madison 3 125 cc

B
TROUBLESHOOTING
ELECTRICAL SYSTEM
MADISON 125 cc. - Euro 3
WORKSHOP MANUAL
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B
CHAPTER
Introduction
MADISON 125 cc
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.
ENGLISH
J
NOTES FOR EASY CONSULTATION
PAGE LAYOUT
X
Y Chapter
X
Y
Z
W
X Motor vehicle model
J Section
W Page N
Z
Date of issue
ABBREVIATIONS
F. Figure
Pag. Page
Pr Paragraph
S Section
Sch Diagram
T Table
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 A and
the new date of issue.
2
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MADISON 125 cc
Introduction
B
CHAPTER
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.
ENGLISH
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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B
Introduction
CHAPTER
MADISON 125 cc
Table of contents
Page
ENGLISH
4
Introduction
2
Checking Switches
Fuses
6
8
General Wiring Diagram
Ignition System
11
14
Charging System
Electrical Starting System
16
18
Light System
Signalling System
20
25
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MADISON 125 cc
Introduction
B
CHAPTER
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
ENGLISH
• 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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B
CHAPTER
Checking Switches
MADISON 125 cc
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 :.
ENGLISH
F. 1
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. 2
6
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Checking Switches
MADISON 125 cc
CHAPTER
POSITION OF SWITCHES AND CONNECTION OF CONNECTORS
1)
2)
3)
4)
5)
6)
7)
Rear stop switch
Horn control
Light switch
Passing
Turn indicator switch
Front stop switch
Main light switch
8)
9)
10)
11)
12)
13)
Engine start switch
Engine stop switch
Mode
Key switch
Side stand switch
Fuse carrier
1
6
7
8
2
11
R
B-GR
3
10
13
4
AR
N
ENGLISH
9
1
5
2
0FF
ON
9
VL
ON
11
12
13
N
N
BL-R
BL-N
VR-N
BL
N
GL-B
10
R
B-BL
M
0FF
R
B-GR
0FF
8
GL-B
7
GL-BL
GL-N
6
L
N
ON
5
R
B-R
LO
4
VR
BL
0FF
RS
BL
HI
B-N
3
RS
GL-N
AZ-B
B-N
12
OFF
ON
ON
N
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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B
CHAPTER
Fuses
MADISON 125 cc
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.
:” (sound-emitting function).
NOTE: put the Tester on “:
- If the tester is showing “I” and no sound is given, replace the fuse.
ENGLISH
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.
F. 3
8
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Fuses
MADISON 125 cc
CHAPTER
FUSES
The electrical equipment includes 10 fuses.
Before replacing a fuse, locate and eliminate the fault causing its interruption.
2
3
4
5
6
7
8
15 A Lights
7.5 A Turn indicators/stop
3 A “ENGINE STOP”
10 A Key
30 A Main
Not active
7.5 A Radiator fan
5 A 12 V Socket
9)
30 A Recharge protection fuse
ENGLISH
1
1)
2)
3)
4)
5)
6)
7)
8)
F. 4
F. 5
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B
CHAPTER
Fuses
MADISON 125 cc
CHECKING CONNECTORS
- Check connectors for corrosion and damp.
- Disconnect connectors.
- Dry terminals with compressed air.
F. 6
ENGLISH
- 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.
F. 7
- Plug in connectors.
NOTE: the “click” sound means that all connector parts are correctly assembled.
F. 8
- 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. 9
10
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B
General Wiring Diagram
MADISON 125 cc
CHAPTER
GENERAL WIRING DIAGRAM
BL-N
GL-B
N
BL-R
BL
VR-N
3
2
5
4
OFF
ON
VL
N
VR
1
N
12V
12Ah
6
R
B-GR
R
LUCI
BL
AZ-B
GL-N
B-N
VR
VL
M
AR
N
R
0FF
HORN
ON
7
AR
N
<
BL
<
B
16
<
N
VL
W
N
35 w
CHASSIS MASS NODE
NODO
MASSE ZONA
INTELAIO
REGULATOR
ZONE
REGOLATORE
AZ-B
35 w
N
ENGLISH
GL-N
VR
M
VL
TURN
BL
BL-R
N
BL-R
GL-VL
BL-R
GL-B
BL-N
VR-N
16 8
B
B-N
GL-N
AZ-B
L
GL
AZ-GR
31
7.5 A
5A
BL
B-N
HI
LO
30 A
R-VR
AZ-B
GL-N
B-N
VR
VL
M-N
AR
N
Diodo 2A
15 7
32
0FF
PASSING
M-N
BL
BL-R
R
GL-VL
AZ-GR
10 A
30
29
BL-N
AZ-GR
13 5
33
B-GR
BL
3A
11 3
34
BL
R-VR
AR
FUSE 7.5 A
1 9
10 2
35
FUSE 15 A
ON
B-GR
R
R-BL
36
N
B-N
W
AZ-B
5
B-N
RS
AZ-B
B-N
RS
VR
N
N
VL
N
N
VL
VR
8
N
35 w
B-R
N
RS
RS
N
N
35 w
B-R
AR-BL
AZ-B
BL
28
R
B-N
<
N
16
VR
W
B-R
27
M-B
N
B-R
<
N
N
9
N-R
N
+12 DIRETTO BATTERIA
BL-R
9
B-VL
8
TEMPERATURA H2O
GL-BL
7
BAR - OIL
VR
2
GL-R
1
SEGNALE SONDA C/KM
AZ-B
3
SONDA C/KM
RS
4
LIVELLO CARBURANTE
BL
R-N
5
CONNETORE
CRUSCOTTO B
MODE
6
SOTTO CHIAVE
24 23 22 21 20 19 18 17 16 15 14 13
GL-B
12 11 10
ENGINE STOP
10
B-VR
GR
N
VL
B-N
GR-R
B
R.P.M
>
>
VL
R
VL
R
RS
RS
N
VR
N
>
>
RS
N
BL-N
GR-R
GL-N
RS
BL
B-R
N
GL-B
GL-B
R
GL-N
BL
BL
RS
0FF
0FF
ON
ON
START ENGINE STOP
MODE
10 W
5W
RS
N
LIGHTS
5w
21w
26
GL-N
RS
R-VR
B-R
>
R
GL-B
R-B
N
B-BL
VR
GL-B
GL-BL
10 W
B-BL
R
5w
21w
B-GR
R
GL
W
GL
N
R-VR
INTERRUTTORE
TERMICO VENTOLA
100º - 95º
020.023.00
2
25
11
12
GL-N
N
GL-B
N
N
N
13
1/4 W 1KS
BL
24
N
<1B
4
<8B
MASSA AL
RADIATORE
N
3
M
AR
02412900
<
GL-B
<
B
VR
M
15
BL
VR
<18 B
N
VR
B-VR
GL-BL
13 B >
GL-R VR
B
N
VR
BL
N
R
VR
B-VL
21
14
8>
3>
7>
M-B
GL-R
<19B
N
N
M-B
6>
BAR - OIL
CAVALLETTO
Open
Close
22
5>
8
N
7
GL
6
R
N
5
23
7B<
N
GR
N
GR
N
AR
N
UP
VR
PICK
16
20
17
19
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11
B
CHAPTER
General Wiring Diagram
MADISON 125 cc
KEY TO GENERAL WIRING DIAGRAM
1)
BATTERY
2)
PROVISION FOR ANTI-THEFT SYSTEM
3)
SWITCH WITH KEY
4)
HORN
5)
FLASHLIGHT
6)
REAR LEFT STOP SWITCH
7)
LEFT SWITCH
8)
HEADLIGHTS
9)
AMBIENT TEMPERATURE PROBE
ENGLISH
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
16) COIL
17) WATER TEMPERATURE SENSOR
18) FUEL PROBE
19) VOLTAGE REGULATOR
20) FLYWHEEL
21) REV COUNTER SENSOR
22) SIDE STAND SWITCH
23) RADIATOR FAN
24) STARTER MOTOR
25) HELMET COMPARTMENT LIGHT
26) REAR LIGHTS
27) REMOTE SWITCH
28) REMOTE START SWITCH (BLACK)
29) FUSE, 30 A
30) FUSE, 5 A
31) FUSE, 7.5 A
32) FUSE, 30 A
33) FUSE, 10 A
34) FUSE, 3 A
35) FUSE, 7.5 A
36) FUSE, 15 A
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General Wiring Diagram
MADISON 125 cc
CHAPTER
GENERAL WIRING DIAGRAM
COLOUR KEY
N-R
BLACK/RED
WHITE/PURPLE
R
RED
R-VR
RED/GREEN
B-GR
WHITE/GREY
RS
PINK
BL
BLUE
RS-N
PINK/BLACK
BL-N
BLUE/BLACK
VL
PURPLE
BL-R
BLUE/RED
VL-N
PURPLE/BLACK
BL-VR
BLUE/GREEN
VR-N
GREEN/BLACK
GL
YELLOW
VR
GREEN
GL-B
YELLOW/WHITE
AR
ORANGE
GL-N
YELLOW/BLACK
AR-B
ORANGE/WHITE
GL-V
YELLOW/GREEN
AR-VR
ORANGE/GREEN
GL-R
YELLOW/RED
AR-BL
ORANGE/BLUE
GL-BL
YELLOW/BLUE
AZ
LIGHT BLUE
GR
GREY
AZ-B
LIGHT BLUE/WHITE
GR-R
GREY/RED
AZ-GR
LIGHT BLUE/GREY
M
BROWN
B
WHITE
M-B
BROWN/WHITE
B-VR
WHITE/GREEN
M-N
BROWN/BLACK
B-N
WHITE/BLACK
N
BLACK
B-R
WHITE/RED
B-BL
WHITE/BLUE
ENGLISH
B-VL
INSTRUMENT BOARD CONNECTOR CONFIGURATION
1)RPM
9) BATTERY POSITIVE
17)NEGATIVE
2)RIGHT TURN INDICATOR
10) -
18)FUEL PROBE
3)LOW BEAM LIGHTS
11) -
19)TEMPERATURE PROBE
4)PARKING LIGHTS
12) ENGINE STOP
20)-
5)AMBIENT TEMPERATURE
13) HALL SENSOR INPUT
21)-
6)POSITIVE WITH KEY ON
14) MODE BUTTON
22)-
7)HALL SENSOR V DC
15) HIGH BEAM LIGHTS
23)-
8)BAR-OIL
16) LEFT TURN INDICATOR
24)-
INSTRUMENT BOARD CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
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B
Ignition System
CHAPTER
MADISON 250 I.E.
IGNITION SYSTEM
TROUBLESHOOTING
1 SPARK PLUG IS NOT SPARKING. CHECK:
1.
Spark plug
2.
Spark plug cap resistance
3.
HV coil
4.
Pick-up resistance
5.
Wiring connections
ENGLISH
1.1 Spark plug
- Check condition of spark plug.
- Check type of spark plug.
- Check gap between electrodes: 0.6 ÷ 0.7 mm.
0,6÷0,7 mm
F. 10
1.2 Spark plug cap resistance
- Remove spark plug cap.
NOTE: when removing spark plug cap, do not pull.
- To remove
Turn anti-clockwise.
- To connect
Turn clockwise.
- Before connecting the spark plug cap, check the HV cable and cut off a piece of approximately 5 mm.
:) to spark plug cap, as follows:
- Connect Tester (K:
- Terminal (+) of Tester
Spark plug side (1).
- Terminal (-) of Tester
High voltage cable side (2).
: at 20°C.
- Spark plug cap resistance: 5 K:
2
F. 11
14
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Ignition System
MADISON 250 I.E.
B
CHAPTER
ENGLISH
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:
: at 20°C.
- Compliant: 2.50 ÷ 3.50 K:
F. 13
1.4 Check pick-up (flywheel)
- Remove wiring connector from flywheel cover.
:) to connector on flywheel cover (R).
- Connect Tester (:
Connection n°2.
- Terminal (+) of Tester
- Terminal (-) of Tester
Chassis grounding.
- Resistance measured must be: 105 ÷ 124 : at 20°C
R
2
F. 14
1.5 Cable connection
- Check connections of ignition system (refer to the wiring diagram), paying attention to the cable colours and to
how they are connected to the various connectors.
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CHAPTER
Charging System
MADISON 125 cc
CHARGING SYSTEM
TROUBLESHOOTING
1 IF THE BATTERY CANNOT BE CHARGED, CHECK:
1.
30 A Fuse (helmet compartment)
2.
Battery
3.
Charging voltage
4.
Stator coil resistance
5.
Charging system wiring
ENGLISH
1.1 30 A Fuse (helmet compartment)
- Remove relative fuse.
:) to fuse.
- Connect Tester (:
- Check continuity of fuse.
- If fuse has blown: eliminate cause of short-circuit and replace fuse with an identical one.
F. 15
1.2 Battery
- Remove battery and connect Tester (20 V DC), as follows:
Battery (+) pole.
- Terminal (+) of Tester
- Terminal (-) of Tester
Battery (-) pole.
- If voltage level is lower than 12.4 V, recharge using a suitable battery charger.
- After charging the battery, do not use it for approximately 30 minutes, then measure voltage level again.
- 12.8 V or more
Battery is charged.
- 12.5 V
Battery needs to be recharged.
- 12.0 V
Replace battery.
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Charging System
MADISON 125 cc
B
CHAPTER
.
12V
-
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. 5000 RPM.
- The voltage measured should be: 12.80 ÷ 14 V
+
ENGLISH
F. 16
1.4 Check stator recharging resistance
- Remove wiring connector from flywheel cover.
:) to connector on flywheel cover (R).
- Connect Tester (:
- Make sure resistance measured between connections 3-5, 1-5 and 1-3 is 0.2 ÷ 0.8 :
NOTE: always check grounding isolation of three terminals.
1
5
R
3
F. 17
1.5 Checking wiring connections
- Check connections of the entire charging system.
- See “Wiring Diagram”.
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CHAPTER
Electrical Starting System
MADISON 125 cc
ELECTRICAL STARTING SYSTEM
TROUBLESHOOTING
1 IF STARTER MOTOR DOES NOT WORK, CHECK:
ENGLISH
1.
7.5 A fuse N° 2, 3 A fuse N° 3, 30 A fuse N° 5
2.
Battery
3.
Starter motor
4.
Remote start switch / Remote start circuit interruption switch
5.
Key switch
6.
Engine stop switch
7.
Side stand switch
8.
Start switch (START)
9.
Front/rear stop switch
10.
Starting system wiring connections
1.1 7.5 A fuse N° 2, 3 A fuse N° 3, 30 A fuse N° 5
- Remove relative fuse.
:) to fuse.
- Connect Tester (:
- Check continuity of fuse.
- If fuse has blown: eliminate cause of short-circuit and replace fuse with an identical one.
Tester :
:)
F. 18
1.2 Battery
- Check condition of battery.
- See “Checking Battery” (page 16).
-
1.3 Check starter motor
- Using two cables, connect a 12 V battery to the starter motor and check if the latter is working.
N
F. 19
18
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12V
N
+
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MADISON 125 cc
Electrical Starting System
B
CHAPTER
1.4 Remote start switch (black connector - Code n°02502500) - Remote start circuit interruption switch
(white connector - 02504300)
- Detach remote switch connector.
:) and a battery (12 V) to remote switch terminals, as follows:
- Connect Tester (:
- Battery (+) pole
Terminal (86).
- Battery (-) pole
Terminal (85).
WARNING: never invert battery connections on remote switch terminals.
- Terminal (+) of Tester
Terminal (87).
- Terminal (-) of Tester
Terminal (30).
- Check continuity.
+
12V
.
ENGLISH
N
85
87
30
86
F. 20
1.5 Key switch
- See “Checking switches” section (on page 6/7).
1.6 Engine stop switch
- See “Checking switches” section (on page 6/7).
1.7 Side stand switch
- See “Checking switches” section (on page 6/7).
1.8 Start switch
- See “Checking switches” section (on page 6/7).
1.9 Front/rear stop switch
- See “Checking switches” section (on page 6/7).
1.10 Wiring connections
- Check connections of starting system.
- See “Wiring Diagram”.
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CHAPTER
Light System
MADISON 125 cc
LIGHT SYSTEM
TROUBLESHOOTING
1 IF LIGHTING SYSTEM DOES NOT WORK, CHECK:
1.
15 A fuse n°1
2.
Battery
3.
Key switch
4.
Light switch
5.
Light switch and “passing” button
6.
Connection of light system wiring
ENGLISH
1.1 15 A fuse N°1 (lights)
- Remove relative fuse.
:) to fuse.
- Connect Tester (:
- Check continuity of fuse.
- If fuse has blown: eliminate cause of short-circuit and replace fuse with an identical one.
Tester :
:)
F. 21
1.2 Battery
- Check condition of battery.
- See “Checking Battery” (page 16).
1.3 Key switch
- Check key switch.
- See “Checking switches” section (page 6/7).
1.4 Light switch (right switch)
- See “Checking switches” section (page 6/7).
1.5 Light switch/”passing” button (left switch)
- See “Checking switches” section (page 6/7).
1.6 Wiring connections
- Check connections of the light system.
- See “Wiring Diagram”.
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ISSUE
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B
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).
W
5
W
N
RS
N
35 w
35 w
N
B-N
35 w
N
AZ-B
B-N
RS
N
35 w
AZ-B
B-N
AZ-B
ENGLISH
5
RS
2.2 Check voltage level
- Connect Tester (20 V DC) to four-way connector as follows:
- Terminal (+) of Tester
White/black cable (1).
- Terminal (-) of Tester
Black cable (2).
- Turn key “ON”.
- Flick light switch to ( ) symbol.
- Flick light switch to (HI) symbol.
- Power measured must be >12 V.
2
1
F. 22
3 IF HIGH BEAM INDICATOR LIGHT DOES NOT COME ON
3.1 Check voltage level.
- Connect Tester (20 V DC) to instrument board connector as follows:
- Terminal (+) of Tester
White/Black cable (PIN 15) (1).
- Terminal (-) of Tester
Black cable (PIN 17) (2).
- Turn key “ON”.
- Flick light switch to ( ) symbol.
- Flick light switch to (HI) symbol.
- Power measured must be >12 V.
- If system works, replace instrument board
2
B-VR
GR
N
VL
B-N
R
B
1
24 23 22 21 20 19 18 17 16 15 14 13
GL-BL
BL
R-N
RS
AZ-B
VR
GL-R
BL-R
GL-B
12 11 10 9 8 7 6 5 4 3 2 1
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B
Light System
CHAPTER
MADISON 125 cc
4 IF LOW BEAM LIGHT DOES NOT COME ON
4.1 Check lamp and lamp socket.
- See “Checking switches” section (page 6).
5
W
5
W
N
RS
RS
N
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).
- Terminal (-) of Tester
Black cable (2).
- Turn key “ON”.
- Flick light switch to ( ) symbol.
- Flick light switch to (LO) symbol.
- Power measured must be >12 V.
35 w
35 w
N
AZ-B
B-N
RS
B-N
B-N
35 w
N
35 w
AZ-B
N
ENGLISH
AZ-B
1
2
F. 24
5 IF LOW BEAM INDICATOR LIGHT DOES NOT COME ON
5.1 Check voltage level.
- Connect Tester (20 V DC) to instrument board connector as follows:
- Terminal (+) of Tester
White/Light Blue cable (PIN 3) (1).
- Terminal (-) of Tester
Black cable (PIN 17) (2).
- Turn key “ON”.
- Flick light switch to ( ) symbol.
- Flick light switch to (LO) symbol.
- Power measured must be >12 V.
- If system works, replace instrument board.
B-VR
GR
N
VL
B-N
R
B
2
24 23 22 21 20 19 18 17 16 15 14 13
F. 25
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GL-BL
BL
R-N
RS
AZ-B
VR
GL-R
BL-R
GL-B
12 11 10 9 8 7 6 5 4 3 2 1
1
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B
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).
- Turn key “ON”.
- Flick light switch to (
) symbol.
- Power measured must be >12 V.
- If system works, replace instrument board.
B-VR
GR
N
VL
B-N
R
B
2
ENGLISH
24 23 22 21 20 19 18 17 16 15 14 13
GL-BL
BL
R-N
RS
AZ-B
VR
GL-R
BL-R
GL-B
12 11 10 9 8 7 6 5 4 3 2 1
1
F. 26
7 IF TAIL LIGHT DOES NOT COME ON
7.1 Check lamp and lamp socket.
- See “Checking switches” section (page 6/7).
7.2 Check voltage level.
- Connect Tester (20 V DC) to six-way connector of tail light wiring, as follows:
- Terminal (+) of Tester
Pink cable (1).
- Terminal (-) of Tester
Black cable (2).
- Turn key “ON”.
- Flick light switch to (
) symbol.
- Power measured must be >12 V.
5
W
RS N
RS N
AZ-B
16
W
N
N
B-N
N
B-N
N
N
N
VL
VR
RS
AZ-B
B-N
2
35 w
N
35 w
35 w
N
VL
VR
RS
AZ-B
B-N
VL
N
W
N
35 w
16
VR
AZ-B
1
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B
Light System
CHAPTER
MADISON 125 cc
8 IF FRONT PARKING LIGHT DOES NOT COME ON
8.1 Check lamp and lamp socket.
- See “Checking switches” section (page 6/7).
5
W
5
W
N
RS
RS
N
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).
- Terminal (-) of Tester
Black cable (2).
- Turn key “ON”.
- Flick light switch to (
) symbol.
- Power measured must be >12 V.
35 w
B-N
35 w
N
AZ-B
B-N
RS
B-N
35 w
N
35 w
AZ-B
N
ENGLISH
AZ-B
2
1
F. 28
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MADISON 125 cc
Signalling System
B
CHAPTER
SIGNALLING SYSTEM
TROUBLESHOOTING
1 IF THE REV COUNTER SENSOR DOES NOT SIGNAL SPEED
ENGLISH
2
B
N
GL-BL
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).
- Terminal (-) tester
Black cable (2).
- Turn key “ON”.
- Put “Engine stop” button in starting position.
- Power measured must be 5±0,5 V=.
1
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Signalling System
CHAPTER
MADISON 125 cc
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).
- Turn key “ON”.
- Put “Engine stop” button in starting position.
- Let wheel run in riding direction and check power as follows:
1
B-VR
GR
N
VL
B-N
R
B
2
24 23 22 21 20 19 18 17 16 15 14 13
BL-R
GL-B
GL-BL
BL
R-N
RS
AZ-B
VR
GL-R
12 11 10 9 8 7 6 5 4 3 2 1
ENGLISH
F. 30
- Sensor (3)
- Power
Gap between screws (5).
5±0,5 V=.
3
5
F. 31
- Sensor (3)
- Power
Screw head (4).
0.20±0,5 V=.
3
F. 32
4
- Check continuity of white cable (Tester :) between PIN 13 of terminal board and terminal plugged into the
three-way connector on system side.
- Continuity: replace rev counter sensor.
- No continuity: white cable interrupted.
- Repair, see “Circuit Diagram”.
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Signalling System
MADISON 125 cc
B
CHAPTER
2. CHECKING H2O TEMPERATURE AND FUEL INDICATORS
2.1 Check H2O temperature indicator
- Make sure that on the 5th notch (A) the resistance of the thermistor is ~ 280 : at 80°.
- Make sure that on the 9th notch (B) the red light comes on and the resistance of the thermistor is < 102 : at 118°.
B
A
ENGLISH
F. 33
2.2 Check fuel indicator
A) Fuel indicator on 0:
- Resistance of fuel probe > 61 :.
- ~ 3 litres of fuel
B) Fuel indicator on 1/2:
- Resistance of fuel probe ~ 34 :.
- ~ 6 litres of fuel
C) Fuel indicator on 1:
- Resistance of fuel probe < 13 :.
- ~ 9 litres of fuel (full).
C
B
A
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B
Signalling System
CHAPTER
MADISON 125 cc
3 IF HORN DOES NOT WORK
3.1 Horn switch
- See “Checking switches” section (page 6/7).
0FF
HI
ON
LO
PASSING
R
AR
N
M
VL
VR
B-N
BL
B-N
3
GL-N
AZ-B
3.2 Check grounding
:) to connector of left hand switch (3) as follows:
- Connect Tester (:
- Terminal (+) of tester
Black cable (1).
- Terminal (-) of tester
Chassis grounding (2).
0FF
ON
L
LUCI
TURN
HORN
BL
AZ-B
GL-N
B-N
VR
VL
M
AR
N
ENGLISH
R-VR
AZ-B
GL-N
B-N
VR
VL
M-N
AR
N
2
1
F. 35
3.3 Horn
- Disconnect horn cables (3)
- Connect Tester (20 V DC) to terminals as follows:
- Terminal (+) of tester
Blue cable (1).
- Terminal (-) of Tester
Orange cable (2).
- Turn key “ON”.
- Press “Horn” button.
- If power is > 12 V, replace horn.
CAUTION: never invert position of cables.
1
BL
AR
2
3
F. 36
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Signalling System
MADISON 125 cc
B
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.
1
BL
AR
3
2
ENGLISH
F. 37
4 IF OIL PRESSURE SWITCH IS NOT PROVIDING A SIGNAL OR IS PROVIDING AN INCORRECT SIGNAL
4.1 Check pressure switch
- Remove wiring connector from flywheel cover
:) to connector on flywheel cover (R).
- Connect Tester (:
Flywheel connector terminal (4).
- Terminal (+) of tester
- Terminal (-) of tester
Engine grounding (M).
: = 0).
- A) Engine is off
Continuity (:
: = infinite).
- B) As soon as engine is started
No continuity (:
- Not compliant: replace sensor (see “Engine Manual”).
R
4
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CHAPTER
Signalling System
MADISON 125 cc
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. The alarm message will be maintained as long as the signal coming from the probe is low (=grounded).
If the vehicle is not running (RPM=0), no alarm message will appear despite the pressure switch being deactivated
(closed); however, in order to check correct operation of the instruments, pressure switch closing is signalled
during the 8 seconds subsequent to switching the key on, irrespective of whether there is a signal on the rev
counter wire or not; after 8 seconds, alarm display will relate to the engine running.
- The alarm is displayed irrespective of the function selected.
- During alarm conditions, the button’s function is disabled.
ENGLISH
F. 39
4.3 OIL alarm disabling
The OIL alarm (CHECK or CHANGE) can only be disabled by authorised personnel following the procedure
described here below:
- Turn key switch “OFF”.
- With key “OFF”, press “MODE” button.
- With “MODE” button pressed, turn key “ON”.
The system will now delete the OIL alarm; this procedure, that the Authorised Service Centre will need to inform
the system that maintenance has been performed, will result in the display of a confirmation message for ~ 15
seconds.
F. 40
NOTE: while the confirmation message is being displayed, the button will be disabled.
The OIL alarm can be disabled at any moment even before the meter associated to this function has
reached zero.
Once the alarm has been disabled, the system will automatically put the instrument in its standard
operating mode.
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Signalling System
B
CHAPTER
5. IF STOP LIGHT DOES NOT COME ON
5.1 Check 7.5 A fuse N°2
- Remove relative fuse.
:) to fuse.
- Connect Tester (:
- Check continuity of fuse.
- If fuse has blown: eliminate cause of short-circuit and replace fuse with an identical one.
ENGLISH
Tester :
:)
F. 41
5.2. Lamp and lamp socket
- See “Checking switches” section (page 6/7).
5.3. Stop light (front/rear)
- See “Checking switches” section (page 6/7).
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B
CHAPTER
Signalling System
MADISON 125 cc
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”.
- Operate brake lever (right or left)
- Power measured must be >12 V.
5
W
RS N
RS N
AZ-B
B-N
N
16
W
N
N
N
VL
VR
RS
AZ-B
B-N
N
N
N
VL
VR
RS
AZ-B
B-N
ENGLISH
2
35 w
N
35 w
35 w
B-N
N
N
W
VL
35 w
16
VR
AZ-B
1
F. 42
6. IF TURN INDICATORS DO NOT FLASH
6.1 Lamp and lamp socket
- See “Checking switches” section (page 6/7).
6.2 Turn indicator switch
- See “Checking switches” section (page 6/7).
6.3 Check voltage level
- Connect Tester (20 V DC) to flashlight as follows:
- Terminal (+) of Tester
White/Grey cable (1).
- Terminal (-) of tester
Chassis grounding (2).
- Turn key “ON”.
- Power input to flashlight (White/Grey cable) must be >12 V.
M-N
B-GR
1
F. 43
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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.
1
M-N
B-GR
ENGLISH
2
F. 44
6.5 Check Brown/Black cable
:) to brown/black cable as follows:
- Connect Tester (:
Brown/Black cable (1) leading from flasher relay.
- Terminal (+) of tester
- Terminal (-) of tester
Brown/Black cable (2) leading to left switch.
- Check continuity.
1
M-N
HI
LO
AR
N
M
VL
R
0FF
ON
L
LUCI
HORN
TURN
R-VR
AZ-B
GL-N
B-N
VR
VL
M-N
AR
BL-N
BL
AZ-B
GL-N
B-N
VR
VL
M
AR
N
PASSING
VR
B-N
0FF
ON
GL-N
AZ-B
B-N
BL
B-GR
2
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CHAPTER
Signalling System
MADISON 125 cc
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).
- Check right indicators:
W
5
RS N
RS N
AZ-B
AZ-B
35 w
W
N
VL
VR
RS
AZ-B
B-N
N
VR
N
N
N
VL
VR
RS
AZ-B
B-N
N
N
ENGLISH
3
B-N
N
16
B-N
N
35 w
35 w
N
W
VL
35 w
16
1
F. 46
Green cable (2).
- Terminal (-) of Tester
- Terminal (-) of Tester
Black cable (3).
- Turn key “ON”.
- Turn “Turn” switch from left to right.
- In both cases, power measured must be > 12 V.
5
W
RS N
RS N
AZ-B
F. 47
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16
W
N
N
N
N
B-N
N
B-N
N
VL
VR
RS
AZ-B
B-N
3
35 w
VR
35 w
35 w
N
VL
VR
RS
AZ-B
B-N
VL
N
W
N
35 w
16
N
AZ-B
2
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B
CHAPTER
7. IF RADIATOR FAN DOES NOT WORK
7.1 Check 7.5 A fuse N° 7
- Remove relative fuse.
:) to fuse.
- Connect Tester (:
- Check continuity of fuse.
- If fuse has blown: eliminate cause of short-circuit and replace fuse with an identical one.
ENGLISH
Tester :
:)
F. 48
+
2
N
N
R
.
12V
-
7.2 Check motor fan
- Disconnect connector of fan and power the latter by means of the battery, as follows:
Red (1) cable
- Battery (+) cable
- Battery (-) cable
Black (2) cable
- Fan does not work: replace it.
AZ
1
F. 49
7.3 Check thermal switch (on front side of radiator)
- Detach the two yellow cables from the thermal switch.
- Provide a jumper between the two yellow cables.
- Turn key “ON”.
- Fan works: replace thermal switch.
+12 V WITH KEY ON
FUS 7,5A
AZ/GR
GL
GL
N
GL
N
R
100°-95°
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Signalling System
CHAPTER
MADISON 125 cc
7.4 Check ground continuity of black cable
:) as follows:
- Connect Tester (:
- 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.
+12 V WITH KEY ON
2
ENGLISH
FUS 7,5A
AZ/GR
1
GL
GL
N
GL
GL
N
R
100°-95°
F. 51
7.5 Check continuity of yellow cable
:) to yellow cable leading from thermal switch to radiator fan connector, as follows:
- Connect Tester (:
- Terminal (+) of tester
Yellow cable (1).
- Terminal (+) of tester
Yellow cable (2).
- No continuity: the relative yellow cable is interrupted.
- Repair, see “Wiring Diagram”.
- Continuity: yellow cable leading from fuse holder to thermal switch is interrupted.
- Repair; see “Wiring Diagram”.
+12 V WITH KEY ON
FUS 7,5A
AZ/GR
GL
1
GL
GL
100°-95°
N
GL
N
R
2
F. 52
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Signalling System
MADISON 125 cc
B
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.
m3
~m
ENGLISH
F. 53
8.2 Check power delivered to electric starter
- Disconnect starter connector.
- Connect Tester (DC20V) to wiring connector, as follows:
- Terminal (+) of tester
Blue cable (1).
- Terminal (-) of Tester
Brown cable (2).
- Start engine.
- Power measured must be 12 V.
+12 V WITH KEY ON
1
2
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Signalling System
CHAPTER
MADISON 125 cc
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.
- Repair. See “Wiring Diagram”.
ENGLISH
BL
M
M
N
M-B
GL-R
02412900
+12 V WITH KEY ON
4 5 6 7 8
3
AR
F. 55
8.4 Check continuity of brown cable
:) between electric starter and electronic control unit, as follows:
- Connector Tester (:
- Terminal (+) of tester
Brown cable (starter) (1).
- Terminal (-) of tester
Brown cable (control unit - PIN 7) (2).
- No continuity: brown cable interrupted
- Repair. See “Wiring Diagram”.
BL
M
M
N
M-B
GL-R
02412900
+12 V WITH KEY ON
1
AR
4 5 6 7 8
3
F. 56
2
NOTE: if tests are all positive, replace electronic control unit.
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