Malaguti F10 2008 Workshop Manual
  1. Manuals
  2. Brands
  3. Malaguti Manuals
  4. Scooter
  5. F10 2008
  6. Workshop manual

Malaguti F10 2008 Workshop Manual

50cc euro 2
Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Malaguti F10 2008

Summary of Contents for Malaguti F10 2008

  • Page 2: Table Of Contents

    T A B L E O F C O N T E N T S Pag. Pag. Recharging system Introduction Battery cannot be charged Manual updates Notes for easy consultation Lighting system Page layout The entire lighting system does not work Modified pages Headlight does not work Additional pages Editing symbols Instrument board indicator light does not come on Abbreviations Rear light does not come on Technical term dictionary Signalling system General wiring diagram The entire signalling system does not work Key to general wiring diagram Horn is not working...

  • Page 3: Introduction

    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 fit 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.

  • Page 4: Notes For Easy Consultation

    I N T R O D U C T I O N NOTES FOR EASY CONSULTATION PAGE LAYOUT T I T O L O S E Z I O N E SECTION TITLE PAGE NUMBER NUMERO DI PAGINA 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 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.

  • Page 6: Abbreviations

    I N T R O D U C T I O N AbbREvIATIONS • Figure • Tightening torque • Page • Paragraph • Section • Diagram • Table • 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.

  • Page 7: Technical Term Dictionary

    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 flywheel) • A: Ampere: the unit of electric current •...

  • Page 8: General Wiring Diagram

    G E N E R A L W I R I N G D I A G R A M LOCK LOCK CHECK CHECK LIGHTS LIGHTS START START TURN TURN HORN HORN < < > > GL-B GL-B B/VR B/VR B/VR B/VR B-VR...

  • Page 9: Key To General Wiring Diagram

    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 15) CAPACITOR, 50 V - 2200 UF 2) FLYWHEEL MAGNETO 16) CDI CONTROL UNIT 3) HORN WITH SHIELDING 17) VOLTAGE REGULATOR 4) 23.5 W FLASHLIGHT 18) COIL 5) STOP SWITCH 19) FUEL LEVEL SENSOR 6) LEFT HAND SWITCH 20) OIL INDICATOR SWITCH 7) FRONT LEFT TURN INDICATOR 21) REAR RIGHT TURN INDICATOR 8) DOUBLE HEADLIGHT...

  • Page 10: Colour Key

    G E N E R A L W I R I N G D I A G R A M COLOUR KEY ORANGE GL-vR YELLOW - GREEN LIGHT BLUE GL-R YELLOW - RED AZ-b LIGHT BLUE - WHITE GR GREY WHITE BROWN b-vR WHITE - GREEN M-N BROWN - BLACK b-bL WHITE - BLUE M-b BROWN - WHITE b-R...

  • Page 11: Checking Switches

    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 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. CONNECTION OF THE SWITCHES DESCRIbED IN THIS MANUAL •...

  • Page 12: Position Of Switches And Continuity Of Contacts

    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 REAR STOP SWITCH TURN INDICATOR SWITCH HORN CONTROL FRONT STOP SWITCH LIGHT SWITCH “START” SWITCH 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.

  • Page 13: Checking Fuses

    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: • Connect Tester (code n°08611200) to fuse and check continuity. Put the Tester on “Ω” (sound-emitting function). •...

  • Page 14: Location Of Electrical Components

    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 Oil indicator switch “CDI” control unit Battery Horn Starting relay Capacitor (50 V - 2200 UF) Flashlight Wire terminals for connection to ground Fuel level sensor Voltage regulator Connector for anti-theft system HV coil Stator connector...

  • Page 15: Ignition System

    I G N I T I O N S Y S T E M FAULTY IGNITION Check: Condition of spark plug Spark plug cap resistance HV coil Resistance of stator pick-up Resistance of control unit power supply Continuity of key switch Connections of ignition system Condition of spark plug •...
  • Page 16 I G N I T I O N S Y S T E M Tester (Ω) Tester Ω Coil H. v. A) Primary winding resistance • Connect Tester (Ω). • Compliant: 0.6 ÷ 0.9 Ω at 20° C. F. 5 b) Secondary winding resistance •...
  • Page 17 I G N I T I O N S Y S T E M Tester (KΩ) Control unit power supply • Detach connector of flywheel. • Connect Tester (K Ω). • Terminal (+) of Tester Red/black cable (1). • Terminal (-) of Tester Engine grounding (). • Resistance: 790 ÷ 850 Ω at 20° C. Replace stator.

  • Page 18: Electrical Starting System

    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: Fuse, 10 A Battery Starter motor Starter relay Key switch Front/rear “Stop”...
  • Page 19 E L E C T R I C A L S T A R T I N G S Y S T E M Starter motor • Use a bridge cable () to connect the positive battery terminal (1) to the cable of the starter motor (), as shown in the figure. • Check operation of the starter motor. To connect, use cables that are compatible with the power draw of the starter motor. F.
  • Page 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 Key switch • Turn key “OFF” and then “ON”. • Check continuity. Tester (Ω). • See “Checking switches” (P. 12). Replace key switch. Front/rear “Stop”...
  • Page 21 E L E C T R I C A L S T A R T I N G S Y S T E M Start switch • Disconnect four-way connector of right hand switch. • Connect Tester (Ω). • Check continuity of “Start” button. •...

  • Page 22: Recharging System

    R E C H A R G I N G S Y S T E M bATTERY CANNOT bE CHARGED • Check: Fuse, 10 A Battery charging voltage Charging coil resistance Recharging system connections Fuse, 10 A • Remove fuse. •...
  • Page 23 R E C H A R G I N G S Y S T E M Charging coil resistance Tester (Ω) • Detach connector of flywheel. • Connect Tester (Ω) as follows: • Terminal (+) of Tester White cable (1). • Terminal (-) of Tester Engine grounding (). • Charging coil resistance: 1 ÷ 1.2 Ω at 20°C. R/VR Replace stator.

  • Page 24: Lighting System

    L I G H T I N G S Y S T E M THE ENTIRE LIGHTING SYSTEM DOES NOT WORK • Check: Fuse, 7.5 A Light switch Resistance of lights coil (stator) Continuity of red/green cable Continuity of yellow cable Connection of lighting system Fuse, . A •...
  • Page 25 L I G H T I N G S Y S T E M Tester (Ω) Resistance of lights coil (stator) • Detach connector of flywheel. R/VR • Connect Tester (Ω) as follows: • Terminal (+) of Tester Red/green cable (1). • Terminal (-) of Tester Engine grounding (). • Lights coil resistance: 0.6 ÷ 0.9 Ω at 20° C. Replace key switch.
  • Page 26 L I G H T I N G S Y S T E M • Connections of lighting system • Check connections of lighting system. Replace voltage regulator (code n: 0601100). Resume connections of lighting system. See “Wiring Diagram” (P. 8).

  • Page 27: Headlight Does Not Work

    L I G H T I N G S Y S T E M THE HEADLIGHT DOES NOT WORK Check: Continuity of light bulb and relative coupling Voltage delivered to lamp socket Continuity of light bulb and relative coupling • Remove light bulb.

  • Page 28: Instrument Board Indicator Light Does Not Come On

    L I G H T I N G S Y S T E M THE INSTRUMENT bOARD LIGHT INDICATOR LIGHT DOES NOT WORK Check: Continuity of light bulb and relative coupling Voltage delivered to instrument board Continuity of light bulb and relative coupling •...

  • Page 29: Rear Light Does Not Come On

    L I G H T I N G S Y S T E M REAR LIGHT DOES NOT COME ON Check: Continuity of light bulb and relative coupling Voltage delivered to lamp socket Continuity of light bulb and relative coupling •...

  • Page 30: Signalling System

    S I G N A L L I N G S Y S T E M THE ENTIRE SIGNALLING SYSTEM DOES NOT WORK Check: Continuity of fuse 10 A Condition of battery Key switch Connections of signalling system Continuity of fuse 10 A. •...
  • Page 31 S I G N A L L I N G S Y S T E M Key switch • Turn key “OFF” and then “ON”. • Check continuity. Tester (Ω). • See “Checking switches” (P. 12). Replace key switch. Connections of signalling system • Check connections of signalling system. •...

  • Page 32: Horn Is Not Working

    S I G N A L L I N G S Y S T E M HORN IS NOT WORKING Tester (Ω) Check: Horn switch Voltage delivered to horn Ground connection of horn Horn switch • Disconnect six-way connector of left hand switch. •...
  • Page 33 S I G N A L L I N G S Y S T E M Ground connection of horn • Disconnect black cable from terminal of horn. • Using a bridge cable (1), connect horn terminal () to chassis ground connection (). • Turn key “ON”. • Press Horn button to activate horn. Resume connection between black cable and chassis F. 23 ground connection.

  • Page 34: Stop" Light Does Work

    S I G N A L L I N G S Y S T E M STOP LIGHT DOES NOT WORK Check: Continuity of light bulb and relative coupling Front and rear brake switch Light bulb coupling voltage Continuity of light bulb and relative coupling •...
  • Page 35 Tester (DC 0 v) F. 25...

  • Page 36: Turn Indicators And Relative Indicator Light Do Not Work

    S I G N A L L I N G S Y S T E M TURN INDICATORS AND RELATIvE INDICATOR LIGHT DO NOT WORK Check: Turn indicator switch Tester (Ω) Voltage level of flashlight Continuity of brown/black cable Turn indicator switch •...
  • Page 37 S I G N A L L I N G S Y S T E M Tester (DC 0 v) Voltage level of flashlight • Disconnect flashlight connector. • Connect Tester (0 v DC) as follows: • Terminal (+) of Tester blue cable (1). • Terminal (-) of Tester Chassis grounding (). • Turn key “ON”.

  • Page 38: The Mix Oil Signal Does Not Work

    S I G N A L L I N G S Y S T E M THE MIX OIL SIGNAL DOES NOT WORK Tester (Ω) Check: Oil probe Probe voltage Oil probe • Detach connector of oil probe and take the probe out of tank. •...

  • Page 39: Fuel Reserve Indicator Light Is Not Working

    S I G N A L L I N G S Y S T E M FUEL LEvEL INDICATION IS NOT CORRECT Check: Fuel level sensor Continuity of grey cable Ground connection • Fuel level sensor • Disconnect connector of fuel level sensor (S). • Provide a jumper (1) between Grey cable and black cable of connector (system side). •...
  • Page 40 S I G N A L L I N G S Y S T E M Check ground connection (black cable) • Connect Tester (Ω). • Check continuity of black cable between fuel sensor and chassis ground connection. Replace fuel level indicator. black cable is interrupted: repair. See “Wiring Diagram”...

Table of Contents