Malaguti MADISON 3 125 cc Workshop Manual
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Malaguti MADISON 3 125 cc Workshop Manual

Electrical system
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TROUBLESHOOTING
ELECTRICAL SYSTEM
MADISON 125 cc. - Euro 3
WORKSHOP MANUAL

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Summary of Contents for Malaguti MADISON 3 125 cc

  • Page 1 TROUBLESHOOTING ELECTRICAL SYSTEM MADISON 125 cc. - Euro 3 WORKSHOP MANUAL...

  • Page 2: Introduction

    - We recommend you follow the information given in this publication 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.
  • Page 3 - “Malaguti S.p.A.” declines all responsibility for damage of any kind caused by use of inadequate systems for checking the electrical and electronic equipment. - “Malaguti” reserves the right to make any and all changes to its vehicles as it deems fit and appropriate at any time without prior notice.

  • Page 4: Table Of Contents

    Introduction MADISON 125 cc CHAPTER Table of contents Page Introduction Checking Switches Fuses General Wiring Diagram Ignition System Charging System Electrical Starting System Light System Signalling System 08.06 PAGE ISSUE...
  • Page 5 Introduction MADISON 125 cc CHAPTER TECHNICAL TERM DICTIONARY • Multimeter (Tester) (code n° 08609500) • (DC): direct current (supply from battery) • (AC): alternating current (supply from flywheel) • A: Ampere = the unit of electric current • W: Watt = the unit of electric power (result of Volts by Amps A x V = W) •...

  • Page 6: Checking Switches

    Checking Switches MADISON 125 cc CHAPTER CHECKING SWITCHES CHECKING PROCEDURES - Using a Tester (code n°08609500), check switches. In particular, check continuity between terminals to make sure they are correctly connected. - Replace the switch, even if only one of the possible combinations does not give the requested result. Set the tester to function F.
  • Page 7 Checking Switches MADISON 125 cc CHAPTER POSITION OF SWITCHES AND CONNECTION OF CONNECTORS Rear stop switch Engine start switch Horn control Engine stop switch Light switch Mode Passing Key switch Turn indicator switch Side stand switch Front stop switch Fuse carrier Main light switch NOTE: the start switch is closed when the START button is pressed.

  • Page 8: Fuses

    Fuses MADISON 125 cc CHAPTER FUSES CHECKING FUSES CAUTION: when checking fuses, always turn the main switch “OFF” or short-circuits may occur. Checking procedure: - Connect Tester (code n°08609500) to fuse and check continuity. NOTE: put the Tester on “ ” (sound-emitting function). - If the tester is showing “I”...
  • Page 9 Fuses MADISON 125 cc CHAPTER FUSES The electrical equipment includes 10 fuses. Before replacing a fuse, locate and eliminate the fault causing its interruption. 15 A Lights 7.5 A Turn indicators/stop “ENGINE STOP” 10 A Key 30 A Main Not active 7.5 A Radiator fan 12 V Socket F.
  • Page 10 Fuses MADISON 125 cc CHAPTER CHECKING CONNECTORS - Check connectors for corrosion and damp. - Disconnect connectors. - Dry terminals with compressed air. F. 6 - Connect and disconnect connector two or three times. - Pull connector to make sure it is correctly plugged in. - If terminal is disconnected, bend stop (A) and refit terminal in connector.

  • Page 11: General Wiring Diagram

    General Wiring Diagram MADISON 125 cc CHAPTER GENERAL WIRING DIAGRAM 12Ah 12Ah B-GR B-GR BL BL 36 36 BL BL FUSE 15 A R-VR R-VR 35 35 B-GR B-GR FUSE 7.5 A GL-N GL-N BL BL AZ-B AZ-B 34 34 R-VR R-VR BL BL...
  • Page 12 General Wiring Diagram MADISON 125 cc CHAPTER KEY TO GENERAL WIRING DIAGRAM BATTERY PROVISION FOR ANTI-THEFT SYSTEM SWITCH WITH KEY HORN FLASHLIGHT REAR LEFT STOP SWITCH LEFT SWITCH HEADLIGHTS AMBIENT TEMPERATURE PROBE 10) INSTRUMENT BOARD 11) RIGHT SWITCH 12) REAR RIGHT STOP SWITCH 13) POWER SUPPLY SOCKET FOR RECHARGING (12 V) 14) ELECTRONIC CONTROL UNIT 15) ELECTRIC STARTER ON CARBURETTOR...
  • Page 13 General Wiring Diagram MADISON 125 cc CHAPTER GENERAL WIRING DIAGRAM COLOUR KEY BLACK/RED B-VL WHITE/PURPLE B-BL WHITE/BLUE R-VR RED/GREEN B-GR WHITE/GREY PINK BLUE RS-N PINK/BLACK BL-N BLUE/BLACK PURPLE BL-R BLUE/RED VL-N PURPLE/BLACK BL-VR BLUE/GREEN VR-N GREEN/BLACK YELLOW GREEN GL-B YELLOW/WHITE ORANGE GL-N YELLOW/BLACK...

  • Page 14: Ignition System

    Ignition System MADISON 250 I.E. CHAPTER IGNITION SYSTEM TROUBLESHOOTING 1 SPARK PLUG IS NOT SPARKING. CHECK: Spark plug Spark plug cap resistance HV coil Pick-up resistance Wiring connections 1.1 Spark plug - Check condition of spark plug. - Check type of spark plug. - Check gap between electrodes: 0.6 ÷...
  • Page 15 Ignition System MADISON 250 I.E. CHAPTER 1.3 HV coil A) Primary winding resistance - Connect tester ( ). - Compliant: 0.6 ÷ 0.8 at 20°C. F. 12 B) Secondary winding resistance - Connect tester (K ). - Compliant: 2.50 ÷ 3.50 K at 20°C.

  • Page 16: Charging System

    Charging System MADISON 125 cc CHAPTER CHARGING SYSTEM TROUBLESHOOTING 1 IF THE BATTERY CANNOT BE CHARGED, CHECK: 30 A Fuse (helmet compartment) Battery Charging voltage Stator coil resistance Charging system wiring 1.1 30 A Fuse (helmet compartment) - Remove relative fuse. - Connect Tester ( ) to fuse.
  • Page 17 Charging System MADISON 125 cc CHAPTER 1.3 Checking charging voltage (use a charged battery) - Connect Tester (20 V DC) to battery as follows: - Terminal (+) of Tester Battery (+) pole. - Terminal (-) of Tester Battery (-) pole. - Run engine at approx.

  • Page 18: Electrical Starting System

    Electrical Starting System MADISON 125 cc CHAPTER ELECTRICAL STARTING SYSTEM TROUBLESHOOTING 1 IF STARTER MOTOR DOES NOT WORK, CHECK: 7.5 A fuse N° 2, 3 A fuse N° 3, 30 A fuse N° 5 Battery Starter motor Remote start switch / Remote start circuit interruption switch Key switch Engine stop switch Side stand switch...
  • Page 19 MADISON 125 cc Electrical Starting System CHAPTER 1.4 Remote start switch (black connector - Code n°02502500) - Remote start circuit interruption switch (white connector - 02504300) - Detach remote switch connector. - Connect Tester ( ) and a battery (12 V) to remote switch terminals, as follows: - Battery (+) pole Terminal (86).

  • Page 20: Light System

    Light System MADISON 125 cc CHAPTER LIGHT SYSTEM TROUBLESHOOTING 1 IF LIGHTING SYSTEM DOES NOT WORK, CHECK: 15 A fuse n°1 Battery Key switch Light switch Light switch and “passing” button Connection of light system wiring 1.1 15 A fuse N°1 (lights) - Remove relative fuse.
  • Page 21 Light System MADISON 125 cc CHAPTER 2 IF HIGH BEAM LIGHT DOES NOT COME ON 2.1 Check lamp and lamp socket. - See “Checking switches” section (page 6/7). 2.2 Check voltage level - Connect Tester (20 V DC) to four-way connector as follows: - Terminal (+) of Tester White/black cable (1).
  • Page 22 Light System MADISON 125 cc CHAPTER 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).
  • Page 23 Light System MADISON 125 cc CHAPTER 6 IF INSTRUMENT BOARD LIGHTING DOES NOT WORK 6.1 Check voltage level. - Connect Tester (20 V DC) to instrument board connector as follows: - Terminal (+) of Tester Pink cable (PIN 4) (1). - Terminal (-) of Tester Black cable (PIN 17) (2).
  • Page 24 Light System MADISON 125 cc CHAPTER 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).

  • Page 25: Signalling System

    Signalling System MADISON 125 cc CHAPTER SIGNALLING SYSTEM TROUBLESHOOTING 1 IF THE REV COUNTER 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).
  • Page 26 Signalling System MADISON 125 cc CHAPTER 1.2 Check instrument board signal - Connect Tester (20 V DC) to instrument board connector, without disconnecting the latter, as follows: - Terminal (+) Tester White cable of instrument board (PIN 13) (1). - Terminal (-) Tester Black cable of instrument board (PIN 17) (2).
  • Page 27 Signalling System MADISON 125 cc CHAPTER 2. CHECKING H O TEMPERATURE AND FUEL INDICATORS 2.1 Check H O temperature indicator - Make sure that on the 5 notch (A) the resistance of the thermistor is ~ 280 at 80°. - Make sure that on the 9 notch (B) the red light comes on and the resistance of the thermistor is <...
  • Page 28 Signalling System MADISON 125 cc CHAPTER 3 IF HORN DOES NOT WORK 3.1 Horn switch - See “Checking switches” section (page 6/7). 3.2 Check grounding - Connect Tester ( ) to connector of left hand switch (3) as follows: - Terminal (+) of tester Black cable (1).
  • Page 29 Signalling System MADISON 125 cc CHAPTER 3.4 Check voltage level. - Connect Tester (20 V DC) to horn (3) as follows: - Terminal (+) of tester Blue cable (1). - Terminal (-) of tester Chassis grounding (2). - Turn key “ON”. - Power measured must be >12 V.
  • Page 30 Signalling System MADISON 125 cc CHAPTER 4.2 Oil pressure indicator alarm Every time the sensor closes the circuit, the relative alarm message appears on the display; the message “OIL” should become steadily lit whereas “bar” and the oil icon should start flashing; to avoid false alarms, this condition occurs only if the pressure switch remains deactivated for a period of no less than 3.5-4.0 seconds.
  • Page 31 Signalling System MADISON 125 cc CHAPTER 5. IF STOP LIGHT DOES NOT COME ON 5.1 Check 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. Tester F.
  • Page 32 Signalling System MADISON 125 cc CHAPTER 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”.
  • Page 33 Signalling System MADISON 125 cc CHAPTER 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.
  • Page 34 Signalling System MADISON 125 cc CHAPTER 6.6 Check voltage level - Connect Tester (20 V DC) to six-way connector of tail light wiring, as follows: - Check left indicators: - Terminal (+) of Tester Purple cable (1). - Terminal (-) of Tester Black cable (3).
  • Page 35 Signalling System MADISON 125 cc CHAPTER 7. IF RADIATOR FAN DOES NOT WORK 7.1 Check 7.5 A fuse N° 7 - 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. Tester F.
  • Page 36 Signalling System MADISON 125 cc CHAPTER 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 jumper between the black cable and a grounded point of the chassis.
  • Page 37 Signalling System MADISON 125 cc CHAPTER 8. IF ELECTRIC STARTER DOES NOT WORK 8.1 Check electric starter - Take starter off carburettor and power up by means of a 12 V battery. In the meantime, check how the length of the piston changes. - If length does not change in 5 minutes: replace electric starter.
  • Page 38 Signalling System MADISON 125 cc CHAPTER 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.

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