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I N T R O D U C T I O N

I N T R O D U C T I O N

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 dif

fi

 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.


Summary of Contents for X3Motard

Page 1: ......

Page 2: ...on 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...

Page 3: ...e 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 an...

Page 4: ...etter 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 si...

Page 5: ...GER OF EXPLOSION Indicates operations which may constitute a risk of explosion TOXIC FUMES Indicates a possibility of intoxication or inflammation of the upper respiratory tract MECHANICAL MAINTENANCE...

Page 6: ...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 num...

Page 7: ...nit of electric power result of Volts by Amps A x V W OHM the unit of electrical resistance Infinite OHM tester prods disconnected or cable interrupted OHM 0 continuity with tester prods connected and...

Page 8: ...8 4 3 2 1 41 40 33 35 37 39 34 32 29 27 28 26 25 24 23 21 19 18 16 15 9 13 11 10 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 G E N E R A L W I R I N G D I A G R A M...

Page 9: ...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...

Page 10: ...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 YELL...

Page 11: ...LE COLOUR FUNCTION 1 N NEGATIVE 10 2 VR RIGHT HAND TURN INDICATOR 11 B N HIGH BEAM LIGHT 3 VL LEFT HAND TURN INDICATOR 12 4 GL R HALL SENSOR INPUT 13 5 R MODE BUTTON SIGNAL 14 BL 12 V WITH KEY ON 6 GR...

Page 12: ...I T C H E S C H E C K I N G S W I T C H E S 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...

Page 13: ...N O F E L E C T R I C A L C O M P O N E N T S 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 1 Thermal switch 2 Horn 3 PTC fuel heater 4 Neutral switch 5 Side stand switch 6 HV coil 7 St...

Page 14: ...E C T R I C A L C O M P O N E N T S 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 12 Digital instrument board 13 Key switch 14 Clutch switch 15 Battery 16 Diode set 17 Light relay 18 CD...

Page 15: ...Pull connector to make sure it is correctly plugged in If terminal is disconnected bend stop A and refit terminal in connector The click sound means that all connector parts are correctly assembled P...

Page 16: ...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 terminal...

Page 17: ...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 s...

Page 18: ...e 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 s...

Page 19: ...des 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...

Page 20: ...ding 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...

Page 21: ...o way connector of flywheel 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...

Page 22: ...al 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 circu...

Page 23: ...otor 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...

Page 24: ...y 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 Termina...

Page 25: ...minal 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...

Page 26: ...ct 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 connec...

Page 27: ...stem 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...

Page 28: ...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 resistan...

Page 29: ...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 Termina...

Page 30: ...use 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...

Page 31: ...rminal 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 T...

Page 32: ...T I N G S Y S T E M 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 diod...

Page 33: ...e 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 Test...

Page 34: ...T I N G S Y S T E M L I G H T I N G S Y S T E M 3 Light switch Check continuity of light switch see Checking switches on P 16 Replace left hand switch Repair wiring of headlight and or instrument boar...

Page 35: ...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 foll...

Page 36: ...al 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...

Page 37: ...onnection 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...

Page 38: ...ts 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...

Page 39: ...t 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 resum...

Page 40: ...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 G...

Page 41: ...wer measured must be 12 V Blue cable between key switch and flashlight is interrupted Resume connection See Wiring diagram P 8 3 Continuity of brown cable Disconnect flashlight connector Disconnect le...

Page 42: ...le 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...

Page 43: ...mission 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 Repl...

Page 44: ...or 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 Rep...

Page 45: ...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...

Page 46: ...nter 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 flywheel magneto connector...

Page 47: ...obe 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 int...

Page 48: ...n 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 Ter...

Page 49: ...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 HEA...

Page 50: ...eater 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...

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