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Malaguti CNK 50 DRAKON Workshop Manual

Identification of electrical system failures
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IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES
CNK 50 DRAKON
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Summary of Contents for Malaguti CNK 50 DRAKON

  • Page 1 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES CNK 50 DRAKON WORKSHOP MANUALS...

  • Page 3: Table Of Contents

    IDENTIFICATION OF ELECTRICAL INDEX SYSTEM FAILURES DRAKON 50 NKD INDEX 1 - INDEX..........................2 - ELECTRICAL SYSTEM....................ELECTRICAL SYSTEM CODE ....................3 - ELECTRICAL COMPONENTS..................4 - CHECKING THE CONNECTIONS..................5 - CHECKING THE SWITCHES.................... SWITCH CONNECTIONS AS SHOWN IN THIS MANUAL ............

  • Page 4: Electrical System

    ELECTRI- IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES ELECTRICAL SYSTEM DRAKON 50 NKD 05188053 03/06...

  • Page 5: Electrical System Code

    IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD ELECTRICAL SYSTEM ELECTRICAL SYSTEM CODE COLOUR CODE Orange 1) Instrument panel Light blue AZ-B Light blue-White 2) Main switch White 3) Oil gauge indicator switch White - Black 4) Neutral gear switch B-MA White - Brown 5) Regulator...

  • Page 6: Electrical Components

    ELECTRI- IDENTIFICATION OF ELECTRICAL COMPONENTI ELETTRICI SYSTEM FAILURES ELECTRICAL COMPONENTS DRAKON 50 NKD 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 05188001 05188005 05188006 05188091...
  • Page 7 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD 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 05188007 05188012 05188006 05188011 05188090...

  • Page 8: Checking The Connections

    CHECKING THE CONNECTIONS IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES CHECKING THE CONNECTIONS DRAKON 50 NKD Check rust and moisture of connectors. 1) Disconnect • Connectors 2) Dry each terminal with an air blower. 05188013 3) Connect and disconnect the connector twice or three times.

  • Page 9: Checking The Switches

    CHECKING THE SWITCHES IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES CHECKING THE SWITCHES ELECTRICAL SYSTEM DRAKON 50 NKD • Set the Tester selector to “ ”. • Insert the terminals of the tester in the connector corresponding to the cables in question. •...

  • Page 10: Ignition System

    IGNITION IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES IGNITION SYSTEM DRAKON 50 NKD 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...
  • Page 11 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD 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: INCORRECT 5-6 K a 20 °C.
  • Page 12 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES IGNITION SYSTEM DRAKON 50 NKD 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: INCORRECT 640-780...

  • Page 13: Electrical Starting System

    IDENTIFICATION OF ELECTRICAL ELECTRICAL STARTING SYSTEM SYSTEM FAILURES DRAKON 50 NKD 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-...
  • Page 14 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES ELECTRICAL STARTING SYSTEM DRAKON 50 NKD 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 •...
  • Page 15 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD ELECTRICAL STARTING SYSTEM 3 Starter WARNING A wire for the jumper lead must have the equivalent • Connect battery positive terminal (1) and starter capacity as that of the battery lead or more, other- motor cable (2) using a jumper lead (3) as shown in wise it may cause the jumper lead to be burned.
  • Page 16 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES ELECTRICAL STARTING SYSTEM DRAKON 50 NKD 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 17 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD 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) •...

  • Page 18: Recharge System

    IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES RECHARGE SYSTEM DRAKON 50 NKD 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 NO CONTINUITY •...
  • Page 19 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD 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: INCORRECT 0,2 ~0,7 a 20 °C...

  • Page 20: Lights System

    LIGHTS IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES LIGHTS SYSTEM DRAKON 50 NKD 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 (-)
  • Page 21 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD LIGHTS SYSTEM 2 Check voltage regulator • Connect the Tester (AC) to the connector of the regulator (leaving it inserted). Terminal (+) Tester Purple - yellow cable (1) Terminal (-) Tester Black lead (2) •...

  • Page 22: Lighting System Check

    IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES LIGHTS SYSTEM DRAKON 50 NKD LIGHTING SYSTEM CHECK THE LOW BEAM, HIGH BEAM AND HIGH BEAM INDICATOR DO NOT COME ON 1 Bulb and bulb socket • Check the bulb and bulb socket for continuity NO CONTINUITY CONTINUITY Replace bulb or bulb socket...
  • Page 23 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD LIGHTS SYSTEM THE TAILLIGHT FAILS TO COME ON 1 Bulb and bulb socket • Check the bulb and bulb socket for continuity NO CONTINUITY CONTINUITY Replace bulb or bulb socket 2 Checking the light holder voltage •...

  • Page 24: Signal System

    10 - SIGNAL IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD TROUBLE SHOOTING THE TURN INDICATORS, STOP LIGHT AND INSTRUMENT PANEL LIGHTS DO NOT COME ON; THE REV COUNTER AND HORN DO NOT WORK Check 1) Fuse 10A 2) Battery 3) Main switch 4) Signal system wiring...
  • Page 25 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM 3 Main switch • Disconnect connector (1) of the main switch • Turn the main switch to “ON” • Connect Tester ( ) and check the continuity as follows: Terminal (+) Orange lead (2) Terminal (-) Green lead (3)

  • Page 26: Checking The Signal System

    IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD CHECKING THE SIGNAL SYSTEM THE HORN DOES NOT WORK 1 Horn switch • Disconnect the nine core connector of the left side switch. • Connect Tester ( ) to the connector •...
  • Page 27 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM 2 Power supply check • Connect Tester (DC 20 V) as follows: Terminal (+) Orange lead (1) Terminal (-) Chassis ground (2) • Turn the main switch to “ON” • Press the button (Horn) to activate the horn INCORRECT •...
  • Page 28 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD THE STOP LIGHT FAILS TO COME ON 1 Bulb and bulb socket • Check the bulb and bulb socket for continuity NO CONTINUITY CONTINUITY Replace bulb or bulb socket 2 Front and rear brake switch •...
  • Page 29 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM 3 Voltage check • Connect Tester (DC 20V) to the bulb socket connector Terminal (+) Red lead (1) Terminal (-) Black lead (2) • Turn the main switch to “ON” •...
  • Page 30 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD THE TURN INDICATORS AND THEIR INDICATOR PANEL LIGHTS DO NOT WORK 1 Bulb and bulb socket • Check the bulb and bulb socket for continuity NO CONTINUITY CONTINUITY Replace bulb or bulb socket 2 Turn indicator switch.
  • Page 31 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM 3 Flasher relay voltage check • Disconnect connector of flasher relay • Connect Tester (DC 20 V) as follows: Terminal (+) Blue lead (1) Terminal (-) Chassis ground (2) • Turn the main switch to “ON” INCORRECT •...
  • Page 32 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD 5 Check voltage of right and left light holder • Connect Tester (DC 20V) to the bulb socket connector (A) Left flasher light Terminal (+) Purple lead (1) Terminal (-) Chassis ground (3) (B) Right flasher light Terminal (+)
  • Page 33 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM NEUTRAL GEAR INDICATOR COMES ON ONLY WITH “CHECK” 1 Neutral switch check • Connect Tester ( ) and check the continuity between the neutral switch and the ground Neutral switch (1) Chassis ground (2) Gears in neutral Continuity...
  • Page 34 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD 2 Meter assembly check WARNING After disassembling the cable terminal, check • Disconnect connector of meter assembly (1) that the neutral switch is tightened properly. • Disconnect cable terminal (2) of neutral switch •...
  • Page 35 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM WHEN THE “MODE” BUTTON IS PRESSED, THE DISPLAY DOES NOT CHANGE FUNCTION 1 “Mode” button check • Disconnect the nine core connector of the left side switch. • Connect Tester ( ) as follows: Terminal (+) Yellow lead (1) Terminal (-)
  • Page 36 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD NOTE 2 Power supply check If there is no current in the blue cable the horn does not work either. • Disconnect the nine core connector of the left side switch.
  • Page 37 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM 3 Check the red lead for continuity • Connect Tester ( ) as follows: Terminal (+) Red lead (1) (PIN6) Terminal (-) Red lead (2) LH SWITCH DIGITAL INSTRUMENT NO CONTINUITY CONTINUITY Faulty red lead.
  • Page 38 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD THE TACHOMETER IS FAULTY 1 Check continuity of the feed cable • Connect Tester ( ) as follows: Terminal (+) Tester Purple - yellow cable (1) Terminal (-) Tester White - brown cable (2) (PIN 12) DIGITAL INSTRUMENT 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NO CONTINUITY...
  • Page 39 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM THE FUEL LIGHT FAILS TO COME ON 1 Fuel probe check • Disconnect the connector of the fuel probe • Make a bridge between the grey cable and the black cable of the connector on the system side.
  • Page 40 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD OIL MIX PANEL INDICATOR COMES ON ONLY WITH “CHECK” 1 Check the oil level gauge • Disconnect the connector of the oil level gauge and remove it from the oil tank. •...
  • Page 41 IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES DRAKON 50 NKD SIGNAL SYSTEM WATER TEMPERATURE INDICATOR AND PANEL INDICATOR (RED) DO NOT WORK CORRECTLY • The engine is hot and the warning light of the digital RED WARNING LIGHT instrument is at “0”; proceed ass follows: FLASHES AND TEMPERATURE disconnect the white –...

  • Page 42: Configuration Of The Digital Instrument Connector

    IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES SIGNAL SYSTEM DRAKON 50 NKD CONFIGURATION OF THE DIGITAL INSTRUMENT CONNECTOR PIN Meaning Colour PIN Meaning Colour Right arrow Green Water temperature indicator light White - Green Left arrow Purple Under key (+12V) Blue White - Brown Neutral Black - Red Negative lead...

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