MO Xtm-Xsm 50 Troubleshooting ENG
Contents
1. 2 2 lt x 2 0 0 9 9 0 901 lt DP W W 2 HOLIMS 02 04 QO 1 OLANOVA TASHM Q Q 14 ELECTRIC SYSTEM TROUBLESHOOTING 2 Troubleshooting B LIGHT SYSTEM TROUBLESHOOTING JN warne the vehicle s lights come on when the key is in its ON position If the lights do not work proceed as follows O Check the light coil resistance F8 FLYWHEEL Disconnect the flywheel connector and connect the tester Tester terminal yellow cable Tester terminal white cable Light coil resistance 0 2 0 40 20 C Not compliant replace the flywheel Compliant continue searching B Make sure that the cables of the regulator connector are correctly positioned and firmly secured in place see wiring diagram C Check continuity tester between the yellow cable leading from the flywheel and the purple yellow cable leading to the regulator Check ground continuity tester between the black cable the regulator and a grounded point of the frame to be tested after disconnecting the regulator terminal board E Check the voltage regulator F9 Connect the tester AC to the regulator connector leaving the latte2. VOL 19 1 ra 5 90 919 yoeig enig ng 19 5 1 i 19 SUM 34617 z OLANOVW AIA TASHM N 18 TT N Sd YD 21 ene ee tet t _ _ SS 2 gt 2 393 lt lt 5 2 218 2 9 NYAL JJO NHOH 001 ofo
3. 5 2 z 2 lt 5 6 9 0 HOLIMS 4018 1 JAQON 901 ayog LNAWNYLSNI lt 0 lt gt 2 YOLVOIGNI LHOIY YOLVOIGNI 1331 HOLIMS AJA 1 LHOIY 1431 ELECTRIC SYSTEM TROUBLESHOOTING 4 Troubleshooting B CONNECTION OF THE SWITCHES DESCRIBED IN THIS MANUAL RH CONTROL This manual contains connection diagrams like the one illustrated hereby which illustrate how switch terminals should be connected key switch brake switch MODE button 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 which there is a condition of continuity i e a closed circuit in a certain position of the switch In this diagram B MA and there is continuous contact when the switch is ON 05 03 0 9 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting CHAPTER IGNITION SYSTEM CIRCUIT ES gt 7149801 5155209 4 02 04 00095410 9 2206 2 1 eusres p 22 1 4
4. 5 9 oe 1504 Vol eng E YOLVINOAY UMOIG S IUNA 19 SUM oo gpm 97 me E A 00095110 poo 2206 2 1 a ZV YAP QO 133HM i ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting Si ee es m O 52 gt 22 8 51121818 511812181 151018 CO Q 7 7 _ 5 eo NO O IQON
5. ed s 0 20 0 2050777 pag _ 9 9 35104 MoA dnd 19 1 18 MO 9A 9 u 19 UM YOLVINDAY UMOIG SHUMA el OBITUM SWUM Ss 02 04 9 2 YA 19 N QO N loo Co 2 abuelo eee N OLJN YN 1 V ee T y A o T ee 01 EE EE ET 81 3
6. E 440 2 440 gt lt lt a 5 HOLIMS 2 5 10 ELECTRIC SYSTEM TROUBLESHOOTING 2 Troubleshooting eam BL IGNITION SYSTEM TROUBLESHOOTING A Check resistance of the spark plug cap Detach the spark plug cap from the H V cable and connect the tester as follows 1 Tester terminal side 1 Tester terminal gt side 2 Spark plug resistance 5 20 Not compliant replace spark plug cap hii B Check resistance of the electronic control unit Connect the tester to the control unit as follows F2 Tester terminal cable Tester terminal p lead terminal green cable Secondary winding resistance 5 6 kQ 20 C Not compliant replace the control unit C Check resistance of power supply cable green cable Connect the tester to the flywheel as follows Tester terminal gt green cable Tester terminal y white cable Power supply resistance 640 780 20 C Not compliant replace the flywheel magneto D Check pick up resistance red cable FLYWHEEL Connect the tester to the flywheel as follows Tester terminal gt red cable Tester terminal 3 white cable Pick up resistance 100 140 Q 20 C Not compliant replace the flywheel magneto E Check key switch Disconnect the
7. 15 Signalling Systemi A 20 Turn indicator Troubleshooting 21 Stop light troubleshooting 23 FORA TOURS 24 Water temperature probe troubleshooting 25 Mixture oil indicator light troubleshooting 25 fuel reserve indicator light troubleshooting 26 Neutral indicator light troubleshooting 26 Speedometer sensor troubleshooting 26 MODE button TOUDIESHOOUNG 26 Revolution counter troubleshooting 27 Configuration of the digital instrument 27 28 1203 3000 ELECTRIC SYSTEM TROUBLESHOOTING Introduction 2 Malaguti reserves the right to make and all changes to its vehicles as deems fit appropriate at any time without prior notice e No part of this publication whether text or illustrations may be re
8. 29 0503 70 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting LEFT CONTROL HEADLIGHT LEFT INDICATOR RIGHT INDICATOR INSTRUMENT BOARD VR M VL AR N KEY SWITCH lt gt gt LOCK 6 ON LIGHTS 2 84 ziaja on oe JE _ E FLY WHEEL MAGNETO VL GL Blue Red R RS N 10 FUS FUSE Red gt 2 a lt Yellow A A NEUTRAL WATER TEMPERATURE REAR STOP SWITCH LEFT INDICATOR TAIL AND RIGHT INDICATOR PROBE STOP LIGHT 0000 e OIL INDICATOR SWITCH FUEL RISERVE SENSOR RIGHT CONTROL REGULATOR 5 SENSOR COLOUR KEY Orange Light blue White White White Black White Brown White Red White Green Blue Blue White Blue Black Blue Red Yellow Yellow White Yellow Black Yellow Red Yellow Green Gre
9. Blue Red R RS N 2 Z VL GL_ Purple Yellow 10A FUSE Red fe 7 z 7 DATE 30 07 03 E 5 aje 5 Lazzaro di Savena BOLOGNA 1 2 gt NEUTRAL Wiring Diagram XTM XSM E WATER TEMPERATURE Enduro Motard 50 REAR STOP SWITCH FUEL RISERVE STOP SWITC LEFT INDICATOR RIGHT INDICATOR PROBE STOP LIGHT 1 SENSOR 02 04 eae 0 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting IDEE IN LEFT CONTROL RIGHT CONTROL KEY SWITCH gt lt 2 LOW BEAM 7 7 OFF HIGH BEAM LIGHT lt gt gt PARKING LOCK LIGHT INSTRUMENT BOARD OFF R 2 2 FRONT STOP SWITCH LIGHTS TURN HORN R INDICATOR LIGHT INS LEFT INDICATOR RIGHT INDICATOR 20 S 2 BERERA gt 2 gt 4 0
10. sy 2 HOLIMS LHOIY 1 4015 2 285 YOLVOIGNI YOLVOIGNI 1 31 0109 19 YOSNIS 1 Naa HOLIMS 4018 W TA W YOLVOIGNI 1 31 TA 1 1391 9515 VOL A NYOH LHOMHSV ACL 02 04 QO Q Q 20 ELECTRIC SYSTEMTROUBLESHOOTING Troubleshooting TURN INDICATOR TROUBLESHOOTING If the turn indicators do not blink A Check the turn indicator switch F12 Disconnect the 5 way connector from the left hand switch tester Put the button in left hand indicator position Tester terminal gt Tester terminal Put the button in right hand indicator position Tester terminal p gt 5 Tester terminal There must be continuity in both cases No continuity replace the left hand switch Continuity continue searching B Check the voltage delivered to the flashlight F13 Disconnect the flashlight connector and con
11. 3 Tester terminal black cable Turn the key to ON Start the engine at 7000 RPM The voltage measured should be 12 volts Not compliant continue searching C Check continuity of the pink cable Connect the tester Q as follows F11 Tester terminal terminal 1 Tester terminal terminal2 Nocontinuity the pink cable leading from the key switch to the tail light is interrupted Repair see wiring dia gram PARKING LIGHTS STOP LIGHTS WARNING if the ground connection is lacking black cable the stop light will not come on either q 18 2000 02 04 ELECTRIC SYSTEM TROUBLESHOOTING 2 Troubleshooting If the number plate light is not workin roceed as follows A SWITZERLAND version only Check continuity of the lamp and lamp socket Discontinuity replace the lamp and or lamp socket Continuity continue searching it SWITZERLAND version only Check continuity of the pink cable Connect the tester Q between the pink cable of the tail light lamp socket and the pink cable of the number plate light lamp socket continuity the pink cable is interrupted Repair see wiring diagram Continuity there is no grounding point Repair by providing a jum
12. 001 lt T L O HOLIMS N ver ws ELECTRIC SYSTEM TROUBLESHOOTING 2 Troubleshooting CHARGING SYSTEM TROUBLESHOOTING If the battery is still flat after it has been replaced or recharged proceed as follows A Check charging voltage Connect the tester 20 DC to the battery as F5 Tester terminal gt battery pole Tester terminal p battery pole Start the engine at approx 7000 RPM 9 Voltage measured 13 5 14 compliant continue searching B Check the flywheel magneto charging coil FLYWHEEL Disconnect the connectors from the flywheel magneto and connect the tester as follows F6 Tester terminal gt yellow cable Tester terminal white cable Charging coil resistance 0 2 0 40 20 C Not compliant replace the flywheel Compliant continue searching C Check that the cables have been connected to the regulator connector in the right sequence see wiring diagram D Check continuity tester of the yellow purple cable leading from the flywheel to the regulator Check continuity of the yellow cable tester leading from the regulator to the battery pole F Check continuity tester of the black grounding cable connected to the regulator connector G Check the rectifier diode F7 The diode is under the seat connected to the yellow cable leading to the
13. pole of the battery Remove the diode and connect the tester as follows Tester terminal terminal 1 Tester terminal terminal 2 The value measured must be 435 Not compliant replace the diode WARNING to avoid troublesome inconveniences on electrical components make sure the diode is fitted before connecting the battery H If all checks have positive results replace the regulator 0503 0 13 D ES 7149801 wola 00096 0 2206 pelo Z 9 01822815 ed s 0 Z0 0 22 7 19 1 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting CHAPTER LIGHT SYSTEM CIRCUIT 19 34 19 N 19 8 19 19 31 N 1d 8 18 9 XA YOLVINDAY UMOJIG OVUM SUUNA 346 g ZV eu dOLS N sq
14. A Disconnect the probe connector and provide a jumper between the grey cable and the black cable Turn the switch Light on replace the petrol probe Light off continue searching Check grounding continuity tester between the black cable and a grounded point of the frame Discontinuity black cable interrupted Repair by providing a jumper between the black cable and a grounded point Continuity the cable leading from the probe to the digital instrument is interrupted Repair see wiring dia gram NEUTRAL INDICATOR LIGHT TROUBLESHOOTING A The neutral light stays on even if the vehicle is in gear Check whether the red black cable is grounded Disconnect the red black cable of the neutral switch fastened to the motor casing and connect the tester as follows Tester terminal red black cable Tester terminal grounded to frame Continuity red black cable grounded Repair Discontinuity replace the neutral switch B The neutral light only comes on in check mode Check continuity tester of the red black cable leading from neutral switch to the digital instrument Discontinuity red black cable interrupted Repair Continuity replace the neutral switch SPEEDOMETER SENSOR TROUBLESHOOTING If speed is not signalled proceed as follows make sure the digital instrument is correctly connected see wiring diagram
15. connector and connect the tester Q 1 Tester terminal red white cable Tester terminal blue cable es ae E CONTINUITY KEY ON 1ST CLICK DISCONTINUITY yO 2ND CLICK DISCONTINUITY From chassis n 7086714 Up to chassis n 7086713 2 Tester terminal gt orange cable Tester terminal p green cable KEYOFF _ DISCONTINUITY KEY ON 1ST CLICK CONTINUITY KEY OFF DISCONTINUITY KEY ON 2ND CLICK DISCONTINUITY KEY ON CONTINUITY From chassis n 7086714 Up to chassis n 7086713 3 Tester terminal p yellow cable Tester terminal green black cable DISCONTINUITY SERBS las DISCON LNT KEY OFF DISCONTINUITY KEY ON 1ST CLICK CONTINUITY KEY ON 2ND CLICK NTINUITY From chassis n 7086714 Up to chassis n 7086713 WARNING if the white black cable leading from the switch is grounded motor does start 0204 090 1 ES e 7149801 wold 02 04 x ed s 60 70 06 2 2 1 1 09915
16. in which case they refer to the topic illustrated in the figure and to the relative text or at the top of the page in which case they refer to all the topics dealt with in the page Note The meaning of the symbols should be duly memorised as their scope 15 to avoid having to repeat basic technical concepts or safety recommendations They are therefore to be considered as veritable memory tags case of any doubt as to their meaning consult the page in which they are fully described 0503 000 5 ELECTRIC SYSTEM TROUBLESHOOTING Introduction A CAUTION Recommendations and precautions regarding rider safety and motor vehicle integrity B WARNING Situations entailing the risk of personal injury to maintenance or repair mechanics other workshop personnel or third parties or damage to environment vehicle or equipment FIRE HAZARD Indicates operations 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 technician H Operations to be absolutely avoided ENGINE SERVICE MANUAL Indicates information which may be obtained by referring t
17. lt gt a 2 Flas DE m R ee HORN FLY WHEEL MAGNETO COLOUR KEY Orange Light blue White White White Black White Brown White Red White Green Blue Blue White Blue Black Blue Red Yellow Yellow White Yellow Black CHASSIS WEIGHT SPEEDOMETER JE Yellow Red if SARI Yellow Green Grey Brown VL GL_ Purple Yellow TAIL AND DATE 12 03 03 STOP LIGHT S Lazzaro di Savena BOLOGNA Ret 1 VL GL Red Red lt D zZ 7 2 1 LEFT INDICATOR RIGHT INDICATOR 5 NEUTRAL Yellow 12V BATTERY Wiring Diagram XTM XSM 4 Enduro Motard 50cc REAR STOP SWITCH PROBE FUEL RISERVE ey OIL INDICATOR SENSOR SWITZERLAND LIGHT SWITCH 0 0 02 04 B VR 8
18. 5 Check continuity of the blue cable leading from the left hand switch to lamp socket continuity repair the blue cable see wiring diagram the low beam light and indicator light are not working proceed as follows A SWITZERLAND version only Check left hand switch Connect the tester Q to the switch as follows Tester terminal gt blue cable Tester terminal pink cable Turn the light switch to the HI symbol No continuity replace the left hand switch If the low beam indicator light is not working proceed as follows A SWITZERLAND version only Check continuity of the light bulb Discontinuity replace the light bulb B SWITZERLAND version only Check continuity of the blue cable leading from the left hand switch to the lamp socket of the instru ment board indicator light No continuity the blue cable is interrupted Repair see wiring diagram Continuity there is no grounding point Repair by providing a jumper between the black cable connected to the lamp socket and a grounded point of the frame ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting the tail light does not work proceed as follows A Check continuity of the lamp Discontinuity replace the lamp B Check the voltage delivered to the rear lamp socket Connect the tester AC 20V to the lamp socket F10 Tester terminal
19. ELECTRIC SYSTEM TROUBLESHOOTING XTM 222 ELECTRIC SYSTEM TROUBLESHOOTING Introduction ELECTRICAL SYSTEM TROUBLESHOOTING HON 4 4 5 CONSUITAT ON 4 4 11 CAC 5 PNAC 5 MDO 5 PAE WAU OURS 7 8 8 Connection of the switches described this 9 system ea a a a aE 10 Ignition system troubleshooting 11 12 Charging System troubleshooting 13 14 Light system troubleshooting
20. LESHOOTING Check continuity of the white brown cable leading to the digital instrument and the purple yellow cable leading from the flywheel magneto Discontinuity white brown cable interrupted Repair see wiring diagram Continuity replace the digital instrument CONFIGURATION OF THE DIGITAL INSTRUMENT CONNECTOR Colour Pos Colour 12 wpe 27 ELECTRIC 5 Troubleshooting ELECTRICAL COMPONENT LAYOUT 1 INSTRUMENT BOARD HEADLIGHT HORN SWITCH WITH KEY LEFT CONTROL SPEEDOMETER SENSOR 7 FRONTRIGHT INDICATOR 8 FRONTLEFT INDICATOR 9 RIGHT CONTROL 10 WATER TEMPERATURE PROBE 11 REAR STOP SWITCH 12 OILINDICATOR SWITCH FUEL RESERVE SENSOR FLY WHEEL MAGNETO CDI CONTROL UNIT REGULATOR FLASHLIGHT BATTERY N 3 K 5 O 13 14 15 16 17 18 19 REAR RIGHT INDICATOR 20 TAILAND STOP LIGHT 21 REAR LEFT INDICATOR 22 FRONT STOP SWITCH 23 NEUTRAL INDICATOR LEAD TERMINAL 28 3000 05 03 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting 2 LZ 22 7 222222227 gt S 24 Ye 2 20 S Q 55 2 Ay hb SS f
21. ding a jumper between the black cable connected to the headlight and a grounded point of the frame SWITZERLAND version only If the front parking light does not work Check continuity of the pink cable Connect the tester Q to the pink cable leading from the key switch to the parking light lamp socket No continuity the pink cable is interrupted Repair See wiring diagram Continuity black cable interrupted Repair by providing a jumper between the black cable connected to the parking light lamp socket and a grounded point of the frame If the low beam is not working proceed as follows A SWITZERLAND version only Check continuity of the lamp Discontinuity replace the lamp B SWITZERLAND version only Check left hand switch Connect the tester Q to the switch as follows Tester terminal white blue cable Tester terminal pink cable Turn the switch light to the LO symbol No continuity replace the left hand switch Continuity the white blue cable leading from the left hand switch to the lamp socket 15 interrupted Repair see wiring diagram 16 3000 02 04 ELECTRIC SYSTEM TROUBLESHOOTING 2 Troubleshooting If the low beam light is not working but the low beam indicator light is proceed as follows A SWITZERLAND version only Check continuity of the lamp Discontinuity replace the lamp SWITZERLAND version only
22. ed should be 12 Volts Not compliant blue cable interrupted Repair see wir ing diagram Compliant continue searching GROUNDED D Check continuity of the red cable between the termi nal inserted in the stop switch and the terminal in serted in the tail light Discontinuity red cable interrupted Repair See wiring diagram F 18 L WARNING if the grounding connection is lacking the tail light will not come on either TAILAND STOP LIGHTS O0 0 232 ELECTRIC SYSTEM TROUBLESHOOTING 4 HORN TROUBLESHOOTING If the horn is not working proceed as follows LEFT HAND SWITCH BLOCK A Check the HORN button Disconnect the 5 way connector from the left hand switch and connect the tester Q F19 Tester terminal PS orange terminal Tester terminal black terminal Press the HORN button Discontinuity replace the left hand switch Continuity continue searching B Check grounding of the black cable of the 9 way switch of the harness Connect the OHM tester as follows Tester terminal black cable Tester terminal grounded to frame Nocontinuity black cable interrupted Repair by providing a jumper between the black cable and a grounded point of the frame Continuit
23. if the cables leading to the instrument s connector are correctly inserted replace the speedometer sensor and its electronic transmission MODE BUTTON TROUBLESHOOTING If the functions of the digital instrument are not changed when the Mode button is pressed proceed as fol lows RIGHT HAND CONTROL A Check the MODE button Disconnect the 2 way connector of the MODE but ton and connect the OHM tester as follows 24 Tester terminal terminal 1 Tester terminal terminal 2 Press the MODE button Discontinuity replace the MODE button Continuity continue searching 2 3000 CORDON ELECTRIC SYSTEMTROUBLESHOOTING 4 Troubleshooting Check power supply of the blue cable Connect the tester 20V DC as follows Tester terminal blue cable Tester terminal grounded to the frame Turn the switch Power measured must be 12 V Not compliant the blue cable is interrupted Repair See wiring diagram Check continuity of red cable MODE pulse Connect the OHM tester as follows Tester terminal 3 red cable connector Tester terminal cable digital instrument connector Discontinuity red cable interrupted Repair see wiring diagram Continuity replace the digital instrument REVOLUTION COUNTER TROUB
24. igital instrument Discontinuity the white green cable is interrupted Repair See wiring diagram Warning the red light will also blink if the white green water temperature probe cable has come loose MIXTURE OIL INDICATOR LIGHT TROUBLESHOOTING If the mixture oil indicator light only comes in check mode proceed as follows A Check the oil probe Take the oil probe out of the tank disconnect the con nector and connect the OHM tester 22 Tester terminal coupling 1 Tester terminal coupling 2 Whilst keeping the probe upright float A must run freely and position itself at the base of the probe Discontinuity the probe is faulty Repair Continuity continue searching B Check the grounding continuity of the black cable of the connector plugged into the probe Disconnect the connector from the probe and connect the OHM tester 23 Tester terminal black cable Tester terminal 3 grounded to frame Discontinuity the black cable is interrupted Repair by providing a jumper between the black cable and a ground ed point of the frame Continuity the white cable leading from the probe to the digital instrument is interrupted Repair See wiring diagram CODON ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting FUEL RESERVE INDICATOR LIGHT TROUBLESHOOTING If the fuel reserve indicator light only comes on in check mode proceed as follows
25. moved from the manual as they remain applicable to the servicing of pre modified models table of contents will be duly updated in the event that new pages are inserted which render the consulta tion of the manual difficult IMPORTANT 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 NOTES FOR EASY CONSULTATION PAGE LAYOUT Chapter Section title Z Date of issue 4 000 s 0503 D ELECTRIC SYSTEM TROUBLESHOOTING Introduction MODIFIED PAGES Modified pages shall bear the same number as those in the previous edition pre modified ones followed by the letter M with the date of issue appearing in the appropriate box e Modified pages may contain new illustrations this case the added illustration or illustrations will bear the number of the illustration on the former page followed by a letter ADDITIONAL PAGES e Any additional pages shall bear the last number of the section to which they belong followed by the letter A and the date of issue EDITING SYMBOLS e Symbols have been provided for quick and easy reference see page 6 identifying situations requiring utmost attention or providing practical suggestions or simple information e These symbols may appear next to a text in which case they refer solely to the text itself next to a figure
26. nect the 20 V DC tester Tester terminal p gt Tester terminal frame Turn the key ON Voltage 0 blue cable interrupted Repair see wiring diagram Voltage 12 Volts continue searching roceed as follows green cable brown cable purple cable brown cable blue cable cable grounded to C Check continuity of brown cable Connect the OHM tester between the terminal plugged into the flashlight connector the terminal plugged into the 5 way connector of the left hand switch both connectors must be disconnected Continuity replace the flashlight No continuity brown cable interrupted Repair see wiring diagram 0503 30 21 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting Check the voltage delivered to the lamp socket connector of the turn indicators proceed as follows A Check the right indicator F14 RIGHT TURN INDICATOR Disconnect the terminal of the right hand lamp socket and connect the tester 20V DC Tester terminal green cable Tester terminal black cable Key switch position Put the switch in right hand indicator position Voltage 12 Volts compliant Not compliant the circuit between the turn indicator switch and the lamp socket connector is fault
27. o said manual L SPARE PARTS CATALOGUE Indicates information which may be obtained by referring to said catalogue 6 0 alar gt ELECTRIC SYSTEM TROUBLESHOOTING 2 Introduction ABBREVIATIONS Figure Cs Pr Bsecton Note The letter Vin the illustrations refers to retaining or adjusting screws The number following this letter refers to the number of the same type of screw in the unit or component described and illustrated Letters not followed by a number indicate a single screw case of different screws being referred to in the illustration the letter Vis followed by a number 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 motorbike is perfectly stable The front wheel should preferably be anchored to the equipment A F 4 integral with the lifting board A ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting CHAPTER WIRING DIAGRAM z HOLIMS sisseyo YOSNAS 1 4018 d gaasi 1914 Bore le YOLVOIGNI 1431 HOLIMS 4018 0009 L0 poo 1 2206 TWHLNAAN Busnes 1 12201 8 9 2 w
28. per between the black cable connected to the lamp socket and a grounded point of the frame Tea 0 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting CHAPTER SIGNALLING SYSTEM CIRCUIT 7149801 815540 wog HOLIMS YOSNAS YOLVOIGNI 110 1304 0009 210 poo YALVM 2206 Ip 4 22 1 4 YA 15 a ZV N d 4 1 1 219 AA 212 2 SY 1 N 9910 19 PSY MOISA 4 19 19 SUUM MOll8A MO 9A y92e1g YM SHUM 34617 9 19 19 SH 19 YA 14718 Ne 2 6 9 430 H LIMS 4018 LNOWS 2201 Guvod LNAWNYLSNI lt 10 lt gt
29. produced or circulated Malaguti re serves all rights over this publication Reasons must be given for any request for permission written thereto FIRST EDITION 05 03 INTRODUCTION This publication describes necessary steps for troubleshooting concerning the electrical system of the models indicated on the front page and of the possible service operations which are necessary for their solution supplies the trade technicians authorised customer service centres with the necessary information for operating in compliance with the modern concepts of good practice and safety at work e Further information can be derived from the Chassis workshop manual from the Engine workshop manual from the Spare Parts catalogue All described operations must be performed by technicians with the necessary skill and experience e The steps for the removal of body parts and of electrical and mechanical components to allow access to wiring or electric components to service can be taken from the Chassis Workshop Manual e We recommend you follow the information given this publication with care e For any further information you may need refer to the Malaguti S p A Technical Department MANUAL UPDATES Updated pages of this publication will be delivered by us in a reasonable time already punched and therefore ready to be incorporated in the Manual The superseded sheets should not be re
30. r plugged in Tester terminal purple yellow cable Tester terminal 3 black cable Start the engine at 7000 RPM The voltage measured should be 12 volts Not compliant replace the regulator Compliant continue searching F Check continuity tester of the yellow cable leading from the regulator to the key switch G Check the key switch see page 11 SWITZERLAND version only Check continuity tester of the pink cable leading from the key switch to the left hand switch If there is no continuity replace the left hand switch 0204 ese 15 ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting the headlights are not working proceed as follows A Check continuity of the lamp and lamp socket Discontinuity replace the lamp and or lamp socket Continuity continue searching B Check voltage delivered to the front lamp socket Connect the tester 20V AC to the lamp socket Tester terminal pink cable Tester terminal black cable Turn the key to ON Start the engine at 7000 RPM The voltage measured should be 12 volts Not compliant continue searching C Check continuity of the pink cable Connect the tester Q to the pink cable leading from the key switch to the headlight connector continuity the pink cable is interrupted Repair see wiring diagram Continuity black cable interrupted Repair by provi
31. y Brown Black Red Pink Purple Green VL GL_ Purple Yellow DATE 16 05 03 5 Lazzaro di Savena BOLOGNA Ret 1 Wiring Diagram Enduro 5 Motard 50cc cod 01736000 01 WIRING COLOURS CHANGED 0508 ELECTRIC SYSTEM TROUBLESHOOTING 2 tava A Troubleshooting IN LEFT CONTROL RIGHT CONTROL HEADLIGHT KEY SWITCH 2 LEFT INDICATOR RIGHT INDICATOR 2 lt gt gt INSTRUMENT BOARD CE gt 2 2 2 amp gt gt 0 al 5 ELE 2 amp eel 526 CHASSIS WEIGHT BL N SPEEDOMETER JE SENSOR HORN FLY WHEEL MAGNETO Orange VL GL Light blue White White White Black White Brown REGULATOR White Red White Green Blue Blue White Blue Black __ Z Blue Red Yellow Yellow White Yellow Black Yellow Red Yellow Green Grey Brown
32. y Repair see wiring diagram B Check left indicator F15 Disconnect the left lamp socket terminal and connect the tester 20 V DC Tester terminal purple cable Tester terminal black cable Key switch position Put the switch in left hand indicator position Voltage 12 Volts compliant Not compliant the circuit between the turn indicator switch and the lamp socket connector is faulty Repair see wiring diagram me 00 ELECTRIC 4 Troubleshooting eam B STOP LIGHT TROUBLESHOOTING If the stop light is not working proceed as follows A Check continuity the lamp and lamp socket with a tester 0 Discontinuity replace the lamp or lamp socket Continuity continue searching Check front and rear stop light switch L STOP SWITCH hi Disconnect the red and blue terminals and connect the tester to the switch terminals 16 Tester terminal v terminal 1 Tester terminal Mb _ terminal 2 Operate the brake lever Discontinuity replace the stop light switch Continuity continue searching C Check the voltage delivered to the blue cable insert STOP SWITCH ed in the stop light switch 20 V DC tester F17 Tester terminal blue cable Tester terminal groundedtothe frame Turn the key ON The voltage measur
33. y continue searching C Check voltage delivered to the horn Disconnect the terminals of the horn and connect the tester 20V DC F20 Tester terminal blue terminal Tester terminal orange terminal Key switch in ON position Press the HORN button Voltage 12V replace the horn No power continue searching D Check voltage delivered to blue cable F21 20 V DC Tester Tester terminal blue terminal Tester terminal grounded to frame Key switch in ON position No power blue cable interrupted repair See wiring dia gram Voltage 12V orange cable interrupted between the terminal inserted in the 5 way connector of the harness and the termi nal inserted in the horn Repair see wiring diagram 24 000 ELECTRIC SYSTEM TROUBLESHOOTING 4 Troubleshooting B WATER TEMPERATURE PROBE TROUBLESHOOTING If the motor is hot and the instrument s indicator is reading 0 proceed as follows Disconnect the white green cable of the water temperature probe and ground it A Red light on and digital temperature scale at maximum level Replace the water temperature probe head Red light blinking and digital temperature scale signalling only one notch Check continuity tester of the white green cable leading from the water temperature probe to the digital 0 instrument i Continuity replace the d
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