- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM INDEX CHAPTER Index Sect. Page INTRODUCTION Publication update Consultation notes Configuration of the pages Pages modified Pages added Symbols used Abbreviations used DIAGNOSTICS Electrical components General wiring diagram Instrument panel connector configuration Controlling the switches Control procedures Connection of switches illustrated in this manual...
INTRODUCTION CHAPTER • 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.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM INTRODUCTION CHAPTER CONSULTATION NOTES PAGE CONFIGURATION Chapter Section title Page No. 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.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM INTRODUCTION CHAPTER ATTENTION! Precautionary tips and information about the motorcyclist’s safety (the person using the motorcycle) and for protecting the integrity of the motorcycle itself. 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.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM INTRODUCTION CHAPTER ABBREVIATIONS USED Figure Tightening torque Page Paragraph Section Diagram Table 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.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM General Wiring Diagram CHAPTER GENERAL WIRING DIAGRAM COLOUR KEY BLACK/RED B-VL WHITE/MAUVE B-BL WHITE/BLUE R-VR RED/GREEN B-GR WHITE/GREY PINK BLUE RS-N PINK/BLACK BL-N BLUE/BLACK MAUVE BL-R BLUE/RED VL-N MAUVE/BLACK BL-VR BLUE/GREEN VR-N GREEN/BLACK YELLOW GREEN...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM General Wiring Diagram CHAPTER GENERAL WIRING DIAGRAM LEGEND FLYWHEEL 39) REAR STOP SWITCH MAIN SWITCH 40) FLASHER RELAY HORN 41) REGULATOR BATTERY 42) ANTI-THEFT PREDISPOSITION 15 A FUSE 7.5 A FUSE 5 A FUSE 15 A FUSE 30 A FUSE 10) 5 A FUSE...
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Controlling the Switches CHAPTER 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.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Controlling the Switches 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.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Controlling the Switches CHAPTER POSITION OF THE SWITCHES AND CONNECTORS CONNECTIONS Rear stop switch Engine start switch Horn command Engine stop switch Lights switch Mode Passing Main switch Indicators switch Side stand switch Front stop switch Fuses plate Main lights switch...
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Ignition System CHAPTER ELECTRICAL COMPONENTS: MAGNETIC FLYWHEEL MAIN SWITCH 5 A FUSE (No.3) 15 A FUSE (No.4) 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: The main 30A fuse, the 15A fuse and the 5A fuse...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Ignition System CHAPTER 3. Spark plug 0,6÷0,7 mm - Check plug conditions. - Verify the type of plug. - Check the distance between the electrode: 0.6÷0.7 mm. NOT CONFORMING CONFORMING - Faulty spark plug: replace. 4.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Ignition System CHAPTER - 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.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Ignition System CHAPTER 8. Engine stop switch - Disconnect the six-way and two-way connectors of the right-hand switch (3). START ENGINE STOP ENGINE STOP MODE LIGHTS - Position the “Engine Stop” push button on the symbol - Connect the Multimeter ( ) as follows: GL-BL...
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Charging System CHAPTER CHARGING SYSTEM CIRCUIT 06.05 EDITION PAGE SECTION 2...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Charging System CHAPTER ELECTRICAL COMPONENTS: MAGNETIC FLYWHEEL BATTERY 12) 30 A FUSE (No. 8) 41) VOLTAGE REGULATOR FAILURE DIAGNOSIS If the battery fails to recharge, check the: Fuse (30 A) Battery Charging voltage Stator coil resistance Charging system wiring 1.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Charging System CHAPTER 4. Verify stator recharging resistance - Remove the three-way connector of the magnetic flywheel and connect the Multimeter ( ) as follows: - (+) Multimeter terminal Red cable. - (-) Multimeter terminal Red cable.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start System CHAPTER ELECTRIC STARTING SYSTEM CIRCUIT 06.05 PAGE EDITION SECTION 2...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start System CHAPTER ELECTRICAL COMPONENTS: MAIN SWITCH BATTERY 5 A FUSE (3) 15 A FUSE (4) 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) FAILURE DIAGNOSIS...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start System CHAPTER 3. Battery OUT OF SPEC - Check battery conditions. - See page 22. - Replace the battery. SPEC 4. Check the starter motor - Connect a 12 V battery to the starter motor with two cables (see figure).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start System CHAPTER 6. Starting circuit interruption relay - Disconnect the (white) relay connector. - Connect the Multimeter ( ) and a battery (12 V) to the relay terminals as follows. - (+) battery pole Terminal (86).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start System CHAPTER 10. Start switch - Disconnect the six-way right-hand switch connector (3) and connect the Multimeter ( ) as follows: ENGINE STOP ENGINE STOP MODE START LIGHTS - (+) Multimeter terminal White/red cable (1).
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start System CHAPTER CHECKING THE STARTER MOTOR 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...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start 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. OUT OF SPEC -Scrape the mica until you have the SPEC...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start System CHAPTER 1.5 Brush spring - Measure the brush spring load (1). - Brush spring load: 570÷920 g. COLLAPSED/OUT OF SPEC SPEC -Replace the whole unit. WORN/DAMAGED 1.6 Bearing and oil seal - Inspect bearing and oil seal.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Electric Start 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 - Put a thin layer of molybdenum grease on the starter motor bearings.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER LIGHTING SYSTEM CIRCUIT 06.05 EDITION PAGE SECTION 2...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER ELECTRICAL COMPONENTS: MAIN SWITCH BATTERY 15 A FUSE (No. 1) 17) TAILLIGHT 19) NUMBER PLATE LIGHT 32) RIGHT-HAND SWITCH 33) INSTRUMENT PANEL 36) HEADLIGHT 38) LEFT-HAND SWITCH FAILURE DIAGNOSIS If the headlight, lights, low beam indicator, high beam indicator or front and rear parking lights fail to come on, check the: 15 A fuse (No.1)
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER NOT CONFORMING 4. Lights switch (right-hand switch) - See the “controlling the switches” section (page 13). - Replace the right -hand switch. CONFORMING 5. Lights switch/“passing” push button NOT CONFORMING (left-hand switch) - See the “controlling the switches”...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER CONTROLLING THE LIGHTING SYSTEM 1. THE HIGH BEAM LIGHT IS NOT TURNING ON NO CONTINUITY 1.1 Check the lamp and lamp holder - See the “controlling the switches” section (page 13). - Replace the lamp and/or lamp CONTINUITY holder.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER 3. THE LOW BEAM LIGHT IS NOT TURNING ON NO CONTINUITY 3.1 Check the lamp and lamp holder - See the “controlling the switches” section (page 13). - Replace the lamp and/or lamp CONTINUITY holder.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER 4. THE LOW BEAM INDICATOR IS NOT TURNING ON 4.1 Check voltage - Connect the Multimeter (20 Vdc) to the instrument panel connector as follows: 24 23 22 21 20 19 18 17 16 15 14 13 - (+) Multimeter terminal White/azure cable (Pin 3) (1).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER 6. THE TAILLIGHT IS NOT TURNING ON OUT OF SPEC 6.1 Check the lamp and lamp holder - See the “controlling the switches” section (page13). - Replace the lamp and/or lamp TO SPEC holder.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Lighting System CHAPTER 7. THE FRONT PARKING LIGHT IS NOT TURNING ON OUT OF SPEC 7.1 Check lamp and lamp holder - See the “controlling the switches” section (page13). - Replace the lamp and/or lamp holder.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER SIGNALLING SYSTEM CIRCUIT 06.05 EDITION PAGE SECTION 2...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER ELECTRICAL COMPONENTS: MAIN SWITCH HORN BATTERY 7.5 A FUSE (No. 2) 30 A FUSE (No. 5) 17) TAILLIGHT (STOP) 22) PICKOFF c/Km 23) FUEL PROBE 24) THERMISTOR 30) “C.D.I.” 31) FRONT STOP SWITCH 32) RIGHT-HAND SWITCH 33) INSTRUMENT PANEL...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 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).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 2.3 Check voltage - Connect the Multimeter (20 Vdc) to the flasher relay as B-GR follows: - (+) Multimeter terminal White/grey cable (1). - (-) Multimeter terminal Chassis earth (2). - Put the key in the “ON”...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 2.5 Check the brown/black cable B-GR - Connect the Multimeter ( ) to the brown/black cable as follows: - (+) Multimeter terminal Black/brown cable (1) HORN PASSING PASSING LUCI TURN flasher relay output.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 3. THE HORN IS NOT WORKING NO CONTINUITY 3.1 Horn switch - See the “controlling the switches” section (page 13). - Replace the left-hand switch. CONTINUITY 3.2 Verify earth - Connect the Multimeter ( ) to the left-hand switch HORN PASSING...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 3.4 Check voltage - 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”...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 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). NO CONTINUITY CONTINUITY - Black cable interrupted.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 5. THE REVOLUTION COUNTER IS NOT WORKING 7 6 5 4 3 2 5.1 Continuity of the yellow/red cable 7 6 5 4 3 2 - Disconnect the “C.D.I.” connector (3) and the instrument panel connector (4).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 6. TEMPERATURE INDICATOR NOT WORKING 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).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 7. INSTRUMENT PANEL NOT CHANGING FUNCTION 7.1 “Mode” push button START ENGINE STOP ENGINE STOP MODE LIGHTS - Disconnect the 2-way connector of the right-hand switch (3) and connect the Multimeter ( ) as follows: - (+) Multimeter terminal Red cable (1).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 7.3 Red cable continuity - Connect the Multimeter ( ) as follows: - (+) Multimeter terminal Red cable (1). START ENGINE STOP ENGINE STOP MODE LIGHTS - (-) Multimeter terminal Red cable (2).
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Signalling System CHAPTER 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.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Cooling System CHAPTER COOLING SYSTEM CIRCUIT 06.05 PAGE EDITION SECTION 2...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Cooling system CHAPTER ELECTRICAL COMPONENTS: MAIN SWITCH BATTERY 11) 7.5 A FUSE (No. 7) 20) FAN 27) THERMAL SWITCH FAILURE DIAGNOSIS THE FAN MOTOR IS NOT WORKING 1. 7.5 A FUSE (No. 7) NO CONTINUITY - See the “controlling the switches”...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Cooling System CHAPTER 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 ( ) to the thermal switch terminals.
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Automatic Cold Start System CHAPTER AUTOMATIC COLD START SYSTEM CIRCUIT 06.05 EDITION PAGE SECTION 2...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Automatic Cold Start System CHAPTER ELECTRICAL COMPONENTS MAIN SWITCH BATTERY 5 A FUSE (No. 3) 30 A FUSE (No. 5) 25) ELECTRIC STARTER 26) THERMAL SWITCH 30) C.D.I. 32) RIGHT-HAND SWITCH (ENGINE STOP) FAILURE DIAGNOSIS THE AUTOMATIC COLD START SYSTEM DEVICE IS NOT WORKING 1.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Automatic Cold Start System CHAPTER 3. Check voltage - Disconnect the electric starter connector. - Connect the Multimeter (20 Vdc) as follows: - (+) multimeter terminal Yellow/white cable(1). GL-B VR-N - (-) multimeter terminal Chassis earth (2).
- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Fuel Pump System CHAPTER FUEL PUMP SYSTEM CIRCUIT 06.05 PAGE EDITION SECTION 2...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Fuel Pump System CHAPTER ELECTRICAL COMPONENTS: MAIN SWITCH BATTERY 5 A FUSE (No. 3) 30 A FUSE (No. 5) 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.”...
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Fuel Pump System CHAPTER THE FUEL PUMP IS NOT WORKING. 1. 5 A Fuse (No. 6) NO CONTINUITY - See the “controlling the switches” section (page 13) - Replace the fuse. CONTINUITY NO CONTINUITY 2.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Fuel Pump System CHAPTER CONNECTIONS FAULTY 5. Check wiring - Check connections of the whole fuel pump system (see “circuit diagram”). - Restore wiring. - See “Circuit diagram” - Replace the “C.D.I.” 6.
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- DIAGNOSTICS FAILURE DIAGNOSIS OF THE ELECTRICAL SYSTEM Fuel Pump System CHAPTER 06.05 PAGE EDITION SECTION 2...
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