Malaguti F12R AIR 50 cc. - Euro 2 Workshop Manual

Malaguti
Brand
Malaguti
Model
F12R AIR 50 cc. - Euro 2
Type
Workshop Manual

This manual is also suitable for

F12R L.C. 50 cc. - Euro 2
B
TROUBLESHOOTING
ELECTRICAL AND IGNITION SYSTEM
WORKSHOP MANUAL
2 02.07
B
F12R L.C. 50 cc.
Introduction
CHAPTER
PAGE ISSUE
Table of contents
Sez. Pag.
INTRODUCTION 1 3
Manual updates 1 3
Notes for easy consultation 1 4
Page layout 1 4
Modied pages 1 4
Additional pages 1 4
Editing symbols 1 4
Abbreviations 1 6
ELECTRICAL COMPONENTS 2 7
GENERAL WIRING DIAGRAM 2 8
Colour key 2 9
Key to general wiring diagram 2 9
Congurazione connettore cruscotto 2 10
CHECKING SWITCHES 2 11
Checking procedures 2 11
Connection of switches 2 11
Position of switches and connection of connectors 2 12
FUSE 2 13
Checking fuses 2 13
IGNITION SYSTEM 2 14
Troubleshooting 2 14
STARTING SYSTEM 2 17
Troubleshooting 2 17
CHARGING SYSTEM 2 21
Troubleshooting 2 21
LIGHTING SYSTEM 2 23
Troubleshooting 2 23
SIGNALLING SYSTEM 2 28
Troubleshooting 2 28
02.07 3
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Introduction
B
CHAPTER
ISSUE PAGE
• 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. 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 (Elec-
tronic 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 con-
sultation of the manual difcult.
• 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 ISSUE : 02/07
4 02.07
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F12R L.C. 50 cc.
Introduction
CHAPTER
PAGE ISSUE
NOTES FOR EASY CONSULTATION
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 6), 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).
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.
W
Z
Y
X
Y Chapter
X Section title
W Page N°
Z Date of issue
(RIGHT HAND PAGE)
PAGE LAYOUT
02.07 5
F12R L.C. 50 cc.
Introduction
B
CHAPTER
ISSUE PAGE
R
M
L
H
F
A
B
D
C
I
G
E
A) CAUTION! Recommendations and precautions
regarding rider safety and motor 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 inammation
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
6 02.07
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F12R L.C. 50 cc.
Introduction
CHAPTER
PAGE ISSUE
ABBREVIATIONS
A
F Figure
Cs Tightening torque
P Page
Pr Paragraph
S Section
Sc Diagram
T Table
V Screw
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 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.
02.07 7
F12R L.C. 50 cc.
Electrical Components
B
CHAPTER
ISSUE PAGE
ELECTRICAL COMPONENTS
1) AMBIENT TEMPERATURE PROBE
2) KEY SWITCH
3) RECHARGING SOCKET
4) OIL INDICATOR SWITCH
5) HORN
6) FLASHLIGHT
7) VOLTAGE REGULATOR
8) “CDI” CONTROL UNIT
9) STARTING RELAY
10) GROUNDING WIRE TERMINALS
11) H
2
O TEMPERATURE SENSOR
12) BATTERY
13) FUEL RESERVE SWITCH
14) CHOKE CONTROL
15) FUEL LEVEL SENSOR
8 02.07
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F12R L.C. 50 cc.
General Wiring Diagram
CHAPTER
PAGE ISSUE
ON
0FF
ON
0FF
N
N
N
VL
N
VR
VR
VL
AR
N
N
B-R
VR
VR
VL
VR
B
GL
R
AR
HORN
R
L
TURN
N
START
BL
N
BL
B-R
R
+
-
VL
RS
R
N
VR
M
R
BL
BL
R
BL
VL
VR
PREDISPOSIZIONE
ALLARME
N
N
BL
B
N
N-
R
1
2
3
4
5
6
7
8
9
10
11
12
24
23
22
21 20
19
18
17
16
15
14
13
10
W
10
W
10
W
35
W
35
W
10
W
OFF
ON
N
BL
GL
-B
BL
-R
VR
-N
BL
-N
ON
0FF
BL
MODE
VL
AR
N
VL
RS
RS
BL
N
VR
VL
AZ
M-
N
M-
N
GR
-R
GR
-R
N
N
B-R
BL
GL-BL
GL
-B
GL
-B
N
AZ
BL
BL
-R
BL
-R
BL
-R
BL
-R
N
R
AZ
BL
RS
R
R-
VR
N-R
N
N
BL
B-
VL
N
B-
VR
GR
N
GL
GL-R
M-
N
N
N
NN
N
VR
VL
R
RS
10
A
7.5
A
RS
RS
RS
N-R
BL
GL
-B
L
B-
VL
BL
-R
B
GR
-R
VL
N
GR
B-
VR
BL
-V
R
RS
RS
RS
N
N
BL
-N
VR
-N
VR
N
N
5 A
N-
R
GL
+
M-
N
AR
AZ
N
BL
-R
B-
VL
BL
VR
N
BL
BL
-V
R
VR
N-R
N
GR
-R
B-R
A
AB
B
AZ
BL
-R
Inte
rr
uttore
spia
olio
m
ix.
Inter
r
uttore
riser
va
carburante
Sonda
livello
carburante
MODE
Signal
rinvio
Alim
. 5
V
Alim
.
12V
V
.bat.
Alim
.
12V
sotto
chiave.
Sensore
temperatura
acqua.
Run STOP
Pick UP
Uscita ricarica / luci
A
lim
.
Centralin
a
<
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
Imp. Luci / starter
<
>>>
<
>
>
>
>
<
>
BL
-R
GR
-R
GR
B-
VR
B
GL
-BL
BL
-V
R
N
BL
B-
VL
RS
RS
RS
VR
VL
N-R
H8 H8
1
2
3
4
5
6
7
8
9
10
11
12 13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
02.07 9
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General Wiring Diagram
B
CHAPTER
ISSUE PAGE
GENERAL WIRING DIAGRAM
GL-B YELLOW/WHITE
GL-V YELLOW/GREEN
GL-R YELLOW/RED
GR GREY
M BROWN
M-N BROWN/BLACK
M-B BROWN/WHITE
N BLACK
N-R BLACK/RED
R RED
R-VR RED/GREEN
RS PINK
VL PURPLE
VR GREEN
KEY TO GENERAL WIRING DIAGRAM
1) FLYWHEEL MAGNETO
2) CHOKE CONTROL
3) ELECTRICAL STARTER
4) BATTERY
5) FUSE, 10 A
6) FUSE, 5 A
7) FUSE, 7.5 A
8) STARTING RELAY
9) STARTER MOTOR
10) REAR LEFT TURN INDICATOR
11) 5W PARKING LIGHT / 10W STOP LIGHT
12) REAR RIGHT TURN INDICATOR
13) OIL INDICATOR SWITCH
14) FUEL RESERVE SWITCH
15) H
2
O TEMPERATURE SENSOR
16) FUEL LEVEL SENSOR
COLOUR KEY
AR ORANGE
AR-BL ORANGE/BLUE
R-VR RED/GREEN
AZ LIGHT BLUE
B WHITE
B-VL WHITE/PURPLE
B-VR WHITE/GREEN
B-VL WHITE/PURPLE
B-BL WHITE/BLUE
B-R WHITE/RED
BL BLUE
BL-R BLUE/RED
BL-VR BLUE/GREEN
GL YELLOW
GL-BL YELLOW/BLUE
17) VOLTAGE REGULATOR
18) “CDI” CONTROL UNIT
19) SENSOR TRANSMISSION
20) FRONT LEFT TURN INDICATOR
21) FRONT STOP SWITCH
22) RIGHT HAND SWITCH
23) KEY SWITCH
24) RECHARGING SOCKET
25) INSTRUMENT BOARD
26) AMBIENT TEMPERATURE PROBE
27) DOUBLE HEADLIGHT
28) LEFT SWITCH
29) REAR STOP SWITCH
30) FRONT LEFT TURN INDICATOR
31) FLASHLIGHT
32) HORN
10 02.07
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F12R L.C. 50 cc.
Checking Switches
CHAPTER
PAGE ISSUE
INSTRUMENT BOARD CONNECTOR CONFIGURATION
1) RPM RS
2) RIGHT TURN INDICATOR VR
3) LIGHT INDICATOR RS
4) BACKLIGHTING RS
5) AMBIENT TEMPERATURE N-R
6) KEY ACTIVATION (+12V) BL
7) VDC HALL SENSOR (+5V) GL-BL
8) MIXTURE OIL B-VL
9) BATTERY POSITIVE BL-R
10) - -
11) - -
12) - -
13) HALL SENSOR SIGNAL B
14) MODE BUTTON GR-R
15) - -
16) LEFT TURN INDICATOR VL
17) GND (-) N
18) FUEL PROBE GR
19) WTEMP RESIST. PROBE B/VR
20) - -
21) - -
22) - -
23) - -
24) FUEL RES. WARNING LIGHT BL-VR
24 PIN
02.07 11
F12R L.C. 50 cc.
Checking Switches
B
CHAPTER
ISSUE PAGE
F. 1
CHECKING SWITCHES
CHECKING PROCEDURES
- Using a Tester (code n°08609500), check switches. In particular, check continuity between terminals to
make sure they are correctly connected.
- Replace the switch, even if only one of the possible combinations does not give the requested result.
Set the tester to function Ω.
F. 2
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 rst column from the left indicates the different positions of the switch, the top line the colour of the
wires connected to the switch terminals.
- The “ ” symbol 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:
- “B/R” and “N” there is continuous contact when the switch is “ON”.
12 02.07
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Checking Switches
CHAPTER
PAGE ISSUE
1
2
3
4
5
6
7
7
1
2
3
4
5
6
R
BL
R
L
VR
VL
M-
N
ON
0FF
AR
AZ
R
BL
ON
0FF
BL
GR
-R
ON
0FF
N
B-R
OFF
ON
N
BL
GL
-B
BL
-R
VR
-N
BL
-N
POSITION OF SWITCHES AND CONNECTION OF CONNECTORS
1) REAR STOP SWITCH
2) TURN INDICATOR SWITCH
3) HORN CONTROL
4) FRONT STOP SWITCH
5) “MODE” BUTTON SWITCH
6) START SWITCH
7) KEY SWITCH
NOTE: the start switch is closed when the START button is pressed.
The STOP switch is closed when the brake lever is operated.
02.07 13
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Fuses
B
CHAPTER
ISSUE PAGE
C
B
A
A) 10A Main / Recharging
B) 5A Stop / Turn indicators / Horn
C) 7.5A Lights / Starter
FUSES
CHECKING FUSES
CAUTION: when checking fuses, always turn the main switch “OFF” or short-circuits may occur.
Checking procedure:
- Connect Tester (code n°08609500) to fuse and check continuity.
NOTE: 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 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 res to break out.
F. 3
F. 4
14 02.07
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F12R L.C. 50 cc.
Starting System
CHAPTER
PAGE ISSUE
IGNITION SYSTEM
If the ignition system is not working, check:
1) CONDITION OF SPARK PLUG
2) SPARK PLUG CAP RESISTANCE
3) RESISTANCE OF “CDI” CONTROL UNIT
4) RESISTANCE OF START PICK-UP
5) CONTINUITY OF KEY SWITCH
6) CONNECTIONS OF IGNITION SYSTEM
2
1
2. Spark plug cap resistance
- Remove spark plug cap.
- NOTE: when removing spark plug cap, do not pull.
- To remove
turn anti-clockwise.
- To connect
turn clockwise.
- Before connecting the spark plug cap, check the HV cable and cut off a piece of approximately 5 mm.
- 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.
- Not compliant: replace spark plug cap.
1. Condition of spark plug
- Check condition of spark plug.
- See Engine Workshop Manual.
- Not compliant: replace spark plug.
F. 5
F. 6
Tester (kΩ)
02.07 15
F12R L.C. 50 cc.
Starting System
B
CHAPTER
ISSUE PAGE
3. Resistance of “CDI” control unit (red)
- Connect Tester (2kΩ) to “CDI”, as follows:
- Terminal (+) of Tester
HV screw (V).
- Terminal (-) of Tester
PIN 1 (GND).
- Resistance: 525 ÷ 640 Ω at 20°C (F.7a).
- Terminal (+) of Tester
PIN 1 (GND).
- Terminal (-) of Tester
PIN 2 (PICK-UP).
- Resistance: 335 ÷ 385 Ω at 20°C (F.7b).
- Not compliant: Replace “CDI” control unit (code n° 02411000).
4. Stator pick-up resistance
- Remove two-way connector of wiring.
- Connect Tester (Ω) to connector of ywheel magneto (V).
- Terminal (+) of Tester
Red cable (1).
- Terminal (-) of Tester
Ground (2).
- Stator pick-up resistance: 195 ÷ 205 Ω at 20°C.
- Not compliant: replace stator.
F. 7a
1
V
1
2
1
F. 7b
GL
R
F. 8
2
V
Tester (2kΩ) Tester (2kΩ)
Tester (Ω)
16 02.07
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F12R L.C. 50 cc.
Starting System
CHAPTER
PAGE ISSUE
6. Connections of ignition system
- Check connections of ignition system.
- NOTE: pay attention to correctly insert cables into connector (C) of “CD1” control unit.
- Not compliant: resume connections of ignition system.
See "Wiring Diagram”.
5. Continuity of key switch
- Disconnect key switch from system.
- Connect Tester (Ω) as follows:
- Terminal (+) of Tester
Yellow/white cable (1).
- Terminal (-) of Tester
Black cable (2).
- Turn key “OFF” and then “ON”.
- Check continuity of key switch.
- Not compliant: replace key switch.
see “Checking switches” on page 11
F. 9
OFF
ON
N
BL
GL
-B
BL
-R
VR
-N
BL
-N
1
2
C
F. 10
1
2
3
4
POS. CABLE DESTINATION
1 GND (N)
2 PICK-UP (GL/R)
3 ENGINE STOP (GL/B)
4 REGULATOR (B)
Tester (Ω)
02.07 17
F12R L.C. 50 cc.
Ignition System
B
CHAPTER
ISSUE PAGE
STARTING SYSTEM
If the starting system is not working, check:
1) CONTINUITY OF 10A / 5A FUSE
2) CONDITION OF BATTERY
3) OPERATION OF STARTER MOTOR
4) OPERATION OF STARTING RELAY
5) KEY SWITCH
6) FRONT/REAR STOP SWITCH
7) START SWITCH (START)
8) CONNECTION OF STARTING SYSTEM
1. Continuity of 10A / 5A fuse
- Remove fuse.
- Connect Tester (Ω) to fuse.
- Check continuity of fuse.
- Not compliant: replace fuse.
2. Condition of battery
- Check condition of battery.
- Minimum voltage: 12.5 V.
- Density of electrolytic solution: 1.280 g/dm
3
- Not compliant: clean terminals.
Recharge or replace battery.
F. 11
F. 12
BATTERIA
+
-
12
V
5Ah
Tester (Ω)
18 02.07
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F12R L.C. 50 cc.
Ignition System
CHAPTER
PAGE ISSUE
3. Starter motor
- Use a bridge cable (3) to connect the positive battery terminal (1) to the cable of the starter motor (2), as
shown in the gure.
WARNING: for the bridge, use a cable that can withstand the power draw of the starter motor otherwise
it would burn out.
- Check operation of the starter motor.
- Not compliant: replace starter motor.
4. Starting relay
- Connect the battery to the terminals of the starting relay (4) using bridge cables (1), as follows:
- (+) cable of battery
Red cable.
- (-) cable of battery
Red/white cable.
CAUTION: never invert battery connections.
When connecting the battery to the relay, avoid triggering short-circuits between the
positive and negative terminals.
- Check operation of the starter motor.
- Not compliant: replace starting relay.
F. 13
1
2
3
F. 14
1
B-R
R
RBL
R
B-R
R
BL
4
02.07 19
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Ignition System
B
CHAPTER
ISSUE PAGE
5. Key switch
- Disconnect key switch from system.
- Connect Tester (Ω) as follows:
- Terminal (+) of Tester
Blue/Red cable (1).
- Terminal (-) of Tester
Blue cable (2).
- Turn key “OFF” and then “ON”.
- Check continuity of key switch.
- Not compliant: replace key switch.
see “Checking switches” on page 11
6. Front/rear stop switch
- Disconnect switch cables (A).
- Connect Tester (Ω) to terminals (T1-T2).
- Check continuity between terminals.
- Not compliant: replace stop switch.
See “Checking switches” on page 11
F. 15
OFF
ON
N
BL
GL
-B
BL
-R
VR
-N
BL
-N
F. 16
A
T.1 T.2
1
2
1) Front or rear brake lever
pulled
2) Front or rear brake lever
not pulled
Tester (Ω)
Tester (Ω)
1
2
20 02.07
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F12R L.C. 50 cc.
Ignition System
CHAPTER
PAGE ISSUE
7. Start switch (START)
- Detach four-way connector of right hand switch.
- Connect Tester (Ω) to connector, as follows:
- Terminal (+) of Tester
White/red cable (1).
- Terminal (-) of Tester
Black cable (2).
- Press “START” button.
- Check continuity.
- Not compliant: replace right hand switch.
8. Connections of starting system
- Check connections of starting system.
- Not compliant: resume connections of starting system.
See “Wiring Diagram”.
ON
0FF
N
START
ON
0FF
BL
MODE
GR
-R
N
B-R
BL
GR
-R
B-R
F. 17
Tester (Ω)
2
1
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Malaguti F12R AIR 50 cc. - Euro 2 Workshop Manual

Malaguti
Brand
Malaguti
Model
F12R AIR 50 cc. - Euro 2
Type
Workshop Manual
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