F12 MAX 200 cc - Shop Malaguti

Transcription

MALAGUTI - F12 MAX 200 cc
ELECTRIC SYSTEM TROUBLESHOOTING
1
05/03
• Malaguti reserves the right to make any and all changes to its vehicles as it deems fit and opportune at any time
without prior notice.
• All rights reserved. No part of this publication, whether text or illustrations, may be reproduced or circulate without
the prior written permission from Malaguti
Malaguti. Reasons must be given for any request for permission thereto.
FIRST EDITION: 08/03
INTRODUCTION
• The present publication describes all the necessary steps for the troubleshooting concerning the electric system (of
the models indicated on the front page) and of the possible service operations, which are necessary for their solution.
It supplies the trade technicians (Authorized Customer Service Centres) with the necessary information for operating
in compliance with the modern concepts of "good practice" and "work safety".
• Further information can be derived from the "Cycling Section" of the workshop manual - from the Engine Section of the
workshop manual - from the Spare Parts catalogue.
• All described operations require the necessary skill and experience by the technicians.
• The steps for the removal of body parts and of electric and mechanical components, to allow the access to wiring or
electric components to service, can be taken from the Cycling Section of the Workshop Manual.
• We recommend to follow with care the information given in this publication.
• For any further information you may need, refer to Malaguti Customer Service Department.
PUBLICATION UPDATES
• The up-date pages of this publication will be delivered by us (in due course) already punched and therefore ready for
insertion in the Manual.
The superseded sheets should not be removed from the manual as they remain applicable to the servicing of premodified models.
• The table of contents will be duly updated in case of the insertion of new pages causing difficulty in the rational
consultation of the manual.
Eurograph - Studio Baravelli - BO
• IMPORTANT! The manual for the electric system troubleshooting is to be considered as an essential work instrument
to be properly kept up-to-date so as to maintain its “validity” over time.
MALAGUTI - 40068 S. Lazzaro di Savena (Bologna)
Via Emilia, 498 - Tel. 051/6224811 - Fax 051/6255160
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08/03
NOTES FOR EASY CONSULTATION
PAGE LAYOUT
X
X
Motor-bike
W
Page No.
Z
Date of issue
model
Note: When no indication is reported in the box marked by
an X , the information in the page refers to all the models
of the full range of engines of each manufacturer .
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 date of issue appearing in the appropriate box.
• Any modified illustrations shall bear the same numbers as the
pre-modified ones followed by a letter.
W
Z
ADDITIONAL PAGES
• Any additional pages shall bear the last number of the section
to which they belong followed by the letter A together with the
date of issue
issue.
Before any servicing, make sure that the motor-bike is perfectly stable.
The front wheel should preferably be anchored to the equipment (A) integral with the lifting board.
A
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F12 MAX 200 cc
Description
P
Switches connection illustrated in this manual
6
Ignition system circuit
6
Spark plug
6
Spark plug cap resistance
6
Ignition coil
7
Magneto flywheel
7
Pick-up
7
Cables connection
7
Electric start system circuit
8
Fuse
8
Battery
8
Charging voltage check
8
Stator recharge resistance check
8
Starter check
9
Key switch
9
Starter circuit break relay (1° relay)
10
Starter relay (2° relay)
10
Front/back stop light
10
Engine stop switch (engine stop)
11
Side stand switch
12
Start switch
14
Electric starter
16
Warm-start system circuit
18
Driving beam, low beam, parking light, dashboard light and rear light do not work
18
Driving beam does not switch on
19
Low beam does not switch on
20
Driving beam indicator does not work
21
Low beam indicator does not work
21
“Passing” push button (right comm.) does not work
22
Parking light, rear light and dashboard light do not work
23
Stop light does not work
24
Turn indicators circuit
25
Turn indicators failure identification
25
Failures identification of the horn
27
Fuel indicator
28
Temperature indicator
28
Radiator fan
28
DIGIT control does not change function
30
Dashboard connector configuration chart
32
Frame drawing with wiring harness and position of the various electrical components
33
Electric diagram
34
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F12 MAX 200 cc
SWITCHES CONNECTION ILLUSTRATED IN THIS
MANUAL
RIGHT
COMANDO
CONTROL
DX
• This manual contains diagrams as the one here beside, which illustrate
the connections of the switches terminals (key switch, brake switch,
mode push button, etc...).
• The first column from the left indicates the different positions of the
switch, the upper line indicates the colors of the cables connected to the
terminals of the switch.
• The symbol “
“ indicates those terminals in which there is continuity,
that is to say a close circuit, in a determined position of the switch.
• In this diagram:
“BL/B” and “R” have continuity with the switch in “ON” position.
IGNITION SYSTEM CIRCUIT
SPARK PLUG (F. 1)
• Check the condition of the spark plug.
• Check the type of spark plug (see specifications).
• Check the distance between the electrodes; as from specification.
0,6 ÷ 0,7 mm
mm.
0,6 ÷ 0,7
F. 1
SPARK PLUG CAP RESISTANCE (F. 2)
• Remove the spark plug cap of the H.T. cable.
• Connect the tester (k Ω) as follows:
- Tester terminal (+): side (1)
- Tester terminal (-): side (2)
Ω at 20°C
- As from specification: resistance 5 kkΩ
20°C.
Ω x 1K
2
1
F. 2
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F12 MAX 200 cc
IGNITION COIL
• Remove the spark plug cap of the H.T. cable.
A
A) Primary winding resistance(F. 3):
Ω)
- Connect the tester ((Ω
- As from specification: 0,6 ÷ 0,8 Ω at 20°C
20°C.
F. 3
B) Secondary winding resistance (F. 4)
- Connect the tester (k Ω)
Ω a 20°C
- As from specification: 2,50 ÷ 3,50 kkΩ
20°C.
B
F. 4
MAGNETO FLYWHEEL
1
PICK-UP (F. 5)
• Disconnect the wiring harness’ connector from the
flywheel cover.
Ω) as follows:
• Connect the tester (Ω
- Tester terminal (+): connection n° 2
- Tester terminal (-): to the earth of the engine
- Resistance should be: 105 ÷ 124 Ω at 20° C
5
2
4
3
CABLES CONNECTION
• Check all connections in the ignition system (consulting
the electric diagram), paying attention to the colors of
the cables and their positioning in the various connectors.
F. 5
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F12 MAX 200 cc
ELECTRIC START SYSTEM CIRCUIT
• The electric start takes place through the sequence working of two “relays”, which are both positioned in the rear part,
on the left side of the frame (in order to reach it, it is sufficient to disassemble the “drop”-grid on the right side of the
bottom, at the back).
• The electric start does not work, check:
1) Main fuse (15 A)
2) Battery
3) Starter
4) Key switch
1° relay
5) Starter circuit break relay (1°
relay)
2° relay
6) Starter relay (2°
relay)
7) Front/back brake switch
8) Engine stop switch (engine stop)
9) Side stand switch
10) Start switch (start)
FUSE
• Check the continuity of the 15 A fuse (tester Ω)
• There is no continuity: replace the fuse.
BATTERY
• Check the charging state of the battery, measuring the tension while the circuit is open (positive clamp disconnected).
• 12,4 - 12,8 Volt = sufficient charge
• Lower than 12,3 Volt = it is necessary to re-charge.
A) Charging voltage check (use a charged battery) (F. 6):
- Connect the tester (DC20V) to the battery
- Tester terminal (+):battery pole (+)
- Tester terminal (-):battery pole (-)
- Start the motor at 5000 rev./min.
- As from specification: inspected voltage between
13 - 14 Volt
Volt.
F. 6
B) Stator recharge resistance check (F. 7):
- Remove the wiring harness connector from the magneto
flywheel cover.
Ω) to the flywheel cover’s connector
as follows:
- Tester terminal (+): terminal n° 5
terminal n° 1
- Tester terminal (-):
terminal n° 3
- Resistance of each phase: 0,7 ÷ 0,9 Ω at 20° C
C.
1
5
2
4
3
FLYWHEEL
CONNECTOR
RACCORDO
VOLANO
F. 7
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F12 MAX 200 cc
STARTER CHECK (F. 8)
• Connect, by means of two cables, a 12 Volt 9 A battery to the motor
as follows:
- Battery pole (+): terminal of the starter engine blue cable
- Battery pole (-): at the engine earth
- The starter does not work: replace it.
MOTOR
F. 8
KEY SWITCH
• Disconnect the six-way connector of the switch and connect the
tester ((Ω
Ω) as follows:
A) -
KEY SWITCH
Tester terminal (+): green/black cable
Tester terminal (-): blue/black cable
As from specification: (F. 9)
Key in “OFF” position = continuity
Key in “ON” position = discontinuity
Out of specification: replace the key switch.
F. 9
B) -
Tester terminal (+): blue cable
Tester terminal (-): blue/red cable
As from specification: (F. 10)
Key in “ON” position = continuity
Key in “OFF” position = discontinuity
Out of specification: replace the key switch.
KEY SWITCH
Always check, by consulting the electric diagram, that the
cables are correctly positioned in the various connectors.
F. 10
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F12 MAX 200 cc
STARTER CIRCUIT BREAK RELAY
(1 ST RELAY)
• Disconnect the relay’s connector.
Ω) and a battery to the relay
• Connect the tester ((Ω
as follows (F. 11):
- Battery terminal (+): terminal (2)
- Battery terminal (-): terminal (4)
- Tester terminal (+): terminal (1)
- Tester terminal (-): terminal (3)
- There is no continuity: replace the relay.
F. 11
START RELAY (2 ND RELAY)
• Disconnect the relay’s connector.
Ω) and a battery to the relay
as follows (F. 12):
- Battery terminal (+): terminal (1)
- Battery terminal (-): terminal (2)
- There is no continuity: replace the relay.
F. 12
FRONT/BACK BRAKE SWITCH
• Disconnect the red cable and the white/grey cable from the
brake switch.
Ω) to the switch as follows (F. 13):
-
STOP SWITCH
Tester terminal (+): terminal (1)
Tester terminal (-): terminal (2)
Pull the brake lever:
There is no continuity: replace the brake switch.
There is continuity: continue searching.
1 2
• Check the continuity (tester Ω) of the white/grey cable out
of the fuse carrier (7,5 A) and in the brake switch.
- There is no continuity: the white/grey cable is interrupted –
Repair it (see electric diagram).
- There is continuity: the red cable out of the brake switch,
and in the 1° relay, 2° relay, rear light is interrupted. Find the
interruption and repair it (see electric diagram).
F. 13
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F12 MAX 200 cc
ENGINE STOP SWITCH (ENGINE STOP)
• Disconnect the six-way connector of the right switch (F. 14).
• Position the “Engine stop” push button on the symbol
Ω) as follows:
- Tester terminal (+): yellow/white cable
- Tester terminal (-): yellow/blue cable
blue/white cable
- There is no continuity: replace the right switch.
- There is continuity: continue searching.
RIGHT SWITCHES BLOCK
F. 14
A) Check voltage in the right switch’s two-way connector
(F. 15).
- Connect the tester (DC20V) to the blue cable of the wiring
harness’ connector:
- Tester terminal (+): blue cable.
- Tester terminal (-): to the earth of the frame.
- Put the key in “ON” position.
- The inspected voltage should be equal to 12 Volt
Volt.
- Out of specification: blue cable interrupted. Repair it (see
electric diagram).
- As from specification: replace the horn.
EARTH
F. 15
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F12 MAX 200 cc
SIDE STAND SWITCH
• Disconnect the two-way connector of the switch and connect
the tester (Ω
(Ω)) as follows (F. 16):
• Side stand disconnected
- There is no continuity: replace the switch of the side stand.
SIDE STAND
F. 16
A) Check the continuity of the yellow/white cable out of the
right switch and in the side stand switch (F. 17):
Ω) as follows:
- There is no continuity: yellow/white cable interrupted; repair
it (see electric diagram).
1
2
SIDE STAND
F. 17
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F12 MAX 200 cc
B) Check the continuity in the yellow/white cable out of the side stand switch and in the electronic control unit and
in the 1° relay (F. 18).
- There is no continuity: yellow/white cable interrupted; repair it (see electric diagram).
1°
CONTROL BOARD
SIDE STAND
F. 18
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F12 MAX 200 cc
START SWITCH (START)
• Disconnect the six-way connector of the right switch and
connect the tester (Ω
(Ω)) as follows (F. 19):
- Tester terminal (+): white/red cable
- Tester terminal (-): black cable
• Press the “start” push button.
F. 19
A) Check the earth continuity of the black cable fitted into
the six-way connector of the wiring harness (F. 20):
(Ω)) as follows:
- Tester terminal (+): black cable
- Tester terminal (-): to earth
- There is no continuity: black cable interrupted; repair it by
making a bridge between the black cable and an earth spot
on the frame.
EARTH
F. 20
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F12 MAX 200 cc
B) Check the continuity of the green/black cable out of the right switch and in the key switch (F. 21)
Ω) as follows:
- There is no continuity: green/black cable interrupted; repair it (see electric diagram).
KEY SWITCH
2
1
F. 21
C) Check the continuity of the blue/black cable out of the key switch and in the 1° relay (tester
tester Ω).
- There is no continuity: blue/black cable between the key switch and the 1° relay is interrupted; repair it (see electric
diagram).
- There is continuity: the blue/black cable out of the 1° relay and in the 2° relay is interrupted. Repair it (see electric
diagram).
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F12 MAX 200 cc
ELECTRIC STARTER
• The carburettor has been equipped with an “electric starter”, supplied with direct current.
• As soon as the starting takes place, the starter is supplied with voltage; then, warming up, starts its disconnection
function, by closing the hole of the carburetor’s rich mixture control.
Once the electric starter is completely disconnected, the engine idle should be lowered, by setting it on a standard
speed (1600 ÷ 1800 rev./min.)
• Should the engine idle be too fast, proceed as follows:
KEY SWITCH SUPPLY
A) “Electric starter” voltage check
• Disconnect the starter connector.
• Connect the tester (DC 20V) to the wiring harness
connector, as follows (F. 22):
- Tester terminal (+): blue cable
- Tester terminal (-): brown cable
• Start the engine.
• The inspected voltage should be equal to 12 Volt.
ELECTRIC
STARTER
CONNECTOR
ELECTRONIC CONTROL BOARD
F. 22
- As from specification: disassemble the starter of the
carburettor and supply voltage directly from a 12 Volt battery,
checking from time to time the piston length variations
(F. 23).
- Should it not vary, in a period of 5 minutes:
replace the “electric starter”
starter”.
- Out of specification: continue searching.
m3
~m
F. 23
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F12 MAX 200 cc
B) Check voltage in the blue cable (positive) of the wiring
harness’ two-way connector (F. 24).
• Connect the tester (DC 20V)
20V), as follows:
- Tester terminal (-): to the frame earth
• The inspected voltage should be equal to 12 Volt.
- Out of specification: the blue cable is interrupted: repair it
(see electric diagram).
- As from specification: continue searching.
ELECTRIC STARTER
NEGATIVE
POSITIVE
F. 24
C) Check continuity in the brown cable between the electric starter and the electronic control unit (F. 25).
- Connect the Tester in OHM as follows:
- Tester terminal (+): brown cable (starter)
- Tester terminal (-):brown cable (control unit)
- There is no continuity: brown cable interrupted; repair it (see electric diagram).
- There is continuity: replace the electronic control unit.
KEY SWITCH SUPPLY
F. 25
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F12 MAX 200 cc
LIGHT SYSTEM CIRCUIT
DRIVING BEAM, LOW BEAM, PARKING LIGHT, DASHBOARD LIGHT AND REAR LIGHT DO NOT WORK
A) Verify the efficiency of the 10 A Fuse
B) Right switch light switch check
- Disconnect the right switch’s six-way connector and connect the Tester in OHM as follows:
- Tester terminal (-): pink cable
yellow/black cable
- In both cases, there must be continuity.
C) Check voltage in the red/green cable in the right switch’s six-way connector.
DC 20 V
- Connect the tester (DC
V) as follows (F. 26 bis):
- Tester terminal (+): red/green cable (wiring harness connector)
- Tester terminal (-): to the frame hearth
- The inspected voltage should be equal to 12 Volt.
- Out of specification: the red/green cable between the right switch and the wiring harness of the 10 A fuse carrier is
interrupted. Repair it (see electric diagram).
F. 26 bis
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F12 MAX 200 cc
DRIVING BEAM DOES NOT WORK
A) Check the lamp (12V x 55W) and/or the lamp holder.
LEFT DRIVING
BEAM
55W
B) Check the voltage to the front light wiring harness
(F. 26).
DC 20 V
V) as follows:
- Tester terminal (+): white/black cable terminal
- Tester terminal (-): black cable terminal
- Put the light switch on the symbol (
) (right switch).
- Put the light deviation push button (left switch) on the symbol
HI
driving beam
(HI
HI) (driving
beam).
Volt.
- As from specification: find out the interruption of the white/
black or black cable of the front light wiring harness and
repair it (see electric diagram).
PARKING LIGHTS
3W
RIGHT LOW
BEAMS
65W
C) Left switch’s light push button check
- Disconnect the left switch’s nine-way connector and connect
the Tester in OHM as follows (F. 27):
- Tester terminal (+): yellow/black cable
- Tester terminal (-): white/black cable
- Put the push button on (HI)
- There is no continuity: replace the left switch.
D) Check continuity in the white/black cable
- Tester terminal (+):white/black cable (Left switch
connector)
- Tester terminal (-):white/black cable (front light connector)
- There is no continuity: white/black cable interrupted. Repair
it (see electric diagram).
- There is continuity: black cable of the front light two-way
connector is interrupted (no earth).
Repair it by making a bridge between the black cable of the
light connector and an earth point on the frame.
F. 26
LEFT SWITCHES BLOCK
LIGHTS
F. 27
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F12 MAX 200 cc
THE LOW BEAM DOES NOT WORK
A) Check the lamp (12V x 65W) and/or the lamp holder.
LEFT DRIVING
BEAM
55W
B) Check voltage in the front light wiring harness (F. 28).
DC 20 V
V) as follows:
- Tester terminal (+):white/light blue cable terminal
- Put the light switch on the symbol (
) (right switch).
- Put the light deviation push button (left switch) on the symbol
LO
low beam
(LO
LO) (low
beam).
Volt.
- As from specification: find out the interruption of the white/
light blue or black cable of the front light wiring harness and
repair it (see electric diagram).
C) Left switch’s light push button check
- Disconnect the left switch’s nine-way connector and connect
the Tester in OHM as follows:
- Tester terminal (+):yellow/black cable
- Tester terminal (-):white/light blue cable
- Put the push button on (LO)
D) Check the continuity in the white/light blue cable
- Tester terminal (+):white/light blue cable (left switch
connector)
- Tester terminal (-):white/light blue cable (front light connector.)
- There is no continuity: white/light blue cable interrupted.
- There is continuity: black cable of the front light’s two-way
connector is interrupted (no earth).
Repair it by making a bridge between the light connector
black cable and an earth spot on the frame.
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08/03
F. 28
PARKING LIGHTS
3W
RIGHT LOW
BEAMS
65W
F12 MAX 200 cc
DRIVING BEAM DOES NOT WORK
A) Check the lamp and/or the lamp holder.
B) Check voltage in the dashboard connector.
DC 20 V
V) as follows:
- Tester terminal (+):white/black cable
- Put the light switch on symbol (
).
- Put the left switch on symbol (HI).
- The inspected voltage should be equal to 12 Volt (F. 29).
- Out of specification: the white/black cable is interrupted.
- As from specification: replace the whole dashboard.
INSTRUMENT PANEL
CONNECTOR
INSTRUMENT PANEL
CONNECTOR
12
14
F. 29
LOW BEAM DOES NOT WORK
A) Check voltage in the dashboard connector.
DC 20 V
V) as follows:
- Tester terminal (+):white/light blue cable
- Put the light switch on symbol (
).
- Put the left switch on symbol (LO).
- The inspected voltage should be equal to 12 Volt (F. 30).
- Out of specification: the white/black cable is interrupted.
- As from specification: replace the whole dashboard.
INSTRUMENT PANEL
CONNECTOR
14
F. 30
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F12 MAX 200 cc
“PASSING” PUSH BUTTON (RIGHT SWITCH) DOES NOT
WORK
A) Check continuity in the push button
• Disconnect the left switch’s nine-way connector (F. 31).
• Connect the Tester in OHM as follows:
- Tester terminal (-): white/black cable
- Press the “Passing” push button
LEFT SWITCHES BLOCK
LIGHTS
F. 31
B) Check voltage in the left switch’s connector
(blue cable)
• Connect the tester (DC 20V) as follows (F. 32):
- Tester terminal (+):red/green cable terminal
- Tester terminal (-): to earth.
- Out of specification: the blue cable is interrupted.
LEFT SWITCHES BLOCK
FRAME
MASS
R-VR
LIGHTS
F. 32
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F12 MAX 200 cc
PARKING LIGHT, REAR LIGHT AND DASHBOARD LIGHT DO NOT WORK
A) Check lamps and/or lamps’ holders.
B) Right switch switch check
• Disconnect the right switch’s six-way connector (F. 33).
- Tester terminal (-): pink cable
- Position the light switch on symbol (
).
- There is continuity: the pink cable among the right switch, the dashboard connector, the back light wiring harness
and the front light wiring harness is interrupted.
- Find out the interruption (Tester in OHM) and repair it (see electric diagram).
F. 33
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F12 MAX 200 cc
STOP LIGHT DOES NOT WORK
A) Check the 5 A fuse state.
B) Check the state of the lamp (12V x 21 W) and/or the lamp
holder.
C) Check the brake switch (front/back)
D) Check the voltage of the back wiring harness six-way
connector (F. 34).
• Connect the tester (DC 20V) as follows:
- Tester terminal (+): red cable
- Pull the brake lever.
- As from specification: find out the interruption of the red
and/or black cable of the rear light wiring harness and repair
it.
LEFT TURN
INDICATOR
10W
RIGHT TURN
INDICATOR
10W
PLATE LIGHT 5W
F. 34
E) Check the earth continuity in the black cable of the wiring
harness six-way connector (rear light) (F. 35).
- Tester terminal (+): black cable.
- There is no continuity: Black cable interrupted. Repair it by
making a bridge between the connector and an earth spot.
EARTH
F) Check the continuity in the red cable (output voltage)
among the rear light’s six-way connector, the brakes’ switches
connections and the 2° relay (under the footboard).
- There is no continuity: red cable interrupted. Repair it (see
electric diagram).
Imput
- There is continuity: the white/grey cable (B/GR) (Imput
voltage
voltage) between the two brakes’ switches and the wiring
harness of the 5 A fuse carrier is interrupted.
LEFT TURN
INDICATOR
10W
RIGHT TURN
INDICATOR
10W
PLATE LIGHT 5W
F. 35
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F12 MAX 200 cc
TURN INDICATORS CIRCUIT
TURN INDICATORS FAILURE IDENTIFICATION
A) Check the 7,5 A fuse state and the state of the lamp and/
or the state of the lamp holder.
LEFT SWITCHES BLOCK
B) Check of the “Turn” switch
• Disconnect the left switch’s nine-way connector and connect
the Tester in OHM as follows (F. 36):
-
LIGHTS
Shift the “Turn” push button on the left.
Tester terminal (+): brown cable
Tester terminal (-): violet cable
Shift the “Turn” push button on the right.
Tester terminal (+): brown cable
Tester terminal (-): green cable
- In both cases there must be continuity.
- There is no continuity: replace the left switch
switch.
- Check the continuity of the brown/black cable between the
electronic control unit’s connector and the left switch’s
connector.
F. 36
- Connect the Tester in OHM as follows (F. 37):
- Tester terminal (+): brown/black cable of the electronic
control unit.
- Tester terminal (-):brown/black cable of the left switch.
- There is continuity: replace the electronic control unit
- There is no continuity: the brown/black cable is
LEFT SWITCHES BLOCK
LIGHTS
F. 37
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F12 MAX 200 cc
A) Check of the right indicator (F. 38)
• Disconnect the terminal of the right lamp holder and connect the tester
(DC 20V):
- Tester terminal (+): green cable terminal
• Key of the switch in “ON” position.
• Shift the switch on the right turn:
- Voltage at 12 volt
volt: as from specification.
- Out of specification: the circuit between the turn indicators switch
and the lamp holder’s connector is defective; repair it (see electric
diagram).
RIGHT FRONT TURN
INDICATOR
F. 38
B) Left turn control (F. 39)
• Disconnect the terminal of the left lamp holder and connect the tester
(DC 20V):
- Tester terminal (+): violet cable terminal.
- Tester terminal (-): black cable terminal.
• Switch key in “ON” position.
• Shift the switch on left turn:
- Voltage at 12 volt
volt: as from specification.
- Out of specification: the circuit between the turn indicator switch
and the lamp holder connector is defective; repair it (see electric
diagram).
LEFT FRONT TURN
INDICATOR
F. 39
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F12 MAX 200 cc
HORN FAILURE IDENTIFICATION
LEFT SWITCHES BLOCK
A) Left switch alarm switch check
• Disconnect the connector of the left switch
and connect the Tester in OHM as follows (F.
40):
- Tester terminal (+): orange cable.
- Tester terminal (-): black cable.
- Press the “HORN” push button.
LIGHTS
B) Check earth in the black cable of the wiring
harness nine-way switch.
- There is no continuity: black cable interrupted.
Repair it by making a bridge between the
black cable and an earth spot.
Ωx1
F. 40
HORN
C) Check voltage in the horn terminals (F. 41)
• Disconnect the horn terminals and connect the tester
(DC 20 V) as follows:
- Tester terminal (-): orange cable.
- Press the “HORN” push button.
Volt.
- As from specification: replace the horn.
Do not invert cables.
F. 41
EARTH
HORN
D) Check voltage in the blue cable (F. 42)
• Disconnect the terminal of the horn blue cable and connect
the tester (DC 20 V) as follows:
Volt.
- Out of specification: blue cable interrupted. Repair it (see
electric diagram).
- As from specification: the orange cable out of the left switch
and in the horn is interrupted. Repair it (see electric diagram).
F. 42
27
08/03
F12 MAX 200 cc
FUEL INDICATOR
A) Check fuel indicator
• Disconnect the connector of the fuel indicator and make a bridge
between the grey cable and the black cable (F. 43).
- Pointer indicator on 4/4
4/4: replace the fuel indicator.
- The indicator pointer does not move
move: continue searching.
B) Check the earth continuity in the black cable fitted into the wiring
harness two-way connector.
- There is no continuity: black cable interrupted. Repair it by making
a bridge between the black cable and an earth spot on the frame.
FUEL INDICATOR
F. 43
C) Check the continuity in the grey cable out of the fuel indicator
and in the terminal (n° 15) of the dashboard connector
Tester in OHM
(Tester
OHM).
- There is no continuity: grey cable interrupted. Repair it (see electric
diagram).
- There is continuity: replace the whole dashboard.
TEMPERATURE INDICATOR
A) Check temperature indicator
• Disconnect the terminal of the white/green cable from the indicator
positioned on the thermal part of the engine and take it to earth.
- Dashboard indicator pointer at end of scale
scale: replace the
temperature indicator.
- The pointer does not move
move: continue searching.
B) Check continuity of the white/green cable out of the temperature
indicator and in the terminal (n° 16) of the dashboard connector
Tester in OHM
(Tester
OHM).
- There is no continuity: white/green cable interrupted. Repair it (see
electric diagram).
- There is continuity: replace the whole dashboard.
RADIATOR’S FAN
A) Check the 7,5 A fuse
fuse; if working correctly, continue searching.
12V BATTERY
B) Check the fan rotator
• Disconnect the fan connector and supply voltage by means of a battery
(12 Volt) (F. 44).
- Battery cable (+): red cable.
- Battery cable (-): black cable.
- The fan does not work: replace it.
- The fan works correctly: continue searching.
FAN
F. 44
28
08/03
F12 MAX 200 cc
EARTH
12V BATTERY
5A FUSE
C) Check thermal switch (white upper part)
• Disconnect the two yellow cables from the
thermal switch (F. 45).
- Make a bridge between the two yellow cables.
- The fan works correctly: replace the thermal
switch.
- The fan does not work: continue searching.
FAN
FAN SWITCH
JUMPER
F. 45
12V BATTERY
FAN
5A FUSE
D) Check the earth continuity of the black cable
(F. 46).
- There is no continuity: black cable interrupted.
Repair it by making a bridge between the black
cable and an earth spot on the frame.
FAN SWITCH
F. 46
12V BATTERY
EARTH
5A FUSE
E) Check the continuity of the yellow cable out
of the thermal switch (F. 47) and in the radiator’s
Tester in OHM
fan connector (Tester
OHM).
- Tester terminal (+): yellow cable (1).
- Tester terminal (-): yellow cable (2).
- There is no continuity: the yellow cable in
question is interrupted. Repair it (see electric
diagram).
- There is continuity: the yellow cable out of the
fuse holder and in the thermal switch is
FAN
FAN SWITCH
1
F. 47
29
08/03
2
F12 MAX 200 cc
DIGIT CONTROL DOES NOT CHANGE
FUNCTION
A) Check “MODE” push button (F. 48)
• Disconnect the right switch’s two-way connector and
connect the Tester in OHM as follows:
- Tester terminal (+): red cable.
- Tester terminal (-): blue/yellow cable.
blue/white cable.
- Press the “MODE” push button.
B) Check the power supply to the “MODE” push
button
• Connect the tester (DC 20 V) as follows (F. 49):
- Out of specification: the blue cable is interrupted.
- Repair it by making a bridge with another blue cable
(see electric diagram).
In case the voltage should fail, and “mode”
does not work, it wouldn’t work the starter
either (electric starting).
- As from specification: continue searching.
F. 48
F. 49
30
08/03
F12 MAX 200 cc
2
1
F. 50
C) Check continuity in the red cable (F. 50) out of the right switch’s two-way connector and in the digital dashboard’s
n° 11
connector (n°
11).
Ω) as follows:
- Tester terminal (+): terminal (1).
- Tester terminal (-): terminal (2).
- There is no continuity: the red cable is interrupted. Repair it (see electric diagram).
- There is continuity: defective digital instrument. Replace the whole dashboard.
31
08/03
32
08/03
8
17
7
16
B-VR
Gray Cable: Fuel
Indicator
R-BL B-VL GL-B
9
18
N
Blue Cable: 12v Supply – With the
Key on
Yellow-Blue Cable: 12v Supply – Odometer
Transmission
White-Violet Cable:
Bar Oil
Red-Blue Cable: 12v Supply To Battery
Black Cable:
Earth
Free
White-Green Cable: H2O
Temperature Sensor
BL
6
15
GR
Black Cable:
Earth
R-N
5
14
N
2
11
R
GL-R
1
10
B
Pink Cable: Instrument Panel Lighting
Supply
White-Light Blue Cable:
Dipped headlight
B-AZ VR
3
12
B-N
Red-Black Cable: Outer
Temperature Sensor
RS
4
13
VL
Green Cable: Right Turn
Indicator Supply
Yellow-Red Cable: Revolution
Indicator Supply
White Cable: Odometer
Picking up Device
Red Cable: Mode
Supply
White-Black Cable: Driving Beam
Indicator Supply
Violet Cable: Left Turn
Indicator Supply
INSTRUMENT PANEL CONNECTOR CONFIGURATION CHART
F12 MAX 200 cc
F12 MAX 200 cc
2
ELECTRICAL COMPONENTS
Fuel Indicator
2a
Dashboard
17
18
1
1
12
2 Left - Right switches
3
10
2a Stop Switch
14
Fuses Carrier
15 A : BL/R - AZ
7,5 A : BL - GL
7,5 A : BL - B/GR
10 A : BL - R/VR
11
13
9
18
4
Key Switch
15
Side stand switch
3
Electric Horn
Fan thermal
switch
7
8
4
5
5
6
Incorporated intermittence
electronic control board
Regulator
8
Regulator fuse
carrier 15 A
10
2ND relay
12
Electric starter
12V 9Ah Battery
Coil
16
Picking up device
transmission
6
7
9
1ST relay
11
Temperature sensor 13
33
06/03
17
F12 MAX 200 cc
LEFT DRIVING BEAM
55W
COMPLETE DASHBOARD
RIGHT LOW BEAMS
65W
PARKING LIGHTS
3W
LEFT SWITCHES BLOCK
LEFT FRONT
TURN INDICATOR
(10W)
DOUBLE HEADLIGHT
STOP
SWITCH
KEY SWITCH
STOP
SWITCH
RIGHT
FRONT
TURN
INDICATOR
(10W)
from dashboard
INSTRUMENT
PANEL
CONNECTOR
OUTER TEMPERATURE
INDICATOR
PICKING UP
DEVICE
TRANSMISSION
FRAME MASS
HORN
COLOR LEGEND
FAN
THREE-PHASE FLYWHEEL
FAN THERMAL
SWITCH
REGULATOR
DIODE
ELECTRIC STARTER ON
CARBURETTOR
BATTERY
TEMPERATURE
INDICATOR
FUEL INDICATOR
ELECTRIC DIAGRAM
MOTOR
LEFT TURN
INDICATOR 10W
RIGHT TURN
INDICATOR 10W
PLATE LIGHT 5W
34
06/03
SIDE STAND
COIL
A
AZ
AZ-B
B
B-N
B-R
B-VL
B-VR
BL
BL-N
BL-R
BL-GL
GL
GL-B
GL-N
GL-V
GL-R
GR
GR-R
M
M-B
M-N
N
N-R
R
R-VR
RS
VL
VL-N
VR
ORANGE
LIGHT BLUE
LIGHT BLUE/WHITE
WHITE
WHITE /BLACK
WHITE /RED
WHITE /VIOLET
WHITE /GREEN
BLUE
BLUE/BLACK
BLUE/RED
BLUE/YELLOW
YELLOW
YELLOW /WHITE
YELLOW /BLACK
YELLOW /GREEN
YELLOW /RED
GRAY
GRAY/RED
BROWN
BROWN /WHITE
BROWN /BLACK
BLACK
BLACK/RED
RED
RED/GREEN
PINK
VIOLET
VIOLET/BLACK
GREEN

F12 MAX 200 cc - Shop Malaguti

Transcription

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