Malaguti X3Motard, X3Mnourd 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

TI T OL O S EZ IO NE

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/dm3.

•

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.

21

NO

OK

NO

OK

2

Tester ()

1

OK

F. 9

I G N I T I O N S Y S T E M

IGNITION SYSTEM

7. Pick-up resistance

Disconnect two-way connector of ﬂ ywheel magneto.

Connect Tester () to connector as follows: Terminal (+) of Tester Red terminal (1). Terminal (-) of Tester White terminal (2).

•

Check pick-up resistance: 240  ± 10% at 20°C.•

Replace stator.

8. Connections

Check connections of ignition system.

See “Wiring Diagram”.

•

Resume system’s connections.Replace “CDI” control unit.

22

NO

OK

NO

OK

2

1

Tester ()

2

F. 11

1

F.10

F. 11

E L E C T R I C A L S T A R T I N G S Y S T E M

ELECTRICAL STARTING SYSTEM

FAULTY ELECTRICAL STARTING SYSTEM

Check:

1. Fuse, 15 A

2. Battery

3. Starter motor

4. Starter relay

5. Key switch

6. Neutral switch

7. Clutch switch

8. Start button

9. “Engine stop” button

10. Side stand switch

11. 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.

Connect Tester (V) as follows: Terminal (+) of Tester Battery positive (1). Terminal (-) of Tester Battery negative (2).

Minimum voltage: 12.5 V.

Density of electrolytic solution: 1280 g/dm3. Level of electrolytic solution.

•

23

BATTERIA

+

-

N

12 V

NO

OK

NO

OK

NO

OK

Tester ()

BATTERIA

+

-

N

12 V

2

1

3

4

M

B

F. 12

F. 13

E L E C T R I C A L S T A R T I N G S Y S T E M

ELECTRICAL STARTING SYSTEM

Clean terminals. Top up with distilled water. Recharge or replace battery.

•

3. Starter motor

Connect a 12 V battery to starter motor:

Battery (+) pole Terminal (+) of starter motor (1).

Battery (-) pole Terminal (-) of starter motor (2).

•

Check operation of the starter motor.•

To connect, use cables that are compatible with the power draw of the starter motor.

Replace starter motor.

4. Starter relay

Disconnect starter relay.

Connect a 12 V battery to the starter relay:

Battery (+) pole Terminal (3).

Battery (-) pole Terminal (4).

•

Connect tester () to terminals (B) and (M) of starter relay.

Check continuity.

•

B: Battery cable Starter relay. M: Starter relay cable Starter motor.

Replace starter relay.

24

NO

OK

NO

OK

Tester ()

4

3

1

2

Tester ()

OK

F. 15

F. 14

E L E C T R I C A L S T A R T I N G S Y S T E M

ELECTRICAL STARTING SYSTEM

5. Key switch

Disconnect key switch.

Turn key “ON”.

Connect Tester () as follows: Terminal (+) of Tester Orange cable (1). Terminal (-) of Tester Green cable (2). Check continuity.

•

Replace key switch.

6. Neutral switch

Connect Tester () as follows. Terminal (+) of Tester Neutral switch (3). Terminal (-) of Tester Chassis grounding (4).

Check continuity:

Transmission in neutral Continuity. Vehicle in gear No continuity.

•

Replace neutral switch.

25

NO

OK

NO

OK

1

Tester ()

3 4

2

OK

F. 16

F. 17

E L E C T R I C A L S T A R T I N G S Y S T E M

ELECTRICAL STARTING SYSTEM

7. Clutch switch

Disconnect clutch switch (1).

Connect Tester () as follows. Terminal (+) of Tester T1 clutch switch. Terminal (-) of Tester T2 clutch switch. Check continuity between terminals.

Clutch lever not pulled (1) No continuity.

Clutch lever pulled (2) Continuity.

•

Replace clutch switch.

8. Start button

SDisconnect four-way connector (2).

Connect Tester () as follows. Terminal (+) of Tester White/black cable (2). Terminal (-) of Tester White - green cable (4).

Check continuity between terminals.

•

Replace right hand switch.

26

NO

OK

NO

OK

NO

Tester ()

4

5 6

Tester ()

3 2

1

OK

CLOSE OPEN

F. 18

F. 19

E L E C T R I C A L S T A R T I N G S Y S T E M

ELECTRICAL STARTING SYSTEM

9. “Engine stop” button

Disconnect four-way connector of right hand switch (1) .

Connect Tester () as follows. Terminal (+) of Tester White/black cable (2). Terminal (-) of Tester Black cable (3).

Check continuity between terminals.

•

Replace right hand switch

10. Side stand switch

Disconnect two-way connector (4).

Connect Tester () as follows. Terminal (+) of Tester Terminal (5). Terminal (-) of Tester Terminal (6).

Check continuity between terminals.

•

Replace side stand switch.

11. Connections

Check connections of starting system.

See “Circuit Diagram”.

•

Resume connections.

27

NO

OK

2

1

Tester ()

F. 20

R E C H A R G I N G S Y S T E M

RECHARGING SYSTEM

BATTERY CANNOT BE CHARGED

Check:

1. Fuse, 15 A

2. Battery

3. Recharging voltage

4. Resistance of recharging coil

5. Starter relay

6. Connection of recharging system

1. Fuse, 15 A

Remove relative fuse.

Connect Tester () to fuse.

Check continuity of fuse.

•

Eliminate short-circuit. Replace fuse.

•

Clean terminals. Top up with distilled water. Recharge or replace battery.

•

NO

OK

2. Battery

Check condition of battery.

Connect Tester (20 V DC) as follows: Terminal (+) of Tester Battery positive. Terminal (-) of Tester Battery negative.

Minimum voltage: 12.5 V.

Density of electrolytic solution: 1280 g/dm3. Level of electrolytic solution.

•

28

NO

OK

Tester ()

NO

OK

3

4

OK

2

F. 111 F. 21

F. 22

R E C H A R G I N G S Y S T E M

RECHARGING SYSTEM

3. Recharging voltage

Connect Tester (20 V DC) as follows: Terminal (+) of Tester Battery positive (1). Terminal (-) of Tester Battery negative (2).

Run engine at ~ 5000 RPM.

Check battery voltage.

Battery charging voltage: 12.5 ÷ 14.5 V.

•

Use a fully charged battery.

Recharging circuit is in working order.

4. Charging coil resistance

Disconnect three-way connector of ﬂ ywheel magneto.

Connect Tester (200) as follows: Terminal (+) of Tester White cable (3). Terminal (-) of Tester White cable (4).

•

Measure resistance of charging coil: 1.20 ± 10% at 20°C.•

Replace stator.

29

NO

OK

NO

OK

B

3

B

4

12

OK

Tester ()

F. 23

F. 24

R E C H A R G I N G S Y S T E M

RECHARGING SYSTEM

5. Starter relay

Test A.

Remove starter relay.

Connect Tester () as follows: Terminal (+) of Tester Terminal (1). Terminal (-) of Tester Terminal (2).

•

Check continuity.•

This check must be performed with the 15 A fuse inserted

Test B.

Connect Tester () as follows: Terminal (+) of Tester Pole (B). Terminal (-) of Tester Terminal (3). Terminal (-) of Tester Terminal (4).

During both tests a condition of continuity must be recorded.

•

Replace starter relay.

6. Recharging system connections

Check connections of recharging system.

See “Wiring Diagram”.

•

Resume system’s connections.

Replace voltage regulator.

30

NO

OK

NO

OK

2

1

Tester ()

2

F. 26

1

F. 25

L I G H T I N G S Y S T E M

LIGHTING SYSTEM

THE ENTIRE LIGHTING SYSTEM DOES NOT WORK

Check:

1. Fuse, 15 A

2. Battery

3. Key switch

4. Light relay

5. Connection to lighting system

1. Fuse, 15 A

Remove relative fuse.

Connect Tester () to fuse.

Check continuity of fuse.

•

Eliminate short-circuit. Replace fuse.

•

2. Batteria

Check condition of battery.

Connect Tester (V) as follows: Terminal (+) of Tester Battery positive (1). Terminal (-) of Tester Battery negative (2).

Minimum voltage: 12.5 V.

Density of electrolytic solution: 1280 g/dm3.

Level of electrolytic solution.

•

Clean terminals.

Top up with distilled water.

Recharge or replace battery.

•

31

NO

OK

NO

OK

BATTERIA

+

-

N

12 V

Tester ()

86 85

87

30

Tester ()

2

1

OK

F. 28

F. 27

L I G H T I N G S Y S T E M

LIGHTING SYSTEM

3. Key switch

Disconnect key switch. Turn key “ON”.

Connect Tester () as follows: Terminal (+) of Tester Orange cable (1). Terminal (-) of Tester Green cable (2).

Check continuity.

•

Replace key switch.

4. Light relay

Disconnect light relay.

Connect Tester () and battery (12V) to relay terminals, as follows: Terminal (+) of battery Terminal (86). Terminal (-) of battery Terminal (85). Terminal (+) of Tester Terminal (87). Terminal (-) of Tester Terminal (30).

Check continuity.

•

Never invert battery connections on relay terminals.

Replace light relay.

32

NO

OK

1

2

F. 29

L I G H T I N G S Y S T E M

LIGHTING SYSTEM

5. Connection of lighting system

Check all connections of lighting system.

See “Wiring Diagram”.

•

Resume system’s connections.

Make sure that connection of pink (1) and red (2) cables to diode bridge is correct (see photo).

”Replace the C.D.I. control unit

33

NO

OK

NO

OK

Tester (DC 20 V)

A B

C

1

2

3

F. 31

F. 30

L I G H T I N G S Y S T E M

LIGHTING SYSTEM

THE LOW BEAM LIGHT, HIGH BEAM LIGHT AND RELATIVE INDICATOR LIGHTS DO NOT COME ON

Check:

1. Light bulb and relative coupling

2. Voltage level of lamp socket and instrument board

3. Left hand light switch (3)

1. Light bulb and relative coupling

Check continuity of light bulb and its coupling.•

Replace light bulb or coupling.

2. Check voltage level of lamp socket and instrument board

Connect Tester (20 V DC) to headlight and instrument board connectors. Test A.

Check low beam light. Terminal (+) of Tester Light blue - white cable (1). Terminal (-) of Tester Black cable (2).

Test B.

Check high beam light. Terminal (+) of Tester White - black cable (3). Terminal (-) of Tester Black cable (2).

Test C.

Check high beam and lights indicator light. Terminal (+) of Tester White - Black cable (PIN 11). Terminal (+) of Tester Pink cable (PIN 9). Terminal (-) of Tester Black cable (PIN 1).

Run the engine and press the button to turn on the low beam/high beam lights. Voltage recorded during tests (A-B-C) must be > 12V.

•

Circuit is in working order.

34

NO

OK

NO

L I G H T I N G S Y S T E M

LIGHTING SYSTEM

3. Light switch

Check continuity of light switch (see Checking switches on P.16).•

Replace left hand switchRepair wiring of headlight and/or instrument board. See “Wiring Diagram”.

•

35

Tester (DC 20 V)

NO

OK

NO

OK

2

1

F. 32

L I G H T I N G S Y S T E M

LIGHTING SYSTEM

REAR LIGHT DOES NOT COME ON

Check:

1. Light bulb and relative coupling

2. Voltage level of lamp socket

1. Light bulb and relative coupling

Check continuity of light bulb and its coupling.•

Replace light bulb or coupling.

2. Check voltage level of lamp socket

Connect Tester (20 V DC) to terminals of light bulb coupling, as follows:

Terminal (+) of Tester Blue cable (1). Terminal (-) of Tester Black cable (2). Turn key “ON”.

Power measured must be > 12 V.

•

Resume connections between key switch and tail lamp. See “Wiring diagram” (P.8).

•

Circuit is in working order.

36

Tester ()

1

2

3

Tester (DC 20 V)

4

5

NO

OK

NO

OK

F. 34

F. 33

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

HORN IS NOT WORKING

Check:

1. Light bulb and relative coupling

2. Voltage level

3. Ground connection

1. Horn switch

Disconnect nine-way connector of left hand switch (1). Connect Tester () as follows:

Terminal (+) of Tester Orange cable (2). Terminal (-) of Tester Light blue cable (3).

Press Horn button to activate horn. Check continuity as follows: Button pressed Continuity. Button not pressed No continuity.

•

Replace left hand switch

2. Check voltage level

Connect Tester (20 V DC) as follows:

Terminal (+) of Tester Orange cable (4). Terminal (-) of Tester Chassis grounding (5).

Turn key “ON”.

Press Horn button to activate horn.

Power measured must be > 12 V.

•

Repair power supply line of horn (orange cable). See “Wiring diagram” (P.8).

•

If there is no power entering switch (blue cable), the Mode button will not work (see point 2 on P.44).

37

NO

OK

2

3

4

1

OK

F. 35

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

3. Check ground connection

Disconnect black cable from terminal on horn (1). Using a bridge cable (2), connect horn terminal (3) to chassis ground connection (4).

Turn key “ON”.

Press Horn button to activate horn. Check operation of horn.

•

Replace horn.

Resume connection between black cable and chassis ground connection. See “Wiring Diagram” .

38

Tester ()

4

3

NO

OK

NO

OK

1

2

F. 37

F. 36

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

STOP LIGHT DOES WORK

Check:

1. Light bulb and relative coupling

2. Brake switch

3. Voltage level

1. Light bulb and relative coupling

Check continuity of light bulb and its coupling.•

Replace light bulb or coupling.

2. Front and rear brake switch

Disconnect switch cables. Connect Tester () as follows:

Terminal (+) of Tester Terminal (3). Terminal (-) of Tester Terminal (4).

Check continuity of front brake (1) as follows: Front brake lever pulled Continuity. Front brake lever not pulled No continuity. Check continuity of rear brake (2) as follows: Rear brake pedal pressed Continuity. Rear brake pedal not pressed No continuity.

•

Replace front and/or rear stop switch.

39

Tester (DC 20 V)

2

1

NO

OK

F. 38

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

3. Check voltage level

Connect Tester (20 V DC) as follows:

Terminal (+) of Tester Red cable (1). Terminal (-) of Tester Black cable (2).

Turn key “ON”.

Pull brake lever or press brake pedal.

Power measured must be > 12 V.

•

Red cable is interrupted: resume connection. See “Wiring diagram” (P.8).

•

Circuit is in working order.

If black cable (ground) is interrupted, the tail lamp will not work.

40

Tester ()

1

3

2

NO

OK

F. 39

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

TURN INDICATORS AND RELATIVE INDICATOR LIGHT DO NOT WORK

Check:

1. Turn indicator switch

2. Voltage level of ﬂ ashlight

3. Continuity of brown cable

1. Turn indicator switch

Disconnect nine-way cable of left hand switch. Flick switch to activate right hand turn indicators. Connect Tester () as follows:

Terminal (+) of Tester Brown cable (1). Terminal (-) of Tester Green cable (2).

Check continuity. Flick switch to activate left hand turn indicators. Connect Tester () as follows:

Terminal (+) of Tester Brown cable (1). Terminal (-) of Tester Purple cable (3).

Check continuity.

•

Turn switch is faulty.

Replace left hand switch

•

41

Tester (DC 20 V)

2

1

Tester ()

4

3

NO

OK

NO

OK

F. 41

F. 40

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

2. Voltage level of ﬂ ashlight

Detach ﬂ ashlight connector. Connect Tester (20 V DC) as follows:

Terminal (+) of Tester Blue cable (1). Terminal (-) of Tester Chassis grounding (2). Turn key “ON”.

Power measured must be > 12 V

•

Blue cable between key switch and ﬂ ashlight is interrupted Resume connection. See “Wiring diagram” (P.8).

•

3. Continuity of brown cable

Disconnect ﬂ ashlight connector. Disconnect left hand switch connector. Connect Tester () as follows:

Terminal (+) of Tester Brown cable of left hand control (3). Terminal (-) of Tester Brown cable of ﬂ ashlight (4).

Check continuity.

•

Brown cable between left hand connector and ﬂ ashlight is interrupted. Resume connection. See “Wiring diagram” (P.8).

•

Replace ﬂ ashlight.

42

NO

OK

Tester (DC 20 V)

2

1

Tester (DC 20 V)

2

3

S

L

F. 43

F. 42

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

L’INDICATORE DI DIREZIONE DESTRO O SINISTRO NON FUNZIONA

1. Turn indicator

Left hand turn indicator:

Connect Tester (20 V DC) to connector of light bulb coupling, as follows:

Terminal (+) of Tester Purple cable (1). Terminal (-) of Tester Chassis grounding (2). Turn key “on”.

Operate switch to activate left turn indicators.

Right hand turn indicator:

Connect Tester (20 V DC) to connector of light bulb coupling, as follows:

Terminal (+) of Tester Green cable (3). Terminal (-) of Tester Chassis grounding (2). Turn key “on”.

Operate switch to activate right turn indicators. Power measured must be > 12V in both cases.

•

Wiring between left hand switch and light bulb coupling connector is interrupted. Resume connection. See “Wiring diagram” (P.8).

•

Circuit is in working order.

43

2

Tester ()

1

3

NO

OK

Tester ()

2

1

F.45

F. 44

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

NEUTRAL INDICATOR LIGHT DOES NOT COME ON

Check:

1. Neutral switch

2. Instrument board

1. Neutral switch

Connect Tester () as follows:

Terminal (+) of Tester Neutral switch (1). Terminal (-) of Tester Chassis grounding (2).

Check continuity as follows:

Transmission in neutral Continuity. Vehicle in gear No continuity.

•

Replace neutral switch.

Cable interrupted between neutral switch and instrument board connector Resume connection. See “Wiring diagram” (P.8).

•

Replace Instrument board

After removing the lead terminal, make sure the neutral switch is ﬁ rmly screwed in place.

NO

OK

2. Instrument board

Disconnect instrument board connector (1). Disconnect lead terminal (2) of neutral switch. Connect Tester () as follows:

Terminal (+) of Tester Lead terminal (2). Terminal (-) of Tester Red - black cable PIN 15 (3).

Check continuity.

•

44

3

4

Tester (DC 20 V)

Tester ()

21

F. 46

F. 47

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

NO

OK

NO

OK

DISPLAY FUNCTIONS CANNOT BE CHANGED

Check:

1. “Mode” button

2. Power supply

3. Continuity of red cable

1. Check “Mode” button

Disconnect nine-way connector of left hand switch. Connect Tester () as follows:

Terminal (+) of Tester Yellow cable (1) Terminal (-) of Tester Light blue cable (2).

Press “Mode” button. Check continuity. See “checking switches”.

•

Faulty “Mode” button. Replace left hand switch

•

2. Check power supply

Disconnect nine-way connector of left hand switch. Connect Tester (20 V DC) to connector (system side) as follows:

Terminal (+) of Tester Blue cable (3).

Terminal (-) of Tester Chassis grounding (4). Turn key “ON”. Power measured must be > 12 V.

•

45

1

2

Tester ()

3

4

F. 48

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

NO

OK

3. Check continuity of red cable

Connect Tester () as follows:

Terminal (+) of Tester Red cable PIN 5 (3).

Terminal (-) of Tester Red cable (4).

Check continuity of red cable between left hand switch (1) and instrument board connector (2). See “checking switches”.

•

Red cable is interrupted. Resume connection. See “Wiring diagram” (P.8).

•

Replace instrument board.

OK

“Mode” button is not powered; blue cable is

interrupted. Resume connection. See “Wiring diagram” (P.8).

•

If blue cable is interrupted, horn will not work.

NO

46

1

2

Tester ()

4

3

F. 49

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

NO

OK

REV COUNTER IS NOT WORKING

1. Check rev counter power supply

Connect Tester () as follows:

Terminal (+) of Tester White - green cable PIN 8 (3).

Terminal (-) of Tester White - green cable (4).

Check continuity of white - green cable between ﬂ ywheel magneto connector (1) and instrument board connector (2).

•

White - green cable is interrupted. Resume connection. See “Wiring diagram” (P.8).

•

Replace instrument board.

47

2

Tester ()

3

4

1

F. 50

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

Replace fuel cock (with built-in probe).

LIGHT IS OFF

LIGHT IS ON

FUEL RESERVE WARNING LIGHT DOES NOT COME ON

Check:

1. Fuel probe

2. Continuity of grey cable

3. Ground connection

1. Check fuel probe

Detach connector of probe. Provide jumper between grey cable and black cable of connector on system side.

Turn key on and a wait a few seconds for the fuel warning light to come on.

•

Grey cable is interrupted.

Resume connection. See “Wiring diagram” (P.8).

•

NO

OK

2. Check continuity of grey cable

Connect Tester () as follows:

Terminal (+) of Tester Grey cable PIN 6 (3).

Terminal (-) of Tester Grey cable (4).

Check continuity of grey cable between probe connector (1) and instrument board connector (2).

•

48

Tester ()

2

1

F. 51

S I G N A L L I N G S Y S T E M

SIGNALLING SYSTEM

Black cable between probe connector and ground connection point is interrupted. Resume connection. See “Wiring diagram” (P.8).

•

Replace instrument board.

NO

OK

3. Check ground connection (black cable)

Connect Tester () as follows:

Terminal (+) of Tester Black cable (system side) (1).

Terminal (-) of Tester Chassis grounding (2).

Check continuity.

•

OK

49

1

2

F.52

H E A T S E N S O R C I R C U I T S Y S T E M

HEAT SENSOR CIRCUIT SYSTEM

Blue cable between key switch and heat sensor connector is interrupted. Resume connection. See “Wiring diagram” (P.8).

•

NO

OK

GENERAL MATTERS

The carburettor is ﬁ tted with a heater called “PTC”. It is activated when the “heat sensor” under the left hand side

casing is reading a temperature of < 3°C.

The “PTC” heater keeps the temperature of the carburettor constant, hence facilitating movement of the throttle valve.

CHECKING “PTC” HEATER CIRCUIT AND HEAT SENSOR

1. Check voltage level of “heat sensor”

2. Check voltage level of “PTC” heater

3. Check resistance of “PTC” heater

1. Check voltage level of “heat sensor”

Disconnect two-way connector (1) of heat sensor (2).

Connect Tester (20 V DC) as follows: Terminal (+) of Tester Blue cable. Terminal (-) of Tester Chassis grounding.

Turn key “ON”. Power measured must be > 12 V.

•

50

3

1

2

Tester ()

F. 54

F. 53

H E A T S E N S O R C I R C U I T S Y S T E M

HEAT SENSOR CIRCUIT SYSTEM

Check:

A) Continuity of white - light blue cable between

heat sensor and “PTC” heater. If cable is interrupted, resume connection. B) Black cable (ground connection). If cable is interrupted, resume connection between

“PTC” heater (1) and chassis ground connection.

See “Wiring diagram” (P.8).

•

Circuit is in working order.

NO

OK

2. Check voltage level of “PTC” heater

Provide jumper between blue cable and light blue - white cable of heat sensor connector.

Connect Tester (DC 20V) to cables of “PTC” heater (1) as follows: Terminal (+) of Tester White - light blue (2). Terminal (-) of Tester Black cable (3).

Turn key “ON”. Power measured must be > 12 V.

•

OK

3. Check resistance of “PTC” heater

Unscrew “PTC” heater.•

Connect tester () to two ends of heater.•

Resistance: ~ 11.2  at 20°C.•

NO

Replace “PTC” heater.

Malaguti X3Motard, X3Mnourd Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual