Malaguti XTM POWER UP 2007 Troubleshooting Manual Download Page 1

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-XSM POWER UP 2007

ELECTRIC SYSTEM

TROUBLESHOOTING

WORKSHOP MANUALS

Summary of Contents for XTM POWER UP 2007

Page 1: ...B XTM XSM POWER UP 2007 ELECTRIC SYSTEM TROUBLESHOOTING WORKSHOP MANUALS ...

Page 2: ...diting symbols 5 Abbreviations 7 TROUBLESHOOTING 8 Wiring diagram 8 Key to general wiring diagram 9 Colour key 9 Key to electrical components 10 Connector test 11 Switch tests 12 Connection of the switches described in this manual 12 Key to ignition system 13 Troubleshooting 14 Recharging system key 18 Troubleshooting 19 Lighting system key 21 Troubleshooting 22 Lighting system check 24 Signalling...

Page 3: ...d 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...

Page 4: ...and the new date of issue EDITING SYMBOLS Symbols have been provided for quick and easy reference see page 6 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 figure in which case they refer to the topic illustrated in the figure and to the r...

Page 5: ...ations which may constitute a fire hazard D RISK OF EXPLOSION Indicates operations which may constitute a risk of explosion E TOXIC FUMES Indicates a possibility of intoxication or inflammation of the upper respiratory tract F MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic G ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technic...

Page 6: ...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 specified units and components are reassembled by proceeding in the reverse order of removal Before any servic...

Page 7: ...W ID SX VL 10W ID DX N VR 35W FARO 10W ID SX N VL 10W ID DX N VR N 21W STOP 5W POS RS R AR HT 1 16 ON OFF HORN GR R L VL M VR TURN N N RS F 10A N GL R Vuoto BL GR R GL B AR B R Vuoto BL B GL VR BL N M N RS N BL R R N N GR M N B R RS N B R BL N GL VR B R VL GL B R N VL GL B R N vuoto vuoto B R BL VR N VR GL AR vuoto vuoto R B N B BL B B R B R N N VL GL BL R B N N VR N B VR N GR M GR VR N B VR B N N...

Page 8: ...REAR LEFTTURN INDICATOR 26 GROUND 27 SIDE STAND SWITCH 28 REAR STOP SWITCH 29 SPEEDOMETER SENSOR 30 WATER TEMPERATURE SENSOR 31 AIR TEMPERATURE SENSOR COLOUR KEY This table lists the abbreviations used to identify the colour of the electrical connection cables on the wiring diagram Abbreviations are given on the diagram near the component AR AZ B BL GL GR M N R RS VL VR AZ B B M B N B R B VL B VR ...

Page 9: ...4 5 6 7 8 9 10 11 12 13 14 15 16 17 KEY TO ELECTRICAL COMPONENTS 1 FRONT STOP SWITCH 2 REGULATOR 3 CONTROLUNIT 4 10 A FUSE 5 BATTERY 6 FLASHLIGHT 7 SIDE STAND SWITCH 8 COIL 9 REAR STOP SWITCH 10 MIXER OIL PROBE 11 SOLENOID 12 FUEL PROBE 13 H2 O TEMPERATURE SENSOR 14 HORN 15 DIGITALINSTRUMENTBOARD 16 KEY SWITCH 17 AIR TEMPERATURE SENSOR ...

Page 10: ...tor two or three times 4 Pull connector to make sure it is correctly plugged in 5 If terminal comes loose bend stop A and refit terminal in connector 6 Connect connectors NOTE The click sound means that all connector parts are correctly assembled 7 Check continuity with a Tester NOTE If there is no continuity clean terminals Follow the instructions from step 1 to 7 to check the electrical equipmen...

Page 11: ... W Put indicator on 0 CONNECTION OF THE SWITCHES DESCRIBED IN THIS MANUAL This manual contains connection diagrams like the one illustrated on the left which illustrate how switch terminals should be connected key switch brake switch light switch etc The column on the left indicates the different positions of the switches the first line indicates the colours of the wires connected to the switch te...

Page 12: ...10W ID SX N VL 10W ID DX N VR N 21W STOP 5W POS RS R AR HT 1 16 ON OFF HORN GR R L VL M VR TURN N N RS F 10A N GL R Vuoto BL GR R GL B AR B R Vuoto BL B GL VR BL N M N RS N BL R R N N GR M N B R RS N B R BL N GL VR B R VL GL B R N VL GL B R N vuoto vuoto B R BL VR N VR GL AR vuoto vuoto R B N B BL B B R B R N N VL GL BL R B N N VR N B VR N GR M GR VR N B VR B N N BL BL BL Vuoto BL B GL TPS B VL R ...

Page 13: ...plug Check type of spark plug Gap between electrodes 0 7 mm COMPLIANT 2 Spark plug cap resistance Remove spark plug cap NOTE Never pull spark plug cable to remove cap Connect the Tester K as shown in the figure To remove turn anti clockwise To connect turn clockwise When connecting check spark plug cable and if necessary replace it with a new one Cap resistance 5K 20 a 20 C COMPLIANT Sample spark ...

Page 14: ...ct Tester to HV coil Check resistance of coil s secondary winding Primary winding resistance 7 9 20 a 20 C COMPLIANT 1 2 3 4 Engine Stop button Disconnect four way connector 1 Connect Tester and check continuity between cables White black cable 2 Black cable 3 See Checking connectors on page 11 COMPLIANT Terminal Terminal 1 Terminal Grounded 2 1 2 1 2 Terminal Spark plug cable 1 Terminal Terminal ...

Page 15: ... Connect Tester to connector as follows Terminal Terminal 2 Terminal Terminal 3 1 3 2 COMPLIANT 6 Key switch Disconnect connector 1 of key switch Turn key ON Connect Tester and check continuity as follows Terminal Orange cable 2 Terminal Green cable 3 See Checking connectors on page 11 1 2 3 COMPLIANT NOT COMPLIANT Faulty side stand switch Replace NOT COMPLIANT Faulty key switch Replace ...

Page 16: ...1 of flywheel magneto 2 Connect Tester to connector as follows Terminal White Red Terminal 3 Terminal Blue White Terminal 4 Check pick up resistance Pick up resistance 350 20 a 20 C COMPLIANT 8 Connections Check connections of ignition system See Circuit Diagram COMPLIANT Replace CDI control unit 1 4 3 2 NOT COMPLIANT Replace stator NOT COMPLIANT Resume system s connections ...

Page 17: ...X VL 10W ID DX N VR 35W FARO 10W ID SX N VL 10W ID DX N VR N 21W STOP 5W POS RS R AR HT 1 16 ON OFF HORN GR R L VL M VR TURN N N RS F 10A N GL R Vuoto BL GR R GL B AR B R Vuoto BL B GL VR BL N M N RS N BL R R N N GR M N B R RS N B R BL N GL VR B R VL GL B R N VL GL B R N vuoto vuoto B R BL VR N VR GL AR vuoto vuoto R B N B BL B B R B R N N VL GL BL R B N N VR N B VR N GR M GR VR N B VR B N N BL BL...

Page 18: ...age 12 5 V Density of electrolytic solution 1280 g dm3 Level of electrolytic solution 3 Charging voltage Connect inductive rev counter to spark plug cable Connect Tester 20 V DC to battery Terminal Terminal of battery Terminal Terminal of battery Measure battery voltage Run engine at 5000 RPM Check battery voltage Charging voltage 12 5 14 5 V NOTE Use a fully charged battery NO CONTINUITY Faulty f...

Page 19: ...el magneto 2 Connect Tester to connector as follows Terminal White cable terminal 3 Terminal Grounded 4 Measure resistance of charging coil Charging coil resistance 0 80 20 a 20 C 5 Recharging system connections Check connections of recharging system See Circuit Diagram Replace voltage regulator COMPLIANT COMPLIANT NOT COMPLIANT Replace stator NOT COMPLIANT Resume system s connections 1 2 3 4 ...

Page 20: ...N VR 35W FARO 10W ID SX N VL 10W ID DX N VR N 21W STOP 5W POS RS R AR HT 1 16 ON OFF HORN GR R L VL M VR TURN N N RS F 10A N GL R Vuoto BL GR R GL B AR B R Vuoto BL B GL VR BL N M N RS N BL R R N N GR M N B R RS N B R BL N GL VR B R VL GL B R N VL GL B R N vuoto vuoto B R BL VR N VR GL AR vuoto vuoto R B N B BL B B R B R N N VL GL BL R B N N VR N B VR N GR M GR VR N B VR B N N BL BL BL Vuoto BL B ...

Page 21: ...ighting system coil resistance 2 Continuity of Purple Yellow cable 3 Key switch 4 Connection of lighting system 1 Lighting system coil resistance Disconnect four way connector 1 of flywheel magneto 2 Connect Tester to connector as follows Terminal Yellow red cable terminal 3 Terminal Grounded 4 Measure resistance of lighting system coil Charging coil resistance 0 80 20 a 20 C COMPLIANT NOT COMPLIA...

Page 22: ...and pink cable of regulator connector CONTINUITY 3 Key switch Disconnect connector 1 of key switch Turn key ON Connect Tester and check continuity as follows Terminal Yellow cable 2 Terminal Green black cable 3 See Checking connectors on page 11 COMPLIANT 4 Connections Check all connections to lighting system See Circuit diagram COMPLIANT Replace voltage regulator NO CONTINUITY Purple yellow cable...

Page 23: ...ght bulb and relative coupling Check continuity of light bulb and its coupling 2 Check lamp socket voltage Connect Tester 20V AC to connector of headlight Terminal Pink cable Terminal Black cable Run engine at approx 5000 RPM Power measured must be 12 5V COMPLIANT Circuit is in working order NO CONTINUITY Replace lamp or coupling NOT COMPLIANT Resume connections of headlight See Circuit Diagram ...

Page 24: ...f light bulb and its coupling CONTINUITY 2 Check lamp socket voltage Connect Tester 20VAC to terminals of light bulb coupling Terminal Pink cable terminal Terminal Black cable terminal Run engine at approx 5000 RPM Power measured must be 12 5V COMPLIANT Circuit is in working order NO CONTINUITY Replace lamp or coupling NOT COMPLIANT Resume connections between key switch and rear light See Circuit ...

Page 25: ... light to LO symbol CONTINUITY The white blue cable leading from the left hand switch to the lamp socket is interrupted Repair see Circuit Diagram NO CONTINUITY Replace lamp or coupling NO CONTINUITY Replace left hand switch HIGH BEAM LIGHT DOES NOT COME ON BUT HIGH BEAM INDICATOR LIGHT DOES SWITZERLAND VERSION ONLY 1 Light bulb and relative coupling Check continuity of light bulb and its coupling...

Page 26: ...ace left hand switch HIGH BEAM INDICATOR LIGHT DOES NOT COME ON SWITZERLAND VERSION ONLY 1 Light bulb and relative coupling Check continuity of light bulb and its coupling Check continuity of blue cable leading from left hand switch to lamp socket of instrument board indicator light CONTINUITY CONTINUITY There is no lamp socket grounding point Repair by providing a jumper between black cable conne...

Page 27: ... 2 Check continuity of pink cable Connect Tester between pink cable of tail light lamp socket and pink cable of number plate light lamp socket No continuity pink cable is interrupted Repair see wiring diagram NO CONTINUITY Replace lamp and or lamp socket NO CONTINUITY Pink cable is interrupted Repair see Circuit Diagram CONTINUITY Thereisnolampsocketgroundingpoint Repairby providingajumperbetweenb...

Page 28: ...M N B R RS N B R BL N GL VR B R VL GL B R N VL GL B R N vuoto vuoto B R BL VR N VR GL AR vuoto vuoto R B N B BL B B R B R N N VL GL BL R B N N VR N B VR N GR M GR VR N B VR B N N BL BL BL Vuoto BL B GL TPS B VL R N B VL R N R N Vuoto 24 14 1 2 3 5 7 8 9 10 12 13 15 21 22 23 25 26 28 29 30 31 17 SIGNALLING SYSTEM KEY 1 BATTERY 2 10 A FUSE 3 CONTROLUNIT 5 HORN 7 FLASHLIGHT 8 TURNINDICATORBUTTON 9 HO...

Page 29: ...N DO NOT WORK Check 1 10 A fuse 2 Battery 3 Key switch 4 Connections of signalling system 1 10 A Fuse Remove fuse Connect Tester to fuse Check continuity of fuse CONTINUITY 2 Battery Check condition of battery Minimum voltage 12 5 V Density of electrolytic solution 1280 g dm3 Level of electrolytic solution COMPLIANT NO CONTINUITY Faulty fuse Replace NOT COMPLIANT Clean terminals Recharge or replac...

Page 30: ...connect connector 1 of key switch Turn key ON Connect Tester and check continuity as follows Terminal Orange cable 2 Terminal Green cable 3 See Checking connectors on page 11 COMPLIANT 4 Check connections Check connections of signalling system See Circuit Diagram NOT COMPLIANT Faulty key switch Replace NOT COMPLIANT Resume system s connections ...

Page 31: ...y as follows Terminal Grey cable 2 Terminal Black cable 3 Button pressed Continuity Button not pressed No continuity See Checking connectors on page 11 Comando SX M VR VL GR N ON OFF HORN GR R L VL M VR TURN N 1 2 3 COMPLIANT 2 Check voltage level Connect Tester 20V DC to horn cables 1 Terminal Blue cable 2 Terminal Orange cable 3 Turn key ON Press Horn button to activate horn Power measured must ...

Page 32: ... Check blue cable power supply Connect Tester 20 V DC to horn 1 Terminal Blue cable 2 Terminal Chassis grounding 3 Turn key ON Press Horn button to activate horn Power measured must be 12 5 V BL AR 1 3 2 NOT COMPLIANT Blue cable interrupted See Circuit Diagram COMPLIANT Resume connection of orange cable See Circuit Diagram ...

Page 33: ...oupling CONTINUITY 2 Front and rear brake switch Disconnect switch cables Connect Tester to terminals T1 T2 Check continuity between terminals See Checking switches on page 12 A Front brake switch B Rear brake switch A B 1 Front brake lever operated 2 Front brake lever not operated 1 Rear brake pedal pressed 2 Brake pedal not pressed COMPLIANT NO CONTINUITY Replace lamp or coupling NOT COMPLIANT F...

Page 34: ...eck voltage level Connect Tester 20V DC to connector of light bulb coupling Terminal Red cable 1 Terminal Black cable 2 Turn key ON Pull brake lever or press brake pedal Power measured in both cases must be 12 5V 1 2 COMPLIANT Circuit is in working order NOT COMPLIANT Red cable interrupted resume connection See Circuit Diagram ...

Page 35: ...ct six way connector of left hand switch Connect Tester to connector as follows Press switch to activate right hand turn indicators Terminal Brown cable 2 Terminal Green cable 3 Press switch to activate left hand turn indicators Terminal Brown cable 2 Terminal Purple cable 4 There must be continuity in both cases M VR VL AR N Comando SX M VR VL GR N ON OFF HORN GR R L VL M VR TURN N 1 3 2 4 COMPLI...

Page 36: ...ON Power measured must be 12V COMPLIANT 4 Check continuity of brown cable Disconnect flashlight connector Disconnect left hand switch connector Connect Tester to terminals of respective connectors Check continuity of brown cable CONTINUITY Faulty flashlight Replace NOT COMPLIANT Blue cable between key switch and flashlight interrupted Resume connection See Circuit Diagram NO CONTINUITY Brown cable...

Page 37: ...urple cable 1 Terminal Chassis grounding cable B Right hand turn indicator Terminal Green cable 2 Terminal Chassis grounding cable 1 2 Turn key ON A operate the switch to activate the left hand turn indicators B operate the switch to activate the right hand turn indicators Power measured in both cases must be 12 5V COMPLIANT Circuit is in working order NOT COMPLIANT Cable interrupted between turn ...

Page 38: ...unding point 2 Neutral Continuity Vehicle in gear No continuity COMPLIANT 2 Check instrument board Disconnect instrument board connector 1 Disconnect lead terminal 2 of neutral switch Connect Tester as follows Terminal Red black lead terminal 2 Terminal Red black cable 3 CONTINUITY Replace instrument board NOT COMPLIANT Faulty neutral switch Replace WARNING After removing the lead terminal make su...

Page 39: ...White green cable 3 Press the Mode button Check continuity See Checking connectors on page 11 2 3 1 CONTINUITY 2 Check power supply Disconnect six way connector of right hand switch 1 Connect Tester 20 V DC to connector system side as follows Terminal Blue cable 2 Terminal Chassis grounding 3 Turn key ON Power measured must be 12 5V Comando DX MODE ENGINE STOP ON OFF ON OFF B N N VR N B VR VR N B ...

Page 40: ...d cable 4 Check continuity of red cable between connector of right hand controls 1 and instrument board connector 2 Comando DX MODE ENGINE STOP ON OFF ON OFF B N N VR N B VR VR N B VR B N N R BL B VL R N B R CRUSCOTTO VR GR VL M N GL R GR R vuoto vuoto vuoto 1 18 vuoto vuoto N VL GL BL R BL R N 2 1 4 3 CONTINUITY Replace instrument board NO CONTINUITY Red cable interrupted Resume connection See Ci...

Page 41: ...inuity of purple yellow cable between flywheel magneto connector 1 and instrument board connector 2 1 3 2 4 CONTINUITY Replace instrument board NO CONTINUITY Purple yellow cable interrupted Resume connection See Circuit Diagram FAULTY FUEL INDICATOR 1 Check fuel probe Detach connector of fuel probe Provide jumper between grey cable and black cable of connector on system side Turn key ON and wait a...

Page 42: ...nnector and instrument board connector PIN 6 CONTINUITY 3 Check grounding black cable Connect Tester as follows Terminal Black cable Terminal Chassis grounding Check continuity of grounding of probe connector black cable on system side CONTINUITY Replace instrument board NO CONTINUITY Grey cable interrupted Resume connection See Circuit Diagram NO CONTINUITY Black cable interrupted Resume connecti...

Page 43: ...freely and position itself at the base of the probe continuity Overturn probe no continuity COMPLIANT B Check continuity of grounding of black cable plugged into probe Disconnect connector from probe and connect tester F23 Tester terminal Black cable 1 Tester terminal Chassis grounding 2 CONTINUITY White cable between probe and digital instrument interrupted repair See Circuit Diagram NOT COMPLIAN...

Page 44: ...tion is always provided by the large 7 segment digits at the centre of the display irrespective of the function selected or of any active alarms Current speed can be given in km h or if the setup menu is accessed in mph the selected mode is shown on the display to the right of the numeric value provided The display is updated every 0 5 seconds Displ cc 50cc 50cc The system s size depends on the fo...

Page 45: ...relevant heading appears When the vehicle is at a standstill you can adjust the current time by holding the MODE button down until only the segments of the time function and the relative TIME heading are visible this happens after about 5 seconds Hold down the button to gradually increase the minutes after 10 of these increasing sessions adjustment switches to rapid hour increasing To return to sl...

Page 46: ...e counter can be reset either with the vehicle halted or running Average speed is calculated as the relation between the distance travelled and the time employed to cover this distance measured in seconds the information is acquired in km h or mph depending on the unit of measurement selected with a resolution of 1 decimal unit Calculation of this time function is based on the actual run time of t...

Page 47: ... there is no memorised information the number 00000 will be displayed Information is always calculated in km It can be converted into miles by opening the setup menu In conditions of normal use of the instrument this information cannot be reset TOD function 8 Rev counter function RPM This information is displayed in digital format by the small digits with no further indication The information prov...

Page 48: ...l Reference headings and icons appear when the function is displayed 1 RPM indicator function This information is displayed by the entire bar graph 18 segments and is accompanied by the heading RPM appearing on the top right of the top section of the bar Information is updated every 0 33 sec and is controlled in accordance to the following table rpmx100 RPM 0 up to 14 from 15 to 17 from 18 to 20 f...

Page 49: ...spective of the current function of the battery voltage bar graph The first bar segment the battery icon and the message MIN will start flashing this alarm does not compromise operation of the instrument board that can be used as usual The above alarm indications will however remain As a consequence if you select a new function when this alarm is present and you open a submenu RPM or radiator flui...

Page 50: ...failure of the resistive probe to the instrument board will be signalled by the LED flashing The bar graph is updated every 0 5 seconds and controlled in accordance to the following table temp C 30 30 40 40 50 50 60 60 70 70 80 80 90 90 110 110 8 LED Tolerance 10 Resistance 2449 1661 1148 810 582 426 315 240 N of segments 1 2 3 4 5 6 7 8 The alarm LED will only go off when temperature drops below ...

Page 51: ...ed in a permanent memory If the adjustment menu is opened but no changes are made within 20 seconds the system will automatically switch back to its normal operating mode and will not save the selected unit of measurement If the adjustment menu is opened and you turn the key switch off and on the system will be automatically switched back to its normal operating mode and the selected unit of measu...

Page 52: ... when the status of input n 2 or n 3 of the connector is high which means that the turn indicators are on The signal must reach the instrument board alternated 6 Troubleshooting indicator light function This indicator light is activated by the control unit that signals by means of different timers the presence of faults involving the vehicle input pin 17 If the control unit detects a fault the ind...

Page 53: ...s the selected model Enduro or Motard Third page LCD check for 3 seconds All segments of the LCD are activated As the three pages described above appear the system also checks the indicator lights and backlighting in other words all LED are activated and then go off at the end of the check After the above operations the system is ready for normal operation SLEEP MODE Every time the key switch is t...

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