Malaguti MADISON 3 125 cc Instruction manual

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

208.06
BMADISON 125 cc
Introduction
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XY
Z W
J
INTRODUCTION
-This publication describes all necessary steps for troubleshooting concerning the electrical system and
the possible service operations, which are necessary for their solution. It supplies the trade technicians
(Authorised Service Centres) with the necessary information for operating in compliance with the modern concepts
of “good practice” and “safety at work”.
- 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.
- The steps for 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.
- 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.
NOTES FOR EASY CONSULTATION
PAGE LAYOUT
X
YChapter
XMotor vehicle model
JSection
WPage N
ZDate of issue
ABBREVIATIONS
F. Figure
Pag. Page
Pr Paragraph
SSection
Sch Diagram
TTable
MODIFIED PAGES
- Modified pages shall bear the same number as those in the previous edition, followed by the letter M, with the
new date of issue appearing in the appropriate box.
- Modified pages may contain new illustrations; in this case, the added illustration (or illustrations) will bear the
number of the former illustration, followed by a letter.
- Negative illustration numbers (such as for instance F. 5 ) mean that the previous numbers have been
intentionally omitted.
ADDITIONAL PAGES
- Any additional pages shall bear the last number of the section to which they belong, followed by the letter Aand
the new date of issue.

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FIRST EDITION : 08/06
OPERATIONAL SYMBOLS
IMPORTANT!
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.
ENGINE OFF - operations to be informed with the engine off.
CUT OFF POWER - before performing the operation described, disconnect the battery negative.
MECHANICAL MAINTENANCE - operations to be performed only by an expert mechanic.
ELECTRICAL MAINTENANCE - operations to be performed only by an expert electrical/electronic
technician.
NO! - Operations 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 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.
-No part of this publication, whether text or illustrations, may be reproduced or circulated. “Malaguti”
reserves all rights over this publication. Reasons must be given for any request for permission (written) thereto.

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Introduction
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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

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TECHNICAL TERM DICTIONARY
•Multimeter (Tester) (code n° 08609500)
•V = (DC): direct current (supply from battery)
•V ~ (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)
•::
::
:?: 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 (100 KPa = 1 bar)
•÷= from - to
•~= approximately

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Checking Switches
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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 ::
::
:.
CONNECTION 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 which there is a condition of continuity, i.e. a closed circuit, in a certain
position of the switch.
- In this diagram:
- “B/R” and “N”: there is continuous contact when the switch is “ON”.
F. 1
F. 2

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9
10 11
3
2
1
678
1
4
3
2
5
67
8
9
10
11
12
13
B-GR
R
ON
0FF
LO
HI
AZ-B
GL-N
B-N AR
N
B-GR
R
0FF
ON
ON
0FF
GL-N
RS
RS
BL
B-R
N
GL-BL
GL-B
B-BL
R
OFF
ON
BL-N
VR-N
N
BL
GL-B
BL-R
13
12
N
N
N
5
4
ON
0FF
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 stand is idle.
The STOP switch is closed when the brake lever is operated.

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Fuses
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F. 3
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” 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 extensive damage to the electrical system, malfunctioning of the ignition
and light systems and even fires to break out.

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1 2 3 4 5 6 7 8
FUSES
The electrical 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) 3 A “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

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Fuses
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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.
- 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 Tester as shown in the illustration.
F. 6
F. 7
F. 9
F. 8