Malaguti X3Mnourd Workshop Manual Download

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Summary of Contents for X3Mnourd

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Page 2: ...ion 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...

Page 3: ...he 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...

Page 4: ...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 figure in which case they refer to the topic illustrated in the figure and to the...

Page 5: ...NGER 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 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 ENGIN...

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 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 servicing make sure that the vehicle i...

Page 7: ...nit of electric power result of Volts by Amps A x V W Ω OHM the unit of electrical resistance Infinite 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 ...

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: ...4 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 L...

Page 10: ...E 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 ...

Page 11: ...BLE 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 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 9 RS PARKING LIGHTS 18 BL N HALL SENSOR VDC ...

Page 12: ...W 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 SWITCH 8 ENGINE STOP SWITCH 9 KEY SWITCH 10 REAR STOP SWITCH 11 SIDE STAND SWITCH ...

Page 13: ...O 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 Starter relay 8 Fuse 15 A 9 Flashlight 10 Regulator 11 Fuel probe ...

Page 14: ...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 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 ...

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 Plug in connectors Check continuity Tester Ω If there is no continuity clean terminals As a temporary solution use a contact cleaner Follow the instructions provided above to check the electrical equip...

Page 16: ...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 first column from the left indicates the different positions of the switches the top line indicates the colour of the wires connect...

Page 17: ...g 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 ...

Page 18: ...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 ...

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 Ω 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 Ω 20 at 20 C Replace spark...

Page 20: ...winding 0 9 Ω 10 at 20 C Terminal of Tester Terminal 1 Terminal of Tester Ground 2 Check resistance of coil s secondary winding 7 30 KΩ 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 Ω and check continuity of key switch as follows Terminal of Tester Orange cable 5 Termina...

Page 21: ...o way connector of flywheel magneto Connect Tester Ω to connector as follows Terminal of Tester Red terminal 1 Terminal of Tester White terminal 2 Check pick up resistance 240 Ω 10 at 20 C Replace stator 8 Connections Check connections of ignition system See Wiring Diagram Resume system s connections Replace CDI control unit ...

Page 22: ...ral 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 Ω 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 electr...

Page 23: ...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 Ω to terminals B and M...

Page 24: ...ey switch Turn key ON Connect Tester Ω as follows Terminal of Tester Orange cable 1 Terminal of Tester Green cable 2 Check continuity Replace key switch 6 Neutral switch Connect Tester Ω 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 ...

Page 25: ...erminal 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 Ω as follows Terminal of Tester White black cable 2 Terminal of Tester White green cable 4 Check continuity between terminals Replace ri...

Page 26: ...ect Tester Ω 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 Ω 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 starti...

Page 27: ...ystem 1 Fuse 15 A Remove relative fuse Connect Tester Ω 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 soluti...

Page 28: ...f 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 flywheel magneto Connect Tester 200Ω as follows Terminal of Tester White cable 3 Terminal of Tester White cable 4 Measure resistance of charging coil 1 20Ω 10 at ...

Page 29: ...r Terminal 2 Check continuity This check must be performed with the 15 A fuse inserted Test B Connect Tester Ω 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 con...

Page 30: ...Fuse 15 A Remove relative fuse Connect Tester Ω 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 wate...

Page 31: ... 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 Ω 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 R...

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 diode bridge is correct see photo Replace the C D I control unit ...

Page 33: ...ge 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 ...

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 board See Wiring Diagram ...

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 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 w...

Page 36: ...minal 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 s...

Page 37: ...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 ...

Page 38: ...its coupling Replace light bulb or coupling 2 Front and rear brake switch Disconnect switch cables Connect Tester Ω 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 brak...

Page 39: ...ct 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 ...

Page 40: ... Turn indicator switch Disconnect nine way cable of left hand switch Flick switch to activate right hand turn indicators Connect Tester Ω 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 Ω as follows Terminal of Tester Brown cable 1 Terminal of Tester Purple cable 3 Check continuity Turn ...

Page 41: ...ower 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 left hand switch connector Connect Tester Ω as follows Terminal of Tester Brown cable of left hand control 3 Terminal of Tester Brown cable of flashlight 4 Check continuity Brown cable between left han...

Page 42: ...ble 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 ...

Page 43: ...ansmission 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 firmly screwed in place NO OK 2 Instrument board Disconnect instrument board connector 1 Disconnect lead termin...

Page 44: ...tor of left hand switch Connect Tester Ω 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 T...

Page 45: ...N 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 ...

Page 46: ...unter power supply Connect Tester Ω 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 1 and instrument board connector 2 White green cable is interrupted Resume connection See Wiring diagram P 8 Replace instrument board ...

Page 47: ...robe 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 Ω as follows Terminal of Tester Grey cable PIN 6 3 Terminal of Tester Grey cable 4 Check contin...

Page 48: ...en 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 Ω as follows Terminal of Tester Black cable system side 1 Terminal of Tester Chassis grounding 2 Check continuity OK ...

Page 49: ...t 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...

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 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 OK 3 Check...

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