Malaguti MADISON 3 125 cc, Workshop Manual

Page 1: ...MADISON 125 cc Euro 3 B TROUBLESHOOTING ELECTRICAL SYSTEM WORKSHOP MANUAL ...

Page 2: ...cation 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 NOTES FOR EASY CONSULTATION PAGE LAYOUT X Y Chapter X Motor vehicle model J ...

Page 3: ...ions to be absolutely avoided WARNINGS 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 For checks and calibration use tools of an ascertained quality and never empirical means or tools with a limited reliability Malaguti S p A declines all responsibility for damage of any kind caused ...

Page 4: ...duction CHAPTER PAGE ISSUE ENGLISH Table of contents Page Introduction 2 Checking Switches 6 Fuses 8 General Wiring Diagram 11 Ignition System 14 Charging System 16 Electrical Starting System 18 Light System 20 Signalling System 25 ...

Page 5: ...ctric current W Watt the unit 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 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 o bar the unit of pressure...

Page 6: ...ON OF SWITCHES DESCRIBED IN THIS MANUAL This manual contains connection diagrams like the one illustrated here below 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 switch the top line the colour of the wires connected to the switch terminals The symbol identifies terminals in ...

Page 7: ... R L BL B N M VL VR POSITION OF SWITCHES AND CONNECTION OF CONNECTORS 1 Rear stop switch 8 Engine start switch 2 Horn control 9 Engine stop switch 3 Light switch 10 Mode 4 Passing 11 Key switch 5 Turn indicator switch 12 Side stand switch 6 Front stop switch 13 Fuse carrier 7 Main light switch NOTE the start switch is closed when the START button is pressed The side stand switch is closed when the...

Page 8: ...wing 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 switches on to check operation of the relative electrical systems If the fuse blows again check the relative circuit CAUTION never use fuses with an amperage differing from that indicated Use only fuses and never other materials An unsuitable fuse can cause ...

Page 9: ...trical equipment includes 10 fuses Before replacing a fuse locate and eliminate the fault causing its interruption F 4 F 5 9 30 A Recharge protection fuse 1 15 A Lights 2 7 5 A Turn indicators stop 3 3A ENGINE STOP 4 10 A Key 5 30 A Main 6 Not active 7 7 5 A Radiator fan 8 5 A 12 V Socket ...

Page 10: ...make sure it is correctly plugged in If terminal is disconnected bend stop A and refit terminal in connector Plug in connectors NOTE the click sound means that all connector parts are correctly assembled Check continuity with a Tester NOTE if there is no continuity clean terminals As a temporary solution use a contact cleaner Follow the instructions above to check the electrical equipment Use Test...

Page 11: ... ON BAR OIL BAR OIL TEMPERATURA H2O TEMPERATURA H2O LIVELLO CARBURANTE LIVELLO CARBURANTE 5 w 21w 5 w 21w 5 w 21w 5 w 21w 10 W 10 W 10 W 10 W 5 W 5 W 2 W Diodo 2A Diodo 2A N Open Open Close Close RS RS B N B N AZ B AZ B N RS RS B N B N AZ B AZ B N N N VL VL VR VR BL N BL N VR N VR N N BL BL GL B GL B BL R BL R BL BL N GL B GL B BL R BL R VR N VR N BL N BL N BL BL BL R BL R BL R BL R GL VL GL VL R ...

Page 12: ...GHT SWITCH 12 REAR RIGHT STOP SWITCH 13 POWER SUPPLY SOCKET FOR RECHARGING 12 V 14 ELECTRONIC CONTROL UNIT 15 ELECTRIC STARTER ON CARBURETTOR 16 COIL 17 WATER TEMPERATURE SENSOR 18 FUEL PROBE 19 VOLTAGE REGULATOR 20 FLYWHEEL 21 REV COUNTER SENSOR 22 SIDE STAND SWITCH 23 RADIATOR FAN 24 STARTER MOTOR 25 HELMET COMPARTMENT LIGHT 26 REAR LIGHTS 27 REMOTE SWITCH 28 REMOTE START SWITCH BLACK 29 FUSE 30...

Page 13: ...3 8 BAR OIL 16 LEFTTURN INDICATOR 24 INSTRUMENT BOARD CONNECTOR GENERAL WIRING DIAGRAM COLOUR KEY N R BLACK RED B VL WHITE PURPLE R RED B BL WHITE BLUE R VR RED GREEN B GR WHITE GREY RS PINK BL BLUE RS N PINK BLACK BL N BLUE BLACK VL PURPLE BL R BLUE RED VL N PURPLE BLACK BL VR BLUE GREEN VR N GREEN BLACK GL YELLOW VR GREEN GL B YELLOW WHITE AR ORANGE GL N YELLOW BLACK AR B ORANGE WHITE GL V YELLO...

Page 14: ...park plug Check type of spark plug Check gap between electrodes 0 6 0 7 mm 1 2 Spark plug cap resistance Remove spark plug cap NOTE when removing spark plug cap do not pull To remove Turn anti clockwise To connect Turn clockwise Before connecting the spark plug cap check the HV cable and cut off a piece of approximately 5 mm Connect Tester K to spark plug cap as follows Terminal of Tester Spark pl...

Page 15: ... 50 3 50 K at 20 C 1 4 Check pick up flywheel Remove wiring connector from flywheel cover Connect Tester to connector on flywheel cover R Terminal of Tester Connection n 2 Terminal of Tester Chassis grounding Resistance measured must be 105 124 at 20 C 1 5 Cable connection Check connections of ignition system refer to the wiring diagram paying attention to the cable colours and to how they are con...

Page 16: ...se Check continuity of fuse If fuse has blown eliminate cause of short circuit and replace fuse with an identical one F 15 1 2 Battery Remove battery and connect Tester 20 V DC as follows Terminal of Tester Battery pole Terminal of Tester Battery pole 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 minute...

Page 17: ... pole Run engine at approx 5000 RPM The voltage measured should be 12 80 14 V 1 4 Check stator recharging resistance Remove wiring connector from flywheel cover Connect Tester to connector on flywheel cover R Make sure resistance measured between connections 3 5 1 5 and 1 3 is 0 2 0 8 NOTE always check grounding isolation of three terminals F 17 1 5 Checking wiring connections Check connections of...

Page 18: ...OUBLESHOOTING 1 IF STARTER MOTOR DOES NOT WORK CHECK 1 7 5 A fuse N 2 3 A fuse N 3 30 A fuse N 5 2 Battery 3 Starter motor 4 Remote start switch Remote start circuit interruption switch 5 Key switch 6 Engine stop switch 7 Side stand switch 8 Start switch START 9 Front rear stop switch 10 Starting system wiring connections 1 1 7 5 A fuse N 2 3 A fuse N 3 30 A fuse N 5 Remove relative fuse Connect T...

Page 19: ...NG never invert battery connections on remote switch terminals Terminal of Tester Terminal 87 Terminal of Tester Terminal 30 Check continuity N 12V 12V 85 30 86 87 F 20 1 5 Key switch See Checking switches section on page 6 7 1 6 Engine stop switch See Checking switches section on page 6 7 1 7 Side stand switch See Checking switches section on page 6 7 1 8 Start switch See Checking switches sectio...

Page 20: ... fuse Connect Tester to fuse Check continuity of fuse If fuse has blown eliminate cause of short circuit and replace fuse with an identical one 1 2 Battery Check condition of battery See Checking Battery page 16 1 3 Key switch Check key switch See Checking switches section page 6 7 1 4 Light switch right switch See Checking switches section page 6 7 1 5 Light switch passing button left switch See ...

Page 21: ...d must be 12 V F 22 35 w 35 w 35 w 35 w 35 w 35 w 35 w 35 w 5 W 5 W N B N AZ B RS AZ B AZ B B N B N RS RS N N N N 2 1 3 IF HIGH BEAM INDICATOR LIGHT DOES NOT COME ON 3 1 Check voltage level Connect Tester 20 V DC to instrument board connector as follows Terminal of Tester White Black cable PIN 15 1 Terminal of Tester Black cable PIN 17 2 Turn key ON Flick light switch to symbol Flick light switch ...

Page 22: ...witch to symbol Flick light switch to LO symbol Power measured must be 12 V If system works replace instrument board 4 IF LOW BEAM LIGHT DOES NOT COME ON 4 1 Check lamp and lamp socket See Checking switches section page 6 4 2 Check voltage level Connect Tester 20 V DC to four way connector of wiring as follows Terminal of Tester White Light Blue cable 1 Terminal of Tester Black cable 2 Turn key ON...

Page 23: ...9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 GL B BL R GL BL BL R N RS AZ B VR GL R B VR GR N VL B N R B 2 1 F 26 7 IF TAIL LIGHT DOES NOT COME ON 7 1 Check lamp and lamp socket See Checking switches section page 6 7 7 2 Check voltage level Connect Tester 20 V DC to six way connector of tail light wiring as follows Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Turn key ON Flic...

Page 24: ... N N N N 2 1 8 IF FRONT PARKING LIGHT DOES NOT COME ON 8 1 Check lamp and lamp socket See Checking switches section page 6 7 8 2 Check voltage level Connect Tester 20 V DC to four way connector of headlight wiring as follows Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Turn key ON Flick light switch to symbol Power measured must be 12 V ...

Page 25: ...OUNTER SENSOR DOES NOT SIGNAL SPEED 1 1 Check voltage level Detach three way connector from rev counter sensor and connect Tester 20 V DC as follows Terminal tester Yellow Blue cable 1 Terminal tester Black cable 2 Turn key ON Put Engine stop button in starting position Power measured must be 5 0 5 V F 29 N GL BL B 1 2 ...

Page 26: ...n starting position Let wheel run in riding direction and check power as follows Sensor 3 Gap between screws 5 Power 5 0 5 V Sensor 3 Screw head 4 Power 0 20 0 5 V 1 2 3 4 5 6 7 8 9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 GL B BL R GL BL BL R N RS AZ B VR GL R B VR GR N VL B N R B 1 2 3 5 3 4 F 30 F 31 F 32 Check continuity of white cable Tester between PIN 13 of terminal board and terminal p...

Page 27: ... A the resistance of the thermistor is 280 at 80 Make sure that on the 9th notch B the red light comes on and the resistance of the thermistor is 102 at 118 F 33 2 2 Check fuel indicator A Fuel indicator on 0 Resistance of fuel probe 61 3 litres of fuel B Fuel indicator on 1 2 Resistance of fuel probe 34 6 litres of fuel C Fuel indicator on 1 Resistance of fuel probe 13 9 litres of fuel full F 34 ...

Page 28: ...utton If power is 12 V replace horn CAUTION never invert position of cables BL AR 2 3 1 F 36 3 2 Check grounding Connect Tester to connector of left hand switch 3 as follows Terminal of tester Black cable 1 Terminal of tester Chassis grounding 2 ON ON 0FF 0FF ON ON 0FF 0FF LO LO HI HI LUCI LUCI HORN HORN PASSING PASSING R L TURN TURN BL BL AZ B AZ B GL N GL N B N B N VR VR VL VL M AR AR N BL BL B ...

Page 29: ...2 V BL AR 2 3 1 F 37 4 IF OIL PRESSURE SWITCH IS NOT PROVIDING A SIGNAL OR IS PROVIDING AN INCORRECT SIGNAL 4 1 Check pressure switch Remove wiring connector from flywheel cover Connect Tester to connector on flywheel cover R Terminal of tester Flywheel connector terminal 4 Terminal of tester Engine grounding M A Engine is off Continuity 0 B As soon as engine is started No continuity infinite Not ...

Page 30: ...whether there is a signal on the rev counter wire or not after 8 seconds alarm display will relate to the engine running The alarm is displayed irrespective of the function selected During alarm conditions the button s function is disabled F 39 4 3 OIL alarm disabling The OIL alarm CHECK or CHANGE can only be disabled by authorised personnel following the procedure described here below Turn key sw...

Page 31: ... 7 5 A fuse N 2 Remove relative fuse Connect Tester to fuse Check continuity of fuse If fuse has blown eliminate cause of short circuit and replace fuse with an identical one F 41 Tester 5 2 Lamp and lamp socket See Checking switches section page 6 7 5 3 Stop light front rear See Checking switches section page 6 7 ...

Page 32: ...e Grey cable 1 Terminal of tester Chassis grounding 2 Turn key ON Power input to flashlight White Grey cable must be 12 V B GR M N 1 2 F 43 5 4 Check voltage level Connect Tester 20 V DC to six way connector of tail light wiring as follows Terminal of Tester Red cable 1 Terminal of Tester Black cable 2 Turn key ON Operate brake lever right or left Power measured must be 12 V F 42 N B N N B N AZ B ...

Page 33: ... 2 F 45 6 4 Check flasher relay Connect Tester 20 V DC to flashlight as follows Terminal of Tester Brown Black cable 1 Terminal of tester Chassis grounding 2 Turn key ON Power output from flashlight Brown Black cable must be 12 V 6 5 Check Brown Black cable Connect Tester to brown black cable as follows Terminal of tester Brown Black cable 1 leading from flasher relay Terminal of tester Brown Blac...

Page 34: ... indicators Terminal of Tester Green cable 2 Terminal of Tester Black cable 3 Turn key ON Turn Turn switch from left to right In both cases power measured must be 12 V F 46 F 47 N B N N B N AZ B AZ B 16 16 W W 35 w 35 w 35 w 35 w 35 w 35 w 35 w 35 w 5 W RS N RS N RS B N AZ B N RS B N AZ B N N N VL VR N N VL VR N VL N VR 3 1 N B N N B N AZ B AZ B 16 16 W W 35 w 35 w 35 w 35 w 35 w 35 w 35 w 35 w 5 ...

Page 35: ...identical one 7 2 Check motor fan Disconnect connector of fan and power the latter by means of the battery as follows Battery cable Red 1 cable Battery cable Black 2 cable Fan does not work replace it F 49 12V 12V N R N AZ 7 3 Check thermal switch on front side of radiator Detach the two yellow cables from the thermal switch Provide a jumper between the two yellow cables Turn key ON Fan works repl...

Page 36: ...Wiring Diagram Continuity yellow cable leading from fuse holder to thermal switch is interrupted Repair see Wiring Diagram F 52 N R N GL GL GL GL FUS 7 5A FUS 7 5A AZ GR 100 95 12 V WITH KEY ON 7 4 Check ground continuity of black cable Connect Tester as follows Terminal of tester Black cable 1 Terminal of tester Chassis grounding 2 No continuity black cable interrupted Repair by providing a jumpe...

Page 37: ...V battery In the meantime check how the length of the piston changes If length does not change in 5 minutes replace electric starter mm3 mm3 8 2 Check power delivered to electric starter Disconnect starter connector Connect Tester DC20V to wiring connector as follows Terminal of tester Blue cable 1 Terminal of Tester Brown cable 2 Start engine Power measured must be 12 V F 54 12 V WITH KEY ON 2 1 ...

Page 38: ...nuity brown cable interrupted Repair See Wiring Diagram F 56 BL M 02412900 4 5 6 7 8 3 M B GL R M N AR 12 V WITH KEY ON 1 2 8 3 Check blue cable power supply Connect Tester 20 V DC as follows Terminal of tester Blue cable Tester of terminal chassis grounding Turn key ON Power measured must be 12 V Not compliant blue cable is interrupted Repair See Wiring Diagram F 55 BL M 02412900 4 5 6 7 8 3 M B ...