Malaguti XTM POWER UP 2007 Troubleshooting Manual
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Malaguti XTM POWER UP 2007 Troubleshooting Manual

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ELECTRIC SYSTEM
TROUBLESHOOTING
XTM-XSM POWER UP 2007
WORKSHOP MANUALS

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Summary of Contents for Malaguti XTM POWER UP 2007

  • Page 1 ELECTRIC SYSTEM TROUBLESHOOTING XTM-XSM POWER UP 2007 WORKSHOP MANUALS...

  • Page 2: Table Of Contents

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Introduction CHAPTER ELECTRICAL SYSTEM TROUBLESHOOTING INTRODUCTION ............................... 4 Manual updates ..........................4 Notes for easy consultation ......................4 Page layout ............................4 Modified pages ..........................5 Additional pages ..........................5 Editing symbols ..........................5 Abbreviations ............................ 7 TROUBLESHOOTING ............................

  • Page 3: Introduction

    Introduction CHAPTER • 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. • No part of this publication, whether text or illustrations, may be reproduced or circulated. MALAGUTI reserves all rights over this publication.

  • Page 4: Modified Pages

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Introduction CHAPTER PAGE DX 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 new date of issue appearing in the appropriate box. •...
  • Page 5 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Introduction CHAPTER CAUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity. 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.

  • Page 6: Abbreviations

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Introduction CHAPTER ABBREVIATIONS Figure Tightening torque Page Paragraph Section Diagram Table Screw Note: the letter V in 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.

  • Page 7: Troubleshooting

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Electrical System CHAPTER WIRING DIAGRAM 08.06 PAGE EDIZIONE SECTION 2 SECTION 2...

  • Page 8: Key To General Wiring Diagram

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Electrical System CHAPTER KEY TO GENERAL WIRING DIAGRAM 17) FRONT STOP SWITCH BATTERY 10 A FUSE 18) SOLENOID 19) REGULATOR CONTROL UNIT FLYWHEEL MAGNETO 20) COIL 21) MIXER OIL PROBE HORN 22) FUEL PROBE CHASSIS GROUNDING FLASHLIGHT 23) REAR RIGHT TURN INDICATOR 24) TAIL AND STOP LIGHT...

  • Page 9: Key To Electrical Components

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Electrical Components CHAPTER KEY TO ELECTRICAL COMPONENTS 10) MIXER OIL PROBE 11) SOLENOID FRONT STOP SWITCH 12) FUEL PROBE REGULATOR 13) H O TEMPERATURE SENSOR CONTROL UNIT 14) HORN 10 A FUSE 15) DIGITAL INSTRUMENT BOARD BATTERY 16) KEY SWITCH FLASHLIGHT...

  • Page 10: Connector Test

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Checking the Connections CHAPTER CHECKING CONNECTORS Check connectors for corrosion and damp. Disconnect connectors Dry terminals with compressed air. Connect and disconnect connector two or three times. Pull connector to make sure it is correctly plugged in.

  • Page 11: Switch Tests

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Checking the Switches CHAPTER CHECKING SWITCHES Use a Tester to check continuity between terminals and make sure these are correctly connected. If one of the combinations does not give the requested result, replace the component. NOTE: Operate the “ON-OFF”...

  • Page 12: Key To Ignition System

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Ignition System CHAPTER KEY TO IGNITION SYSTEM 16) “ENGINE STOP” BUTTON CONTROL UNIT FLYWHEEL MAGNETO 20) COIL 27) SIDE STAND SWITCH CHASSIS GROUNDING 14) KEY SWITCH 08.06 ISSUE PAGE SECTION 2 SECTION 2...

  • Page 13: Troubleshooting

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Ignition System CHAPTER TROUBLESHOOTING THE IGNITION SYSTEM DOES NOT WORK (NO SPARKING OR INTERMITTENT SPARKING) 1. Spark plug 2. Spark plug cap resistance 3. HV coil resistance 4. “ENGINE STOP” button 5. Side stand switch 6.
  • Page 14 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Ignition System CHAPTER Terminal (+) Terminal (1) Terminal (-) Grounded (2) HV coil resistance Disconnect orange cable Connect Tester “ ” to HV coil Check resistance of coil’s primary winding Primary winding resistance: ± 0,23 20% a 20°C Terminal (+) Spark plug cable (1)
  • Page 15 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Ignition System CHAPTER Side stand switch Disconnect two-way connector (1) of side stand Connect Tester “ ” to connector, as follows: Terminal (+) Terminal (2) Terminal (-) Terminal (3) NOT COMPLIANT Faulty side stand switch Replace COMPLIANT Key switch...
  • Page 16 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Ignition System CHAPTER Pick-up resistance Disconnect four-way connector (1) of flywheel magneto (2) Connect Tester “ ” to connector, as follows: Terminal (+) White-Red Terminal (3) Terminal (-) Blue-White Terminal (4) Check pick-up resistance NOT COMPLIANT Pick-up resistance: ±...

  • Page 17: Recharging System Key

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Charging System CHAPTER RECHARGING SYSTEM KEY BATTERY 14) KEY SWITCH 10 A FUSE 19) REGULATOR FLYWHEEL MAGNETO 08.06 ISSUE PAGINA SECTION 2 SECTION 2...

  • Page 18: Troubleshooting

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Charging System CHAPTER TROUBLESHOOTING IF BATTERY IS FLAT 1. 10A fuse 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Connections of charging system 10 A fuse Remove fuse NO CONTINUITY Connect Tester “ ” to fuse Check continuity of fuse CONTINUITY Faulty fuse...
  • Page 19 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Charging System CHAPTER Charging coil resistance Disconnect four-way connector (1) of flywheel magneto (2) Connect Tester “ ” to connector, as follows: Terminal (+) White cable terminal (3) Terminal (-) Grounded (4) Measure resistance of charging coil NOT COMPLIANT Charging coil resistance: ±...

  • Page 20: Lighting System Key

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER LIGHTING SYSTEM KEY 19) REGULATOR FLYWHEEL MAGNETO 24) TAIL AND STOP LIGHT 11) LOW BEAM / HIGH BEAM LIGHT 14) KEY SWITCH 08.06 ISSUE PAGE SECTION 2 SECTION 2...

  • Page 21: Troubleshooting

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER TROUBLESHOOTING HEADLIGHT, TAIL LIGHT AND INSTRUMENT BOARD LIGHTS DO NOT COME ON 1. Lighting system coil resistance 2. Continuity of Purple-Yellow cable 3. Key switch 4. Connection of lighting system Lighting system coil resistance Disconnect four-way connector (1) of flywheel magneto (2) Connect Tester “...
  • Page 22 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Troubleshooting CHAPTER Check continuity of purple-yellow cable Disconnect regulator connector Disconnect four-way connector of flywheel magneto NO CONTINUITY Connect Tester “ ” between purple-yellow cable of flywheel connector (system side) and pink cable of regulator connector. Purple-yellow cable interrupted: resume connection See “Circuit Diagram”...

  • Page 23: Lighting System Check

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER CHECKING LIGHTING SYSTEM THE HEADLIGHT DOES NOT COME ON Light bulb and relative coupling NO CONTINUITY Check continuity of light bulb and its coupling Replace lamp or coupling CONTINUITY Check lamp socket voltage Connect Tester “20V AC”...
  • Page 24 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER REAR LIGHT DOES NOT COME ON. Light bulb and relative coupling NO CONTINUITY Check continuity of light bulb and its coupling Replace lamp or coupling CONTINUITY Check lamp socket voltage Connect Tester “20V AC” to terminals of light bulb coupling Terminal (+) Pink cable terminal...
  • Page 25 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER LOW BEAM LIGHT DOES NOT COME ON (SWITZERLAND VERSION ONLY) Light bulb and relative coupling NO CONTINUITY Check continuity of light bulb and its coupling CONTINUITY Replace lamp or coupling Check left switch Connect Tester ( ) to switch as follows: Tester (+) terminal...
  • Page 26 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER HIGH BEAM LIGHT AND INDICATOR LIGHT ARE NOT WORKING (SWITZERLAND VERSION ONLY) Check left switch Connect Tester ( ) to switch as follows: Tester (+) terminal blue cable NO CONTINUITY Tester (-) terminal pink cable Turn light switch to “HI”...
  • Page 27 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER NUMBER PLATE LIGHT DOES NOT COME ON (SWITZERLAND VERSION ONLY) Lamp and lamp socket NO CONTINUITY Check continuity of lamp and lamp socket Replace lamp and/or lamp socket CONTINUITY Check continuity of pink cable Connect Tester ( ) between pink cable of tail light lamp socket and pink cable of number plate light lamp socket.

  • Page 28: Signalling System Key

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER 15) “MODE” BUTTON SIGNALLING SYSTEM KEY 17) FRONT STOP SWITCH 21) OIL INDICATOR SWITCH BATTERY 22) FUEL RESERVE SENSOR 10 A FUSE 23) REAR RIGHT TURN INDICATOR CONTROL UNIT 24) TAIL AND STOP LIGHT HORN 25) REAR LEFT TURN INDICATOR FLASHLIGHT...

  • Page 29: Troubleshooting

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER TROUBLESHOOTING TURN INDICATORS, STOP LIGHT, NEUTRAL AND FUEL INDICATOR LIGHTS DO NOT COME ON; REV COUNTER AND HORN DO NOT WORK Check 1. 10 A fuse 2. Battery 3. Key switch 4. Connections of signalling system 10 A Fuse NO CONTINUITY Remove fuse...
  • Page 30 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Key switch Disconnect connector (1) of key switch Turn key “ON” Connect Tester “ ” and check continuity as follows: Terminal (+) Orange cable (2) NOT COMPLIANT Terminal (-) Green cable (3) See “Checking connectors”...

  • Page 31: Signalling System Check

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Lighting System CHAPTER CHECKING SIGNALLING SYSTEM HORN IS NOT WORKING Horn button Disconnect six-way connector of left hand switch Connect Tester “ ” to connector (1) Press Horn button to activate horn Check continuity as follows: Terminal (+) Grey cable (2) Terminal (-)
  • Page 32 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Check blue cable power supply Connect Tester (20 V DC) to horn (1) Terminal (+) Blue cable (2) Terminal (-) Chassis grounding (3) Turn key “ON” Press Horn button to activate horn Power measured must be 12.5 V COMPLIANT Resume connection of orange cable...
  • Page 33 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER STOP LIGHT DOES NOT COME ON Light bulb and relative coupling NO CONTINUITY Check continuity of light bulb and its coupling Replace lamp or coupling CONTINUITY Front and rear brake switch Disconnect switch cables Connect Tester “...
  • Page 34 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Check voltage level Connect Tester (20V DC) to connector of light bulb coupling Terminal (+) Red cable (1) Terminal (-) Black cable (2) Turn key “ON” Pull brake lever or press brake pedal NOT COMPLIANT Power measured in both cases must be 12.5V Red cable interrupted;...
  • Page 35 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER TURN INDICATORS AND/OR TURN INDICATOR LIGHTS ARE NOT WORKING Light bulb and relative coupling NOT COMPLIANT Check continuity of light bulb and its coupling Replace lamp or coupling CONTINUITY Turn indicator switch Disconnect six-way connector of left hand switch Connect Tester “...
  • Page 36 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Check voltage level of flashlight Disconnect flashlight connector (1) Connect Tester (20V DC) as follows: Terminal (+) Blue cable (2) Terminal (-) Chassis grounding cable (3) NOT COMPLIANT Turn key “ON” Power measured must be 12V Blue cable between key switch and flashlight COMPLIANT interrupted.
  • Page 37 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Check voltage delivered to right hand and left hand lamp sockets Connect Tester (20V DC) to connector of lamp coupling (A) Left hand turn indicator Terminal (+) Purple cable (1) Terminal (-) Chassis grounding cable (B) Right hand turn indicator Terminal (+)
  • Page 38 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER NEUTRAL INDICATOR LIGHT DOES NOT COME ON Check neutral switch Connect Tester “ ” and check continuity between neutral switch and grounding point Neutral switch (1) Grounding point (2) Neutral Continuity Vehicle in gear No continuity NOT COMPLIANT Faulty neutral switch...
  • Page 39 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER WITH “MODE” BUTTON PRESSED, FUNCTIONS ON THE DISPLAY CANNOT BE CHANGED Check “Mode” button Disconnect six-way connector of right hand switch (1) Connect Tester “ ”, as follows Terminal (-) Green-black cable (2) Terminal (-) White-green cable (3) Press the “Mode”...
  • Page 40 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Check continuity of red cable Connect Tester “ ” as follows: Terminal (+) Red cable (3) Terminal (-) Red cable (4) Check continuity of red cable between connector of right hand controls (1) and instrument board connector (2) Comando DX ENGINE...
  • Page 41 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER REV COUNTER IS NOT WORKING Connect Tester “ ” as follows Terminal (+) Purple-yellow cable (3) Terminal (-) Purple-yellow cable (4) Check continuity of purple-yellow cable between flywheel magneto connector (1) and instrument board connector (2) NO CONTINUITY Purple-yellow cable interrupted.
  • Page 42 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Continuity of grey cable Connect Tester “ ” and check continuity of grey NO CONTINUITY cable between fuel probe connector and instrument board connector (PIN 6) CONTINUITY Grey cable interrupted. Resume connection. See “Circuit Diagram”.
  • Page 43 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER FAULTY MIXTURE OIL INDICATOR Check oil probe Take oil probe out of tank, disconnect connector and connect Tester in “ ” Tester (+) terminal coupling 1 Tester (-) terminal coupling 2 Whilst keeping probe upright, float “A” must run freely and position itself at the base of the probe: continuity Overturn probe: no continuity...
  • Page 44 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER CONFIGURATION OF THE DIGITAL INSTRUMENT CONNECTOR Pos. Meaning Pos. Meaning N.C. N.C. RH turn indicator Mixture oil LH turn indicator Temperature probe Wheel sensor input Key activation (+) Neutral Button Battery positive Fuel probe Troubleshooting indicator light N.C.
  • Page 45 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Acceleration function (0-40) This function measures the time employed by the vehicle to reach 40 km/h. This time is displayed by the small digits. After reaching a speed of 40 km/h, the message 0-40 (0-25 if you have selected mph) is replaced by the time employed, which will remain visible for 15 seconds.
  • Page 46 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Chronometer function (LAP) The information is displayed by the small digits, accompanied by the heading LAP that identifies the function displayed. Being the menu controlled by a single button, when the function is activated, the last countdown is displayed;...
  • Page 47 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Totalizer function (TOD) Information is displayed by small digits and is accompanied by the heading TOD. The unit of measurement adopted to display this function is always the same as that adopted for the current speed function.
  • Page 48 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER SECONDARY MENU FUNCTIONS (SUBMENU) The “secondary menu” includes all the functions that are displayed by the bar graph. You can choose which information to display by pressing the MODE button and following the instructions given in the paragraph describing the function of the button itself.
  • Page 49 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Battery charge level indicator function (VBATT) This information is displayed by the bottom section of the bar graph (8 segments) and is accompanied by the battery icon. The bar graph is updated every second and controlled in accordance to the following table: Voltage [Volt] Active segments...
  • Page 50 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Radiator fluid temperature indicator function This information is provided by the bottom section of the bar graph, accompanied by the radiator fluid icon. A connection failure of the resistive probe to the instrument board will be signalled by the LED flashing.
  • Page 51 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER Setup menu: modify unit of measurement Access to the setup menu for modifying the unit of measurement is only possible when the vehicle is at a standstill. Hold the button down after selecting the TOD function for about 5 seconds.
  • Page 52 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER BACKLIGHTING AND INDICATOR LIGHTS Neutral indicator light function Troubleshooting indicator light function The indicator light should come on when the status This indicator light is activated by the control unit of input n°15 (connector) is low, which means that that signals, by means of different timers, the the shift lever is in neutral position.
  • Page 53 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signal System CHAPTER START-UP (SYSTEM STARTING) When vehicle is turned on (key turned from OFF to ON), the system provides the user some information that, for sake of simplicity, is shown on two pages; first page: displays the version and date of release of the software. This information is displayed only during the instrument installation operations.

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