Malaguti CNK 50 DRAKON Workshop Manual

IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES

WORKSHOP MANUALS

CNK 50 DRAKON

B

3

03/06

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

DRAKON 50 NKD

1

INDEX

1 - INDEX

1 - INDEX. .............................................................................................................................. 3

2 - ELECTRICAL SYSTEM. ................................................................................................... 4

ELECTRICAL SYSTEM CODE .................................................................................................... 5

3 - ELECTRICAL COMPONENTS. ........................................................................................ 6

4 - CHECKING THE CONNECTIONS. ................................................................................... 8

5 - CHECKING THE SWITCHES............................................................................................ 9

SWITCH CONNECTIONS AS SHOWN IN THIS MANUAL .......................................................... 9

6 - IGNITION SYSTEM........................................................................................................... 10

7 - ELECTRICAL STARTING SYSTEM . ............................................................................... 13

STARTING CIRCUIT OPERATION .............................................................................................. 13

8 - RECHARGE SYSTEM. ..................................................................................................... 18

TROUBLE SHOOTING................................................................................................................. 18

9 - LIGHTS SYSTEM.............................................................................................................. 20

TROUBLE SHOOTING................................................................................................................. 20

LIGHTING SYSTEM CHECK........................................................................................................ 22

10 -SIGNAL SYSTEM. ............................................................................................................ 24

TROUBLE SHOOTING................................................................................................................. 24

CHECKING THE SIGNAL SYSTEM............................................................................................. 26

CONFIGURATION OF THE DIGITAL INSTRUMENT CONNECTOR .......................................... 42

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

ELECTRICAL SYSTEM

M

BL

AR

N

GR

B

B-N

B

VR

N

ON

0FF

HORN

R

L

TURN

ON

START

B-N

BL

N

FUSE 10A

KA

B

B/N

GL-VR

AZ-B

BL-B

B-N

+

-

R

BL

LOCK

OFF

ON

BL

VR

N

GR

VL

R-N

GL-R

B-MA

BL - R

R

GL-VR

BL - N

1

18

B-

R

B-

R

BL

B

L

VR-N

VR-

N

VR

GL

AR

GL

RS

B-R

AR

BL

GL

N

VL-GL

VL

VR

N

VR-N

BL-R

VR

R

N

R

BL

OFF

GL

VL-GL

GL - R

GL -R

BL - N

BL -N

GL-V

^

NEUTRAL

LO

HI

BL

N

B-R

R

BL

ON

MODE

OFF

RS

N

RELAIS

B-VR

VL

N

RS

R

N

VR

1Kohm

B/R

R

VR

R

VR

B-BL

B-N

B-BL

B-N

VR

R

VR

R

GL

BL

N

BL

B-R

G

B/BL

RS

BL

VR

M

VL

AR

AZ

R

B/BL

RS

B/N

VR

M

VL

AR

BL

R

N

R

BL

B/R

B-BL

N

RS

B-N

G

AZ

RS

B/B

L

BL

AZ

AR

M

VR

VL

15

24

2

1

26

24

28

29

30

31

8

32

33

34

35

9

36

14

17

12

6

7

10

18

19

20

21

4

13

3

16

22

5

05188053

2 - ELECTRI-

11

23

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

DRAKON 50 NKD

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ELECTRICAL SYSTEM

ELECTRICAL SYSTEM CODE

1) Instrument panel

2) Main switch

3) Oil gauge indicator switch

4) Neutral gear switch

5) Regulator

6) Battery

7) Fuse 10A

8) Clutch switch

9) Flasher unit

10) Starting relay

11) Rear stop switch

12) “CDI” control unit

13) Water temperature probe

14) Horn

15) Front stop switch

16) Fuel reserve sensor

17) CDI magneto

18) Starter

19) Left rear flasher light

20) Tail brake and stop light

21) Right rear flasher light

22) Electrical earth of the engine

23) Tachometer counter

24) Right control unit

25) Starter button

26) Right front flasher light

27) High beam

28) Parking light

29) Low beam

30) Left front flasher light

31) Left control unit

32) Horn control

33) Flasher light control

34) Light control

35) MODE button

36) Chassis ground

COLOUR CODE

AR Orange

AZ Light blue

AZ-B Light blue-White

B White

B-N White - Black

B-MA White - Brown

B-R White - Red

B-VR White - Green

BL Blue

BL-B Blue - White

BL-N Blue - Black

BL-R Blue - Red

GL Yellow

GL-B Yellow - White

GL-N Yellow - Black

GL-R Yellow - Red

GL-VR Yellow - Green

GR Grey

M Brown

N Black

R Red

RS Pink

VL Purple

VR Green

VL-GL Purple - Yellow

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

ELECTRICAL COMPONENTS

COMPONENTI ELETTRICI

1) Digital meter assembly

2) Main switch

3) Oil gauge indicator switch

4) Neutral gear switch

5) Regulator

6) Battery

7) Fuse 10A

8) Clutch switch

05188091

1

2

05188001

8

05188006

05188005

6

7

05188002

05188003

05188004

3

4

5

3 - ELECTRI-

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

DRAKON 50 NKD

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ELECTRICAL COMPONENTS

9) Flasher unit

10) Starting relay

11) Rear stop switch

12) “CDI” control unit

13) Water temperature probe

14) Horn

15) Front stop switch

16) Fuel level gauge

05188090

9

05188007

05188012 05188006

15

05188008

05188009

05188010

11

13

10

16

12

14

05188011

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

CHECKING THE CONNECTIONS

Check rust and moisture of connectors.

1) Disconnect

• Connectors

2) Dry each terminal with an air blower.

3) Connect and disconnect the connector twice or three

times.

4) Pull the connector to check that it will not come off.

5) If the terminal comes off, bend up pin (A) and reinsert

the terminal into the connector.

6) Connect

• Connectors

NOTE

The connector parts are assembled properly when they

“click” together.

7) Check for continuity with a Tester.

NOTE

• If there is no continuity, clean the terminals.

• Be sure to perform the steps 1 to 7 when checking the

electrical system.

• For a field remedy, use a contact revitalizer.

• Use the Tester as shown in figure.

05188013

A

05188014

05188015

05188016

4 - CHECKING THE CONNECTIONS

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CHECKING THE SWITCHES

ELECTRICAL SYSTEM

• Set the Tester selector to “ ”.

• Insert the terminals of the tester in the connector

corresponding to the cables in question.

• Check continuity.

SWITCH CONNECTIONS AS SHOWN

IN THIS MANUAL

This manual contains the connection charts (as shown

left) showing the switch terminals (e.g., main switch, brake

switch, lighting switch, etc.)

The left column indicates the different switch positions;

the top line indicates the colours of the conductors con-

nected to the switch terminals.

“ ” indicates the continuity between terminals; i.e., a

closed circuit at the special switch positions.

In this chart, “BL” and “R” are continuous when the switch

is set to “ON”.

05188017

05188018

5 - CHECKING THE SWITCHES

RIGHT-HAND CONTROL

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

IGNITION SYSTEM

THE IGNITION SYSTEM FAILS TO OPERATE

(NO SPARK OR INTERMITTENT SPARK)

Check

1) Spark plug

2) Spark plug cap resistance

3) ”CDI” control unit resistance

4) Main switch

5) Resistance of condenser charging coil

6) Pick-up resistance

7) Ignition system connections

1 Spark plug

• Check the spark plug conditions

• Check the spark plug type

• Check the electrode gap

Electrode gap:

0,7 mm

Standard spark plug:

NGK BR 9ES

INCORRECT

Faulty spark plug ➜

Replace or adjust the electrode gap

CORRECT

2 Spark plug cap resistance

• Remove the spark plug cap

NOTE

Removing the spark plug

➜

Rotate the cap anti-

clockwise

Installing the spark plug

➜

Turn the key clockwise.

• Connect Tester (k ) as follows:

- Terminal (+) Tester ➜ side 1

- Terminal (-) Tester ➜ side 2

Cap resistance:

5K ± 20% a 20°C

INCORRECT

Faulty spark plug cap ➜ Replace

CORRECT

05188060

2

1

6 - IGNITION

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IGNITION SYSTEM

3 ”CDI” control unit resistance

• Connect the Tester (k ) to the control unit as

follows:

- Terminal (+) Tester ➜ Cable A.T. (1)

- Terminal (-) Tester ➜ cable terminal (2)

Secondary coil resistance:

5-6 K a 20 °C.

INCORRECT

“CDI” control unit faulty ➜ Replace

CORRECT

4 Main switch

• Disconnect the main switch from the system

• Connect the Tester ( ) and check the continuity

between the following cables:

• Turn the main switch to “ON”

- Orange (1) ➜ Green (2)

- Yellow (3) ➜ Green - Black (4)

INCORRECT

Faulty main switch ➜ Replace

05188061

CORRECT

2

1

5

6 1

2

3

4

• Turn the main switch to “OFF”

• Check the continuity between the following cables:

- Blue - Red (5) ➜ Blue (6)

See “Checking the switches” page 7

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

IGNITION SYSTEM

5 Resistance of condenser charging coil

• Disconnect flywheel connectors

• Connect Tester ( ) as follows:

- Terminal (+) Tester ➜ Green cable (1)

- Terminal (-) Tester ➜ White cable (2)

Charge coil resistance:

640-780 a 20 °C.

INCORRECT

Replace the yoke

CORRECT

6 Pick-up resistance

• Connect the Tester ( ) to the flywheel as follows:

- Terminal (+) Tester ➜ Red cable (1)

- Terminal (-) Tester ➜ White cable (2)

Pick-up resistance

100-140 a 20 °C.

INCORRECT

Replace the yoke

CORRECT

7 Wiring connections

• Check the ignition system for connections

See “Electrical diagram”

INCORRECT

05188060

1

2

1

2

Repair the system wiring

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

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ELECTRICAL STARTING SYSTEM

STARTING CIRCUIT OPERATION

The starting circuit on this model consists of the starter

motor and the starter relay.

When the main switch is in “ON” position and the starting

button is pressed, the starter motor can operate only if:

THE CLUTCH HANDLE IS PULLED

If the above mentioned conditions are not met, the start-

ing relay cannot be energized.

1) Battery

2) Fuse 10A

3) Main switch

4) Starting switch (start)

5) Clutch switch

6) Starting relay

7) Starter

8) Chassis ground

05188024

2

3

4

5

8

7

6

BL

B/R

BL

7 - ELECTRICAL STARTING SYSTEM

8

1

B

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

ELECTRICAL STARTING SYSTEM

THE STARTER MOTOR FAILS TO OPERATE

Check

1) Fuse 10A

2) Battery

3) Starter

4) Starting relay

5) Main switch

6) Clutch switch

7) Starting switch (start)

8) Wiring connections

1 Fuse 10A

• Remove the fuse

• Connect Tester ( ) to the fuse

• Check the fuse for continuity

Faulty fuse ➜ Replace

NO CONTINUITY

2 Battery

• Check the battery conditions

See “Charge voltage” on page 16

CONTINUITY

INCORRECT

Clean the terminals

Recharge or replace battery

CORRECT

05188063

Minimum voltage: 12,5 V

Specific gravity electrolyte level:

1.280 g/dm3

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

DRAKON 50 NKD

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ELECTRICAL STARTING SYSTEM

3 Starter

• Connect battery positive terminal (1) and starter

motor cable (2) using a jumper lead (3) as shown in

figure.

(4) Starting relay

• Check the starter motor for operation.

WARNING

A wire for the jumper lead must have the equivalent

capacity as that of the battery lead or more, other-

wise it may cause the jumper lead to be burned.

THE STARTER MOTOR

FAILS TO TURN

Faulty starter motor ➜ Replace

THE STARTER MOTOR TURNS

4 Starting relay

• Disconnect the starter relay

• Connect the battery to the starting relay with jumper

leads (1).

Battery cable (+) ➜ White - Red cable

Battery cable (-) ➜ Black cable

• Check the starter motor for operation.

WARNING

• Take care not to reverse the battery connections

because the diode will be damaged.

• Take care to avoid shorting the positive and nega-

tive terminals when connecting the battery to the

relay.

THE STARTER MOTOR

FAILS TO TURN

Faulty starter motor ➜ Replace

THE STARTER MOTOR TURNS

1

2

3

1

05188064

4

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

ELECTRICAL STARTING SYSTEM

5 Main switch

• Disconnect the main switch

• Turn the main switch to “ON”

• Connect Tester (

) and check leads for continuity

Orange cable ➜ Green cable

Yellow lead ➜ Green-Black lead

See “Checking the switches” page 7

INCORRECT

Faulty main switch ➜ Replace

CORRECT

6 Clutch switch

• Disconnect clutch switch (1)

• Connect Tester ( ) and check the terminals for

continuity.

Terminal (T1) ➜ Terminal (T2)

See “Checking the switches” page 7

INCORRECT

CORRECT

1 Clutch lever not

pulled

2 Clutch lever pulled

Faulty clutch switch ➜ Replace

1

05188065

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

DRAKON 50 NKD

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ELECTRICAL STARTING SYSTEM

7 Starting switch (start)

• Disconnect two-way connector (1)

• Connect the Tester ( ) to the connector on the side

of the switch

Terminal (+) Tester ➜ Red cable (2)

Terminal (-) Tester ➜ Blue cable (3)

• Press the “START” button

NO CONTINUITY

CONTINUITY

Faulty starting switch ➜ Replace

8 Wiring connections

• Check the ignition system for connections

INCORRECT

Reset see “Electrical diagram”

1

2

3

05188066

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

RECHARGE SYSTEM

TROUBLE SHOOTING

IF THE BATTERY IS FLAT

Check

1) Fuse 10A

2) Charge voltage

3) Charge coil resistance

4) Recharge system connections

1 Fuse 10A

• Remove the fuse

• Connect Tester ( ) to the fuse

• Check the fuse for continuity

NO CONTINUITY

Faulty fuse ➜ Replace

CONTINUITY

2 Charge voltage

• Connect the inductive rev counter to the spark plug

cable.

• Connect the Tester (DC 20 V) to the battery

Terminal (+) ➜ Terminal (+) of the battery

Terminal (-) ➜ Terminal (-) of the battery

• Measure the battery voltage

• Start the engine and accelerate to 5000 rpm.

• Check the battery voltage

Charge voltage:

13,5 ~ 14,5 V

NOTE

Use a completely charged battery.

CORRECT

The charging circuit operates properly

INCORRECT

05188067

8 - RE-

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

DRAKON 50 NKD

8

RECHARGE SYSTEM

3 Charge coil resistance

• Disconnect flywheel connectors

• Connect Tester ( ) as follows:

Terminal (+) ➜ Terminal of yellow cable (1)

Terminal (-) ➜ Terminal of white cable (2)

Charge coil resistance:

0,2 ~0,7 a 20 °C

INCORRECT

CORRECT

Replace the yoke

4 Recharge system connections

• Check the connections of the recharge system

See “Electrical diagram”

INCORRECT

Repair the system wiring

CORRECT

Replace the voltage regulator

1

2

05188068

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IDENTIFICATION OF ELECTRICAL

SYSTEM FAILURES

LIGHTS SYSTEM

TROUBLE SHOOTING

LIGHTS SYSTEM FAULTY

Check

1) Lighting coil resistance

2) Voltage regulator

3) Main switch

4) Lighting system wiring

1 Lighting coil resistance

• Disconnect flywheel connectors.

• Connect Tester ( ) as follows:

Terminal (+) ➜ Yellow lead terminal (1)

Terminal (-) ➜ White lead terminal (2)

Lighting coil resistance:

0,2~0,7 a 20 °C

INCORRECT

CORRECT

Replace the yoke

2

1

05188069

9 - LIGHTS

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Malaguti CNK 50 DRAKON Workshop Manual

Malaguti CNK 50 DRAKON Workshop Manual

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