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Malaguti CIAK MASTER 50-4T Electric System Troubleshooting

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CIAK MASTER 50-4T
B
ELECTRIC SYSTEM
TROUBLESHOOTING
WORKSHOP MANUALS
B
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Table of contenents
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Table of contents
Sect. Page
INTRODUCTION 1 5
Manual updates 1 5
Notes for easy consultation 1 6
Page layout 1 6
Modified pages 1 6
Additional pages 1 6
Editing symbols 1 6
Abbreviations 1 8
TROUBLESHOOTING 2 9
Electrical components 2 9
General wiring diagram 2 11
Checking switches 2 12
Checking procedures 2 12
Connection of the switches described in this manual 2 12
Checking fuses 2 13
Position of switches and connection of connectors 2 14
Troubleshooting 2 15
Checking light system 2 24
Troubleshooting 2 28
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Introduction
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• Malaguti S.p.a. 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.
INTRODUCTION
• This publication describes all necessary steps for troubleshooting concerning the electrical system and of
the possible service operations, which are necessary for their solution. It supplies the trade technicians
(authorised customer service centres) with the necessary information for operating in compliance with the
modern concepts of “good practice” and “safety at work”.
• Additional information is available in the Engine Service Manual and 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 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.
• IMPORTANT! The “Electrical System Troubleshooting Manual” is to be considered as an essential tool to
be properly kept up-to-date so as to maintain its
“validity”
over time.
FIRST EDITION: 10/05
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Introduction
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W
Z
Y
X
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.
• 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 date of issue.
EDITING SYMBOLS
• Symbols have been provided for quick and easy reference (see page 7). They identify situations requiring
utmost attention, practical advice or simple information.
• These symbols may appear next to a text (in which case they refer solely to the text itself), next to a figure
(in which case they refer to the topic illustrated in the figure and to the relative text), or at the top of the page
(in which case they refer to all the topics dealt with in the page).
Note:
the meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical
concepts or safety recommendations. They are therefore to be considered as veritable “memory tags”. In case
of any doubt as to their meaning, consult the page in which they are fully described.
(RH PAGE)
PAGE LAYOUT
NOTES FOR EASY CONSULTATION
Y Chapter
X Section title
W Page N°
Z Date of issue
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Introduction
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R
M
L
H
F
A
B
D
C
I
G
E
A) CAUTION! Recommendations and precautions regarding
rider safety and vehicle integrity.
B) WARNING! 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.
C) FIRE HAZARD
Indicates operations which may constitute a fire hazard.
D) RISK OF EXPLOSION Indicates operations which may
constitute a risk of explosion.
E) TOXIC FUMES
Indicates a possibility of intoxication or inflammation of
the upper respiratory tract.
F) MECHANICAL MAINTENANCE Operations to be
performed only by an expert mechanic.
G) ELECTRICAL MAINTENANCE
Operations be performed only by an expert electrical/
electronic technician
H) NO! Operations to be absolutely avoided
I) ENGINE SERVICE MANUAL Indicates information which
may be obtained by referring to said manual.
L) SPARE PARTS CATALOGUE
Indicates information which may be obtained by referring
to said catalogue
B
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A
Note:
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.
ABBREVIATIONS
F Figure
Cs Tightening torque
P Page
Pr Paragraph
S Section
Sc Diagram
T Table
V Screw
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SECTION 2
Electrical components
SECTION 2
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ELECTRICAL COMPONENTS
1) HORN
2) SWITCH WITH KEY
3) STARTING RELAY
4) FUEL PROBE
5) HV COIL
6) BATTERY
7) C.D.I. CONTROL UNIT
8) VOLTAGE REGULATOR
9) RESISTANCE
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General wiring diagram
SECTION 2
B - TROUBLESHOOTING
1
2
3
4
6
5
7
8
9
10
11
12
13
14
15
16
17
18
13
19
20
21
22
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General wiring diagram
SECTION 2
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GENERAL WIRING DIAGRAM
COLOUR KEY
N-R BLACK/RED B-R WHITE/RED
R RED BL BLUE
RS PINK BL-R BLUE/RED
VL PURPLE GL YELLOW
VL-N PURPLE/BLACK GL-N YELLOW/BLACK
VR GREEN GL-V YELLOW/GREEN
AR-BL ORANGE/BLUE GL-R YELLOW/RED
AZ LIGHT BLUE GR GREY
AZ-B LIGHT BLUE/WHITE M BROWN
B WHITE M-B BROWN/WHITE
B-N WHITE/BLACK N BLACK
KEY TO THE GENERAL WIRING DIAGRAM
1) 12V BATTERY
2) RELAY
3) STARTER MOTOR
4) REAR LEFT TURN INDICATOR
5) REAR OPTICAL UNIT
6) REAR RIGHT TURN INDICATOR
7) FUEL LEVEL SENSOR
8) VOLTAGE REGULATOR
9) ELECTRICAL STARTER
10) CHASSIS GROUNDING
11) RESISTANCE
12) FRONT RIGHT TURN INDICATOR
13) STOP LIGHT
14) RIGHT HAND SWITCH BLOCK
15) SWITCH WITH KEY
16) INSTRUMENT BOARD
17) HEADLIGHT
18) LEFT HAND SWITCH BLOCK
19) FRONT LEFT TURN INDICATOR
20) HORN
21) FLY WHEEL MAGNETO
22) ELECTRONIC CONTROL UNIT
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SECTION 2
Checking switches
SECTION 2
B - TROUBLESHOOTING
CHECKING SWITCHES
CHECKING PROCEDURES
Using a tester (Code n°08609500), 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.
NOTE: flick the switch from “ON” to “OFF” several
times and select
::
::
:.
Set the tester to its correct “0” position,
before connecting the switches.
CONNECTION OF THE 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, start button, etc.).
- The first column from the left indicates the different positions of the switch
and 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” feature continuity with the button pressed (switch in its “ON”
position).
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Checking switches
SECTION 2
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CHECKING FUSES
CAUTION: when checking fuses, always turn the main switch
“OFF” or short-circuits may occur.
Checking procedure:
- Connect the tester (Code n°08609500) to the fuse and check
continuity.
NOTE: put the tester on “
::
::
:” (sound-emitting function)
- If the tester is showing “I” and no sound is given, replace the fuse.
Replacing procedure:
- Turn the key “OFF”.
- Install a new fuse with a correct amperage rating.
- Turn the key “ON”.
- Turn the 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 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.
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SECTION 2
Checking switches
SECTION 2
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POSITION OF SWITCHES AND CONNECTION OF CONNECTORS
1) Rear stop switch
2) Horn control
3) Light switch
4) Turn indicator switch
5) Front stop switch
6) Main light switch
7) Engine start switch
8) Switch with key
NOTE: The start switch is closed when the START button is pressed.
The STOP switch is closed when the brake lever is operated.
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Ignition system
SECTION 2
B - TROUBLESHOOTING
TROUBLESHOOTING
If the ignition system is not working, check:
1. Spark plug
2. Spark plug cap resistance
3. Pick-up resistance
4. Key switch
5. Wiring connections
1
2
1. Spark plug
- Check condition of spark plug.
- See Engine Service Manual.
COMPLIANT
NOT COMPLIANT
- Faulty spark plug: replace.
2. Spark plug cap resistance
- Remove spark plug cap.
NOTE: when removing spark plug cap, avoid pulling it.
- 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.
- Connect Tester (K
::
::
:) to spark plug cap, as follows:
- Terminal (+) of Tester Spark plug side (1).
- Terminal (-) of Tester High voltage cable side (2).
- Spark plug cap resistance: 5 K
::
::
: at 20°C.
- Replace spark plug cap.
NOT COMPLIANT
NOT COMPLIANT
- Faulty stator: replace.
1
V
COMPLIANT
3. Checking stator pick-up
- Remove two-way connector of wiring and connect Tester
(
::
::
:) to flywheel connector (V).
- Terminal (+) of Tester Terminal (1).
- Terminal (-) of Tester Engine grounding.
- Resistance: 150 ÷ 170
::
::
:.
COMPLIANT
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Ignition system
SECTION 2
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4. Key switch
- Detach four-way connector and white/black cable of the
switch.
- Connect Tester (
::
::
:) as follows:
- Terminal (+) of Tester Black cable (1).
- Terminal (-) of Tester White/black cable (2).
- Key “ON” No continuity.
- Key “OFF” Continuity.
CAUTION:
If the white/black cable is crushed, it can form a
grounding contact and the engine will not start.
1
2
- Replace key switch.
COMPLIANT
NOT COMPLIANT
OK
5. Wiring connections
- Check connections of ignition system.
- See “Wiring Diagram”.
- Replace the C.D.I. control unit.
FAULTY CONNECTIONS
- Repair wiring on the basis of the
“Wiring Diagram”.
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Charging System
SECTION 2
B - TROUBLESHOOTING
+
-
N
12V
.
12V
.
If the battery cannot be charged, check:
1. Fuse (10A)
2. Battery
3. Charging voltage
4. Stator coil resistance
5. Charging system wiring
1. Fuse (10 A)
- See “Checking switches” section (page 12).
2. Battery
- Remove battery and connect Tester (DC 20 V), 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 Replace battery.
BATTERY OK
3. Check charging voltage (use a charged battery)
- Connect Tester (DC 20 V) to battery as follows:
- Terminal (+) of Tester Battery (+) pole.
- Terminal (-) of Tester Battery (-) pole.
- Run engine at approx. 4000 RPM.
- The voltage measured should be: 14 ÷ 14.5 Volts.
NOT COMPLIANT
COMPLIANT
- The recharging circuit is working.
OK
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Charging System
SECTION 2
B - TROUBLESHOOTING
NOT COMPLIANT
- Faulty stator: replace.
1
V
COMPLIANT
4. Checking stator recharging resistance
- Remove two-way connector of wiring and connect Tester
(
::
::
:) to flywheel connector (V).
- Terminal (+) of Tester Terminal (1).
- Terminal (-) of Tester Engine grounding.
- Resistance: 0.7 ÷ 1
::
::
:.
5. Checking wiring connections
- Check connections of the entire charging system.
- See “Wiring Diagram”.
NOT COMPLIANT
COMPLIANT
- Replace Voltage Regulator.
- Put wiring in working order (see
Wiring Diagram).
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Electric starter system
SECTION 2
B - TROUBLESHOOTING
If starter motor does not work, check
1. 10A Fuse
2. Battery
3. Starter motor
4. Starter relay
5. Key switch
6. Start switch
7. Front/rear stop switch
8. Starting system wiring connections
1. Main 10A fuse
- Remove relative fuse.
- Connect Tester (
::
::
:) to fuse.
- Check continuity of fuse.
NO CONTINUITY
CONTINUITY
- Replace fuse.
+
-
N
12V
.
12V
.
N
2. Battery
- Check condition of battery.
- See page 17.
NOT COMPLIANT
- Replace battery.
3. Checking starter motor
- Using two cables, connect 12 V battery to starter motor
(see figure).
MOTOR DOES NOT RUN
- Replace starter motor.
MOTOR RUNS
COMPLIANT
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Electric starter system
SECTION 2
B - TROUBLESHOOTING
+
-
N
12V
.
12V
.
4. Starter relay
- Detach relay connector.
- Connect Tester (
::
::
:) and a battery (12 V) to relay
terminals, as follows.
- Battery (+) pole Terminal (86).
- Battery (-) pole Terminal (85).
Caution: never invert battery connections on relay
terminals.
- Terminal (+) of Tester Terminal (87).
- Terminal (-) of Tester Terminal (30).
NO CONTINUITY
- Replace relay.
CONTINUITY
85
30
86
87
5. Key switch
- Detach four-way connector of switch.
- Connect Tester (
::
::
:) as follows:
- Terminal (+) of Tester Red cable (1)
- Terminal (-) of Tester Brown cable (2)
- Key “ON” Continuity.
- Key “OFF” No continuity.
1
2
COMPLIANT
NOT COMPLIANT
- Replace key switch.
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Electric starter system
SECTION 2
B - TROUBLESHOOTING
6. Start switch
- Detach six-way connector of right hand switch (1)
and connect Tester (
::
::
:) as follows:
- Terminal (+) of Tester
White/red cable.
- Terminal (-) of Tester Black cable.
Press Start button and check continuity.
NO CONTINUITY
- Replace right hand switch.
CONTINUITY
7. Front/rear stop switch
- Disconnect red cable and white/grey cable of stop switch
(3).
- ConnectTester (
::
::
:) as follows:
- Terminal (+) of Tester Terminal (1).
- Terminal (-) of Tester Terminal (2).
Operate brake lever and check continuity.
NO CONTINUITY
- Replace stop switch.
CONTINUITY
3
1
2
8. Wiring connections
- Check connections of the starting system.
- See “Wiring Diagram”.
NOT COMPLIANT
- Put wiring in working order.
1
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SECTION 2
Light system
SECTION 2
B - TROUBLESHOOTING
If headlight, lighting, instrument board, high beam indicator light, front/rear stop light do not come
on and carburettor starter cannot be disengaged, check:
1. 7.5A Fuse
2. Stator
3. Regulator
4. Wiring connections of entire light system / Carburettor throttle
1. 7.5 A fuse
- Remove relative fuse.
- Connect Tester (
::
::
:) to fuse.
- Check continuity of fuse.
- Replace fuse (7.5 A).
NO CONTINUITY
CONTINUITY
- Replace stator.
NOT COMPLIANT
COMPLIANT
2. Stator
- Run engine at 1900-2000 RPM.
NOTE: wait for the throttle to disengage (engine
idling speed stabilised).
- Detach connector (1) of regulator.
- Connect Tester (AC200V) to regulator connector as
follows:
- Terminal (+) of Tester White cable (Pin4)
- Terminal (-) of Tester Chassis grounding
The value read must be approximately 25-40 V (when
throttle is disengaged).
1
Check wiring between regulator, start
and light switch (see Wiring Dia-
gram).
NOT
COMPLIANT
COMPLIANT
3. Regulator
- Plug connector into regulator.
- Run engine at 1900-2000 RPM.
- Connect Tester (AC200V) as follows:
- Terminal (+) of Tester Yellow cable (Pin1)
- Terminal (-) of Tester Black cable (Pin2)
Value read must be approximately 12 Volts.
/