Malaguti F10 2008, Workshop Manual

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Page 2: ...cation of electrical components 14 Ignition system 15 Faulty ignition 15 Electrical starting system 18 Faulty electrical starting system 18 Pag Recharging system 22 Battery cannot be charged 22 Lighting system 24 The entire lighting system does not work 24 Headlight does not work 27 Instrument board indicator light does not come on 28 Rear light does not come on 29 Signalling system 30 The entire ...

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: ...of issue Editing symbols Symbols have been provided for quick and easy reference P 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 the 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: ...ric 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 from to approximatel...

Page 8: ... R VR N B AZ B VR B 071128 GL VR N c 21W 5W ON 0FF N N N VL VR VL AR N B R VR VR VL VR AR HORN R L TURN BL N RELAIS BATTERIA BL B R R N BL R N N M R BL BL R BL VL VR N 10 W 10 W W 15 W 15 W VL AR VL RS VR VL BL M N M N N AR BL R BL R R GL R VR R VR N BL B GR N B AZ M N N N N N VR VL R RS 10 A 7 5 A RS RS RS N N VR N GL M N AR AZ GR M AZ 12V 4 Ah N B VR N GL B B GL B A T B R VR N B VR B B AZ GL B V...

Page 9: ... 8 DOUBLE HEADLIGHT 9 FRONT RIGHT TURN INDICATOR 10 INSTRUMENT BOARD 11 PROVISION FOR ALARM SYSTEM 12 KEY SWITCH 13 RIGHT HAND SWITCH 14 STOP SWITCH 15 CAPACITOR 50 V 2200 UF 16 CDI CONTROL UNIT 17 VOLTAGE REGULATOR 18 COIL 19 FUEL LEVEL SENSOR 20 OIL INDICATOR SWITCH 21 rear right turn indicator 22 parking light 5 w 23 rear left turn indicator 24 starter motor 25 relay 26 fuse 10 a 27 fuse 7 5 a ...

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

Page 11: ...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 terminals The symbol identifies terminals i...

Page 12: ...NTINUITY OF CONTACTS Pos Switches 1 REAR STOP SWITCH 2 TURN INDICATOR SWITCH 3 HORN CONTROL 4 FRONT STOP SWITCH 5 LIGHT switch 6 START SWITCH 7 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 3 2 1 4 7 5 6 ...

Page 13: ... 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 malfunctio...

Page 14: ... R I C A L C O M P O N E N T S 9 Battery 10 Capacitor 50 V 2200 UF 11 Fuel level sensor 12 Connector for anti theft system 13 Stator connector 1 Oil indicator switch 2 Horn 3 Flashlight 4 Voltage regulator 5 CDI control unit 6 Starting relay 7 Wire terminals for connection to ground 8 HV coil ...

Page 15: ...n of spark plug See Engine Workshop Manual or Owner s Manual Replace spark plug 2 Spark plug cap resistance 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...

Page 16: ... at 20 C B Secondary winding resistance Connect Tester KΩ Compliant 3 30 3 60 KΩ at 20 C Replace HV coil 4 Resistance of stator pick up Detach connector of flywheel CAUTION check isolation from ground of cables B VR and B AZ Connect Tester KΩ Terminal of Tester White Green cable 1 Terminal of Tester White Light blue cable 2 Pick up resistance 400 460 Ω at 20 C Replace stator ...

Page 17: ...e 1 Terminal of Tester Engine grounding 2 Resistance 790 850 Ω at 20 C Replace stator 6 Key switch Turn key OFF and then ON Check continuity of key switch Tester Ω See Checking switches P 12 Replace key switch 7 Connections of ignition system Check connections of ignition system See Wiring Diagram P 8 Resume connections of ignition system Replace CDI control unit code n 02415700 ...

Page 18: ...Starter motor 4 Starter relay 5 Key switch 6 Front rear Stop switch 7 Start switch 8 Connection of starting system 1 Fuse 10 A Remove fuse Connect Tester Ω to fuse Check continuity of fuse Replace fuse 2 Battery Check condition of battery Minimum voltage 12 5 V Density of electrolytic solution 1280 g dm3 Recharge or replace battery ...

Page 19: ...ter motor 2 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 Replace starter motor 4 Starter relay Connect the battery to the terminals of the starter relay 4 using bridge cables 1 Pole of battery Red cable Pole of battery White Red cable Check operation of the starter motor Replace starter relay ...

Page 20: ... S T A R T I N G S Y S T E M 5 Key switch Turn key OFF and then ON Check continuity Tester Ω See Checking switches P 12 Replace key switch 6 Front rear Stop switch Disconnect cables of switch A Connect Tester Ω to terminals T1 T2 Check continuity between terminals See Checking switches P 12 Replace Stop switch ...

Page 21: ...sconnect four way connector of right hand switch Connect Tester Ω Check continuity of Start button See Checking switches P 12 Replace right hand switch 8 Connections of starting system Check connections of starting system See Wiring Diagram P 8 Resume connections of starting system ...

Page 22: ... 1 Fuse 10 A Remove fuse Connect Tester Ω to fuse Check continuity of fuse Replace fuse Check condition of battery if necessary replace it 2 Battery charging voltage Connect inductive rev counter to spark plug cable Connect Tester 20 V DC as follows Terminal of Tester Battery positive 1 Terminal of Tester Battery negative 2 Run engine at 5000 RPM Check battery voltage Battery charging voltage 13 5...

Page 23: ...onnect Tester Ω as follows Terminal of Tester White cable 1 Terminal of Tester Engine grounding 2 Charging coil resistance 1 1 2 Ω at 20 C Replace stator NO 4 Recharging system connections Check connections of recharging system See Wiring Diagram P 8 Resume connections of recharging system Replace voltage regulator code n 02601100 ...

Page 24: ...tor 4 Continuity of red green cable 5 Continuity of yellow cable 6 Connection of lighting system 1 Fuse 7 5 A Remove fuse Connect Tester Ω to fuse Check continuity of fuse F 2 P 13 Replace fuse 2 Light switch Disconnect right hand switch connector Connect Tester Ω Check continuity of light switch See Checking switches P 12 Replace right hand switch ...

Page 25: ... of Tester Engine grounding 2 Lights coil resistance 0 6 0 9 Ω at 20 C Replace key switch 4 Continuity of red green cable Disconnect connector of regulator and stator Connect Tester Ω as follows Terminal of Tester Red Green cable regulator 1 Terminal of Tester Red Green cable flywheel 2 Check continuity Repair interrupted Red Green cable 5 Continuity of yellow cable Check continuity of Yellow cabl...

Page 26: ... OK OK L I G H T I N G S Y S T E M 6 Connections of lighting system Check connections of lighting system Resume connections of lighting system See Wiring Diagram P 8 Replace voltage regulator code n 02601100 ...

Page 27: ...ling Remove light bulb Connect Tester Ω to light bulb Check continuity of light bulb Replace light bulb or lamp socket 2 Voltage delivered to lamp socket Connect Tester 20 V DC to headlight and instrument board connectors Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Flick light switch to ON Voltage delivered to lamp socket 12 V The Black or Pink cable are...

Page 28: ...1 Continuity of light bulb and relative coupling Remove light bulb Connect Tester Ω to light bulb Check continuity of light bulb Replace light bulb or lamp socket 2 TVoltage delivered to instrument board Connect Tester 20 V AC to instrument board connector as follows Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Voltage delivered to instrument board 12 V P...

Page 29: ...tive coupling Remove light bulb Connect Tester Ω to light bulb Check continuity of light bulb Replace light bulb or coupling 2 Voltage delivered to lamp socket Connect Tester 20 V AC to connector of headlight as follows Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Flick light switch to ON Voltage delivered to lamp socket 12V Repair interruption of Pink ca...

Page 30: ... 10 A 2 Condition of battery 3 Key switch 4 Connections of signalling system 1 Continuity of fuse 10 A Remove fuse Connect Tester Ω to fuse Check continuity of fuse Replace fuse 2 Condition of battery Check condition of battery Minimum voltage 12 5 V Density of electrolytic solution 1280 g dm3 Recharge or replace battery ...

Page 31: ... 3 Key switch Turn key OFF and then ON Check continuity Tester Ω See Checking switches P 12 Replace key switch 4 Connections of signalling system Check connections of signalling system See Wiring Diagram P 8 Resume connections of signalling system ...

Page 32: ...itch Connect Tester Ω as follows Terminal of Tester Orange cable 1 Terminal of Tester Light blue cable 2 Press Horn button to activate horn Check continuity with button pressed Replace left hand switch 2 Voltage delivered to horn Connect Tester 20 V DC as follows Terminal of Tester Orange cable 1 Terminal of Tester Chassis grounding 2 Turn key ON Press Horn button Power measured must be 12 V Resum...

Page 33: ...orn Disconnect Black cable from terminal of horn Using a bridge cable 1 connect horn terminal 2 to chassis ground connection 3 Turn key ON Press Horn button to activate horn Resume connection between Black cable and chassis ground connection See Wiring Diagram P 8 Replace the horn ...

Page 34: ...nt and rear brake switch 3 Light bulb coupling voltage 1 Continuity of light bulb and relative coupling Remove light bulb Connect Tester Ω to light bulb Check continuity of light bulb and its coupling Replace light bulb or coupling 2 Front and rear brake switch Disconnect switch cables A Connect Tester Ω to terminals T1 T2 Check continuity between terminals See Checking switches P 12 Replace Stop ...

Page 35: ...to connector of light bulb coupling as follows Terminal of Tester Red cable 1 Terminal of Tester Black cable 2 Turn key ON Pull front or rear brake lever Power measured must be 12 V NOTE if the ground connection is interrupted the rear light will not be working Red cable is interrupted resume connection See Wiring Diagram P 8 ...

Page 36: ...lashlight 3 Continuity of brown black cable 1 Turn indicator switch Disconnect six way connector of left hand switch Connect Tester Ω as follows Activate right turn indicators Terminal of Tester Brown Black cable 1 Terminal of Tester Green cable 2 Activate left turn indicators Terminal of Tester Brown Black cable 1 Terminal of Tester Purple cable 3 There must be continuity in both situations Repla...

Page 37: ... Tester Blue cable 1 Terminal of Tester Chassis grounding 2 Turn key ON Voltage must be 12 V Blue cable is interrupted repair See Wiring Diagram P 8 3 Continuity of brown black cable Disconnect flashlight connector Disconnect left hand switch connector Connect Tester Ω to terminals of respective connectors Check continuity of Brown Black cable Brown Black cable is interrupted repair See Wiring Dia...

Page 38: ...g 1 Terminal of Tester Coupling 2 Check continuity If there is continuity the float A will move freely and position itself at the base of the probe Replace oil probe 2 Probe voltage Connect Tester 20 V DC as follows Terminal of Tester Blue cable 1 Terminal of Tester Chassis grounding 2 Turn key ON Voltage delivered to oil probe 12 V White Purple cable is interrupted between probe and instrument bo...

Page 39: ...isconnect connector of fuel level sensor S Provide a jumper 1 between Grey cable and Black cable of connector system side Turn key ON and wait a few seconds The fuel level indicator pointer must be on 4 4 Replace fuel level sensor Grey cable is interrupted repair See Wiring Diagram P 8 NO OK 2 Check continuity of grey cable Connect Tester Ω Check continuity of Grey cable between fuel probe connect...

Page 40: ...T E M NO OK Black cable is interrupted repair See Wiring Diagram P 8 Replace fuel level indicator 3 Check ground connection black cable Connect Tester Ω Check continuity of Black cable between fuel sensor and chassis ground connection ...