Malaguti Centro 50 4T Workshop Manual

2

T A B L E O F C O N T E N T S

TABLE OF CONTENTS

Page

Introduction 3

Manual updates 3

Notes for easy consultation 4

Page layout 4

Modied pages 4

Additional pages 4

Editing symbols 4

Abbreviations 6

Technical term dictionary 7

General Wiring Diagram 8

Key to general wiring diagram 9

Colour key 10

Control unit connector and regulator connector conguration 11

Instrument board connector conguration 12

Switches 13

Checking procedures 13

Connection of switches described in this manual 13

Position of switches and continuity of contacts 14

Fuses 15

Checking fuses 15

Key to fuses 15

Location of components 16

Page

Ignition system 18

The ignition system does not work 18

Charging System 20

Battery cannot be recharged 20

Electrical starting system 22

Starter motor does not work 22

Light system 26

Entire lighting system does not work and carburettor

starter cannot be disengaged 26

High beam light does not come on 29

High beam indicator light does not come on 30

Low beam light does not come on 31

Instrument board lighting does not work 32

Tail light does not come on 33

Front parking light does not come on 34

Signalling system 35

Stop light does not come on 35

Turn indicators do not ash 37

Horn is not working 39

Fuel level indicator is faulty 41

Clock does not work 42

Voltmeter 43

3

I N T R O D U C T I O N

Malaguti reserves the right to make any and all changes to its vehicles as it deems t 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: 08/08

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 difcult.

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.

•

4

I N T R O D U C T I O N

NUMERO DI PAGINA

T I T O L O S E Z I O N E

X

W

NOTES FOR EASY CONSULTATION

PAGE LAYOUT

MODIFIED PAGES

Modied 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.

Modied 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 gure (in which case they refer to the topic illustrated in the gure

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.

•

X

SECTION TITLE

W

PAGE NUMBER

5

I N T R O D U C T I O N

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.

FIRE HAZARD

Indicates operations which may constitute a re hazard.

DANGER OF EXPLOSION

Indicates operations which may constitute a risk of explosion.

TOXIC FUMES

Indicates a possibility of intoxication or inammation of the upper respiratory tract.

MECHANICAL MAINTENANCE

Operations to be performed only by an expert mechanic.

ELECTRICAL MAINTENANCE

Operations be performed only by an expert electrical/electronic technician.

NO!

Operations to be absolutely avoided.

M

ENGINE WORKSHOP MANUAL

Indicates information which may be obtained by referring to said document.

R

SPARE PARTS CATALOGUE

Indicates information which may be obtained by referring to said document.

6

A

I N T R O D U C T I O N

ABBREVIATIONS

F Figure

Cs Tightening torque

P Page

Pr Paragraph

S Section

Sc Diagram

T Table

V 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 specied, 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).

•

7

I N T R O D U C T I O N

TECHNICAL TERM DICTIONARY

Multimeter (Tester) (code n°: 08611200)

V = (DC) : direct current (supply from battery)

V ~ (AC) : alternating current (supply from ywheel)

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

Innite 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 (or bar): the unit of pressure (100 KPa = 1 bar)

÷ : from - to

~ : approximately

•

8

+

-

N

BA

TTERIA 12V

FIAMM O YUASA

9 Ah

ON

0FF

LO

HI

LUCI

HORN

R

L

TURN

60 w

55 w

BL-

R

BL

OF

F

ON

BL-

N

VR-

N

B

L

G

L

-

B

BL-

R

VR-N

BL-N

N

GL-B

N

B/B

L

GL-N

BL

VR

VL

M

GR

N

AZ-

B

GL-N

B-

N

VR

VL

M-

N

AR

AZ

AR

BL

R

BL

BL-R

G

R

GL-N

M

VL

VR

GR

N

AZ-B

B-

N

VL

R

RS

N

VR

VL

R

RS

N

VR

VL

VR

N

VR

ON

0FF

N

B-

R

RS

R/V

R

GL-

V

R

GL-

N

GL

ON

0FF

ON

GL

RS

GL-

N

GL-

V

R

N

LIGHTS

START

BL-R

N

GL-

N

RS

B-

N

VL

VR

BL

B-B

L

GR

B-B

L

VL

FUSE 10

A

VR

N

VL

B-

R

+

-

N

B/

R

VR

B

/B

L

BL-N

GL/VL

N

FUSE 5

A

B

/

B

L

GL/

B

87

30

-

N

RS

N

RS

GR

BL

VR

VL

B-

N

RS

N

BL-R

N

BL-R

R

B-

R

B/B

L

BL

>

GL-B

+

R

FUSE 10

A

2

31

4

1

2

3

4

5

GL

R-VR

N

P.U

B-VR

B

R-VRR-VR

N-VR

R-VR

N

B

-

V

R

G

L

-B

B

M-N

B

AZ

N

GL

G

L

R-V

R

AZ

B

L-

R

B

L-

R

AZ

B

L

R

<

>

R

R-VR

N

1

2

3

4

5 6 7 8 9 10 11 12 13 14 15

16

17

18

19

20212223242526272829303132

G E N E R A L W I R I N G D I A G R A M

9

G E N E R A L W I R I N G D I A G R A M

KEY TO GENERAL WIRING DIAGRAM

1) KEY SWITCH

2) HORN

3) PROVISION FOR ANTI-THEFT SYSTEM

4) STOP SWITCH

5) LEFT HAND SWITCH

6) LEFT HAND TURN INDICATOR

7) RIGHT HAND TURN INDICATOR

8) PARKING LIGHT

9) LOW BEAM / HIGH BEAM LIGHT

10) INSTRUMENT BOARD CONNECTOR

11) CLOCK CONNECTOR

12) RIGHT HAND SWITCH BLOCK

13) STOP SWITCH

14) RECHARGING SOCKET

15) ELECTRONIC CONTROL UNIT

16) FLYWHEEL MAGNETO

17) VOLTAGE REGULATOR WITH INTERMITTENT FUNCTION

18) RESISTANCE FOR ELECTRICAL STARTER (6.8 Ω / 10 W)

19) ELECTRICAL STARTER

20) FUEL LEVEL SENSOR

21) RIGHT HAND TURN INDICATOR

22) PARKING LIGHT

23) STOP LIGHT

24) STOP LIGHT

25) PARKING LIGHT

26) LEFT HAND TURN INDICATOR

27) STARTER MOTOR

28) STARTER RELAY

29) FUSE, 10 A (LIGHTS / CARBURETTOR STARTER)

30) FUSE, 5 A (STOP LIGHT)

31) FUSE, 10 A (MAIN / RECHARGING)

32) BATTERY

10

G E N E R A L W I R I N G D I A G R A M

COLOUR KEY

AR ORAN GE

AR-B ORANGE - WHITE

AR-VR ORANGE - GREEN

AR-BL ORANGE - BLUE

AR-R ORANGE - RED

AZ LIGHT BLUE

AZ-B LIGHT BLUE - WHITE

AZ-GR LIGHT - BLUE GREY

B WHITE

B-VR WHITE - GREEN

B-N WHITE - BLACK

B-R WHITE - RED

B-VL WHITE - PURPLE

B-BL WHITE - BLUE

B-GR WHITE - GREY

BL BLUE

BL-N BLUE - BLACK

BL-R BLUE - RED

BL-VR BLUE - GREEN

GL YELLOW

GL-B YELLOW - WHITE

GL-N YELLOW - BLACK

GL-VL YELLOW - PURPLE

GL-VR YELLOW - GREEN

GL-R YELLOW - RED

GL-BL YELLOW - BLUE

GR GREY

GR-N GREY - BLACK

GR-R GREY - RED

M BROWN

M-B BROWN - WHITE

M-N BROWN - BLACK

N BLACK

R RED

R-VR RED - GREEN

R-N RED - BLACK

RS PINK

RS-N PINK - BLACK

VL PURPLE

VL-N PURPLE - BLACK

VR GREEN

VR-N GREEN - BLACK

VRO OLIVE GREEN

11

1234

5 4 3 2 1

G E N E R A L W I R I N G D I A G R A M

CONTROL UNIT CONNECTOR AND REGULATOR CONNECTOR CONFIGURATION

CONTROL UNIT CONNECTOR REGULATOR CONNECTOR

PIN CABLE COLOUR FUNCTION PIN CABLE COLOUR FUNCTION

1 N GROUND 1 GL LIGHTS / STARTER

2 B-VR PICK-UP 2 N GROUND

3 GL-B STOP (KEY OFF) 3 AZ RECHARGING

4 B POWER SUPPLY (STATOR) 4 B POWER SUPPLY (STATOR)

5 M-N (+) INDICATOR OUTPUT

12

G E N E R A L W I R I N G D I A G R A M

INSTRUMENT BOARD CONNECTOR CONFIGURATION

COLOUR FUNCTION

RS INSTRUMENT BOARD LIGHTING

B-N HIGH BEAM

VL

LEFT HAND TURN INDICATOR

VR

RIGHT HAND TURN INDICATOR

BL WITH KEY ON (+ 12 V)

N NEGATIVE

B-BL FUEL LEVEL PROBE

BL-R DIRECTED TO BATTERY (+ 12 V) FOR CLOCK

GR FUEL LEVEL PROBE

13

S W I T C H E S

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 and lamp

sockets.

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,

MODE button, etc.).

The rst 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 identies 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”.

•

14

1 2 3

4 5 6

7 8

1 5

3

4

2

6

7

8

S W I T C H E S

POSITION OF SWITCHES AND CONTINUITY OF CONTACTS

POS. SWITCHES

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 KEY SWITCH

15

A

C

B

F U S E S

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 res to

break out.

KEY TO FUSES

A MAIN / RECHARGING

B STOP

C LIGHTS / STARTER

•

16

L O C A T I O N O F C O M P O N E N T S

1

3

1

2

3

4

5

6

7

6

1 Fuel probe

2 Spark plug

3 Battery, 12V - 9Ah

4 “C.D.I.” control unit

5 Voltage regulator

6 Horn

7 Ground connection unit

17

L O C A T I O N O F C O M P O N E N T S

12

13

9

8

9

13

12

11

10

8

8 Resistance (6.8 ÷ 7.0 Ω) for electrical starter

9 Key switch

10 Starter relay

11 Recharging socket

12 Provision for anti-theft system

13 Stator pick-up connector

18

I G N I T I O N S Y S T E M

NO

OK

F. 1

Tester (KΩ)

1

2

THE IGNITION SYSTEM DOES NOT WORK

Check:

1. Spark plug

2. Spark plug cap resistance

3. Pick-up resistance

4. Key switch

5. Wiring connections

1. Spark plug

Check condition of spark plug.

See “Engine Workshop Manual”.

•

Faulty spark plug: replace it.

2. Spark plug cap

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 (KΩ) 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 KΩ at 20° C.

•

Replace spark plug cap.

19

I G N I T I O N S Y S T E M

NO

OK

NO

OK

F. 2

Tester (Ω)

V

1

2

3. Pick-up resistance

Remove two-way connector of wiring and connect Tester (Ω) to ywheel connector (V):

Terminal (+) of Tester Terminal (1).

Terminal (-) of Tester Engine grounding (2).

Resistance: 150 ÷ 170 Ω at 20° C.

•

Stator is faulty: replace it.

4. Key switch

See “Checking switches” (P. 13)•

Always check grounding isolation of Yellow/White cable between key switch and CDI

control unit.

Replace key switch.

5. Wiring connections

Check connections of entire ignition system.

See “Wiring Diagram” (P. 8).

•

Repair wiring.

Replace the C.D.I. control unit. (code: 02411900).

20

E L E C T R I C A L S T A R T I N G S Y S T E M

20

OK

NO

OK

NO

BATTERIA

+

-

12

V

9Ah

NO

OK

F. 3

F. 4

R E C H A R G I N G S Y S T E M

BATTERY CANNOT BE RECHARGED

Check:

1. Fuse, 10 A

2. Recharging voltage

3. Resistance of stator

4. Charging system wiring

1. Fuse, 10 A

See “Checking fuses” (P. 15).•

Replace fuse.

Check wiring between 10 A fuse holder (n° 1) and key

switch.

2. Check charging voltage

Connect Tester (DC 20 V):

~ 2000 RPM: 13 V.

> 4000 RPM: 14 ÷ 14.5 V.

•

The recharging circuit is working: replace battery.

Repair. See “Wiring Diagram” (P. 8).

Replace regulator (code n°: 02602800).

Tester (DC 20 V)

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Malaguti Centro 50 4T Workshop Manual

Malaguti Centro 50 4T Workshop Manual

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