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Malaguti F12R L.C. 50 cc Workshop Manual

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Table of Contents
B
TROUBLESHOOTING
ELEcTRIcaL aNd IGNITION SySTEm
F12R L.C. 50 cc. - Euro 2
WORKSHOP maNUaL

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  Summary of Contents for Malaguti F12R L.C. 50 cc

  • Page 1 TROUBLESHOOTING ELEcTRIcaL aNd IGNITION SySTEm F12R L.C. 50 cc. - Euro 2 WORKSHOP maNUaL...
  • Page 2: Table Of Contents

    F12R L.C. 50 cc. Introduction Chapter Table of contents Sez. Pag. INTROdUcTION Manual updates Notes for easy consultation page layout Modified pages additional pages editing symbols abbreviations ELEcTRIcaL cOmPONENTS GENERaL WIRING dIaGRam Colour key Key to general wiring diagram Configurazione connettore cruscotto...
  • Page 3: Manual Updates

    Introduction Chapter • malaguti 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.
  • Page 4: Notes For Easy Consultation 1

    F12R L.C. 50 cc. Introduction Chapter NOTES FOR EaSy cONSULTaTION paGe LaYOUt Chapter Section title page N° Date of issue (RIGHT HAND PAGE) mOdIFIEd PaGES • Modified 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.
  • Page 5 F12R L.C. 50 cc. Introduction Chapter caUTION! recommendations and precautions regarding rider safety and motor vehicle integrity. 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.
  • Page 6: Abbreviations 1

    F12R L.C. 50 cc. Introduction Chapter aBBREVIaTIONS Figure tightening torque page paragraph Section Diagram table 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.
  • Page 7: Electrical Components 2

    F12R L.C. 50 cc. Electrical Components Chapter ELEcTRIcaL cOmPONENTS aMBIeNt teMperatUre prOBe StartING reLaY KeY SWItCh 10) GrOUNDING WIre terMINaLS reCharGING SOCKet 11) h O teMperatUre SeNSOr OIL INDICatOr SWItCh 1) BatterY hOrN 13) FUeL reSerVe SWItCh FLaShLIGht 14) ChOKe CONtrOL...
  • Page 8: General Wiring Diagram 2

    F12R L.C. 50 cc. General Wiring Diagram Chapter 0.07 paGe ISSUe...
  • Page 9: Colour Key

    F12R L.C. 50 cc. General Wiring Diagram Chapter GENERaL WIRING dIaGRam cOLOUR KEy OraNGe GL-B YeLLOW/WhIte ar-BL OraNGe/BLUe GL-V YeLLOW/GreeN r-Vr reD/GreeN GL-r YeLLOW/reD LIGht BLUe GreY WhIte BrOWN B-VL WhIte/pUrpLe BrOWN/BLaCK B-Vr WhIte/GreeN BrOWN/WhIte B-VL WhIte/pUrpLe BLaCK B-BL WhIte/BLUe...
  • Page 10 F12R L.C. 50 cc. Checking Switches Chapter INSTRUmENT BOaRd cONNEcTOR cONFIGURaTION haLL SeNSOr SIGNaL MODe BUttON Gr-r rIGht tUrN INDICatOr LIGht INDICatOr LeFt tUrN INDICatOr BaCKLIGhtING GND (-) aMBIeNt teMperatUre FUeL prOBe KeY aCtIVatION (+1V) VDC haLL SeNSOr (+V) GL-BL WteMp reSISt.
  • Page 11: Checking Switches 2

    F12R L.C. 50 cc. Checking Switches Chapter 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.
  • Page 12: Position Of Switches And Connection Of Connectors

    F12R L.C. 50 cc. Checking Switches Chapter POSITION OF SWITcHES aNd cONNEcTION OF cONNEcTORS rear StOp SWItCh “MODe” BUttON SWItCh Start SWItCh tUrN INDICatOr SWItCh KeY SWItCh hOrN CONtrOL FrONt StOp SWItCh NOTE: the start switch is closed when the Start button is pressed.
  • Page 13: Fuse

    F12R L.C. 50 cc. Fuses Chapter 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).
  • Page 14: Ignition System 2

    F12R L.C. 50 cc. Starting System Chapter IGNITION SySTEm If the ignition system is not working, check: CONDItION OF SparK pLUG SparK pLUG Cap reSIStaNCe reSIStaNCe OF “CDI” CONtrOL UNIt reSIStaNCe OF Start pICK-Up CONtINUItY OF KeY SWItCh CONNeCtIONS OF IGNItION SYSteM 1.
  • Page 15 F12R L.C. 50 cc. Starting System Chapter 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).
  • Page 16: Starting System

    F12R L.C. 50 cc. Starting System Chapter 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).
  • Page 17: Starting System 2

    F12R L.C. 50 cc. Ignition System Chapter STaRTING SySTEm If the starting system is not working, check: CONtINUItY OF 10a / a FUSe CONDItION OF BatterY OperatION OF Starter MOtOr OperatION OF StartING reLaY KeY SWItCh FrONt/rear StOp SWItCh Start SWItCh (Start) CONNeCtION OF StartING SYSteM 1.
  • Page 18 F12R L.C. 50 cc. Ignition System Chapter 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 figure. WARNING: for the bridge, use a cable that can withstand the power draw of the starter motor otherwise it would burn out.
  • Page 19 F12R L.C. 50 cc. Ignition System Chapter 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”.
  • Page 20 F12R L.C. 50 cc. Ignition System Chapter 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).
  • Page 21: Charging System

    F12R L.C. 50 cc. Charging System Chapter cHaRGING SySTEm If the charging system is not working, check: CONtINUItY OF 10a FUSe BatterY CharGING VOLtaGe CharGING COIL reSIStaNCe CONNeCtIONS OF reCharGING SYSteM 1. continuity of 10a fuse - remove fuse. - Connect Tester (Ω) to fuse.
  • Page 22 F12R L.C. 50 cc. Charging System Chapter 3. charging coil resistance - Detach connector of flywheel magneto. - Connect Tester (Ω), as follows: - terminal (+) of tester Yellow cable (1). - terminal (-) of tester Ground (2). - Charging coil resistance: 1 ÷ 1.2 Ω at 20°c.
  • Page 23: Lighting System 2

    F12R L.C. 50 cc. Lighting System Chapter LIGHTING SySTEm If the lighting system is not working, check: CONtINUItY OF 7.a FUSe reSIStaNCe OF LIGhtING SYSteM COIL CONtINUItY OF YeLLOW CaBLe VOLtaGe reGULatOr CONNeCtION OF LIGhtING SYSteM 1. continuity of 7.5a fuse - remove fuse.
  • Page 24 F12R L.C. 50 cc. Lighting System Chapter 3. continuity of yellow cable - Connect connector of flywheel. - Disconnect regulator connector. - Connect Tester (Ω), as follows: - terminal (+) of tester Yellow cable (1). - terminal (-) of tester Black cable (2).
  • Page 25 F12R L.C. 50 cc. Lighting System Chapter If the headlight is not working, check: CONtINUItY OF LIGht BULB aND reLatIVe COUpLING VOLtaGe DeLIVereD tO LaMp SOCKet 1. continuity of light bulb and relative coupling - remove light bulb. - Connect Tester (Ω) to light bulb.
  • Page 26 F12R L.C. 50 cc. Lighting System Chapter If the instrument board indicator lights are not working, check: VOLtaGe DeLIVereD tO INStrUMeNt BOarD 1. Voltage delivered to instrument board - Connect Tester (20 V ac) to instrument board connector, as follows: - terminal (+) of tester pink cable (PIN 3).
  • Page 27 F12R L.C. 50 cc. Lighting System Chapter If the rear light is not working, check: CONtINUItY OF LaMp VOLtaGe DeLIVereD tO LaMp SOCKet 1. continuity of lamp - remove light bulb. - Connect Tester (Ω) to light bulb. - Check continuity of lamp.
  • Page 28: Signalling System 2

    F12R L.C. 50 cc. Signalling System Chapter SIGNaLLING SySTEm If the signalling system is not working, check: CONtINUItY OF 10 a FUSe CONDItION OF BatterY KeY SWItCh CONNeCtIONS OF SIGNaLLING SYSteM 1. continuity of 10a fuse - remove fuse. - Connect Tester (Ω) to fuse.
  • Page 29 F12R L.C. 50 cc. Signalling System Chapter 3. Key switch - Disconnect key switch from system. - turn key “ON” - Connect Tester (Ω), as follows: - terminal (+) of tester Blue/red cable (1). - terminal (-) of tester Blue cable (2).
  • Page 30 F12R L.C. 50 cc. Signalling System Chapter If the horn is not working, check: hOrN SWItCh VOLtaGe DeLIVereD tO hOrN GrOUNDING OF hOrN 1. Horn switch - Disconnect six-way connector of left hand switch. - press Horn button to activate horn.
  • Page 31 F12R L.C. 50 cc. Signalling System Chapter 3. Grounding of horn - Disconnect black cable from terminal of horn. - Connect a bridge cable (1) between terminal (2) and grounding point of chassis (3). - turn key “ON”. - press Horn button to activate horn.
  • Page 32 F12R L.C. 50 cc. Signalling System Chapter 2. continuity of light bulb and relative coupling - remove light bulb. - Connect Tester (Ω) to light bulb. - Check continuity of light bulb and its coupling. - Not compliant: replace light bulb or coupling.
  • Page 33 F12R L.C. 50 cc. Signalling System Chapter If the turn indicators and the relative indicator lights are not working, check: CONtINUItY OF  a FUSe tUrN INDICatOr SWItCh VOLtaGe DeLIVereD tO FLaShLIGht CONtINUItY OF BrOWN/BLaCK CaBLe 1. 5 a fuse - remove fuse.
  • Page 34 F12R L.C. 50 cc. Signalling System Chapter 3. Voltage delivered to flashlight - Detach flashlight connector. - Connect Tester (20 V dc), as follows: - terminal (+) of tester Blue cable (1). - terminal (-) of tester Chassis grounding (2).
  • Page 35 F12R L.C. 50 cc. Signalling System Chapter If right or left turn indicators are not working, check: CONtINUItY OF LIGht BULB aND reLatIVe COUpLING VOLtaGe DeLIVereD tO rIGht Or LeFt LaMp SOCKet 1. continuity of light bulb and relative coupling - remove light bulb.
  • Page 36 F12R L.C. 50 cc. Signalling System Chapter If “mOdE” button is not working, check: CONtINUItY OF “MODe” BUttON VOLtaGe DeLIVereD tO “MODe” BUttON CONtINUItY OF GreY/reD CaBLe 1. continuity of “mOdE” button - Disconnect four-way connector of right hand switch.
  • Page 37 F12R L.C. 50 cc. Signalling System Chapter 2. Voltage delivered to “mOdE” button - Connect Tester (20 V dc) to connector (system side), as follows: Blue cable (1). - terminal (+) of tester - terminal (-) of tester Chassis grounding (2).
  • Page 38 F12R L.C. 50 cc. Signalling System Chapter If H O temperature indicator is not working, check: reSIStaNCe OF h O teMperatUre prOBe - NOTE: the LED and relative icon on the display will start flashing to signal that the probe is not connected.
  • Page 39 F12R L.C. 50 cc. Signalling System Chapter If the mixture oil signal is not correct, check: OIL prOBe VOLtaGe LeVeL CheCK 1. Oil probe - Detach connector of oil probe and take it out of tank. - Connect Tester (Ω) to connector, as follows: - terminal (+) of tester Coupling (1).
  • Page 40 F12R L.C. 50 cc. Signalling System Chapter NOTE: every time the sensor closes (V ), the system activates the alarm procedure, which consists in the oil icon lighting up on the display along with the relative red warning light. The system will in any case remain fully operative.
  • Page 41 F12R L.C. 50 cc. Signalling System Chapter 1. Resistance of fuel probe - probe readings take place in accordance to the following table: Fuel level (litres) Resistance (Ω) Segments not readable ≥ 85 6 - 6. 7 ÷ 84 6.1 - 7 64 ÷...
  • Page 42 F12R L.C. 50 cc. Signalling System Chapter 2. continuity of grey cable - Connect Tester (Ω). - Check continuity of grey cable between fuel probe connector (1) and instrument board connector (PIN 18) (2). - compliant: black cable interrupted (probe connector). repair.
  • Page 43 F12R L.C. 50 cc. Signalling System Chapter Fuel level alarm This alarm is activated by a switch located in the front section of the tank. When the level of fuel in the tank drops to its minimum threshold (less than 2.5 litres), the first segment of the relative bar graph will start flashing along with the ‘fuel’...
  • Page 44 F12R L.C. 50 cc. Signalling System Chapter If the instrument board (speedometer function) is not functioning correctly, check: VOLtaGe DeLIVereD tO reV COUNter SeNSOr SIGNaL SeNt tO INStrUMeNt BOarD CONtINUItY OF WhIte CaBLe 1. Voltage delivered to rev counter sensor - Disconnect three-way connector of rev counter sensor.
  • Page 45 F12R L.C. 50 cc. Signalling System Chapter 2. Signal sent to instrument board - Connect Tester (20 V dc) to connector of instrument board (without disconnecting it), as follows: White instrument board cable (PIN 13) (1). - terminal (+) of tester - terminal (-) of tester Black cable (PIN 17) (2).
  • Page 46 F12R L.C. 50 cc. Signalling System Chapter 3. continuity of white cable - Check continuity of white cable between connector of rev counter sensor (1) and instrument board connector (PIN 13) (2). - No continuity: white cable interrupted. repair. See “Wiring Diagram”.

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