Malaguti F12R AIR 50 cc. - Euro 2 Workshop Manual Download

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F12R L.C. 50 cc. - Euro 2

TROUBLESHOOTING

ELEcTRIcaL aNd IGNITION SySTEm

WORKSHOP maNUaL

Summary of Contents for F12R AIR 50 cc. - Euro 2

Page 1: ...F12R L C 50 cc Euro 2 B TROUBLESHOOTING electrical and ignition system WORKSHOP MANUAL ...

Page 2: ...IRING DIAGRAM 2 8 Colour key 2 9 Key to general wiring diagram 2 9 Configurazione connettore cruscotto 2 10 CHECKING SWITCHES 2 11 Checking procedures 2 11 Connection of switches 2 11 Position of switches and connection of connectors 2 12 FUSE 2 13 Checking fuses 2 13 IGNITION SYSTEM 2 14 Troubleshooting 2 14 STARTING SYSTEM 2 17 Troubleshooting 2 17 CHARGING SYSTEM 2 21 Troubleshooting 2 21 LIGHT...

Page 3: ...he 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 with care For any furth...

Page 4: ...ded for quick and easy reference see page 6 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 top of the page in which case they refer t...

Page 5: ...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 H NO Operations to be ab...

Page 6: ...in the unit or component 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 veh...

Page 7: ... 1 AMBIENT TEMPERATURE PROBE 2 KEY SWITCH 3 RECHARGING SOCKET 4 OIL INDICATOR SWITCH 5 HORN 6 FLASHLIGHT 7 VOLTAGE REGULATOR 8 CDI CONTROL UNIT 9 STARTING RELAY 10 grounding wire terminals 11 H2 O TEMPERATURE SENSOR 12 BATTERY 13 FUEL RESERVE SWITCH 14 CHOKE CONTROL 15 FUEL LEVEL SENSOR ...

Page 8: ... R BL R BL R N R AZ BL RS R R VR N R N N BL B VL N B VR GR N GL GL R M N N N N N N VR VL R RS 10 A 7 5 A RS RS RS N R BL GL BL B VL BL R B GR R VL N GR B VR BL VR RS RS RS N N BL N VR N VR N N 5 A N R GL M N AR AZ N BL R B VL BL VR N BL BL VR VR N R N GR R B R A A B B AZ BL R Interruttore spia olio mix Interruttore riserva carburante Sonda livello carburante MODE Signal rinvio Alim 5V Alim 12V V b...

Page 9: ... LIGHT 12 REAR RIGHT TURN INDICATOR 13 OIL INDICATOR SWITCH 14 FUEL RESERVE SWITCH 15 H2 O TEMPERATURE SENSOR 16 FUEL LEVEL SENSOR COLOUR KEY AR ORANGE AR BL ORANGE BLUE R VR RED GREEN AZ LIGHT BLUE B WHITE B VL WHITE PURPLE B VR WHITE GREEN B VL WHITE PURPLE B BL WHITE BLUE B R WHITE RED BL BLUE BL R BLUE RED BL VR BLUE GREEN GL YELLOW GL BL YELLOW BLUE 17 VOLTAGE REGULATOR 18 CDI CONTROL UNIT 19...

Page 10: ...LIGHT INDICATOR RS 4 BACKLIGHTING RS 5 AMBIENT TEMPERATURE N R 6 KEY ACTIVATION 12V BL 7 VDC HALL SENSOR 5V GL BL 8 MIXTURE OIL B VL 9 BATTERY POSITIVE BL R 10 11 12 13 HALL SENSOR SIGNAL B 14 MODE BUTTON GR R 15 16 LEFT TURN INDICATOR VL 17 GND N 18 FUEL PROBE GR 19 WTEMP RESIST PROBE B VR 20 21 22 23 24 FUEL RES WARNING LIGHT BL VR 24 PIN ...

Page 11: ...CONNECTION OF 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 switch the top line the colour of the wires connected to the switch terminals The symbol identifies terminals...

Page 12: ...ON 0FF N B R OFF ON N BL GL B BL R VR N BL N POSITION OF SWITCHES AND CONNECTION OF CONNECTORS 1 REAR STOP SWITCH 2 TURN INDICATOR SWITCH 3 HORN CONTROL 4 FRONT STOP SWITCH 5 MODE BUTTON 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 ...

Page 13: ...function If the tester is showing I and no sound is given replace the fuse Replacing procedure Turn key OFF Fit a new fuse with a correct amperage rating Turn key ON Turn 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 other mat...

Page 14: ...lug cap NOTE when removing spark plug cap do not pull 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 side 2 Spark plug cap resistance 5 KΩ at 20 C Not compliant replace sp...

Page 15: ...er PIN 1 GND Terminal of Tester PIN 2 PICK UP Resistance 335 385 Ω at 20 C F 7b Not compliant Replace CDI control unit code n 02411000 4 Stator pick up resistance Remove two way connector of wiring Connect Tester Ω to connector of flywheel magneto V Terminal of Tester Red cable 1 Terminal of Tester Ground 2 Stator pick up resistance 195 205 Ω at 20 C Not compliant replace stator F 7a 1 V 1 2 1 F 7...

Page 16: ...tion system See Wiring Diagram 5 Continuity of key switch Disconnect key switch from system Connect Tester Ω as follows Terminal of Tester Yellow white cable 1 Terminal of Tester Black cable 2 Turn key OFF and then ON Check continuity of key switch Not compliant replace key switch see Checking switches on page 11 F 9 OFF ON N BL GL B BL R VR N BL N 1 2 C F 10 1 2 3 4 POS CABLE DESTINATION 1 GND N ...

Page 17: ...RELAY 5 KEY SWITCH 6 FRONT REAR STOP SWITCH 7 START SWITCH START 8 CONNECTION OF STARTING SYSTEM 1 Continuity of 10A 5A fuse Remove fuse Connect Tester Ω to fuse Check continuity of fuse Not compliant replace fuse 2 Condition of battery Check condition of battery Minimum voltage 12 5 V Density of electrolytic solution 1 280 g dm3 Not compliant clean terminals Recharge or replace battery F 11 F 12 ...

Page 18: ... Check operation of the starter motor Not compliant replace starter motor 4 Starting relay Connect the battery to the terminals of the starting relay 4 using bridge cables 1 as follows cable of battery Red cable cable of battery Red white cable CAUTION never invert battery connections When connecting the battery to the relay avoid triggering short circuits between the positive and negative termina...

Page 19: ...k continuity of key switch Not compliant replace key switch see Checking switches on page 11 6 Front rear stop switch Disconnect switch cables A Connect Tester Ω to terminals T1 T2 Check continuity between terminals Not compliant replace stop switch See Checking switches on page 11 F 15 OFF ON N BL GL B BL R VR N BL N F 16 A T 1 T 2 1 2 1 Front or rear brake lever pulled 2 Front or rear brake leve...

Page 20: ...ollows Terminal of Tester White red cable 1 Terminal of Tester Black cable 2 Press START button Check continuity Not compliant replace right hand switch 8 Connections of starting system Check connections of starting system Not compliant resume connections of starting system See Wiring Diagram ON 0FF N START ON 0FF BL MODE GR R N B R BL GR R B R F 17 Tester W 2 1 ...

Page 21: ... Tester Ω to fuse Check continuity of fuse Not compliant replace fuse 2 Battery charging voltage Connect inductive rev counter to spark plug cable Connect Tester 20 VDC to battery as follows Terminal of Tester terminal of battery 1 Terminal of Tester terminal of battery 2 Start engine and run it at 5000 RPM Check battery voltage Charging voltage 13 5 14 5 V Not compliant continue searching NOTE us...

Page 22: ... Terminal of Tester Yellow cable 1 Terminal of Tester Ground 2 Charging coil resistance 1 1 2 Ω at 20 C Not compliant replace stator 4 Connections of recharging system Check connections of recharging system Compliant replace voltage regulator code n 02602600 Not compliant resume connections of recharging system See Wiring Diagram 1 GL R 2 F 20 Tester W ...

Page 23: ...TION OF LIGHTING SYSTEM 1 Continuity of 7 5A fuse Remove fuse Connect Tester Ω to fuse Check continuity of fuse Not compliant replace fuse 2 Lighting system coil resistance Detach connector of flywheel magneto Connect Tester Ω as follows Terminal of Tester Yellow cable 1 Terminal of Tester Ground 2 Lighting system coil resistance 1 1 2 Ω at 20 C Compliant continue searching Not compliant replace s...

Page 24: ...ctor and regulator connector Repair See Wiring Diagram 4 Voltage regulator Connect Tester 20 V AC to connector of regulator leaving it plugged in as follows Terminal of Tester Red green cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Voltage 12 V Not compliant replace voltage regulator code n 02602600 5 Connections of lighting system Check connections of lighting system Not complia...

Page 25: ...connector of headlight as follows Terminal of Tester Pink cable 1 Terminal of Tester Black cable 2 Run engine at 5000 RPM Voltage delivered to lamp socket 12 V Not compliant pink cable is interrupted Repair See Wiring Diagram N 35 W 35 W RS RS N A A B B H8 H8 F 25 1 2 1 Continuity of light bulb and relative coupling Remove light bulb Connect Tester Ω to light bulb Check continuity of light bulb No...

Page 26: ...R B VR BL VR VR PIN 17 PIN 3 Tester AC 20 V 1 Voltage delivered to instrument board Connect Tester 20 V AC to instrument board connector as follows Terminal of Tester Pink cable PIN 3 Terminal of Tester Black cable PIN 17 Run engine at 5000 RPM Voltage delivered to instrument board 12 V Compliant replace instrument board Not compliant pink cable is interrupted Repair See Wiring Diagram NOTE if the...

Page 27: ...b Connect Tester Ω to light bulb Check continuity of lamp Not compliant replace lamp 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 Voltage delivered to lamp socket 12 V Not compliant pink cable is interrupted Repair See Wiring Diagram F 27 1 2 Tester AC 20 V ...

Page 28: ...Y 3 KEY SWITCH 4 CONNECTIONS OF SIGNALLING SYSTEM 1 Continuity of 10A fuse Remove fuse Connect Tester Ω to fuse Check continuity of fuse Not compliant replace fuse 2 Condition of battery Check condition of battery Minimum voltage 12 5 V Density of electrolytic solution 1 280 g dm3 Not compliant clean terminals Recharge or replace battery F 28 BATTERIA 12 V 5Ah F 29 Tester W ...

Page 29: ...nal of Tester Blue Red cable 1 Terminal of Tester Blue cable 2 Check continuity of key switch Not compliant replace key switch See Checking switches on page 11 4 Connections of signalling system Check connections of signalling system Not compliant resume connections of signalling system See Wiring Diagram F 30 OFF ON N BL GL B BL R VR N BL N 1 2 Tester W ...

Page 30: ...nge cable 1 Terminal of Tester Light blue cable 2 Check continuity of switch with button pressed Not compliant replace left hand switch 2 Voltage delivered to horn Connect Tester 20 V DC to horn as follows Terminal of Tester Orange cable 1 Terminal of Tester Chassis grounding 2 Turn key ON Press Horn button Voltage delivered to horn 12 V Not compliant resume connections of horn power supply circui...

Page 31: ...etween black cable and chassis grounding See Wiring Diagram Not compliant replace horn IIf stop light is not working check 1 CONTINUITY OF 5 A FUSE 2 CONTINUITY OF LIGHT BULB AND RELATIVE COUPLING 3 FRONT AND REAR BRAKE SWITCH 4 VOLTAGE DELIVERED TO LIGHT BULB COUPLING 1 Continuity of 5A fuse Remove fuse Connect Tester Ω to fuse Check continuity of fuse Not compliant replace fuse NOTE if 5A fuse i...

Page 32: ...eplace stop switch See Checking switches on page 11 4 Voltage delivered to light bulb coupling Connect Tester 20 V DC 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 Voltage delivered to light bulb coupling 12 V Not compliant red cable interrupted Resume connection See Wiring Diagram NOTE if t...

Page 33: ...use 2 Turn indicator switch Disconnect six way connector of left hand switch Connect Tester Ω to cables 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 cases Not compliant replace left hand switch F...

Page 34: ...nt blue cable interrupted Repair See Wiring Diagram 4 Continuity of brown black cable Detach flashlight connector Disconnect left hand switch connector Connect Tester Ω to terminals of respective connectors Check continuity of brown black cable Compliant replace flashlight Not compliant brown black cable between flashlight and left hand switch interrupted Repair See Wiring Diagram F 40 1 2 F 39 M ...

Page 35: ...o right or left lamp socket Connect Tester 20 V DC to connector of light bulb coupling as follows Left turn indicator A Terminal of tester Purple cable 1 Terminal of Tester Chassis grounding 2 Right turn indicator B Terminal of Tester Green cable 3 Terminal of Tester Chassis grounding 4 Turn key ON Operate switch to activate left turn indicators A Operate switch to activate right turn indicators B...

Page 36: ...3 CONTINUITY OF GREY RED CABLE 1 Continuity of Mode button Disconnect four way connector of right hand switch Connect Tester Ω to connector as follows Terminal of Tester Blue cable 1 Terminal of Tester Grey red cable 2 Press MODE button Check continuity Not compliant replace right hand switch ON 0FF N START ON 0FF BL MODE GR R N B R BL GR R B R F 42 1 2 Tester W ...

Page 37: ...Voltage delivered to Mode button Connect Tester 20 V DC to connector system side as follows Terminal of Tester Blue cable 1 Terminal of Tester Chassis grounding 2 Turn key ON Voltage delivered to right hand switch 12 V Not compliant blue cable interrupted Repair See Wiring Diagram ON 0FF N START ON 0FF BL MODE GR R N B R BL GR R B R F 43 1 2 Tester DC 20 V ON 0FF N START ON 0FF BL MODE GR R N B R ...

Page 38: ...is performed in accordance to the following table Liquid temperature alarm When temperature of liquid reaches its threshold the last segment of the bar graph comes on the relative alarm is activated The liquid temperature warning light will come on To avoid false alarms this alarm is activated only if the contact remains grounded for a period of more than ten seconds F 46 L H C Resistance W Segmen...

Page 39: ...ere is continuity the float will move freely and position itself at the base of the probe Not compliant replace oil probe F 47 2 Check voltage level Connect Tester 20 V DC to connector system side as follows Terminal of Tester Blue cable 1 Terminal of Tester Chassis grounding 2 Turn key ON Voltage delivered to oil probe 12 V Compliant white purple cable interrupted between probe and digital instru...

Page 40: ...this message appears only if the contact remains closed in positive mode for at least 15 seconds The alarm is displayed irrespective of the function selected F 49 If the fuel level signal is not correct check 1 RESISTANCE OF FUEL PROBE 2 CONTINUITY OF GREY CABLE F 50 F 51 NOTE the information is displayed in graphic form by means of a bar graph with eight segments located on the bottom right of th...

Page 41: ...ds THE INDICATOR WARNING LIGHT CHECK IS PERFORMED Bar graph with 0 segments continue searching Bar graph with 8 segments replace fuel probe F 52 GR N 1 S Fuel level litres Resistance Ω Segments 2 5 not readable 3 5 85 1 6 6 5 75 84 2 6 51 7 64 74 3 7 1 7 5 52 63 4 7 6 8 41 51 5 8 1 8 5 30 40 6 8 6 9 15 29 7 9 2 9 9 full 14 8 1 Resistance of fuel probe Probe readings take place in accordance to the...

Page 42: ...fuel probe connector 1 and instrument board connector PIN 18 2 Compliant black cable interrupted probe connector Repair See Wiring Diagram Not compliant grey cable interrupted Repair See Wiring Diagram F 53 2 1 2 3 4 5 6 7 8 9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 RS RS RS N R BL GL BL B VL BL R B GR R VL N GR B VR BL VR VR 1 GR N Tester W ...

Page 43: ...shing along with the fuel icon to warn the user that the vehicle s reserve level has been reached To avoid false alarms this alarm is activated only if the contact remains grounded for a period of more than ten seconds F 54 CAUTION If the probes are faulty the alarm condition will be displayed by the fuel icon and contour of the bar graph flashing but no segment will come on To avoid false alarms ...

Page 44: ...delivered to rev counter sensor Disconnect three way connector of rev counter sensor Connect Tester 20 V DC to connector as follows Terminal of Tester Yellow blue cable 1 Terminal of Tester Black cable 2 Turn key ON Voltage delivered to rev counter sensor 5 0 5 V Not compliant check continuity of black cable and of yellow blue cable 5V see wiring diagram If cables are in good repair replace digita...

Page 45: ...inue searching Tester DC 20 V 3 4 Tester DC 20 V 3 5 F 57b F 57c 2 Signal sent to instrument board Connect Tester 20 V DC to connector of instrument board without disconnecting it as follows Terminal of Tester White instrument board cable PIN 13 1 Terminal of Tester Black cable PIN 17 2 1 2 3 4 5 6 7 8 9 10 11 12 24 23 22 21 20 19 18 17 16 15 14 13 RS RS RS N R BL GL BL B VL BL R B GR R VL N GR B ...

Page 46: ...13 RS RS RS N R BL GL BL B VL BL R B GR R VL N GR B VR BL VR VR 1 N B N BL B GL BL Tester W F 58 ICE alarm When temperature read by the sensor is less than or equal to 4 C the system activates the alarm procedure to signal that the road may be icy this message appears irrespective of the function dis played The relative alarm icon ICE ALARM will come on This alarm message does not have any effect ...

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Malaguti F12R AIR 50 cc. - Euro 2, Workshop Manual

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