Malaguti X3Motard Workshop Manual
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Malaguti X3Motard Workshop Manual

125cc 4t euro3
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Summary of Contents for Malaguti X3Motard

  • Page 2: Table Of Contents

    T A B L E O F C O N T E N T S T A B L E O F C O N T E N T S Page Page Electrical starting system Introduction Faulty electrical starting system Manual updates Notes for easy consultation Recharging system...

  • Page 3: Introduction

    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. •...

  • Page 4: Notes For Easy Consultation

    I N T R O D U C T I O N I N T R O D U C T I O N NOTES FOR EASY CONSULTATION PAGE LAYOUT T I T O L O S E Z I O N E T I T O L O S E Z I O N E SECTION TITLE PAGE NUMBER...
  • Page 5 I N T R O D U C T I O N I N T R O D U C T I O N NOTE Recommendations and precautions regarding rider safety and motor vehicle integrity. CAUTION! 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.

  • Page 6: Abbreviations

    I N T R O D U C T I O N I N T R O D U C T I O N ABBREVIATIONS • Figure • Tightening torque • Page • Paragraph • Section • Diagram • Table •...

  • Page 7: Technical Term Dictionary

    I N T R O D U C T I O N I N T R O D U C T I O N TECHNICAL TERM DICTIONARY • V = (DC) : direct current (supply from battery) • V ~ (AC) : alternating current (supply from fl ywheel) •...

  • Page 8: General Wiring Diagram

    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: Key To General Wiring Diagram

    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 KEY TO GENERAL WIRING DIAGRAM 1) BATTERY 23) FRONT STOP SWITCH...

  • Page 10: Colour Key

    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 COLOUR KEY ORANGE BROWN...

  • Page 11: Instrument Board Connector Confi Guration

    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 INSTRUMENT BOARD CONNECTOR CONFIGURATION CABLE COLOUR FUNCTION...

  • Page 12: Continuity Of Contacts

    C H E C K I N G S 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 MODE BUTTON LIGHT SWITCH TURN INDICATOR SWITCH HORN CONTROL CLUTCH SWITCH...

  • Page 13: Location Of Electrical Components

    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 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 Thermal switch Side stand switch Flashlight...
  • Page 14 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 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 Digital instrument board Diode set Front stop switch...

  • Page 15: Checking Connectors

    C H E C K I N G C O N N E C T O R S C H E C K I N G C O N N E C T O R S CHECKING CONNECTORS • Check connectors for corrosion and damp. •...

  • Page 16: Checking Switches

    C H E C K I N G S W I T C H E S C H E C K I N G S W I T C H E S CHECKING SWITCHES CHECKING PROCEDURES Using a tester (Code n°08611200), check the switches by making sure that there is continuity between terminals and that they are correctly connected.

  • Page 17: Checking Fuses

    C H E C K I N G F U S E S C H E C K I N G F U S E S CHECKING FUSES When checking or replacing fuses, always turn the main switch “OFF” or short-circuits may occur. Checking procedure: •...

  • Page 18: Ignition System

    I G N I T I O N S Y S T E M I G N I T I O N S Y S T E M FAULTY IGNITION Check: Fuse, 15 A Battery Spark plug Spark plug cap resistance Tester (Ω) HV coil resistance Key switch...
  • Page 19 I G N I T I O N S Y S T E M I G N I T I O N S Y S T E M Spark plug • Check condition of spark plug. • Check type of spark plug. •...
  • Page 20 I G N I T I O N S Y S T E M I G N I T I O N S Y S T E M Tester (Ω) Tester Ω HV coil resistance • Disconnect orange cable. • Connect Tester (Ω) to HV coil.
  • Page 21 I G N I T I O N S Y S T E M I G N I T I O N S Y S T E M Tester (Ω) Pick-up resistance • Disconnect two-way connector of fl ywheel magneto. •...

  • Page 22: Electrical Starting System

    E L E C T R I C A L S T A R T I N G S Y S T E M E L E C T R I C A L S T A R T I N G S Y S T E M FAULTY ELECTRICAL STARTING SYSTEM Check: Fuse, 15 A...
  • Page 23 E L E C T R I C A L S T A R T I N G S Y S T E M E L E C T R I C A L S T A R T I N G S Y S T E M •...
  • Page 24 E L E C T R I C A L S T A R T I N G S Y S T E M E L E C T R I C A L S T A R T I N G S Y S T E M Tester (Ω) Key switch •...
  • Page 25 E L E C T R I C A L S T A R T I N G S Y S T E M E L E C T R I C A L S T A R T I N G S Y S T E M Clutch switch •...
  • Page 26 E L E C T R I C A L S T A R T I N G S Y S T E M E L E C T R I C A L S T A R T I N G S Y S T E M Tester (Ω) 9.

  • Page 27: Recharging System

    R E C H A R G I N G S Y S T E M R E C H A R G I N G S Y S T E M BATTERY CANNOT BE CHARGED Check: Fuse, 15 A Battery Recharging voltage Resistance of recharging coil...
  • Page 28 R E C H A R G I N G S Y S T E M R E C H A R G I N G S Y S T E M Recharging voltage • Connect Tester (20 V DC) as follows: •...
  • Page 29 R E C H A R G I N G S Y S T E M R E C H A R G I N G S Y S T E M Tester (Ω) Starter relay • Test A. • Remove starter relay.

  • Page 30: Lighting System

    L I G H T I N G S Y S T E M L I G H T I N G S Y S T E M THE ENTIRE LIGHTING SYSTEM DOES NOT WORK Check: Fuse, 15 A Battery Key switch Light relay Tester (Ω)
  • Page 31 L I G H T I N G S Y S T E M L I G H T I N G S Y S T E M Tester (Ω) Key switch • Disconnect key switch. • Turn key “ON”. •...
  • Page 32 L I G H T I N G S Y S T E M L I G H T I N G S Y S T E M Connection of lighting system • Check all connections of lighting system. • See “Wiring Diagram”.

  • Page 33: The Low Beam Light, High Beam Light And Relative Indicator Lights Do Not Come On

    L I G H T I N G S Y S T E M L I G H T I N G S Y S T E M THE LOW BEAM LIGHT, HIGH BEAM LIGHT AND RELATIVE INDICATOR LIGHTS DO NOT COME ON Check: Light bulb and relative coupling Voltage level of lamp socket and instrument board...
  • Page 34 L I G H T I N G S Y S T E M L I G H T I N G S Y S T E M Light switch • Check continuity of light switch (see Checking switches on P.16). •...

  • Page 35: Rear Light Does Not Come On

    L I G H T I N G S Y S T E M L I G H T I N G S Y S T E M REAR LIGHT DOES NOT COME ON Check: Light bulb and relative coupling Voltage level of lamp socket Light bulb and relative coupling •...

  • Page 36: Signalling System

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M HORN IS NOT WORKING Check: Tester (Ω) Light bulb and relative coupling Voltage level Ground connection Horn switch...
  • Page 37 S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M Check ground connection • Disconnect black cable from terminal on horn (1). •...

  • Page 38: Stop Light Does Not Work

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M STOP LIGHT DOES WORK Check: Light bulb and relative coupling Brake switch Voltage level Light bulb and relative coupling...
  • Page 39 S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M Tester (DC 20 V) Check voltage level • Connect Tester (20 V DC) as follows: •...

  • Page 40: Turn Indicators And Relative Indicator Lights Do Not Work

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M TURN INDICATORS AND RELATIVE INDICATOR LIGHT DO NOT WORK Check: Turn indicator switch Voltage level of fl...
  • Page 41 S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M Tester (DC 20 V) Voltage level of fl ashlight •...

  • Page 42: Right/Left Turn Indicators Do Not Work

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M L’INDICATORE DI DIREZIONE DESTRO O SINISTRO NON FUNZIONA Tester (DC 20 V) Turn indicator •...

  • Page 43: Neutral Indicator Light Does Not Come On

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M NEUTRAL INDICATOR LIGHT DOES NOT COME ON Check: Neutral switch Instrument board Neutral switch...

  • Page 44: Display Functions Cannot Be Changed

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M DISPLAY FUNCTIONS CANNOT BE CHANGED Check: “Mode” button Power supply Tester (Ω) Continuity of red cable...
  • Page 45 S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M • “Mode” button is not powered; blue cable is interrupted.

  • Page 46: Rev Counter Is Not Working

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M REV COUNTER IS NOT WORKING Tester (Ω) Check rev counter power supply •...

  • Page 47: Reserve Warning Light Does Not Come On

    S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M FUEL RESERVE WARNING LIGHT DOES NOT COME ON Check: Fuel probe Continuity of grey cable...
  • Page 48 S I G N A L L I N G S Y S T E M S I G N A L L I N G S Y S T E M Tester (Ω) Check ground connection (black cable) • Connect Tester (Ω) as follows: •...

  • Page 49: Heat Sensor Circuit System

    H E A T S E N S O R C I R C U I T S Y S T E M H E A T S E N S O R C I R C U I T S Y S T E M GENERAL MATTERS The carburettor is fi...
  • Page 50 H E A T S E N S O R C I R C U I T S Y S T E M H E A T S E N S O R C I R C U I T S Y S T E M Check voltage level of “PTC”...

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