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INTRODUCTION
TABLE OF CONTENTS
Pag.
Pag.
Introduction
3
High beam light does not come on
21
Manual updates
3
Low beam light does not come on
22
Notes for easy consultation
4
Instrument board lighting does not work
23
Page layout
4
Tail light does not come on
24
Modified pages
4
Front parking light does not come on
25
Additional pages
4
CHECKING SIGNALLING SYSTEM
Editing symbols
4
Stop light does not come on
26
Abbreviations
6
Turn indicators do not flash
27
Technical term dictionary
7
Horn is not working
29
Fuel level indicator is faulty
31
Key to general wiring diagram
9
Clock does not work
32
Colour key
10
CHECKING INJECTION SYSTEM
ECU control unit connector configuration
11
Instrument board connector configuration
12
Location of injection system components
33
Checking switches
13
Self-diagnosis functions
35
Checking procedures
13
Resetting ‘Coupon’ flashlight (15 short flashes)
36
Connection of switches described in this manual
13
ECU error code table
37
How to connect “Diagnosis tester” (code n° 08612200)
40
Checking fuses
14
How to use “Diagnosis tester”
40
Key to fuses
15
Troubleshooting
41
Checking fuel supply system
72
Position of switches and continuity of contacts
16
Checking pump power draw
72
Checking injector piping
73
TPS calibration
74
Sensor check summary tables
75
CHECKING CHARGING SYSTEM
Battery cannot be charged
17
CHECKING LIGHT SYSTEM
The entire lighting system does not work
18
High beam light does not come on
20
INTRODUCTION
•
•
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 either totally or partially. Malaguti reserves all rights over this publication. Reasons
must be given for any request for permission (written) thereto.
FIRST EDITION: 08/07
INTRODUCTION
•
This publication describes all necessary steps for troubleshooting concerning the electrical system (Electronic Injection System) 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 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.
MANUAL UPDATES
•
Any subsequent updates applying to this Manual will be sent in a reasonable time.
•
The table of contents will be duly updated in the event that new pages are inserted, which render the consultation of the manual difficult.
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.
INTRODUCTION
NOTES FOR EASY CONSULTATION
PAGE LAYOUT
TITOLO SEZIONE
Y
SECTION
X
SECTION TITLE
W
PAGE NUMBER
Z
DATE OF ISSUE
X
W
NUMERO DI PAGINA
SEZ.
B
Y
Z
( D ATA E D I Z I O N E )
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 illustration on the former page, followed by a
letter.
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.
Editing symbols
•
•
Symbols have been provided for quick and easy reference (see page 5), identifying situations requiring utmost attention or providing practical 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).
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.
INTRODUCTION
NOTE
Recommendations and precautions regarding rider safety and motor vehicle integrity.
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.
Indicates operations which may constitute a fire hazard.
FIRE HAZARD
DANGER OF EXPLOSION
Indicates operations which may constitute a risk of explosion.
TOXIC FUMES
Indicates a possibility of intoxication or inflammation of the upper respiratory tract.
Operations to be performed only by an expert mechanic..
MECHANICAL MAINTENANCE
ELECTRICAL MAINTENANCE
Operations be performed only by an expert electrical/electronic technician.
NO!
Operations to be absolutely avoided.
M
R
ENGINE WORKSHOP MANUAL
Indicates information which may be obtained by referring to said catalogue
SPARE PARTS CATALOGUE Indicates information which may be obtained by referring to said catalogue
INTRODUCTION
Abbreviations
•
•
•
•
•
•
•
•
F
Cs
P
Pr
S
Sc
T
V
Figure
Tightening torque
Page
Paragraph
Section
Diagram
Table
Screw
The letter V in the illustrations refers to retaining or adjusting screws.
The number following this letter refers to the number of the same type
of screw in the unit or component described and illustrated. Letters not
followed by a number indicate a single screw. In case of different
screws being referred to in the illustration, the letter V is 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 integral
with the lifting board (A).
A
INTRODUCTION
Technical term dictionary
A. Multimeter (Tester) (code n° 08611200)
A
B
B. Diagnostic Tester (code n° 08612200)
C. Injection test instrument (Code n° 08611600)
D. Adapter wiring (code n° 01745600)
E. Kit (B + D) (code n° 08612800)
C
•
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)
•
Ω : OHM : the unit of electrical resistance
•
OHM infinito : tester prods disconnected or cable interrupted
•
OHM = 0 : continuity with tester prods connected and cable not interrupted
•
PIN : connector terminal
•
Linea : cable between two PINS
•
< : less than
•
< : less than or equal to
•
> : greater than
•
> : greater than or equal to
•
KPa (or bar): the unit of pressure (100 KPa = 1 bar)
•
÷ : from - to
•
~ : approximately
D
GENERAL WIRING DIAGRAM
40
39
38
37
36
35
34
33
32
41
31
30
29
28
27
42
26
25
24
1
23
22
2
21
3
4
5
6
7
8
9
10 11 12 13
14
15
16
17
18 19
20
GENERAL WIRING DIAGRAM
KEY TO GENERAL WIRING DIAGRAM
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22) CHECK VALVE
23) FUEL PUMP
24) HV COIL
25) LAMBDA PROBE
26) REV COUNTER SENSOR
27) ANTI-TIPPING SENSOR
28) AIR SENSOR ON AIR BOX
29) ENGINE TEMPERATURE SENSOR
30) TPS THROTTLE POTENTIOMETER
31) TROUBLESHOOTING SYSTEM
32) RECHARGING SOCKET
33) CONTROL UNIT
34) FRONT STOP SWITCH
35) RIGHT HAND SWITCH
36) INSTRUMENT BOARD AND DIGITAL CLOCK
37) HEADLIGHT (LOW/HIGH BEAM)
38) PARKING LIGHT
39) LEFT/RIGHT TURN INDICATOR
40) LEFT HAND SWITCH
41) REAR STOP SWITCH
42) 30W FLASHLIGHT
VOLTAGE REGULATOR
HORN
KEY SWITCH
BATTERY
FUSE, 10 A
FUSE, 7.5 A
FUSE, 5 A
FUSE, 5 A
FUSE, 30 A
FUSE, 10 A
FUSE, 7.5 A
FUSE, 30 A
FAN RELAY (YELLOW)
INJECTION SYSTEM RELAY (RED)
STARTER MOTOR RELAY (BLACK)
STARTER MOTOR
TAIL LAMP ASSEMBLY
NUMBER PLATE LIGHT
FUEL LEVEL SENSOR
RADIATOR FAN
FUEL INJECTOR
GENERAL WIRING DIAGRAM
COLOUR KEY
AR
AR-B
AR-VR
AR-BL
AR-R
AZ
AZ-B
AZ-GR
B
B-VR
B-N
B-R
B-VL
B-BL
B-GR BL
BL-N
BL-R
BL-VR
GL
GL-B
GL-N
ORANGE
ORANGE - WHITE
ORANGE - GREEN
ORANGE - BLUE
ORANGE - RED
LIGHT BLUE
LIGHT BLUE - WHITE
LIGHT - BLUE GREY
WHITE
WHITE - GREEN
WHITE - BLACK
WHITE - RED
WHITE - PURPLE
WHITE - BLUE
WHITE - GREY
BLUE
BLUE - BLACK
BLUE - RED
BLUE - GREEN
YELLOW
YELLOW - WHITE
YELLOW - BLACK
GL-VL
GL-VR
GL-R
GL-BL
GR GR-N
GR-R
M
M-B
M-N
N
R
R-VR
R-N
RS
RS-N
VL
VL-N
VR
VR-N
VRO
10
YELLOW - PURPLE
YELLOW - GREEN
YELLOW - RED
YELLOW - BLUE
GREY
GREY - BLACK
GREY - RED
BROWN
BROWN - WHITE
BROWN - BLACK
BLACK
RED
RED - GREEN
RED - BLACK
PINK
PINK - BLACK
PURPLE
PURPLE - BLACK
GREEN
GREEN - BLACK
OLIVE GREEN
GENERAL WIRING DIAGRAM
ECU CONTROL UNIT CONNECTOR CONFIGURATION
PIN
CABLE COLOUR
FUNCTION
PIN
COLORE CAVI
FUNZIONE
1
M
+ 12 BATTERY
14
AZ-GR
+ 12 WITH KEY ACTIVATION
2
N
- BATTERY
15
AZ
PICK / UP (+)
3
B-BL
RED RELAY (-)
16
GL-B
PICK / UP (-)
4
VL-N
YELLOW RELAY (-)
17
GL-VR
SENSORS (-)
5
RS-N
COIL (-)
18
AR-N
AIR SENSOR ON AIR BOX
6
-
-
19
AR-B
ENGINE TEMP. SENSOR
7
VR-N
INJECTOR (-)
20
M-B
TPS SENSOR
8
R-N
CHECK VALVE (-)
21
AR-VR
TPS SENSOR + 5V
9
B
MAX. ENGINE TEMP. LED
22
BL-N
ELECTRONIC INJECTION LED
10
AR-BL
BLACK RELAY (-)
23
-
-
11
GL-VL
LAMBDA PROBE (-)
24
GR-N
DIAGNOSIS SOCKET
12
VRO
LAMBDA PROBE (+)
25
-
-
13
B-N
ANTI-TIPPING SENSOR
26
-
-
13 12 11 10 9
8
7
6
5
4
3
2
1
26 25 24 23 22 21 20 19 18 17 16 15 14
11
GENERAL WIRING DIAGRAM
INSTRUMENT BOARD CONNECTOR CONFIGURATION
COLOUR
GR
CONNECTOR
FUEL LEVEL PROBE
B-VR
ENGINE TEMPERATURE PROBE
B-BL
FUEL LEVEL PROBE
BL-N
INJECTION LED (-)
BL
+ 12 WITH KEY ACTIVATION
VR
RIGHT HAND TURN INDICATOR
VL
LEFT HAND TURN INDICATOR
B-N
HIGH BEAM
RS
INSTRUMENT BOARD LIGHTING
N
NEGATIVE
B
MAX. ENGINE TEMPERATURE LED (-)
BL-R
+ 12 CLOCK
12
CHECKING SWITCHES
CHECKING SWITCHES
CHECKING PROCEDURES
Using a tester (Code n°08611200), check the switches by making sure that there is
continuity between terminals and that they are correctly connected.
Replace the switch, even if only one of the possible combinations does not give the
requested result.
Select “Ω” (ohm) function of tester; sound-emitting function.
Using the tester in “Ω” mode, you can also check integrity of the lamps. CONNECTION OF SWITCHES DESCRIBED IN THIS MANUAL
•
•
•
•
This manual contains connection diagrams, like the one illustrated hereby, 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 switches; the
top line indicates 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:
“BL-B” and “R”: there is continuous contact when the switch is “ON”.
13
CHECKING FUSES
CHECKING FUSES
When checking or replacing fuses, always turn the main switch
“OFF” or short-circuits may occur.
Checking procedure:
•
Connect Tester (code n°08611200) to fuse and check continuity.
Put the Tester on “Ω” (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 all switches on to check operation of the relative electrical systems.
•
If the fuse blows again, check the relative circuit.
Never use fuses with an amperage rating 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.
14
CHECKING FUSES
KEY TO FUSES
A
Lights
B
Stop+Indicators
C
Engine accessories subject to key
activation
D
Control unit
B
E
Main
D
F
Fuel pump / E.I. system.
F
G
Fan
H
H
Battery recharging protection
A
15
C
E
G
CHECKING SWITCHES
POSITION OF SWITCHES AND CONTINUITY OF CONTACTS
Pos.
1
Switches
5
1
Rear stop switch
2
2
Horn control
3
7
3
Light switch
4
8
4
Turn indicator switch
5
Front stop switch
6
Main light switch
7
Engine start switch
8
Key switch
6
1
2
3
4
5
6
7
16
8
CHECKING CHARGING SYSTEM
Battery cannot be charged
Check:
1. 30 A fuse (ref. H)
2. Battery
3. Charging voltage
1.
•
•
•
30 A fuse (ref. H)
Tester (Ω)
Remove relative fuse.
Connect Tester (Ω) to fuse.
Check continuity of fuse.
OK
NO
Replace fuse
2.
Battery
Remove battery and connect Tester (20 V DC) as follows:
Terminal (+) of Tester
Battery (+) pole.
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; now measure voltage level again.
12.8 V or more
Battery is charged.
12.5 V
Battery needs to be recharged.
12.0 V ore less Replace battery.
•
•
•
•
•
•
•
•
H
Tester (DC 20 V)
OK
•
•
•
•
•
Check charging voltage (use a charged battery)
+
3.
Connect Tester (20 V DC) to battery as follows:
Terminal (+) of Tester Battery (+) pole.
Terminal (-) of Tester Battery (-) pole.
Run engine at 5000 RPM.
The voltage measured should be: 13.80÷14.10 Volts.
OK
The recharging circuit is working
NO
See “Injection” chapter (p 50/51)
17
BATTERIA
12 V
9Ah
-
CHECKING LIGHT SYSTEM
The entire lighting system does not work
Check:
1. Lighting 10 A fuse (ref. A)
2. Battery
3. Key switch
4. Light switch
5. Connection of wiring of lighting system
1.
•
•
•
Lighting 10 A fuse (ref. A)
Remove relative fuse.
Connect Tester (Ω) to fuse.
Check continuity of fuse.
Tester (Ω)
OK
NO
A
Replace fuse
2.
•
•
Battery
Check condition of battery.
See check on page 17.
OK
NO
•
•
3.
•
•
Clean battery terminals
Recharge or replace battery
Key switch
Check key switch.
See “Checking switches” Pr (p 13).
OK
NO
Replace key switch
18
CHECKING LIGHT SYSTEM
4.
•
Light switch (right hand switch)
See “Checking switches” Pr (p 13).
OK
NO
Replace right hand switch
5.
•
•
Wiring connections
Check connections of the entire lighting system.
See “Wiring Diagram” (p 8).
NO
Resume working condition of lighting system
19
CHECKING LIGHT SYSTEM
High beam light does not come on.
1.
•
Check lamp and lamp socket
See “Checking switches” Pr (p 13).
OK
NO
Replace lamp and/or lamp socket.
2.
Check voltage
•
•
•
Connect Tester (20 V DC) to headlight 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
NO
•
•
•
Tester (DC 20 V)
White/black cable between left hand switch and headlight connector is interrupted.
Repair.
See “Wiring Diagram” (p 8).
20
1
CHECKING LIGHT SYSTEM
High beam light does not come on.
1.
•
Check lamp and lamp socket
See “Checking switches” Pr (p 13).
OK
NO
Replace lamp and/or lamp socket.
2.
Check voltage
•
•
•
Connect Tester (20 V DC) to instrument board 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
OK
•
•
•
Tester (DC 20 V)
Instrument board wiring is interrupted.
Repair.
See “Wiring Diagram” (p 8).
NO
•
•
•
The white/black cable between left hand switch,
headlight and instrument board connector is
interrupted.
Repair.
See “Wiring Diagram” (p 8).
21
1
CHECKING LIGHT SYSTEM
Low beam light does not come on.
1.
•
Check lamp and lamp socket
See “Checking switches” Pr (p 13).
OK
NO
Tester (DC 20 V)
Replace lamp and/or lamp socket.
2.
•
•
•
Connect Tester (20 V DC) to headlight connector 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.
2
NO
•
•
•
1
Check voltage
White/light blue cable between left hand switch and headlight is interrupted.
Repair.
See “Wiring Diagram” (p 8).
22
CHECKING LIGHT SYSTEM
Instrument board lighting does not work
1.
Check voltage
•
•
•
Connect Tester (20 V DC) to instrument board connector as follows:
Terminal (+) of Tester
Pink cable (1).
Terminal (-) of Tester
Black cable (2).
•
•
Turn key “ON”.
Flick light switch to (
•
Power measured must be >12 V.
Tester (DC 20 V)
) symbol.
OK
NO
2
•
•
•
Instrument board wiring is interrupted.
Repair.
See “Wiring Diagram” (p 8).
•
•
•
Pink cable between right hand switch, headlight and
instrument board connector is interrupted.
Repair.
See “Wiring Diagram” (p 8).
23
1
CHECKING LIGHT SYSTEM
Tail light does not come on
1.
•
Check lamp and lamp socket
See “Checking switches” Pr (p 13).
OK
NO
Replace lamp and/or lamp socket.
2.
Check voltage
•
•
•
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 (
•
Power measured must be >12 V.
1
) symbol.
2
OK
•
•
•
Tester (DC 20 V)
Wiring of tail light is interrupted.
Repair.
See “Wiring Diagram” (p 8).
NO
•
•
•
Pink cable between tail light connector and right
hand switch is interrupted.
Repair.
See “Wiring Diagram” (p 8).
24
CHECKING LIGHT SYSTEM
Front parking light does not come on.
1.
•
Check lamp and lamp socket
See “Checking switches” Pr (p 13).
OK
NO
Tester (DC 20 V)
Replace lamp and/or lamp socket.
2.
Check voltage
•
•
•
Connect Tester (20 V DC) to two-way connector of wiring, as follows:
Terminal (+) of Tester
Pink cable (1).
Terminal (-) of Tester
Ground (2).
•
•
Turn key “ON”.
Flick light switch to (
•
Power measured must be >12 V.
) symbol.
1
OK
•
•
•
Black cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
NO
•
•
•
Pink cable between parking light connector and
right hand switch is interrupted.
Repair.
See “Wiring Diagram” (p 8).
25
2
CHECKING SIGNALLING SYSTEM
Stop light does not come on.
1.
•
•
•
7.5 A stop+indicator fuse (ref. B)
Remove relative fuse.
Connect Tester (Ω) to fuse.
Check continuity of fuse.
Tester (Ω)
OK
NO
Replace fuse.
2.
•
B
Check lamp and lamp socket
See “Checking switches” Pr (p 13).
OK
NO
Replace lamp and/or lamp socket.
3.
•
VCheck stop switch (front/rear)
See “Checking switches” Pr (p 13).
OK
NO
Replace stop light switch.
4.
•
•
•
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.
•
Power measured must be >12 V.
1
2
OK
•
•
•
Tester (DC 20 V)
Check voltage
Wiring of tail light (3) is faulty.
Repair.
See “Wiring Diagram” (p 8).
NO
•
•
•
Red cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
26
3
CHECKING SIGNALLING SYSTEM
TURN INDICATORS DO NOT FLASH
1.
•
•
•
7.5 A stop+indicator fuse (ref. B)
Remove relative fuse.
Connect Tester (Ω) to fuse.
Check continuity of fuse.
Tester (Ω)
OK
NO
Replace fuse.
2.
•
B
Check lamp and lamp socket
See “Checking switches” Pr (p 13).
OK
NO
Replace lamp and/or lamp socket.
3.
•
Check turn indicator switch
See “Checking switches” Pr (p 13).
OK
NO
•
•
4.
Turn indicator switch is faulty.
Replace left hand switch.
Tester (20 V DC)
Check voltage
•
•
•
Connect Tester (20 V DC) 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.
2
OK
NO
•
•
•
Circuit between fuse box and flashlight is faulty.
Repair.
See “Wiring Diagram” (p 8).
27
1
CHECKING SIGNALLING SYSTEM
OK
5.
Check flashlight
•
•
Install jumper between brown/black cable and white/grey cable.
Turn key “ON” and flick “TURN” switch right and left.
•
In both cases, the indicators must remain steadily lit.
OK
•
•
Flashlight is faulty.
Replace it.
NO
•
•
•
Brown/black cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
28
CHECKING SIGNALLING SYSTEM
HORN IS NOT WORKING
1.
•
Horn switch
See “Checking switches” Pr (p 13).
OK
NO
Tester (DC 20 V)
Replace left hand switch.
2.
Check voltage
•
•
•
Connect Tester (20 V DC) to connector of left hand switch (3) as follows:
Terminal (+) of Tester
Blue cable (1).
Terminal (-) of Tester
Chassis grounding (2).
•
Turn key “ON”.
•
Power measured must be >12 V.
3
OK
NO
•
•
•
3.
2
1
Blue cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
Horn
•
•
•
•
Disconnect horn cables (3).
Connect Tester (20 V DC) to terminals as follows:
Terminal (+) of Tester
Orange cable (1).
Terminal (-) of Tester
Black cable (2).
•
•
Turn key “ON”.
Press “HORN” button.
•
Power measured must be >12 V.
Tester (DC 20 V)
2
Never invert position of cables.
1
OK
NO
Replace horn.
29
3
CHECKING SIGNALLING SYSTEM
NO
4.
Tester (Ω)
Check grounding
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Check continuity.
Black cable (1).
Chassis grounding (2).
1
OK
•
•
•
Orange cable between left hand switch and horn
is interrupted.
Repair.
See “Wiring Diagram” (p 8).
NO
•
•
•
Black cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
30
2
CHECKING SIGNALLING SYSTEM
FUEL LEVEL INDICATOR IS FAULTY
1.
Tester (Ω)
Check fuel probe
•
•
Take fuel probe out of fuel tank (see “Workshop Manual”)
Detach connector of probe.
•
•
•
Connect Tester (Ω) to probe connector as follows:
Terminal (+) of Tester
Yellow/white cable (1).
Terminal (-) of Tester
Green cable (2).
•
•
•
Check resistance of probe:
Float up (A)
Float down (B)
•
•
•
Connect Tester (Ω) to probe connector as follows:
Terminal (+) of Tester
White/blue cable (3).
Terminal (-) of Tester
Green cable (2).
•
•
•
Check resistance of probe:
Float up (A)
Float down (B)
1
A
Resistance 34 Ω.
Resistance 568 Ω.
B
Tester (Ω)
Resistance 568 Ω.
Resistance 34 Ω.
3
NO
OK
•
•
2.
2
Fuel probe is faulty.
Replace.
2
A
B
Check grounding
•
•
•
Connect Tester (Ω) to fuel probe connector (system side) as follows;
Terminal (+) of Tester
Black cable (1).
Terminal (-) of Tester
Chassis grounding (2).
•
Check continuity
Tester (Ω)
1
OK
NO
•
•
Black cable is interrupted.
Repair by providing a jumper between black cable
and grounded point of chassis.
31
2
CHECKING SIGNALLING SYSTEM
OK
3.
•
Check continuity of grey cable and white/blue cable between probe connector and instrument board
wiring connector.
Tester on Ω.
OK
•
Replace instrument board
NO
•
•
•
Wiring interrupted (grey cable and/or white/blue
cable).
Repair.
See “Wiring Diagram” (p 8).
CLOCK DOES NOT WORK
1.
1
Check voltage
•
•
•
•
Detach two-way connector of clock.
Connect Tester (20 V DC) as follows:
Terminal (+) of Tester
Blue/red cable (1).
Terminal (-) of Tester
Black cable (2).
•
Power measured must be > 12 V (key “OFF”).
OK
•
•
Clock is faulty
SReplace.
NO
•
•
•
Blue/red or black cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
32
Tester (DC 20 V)
2
CHECKING INJECTION SYSTEM
LOCATION OF INJECTION SYSTEM COMPONENTS
8
5
1
6
2
7
3
7
6
4
1
2
3
5
4
1
Battery
4
O2 sensor (Lambda probe)
7
Intake air temperature sensor
2
Anti-tipping sensor
5
Spark plug
8
Fuel pump
3
HV coil
6
Idling check valve
33
8
CHECKING INJECTION SYSTEM
9
17
16
15
14
14
10
15
11
16
12
17
13
9
10
11
12
13
9
Injection system relay (red)
12
Regulator
15
Injection indicator light (orange)
10
Engine revolution sensor (Pick-up) connector
13
ECU (Engine Control Unit)
16
Fuel injector
11
Water temperature sensor
14
Diagnosis socket
17
TPS sensor
34
CHECKING INJECTION SYSTEM
SELF-DIAGNOSIS FUNCTIONS
•
If the ECU is sent an abnormal signal by a sensor, while the vehicle is running, the injection warning light will
come on.
•
Depending on the fault, the ECU can interrupt operation of the engine or not.
•
The number of flashes of the warning light identifies the fault.
LONG FLASHES
SHORT FLASHES
A.
TENTHS (L.F).
UNITS (S.F.).
There is only one error
•
Injector disconnected
•
•
•
•
Key “ON” (Engine “OFF”)
Injection warning light check (for 10 seconds)
1 long flash (L.F.)
2 short flashes (S.F.)
•
Once the error has been coded, the LED will stay on for 10 seconds; error coding is thus repeated.
B.
•
•
Error code 12
There are several errors
•
Key “ON” (Engine “OFF”)
The injection warning light comes on and remains lit for 10 seconds; it thus starts flashing to code the first
error.
Once the first error has been coded, the light stays on for 10 seconds; second error coding thus begins; once
the second error has been coded, the light stays on for 10 seconds. This sequence is repeated until the last
error has been coded. Once the last error has been coded, the light stays on for 10 seconds and then repeats
coding from the first error.
•
•
•
This cycle continues until the engine is started (light becomes steadily lit) or until the error is reset.
Once the error has been reset, it must be deleted using the diagnosis tester (code n°08612200).
See instruction manual attached to Kit 08612800.
35
CHECKING INJECTION SYSTEM
RESETTING ‘COUPON’ FLASHLIGHT (15 SHORT FLASHES)
To reset the ‘coupon’ flashlight, proceed as follows:
1.
Turn ignition key “OFF”.
.
Turn throttle grip to its fully open position.
.
Keep throttle fully open and turn key “ON” (injection warning light is off).
.
After about 10 seconds, the injection light will stay on for about 5 seconds.
.
Within this 5 second period (when light is steadily lit), close throttle grip and turn
key “OFF”.
.
Turn key “ON” and check if “SERVICE” signal has been reset. If it has been reset,
the injection light will only be activated for the initial check.
If the light keeps flashing (15 S.F.), repeat the procedure from step 1.
The “SERVICE” signal will not appear if there are errors in the injection
system.
36
CHECKING INJECTION SYSTEM
ecu error code table
N° of flashes
(E.I. indicator)
Error
code
Part
Fault
Probable cause
1 L.C.
1
“TPS”
TPS LOW
•
•
•
•
Incorrect TPS calibration
Faulty wiring
Faulty TPS
Faulty ECU
2 L.C.
2
“TPS”
TPS HIGH
•
TPS disconnected
3 L.C.
3
H2O temperature sensor
Temperature H2O LOW
•
•
•
Faulty wiring
H2O temperature sensor damaged
ECU damaged
H2O temperature sensor disconnected
H2O temperature sensor damaged
Faulty wiring
ECU damaged
4 L.C.
4
H2O temperature sensor
Temperature H2O HIGH
•
•
•
•
5 L.C.
5
Air intake
temperature sensor
LOW air temperature
•
•
•
Faulty wiring
Intake air temperature sensor faulty
ECU damaged
6 L.C.
6
Air intake
temperature sensor
HIGH air temperature
•
•
•
•
Intake air temperature sensor disconnected
Intake air temperature sensor faulty
Faulty wiring
ECU damaged
7 L.C.
7
ECU
LOW air pressure
•
ECU damaged
8 L.C.
8
ECU
HIGH air pressure
•
ECU damaged
9 L.C.
9
-
LOW battery voltage
•
•
•
Stator damaged
Voltage regulator damaged
Faulty wiring
1 L.L.
10
-
HIGH battery voltage
•
•
Voltage regulator damaged
Faulty wiring
1 L.L. + 1 L.C.
11
Injector
Fault detected in injector
•
•
•
Faulty wiring
Injector damaged
ECU damaged
37
CHECKING INJECTION SYSTEM
N° of flashes
(E.I. indicator)
Error
code
Part
Fault
Probable cause
Injector disconnected
Faulty wiring
Injector damaged
ECU damaged
1 L.L. + 2 L.C.
12
Injector
Fault detected in injector
•
•
•
•
1 L.L. + 3 L.C.
13
Idling check valve
Irregular idling
•
•
•
Faulty wiring
Idling check valve damaged
ECU damaged
•
•
Idling check valve disconnected
Faulty wiring (fault is signalled only when engine is running or during
engine starting)
Idling check valve damaged
ECU damaged
1 L.L. + 4 L.C.
14
Idling check valve
Irregular idling
1 L.L. + 5 L.C.
15
Fan relay (yellow)
•
Radiator fan relay fault
•
detected
•
Faulty wiring
Relay damaged
ECU damaged
Relay disconnected
Faulty wiring
Relay damaged
ECU damaged
•
•
1 L.L. + 6 L.C.
16
Fan relay (yellow)
•
Radiator fan relay fault •
detected
•
•
1 L.L. + 7 L.C.
17
Injection system relay (red)
•
Injection system fault
•
detected
•
Faulty wiring
Relay damaged
ECU damaged
Relay disconnected (results also in error 12 and 14)
Faulty wiring
Relay damaged
ECU damaged
Faulty wiring
Relay damaged
ECU damaged
1 L.L. + 8 L.C.
18
Injection system relay (red)
•
Injection system fault •
detected
•
•
1 L.L. + 9 L.C.
19
Start relay (black)
•
Starting system fault
•
detected
•
-
20
-
-
NOT USED
-
21
-
-
NOT USED
-
22
-
-
NOT USED
38
CHECKING INJECTION SYSTEM
N° of flashes
(E.I. indicator)
2 L.L. + 3 L.C.
2 L.L. + 4 L.C.
Error
code
23
24
Part
Fault
Probable cause
LAMBDA PROBE
•
Lambda probe fault detected
•
(fault is only detected when
•
engine is running)
•
Lambda probe damaged
Lambda probe disconnected
Faulty wiring
ECU damaged
Anti-tipping sensor
Anti-tipping sensor
fault detected
•
•
•
•
Anti-tipping sensor disconnected
Anti-tipping sensor damaged
Faulty wiring
ECU damaged
•
•
•
•
Anti-tipping sensor activated
Faulty wiring
Anti-tipping sensor damaged
ECU damaged
2 L.L. + 5 L.C.
25
Anti-tipping sensor
Anti-tipping sensor
fault detected
-
26
-
-
NOT USED
-
27
-
-
NOT USED
2 L.L. + 8 L.C.
28
ECU
HIGH ECU temperature
2 L.L. + 9 L.C.
29
ECU
3 L.L.
30
PICK-UP
3 L.L. + 1 L.C.
31
PICK-UP
3 L.L. + 2 L.C.
32
-
•
ECU damaged
•
ECU damaged
PICK-UP fault detected
•
•
•
PICK-UP disconnected
Faulty wiring
ECU damaged
PICK-UP fault detected
•
•
Faulty pick-up
ECU damaged
•
•
•
•
•
HV coil disconnected
HV coil damaged
ECU damaged
Faulty wiring
Each situation disables sparking (e.g. error n° 25 also activates error
n° 32)
LOW ECU temperature
Ignition system fault detected
39
CHECKING INJECTION SYSTEM
CHOW TO CONNECT THE “DIAGNOSIS TESTER”
(code n° 08612200)
Remove upper front fairing (see “Chassis” manual):
Remove cap of diagnosis socket.
Connect “Diagnosis tester” to socket (P) of vehicle.
P
How to use “Diagnosis tester”
Refer to the instruction manual attached to the Tester (see injection checking kit, code
n°08612800).
40
CHECKING INJECTION SYSTEM
troubleshooting
ERROR CODE N° 1:
FAULT:
1.
(1 S.F.)
“TPS” LOW
Perform “TPS” calibration (see p 74)
OK
2.
Tester (DC 20 V)
Check voltage
17
•
Connect control wiring (ECU connected).
•
•
•
Connect Tester (20 V DC) as follows:
PIN 21.
Terminal (+) of Tester
Terminal (-) of Tester
PIN 17.
•
Turn key “ON”.
•
Power measured must be < 5 V.
21
Power must never be > 5 V.
NO
OK
•
•
Check continuity of line 17 (GL-VR cable) and line
21 (AR-VR cable), 20 (M-B).
See “Wiring Diagram” (p 8).
OK
•
3.
ECU is faulty
(> 5 V ECU is faulty)
Check TPS sensor
•
Connect control wiring (ECU connected).
•
•
•
Connect Tester (20 V DC) as follows:
PIN 21.
Terminal (+) of Tester
Terminal (-) of Tester
PIN 20.
•
Turn key “ON”.
•
•
A) With throttle closed
B) With throttle open
Voltage: ~ 3.40 V
Voltage: ~ 0.59 V
NO
41
20
21
Tester (DC 20 V)
CHECKING INJECTION SYSTEM
NO
4.
Tester (20KΩ)
Check resistance of TPS sensor
•
Connect control wiring (ECU disconnected).
•
•
•
A. Connect Tester (20KΩ) as follows:
Terminal (+) of Tester
PIN 21.
Terminal (-) of Tester
PIN 17.
•
Resistance measured must be: 1150 Ω ± 15% at 25°C.
•
•
•
B. Connect Tester (20KΩ) as follows:
Terminal (+) of Tester
PIN 20.
Terminal (-) of Tester
PIN 17.
•
•
“TPS” fully closed
“TPS” fully open
17
21
Resistance: 1010 Ω ± 15% at 25°C.
Resistance: 1820 Ω ± 15% at 25°C.
NO
•
•
•
Faulty TPS.
Replace throttle housing.
Perform calibration of “TPS” (see p 74).
Tester (20KΩ)
17
42
20
CHECKING INJECTION SYSTEM
ERROR CODE N° 2:
FAULT:
1.
(2 S.F.)
“TPS” HIGH
Make sure TPS is correctly connected.
NO
OK
•
2.
•
Resume connection of sensor.
Check continuity of lines 21 (AR-VR), 20 (M-B) and 17 (GL-VR)
See “Wiring Diagram” (p 8).
43
CHECKING INJECTION SYSTEM
ERROR CODE N° 3:
(3 S.F.)
FAULT:
LOW H2O TEMPERATURE
1.
Check resistance of H2O sensor
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (20KΩ) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: (see following table)
Tester (20KΩ)
17 19
PIN 19.
PIN 17.
Temperature °C
Resistance (Ω)
Temperature °C
Resistance (Ω)
10 °C
20 °C
30 °C
50 °C
3700 ± 5%
2450 ± 5%
1660 ± 5%
810 ± 5%
70 °C
90 °C
100 °C
110 °C
428 ± 2%
240 ± 2%
184 ± 2%
142 ± 2%
VEDERE
TABELLA
NO
OK
•
•
Check continuity of lines 19 (AR-B cable) and 17
(GL-VR cable).
See “Wiring Diagram” (p 8).
OK
•
2.
•
•
•
•
•
•
Tester (Ω)
Check isolation between lines 19 and 17
Connect control wiring (ECU disconnected).
Detach connector of H2O sensor.
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
17 19
PIN 19.
PIN 17.
Resistance measured must be: infinite (>1M Ω).
NO
OK
•
Replace H2O sensor.
ECU is faulty.
•
•
Resume isolation between line 17 and 19.
See “Wiring Diagram” (p 8).
44
CHECKING INJECTION SYSTEM
ERROR CODE N° 4:
(4 S.F.)
FAULT:
HIGH H2O TEMPERATURE
1.
Make sure H2O sensor is correctly connected.
If the sensor is not connected and the fan relay test is performed, the test result will be OK but the fan
will not work.
NO
OK
•
2.
•
Resume connection of sensor
Check resistance of H2O sensor
See error code n°3.
OK
3.
•
•
Tester (DC 20 V)
17 19
Check voltage
Connect control wiring (ECU connected).
Detach connector of H2O sensor.
•
•
•
Connect Tester (20 V DC) as follows:
Terminal (+) of Tester
PIN 19.
Terminal (-) of Tester
PIN 17.
•
Turn key “ON”.
•
Power measured must be < 5 V.
Power must never be > 5 V.
OK
NO
•
•
ECU is faulty.
Replace.
45
CHECKING INJECTION SYSTEM
Tester (Ω)
OK
2
4.
Check resistive values (for instrument board temperature indicator)
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester Terminal (-) of Tester
•
Resistance: see table PIN 2 (Ground)..
B-VR cable (instrument board connector).
Temperature °C
Resistance (Ω)
Temperature °C
Resistance (Ω)
20 °C
30 °C
40 °C
60 °C
80 °C
90 °C
~ 700
~ 455
~ 294
~ 137
~ 69,5
~ 51,9
95 °C
100 °C
105 °C
110 °C
115 °C
120 °C
~ 45
~ 39,5
~ 34,5
~ 30,5
~ 26,5
~ 23,9
•
•
•
•
Max. permissible temperature for use of engine
Temperature for opening thermostatic valve
Temperature for fan activation
Temperature warning light (red) comes on
OK
•
•
Replace instrument board.
H2O sensor is faulty.
Replace.
=
=
=
=
120 °C
70 °C
98 °C (160cc) - 102 °C (125cc)
~ 117 °C
NO
OK
•
•
VEDERE
TABELLA
Check continuity of B-VR cable between connector
of H 2O sensor (PIN 3) and instrument board
connector.
NO
•
•
Repair interruption of B-VR cable.
See “Wiring Diagram” (p 8).
46
B-VR
CHECKING INJECTION SYSTEM
ERROR CODE N° 5:
FAULT:
1.
•
(5 S.F.)
LOW AIR INTAKE TEMPERATURE
Tester (20KΩ)
Check resistance of air temperature sensor (A)
A
Resistance measured must be: (see following table)
Temperature °C
Resistance (Ω)
Temperature °C
Resistance (Ω)
10 °C
20 °C
5500 ± 5%
3680 ± 5%
25 °C
30 °C
2890 ± 5%
2460 ± 5%
OK
NO
•
•
2.
Replace air temperature sensor.
See Chassis manual: filter box.
Check lines 17 (GL-VR) and 18 (AR-N)
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (20KΩ) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
The resistive value must correspond to the value measured on the air temperature sensor (see table above).
Tester (20KΩ)
17
PIN 18.
PIN 17.
OK
•
•
VEDERE
TABELLA
ECU is faulty.
Replace.
NO
•
•
•
Line 17 and/or line 18 is interrupted or has shortcircuited.
Repair.
See “Wiring Diagram” (p 8).
47
18
VEDERE
TABELLA
CHECKING INJECTION SYSTEM
ERROR CODE N° 6:
FAULT:
1.
(6 S.F.)
LOW AIR INTAKE TEMPERATURE
Make sure air temperature sensor is correctly connected.
Check if any water has seeped into the connector.
OK
NO
•
2.
•
Resume connection of sensor
Check resistance of air temperature sensor
See error code n°5.
OK
3.
•
Check Line 17 and Line 18
See error code n°5.
OK
4.
Tester (DC 20 V)
Check voltage of Line 18
17
•
Connect control wiring (ECU connected).
•
•
•
Connect Tester (20 V DC) as follows:
PIN 18.
Terminal (+) of Tester
Terminal (-) of Tester
PIN 17.
•
•
Detach connector of air temperature sensor.
Turn key “ON”.
•
The voltage measured should be: < 5 V
NO
•
•
ECU is faulty.
Replace.
48
18
CHECKING INJECTION SYSTEM
•
•
•
•
ERROR CODE N°7:
FAULT:
(7 L.C.)
LOW AIR PRESSURE
ERROR CODE N°8:
FAULT:
(8 L.C.)
HIGH AIR PRESSURE
ECU is damaged.
Replace.
ECU is damaged.
Replace.
49
CHECKING INJECTION SYSTEM
ERROR CODE N°9:
FAULT:
1.
Check stator
A.
Check resistance of three-phase line
•
Disconnect three-way connector of stator.
•
•
•
•
Connect Tester (Ω) as follows:
Phase 1
2
Phase 2
3
Phase 1
3
B.
(9 S.F.)
LOW BATTERY VOLTAGE
Resistance: 0.3 ÷ 0.4 Ω.
Resistance: 0.3 ÷ 0.4 Ω.
Resistance: 0.3 ÷ 0.4 Ω.
Check voltage output of stator
•
•
Keep stator connector disconnected.
Start engine.
•
•
•
•
Connect Tester (200 V AC) as follows:
Phase 1
2
at 1700 RPM 17 ÷ 18 V ~.
Phase 2
3
at 5000 RPM 50 ÷ 55 V ~.
Phase 1
3
at 8000 RPM 80 ÷ 85 V ~.
OK
NO
•
2.
•
Stator is faulty.
Check wiring of charging system
See “Wiring Diagram” (p 8).
OK
NO
•
•
A: Tester (Ω)
B: Tester (AC 200 V)
Put wiring in working order.
Replace voltage regulator.
50
CHECKING INJECTION SYSTEM
ERROR CODE N°10:
FAULT:
1.
•
(1 L.F.)
HIGH BATTERY VOLTAGE
Check wiring of charging system
See “Wiring Diagram” (p 8).
OK
•
Voltage regulator is faulty.
NO
•
Put wiring in working order.
51
CHECKING INJECTION SYSTEM
ERROR CODE N°11:
FAULT:
1.
(1 L.F. + 1 S.F.)
INJECTOR FAULT DETECTED
Check resistance of injector
•
Connect Tester (Ω).
•
Resistance measured must be: 12.3 ± 0.9 Ω at 20 °C.
OK
NO
•
•
•
Connect control wiring (ECU disconnected).
Disconnect red relay.
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: 12.3 ± 0.9 Ω at 20 °C.
ECU is faulty.
Injector is faulty.
PIN 7.
AR-R cable (87) (red relay base).
OK
•
Tester (Ω)
Tester (Ω)
7
NO
•
•
•
Faulty wiring.
Repair.
See “Wiring Diagram” (p 8).
AR-R
52
CHECKING INJECTION SYSTEM
ERROR CODE N°12:
FAULT:
1.
(1 L.F. + 2 S.F.)
INJECTOR FAULT DETECTED
Check if injector is correctly connected.
NO
OK
•
2.
•
Resume connection.
Check resistance of injector
See error code n° 11.
2
OK
3.
Check isolation from ground of line 7
•
•
Connect control wiring (ECU disconnected).
Detach injector connector.
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: infinite (>1M Ω). PIN 7.
PIN 2.
OK
•
ECU is faulty.
NO
•
Remove short-circuit of line 7.
53
7
Tester (Ω)
CHECKING INJECTION SYSTEM
ERROR CODE N°13:
FAULT:
1.
(1 L.F. + 3 S.F.)
IRREGULAR IDLING
Check activation of idling check valve
Tester (Ω)
•
Connect Diagnosis tester.
•
Select “Parameters in real time” (see instruction manual attached to kit 08612800) and move the selection
bar to line n° 20 (opening degrees of idling check valve).
•
Start vehicle and wait until the fan is activated.
•
•
•
Wait for the fan to go off and check if the temperature approaches the activation setting of the fan:
125 cc.
~ 95° C
160 cc.
~ 99° C
•
Once the indicated temperature has been reached and with the vehicle idling, check the opening degrees of
the idling check valve (line n° 20). The value measured must be:
125 cc.
min. 130 - max. 210
160 cc.
min. 130 - max. 240
•
•
NO
2.
Check resistance of idling check valve
•
Detach connector of check valve.
•
Connect Tester (Ω).
•
Resistance measured must be: 24.8 ± 10% Ω at 25 °C.
Tester (Ω)
OK
NO
•
•
•
•
Connect control wiring (ECU disconnected).
Connect connector of check valve.
Disconnect red relay.
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: 24.8 ± 10% Ω at 25 °C.
ECU is faulty.
Idling check valve is faulty.
AR-R
PIN 8.
AR-R cable (87) (red relay base).
NO
OK
•
8
•
•
•
Faulty wiring.
Repair.
See “Wiring Diagram” (p 8).
54
CHECKING INJECTION SYSTEM
ERROR CODE N°14:
FAULT:
1.
(1 L.F. + 4 S.F.)
IRREGULAR IDLING
Check if idling check valve is correctly connected
OK
NO
•
2.
•
Resume connection.
Check resistance of idling check valve
See error code n° 13.
2
OK
3.
8
Check isolation from ground of line 8
•
•
Connect control wiring (ECU disconnected).
Detach connector of check valve.
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: infinite (>1M Ω).
PIN 8.
PIN 2.
OK
•
ECU is faulty.
NO
•
Remove short-circuit of line 8.
55
Tester (Ω)
CHECKING INJECTION SYSTEM
ERROR CODE N°15:
FAULT:
1.
(1 L.F. + 5 S.F.)
FAN RELAY (yellow) FAULT DETECTED
Check fan relay (yellow)
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: 80 ÷ 90 Ω .
Tester (Ω)
PIN 86 (a).
PIN 85 (b).
b
OK
NO
•
2.
Replace relay.
a
Check voltage
a
•
Detach relay from base (yellow).
•
•
•
Connect Tester (20 V DC) as follows:
AZ-GR cable (a).
Terminal (+) of Tester
Terminal (-) of Tester
VL-N cable (b).
•
Turn key “ON”.
•
Voltage measured should be: > 12 V.
NO
56
b
Tester (DC 20 V)
CHECKING INJECTION SYSTEM
NO
3.
a
Check AZ/GR cable
•
•
•
Connect Tester (20 V DC) as follows:
Terminal (+) of Tester
AZ-GR cable (a).
Terminal (-) of Tester
Ground (wire terminals) (b).
•
Turn key “ON”.
•
Voltage measured should be: > 12 V.
OK
NO
•
•
•
4.
b
AZ-GR cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
Check continuity of line 4 (VL-N)
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
Tester (Ω)
ECU is faulty.
4
PIN 4.
VL-N cable (yellow base).
OK
•
Tester (DC 20 V)
NO
•
•
•
VL-N cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
57
VL-N
CHECKING INJECTION SYSTEM
ERROR CODE N°16:
FAULT:
1.
(1 L.F. + 6 S.F.)
FAN RELAY (yellow) FAULT DETECTED
Check if relay is correctly connected
OK
NO
•
2.
•
Resume connection.
Check fan relay
See error code n° 15.
2
OK
3.
Check isolation from ground of line 4
(Line 4 short-circuited •
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: infinite (>1M Ω).
PIN 4.
PIN 2.
OK
•
ECU is faulty.
fan is always on)
NO
•
Remove short-circuit of line 4 (VL-N).
58
4
Tester (Ω)
CHECKING INJECTION SYSTEM
ERROR CODE N°17:
FAULTY:
1.
(1 L.F. + 7 S.F.)
INJECTION RELAY (red) FAULT DETECTED
Check injection relay (red)
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: 80 ÷ 90 Ω .
Tester (Ω)
PIN 86 (a).
PIN 85 (b).
b
OK
NO
•
2.
Replace relay.
a
Check voltage
•
Detach relay from base (red).
•
•
•
Connect Tester (20 V DC) as follows:
AZ-GR cable (a).
Terminal (+) of Tester
Terminal (-) of Tester
B-BL cable (b).
•
Turn key “ON”.
•
Voltage measured should be: > 12 V.
Tester (DC 20 V)
b
a
NO
59
CHECKING INJECTION SYSTEM
NO
•
•
•
Connect Tester (20 V DC) as follows:
Terminal (+) of Tester
AZ-GR cable (a).
Terminal (-) of Tester
Ground (wire terminals) (b).
•
Turn key “ON”.
•
Voltage measured should be: > 12 V.
OK
AZ-GR cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
b
Check continuity of line 3 (B-BL)
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
Tester (Ω)
PIN 3.
B-BL cable (red base).
OK
•
a
NO
•
•
•
3.
Tester (DC 20 V)
ECU is faulty.
3
NO
•
•
•
B-BL cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
60
B-BL
CHECKING INJECTION SYSTEM
ERROR CODE N°18:
FAULTY:
1.
(1 L.F. + 8 S.F.)
INJECTION RELAY (red) FAULT DETECTED
Check if injection relay (red) is correctly connected
If the relay is disconnected, you will also be shown errors 12 and 14.
OK
NO
•
2.
•
Resume connection.
Check injection relay
See error code n° 17.
2
OK
3.
Check isolation from ground of line 3 (B-BL)
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: infinite (>1M Ω).
PIN 3.
PIN 2.
OK
•
ECU is faulty.
NO
•
Remove short-circuit of line 3 (B-BL).
61
3
Tester (Ω)
CHECKING INJECTION SYSTEM
ERROR CODE N°19:
FAULT:
Tester (Ω)
Check start relay (black)
+
1.
(1 L.F. + 9 S.F.)
START RELAY (black) FAULT DETECTED
•
Detach relay from base (black).
•
•
(+) Battery
(-) Battery
PIN 86 (a).
PIN 85 (b).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
PIN 87 (c).
PIN 30 (d).
•
Check continuity.
BATTERIA
12 V
9Ah
-
b
85
87
OK
c
NO
d
30
86
a
•
2.
Relay is faulty.
Check voltage
•
Detach relay from base (black).
•
•
•
Connect Tester (20 V DC) as follows:
B-R cable (86) (a).
Terminal (+) of Tester
Terminal (-) of Tester
Grounding node (b).
•
•
•
Turn key “ON”.
Operate brake lever.
Press “START” button.
•
Voltage measured should be: > 12 V.
Tester (DC 20 V)
OK
a
NO
•
•
•
b
Check continuity of B-R cable.
Check “STOP” switch.
Check “START” switch..
62
CHECKING INJECTION SYSTEM
OK
3.
Tester (Ω)
Check continuity of line 10 (AR-BL)
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
10
PIN 10.
AR-BL cable (black base).
OK
•
ECU is faulty.
NO
•
•
•
AR-BL cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
63
AR-BL
CHECKING INJECTION SYSTEM
ERROR CODE N°23:
FAULTY:
(2 L.F. + 3 S.F.)
LAMBDA PROBE FAULT DETECTED
This fault is only signalled when the engine is running. The Lambda probe is activated when the H2O
temperature is higher than 35 °C and only after a certain number of cycles.In caso di anomalia il guasto
Any faults are signalled after 3 minutes from H2O reaching 35 °C.
1.
Check that Lambda probe connection is correct
OK
2.
Check isolation from ground of line 12 (+) and line 11 (-)
OK
NO
•
•
3.
11
Check signal
•
Connect control wiring (ECU connected).
•
•
•
Connect Tester (20 V DC) as follows:
PIN 12.
Terminal (+) of Tester
Terminal (-) of Tester
PIN 11.
•
Start engine and wait for solenoid valve to cut in.
•
•
•
A) With engine idling, voltage varies between 0 V and 1V.
B) With throttle fully open, voltage is ~ 1 V.
C) During release stage, voltage is ~ 0V.
Voltage = 0
•
Resume working condition of line 12 and/or line 11.
See “Wiring Diagram” (p 8).
ECU is faulty.
Constant voltage > 0
•
Replace Lambda probe.
64
12
Tester (DC 20 V)
CHECKING INJECTION SYSTEM
ERROR CODE N°24:
FAULT:
1.
NO
Detach two-way connector of anti-tipping sensor (A).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
•
When sensor is horizontal: no continuity.
If sensor is tilted through 45°: continuity.
OK
NO
•
•
•
Connect Tester (20 V DC) as follows:
PIN 13.
Terminal (+) of Tester
Terminal (-) of Tester
PIN 17.
•
Turn key “ON”.
•
Voltage measured should be: < 5 V.
Voltage = 0
2
1
•
Anti-tipping sensor is faulty.
Voltage > 5 V
17
•
ECU is faulty.
Check continuity of line 13 (B-N) and of line 17 (GL-VR)
See “Wiring Diagram” (p 8).
OK
•
A
Check voltage
Connect control wiring (ECU connected).
•
Resume connection.
Terminal (1).
Terminal (2).
•
4.
•
Check anti-tipping sensor
•
3.
Tester (Ω)
Check if anti-tipping sensor is correctly connected
OK
2.
(2 L.F. + 4 S.F.)
ANTI-TIPPING SENSOR FAULT DETECTED
ECU is faulty.
NO
•
•
•
Faulty wiring.
Repair.
See “Wiring Diagram” (p 8).
65
13
Tester (DC 20 V)
CHECKING INJECTION SYSTEM
ERROR CODE N°25:
FAULT:
1.
(2 L.F. + 5 S.F.)
ANTI-TIPPING SENSOR FAULT DETECTED
Check if anti-tipping sensor is correctly installed (perfectly horizontal)
This fault becomes visible through activation of the anti-tipping sensor (sensor tilted beyond 45°).
OK
2.
•
Check sensor
See error code n°24.
OK
2
3.
Check isolation from ground of line 13 (B-N)
•
Connect control wiring (ECU disconnected).
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: infinite (>1M Ω).
PIN 13.
PIN 2.
OK
•
ECU is faulty.
NO
•
Remove short-circuit of line 13 (B-N).
66
Tester (Ω)
13
CHECKING INJECTION SYSTEM
•
•
•
•
ERROR CODE N°28:
FAULT:
(2 L.F. + 8 S.F.)
LOW “ECU” TEMPERATURE
ERROR CODE N°29:
FAULT:
(2 L.F. + 9 S.F.)
HIGH “ECU” TEMPERATURE
ECU is damaged.
Replace.
ECU is damaged.
Replace.
67
CHECKING INJECTION SYSTEM
ERROR CODE N°30:
FAULT:
1.
(3 L.F.)
PICK-UP FAULT DETECTED
Check if PICK-UP connector (A) is correctly connected
NO
A
OK
•
2.
Resume connection.
Check isolation from ground of line 15 (+) (AZ) and of line 16 (-) (GL-B)
NO
OK
•
3.
Remove short-circuiting of line 15 (AZ) and/or line
16 (GL-B).
Check isolation between line 15 (+) (AZ) and line 16 (-) (GL-B)
If lines 15 and 16 are short-circuited together, the fault is not signalled when the engine is off.
When engine is started, error is not signalled: RPM = ZERO appears.
OK
•
ECU is faulty.
NO
•
Remove short-circuit between lines 15 (AZ) and 16
(GL-B).
68
CHECKING INJECTION SYSTEM
ERROR CODE N°31:
(3 L.F. + 1 S.F.)
FAULT:
PICK-UP FAULT DETECTED
1.
Tester (2KΩ)
Check PICK-UP resistance
•
Detach connector of PICK-UP.
•
•
•
Connect Tester (2KΩ) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: 240 ÷ 280 Ω at 25 °C ± 3 °C
White cable (a).
Grey cable (b).
OK
Replace stator.
Check continuity of line 15 (AZ) and line 16 (GL-B)
•
•
Connect control wiring (ECU disconnected).
Reconnect PICK-UP connector.
•
•
•
Connect Tester (2KΩ) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
•
Resistance measured must be: 240 ÷ 280 Ω at 25 °C ± 3 °C
Tester (2KΩ)
PIN 15.
PIN 16.
15
OK
•
a
NO
•
2.
b
ECU is faulty.
NO
•
Repair interruption of line 15 (AZ) and/or line 16
(GL-B).
69
16
CHECKING INJECTION SYSTEM
ERROR CODE N° 32:
FAULT:
1.
(3 L.F. + 2 S.F.)
HV COIL FAULT DETECTED
Check if HV coil connector is properly connected
OK
NO
•
2.
Tester (20KΩ)
A) Primary winding resistance: 0.45 ± 10% Ω at 25 °C
•
B) Secondary winding resistance: 3.2 ± 10% KΩ at 25 °C
OK
NO
•
•
Resume connection.
Check resistance of HV coil.
•
3.
Tester (Ω)
HV coil is faulty.
Tester (20KΩ)
Check resistance of spark plug cap (shielded)
Spark plug cap resistance: 5 KΩ at 25 °C
OK
NO
•
Spark plug cap is faulty.
70
CHECKING INJECTION SYSTEM
OK
4.
Tester (Ω)
5
Check continuity of line 5 (RS-N)
•
•
Connect control wiring (ECU disconnected).
Detach HV coil connector.
•
•
•
Connect Tester (Ω) as follows:
Terminal (+) of Tester
Terminal (-) of Tester
PIN 5.
RS-N cable.
OK
NO
•
•
•
5.
RS-N
Line 5 (RS-N) is interrupted.
Repair.
See “Wiring Diagram” (p 8).
Check voltage
Tester (DC 20 V)
•
•
Connect control wiring (ECU connected).
Detach HV coil connector.
•
•
•
Connect Tester (20 V DC) as follows:
Terminal (+) of Tester
AR-R cable.
Terminal (-) of Tester
PIN 2.
•
Turn key “ON”.
•
Voltage measured should be: > 12 V for about 5 seconds.
2
OK
NO
AR-R
•
ECU is faulty.
•
•
•
AR-R cable is interrupted.
Repair.
See “Wiring Diagram” (p 8).
71
CHECKING INJECTION SYSTEM
checking fuel supply system
•
•
•
Install special tool (code n°08607400) for checking pressure of fuel between fuel
pump and hose.
Turn key “ON”.
When battery voltage is > 12 V, check if pressure is 2.5 bar.
checking pump power draw
The pump’s power draw can vary depending on:
•
power supply voltage
•
pump break-in
•
pressure
•
condition of delivery filter.
To check power draw, proceed as follows:
•
sdetach connector of red remote switch activating the pump
•
with key switch “OFF”, provide a jumper between the AR-R cable and AR cable of
the red base, using the prods of the tester in ammetric mode.
•
Check pump operation and its power draw.
Power draw = 1.4 ÷ 1.8 A
This power draw applies to:
•
•
•
•
power supply voltage = > 12 V
pump broken-in
system pressure = 2.5 bar (250 KPa)
clean fuel filter.
Dirty filters will increase the power draw.
If an excessive power draw is measured (> 5 A), replace the pump.
72
Tester (10 A)
CHECKING INJECTION SYSTEM
CHECKING HYDRAULIC INJECTOR CIRCUIT
•
Loosen the screw (V).
•
Remove the injector.
V
When refitting, pay attention not to damage the O-ring (O).
Wrench screw as shown in the figure.
•
Connect “Diagnosis tester”.
•
Activate the injector by means of the “Active diagnosis” function: Injector test (see
instruction manual attached to kit 08612800).
•
The injector is activated 5 times.
•
Make sure that fuel is sprayed every time the injector is activated.
An injector with a low capacity will adversely affect maximum performance.
An injector with insufficient tightness will adversely affect idling speed and
starting after a short stop with the engine warm.
If you notice that the injector is clogged, replace it.
•
O
Test tightness of the injector. Dry the injector outlet with compressed air. Wait a
minute to check for leaks from the injector outlet. Minor oozing is normal.
Threshold = 1 drop every minute. The injector features 3 holes.
73
V
Nm
9
CHECKING INJECTION SYSTEM
TPS CALIBRATION
1
THE TPS CALIBRATION PROCEDURE MUST BE PERFORMED WHEN THE FOLLOWING
COMPONENTS ARE REPLACED: THROTTLE HOUSING, ECU, THROTTLE CABLE.
•
Connect the diagnosis tester to the diagnosis socket on the vehicle.
•
Move the selection bar (use the up or down arrow key) to CALIBRATION (1) and confirm by pressing the OK
key.
2
•
The calibration sub-menu will appear on the display, which features two selectable options (2):
1. RESET LAMBDA MAP
2. CALIBRATION
•
Move the selection bar (use the up or down arrow key) to CALIBRATION and confirm by pressing the OK key
(2).
•
The following message appears on the display: PRESS OK TO CONFIRM OR ESC TO QUIT (3).
•
Begin the procedure by pressing OK.
•
Turn the throttle grip to the end of its stroke and then guide it to its idling position.
•
Confirm calibration by pressing OK (4).
•
The following confirmation message will appear on the display:
CALIBRATION COMPLETED (5).
•
Press ESC to return to the main menu.
•
Turn key OFF and disconnect the tester.
3
4
5
74
CHECKING INJECTION SYSTEM
SENSOR CHECK SUMMARY TABLES
PART
TPS SENSOR
SIGNAL
VALUE
PIN 1
PIN 4
1150 ± 15%
Ω
25 °C
PIN 2
PIN 4 (closed)
1010 ± 15%
Ω
25 °C
PIN 2
PIN 4 (fully open)
1820 ± 15%
Ω
25 °C
PART
VALUE
COOLANT TEMPERATURE SENSOR
PART
PART
RESISTANCE
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
3700 ± 5%
Ω
10 °C
2450 ± 5%
Ω
20 °C
2000 ± 5%
Ω
25 °C
1660 ± 5%
Ω
30 °C
VALUE
INTAKE AIR TEMPERATURE SENSOR
HV COIL
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
5500 ± 5%
Ω
10 °C
3680 ± 5%
Ω
20 °C
2892 ± 5%
Ω
25 °C
2460 ± 5%
Ω
30 °C
VALUE
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
PRIMARY
0,45 ± 10%
Ω
25 °C
SECONDARY
3,2 ± 10%
KΩ
25 °C
PART
VALUE
5
SPARK PLUG CAP
75
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
kΩ
25 °C
CHECKING INJECTION SYSTEM
PART
VALUE
12,3 ± 0,9%
INJECTOR
PART
VALUE
24,8 ± 10%
IDLING CHECK VALVE
PART
STATOR PICK-UP
THREE-PHASE STATOR RECHARGING LINE
PHASE
VALUE
-
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
Ω
20 °C ± 2
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
Ω
25 °C ± 3
U N I T
O F T E S T I N G
MEASUREMENT
TEMPERATURE
243 - 283
Ω
25 °C ± 3
1
2
0,4 - 0,6
Ω
25 °C ± 3
2
3
0,4 - 0,6
Ω
25 °C ± 3
1
3
0,4 - 0,6
Ω
25 °C ± 3
76
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