Malaguti XTM POWER UP 2007 User manual

B
XTM-XSM POWER UP 2007
ELECTRIC SYSTEM
TROUBLESHOOTING
WORKSHOP MANUALS

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08.06 3
Introduction CHAPTER
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ELECTRICSYSTEMTROUBLESHOOTING
ENGLISH
SECTION 1
B- TROUBLESHOOTING
BELECTRICAL SYSTEM TROUBLESHOOTING
INTRODUCTION............................................................................................................................................... 4
Manualupdates ................................................................................................................................ 4
Notes for easy consultation .............................................................................................................. 4
Pagelayout ...................................................................................................................................... 4
Modifiedpages ................................................................................................................................. 5
Additionalpages............................................................................................................................... 5
Editing symbols................................................................................................................................ 5
Abbreviations .................................................................................................................................... 7
TROUBLESHOOTING ...................................................................................................................................... 8
Wiringdiagram ................................................................................................................................. 8
Keyto general wiring diagram .......................................................................................................... 9
Colourkey ........................................................................................................................................ 9
Key to electrical components ......................................................................................................... 10
Connectortest............................................................................................................................... 11
Switch tests .................................................................................................................................. 12
Connection of the switches described in this manual ..................................................................... 12
Key to ignition system................................................................................................................... 13
Troubleshooting ............................................................................................................................. 14
Recharging system key................................................................................................................. 18
Troubleshooting ............................................................................................................................. 19
Lighting system key ...................................................................................................................... 21
Troubleshooting ............................................................................................................................. 22
Lighting system check .................................................................................................................. 24
Signalling system key ................................................................................................................... 29
Troubleshooting ............................................................................................................................. 30
Signalling system check ............................................................................................................... 32

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B- TROUBLESHOOTING
FIRST EDITION: 08/06
YChapter
XSection title
WPageN°
ZDateof issue
•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
reservesall rightsover thispublication. Reasonsmust begiven forany requestfor permission(written) thereto.
INTRODUCTION
•This publicationdescribes all necessarysteps for troubleshooting concerning the electrical system (ofthe
models indicated on the front page) and of 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 and from the Spare Parts catalogue.
•All described operations must be performed by technicians with the necessary skill and experience.
•The steps for the removal of body parts and of electric and mechanical components, to allow access to wiring
or electric components to service, can be taken from the Chassis Workshop Manual.
•We recommendyou follow theinformation given in this publicationwith care.
•Forany furtherinformation youmay need, refer to theMALAGUTI Service Centre.
MANUAL UPDATES
•Updated pagesof thispublication will be delivered byus (ina reasonabletime) alreadypunched andtherefore
readyto beincorporatedin theManual. Thesupersededsheets shouldnot be removedfrom themanualas they
remainapplicable tothe servicingof pre-modified models.
•Thetable of contents willbedulyupdatedinthe event thatnewpagesareinserted,which rendertheconsultation
ofthe 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

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ENGLISH
SECTION 1
B- TROUBLESHOOTING
W
Z
Y
X
MODIFIEDPAGES
•Modified pages shallbear thesame number asthose inthe previous edition/pre-modified ones,
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 illustration on the former page, followed by a letter.
ADDITIONALPAGES
•Any additional pages shall bear the last number ofthe section to whichthey belong, followed bythe letter Aand
the new date of issue.
EDITINGSYMBOLS
•Symbols have been provided for quick and easy reference (see page 6), identifying situations requiring
utmostattention or providingpractical suggestions or simple information.
•These symbols may appear next to a text (in which case they refer solely to the text itself), next to a figure
(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 is to avoid having to repeat basic
technical concepts or safety recommendations. They are therefore to be considered as veritable “memory
tags”. In case of any doubt as to their meaning, consult the page in which they are fully described.
PAGE DX

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SECTION 1
B- TROUBLESHOOTING
R
M
L
H
F
A
B
D
C
I
G
E
A) CAUTION! Recommendationsand precautions regardingrider
safetyand motor vehicleintegrity.
B) WARNING! Situations entailing the risk of personal injury to
maintenanceor repairmechanics, otherworkshop personnelor
thirdparties, ordamage toenvironment, vehicle orequipment.
C) FIREHAZARD
Indicates operations which may constitute a fire hazard.
D) RISK OF EXPLOSION Indicates operations which may
constitute a risk of explosion.
E) TOXIC FUMES
Indicatesa possibilityofintoxication orinflammationof theupper
respiratorytract.
F) MECHANICAL MAINTENANCE Operationstobeperformedonly
by an expert mechanic.
G) ELECTRICALMAINTENANCE
Operationsbe performed onlyby anexpert electrical/electronic
technician
H) NO! Operations tobe absolutely avoided
I) ENGINE SERVICE MANUAL Indicates information which may
beobtained by referringto said manual.
L) SPAREPARTS CATALOGUE
Indicatesinformation whichmay beobtained by referringto said
catalogue

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08.06 7
Introduction CHAPTER
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ENGLISH
SECTION 1
B- TROUBLESHOOTING
F4
A
FFigure
Cs Tighteningtorque
PPage
Pr Paragraph
SSection
Sc Diagram
TTable
VScrew
ABBREVIATIONS
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.In case ofdifferent screws being referredto in theillustration, theletter
Vis followed by a number and 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 vehicle is perfectly stable.
The front wheel should preferably be anchored to the equipment (A- F. 4) integral with the lifting board.

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808.06
CHAPTER
PAGE
ELECTRIC SYSTEM TROUBLESHOOTING
ENGLISH
SECTION 2
Electrical System
SECTION 2
B- TROUBLESHOOTING
EDIZIONE
M
BL
AR
BL
BB
N
M
VR
VL
AR
N
M
VR
VL
GR
N
K A
B
R
+
-
N
LOCK OFF ON
VR
GR
VL
M-N
GL-R
GR-R
vuoto
vuoto
vuoto
1
18
LUCI
BL
VR-N
VR
GL
AR
VL-GL
RS
BL-R
BL-R
N
R
VL-GL
GL-R
B
BL-B
B-R
MODE
R
ENGINE
STOP
ON
OFF ON
OFF
BL
R
10W
ID
SX
VL
10W
ID
DX
N
VR
35W
FARO
10W
ID
SX
N
VL
10W
ID
DX
N
VR
N
21W
STOP
5W
POS
RS
R
AR
HT
1
16
+
ON
OFF
HORN
GR
R
L
VL
M
VR
TURN
N
+
+
N
RS
F 10A
N
GL-R
Vuoto
BL
GR-R
GL-B
AR
B-R
Vuoto
BL-B
GL-VR
BL-N
M-N
RS-N
/ /
BL
R
R-N
N
GR
M-N
B-R
RS-N
B-R
BL-N
GL-VR
B-R
VL-GL
B
R
N
VL-GL
B
R
N
vuoto
vuoto
B-R
BL
VR/N
VR
GL
AR
vuoto
vuoto
R
B
N
B
BL-B
B-R
B-R
N
N
VL-GL
BL-R
B-N
N
VR-N
B-VR
N
GR
M
GR
VR-N
B-VR
B-N
N
BL
BL
BL
Vuoto
BL
B-GL TPS
B-VL
R-N
B-VL
R-N
R-N
1
2
3456 7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
30
31
16
17
WIRING DIAGRAM

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ENGLISH
SECTION 2
Electrical System
SECTION 2
B- TROUBLESHOOTING
KEY TO GENERAL WIRING DIAGRAM
1) BATTERY
2) 10 AFUSE
3) CONTROLUNIT
4) FLYWHEELMAGNETO
5) HORN
6) CHASSISGROUNDING
7) FLASHLIGHT
8) TURNINDICATORBUTTON
9) HORNBUTTON
10) FRONTLEFTTURNINDICATOR
11) LOW BEAM / HIGH BEAM LIGHT
12) FRONTRIGHTTURNINDICATOR
13) INSTRUMENTBOARD
14) KEY SWITCH
15) “MODE”BUTTON
16) “ENGINESTOP”BUTTON
17) FRONTSTOPSWITCH
18) SOLENOID
19) REGULATOR
20) COIL
21) MIXEROILPROBE
22) FUELPROBE
23) REARRIGHTTURNINDICATOR
24) TAILANDSTOPLIGHT
25) REARLEFTTURNINDICATOR
26) GROUND
27) SIDESTANDSWITCH
28) REAR STOPSWITCH
29) SPEEDOMETER SENSOR
30) WATERTEMPERATURE SENSOR
31) AIRTEMPERATURESENSOR
COLOUR KEY
This table lists the abbreviations used to identify the colour of the electrical connection cables on the wiring
diagram.
Abbreviationsare givenon thediagram, nearthe component
AR
AZ
B
BL
GL
GR
M
N
R
RS
VL
VR
AZ-B
B-M
B-N
B-R
B-VL
B-VR
BL-B
BL-GL
BL-N
BL-R
GL-B
GL-N
GL-R
GL-VR
GR-R
M-N
R-N
RS-N
VL-GL
VR-N
Orange
Lightblue
White
Blue
Yellow
Grey
Brown
Black
Red
Pink
Purple
Green
Light blue White
WhiteBrown
White Black
White Red
White Purple
WhiteGreen
Blue White
Blue Yellow
Blue Black
BlueRed
Yellow White
Yellow Black
YellowRed
YellowGreen
GreyRed
Brown Black
Red Black
Pink Black
PurpleYellow
Green Black

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ENGLISH
SECTION 2
Electrical Components
SECTION 2
B- TROUBLESHOOTING
1234
5
6
7
8
910111213
14
15
16
17
KEY TO ELECTRICAL COMPONENTS
1) FRONTSTOPSWITCH
2) REGULATOR
3) CONTROLUNIT
4) 10 AFUSE
5) BATTERY
6) FLASHLIGHT
7) SIDESTANDSWITCH
8) COIL
9) REARSTOP SWITCH
10) MIXEROIL PROBE
11) SOLENOID
12) FUELPROBE
13) H2OTEMPERATURE SENSOR
14) HORN
15) DIGITALINSTRUMENTBOARD
16) KEY SWITCH
17) AIRTEMPERATURESENSOR

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ENGLISH
SECTION 2
Checking the Connections
SECTION 2
B- TROUBLESHOOTING
A
CHECKING CONNECTORS
Checkconnectors for corrosionand damp.
1. Disconnect
 connectors
2. Dry terminals with compressed air.
3. Connectand disconnectconnector two or
three times.
4. Pull connector to make sure it is correctly
pluggedin.
5. If terminal comes loose, bend stop (A) and
refitterminal in connector.
6. Connect
connectors
NOTE:
The “click” sound means that all
connector parts are correctly assembled.
7. Check continuity with a Tester.
NOTE:
If there is no continuity, clean terminals.
Follow the instructions from step 1 to 7 to
check the electrical equipment.
As a temporary solution, use a contact
cleaner.
Use Tester as shown in the illustration.

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SECTION 2
Checking the Switches
SECTION 2
B- TROUBLESHOOTING
CHECKING SWITCHES
Use a Tester to check continuity between terminals
andmake surethese arecorrectly connected. If one of
the combinations does not give the requested result,
replacethe component.
NOTE:
Operate the “ON-OFF” switch several times.
Put Tester selector on “W”.
Put indicator on “0”.
CONNECTION OF THE SWITCHES
DESCRIBED IN THIS MANUAL
Thismanualcontains connectiondiagrams,likethe one
illustrated on the left, which illustrate how switch
terminals should be connected (key switch, brake
switch, light switch, etc.).
Thecolumn on theleft indicates thedifferent positions
of the switches; the first line indicates the colours of
the wires connected to the switch terminals.
“•”meansthat thereiscontinuity betweentheterminals;
namelyaclosedcircuitin acertainpositionoftheswitch.
In this example, there is continuity between “Br” and
“R” when the switch is “ON”.

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ENGLISH
SECTION 2
Ignition System
SECTION 2
B- TROUBLESHOOTING
M
BL
AR
BL
BB
N
M
VR
VL
AR
N
M
VR
VL
GR
N
KA
B
R
+
-
N
LOCK OFF ON
VR
GR
VL
M-N
GL-R
GR-R
vuoto
vuoto
vuoto
1
18
LUCI
BL
VR-N
VR
GL
AR
VL-GL
RS
BL-R
BL-R
N
R
VL-GL
GL-R
B
BL-B
B-R
MODE
R
ENGINE
STOP
ON
OFF
ON
OFF
BL
R
10W
ID
SX
VL
10W
ID
DX
N
VR
35W
FARO
10W
ID
SX
N
VL
10W
ID
DX
N
VR
N
21W
STOP
5W
POS
RS
R
AR
HT
1
16
+
ON
OFF
HORN
GR
R
L
VL
M
VR
TURN
N
+
+
N
RS
F 10A
N
GL-R
Vuoto
BL
GR-R
GL-B
AR
B-R
Vuoto
BL-B
GL-VR
BL-N
M-N
RS-N
//
BL
R
R-N
N
GR
M-N
B-R
RS-N
B-R
BL-N
GL-VR
B-R
VL-GL
B
R
N
VL-GL
B
R
N
vuoto
vuoto
B-R
BL
VR/N
VR
GL
AR
vuoto
vuoto
R
B
N
B
BL-B
B-R
B-R
N
N
VL-GL
BL-R
B-N
N
VR-N
B-VR
N
GR
M
GR
VR-N
B-VR
B-N
N
BL
BL
BL
Vuoto
BL
B-GL
TPS
B-VL
R-N
B-VL
R-N
R-N
Vuoto
3
4
6
14
20
27
16
KEY TO IGNITION SYSTEM
3) CONTROLUNIT
4) FLYWHEELMAGNETO
6) CHASSISGROUNDING
14) KEY SWITCH
16) “ENGINESTOP” BUTTON
20) COIL
27) SIDESTANDSWITCH

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SECTION 2
Ignition System
SECTION 2
B- TROUBLESHOOTING
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. Key switch
7. Pick-up resistance
8. System connections
1. Spark plug
- Check condition of spark plug
- Check type of spark plug
Gapbetween electrodes:
0.7 mm
COMPLIANT
2. Spark plug cap resistance
- Removespark plug cap
NOTE
Never pull spark plug cable to remove cap
- ConnecttheTester (K

)as shownin thefigure
To remove, turn anti-clockwise
To connect, turn clockwise
- When connecting, check spark plug cable and
if necessary replace it with a new one.
Capresistance:
5K 

±20% a 20°C
COMPLIANT
Sample spark plug:
NGK BR9ES
Spark plug not in working order Replace or
adjustgap betweenelectrodes
NOT COMPLIANT
Terminal (+) Spark plug side (1)
Terminal (-) Spark plug cable side (2)
2
1
Faulty spark plug cap Replace
NOT COMPLIANT

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SECTION 2
Ignition System
SECTION 2
B- TROUBLESHOOTING
3. HV coil resistance
- Disconnectorange cable
- Connect Tester “

” to HV coil
- Check resistance of coil’s primary winding
Primary winding resistance:
0,23 

±20% a 20°C
- Connect Tester “

” to HV coil
- Check resistance of coil’s secondary winding
Primary winding resistance:
7,9





±20% a 20°C
COMPLIANT
1
23
4. “Engine Stop” button
- Disconnectfour-way connector(1)
- Connect Tester “

” and check continuity
betweencables
White-black cable (2) Black cable (3)
See“Checking connectors” on page 11
COMPLIANT
Terminal (+) Terminal (1)
Terminal (-) Grounded (2)
1
2



1
2



Terminal (+) Spark plug cable (1)
Terminal (-) Terminal (2)
NOT COMPLIANT
Faulty HV coil Replace
NOT COMPLIANT
Faulty “Engine Stop” button Replace

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SECTION 2
Ignition System
SECTION 2
B- TROUBLESHOOTING
5. Side stand switch
- Disconnect two-way connector (1) of side stand
- Connect Tester “

” to connector, as follows:
Terminal (+) Terminal (2)
Terminal (-) Terminal (3)
1
32
COMPLIANT
6. Key switch
- Disconnect connector (1) of key switch
- Turnkey “ON”
- Connect Tester “

” and check continuity as
follows:
Terminal (+) Orangecable (2)
Terminal (-) Greencable (3)
See“Checking connectors” on page 11
1
23
COMPLIANT
NOTCOMPLIANT
Faulty side stand switch Replace
NOT COMPLIANT
Faulty key switch Replace

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ENGLISH
SECTION 2
Ignition System
SECTION 2
B- TROUBLESHOOTING
7. Pick-up resistance
- Disconnect four-way connector (1) of flywheel
magneto(2)
- Connect Tester “

” to connector, as follows:
Terminal (+) White-RedTerminal (3)
Terminal (-) Blue-WhiteTerminal (4)
- Checkpick-up resistance
Pick-upresistance:
350 

±20% a 20°C
COMPLIANT
8. Connections
- Check connections of ignition system
See“Circuit Diagram”.
COMPLIANT
Replace“CDI” control unit
1
4
3
2
NOT COMPLIANT
Replacestator
NOT COMPLIANT
Resume system’s connections

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ENGLISH
SECTION 2
Charging System
SECTION 2
B- TROUBLESHOOTING
PAGINA
M
BL
AR
BL
BB
N
M
VR
VL
AR
N
M
VR
VL
GR
N
KA
B
R
+
-
N
LOCK OFF ON
VR
GR
VL
M-N
GL-R
GR-R
vuoto
vuoto
vuoto
1
18
LUCI
BL
VR-N
VR
GL
AR
VL-GL
RS
BL-R
BL-R
N
R
VL-GL
GL-R
B
BL-B
B-R
MODE
R
ENGINE
STOP
ON
OFF
ON
OFF
BL
R
10W
ID
SX
VL
10W
ID
DX
N
VR
35W
FARO
10W
ID
SX
N
VL
10W
ID
DX
N
VR
N
21W
STOP
5W
POS
RS
R
AR
HT
1
16
+
ON
OFF
HORN
GR
R
L
VL
M
VR
TURN
N
+
+
N
RS
F 10A
N
GL-R
Vuoto
BL
GR-R
GL-B
AR
B-R
Vuoto
BL-B
GL-VR
BL-N
M-N
RS-N
//
BL
R
R-N
N
GR
M-N
B-R
RS-N
B-R
BL-N
GL-VR
B-R
VL-GL
B
R
N
VL-GL
B
R
N
vuoto
vuoto
B-R
BL
VR/N
VR
GL
AR
vuoto
vuoto
R
B
N
B
BL-B
B-R
B-R
N
N
VL-GL
BL-R
B-N
N
VR-N
B-VR
N
GR
M
GR
VR-N
B-VR
B-N
N
BL
BL
BL
Vuoto
BL
B-GL
TPS
B-VL
R-N
B-VL
R-N
R-N
Vuoto
1
2
19
4
14
RECHARGING SYSTEM KEY
1) BATTERY
2) 10 AFUSE
4) FLYWHEELMAGNETO
14) KEY SWITCH
19) REGULATOR

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ENGLISH
SECTION 2
Charging System
SECTION 2
B- TROUBLESHOOTING
TROUBLESHOOTING
IF BATTERY IS FLAT
1. 10A fuse
2. Battery
3.Charging voltage
4. Charging coil resistance
5. Connections of charging system
1. 10 A fuse
- Removefuse
- Connect Tester “

” to fuse
- Check continuity of fuse
2. Battery
- Check condition of battery
- Minimum voltage: 12.5 V
- Density of electrolytic solution: 1280 g/dm3
- Level of electrolytic solution
3. Charging voltage
- Connect inductive rev counter to spark plug
cable
- Connect Tester (20 V DC) to battery.
Terminal (+) Terminal (+) of battery
Terminal (-) Terminal (-) of battery
- Measurebattery voltage
- Runengine at5000 RPM
- Checkbattery voltage
Charging voltage:
12.5 ~ 14.5 V
NOTE: Use a fully charged battery
NOCONTINUITY
Faulty fuse Replace
COMPLIANT
NOT COMPLIANT
- Cleanterminals
- Rechargeor replacebattery
- Top up with distilled water
COMPLIANT
Rechargingcircuit is inworking order
CONTINUITY
NOT COMPLIANT

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ELECTRIC SYSTEM TROUBLESHOOTING
ENGLISH
SECTION 2
Charging System
SECTION 2
B- TROUBLESHOOTING
PAGINA
4. 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
Charging coil resistance:
0.80 

±20% a 20°C
5. Recharging system connections
- Check connections of recharging system
See“Circuit Diagram”.
Replacevoltageregulator
COMPLIANT
COMPLIANT
NOT COMPLIANT
Replacestator
NOT COMPLIANT
Resume system’s connections
1
2
34

B
08.06 21
CHAPTER
PAGEISSUE
ELECTRIC SYSTEM TROUBLESHOOTING
ENGLISH
SECTION 2
Lighting System
SECTION 2
B- TROUBLESHOOTING
M
BL
AR
BL
BB
N
M
VR
VL
AR
N
M
VR
VL
GR
N
K
A
B
R
+
-
N
LOCK OFF ON
VR
GR
VL
M-N
GL-R
GR-R
vuoto
vuoto
vuoto
1
18
LUCI
BL
VR-N
VR
GL
AR
VL-GL
RS
BL-R
BL-R
N
R
VL-GL
GL-R
B
BL-B
B-R
MODE
R
ENGINE
STOP
ON
OFF
ON
OFF
BL
R
10W
ID
SX
VL
10W
ID
DX
N
VR
35W
FARO
10W
ID
SX
N
VL
10W
ID
DX
N
VR
N
21W
STOP
5W
POS
RS
R
AR
HT
1
16
+
ON
OFF
HORN
GR
R
L
VL
M
VR
TURN
N
+
+
N
RS
F 10A
N
GL-R
Vuoto
BL
GR-R
GL-B
AR
B-R
Vuoto
BL-B
GL-VR
BL-N
M-N
RS-N
//
BL
R
R-N
N
GR
M-N
B-R
RS-N
B-R
BL-N
GL-VR
B-R
VL-GL
B
R
N
VL-GL
B
R
N
vuoto
vuoto
B-R
BL
VR/N
VR
GL
AR
vuoto
vuoto
R
B
N
B
BL-B
B-R
B-R
N
N
VL-GL
BL-R
B-N
N
VR-N
B-VR
N
GR
M
GR
VR-N
B-VR
B-N
N
BL
BL
BL
Vuoto
BL
B-GL
TPS
B-VL
R-N
B-VL
R-N
R-N
Vuoto
11
24
19
4
14
LIGHTING SYSTEM KEY
4) FLYWHEELMAGNETO
11) LOW BEAM / HIGH BEAM LIGHT
14) KEY SWITCH
19) REGULATOR
24)TAIL AND STOP LIGHT