Malaguti CIAK MASTER 50-4T Workshop Manual

ELECTRIC SYSTEM

TROUBLESHOOTING

B

CIAK MASTER 50-4T

WORKSHOP MANUALS

B - TROUBLESHOOTING

ELECTRIC SYSTEM TROUBLESHOOTING

Table of contenents

Table of contents

Sect. Page

INTRODUCTION 1 5

Manual updates 1 5

Notes for easy consultation 1 6

Page layout 1 6

Modified pages 1 6

Additional pages 1 6

CHAPTER

B

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

Troubleshooting 2 28

ENGLISH

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Introduction

• Malaguti S.p.a. reserves the right to make any and all changes to its vehicles as it deems fit and appropriate

at any time without prior notice.

• No part of this publication, whether text or illustrations, may be reproduced or circulated. Malaguti
reserves all rights over this publication. Reasons must be given for any request for permission (written) thereto.

FIRST EDITION: 10/05

CHAPTER

INTRODUCTION

• This publication describes all necessary steps for troubleshooting concerning the electrical system and of

the possible service operations, which are necessary for their solution. It supplies the trade technicians
(authorised customer service centres) with the necessary information for operating in compliance with the
modern concepts of “good practice” and “safety at work”.

• Additional information is available in the Engine Service Manual and Spare Parts Catalogue.

B

• 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 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 difficult.

• IMPORTANT! 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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CHAPTER

NOTES FOR EASY CONSULTATION

PAGE LAYOUT

Y Chapter

X Section title

W Page N°

Z Date of issue

Introduction

X

Y

Z

(RH PAGE)

MODIFIED PAGES

• Modified pages shall bear the same number as those in the previous edition/pre-modified ones, followed by the
letter M, with the date of issue appearing in the appropriate box.

• Modified 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 date of issue.

EDITING SYMBOLS

• Symbols have been provided for quick and easy reference (see page 7). They identify situations requiring

utmost attention, practical advice or simple information.

W

• 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 to all the topics dealt with in the page).

Note:

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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Introduction

A) CAUTION! Recommendations and precautions regarding

rider safety and vehicle integrity.

CHAPTER

A

B

B) WARNING! 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.

C) FIRE HAZARD

Indicates operations 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.

B

C

ENGLISH

D

E

F

G) ELECTRICAL MAINTENANCE

Operations be performed only by an expert electrical/
electronic technician

H) NO! Operations to be absolutely avoided

I) ENGINE SERVICE MANUAL Indicates information which

may be obtained by referring to said manual.

L) SPARE PARTS CATALOGUE

Indicates information which may be obtained by referring
to said catalogue

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H

I

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L

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ABBREVIATIONS

F Figure

Cs Tightening torque

P Page

Pr Paragraph

S Section

Sc Diagram

T Table
V Screw

Note:

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 specified, units and components are reassembled by proceeding in the reverse order of
removal.

Introduction

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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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

B - TROUBLESHOOTING

ELECTRIC SYSTEM TROUBLESHOOTING

Electrical components

CHAPTER

B

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CHAPTER

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General wiring diagram

11

13

14

ENGLISH

15

16

10

8

9

7

6

17

18

13

19

20

21

5

4

3

2

1

22

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General wiring diagram

GENERAL WIRING DIAGRAM

COLOUR KEY

N-R BLACK/RED B-R WHITE/RED

R RED BL BLUE

RS PINK BL-R BLUE/RED

VL PURPLE GL YELLOW

VL-N PURPLE/BLACK GL-N YELLOW/BLACK

VR GREEN GL-V YELLOW/GREEN

AR-BL ORANGE/BLUE GL-R YELLOW/RED

AZ LIGHT BLUE GR GREY

AZ-B LIGHT BLUE/WHITE M BROWN

CHAPTER

B

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 LEFT TURN INDICATOR

5) REAR OPTICAL UNIT

6) REAR RIGHT TURN INDICATOR

7) FUEL LEVEL SENSOR

8) VOLTAGE REGULATOR

9) ELECTRICAL STARTER

10) CHASSIS GROUNDING

11) RESISTANCE

12) FRONT RIGHT TURN INDICATOR

ENGLISH

13) STOP LIGHT

14) RIGHT HAND SWITCH BLOCK

15) SWITCH WITH KEY

16) INSTRUMENT BOARD

17) HEADLIGHT

18) LEFT HAND SWITCH BLOCK

19) FRONT LEFT TURN INDICATOR

20) HORN

21) FLY WHEEL MAGNETO

22) ELECTRONIC CONTROL UNIT

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CHECKING SWITCHES

CHECKING PROCEDURES

Using a tester (Code n°08609500), 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.

NOTE: flick the switch from “ON” to “OFF” several

times and select
Set the tester to its correct “0” position,
before connecting the switches.

::

:.

::

Checking 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 of the wires connected to the switch terminals.

- The “ ” symbol identifies terminals in which there is a condition of continuity,
i.e. a closed circuit, in a certain position of the switch.

- In this diagram:

“B/R” and “N” feature continuity with the button pressed (switch in its “ON”

position).

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