Malaguti CIAK 150cc Troubleshooting Manual

Electric system

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MALAGUTI CIAK 125/150

MALAGUTI CIAK 125/150 cc cc cc cc cc

MALAGUTI CIAK 125/150

IDENTIFICAZIONE GUASTI IMPIANTO ELETTRICO

FEHLERSUCHE IM ELEKTRISCHEN SYSTEM

ELECTRIC SYSTEM TROUBLESHOOTING

IDENTIFICATION DES PANNES DANS L'INSTALLATION ELECTRIQUE

IDENTIFICACION AVERIAS INSTALACION ELECTRICA

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Summarization of Contents

Introduction and Manual Overview

Publication Updates and Information

Manual Navigation and Page Structure

Motorcycle Model Identification

Identifies the specific motorcycle model covered by the manual.

Page Numbering and Symbol Key

Explains the manual's page numbering and symbol system.

Notation for Page Modifications and Additions

Details how updated or new pages are marked within the manual.

Pre-Intervention Safety and Stability

Ensure Motorcycle Stability

Crucial step to ensure the vehicle is stable before any work.

Secure Front Wheel Anchor

Anchor the front wheel to the lifting equipment for safety.

Engine Starting Issues Diagnosis

Check Automatic Electric Starter

Procedures to verify the automatic electric starter's function.

Verify Starter Motor Power Supply

Test the electrical supply to the starter motor.

Check Yellow Cable Continuity

Test continuity of the yellow cable for breaks.

Engine Starting Component Checks

Check White/Black Cable Continuity

Test continuity of the white/black cable for breaks.

Measure 5 Ohm Resistance

Measure the resistance of a specific component (5 Ohm).

Magneto Flywheel Checks

Magneto Flywheel Resistance Checks

Measure winding resistances of the magneto flywheel.

Ignition Coil Checks

Ignition Coil Winding Resistance

Measure winding resistances of the ignition coil.

Kick-Starter Engine Start Diagnosis

Battery Charge Verification

Assess the battery's charge level and condition.

Starting Motor Operation Check

Test the starting motor's functionality.

Starter Button Continuity Test

Verify the continuity of the starter button.

Starting Relay and Circuitry Checks

Verify Cable Connections to Relay

Ensure correct wire fitment into the relay connector.

Test Relay Operation via Bridging

Use temporary connections to test relay function.

Check Red Cable Voltage Supply

Measure voltage at the red cable terminal.

Engine Stoppage Troubleshooting

Key Commutator Function Check

Inspect the key commutator for correct operation.

Troubleshooting Engine Stoppage

Steps to diagnose why the engine stops.

Troubleshooting Engine Not Stopping

Steps to diagnose why the engine fails to stop.

Battery Charging Fault Diagnosis

Check 15A Fuse Continuity

Test the 15 Amp fuse for electrical continuity.

Assess Battery Charge Condition

Measure battery voltage to determine charge level.

Charging Voltage Measurement

Verify the voltage output of the charging system.

Charging Coil Voltage Test

Measure the voltage generated by the charging coil.

Voltage Regulator and Circuit Diagnosis

Brown/White Cable Continuity Test

Test continuity of the brown/white cable to regulator.

Blue/Red Cable Continuity Test

Test continuity of the blue/red cable to battery.

Regulator Diode Function Test

Verify the function of the two diodes on the regulator output.

Key Switch and Fuse Checks

Verify 15A Fuse Status

Check the continuity of the 15 Amp fuse.

Inspect Key Commutator Wiring

Check the correct wire sequence to the key commutator.

Check Blue/Red Cable Voltage Input

Measure the voltage supplied to the blue/red cable.

Fuel Indicator Fault Diagnosis

Fuel Sensor Function Test

Test the fuel sensor by bridging its cables.

Black Sensor Cable Continuity

Test continuity of the black cable from the fuel sensor.

White/Green Sensor Cable Continuity

Test continuity of the white/green cable from the sensor.

Low Fuel Warning Light Diagnosis

Test Low Fuel Sensor Function

Bridge grey and black cables to test sensor.

Grey Cable Continuity Check

Test continuity of the grey cable for the warning light.

Horn Operation Diagnosis

Check Horn Switch Continuity

Test the continuity of the horn switch.

Horn Voltage and Circuit Diagnosis

Check Voltage at Horn Terminals

Measure voltage at the horn terminals.

Blue Cable Voltage Check

Measure voltage supply to the blue cable.

Turn Indicator System Diagnosis

Check Turn Indicator Switch

Inspect the turn indicator switch for faults.

Check Flasher Unit Voltage

Measure voltage supplied to the flasher unit.

Check Brown Cable Continuity

Test continuity of the brown cable to the indicator.

Turn Indicator Voltage Diagnosis

Check Right Indicator Voltage Supply

Measure voltage at the right indicator connector.

Check Left Indicator Voltage Supply

Measure voltage at the left indicator connector.

Lighting System Component Diagnosis

Light Switch Functionality Test

Verify the operation of the main light switch.

Magneto Lighting Coil Voltage Test

Measure voltage output from the lighting coil.

Magneto Lighting Coil Resistance Test

Measure resistance of the lighting coil.

Voltage Regulator and Associated Circuit Diagnosis

Check Voltage Regulator Output

Measure the voltage output of the regulator.

Yellow Cable Continuity to Regulator

Test continuity of the yellow cable to the regulator.

Front Headlight Fault Diagnosis

Check Lamp and Holder Continuity

Test continuity of the headlight bulb and holder.

Check High/Low Beam Switch Operation

Inspect the high/low beam switch for proper function.

Check Yellow/Black Cable Continuity

Test continuity of the yellow/black cable for breaks.

Low Beam Headlight Diagnosis

Inspect Low Beam Light Switch

Verify the operation of the low beam light switch.

Check Low Beam Lamp Holder Voltage

Measure voltage at the low beam lamp holder.

Check Blue/White Cable Continuity

Test continuity of the blue/white cable for the low beam.

Rear Light Diagnosis

Check Rear Bulb and Holder Continuity

Test continuity of the rear light bulb and holder.

Check Rear Lamp Holder Voltage

Measure voltage at the rear lamp holder.

Check Pink Cable Continuity (Rear Light)

Test continuity of the pink cable for the rear light.

Check Black Cable Continuity (Rear Ground)

Test continuity of the black ground cable for the rear light.

Stop Light Diagnosis

Inspect Stop Light Bulb and Holder

Check the stop light bulb and holder assembly.

Check Stop Switch Functionality

Verify the operation of the stop switch.

Check Stop Light Connector Voltage

Measure voltage at the stop light connector.

Malaguti CIAK 150cc Troubleshooting Manual

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