Malaguti F10 2008 Workshop Manual

Brand: Malaguti

Model: F10 2008

Type: Workshop Manual

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

Pag.

Introduction 3

Manual updates 3

Notes for easy consultation 4

Page layout 4

 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

Checking switches 11

Connection of switches described in this manual 11

Position of switches and continuity of contacts 12

Checking fuses 13

Location of electrical components 14

Ignition system 15

Faulty ignition 15

Electrical starting system 18

Faulty electrical starting system 18

Pag.

Recharging system 22

Battery cannot be charged 22

Lighting system 24

The entire lighting system does not work 24

Headlight does not work 27

Instrument board indicator light does not come on 28

Rear light does not come on 29

Signalling system 30

The entire signalling system does not work 30

Horn is not working 32

“Stop” light does work 34

Turn indicators and relative indicator light do not work 36

The mix oil signal does not work 38

Fuel reserve indicator light is not working 39

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

Malaguti

No part of this publication, whether text or illustrations, may be reproducedMalaguti



FIRST EDITION: 06/08

INTRODUCTION

This publication describes all necessary steps for troubleshooting concerning the electrical system (Electronic Injection System) and of the possible service operations,

trade technicians (Authorised Service Centres) with the necessary information for operating in compliance with the



Further information can be derived from the “Chassis” workshop manual, from the “Engine” workshop manual and from the Spare Parts catalogue



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





For any further information you may need, refer to the Malaguti S.p.A. 





MANUAL UPDATES

Any subsequent updates 

The table of contents

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.

•

NUMERO DI PAGINA

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

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

NOTES FOR EASY CONSULTATION

PAGE LAYOUT

MODIFIED PAGES

M, with the new date





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

EDITING SYMBOLS

Symbols have been provided for quick and easy reference             



These symbols may appear next to a text (in which case they refer solely to the text itself), next to a gure

and to the relative text), or at the top of 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.

•

SECTION TITLE

PAGE NUMBER

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.

ENGINE WORKSHOP MANUAL

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

SPARE PARTS CATALOGUE

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

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).

•

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

TECHNICAL TERM DICTIONARY

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

•

0FF

B-R

HORN

TURN

RELAIS

TTERIA

B-R

BL-R

M-N

BL-R

R-VR

B-AZ

M-

10 A

7.5

M-N

12V

4 Ah

B-VR

GL-B B

GL-B

A.T

R/VR

B/VR

B/AZ

B/VR

R/N

R/VR

B/AZ

B-AZ

B-VR

R-VR

BL-R

Tegolo

BL-R

0FF

-B

-R

0FF

-R

-N

-B

LIGHTS START

GL-B

-R

B-N

LOCK

OFF

CHECK

VLV

VRV

RSR

VRV

RSR

N.c.

R/VR

B/AZ

B/VR

071128

GL-VR

N.c.

21W

0FF

B-R

HORN

TURN

RELAIS

TTERIA

B-R

BL-R

M-N

BL-R

R-VR

B-AZ

M-

10 A

7.5

M-N

12V

4 Ah

B-VR

GL-B B

GL-B

A.T

R/VR

B/VR

B/AZ

B/VR

R/N

R/VR

B/AZ

B-AZ

B-VR

R-VR

BL-R

Tegolo

BL-R

0FF

-B

-R

0FF

-R

-N

-B

LIGHTS START

GL-B

-R

B-N

LOCK

OFF

CHECK

VLV

VRV

RSR

VRV

RSR

N.c.

R/VR

B/AZ

B/VR

071128

GL-VR

N.c.

21W

19 18

202122232425262728

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) ELECTRICAL STARTER

2) FLYWHEEL MAGNETO

3) HORN WITH SHIELDING



5) STOP SWITCH

6) LEFT HAND SWITCH

7) FRONT LEFT TURN INDICATOR

8) DOUBLE HEADLIGHT

9) FRONT RIGHT TURN INDICATOR

10) INSTRUMENT BOARD

11) PROVISION FOR ALARM SYSTEM

12) KEY SWITCH

13) RIGHT HAND SWITCH

14) STOP SWITCH

15) CAPACITOR, 50 V - 2200 UF

16) CDI CONTROL UNIT

17) VOLTAGE REGULATOR

18) COIL

19) FUEL LEVEL SENSOR

20) OIL INDICATOR SWITCH

21) REAR RIGHT TURN INDICATOR

22) PARKING LIGHT, 5 W

23) REAR LEFT TURN INDICATOR

24) STARTER MOTOR

25) RELAY

26) FUSE, 10 A



28) 12 V BATTERY

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

COLOUR KEY

AR ORANGE

AZ LIGHT BLUE

AZ-B LIGHT BLUE - WHITE

B WHITE

B-VR WHITE - GREEN

B-BL WHITE - BLUE

B-R WHITE - RED

B-VL WHITE - PURPLE

BL BLUE

BL-VR BLUE - GREEN

BL-R BLUE - RED

GL YELLOW

GL-B YELLOW - WHITE

GL-VR 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

C H E C K I N G 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



Replace the switch, even if only one of the possible combinations does not give the



Select “Ω” (ohm) function of tester; sound-emitting function.

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,







The “ 



In this diagram:

“BL-B” and “R”: there is continuous contact when the switch is “ON”.

•

1 42 3

C H E C K I N G S W I T C H E S

POSITION OF SWITCHES AND CONTINUITY OF CONTACTS

POS. SWITCHES

1 REAR STOP SWITCH

2 TURN INDICATOR SWITCH

3 HORN CONTROL

4 FRONT STOP SWITCH

5 LIGHT SWITCH

6 “START” SWITCH

7 KEY SWITCH

NOTE







A B

C H E C K I N G F U S E S

When checking or replacing fuses, always turn the main switch

“OFF” or short-circuits may occur.

Checking procedure:



Put the Tester on “Ω” (sound-emitting function).



Replacing procedure:





Turn key “ON”





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.

 



•

76 8 10

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

9 Battery

10 Capacitor (50 V - 2200 UF)

11 Fuel level sensor

12 Connector for anti-theft system

13 Stator connector

1 Oil indicator switch

2 Horn

3 Flashlight

4 Voltage regulator

5 “CDI” control unit

6 Starting relay

7 Wire terminals for connection to ground

8 HV coil





Tester (KΩ)

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

FAULTY IGNITION

Check:

 

 

 

 

 

 

 

1. Condition of spark plug





•



2. Spark plug cap resistance



NOTE: when removing spark plug cap, avoid pulling it.

To remove   

To connect turn clockwise





Terminal (+) of Tester Spark plug side (1)

Terminal (-) of Tester   



•



Tester (Ω)

Tester KΩ

Tester Ω





Tester (KΩ)



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

3. Coil H. V.

A) Primary winding resistance

Connect 

Compliant: 0.6 ÷ 0.9 Ω at 20° C

•

B) Secondary winding resistance

Connect

Tester (KΩ)

Compliant: 3.30 ÷ 3.60 KΩ at 20° C

•



4. Resistance of stator pick-up•





•

Connect

Tester (KΩ).

Terminal (+) of Tester White/Green 

Terminal (-) of Tester White/Light blue cable (2)

•

Pick-up resistance:

400 ÷ 460 Ω at 20°C•



Tester (KΩ)



OK NO

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

5. Control unit power supply



Connect Tester (K Ω).

Terminal (+) of Tester Red/Black cable (1)

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

Resistance: 790 ÷ 850 Ω at 20° C

•



6. Key switch•

Turn key “OFF” and then “ON

Tester (Ω)



•



7. Connections of ignition system





•



Replace “CDI” control unit (code n°: 02415700



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

FAULTY ELECTRICAL STARTING SYSTEM

Check:

 

 

 

 

 

 

 

 

1. Fuse, 10 A



Connect Tester (Ω)



•



2. Battery



Minimum voltage: 12.5 V

Density of electrolytic solution: 1280 g/dm



•







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

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





•

To connect, use cables that are compatible with the power draw of the starter motor.



4. Starter relay

Connect the battery to the terminals of the starter relay (4) using bridge cables (1)

Pole (+) of battery Red

Pole (-) of battery White/Red 

•

•



Tester (Ω)







1) Leva freno



2) Leva freno



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

5. Key switch

Turn key “OFF” and then “ON

Tester (Ω)



•



6. Front/rear “Stop” switch

Disconnect cables of switch (A)

Connect Tester (Ω)





•



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Malaguti F10 2008 Workshop Manual

Malaguti F10 2008 Workshop Manual

Malaguti F10 2008 Workshop Manual

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