fuel Pump System

ENGLISH

1. 5 A Fuse (No. 6)

- See the “controlling the switches” section (page 13)

CONTINUITY

2. Main switch

- See the “controlling the switches” section (page 13)

CONTINUITY

3. Engine stop switch

- See the “controlling the switches” section (page 13)

CONTINUITY

NO CONTINUITY

- Replace the fuse.

NO CONTINUITY

- Replace the main switch.

NO CONTINUITY

- Replace the right-hand switch.

4. Fuel pump relay

- Disconnect the relay from the connector (black).

- Connect the Multimeter (
relay terminals as follows:

- (+) battery pole Terminal 86.

- (-) battery pole Terminal 85.

CAUTION: Do not reverse battery connections on the
relay terminals.

- (+) Multimeter terminal Terminal 87.

- (-) Multimeter terminal Terminal 30.



) and a battery (12 V) to the



CONTINUITY

NO CONTINUITY

- Replace the relay.

86

12V

.

85

87
30

62 06.05

PAGE EDITION

SECTION 2

B - DIAGNOSTICS

+

-

12V

.

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Fuel Pump System

CHAPTER

B

5. Check wiring

- Check connections of the whole fuel pump system (see
“circuit diagram”).

OK

- Replace the “C.D.I.”

6. 1st fuel pump check

- Disconnect the fuel pump connector.

- Connect the Multimeter (

- (+) multimeter terminal Blue/black cable (1).

- (-) multimeter terminal Black cable (2).

- Measure fuel pump resistance.

- Fuel pump resistance: 2÷3



) to the pump as follows:





 at 20°C.



CONNECTIONS FAULTY

- Restore wiring.

- See “Circuit diagram”

1

BL-N

N

2

ENGLISH

M

TO SPEC

7. 2nd fuel pump check

- Get petrol to the pump using a supplementary tank (3).

- Extract the tube (4) from the carburet and place it in a
container.

- Connect a battery (12 V) to the pump connector using two
wires as illustrated.

- (+) battery pole Blue/black cable (1).

- (-) battery pole Black cable (2).

CAUTION: Do not reverse battery polarity: the pump
could be irreparably damaged.

- Fuel is coming through the tube (4): the pump is OK.

- No fuel coming through the tube (4): Replace the fuel
pump.

OUT OF SPEC

- Replace the fuel pump.

.

12V

3

1

BL-N

M

N

4

2

06.05 63

EDITION PAGE

SECTION 2

B

ENGLISH

CHAPTER

B - DIAGNOSTICS

FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM

Fuel Pump System

64 06.05

PAGE EDITION

SECTION 2