Malaguti Centro 50 4T Workshop Manual

2

T A B L E O F C O N T E N T S

TABLE OF CONTENTS

Page

Introduction 3

Manual updates 3

Notes for easy consultation 4

Page layout 4

Modied pages 4

Additional pages 4

Editing symbols 4

Abbreviations 6

Technical term dictionary 7

General Wiring Diagram 8

Key to general wiring diagram 9

Colour key 10

Control unit connector and regulator connector conguration 11

Instrument board connector conguration 12

Switches 13

Checking procedures 13

Connection of switches described in this manual 13

Position of switches and continuity of contacts 14

Fuses 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 light does not come on 30

Low beam light does not come on 31

Instrument board lighting does not work 32

Tail light does not come on 33

Front parking light does not come on 34

Signalling system 35

Stop light does not come on 35

Turn indicators do not ash 37

Horn is not working 39

Fuel level indicator is faulty 41

Clock does not work 42

Voltmeter 43

3

I N T R O D U C T I O N

Malaguti reserves the right to make any and all changes to its vehicles as it deems t and appropriate at any time without prior notice.
No part of this publication, whether text or illustrations, may be reproduced or circulated either totally or partially. Malaguti reserves all rights over this publication. Reasons

must be given for any request for permission (written) thereto.

FIRST EDITION: 08/08

INTRODUCTION

This publication describes all necessary steps for troubleshooting concerning the electrical system (Electronic Injection System) and of the possible service operations,

which are necessary for their solution. It supplies the trade technicians (Authorised Service Centres) with the necessary information for operating in compliance with the
modern concepts of “good practice” and “safety at work”.

Further information can be derived from the “Chassis” workshop manual, from the “Engine” workshop 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 with care.

For any further information you may need, refer to the Malaguti S.p.A. Technical Department.

It is essential to follow the instructions with great care. Work carried out carelessly or, worse still, work that has not been accomplished, can cause injuries and damage or,
in the less serious cases, tiresome complaints.

MANUAL UPDATES

Any subsequent updates applying to this Manual will be sent in a reasonable time.

The table of contents will be duly updated in the event that new pages are inserted, which render the consultation of the manual difcult.

The Electrical System Troubleshooting Manual is to be considered as an essential tool to be properly kept up-to-date so as to maintain its “validity”
over time.

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4

I N T R O D U C T I O N

NUMERO DI PAGINA

TI T O L O S E Z I O N E

X

W

NOTES FOR EASY CONSULTATION

PAGE LAYOUT

MODIFIED PAGES

Modied pages shall bear the same number as those in the previous edition, followed by the letter M, with the new date of issue appearing in the appropriate box.
Modied pages may contain new illustrations; in this case, the added illustration (or illustrations) will bear the number of the illustration on the former page, followed by a
letter.

ADDITIONAL PAGES

Any additional pages shall bear the last number of the section to which they belong, followed by the letter A and the new date of 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 gure (in which case they refer to the topic illustrated in the gure
and to the relative text), or at the top of the page (in which case they refer to all the topics dealt with in the page).

The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations. They
are therefore to be considered as veritable “memory tags”. In case of any doubt as to their meaning, consult the page in which they are fully described.

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SECTION TITLE

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PAGE NUMBER

5

I N T R O D U C T I O N

NOTE

Recommendations and precautions regarding rider safety and motor vehicle integrity.

CAUTION!
Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment,
vehicle or equipment.

FIRE HAZARD

Indicates operations which may constitute a re hazard.

DANGER OF EXPLOSION

Indicates operations which may constitute a risk of explosion.

TOXIC FUMES

Indicates a possibility of intoxication or inammation 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 MANUAL

Indicates information which may be obtained by referring to said document.

R

SPARE PARTS CATALOGUE

Indicates information which may be obtained by referring to said document.

6

A

I N T R O D U C T I O N

ABBREVIATIONS

F Figure
Cs Tightening torque
P Page
Pr Paragraph
S Section
Sc Diagram
T Table
V Screw

the letter V in the illustrations refers to retaining or adjusting screws.
The number following this letter refers to the number of the same type
of screw 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 specied, 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 the equipment
integral with the lifting board (A).

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7

I N T R O D U C T I O N

TECHNICAL TERM DICTIONARY

Multimeter (Tester) (code n°: 08611200)

V = (DC) : direct current (supply from battery)
V ~ (AC) : alternating current (supply from ywheel)
A: Ampere: the unit of electric current
W: Watt: the unit of electric power

(result of Volts by Amps A x V = W)

Ω: OHM: the unit of electrical resistance
Innite 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
~ : approximately

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8

+

-

N

BA

TTERIA 12V

FIAMM O YUASA

9 Ah

ON

0FF

LO

HI

LUCI

HORN

R

L

TURN

60 w

55 w

BL-

R

BL

OF

F

ON

BL-

N

VR-

N

N

B

L

G

L

-

B

BL-

R

VR-N
BL-N

N

GL-B

N

B/BLGL-N

BL

VR

VL

M

GR

N

AZ-

B

GL-N

B-

N

VR

VL

M-

N

AR

AZ

AR

BL

R

BL

BL-R
BL-R

G

R

GL-N

M

VL

VR

GR

N

AZ-B

B-

N

N

N

VL

R

RS

N

VR

VL

R

RS

N

VR

VL

VR

N

VR

ON

0FF

N

B-

R

RS

RS

R/V

R

GL-

V

R

GL-

N

GL

ON

0FF

ON

GL

RS

GL-

N

GL-

V

R

N

LIGHTS

START

BL-R

N

GL-

N

N

RS

B-

N

VL

VR

BL

B-B

L

GR

B-B

L

VL

FUSE 10

A

VR

N

VL

B-

R

+

-

N

N

B/

R

VR

B

/B

L

BL-N

GL/VL

N

FUSE 5

A

B

/

B

L

GL/

B

87

30

-

N

RSRSRS

N

N

RS

GR

BL

VR

VL

B-

N

RS

N

BL-R

N

BL-R

R

B-

R

B/B

L

BL

>

GL-B

+

R

FUSE 10

A

2314

1

2

3

4

5

GL

R-VR

N

P.U

B-VR

B

R-VRR-VR

N-VR

R-VR

R-VR

N

B

-

V

R

G

L

-B

B

M-N

B

AZ

N

GL

G

L

R-V

R

AZ

B

L-

R

B

L-

R

AZ

B

L

R

<
>

R

R

R

R-VR

R-VR

N

1

2

3

4

5 6 7 8 9 10 11 12 13 14 15

16

17

18

19

20212223242526272829303132

G E N E R A L W I R I N G D I A G R A M

9

G E N E R A L W I R I N G D I A G R A M

KEY TO GENERAL WIRING DIAGRAM

1) KEY SWITCH

2) HORN

3) PROVISION FOR ANTI-THEFT SYSTEM

4) STOP SWITCH

5) LEFT HAND SWITCH

6) LEFT HAND TURN INDICATOR

7) RIGHT HAND TURN INDICATOR

8) PARKING LIGHT

9) LOW BEAM / HIGH BEAM LIGHT

10) INSTRUMENT BOARD CONNECTOR

11) CLOCK CONNECTOR

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 RELAY

29) FUSE, 10 A (LIGHTS / CARBURETTOR STARTER)

30) FUSE, 5 A (STOP LIGHT)

31) FUSE, 10 A (MAIN / RECHARGING)

32) BATTERY

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G E N E R A L W I R I N G D I A G R A M

COLOUR KEY

AR ORAN GE

AR-B ORANGE - WHITE

AR-VR ORANGE - GREEN

AR-BL ORANGE - BLUE

AR-R ORANGE - RED

AZ LIGHT BLUE

AZ-B LIGHT BLUE - WHITE

AZ-GR LIGHT - BLUE GREY

B WHITE

B-VR WHITE - GREEN

B-N WHITE - BLACK

B-R WHITE - 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 - BLACK

VR GREEN

VR-N GREEN - BLACK

VRO OLIVE GREEN

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1234

5 4 3 2 1

G E N E R A L W I R I N G D I A G R A M

CONTROL UNIT CONNECTOR AND REGULATOR 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

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G E N E R A L W I R I N G D I A G R A M

INSTRUMENT BOARD 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

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S W I T C H E S

CHECKING PROCEDURES

Using a Tester (Code n°08611200), check the switches by making sure that there is

continuity between terminals and that they are correctly connected.
Replace the switch, even if only one of the possible combinations does not give the
requested result.

Select “Ω” (ohm) function of tester; sound-emitting function.

Using the tester in “Ω” mode, you can also check integrity of the lamps 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 rst 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 identies terminals in which there is a condition of continuity, i.e.
a closed circuit, in a certain position of the switch.

In this diagram:

“BL-B” and “R”: there is continuous contact when the switch is “ON”.

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14

1 2 3

4 5 6

7 8

1 5

3

4

2

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

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A

C

B

F U S E S

CHECKING FUSES

When checking or replacing fuses, always turn the main switch
“OFF” or short-circuits may occur.

Checking procedure:

Connect Tester (code n°08611200

) to fuse and check continuity.

Put the Tester on “Ω” (sound-emitting 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 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 exten sive dama ge to the electrical system,

malfunctioning of the ignition and light systems and even res to

break out.

KEY TO FUSES

A MAIN / RECHARGING

B STOP

C LIGHTS / STARTER

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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

17

L O C A T I O 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

18

I G N I T I O N S Y S T E M

NO

NO

OK

OK

F. 1

Tester (KΩ)

1

2

THE IGNITION SYSTEM DOES NOT WORK

Check:

1. Spark plug

2. Spark plug cap resistance

3. Pick-up resistance

4. Key switch

5. Wiring connections

1. Spark plug

Check condition of spark plug.
See “Engine Workshop Manual”.

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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 side (2).
Spark plug cap resistance: 5 KΩ at 20° C.

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Replace spark plug cap.

19

I G N I T I O N S Y S T E M

NO

OK

OK

NO

NO

OK

OK

F. 2

Tester (Ω)

V

1

2

3. Pick-up resistance

Remove two-way connector of wiring and connect Tester (Ω) to ywheel connector (V):

Terminal (+) of Tester Terminal (1).
Terminal (-) of Tester Engine grounding (2).

Resistance: 150 ÷ 170 Ω at 20° C.

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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).

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Repair wiring.

Replace the C.D.I. control unit. (code: 02411900).

20

E L E C T R I C A L S T A R T I N G S Y S T E M

20

OK

NO

OK

NO

BATTERIA

+

-

12

V

9Ah

NO

OK

F. 3

F. 4

R E C H A R G I N G S Y S T E M

BATTERY CANNOT BE RECHARGED

Check:

1. Fuse, 10 A

2. Recharging 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.

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The recharging circuit is working: replace battery.

Repair. See “Wiring Diagram” (P. 8).

Replace regulator (code n°: 02602800).

Tester (DC 20 V)

21

E L E C T R I C A L S T A R T I N G S Y S T E M

21

NO

NO

NO

OK

OK

F. 5

Tester (Ω)

V

1

2

R E C H A R G I N G S Y S T E M

3. Resistance of stator

Remove two-way connector of wiring and connect Tester (Ω) to ywheel connector (V):
Terminal (+) of Tester Terminal (1).
Terminal (-) of Tester Engine grounding (2).

Resistance: 0.7 ÷ 1 Ω at 20° C.

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Stator is faulty: replace it.

4. Checking wiring connections

Check connections of the entire charging system.
See “Wiring Diagram” (P. 8).

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Put wiring in working order.

Replace regulator (code n°: 02602800).

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E L E C T R I C A L S T A R T I N G S Y S T E M

NO

F. 6

OK

OK

STARTER MOTOR DOES NOT WORK

Check:

1. Fuse, 10 A / 5 A

2. Battery

3. Starter motor

4. Starter relay

5. Key switch

6. Start switch

7. Front/rear “Stop” switch

8. Starting system wiring connections

1. Fuse, 10 A / 5 A

See “Checking 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 charged.
12,5 V Battery needs to be recharged.
12,0 V Replace battery.

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23

E L E C T R I C A L S T A R T I N G S Y S T E M

OK

NO

F. 7

N

OK

F. 8

Tester (Ω)

8586

30

87

NO

OK

3. Checking starter motor

Using two cables, connect a 12 V battery 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).

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Never invert battery connections on relay terminals.

Replace relay.

24

E L E C T R I C A L S T A R T I N G S Y S T E M

OK

NO

OK

F. 9

NO

Tester (Ω)

OK

5. Key switch

See “Checking switches” (P. 13)•

Replace 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.

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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

25

E L E C T R I C A L S T A R T I N G S Y S T E M

OK

F. 10

Tester (Ω)

BL R

1

2 3

NO

OK

NO

7. Front/rear “Stop” switch

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.

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Replace “Stop” switch.

8. Wiring connections

Check connections of entire starting system.
See “Wiring Diagram” (P. 8).

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Put wiring in working order.

26

E L E C T R I C A L S T A R T I N G S Y S T E M

26

OK

NO

OK

NO

F. 11

F. 12

Tester (AC 200 V)

5

4

3

2

1

1

2

L I G H T S Y S T E M

ENTIRE LIGHTING SYSTEM DOES NOT WORK AND CARBURETTOR STARTER CANNOT BE
DISENGAGED

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: 25 ÷ 40 V.

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27

E L E C T R I C A L S T A R T I N G S Y S T E M

27

OK

NO

OK

NO

OK

NO

F. 13

Tester (AC 200 V)

5

4

3

2

1

1

2

L I G H T S Y S T E M

4. Regulator voltage output

Ret connector in voltage regulator.
Run engine at 1900/2000 RPM.

Connect Tester (200 V AC) to connector 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.

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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 of White cable between stator and regulator connector.•

28

E L E C T R I C A L S T A R T I N G S Y S T E M

28

NO

OK

NO

F. 14

Tester (Ω)

5

4

3

2

1

1

2

L I G H T S Y 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.

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Resume ground connection (Black cable).
See “Wiring Diagram” (P. 8).

29

E L E C T R I C A L S T A R T I N G S Y S T E M

29

OK

NO

2 1

NO

OK

NO

F. 15

L I G H T S Y S T E M

HIGH BEAM LIGHT DOES NOT COME ON

1. Check lamp and lamp socket

See Pr. “Checking Switches” (P. 13).•

Replace lamp and/or lamp socket.

3. Check voltage

Connect Tester (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.•

Whi te/blac k 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)

See Pr. “Checking Switches” (P. 13).•

Replace left hand switch

30

E L E C T R I C A L S T A R T I N G S Y S T E M

30

OK

OK

2

1

NO

NO

RS B-N VL VR BL N B-BL BL-R

GR

N R

F. 16

L I G H T S Y S T E M

HIGH BEAM INDICATOR LIGHT DOES NOT COME ON

1. Check lamp and lamp socket

See Pr. “Checking Switches” (P. 13).•

Replace lamp and/or lamp socket.

2. Check 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 board connector is interrupted: repair it.
See “Wiring Diagram” (P. 8).

Tester (AC 20 V)

31

E L E C T R I C A L S T A R T I N G S Y S T E M

31

2

1

OK

NO

NO

NO

F. 17

OK

L I G H T S Y S T E M

LOW BEAM LIGHT DOES NOT COME ON

1. Check lamp and lamp socket

See Pr. “Checking Switches” (P. 13).•

Replace lamp and/or lamp socket.

3. Check voltage

Connect Tester (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 Pr. “Checking Switches” (P. 13).•

Replace left hand switch

32

E L E C T R I C A L S T A R T I N G S Y S T E M

32

OK

NO

1 2

RS B-N VL VR BL N B-BL BL-R

GR

N R

F. 18

L I G H T S Y S T E M

INSTRUMENT BOARD LIGHTING DOES NOT WORK

1. Check voltage

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

.

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 V)

33

E L E C T R I C A L S T A R T I N G S Y S T E M

33

OK

NO

OK

NO

1

2

F. 19

3

L I G H T S Y S T E M

TAIL LIGHT DOES NOT COME ON

1. Check lamp and lamp socket

See Pr. “Checking Switches” (P. 13).•

Replace lamp and/or lamp socket.

2. Check 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 Diagram” (P. 8).

Tester (AC 20 V)

34

E L E C T R I C A L S T A R T I N G S Y S T E M

34

OK

NO

OK

NO

Tester (AC 20 V)

1

2

F. 20

L I G H T S Y S T E M

FRONT PARKING LIGHT DOES NOT COME ON

1. Check lamp and lamp socket

See Pr. “Checking Switches” (P. 13).•

Replace 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 “Wiring Diagram” (P. 8).

35

OK

NO

OK

NO

OK

NO

F. 21

S I G N A L L I N G S Y S T E M

STOP LIGHT DOES 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.

36

OK NO

OK

1

2

3

Tester (DC 20 V)

F. 22

S I G N A L L I N G S Y S T E M

4. Check voltage

Connect Tester (20 V DC) to 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).

37

OK

NO

NO

2

1

Tester (DC 20 V)

OK

OK

NO

5

4

3

2

1

M/N B AZ N GL

F. 23

S I G N A L L I N G S Y S T E M

TURN INDICATORS DO NOT FLASH

In this vehicle, the ashing function is incorporated in voltage regulator.

1. Check turn indicator switch.

See Pr. “Checking Switches” (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/Black cable is interrupted: repair it.
See “Wiring Diagram” (P. 8).

38

OK

NO

OK

NO

NO

OK

2

1

Tester (DC 20 V)

5

4

3

2

1

M/N B AZ N GL

F. 24

5

4

3

2

1

M/N B AZ N GL

F. 25

A

S I G N A L L I N G S Y S T E M

4. Check regulator

Connector (A) detached.
Provide a jumper between Brown/Black cable (PIN 5) and Light blue cable (PIN 3).
Turn key “ON”.
Operate right/left turn indicator switch to make sure that indicators come on and remain steadily lit.

•

•

•

•

3. Check voltage (Test “B”)

Keep connector detached from regulator and connect Tester (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 (tests have not been
performed correctly).

If ground connection (pin 2) or power supply (pin 3) are lacking, the regulator will
cause malfunctioning of the lighting circuit and battery recharging system, as well as
disengagement of the carburettor “starter”.

39

OK

NO

2

1

OK

NO

3

F. 26

S I G N A L L I N G S Y S T E M

HORN IS NOT WORKING

1. Horn switch

See Pr. “Checking 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)

40

NO

1

2

NO

OK

OK

OK

1

2

3

Tester (DC 20 V)

F. 27

F. 28

S I G N A L L I N G S Y S T E M

4. Check ground connection.

Connect Tester (Ω) as follows:
Terminal (+) of Tester Black cable (1).
Terminal (-) of Tester Chassis grounding (2).

Check continuity.

•

•

•

•

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 of cables.

Replace horn.

41

NO

OK

1

2

1

2

OK

A

B

3

2

A

B

NO

F. 29

F. 30

S I G N A L L I N G S Y S T E M

FUEL LEVEL INDICATOR IS FAULTY

1. Check fuel probe

Take fuel probe out of fuel tank (see “Workshop Manual, Chassis Section”)

Detach connector of probe.

Connect Tester (Ω) to probe connector as follows:
Terminal (+) of Tester Yellow/White cable (1).
Terminal (-) of Tester Green cable (2).
Check resistance of 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 grounding (2).
Check continuity

•

•

•

•

Black cable is interrupted: repair by providing a

jumper between Black cable and grounded point
of chassis.

•

Tester (Ω)

Tester (Ω)

Tester (Ω)

42

OK

NO

OK

NO

2

Tester (DC 20 V)

1

F. 31

RS

B-N

VL

VR

BL

N

B-BL

BL-R

GR

N

R

OK

S I G N A L L I N G S Y S T E M

3. Check Grey and White/Blue cables

Check continuity of Grey cable and White/Blue cable between probe connector and instrument board 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 interrupted: repair it.

See “Wiring Diagram” (P. 8).

43

F. 32

H

L

F

E

1/2

- +

F. 33

H

L

F

E

1/2

- +

B

A

C

S I G N A L L I N G S Y S T E M

VOLTMETER

BATTERY AND RECHARGING SYSTEM ARE WORKING

1. The battery and recharging system are working

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): the indicator moves towards maximum charging level (B-F.32).
Voltage measured: ~ 14.5 V.
Key “OFF”: indicator returns to end of stroke (C-F.33).

•

•

•

•

•

During use of the vehicle, it is normal for the indicator to shake slightly.

FAULTY BATTERY 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 ywheel or regulator (no 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): in idling condition, the indicator does not move from the previously indicated level.

During use, the indicator slowly returns to the end of its stroke to signal that there is no charge (see “Recharging

System”) (C-F.33).

•

•

•

44

F. 34

H

L

F

E

1/2

- +

F. 35

H

L

F

E

1/2

- +

E

D

S I G N A L L I N G S Y S T E M

3. Battery and/or 10 A fuse are interrupted

Key “ON” (engine off): indicator does not move (C-F.33).
Key “ON” (engine started using the starter lever): the indicator moves 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 at (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 rst notch (E-F.35).
Replace battery.

•

•

•