Malaguti Centro 50 4T, Workshop Manual

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Page 2: ...ses 15 Checking fuses 15 Key to fuses 15 Location of components 16 Page Ignition system 18 The ignition system does not work 18 Charging System 20 Battery cannot be recharged 20 Electrical starting system 22 Starter motor does not work 22 Light system 26 Entire lighting system does not work and carburettor starter cannot be disengaged 26 High beam light does not come on 29 High beam indicator ligh...

Page 3: ...kshop manual and from the Spare Parts catalogue All described operations must be performed by technicians with the necessary skill and experience The steps for the removal of body parts and of electric and mechanical components to allow access to wiring or electric components to service can be taken from the Chassis Workshop Manual We recommend you follow the information given in this publication ...

Page 4: ...issue Editing symbols Symbols have been provided for quick and easy reference see page 5 identifying situations requiring utmost attention or providing practical suggestions or simple information These symbols may appear next to a text in which case they refer solely to the text itself next to a figure in which case they refer to the topic illustrated in the figure and to the relative text or at t...

Page 5: ...OSION Indicates operations which may constitute a risk of explosion TOXIC FUMES Indicates a possibility of intoxication or inflammation of the upper respiratory tract MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician NO Operations to be absolutely avoided M ENGINE WORKSHOP M...

Page 6: ...onent described and illustrated Letters not followed by a number indicate a single screw In case of different screws being referred to in the illustration the letter V is followed by a number and a small letter for instance V4a Unless otherwise specified units and components are reassembled by proceeding in the reverse order of removal Before any servicing make sure that the vehicle is perfectly s...

Page 7: ...the unit of electric power result of Volts by Amps A x V W Ω OHM the unit of electrical resistance Infinite OHM tester prods disconnected or cable interrupted OHM 0 continuity with tester prods connected and cable not interrupted PIN connector terminal Line cable between two PINS less than less than or equal to greater than greater than or equal to KPa or bar the unit of pressure 100 KPa 1 bar fro...

Page 8: ... N GL ON 0FF ON GL RS GL N GL VR N LIGHTS START BL R N GL N N RS B N VL VR BL B BL GR B BL VL FUSE 10 A VR N VL B R N N B R VR B BL BL N GL VL N FUSE 5 A B BL GL B 87 30 N RS RS RS N N RS GR BL VR VL B N RS N BL R N BL R R B R B BL BL GL B R FUSE 10 A 2 3 1 4 1 2 3 4 5 GL R VR N P U B VR B R VR R VR N VR R VR R VR N B VR GL B B M N B AZ N GL GL R VR AZ BL R BL R AZ BL R R R R R VR R VR N 1 2 3 4 5...

Page 9: ... 12 RIGHT HAND SWITCH BLOCK 13 STOP SWITCH 14 RECHARGING SOCKET 15 ELECTRONIC CONTROL UNIT 16 FLYWHEEL MAGNETO 17 VOLTAGE REGULATOR WITH INTERMITTENT FUNCTION 18 RESISTANCE FOR ELECTRICAL STARTER 6 8 Ω 10 W 19 ELECTRICAL STARTER 20 FUEL LEVEL SENSOR 21 RIGHT HAND TURN INDICATOR 22 PARKING LIGHT 23 STOP LIGHT 24 STOP LIGHT 25 PARKING LIGHT 26 LEFT HAND TURN INDICATOR 27 STARTER MOTOR 28 STARTER REL...

Page 10: ...E RED B VL WHITE PURPLE B BL WHITE BLUE B GR WHITE GREY BL BLUE BL N BLUE BLACK BL R BLUE RED BL VR BLUE GREEN GL YELLOW GL B YELLOW WHITE GL N YELLOW BLACK GL VL YELLOW PURPLE GL VR YELLOW GREEN GL R YELLOW RED GL BL YELLOW BLUE GR GREY GR N GREY BLACK GR R GREY RED M BROWN M B BROWN WHITE M N BROWN BLACK N BLACK R RED R VR RED GREEN R N RED BLACK RS PINK RS N PINK BLACK VL PURPLE VL N PURPLE BLA...

Page 11: ...EGULATOR CONNECTOR CONFIGURATION CONTROL UNIT CONNECTOR REGULATOR CONNECTOR PIN CABLE COLOUR FUNCTION PIN CABLE COLOUR FUNCTION 1 N GROUND 1 GL LIGHTS STARTER 2 B VR PICK UP 2 N GROUND 3 GL B STOP KEY OFF 3 AZ RECHARGING 4 B POWER SUPPLY STATOR 4 B POWER SUPPLY STATOR 5 M N INDICATOR OUTPUT ...

Page 12: ...OARD CONNECTOR CONFIGURATION COLOUR FUNCTION RS INSTRUMENT BOARD LIGHTING B N HIGH BEAM VL LEFT HAND TURN INDICATOR VR RIGHT HAND TURN INDICATOR BL WITH KEY ON 12 V N NEGATIVE B BL FUEL LEVEL PROBE BL R DIRECTED TO BATTERY 12 V FOR CLOCK GR FUEL LEVEL PROBE ...

Page 13: ...and lamp sockets CONNECTION OF THE SWITCHES DESCRIBED IN THIS MANUAL This manual contains connection diagrams like the one illustrated hereby which illustrate how switch terminals should be connected key switch brake switch MODE button etc The first column from the left indicates the different positions of the switches the top line indicates the colour of the wires connected to the switch terminal...

Page 14: ...6 7 8 S W I T C H E S POSITION OF SWITCHES AND CONTINUITY OF CONTACTS Pos Switches 1 REAR STOP SWITCH 2 HORN CONTROL 3 LIGHT SWITCH 4 TURN INDICATOR SWITCH 5 FRONT STOP SWITCH 6 MAIN LIGHT SWITCH 7 ENGINE START SWITCH 8 KEY SWITCH ...

Page 15: ...ing procedure Turn key OFF Fit a new fuse with a correct amperage rating Turn key ON Turn all switches on to check operation of the relative electrical systems If the fuse blows again check the relative circuit Never use fuses with an amperage rating differing from that indicated Use only fuses and never other materials An unsuitable fuse can cause extensive damage to the electrical system malfunc...

Page 16: ...16 L O C A T I O N O F C O M P O N E N T S 1 3 1 2 2 3 4 4 5 5 6 7 7 6 1 Fuel probe 2 Spark plug 3 Battery 12V 9Ah 4 C D I control unit 5 Voltage regulator 6 Horn 7 Ground connection unit ...

Page 17: ... N O F C O M P O N E N T S 12 13 9 8 9 13 12 11 11 10 10 8 8 Resistance 6 8 7 0 Ω for electrical starter 9 Key switch 10 Starter relay 11 Recharging socket 12 Provision for anti theft system 13 Stator pick up connector ...

Page 18: ...al Faulty spark plug replace it 2 Spark plug cap Remove spark plug cap NOTE when removing spark plug cap avoid pulling it To remove turn anti clockwise To connect turn clockwise Before connecting the spark plug cap check the HV cable and cut off a piece of approximately 5 mm Connect Tester KΩ to spark plug cap as follows Terminal of Tester Spark plug side 1 Terminal of Tester High voltage cable si...

Page 19: ...l 1 Terminal of Tester Engine grounding 2 Resistance 150 170 Ω at 20 C Stator is faulty replace it 4 Key switch See Checking switches P 13 Always check grounding isolation of Yellow White cable between key switch and CDI control unit Replace key switch 5 Wiring connections Check connections of entire ignition system See Wiring Diagram P 8 Repair wiring Replace the C D I control unit code 02411900 ...

Page 20: ...echarging voltage 3 Resistance of stator 4 Charging system wiring 1 Fuse 10 A See Checking fuses P 15 Replace fuse Check wiring between 10 A fuse holder n 1 and key switch 2 Check charging voltage Connect Tester DC 20 V 2000 RPM 13 V 4000 RPM 14 14 5 V The recharging circuit is working replace battery Repair See Wiring Diagram P 8 Replace regulator code n 02602800 Tester DC 20 V ...

Page 21: ... way connector of wiring and connect Tester Ω to flywheel connector V Terminal of Tester Terminal 1 Terminal of Tester Engine grounding 2 Resistance 0 7 1 Ω at 20 C Stator is faulty replace it 4 Checking wiring connections Check connections of the entire charging system See Wiring Diagram P 8 Put wiring in working order Replace regulator code n 02602800 ...

Page 22: ...hecking fuses P 15 Replace fuse Eliminate short circuit of wiring 2 Battery Remove battery and connect Tester 20 V DC as follows Terminal of Tester Battery pole Terminal of Tester Battery pole If voltage level is lower than 12 4 V recharge using a suitable battery charger After charging the battery do not use it for approximately 30 minutes now measure voltage level again 12 8 V or more Battery is...

Page 23: ...ry to the starter motor and check if the latter is working Replace starter motor 4 Starter relay Detach relay connector Connect Tester Ω and battery 12V to relay terminals as follows Battery pole Terminal 86 Battery pole Terminal 85 Terminal of Tester Terminal 87 Terminal of Tester Terminal 30 Never invert battery connections on relay terminals Replace relay ...

Page 24: ...place key switch 6 Start switch Detach six way connector of right hand switch and connect Tester Ω as follows Terminal of Tester White Red cable Terminal of Tester Black cable Press Start button and check continuity Replace right hand switch GL V RS GL B GL N B R N ON 0FF ON 0FF ON GL LIGHTS START GL V RS GL B GL N B R N ...

Page 25: ... Disconnect Red and Blue cable from Stop switch 1 Connect Tester Ω as follows Terminal of Tester Terminal 2 Terminal of Tester Terminal 3 Operate brake lever and check continuity Replace Stop switch 8 Wiring connections Check connections of entire starting system See Wiring Diagram P 8 Put wiring in working order ...

Page 26: ...ed Check 1 Fuse 10 A 2 Stator 3 Continuity of White cable stator 4 Regulator voltage output 5 Ground connection cable 1 Fuse 10 A See Checking fuses P 15 Replace fuse 2 Stator Run engine at 1900 2000 RPM Detach connector of voltage regulator Connect Tester 200 V AC to voltage regulator connector as follows Terminal of Tester White cable PIN 4 1 Terminal of Tester Chassis grounding 2 Value measured...

Page 27: ...nector of voltage regulator as follows Terminal of Tester Yellow cable PIN 1 1 Terminal of Tester Black cable PIN 2 2 Value read must be approximately 12 Volts Check wiring Yellow and Red Green cable between regulator carburettor starter and light switch See Wiring Diagram P 8 Replace stator Repair interrupted White cable See Wiring Diagram P 8 3 Continuity of White cable stator Check continuity o...

Page 28: ... S T E M Replace regulator code n 02602800 5 Check ground connection Disconnect regulator connector Connect Tester Ω to regulator connector as follows Terminal of Tester Black cable PIN 2 1 Terminal of Tester Chassis grounding 2 Check continuity Resume ground connection Black cable See Wiring Diagram P 8 ...

Page 29: ...ter 20 V AC to headlight connector as follows Terminal of Tester White Black cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Flick light switch to symbol Flick light switch to HI symbol Power measured must be 12 V White black cable between left hand switch and headlight connector is interrupted repair it See Wiring Diagram P 8 Tester AC 20 V 2 Check light switch left hand switch Se...

Page 30: ... voltage Connect Tester 20 V AC to instrument board connector as follows Terminal of Tester White Black cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Flick light switch to symbol Flick light switch to HI symbol Power measured must be 12 V Instrument board wiring is interrupted repair it See Wiring Diagram P 8 White Black cable between left hand switch headlight and instrument boa...

Page 31: ...ster 20 V AC to headlight connector as follows Terminal of Tester White Light Blue cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Flick light switch to symbol Flick light switch to LO symbol Power measured must be 12 V White Light Blue cable between left hand switch and headlight is interrupted repair See Wiring Diagram P 8 Tester AC 20 V 2 Check light switch left hand switch See ...

Page 32: ... AC to instrument board connector as follows Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Flick light switch to symbol Power measured must be 12 V Instrument board wiring is interrupted repair it See Wiring Diagram P 8 Pink cable between right hand switch headlight and instrument board connector is interrupted repair it See Wiring Diagram P 8 Tester AC 20...

Page 33: ...k voltage Connect Tester 20 V AC to six way connector of tail light wiring as follows Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Flick light switch to symbol Power measured must be 12 V Wiring of tail light 3 is interrupted repair it See Wiring Diagram P 8 Pink cable between tail light connector and right hand switch is interrupted repair it See Wiring ...

Page 34: ...lamp and or lamp socket 2 Check voltage Connect Tester 20 V AC to two way connector of wiring as follows Terminal of Tester Pink cable 1 Terminal of Tester Ground 2 Run engine at 5000 RPM Flick light switch to symbol Power measured must be 12 V Black cable is interrupted repair it See Wiring Diagram P 8 Pink cable between parking light connector and right hand switch is interrupted repair it See W...

Page 35: ...es not come on 1 Stop fuse 5 A See Checking fuses P 15 Replace fuse Eliminate short circuit of wiring 2 Check lamp and lamp socket See Pr Checking Switches P 13 Replace lamp and or lamp socket 3 Check Stop switch front rear See Pr Checking Switches P 13 Replace Stop switch ...

Page 36: ...six way connector of tail light wiring as follows Terminal of Tester Red cable 1 Terminal of Tester Black cable 2 Turn key ON Operate right and left brake levers Power measured must be 12 V Red cable is interrupted repair it See Wiring Diagram P 8 Wiring of tail light 3 is faulty repair it See Wiring Diagram P 8 ...

Page 37: ...ches P 13 Turn indicator switch is faulty Replace left hand switch 2 Check voltage Test A Detach connector from regulator and connect Tester 20 V DC as follows Terminal of Tester Light blue cable PIN 3 1 Terminal of Tester Black cable PIN 2 2 Turn key ON Power measured must be 12 V Check continuity of Brown Black cable between PIN 5 of regulator connector and connector of left hand switch Brown Bl...

Page 38: ...r 20 V DC as follows Terminal of Tester Light blue cable PIN 3 1 Terminal of Tester Chassis grounding 2 Turn key ON Power measured must be 12 V Light blue cable between key switch and regulator connector PIN 3 is interrupted repair it See Wiring Diagram P 8 Always check continuity of Black cable PIN 2 and chassis ground connection Replace voltage regulator Repeat all checks from the beginning test...

Page 39: ... Switches P 13 Replace left hand switch 2 Check voltage Connect Tester 20 V DC to connector of left hand switch 3 as follows Terminal of Tester Blue cable 1 Terminal of Tester Chassis grounding 2 Turn key ON Power measured must be 12 V Blue cable is interrupted repair it See Wiring Diagram P 8 Tester DC 20 V ...

Page 40: ...ntinuity Orange cable between left hand switch and horn is interrupted repair it See Wiring Diagram P 8 Black cable is interrupted repair it See Wiring Diagram P 8 Tester Ω 3 Horn Disconnect horn cables 3 Connect Tester DC 20 V to terminals as follows Terminal of Tester Orange cable 1 Terminal of Tester Black cable 2 Turn key ON Press HORN button Power measured must be 12 V Never invert position o...

Page 41: ...f probe Float up A Resistance 34 Ω Float down B Resistance 568 Ω Terminal of Tester White Blue cable 3 Terminal of Tester Green cable 2 Check resistance of probe Float up A Resistance 568 Ω Float down B Resistance 34 Ω Fuel probe is faulty replace it 2 Check ground connection Connect Tester Ω to fuel probe connector system side as follows Terminal of Tester Black cable 1 Terminal of Tester Chassis...

Page 42: ...rd wiring connector Tester Ω Replace instrument board Wiring is interrupted Grey and or White Blue cable repair it See Wiring Diagram P 8 CLOCK DOES NOT WORK 1 Check voltage Detach two way connector of clock Connect Tester 20 V DC as follows Terminal of Tester Blue Red cable 1 Terminal of Tester Black cable 2 Power measured must be 12 V key OFF Clock is faulty replace it Blue Red or Black is inter...

Page 43: ... or recharging system 1 Faulty regulator excessive recharging Key ON engine off the indicator moves thus indicating actual battery voltage A F 32 Voltage measured 12 3 12 6 V Key ON engine started when revving up to over 4000 RPM the indicator moves beyond the maximum recharging mark B F 32 Key OFF indicator returns to end of stroke C F 33 2 Faulty flywheel or regulator no recharging Key ON engine...

Page 44: ...beyond maximum recharging position and rests against the glass of the instrument board D F 34 Key OFF the indicator remains against the glass of the instrument board until the fuse and or battery are replaced D F 34 4 Battery is flat V 0 Key ON engine off indicator does not move C F 33 Key ON engine started using the starter lever in idling condition after a few minutes the indicator reaches the f...