Malaguti CIAK MASTER 50-4T Electric System Troubleshooting
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Malaguti CIAK MASTER 50-4T Electric System Troubleshooting

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ELECTRIC SYSTEM
TROUBLESHOOTING
CIAK MASTER 50-4T
WORKSHOP MANUALS

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Summary of Contents for Malaguti CIAK MASTER 50-4T

  • Page 1 ELECTRIC SYSTEM TROUBLESHOOTING CIAK MASTER 50-4T WORKSHOP MANUALS...

  • Page 2: Table Of Contents

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Table of contenents CHAPTER Table of contents Sect. Page INTRODUCTION Manual updates Notes for easy consultation Page layout Modified pages Additional pages Editing symbols Abbreviations TROUBLESHOOTING Electrical components General wiring diagram Checking switches Checking procedures Connection of the switches described in this manual Checking fuses Position of switches and connection of connectors...

  • Page 3: Introduction

    Introduction CHAPTER • Malaguti S.p.a. 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

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Introduction CHAPTER NOTES FOR EASY CONSULTATION PAGE LAYOUT Chapter Section title Page N° Date of issue (RH PAGE) MODIFIED PAGES • Modified pages shall bear the same number as those in the previous edition/pre-modified ones, followed by the letter M, with the date of issue appearing in the appropriate box.
  • Page 5 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Introduction CHAPTER CAUTION! Recommendations and precautions regarding rider safety and 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

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Introduction CHAPTER ABBREVIATIONS 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.

  • Page 7: Electrical Components

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Electrical components CHAPTER ELECTRICAL COMPONENTS HORN SWITCH WITH KEY STARTING RELAY FUEL PROBE HV COIL BATTERY C.D.I. CONTROL UNIT VOLTAGE REGULATOR RESISTANCE 10.05 ISSUE PAGE SECTION 2 SECTION 2...
  • Page 8 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING General wiring diagram CHAPTER 10.05 PAGE ISSUE SECTION 2 SECTION 2...

  • Page 9: General Wiring Diagram

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING General wiring diagram CHAPTER GENERAL WIRING DIAGRAM COLOUR KEY BLACK/RED WHITE/RED BLUE PINK BL-R BLUE/RED PURPLE YELLOW VL-N PURPLE/BLACK GL-N YELLOW/BLACK GREEN GL-V YELLOW/GREEN AR-BL ORANGE/BLUE GL-R YELLOW/RED LIGHT BLUE GREY AZ-B LIGHT BLUE/WHITE BROWN WHITE BROWN/WHITE WHITE/BLACK...

  • Page 10: Checking Switches

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Checking switches CHAPTER CHECKING SWITCHES CHECKING PROCEDURES Using a tester (Code n°08609500), 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.

  • Page 11: Checking Fuses

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Checking switches CHAPTER CHECKING FUSES CAUTION: when checking fuses, always turn the main switch “OFF” or short-circuits may occur. Checking procedure: - Connect the tester (Code n°08609500) to the fuse and check continuity. NOTE: put the tester on “ ” (sound-emitting function) - If the tester is showing “I”...

  • Page 12: Position Of Switches And Connection Of Connectors

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Checking switches CHAPTER POSITION OF SWITCHES AND CONNECTION OF CONNECTORS Rear stop switch Horn control Light switch Turn indicator switch Front stop switch Main light switch Engine start switch Switch with key 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: Troubleshooting

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Ignition system CHAPTER TROUBLESHOOTING If the ignition system is not working, check: Spark plug Spark plug cap resistance Pick-up resistance Key switch Wiring connections 1. Spark plug - Check condition of spark plug. - See Engine Service Manual. NOT COMPLIANT COMPLIANT - Faulty spark plug: replace.
  • Page 14 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Ignition system CHAPTER 4. Key switch - Detach four-way connector and white/black cable of the switch. - Connect Tester ( ) as follows: - Terminal (+) of Tester Black cable (1). - Terminal (-) of Tester White/black cable (2).
  • Page 15 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Charging System CHAPTER If the battery cannot be charged, check: Fuse (10A) Battery Charging voltage Stator coil resistance Charging system wiring 1. Fuse (10 A) - See “Checking switches” section (page 12). 2. Battery - Remove battery and connect Tester (DC 20 V), as follows: - Terminal (+) of Tester Battery (+) pole.
  • Page 16 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Charging System CHAPTER 4. Checking stator recharging resistance - Remove two-way connector of wiring and connect Tester ( ) to flywheel connector (V). - Terminal (+) of Tester Terminal (1). - Terminal (-) of Tester Engine grounding.
  • Page 17 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Electric starter system CHAPTER If starter motor does not work, check 10A Fuse Battery Starter motor Starter relay Key switch Start switch Front/rear stop switch Starting system wiring connections 1. Main 10A fuse NO CONTINUITY - Remove relative fuse.
  • Page 18 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Electric starter system CHAPTER 4. Starter relay - Detach relay connector. - Connect Tester ( ) and a battery (12 V) to relay terminals, as follows. - Battery (+) pole Terminal (86). - Battery (-) pole Terminal (85).
  • Page 19 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Electric starter system CHAPTER 6. Start switch - Detach six-way connector of right hand switch (1) and connect Tester ( ) as follows: - Terminal (+) of Tester White/red cable. - Terminal (-) of Tester Black cable.
  • Page 20 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Light system CHAPTER If headlight, lighting, instrument board, high beam indicator light, front/rear stop light do not come on and carburettor starter cannot be disengaged, check: 7.5A Fuse Stator Regulator Wiring connections of entire light system / Carburettor throttle 1.
  • Page 21 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Light system CHAPTER 4. Checking grounding of regulator. - Connect Tester (AC200V) to regulator connector as follows: - Terminal (+) of Tester Yellow cable (Pin1) - Terminal (-) of Tester Chassis grounding Run engine at 1900-2000 RPM. Value read must be approximately 12 Volts.

  • Page 22: Checking Light System

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Light system CHAPTER CHECKING LIGHT SYSTEM 1. HIGH BEAM LIGHT DOES NOT COME ON. NO CONTINUITY 1.1 Check lamp and lamp socket. - See the “Checking switches” section (on page 12). - Replace lamp and/or lamp socket. CONTINUITY 1.2 Checking voltage level.
  • Page 23 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Light system CHAPTER 3. LOW BEAM LIGHT DOES NOT COME ON. NO CONTINUITY 3.1 Check lamp and lamp socket. - See the “Checking switches” section (on page 12). - Replace lamp and/or lamp socket. CONTINUITY 3.2 Checking voltage level.
  • Page 24 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Light system CHAPTER 4. INSTRUMENT BOARD LIGHTING DOES NOT WORK. 4.1 Check voltage level - Connect Tester (AC 20 V) to instrument board connector as follows: - Terminal (+) of Tester Pink cable (1). - Terminal (-) of Tester Black cable (2).
  • Page 25 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Light system CHAPTER 6. FRONT STOP LIGHT DOES NOT COME ON NOT COMPLIANT 6.1 Check lamp and lamp socket - See “Checking switches” section (on page 12). - Replace lamp and/or lamp socket. COMPLIANT 6.2 Check voltage level. - Connect Tester (AC 20 V) to cables of stop light as follows: - Terminal (+) of Tester...

  • Page 26: Troubleshooting

    - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signalling system CHAPTER TROUBLESHOOTING 1. STOP LIGHT DOES NOT COME ON NO CONTINUITY 1.1 Check 10 A fuse - See “Checking switches” section (on page 12). - Replace fuse. CONTINUITY NO CONTINUITY 1.2 Lamp and lamp socket - See “Checking switches”...
  • Page 27 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signalling system CHAPTER 2. TURN INDICATORS DO NOT FLASH. NOTE: in this vehicle, flashing function is incorporated in voltage regulator. NO CONTINUITY 2.1 Lamp and lamp socket - See “Checking switches” section (on page 12). - Replace lamp and/or lamp socket.
  • Page 28 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signalling system CHAPTER 2.4 Checking voltage level - Detach connector from regulator and connect Tester (DC 20 V), as follows: - Terminal (+) of tester Blue cable (Pin3). - Terminal (-) of Tester Black cable (Pin2). - Turn key “ON”.
  • Page 29 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signalling system CHAPTER 3. HORN IS NOT WORKING NO CONTINUITY 3.1 Horn switch - See “Checking switches” section (on page 12). - Replace left hand switch. CONTINUITY 3.2 Checking grounding - Connect Tester ( ) to connector of left hand switch (3), as follows: - Terminal (+) of Tester Black cable (1).
  • Page 30 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signalling system CHAPTER 3.4 Checking voltage level - Connect Tester (DC 20 V) to horn (3), as follows: - Terminal (+) of tester Blue cable (1). - Terminal (-) of tester Chassis grounding (2). - Turn key “ON”. - Value read must be 12 V.
  • Page 31 - TROUBLESHOOTING ELECTRIC SYSTEM TROUBLESHOOTING Signalling system CHAPTER 4.2 Checking instrument board - Detach connector of instrument board and deliver power to connector using two leads. - Battery (+) cable Blue cable (1) - Battery (-) cable White/Green cable (2). INDICATOR HAND IS POINTING TO “FULL”...

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