Malaguti CIAK MASTER 50-4T Electric System Troubleshooting Download

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CIAK MASTER 50-4T

ELECTRIC SYSTEM

TROUBLESHOOTING

WORKSHOP MANUALS

Summary of Contents for CIAK MASTER 50-4T

Page 1: ...CIAK MASTER 50 4T B ELECTRIC SYSTEM TROUBLESHOOTING WORKSHOP MANUALS ...

Page 2: ...age layout 1 6 Modified pages 1 6 Additional pages 1 6 Editing symbols 1 6 Abbreviations 1 8 TROUBLESHOOTING 2 9 Electrical components 2 9 General wiring diagram 2 11 Checking switches 2 12 Checking procedures 2 12 Connection of the switches described in this manual 2 12 Checking fuses 2 13 Position of switches and connection of connectors 2 14 Troubleshooting 2 15 Checking light system 2 24 Troub...

Page 3: ...nd Spare Parts Catalogue All described operations must be performed by technicians with the necessary skill and experience The steps for 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 with care For any further i...

Page 4: ... Symbols have been provided for quick and easy reference see page 7 They identify situations requiring utmost attention practical advice 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 top of the page in which case they...

Page 5: ...ons which may constitute a fire hazard D RISK OF EXPLOSION Indicates operations which may constitute a risk of explosion E TOXIC FUMES Indicates a possibility of intoxication or inflammation of the upper respiratory tract F MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic G ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician...

Page 6: ... 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 stable The front wheel should preferably be anchored to ...

Page 7: ...YSTEM TROUBLESHOOTING ENGLISH SECTION 2 Electrical components SECTION 2 B TROUBLESHOOTING ELECTRICAL COMPONENTS 1 HORN 2 SWITCH WITH KEY 3 STARTING RELAY 4 FUEL PROBE 5 HV COIL 6 BATTERY 7 C D I CONTROL UNIT 8 VOLTAGE REGULATOR 9 RESISTANCE ...

Page 8: ...B 10 10 05 CHAPTER PAGE ISSUE ELECTRIC SYSTEM TROUBLESHOOTING ENGLISH SECTION 2 General wiring diagram SECTION 2 B TROUBLESHOOTING 1 2 3 4 6 5 7 8 9 10 11 12 13 14 15 16 17 18 13 19 20 21 22 ...

Page 9: ...LUE GR GREY AZ B LIGHT BLUE WHITE M BROWN B WHITE M B BROWN WHITE B N WHITE BLACK N BLACK KEY TO THE GENERAL WIRING DIAGRAM 1 12V BATTERY 2 RELAY 3 STARTER MOTOR 4 REAR LEFTTURN INDICATOR 5 REAR OPTICAL UNIT 6 REAR RIGHTTURN INDICATOR 7 FUEL LEVEL SENSOR 8 VOLTAGE REGULATOR 9 ELECTRICALSTARTER 10 CHASSIS GROUNDING 11 RESISTANCE 12 FRONTRIGHTTURN INDICATOR 13 STOP LIGHT 14 RIGHT HAND SWITCH BLOCK 1...

Page 10: ...t the tester to its correct 0 position before connecting the switches 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 start button etc The first column from the left indicates the different positions of the switch and the top line the colour...

Page 11: ...n If the tester is showing I and no sound is given replace the fuse Replacing procedure Turn the key OFF Install a new fuse with a correct amperage rating Turn the key ON Turn the switches on to check operation of the relative electrical systems If the fuse blows again check the relative circuit CAUTION never use fuses with an amperage rating differing from that indicated Use only fuses and never ...

Page 12: ... POSITION OF SWITCHES AND CONNECTION OF CONNECTORS 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 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: ...OTE 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 K to spark plug cap as follows Terminal of Tester Spark plug side 1 Terminal of Tester High voltage cable side 2 Spark plug cap resistance 5 K at 20 C Replace spark plug cap NOT COM...

Page 14: ... of Tester Black cable 1 Terminal of Tester White black cable 2 Key ON No continuity Key OFF Continuity CAUTION If the white black cable is crushed it can form a grounding contact and the engine will not start 1 2 Replace key switch COMPLIANT NOT COMPLIANT OK 5 Wiring connections Check connections of ignition system See Wiring Diagram Replace the C D I control unit FAULTYCONNECTIONS Repair wiring ...

Page 15: ...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 charged 12 5 V Battery needs to be recharged 12 0 V Replace battery BATTERY OK 3 Check charging voltage use a charged battery Connect Tester DC 20 V to battery ...

Page 16: ...g 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 Resistance 0 7 1 5 Checking wiring connections Check connections of the entire charging system See Wiring Diagram NOT COMPLIANT COMPLIANT Replace Voltage Regulator Put wiring in working order see Wiring Diagram ...

Page 17: ...tart switch 7 Front rear stop switch 8 Starting system wiring connections 1 Main 10A fuse Remove relative fuse Connect Tester to fuse Check continuity of fuse NOCONTINUITY CONTINUITY Replace fuse N 12V 12V N 2 Battery Check condition of battery See page 17 NOT COMPLIANT Replace battery 3 Checking starter motor Using two cables connect 12 V battery to starter motor see figure MOTOR DOES NOT RUN Rep...

Page 18: ...Battery pole Terminal 86 Battery pole Terminal 85 Caution never invert battery connections on relay terminals Terminal of Tester Terminal 87 Terminal of Tester Terminal 30 NOCONTINUITY Replace relay CONTINUITY 85 30 86 87 5 Key switch Detach four way connector of switch Connect Tester as follows Terminal of Tester Red cable 1 Terminal of Tester Brown cable 2 Key ON Continuity Key OFF No continuity...

Page 19: ...ck cable Press Start button and check continuity NOCONTINUITY Replace right hand switch CONTINUITY 7 Front rear stop switch Disconnect red cable and white grey cable of stop switch 3 ConnectTester as follows Terminal of Tester Terminal 1 Terminal of Tester Terminal 2 Operate brake lever and check continuity NOCONTINUITY Replace stop switch CONTINUITY 3 1 2 8 Wiring connections Check connections of...

Page 20: ...Replace stator NOT COMPLIANT COMPLIANT 2 Stator Run engine at 1900 2000 RPM NOTE wait for the throttle to disengage engine idling speed stabilised Detach connector 1 of regulator Connect Tester AC200V to regulator connector as follows Terminal of Tester White cable Pin4 Terminal of Tester Chassis grounding The value read must be approximately 25 40 V when throttle is disengaged 1 Check wiring betw...

Page 21: ...ounding Run engine at 1900 2000 RPM Value read must be approximately 12 Volts Black cable Pin2 interrupted Repair by providing jumper between regulator Pin2 and grounding point on chassis S CAUTION For the above mentioned voltage measurements use an analogue tester for alternating voltage measurements and keep engine at idling speed to obtain an alternating voltage with a frequency level as close ...

Page 22: ...CATOR LIGHT DOES NOT COME ON 2 1 Check voltage level Connect Tester AC 20 V to instrument board connector as follows Terminal ofTester White blackcable 1 Terminal of Tester Black cable 2 Run engine at approx 2000 RPM Flick light switch to symbol Flick light switch to HI symbol Value read must be approximately 12 Volts 1 2 NOT COMPLIANT COMPLIANT System is working Check lamp and lamp socket of inst...

Page 23: ...amp and or lamp socket CONTINUITY 3 2 Checking voltage level Detach cables of headlight and connect Tester DC 20V as follows Terminal of Tester Blue white cable 1 Terminal of Tester Black cable 2 Run engine at approx 2000 RPM Flick light switch to symbol Flick light switch to LO symbol Value read must be approximately 12 Volts 2 1 BL B N NOT COMPLIANT The blue white cable between left hand switch ...

Page 24: ...ight switch to symbol Value read must be approximately 12 Volts NOT COMPLIANT 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 Run engine at approx 2000 RPM Flick light switch to symbol Value read must be approximately 12 Volts NOT COMPLIANT Pink cable b...

Page 25: ...ge 12 NOT COMPLIANT 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 Pink cable 1 Terminal of Tester Black cable 2 Run engine at approx 2000 RPM Flick light switch to symbol Value read must be approximately 12 Volts 2 1 RS N Pink cable between headlight and right hand switch is interrupted Repair See Wiri...

Page 26: ...NUITY Replace stop switch CONTINUITY NOT COMPLIANT TROUBLESHOOTING 1 STOP LIGHT DOES NOT COME ON 1 1 Check 10 A fuse See Checking switches section on page 12 1 4 Checking voltage level Connect Tester DC 20 V to tail light as follows Terminal of Tester Red cable 1 Terminal of Tester Black cable 2 Turn key ON Operate brake lever Value read must be approximately 12 Volts 1 2 Red cable is interrupted ...

Page 27: ... indicator switch See Checking switches section on page 12 NOCONTINUITY Fault turn indicator switch Replace left hand switch CONTINUITY 2 3 Checking voltage level test A 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 Value read must be approximately 12 Volts Check continuity of brown cable bet...

Page 28: ...LIANT Blue cable between key switch and regulator connector Pin3 is interrup ted Repair see wiring diagram 2 5 Checking regulator test B Provide jumper between brown cable Pin5 and blue cable Pin3 of connector A Turn key ON Operate right left turn indicator switch to make sure that indicators come on and remain steadily lit INDICATORSARE ALWAYS ON Replace voltage regulator INDICATORS DO NOT COME O...

Page 29: ...ITY Black cable is interrupted Repair See Wiring Diagram CONTINUITY 3 3 Horn Disconnect horn cables 3 Connect Tester DC 20 V to terminals as follows Terminal of tester Blue cable 1 Terminal of Tester Orange cable 2 Turn key ON Press HORN button Value read must be approximately 12 Volts CAUTION never invert position of cables 2 3 1 COMPLIANT Replace horn NOT COMPLIANT 3 HORN IS NOT WORKING 3 1 Horn...

Page 30: ... read must be 12 V NOT COMPLIANT Blue cable between key switch and horn is interrupted Repair see wiring diagram COMPLIANT Orange cable between left hand switch and horn is interrupted Repair See Wiring Diagram Fuel probe is faulty Replace INDICATOR HAND ON INSTRUMENT BOARD DOES NOT MOVE INDICATOR HAND IS POINTING TO FULL 1 4 FUEL LEVEL INDICATOR IS NOT WORKING 4 1 Fuel probe Detach connector of p...

Page 31: ...instrumentboardisinterrupted Repair see wiring diagram 5 1 Fuel probe Detach connector of probe Provide jumper between grey cable and black cable of three way wiring connector 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 ON INSTRUMENT BOARD DOES NOT MOVE ...

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