Malaguti Centro 50 4T Workshop Manual
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Malaguti Centro 50 4T Workshop Manual

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  • Page 2: Table Of Contents

    T A B L E O F C O N T E N T S TABLE OF CONTENTS Page Page Introduction Ignition system Manual updates The ignition system does not work Notes for easy consultation Page layout Charging System Modified pages Battery cannot be recharged Additional pages Editing symbols Electrical starting system Abbreviations Starter motor does not work Technical term dictionary Light system General Wiring Diagram Entire lighting system does not work and carburettor...

  • Page 3: Introduction

    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 fit 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.

  • Page 4: Notes For Easy Consultation

    I N T R O D U C T I O N NOTES FOR EASY CONSULTATION PAGE LAYOUT T I T O L O S E Z I O N E SECTION TITLE PAGE NUMBER NUMERO DI PAGINA MODIFIED PAGES • Modified 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.
  • Page 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.

  • Page 6: Abbreviations

    I N T R O D U C T I O N ABBREvIATIONS • Figure • Tightening torque • Page • Paragraph • Section • Diagram • Table • 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.

  • Page 7: Technical Term Dictionary

    I N T R O D U C T I O N TECHNICAL TERM DICTIONARY Multimeter (Tester) (code n°: 081100) • v = (DC) : direct current (supply from battery) • v ~ (AC) : alternating current (supply from flywheel) • A: Ampere: the unit of electric current • W: Watt: the unit of electric power (result of Volts by Amps A x v = W) •...

  • Page 8: General Wiring Diagram

    G E N E R A L W I R I N G D I A G R A M 10 11 AZ-B HORN 60 w 55 w LUCI START TURN LIGHTS B-VR R-VR R-VR R-VR R-VR R-VR R-VR R-VR N-VR <...

  • Page 9: Key To General Wiring Diagram

    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 17) VOLTAGE REGULATOR WITH INTERMITTENT FUNCTION 1) KEY SWITCH 18) RESISTANCE FOR ELECTRICAL STARTER (6.8 Ω / 10 W) HORN 19) ELECTRICAL STARTER PROVISION FOR ANTI-THEFT SYSTEM...

  • Page 10: Colour Key

    G E N E R A L W I R I N G D I A G R A M COLOUR KEY ORAN GL-vL YELLOW - PURPLE AR-B ORANGE - WHITE GL-vR YELLOW - GREEN AR-vR ORANGE - GREEN GL-R YELLOW - RED AR-BL ORANGE - BLUE...

  • Page 11: Control Unit Connector And Regulator Connector Configuration

    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 CABLE COLOUR FUNCTION CABLE COLOUR FUNCTION GROUND LIGHTS / STARTER B-VR PICK-UP GROUND...

  • Page 12: Instrument Board Connector Configuration

    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 INSTRUMENT BOARD LIGHTING HIGH BEAM LEFT HAND TURN INDICATOR RIGHT HAND TURN INDICATOR WITH KEY ON (+ 12 V) NEGATIVE B-BL FUEL LEVEL PROBE...

  • Page 13: Switches

    S W I T C H E S CHECKING PROCEDURES Using a Tester (Code n°081100), 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”...

  • Page 14: Position Of Switches And Continuity Of Contacts

    S W I T C H E S POSITION OF SWITCHES AND CONTINUITY OF CONTACTS POS. SWITCHES REAR STOP SWITCH HORN CONTROL LIGHT SWITCH TURN INDICATOR SWITCH FRONT STOP SWITCH MAIN LIGHT SWITCH ENGINE START SWITCH KEY SWITCH...

  • Page 15: Fuses

    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°081100) 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: •...

  • Page 16: Location Of Components

    L O C A T I O N O F C O M P O N E N T S “C.D.I.” control unit Horn Fuel probe Ground connection unit Voltage regulator Spark plug Battery, 12V - 9Ah...
  • Page 17 L O C A T I O N O F C O M P O N E N T S Resistance (6.8 ÷ 7.0 Ω) for electrical starter Starter relay Provision for anti-theft system Key switch Recharging socket Stator pick-up connector...

  • Page 18: Ignition System

    I G N I T I O N S Y S T E M THE IGNITION SYSTEM DOES NOT WORK Check: Spark plug Spark plug cap resistance Pick-up resistance Key switch Wiring connections Spark plug • Check condition of spark plug. •...
  • Page 19 I G N I T I O N S Y S T E M Tester (Ω) Pick-up resistance • Remove two-way connector of wiring and connect Tester (Ω) to flywheel connector (V): • Terminal (+) of Tester Terminal (1). • Terminal (-) of Tester Engine grounding (). • Resistance: 150 ÷ 170 Ω at 20° C. Stator is faulty: replace it.

  • Page 20: Charging System

    E L E C T R I C A L S T A R T I N G S Y S T E M R E C H A R G I N G S Y S T E M BATTERY CANNOT BE RECHARGED Check: Fuse, 10 A...
  • Page 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 R E C H A R G I N G S Y S T E M Resistance of stator Tester (Ω) •...

  • Page 22: Electrical Starting System

    E L E C T R I C A L S T A R T I N G S Y S T E M STARTER MOTOR DOES NOT WORK Check: Fuse, 10 A / 5 A Battery Starter motor Starter relay Key switch Start switch Front/rear “Stop”...
  • Page 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 Checking starter motor • Using two cables, connect a 1 v battery to the starter motor and check if the latter is working. Replace starter motor.
  • Page 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 Key switch • See “Checking switches” (P. 13) Replace key switch. Start switch Tester (Ω) • Detach six-way connector of right hand switch and connect Tester (Ω) as follows: •...
  • Page 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 Tester (Ω) Front/rear “Stop” switch • Disconnect Red and Blue cable from “Stop” switch (1). • Connect Tester (Ω) as follows: • Terminal (+) of Tester Terminal (). • Terminal (-) of Tester Terminal (). •...
  • Page 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 L I G H T S Y S T E M ENTIRE LIGHTING SYSTEM DOES NOT WORK AND CARBURETTOR STARTER CANNOT BE DISENGAGED Check: Fuse, 10 A...
  • Page 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 L I G H T S Y S T E M Continuity of White cable (stator) •...

  • Page 28: Light System

    E L E C T R I C A L S T A R T I N G S Y S T E M L I G H T S Y S T E M Check ground connection Tester (Ω) •...

  • Page 29: High Beam Light Does Not Come On

    E L E C T R I C A L S T A R T I N G S Y S T E M L I G H T S Y S T E M HIGH BEAM LIGHT DOES NOT COME ON Check lamp and lamp socket •...

  • Page 30: High Beam Indicator Light Does Not Come On

    E L E C T R I C A L S T A R T I N G S Y S T E M L I G H T S Y S T E M HIGH BEAM INDICATOR LIGHT DOES NOT COME ON Check lamp and lamp socket •...

  • Page 31: Low Beam Light Does Not Come On

    E L E C T R I C A L S T A R T I N G S Y S T E M L I G H T S Y S T E M LOW BEAM LIGHT DOES NOT COME ON Check lamp and lamp socket •...

  • Page 32: Instrument Board Lighting Does Not Work

    E L E C T R I C A L S T A R T I N G S Y S T E M L I G H T S Y S T E M INSTRUMENT BOARD LIGHTING DOES NOT WORK Check voltage •...

  • Page 33: Tail Light Does Not Come On

    E L E C T R I C A L S T A R T I N G S Y S T E M L I G H T S Y S T E M TAIL LIGHT DOES NOT COME ON Check lamp and lamp socket •...

  • Page 34: Front Parking Light Does Not Come On

    E L E C T R I C A L S T A R T I N G S Y S T E M L I G H T S Y S T E M FRONT PARKING LIGHT DOES NOT COME ON Check lamp and lamp socket •...

  • Page 35: Signalling System

    S I G N A L L I N G S Y S T E M STOP LIGHT DOES NOT COME ON “Stop” fuse,  A • See “Checking fuses” (P. 15). Replace fuse. Eliminate short-circuit of wiring. Check lamp and lamp socket •...
  • Page 36 S I G N A L L I N G S Y S T E M Check voltage Tester (DC 0 v) • Connect Tester (0 v DC) to six-way connector of tail light wiring, as follows: • Terminal (+) of Tester Red cable (1). • Terminal (-) of Tester Black cable (). • Turn key “ON”. • Operate right and left brake levers. •...

  • Page 37: Turn Indicators Do Not Flash

    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 flashing function is incorporated in voltage regulator. Check turn indicator switch. • See Pr. “Checking Switches” (P. 13). Turn indicator switch is faulty.
  • Page 38 S I G N A L L I N G S Y S T E M Check voltage (Test “B”) Tester (DC 0 v) • Keep connector detached from regulator and connect Tester (0 v DC), as follows: • Terminal (+) of Tester Light blue cable -PIN 3- (1). • Terminal (-) of Tester Chassis grounding (). • Turn key “ON”. •...

  • Page 39: Horn Is Not Working

    S I G N A L L I N G S Y S T E M HORN IS NOT WORKING Horn switch • See Pr. “Checking Switches” (P. 13). Tester (DC 0 v) Replace left hand switch Check voltage • Connect Tester (0 v DC) to connector of left hand switch () as follows: •...
  • Page 40 S I G N A L L I N G S Y S T E M Horn Tester (DC 0 v) • Disconnect horn cables (). • Connect Tester (DC 0 v) to terminals, as follows: • Terminal (+) of Tester Orange cable (1). • Terminal (-) of Tester Black cable (). • Turn key “ON”. • Press “HORN” button. Power measured must be > 1 v.

  • Page 41: Fuel Level Indicator Is Faulty

    S I G N A L L I N G S Y S T E M FUEL LEvEL INDICATOR IS FAULTY Tester (Ω) 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). Green cable (). •...

  • Page 42: Clock Does Not Work

    S I G N A L L I N G S Y S T E M 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 Tester (DC 0 v) Check voltage •...

  • Page 43: Voltmeter

    S I G N A L L I N G S Y S T E M vOLTMETER BATTERY AND RECHARGING SYSTEM ARE WORKING The battery and recharging system are working • Key “ON” (engine off): the indicator moves thus indicating actual battery voltage (A-F.). • Voltage measured: 1. ÷ 1. v. • Key “ON” (engine started): the indicator moves towards maximum charging level (B-F.). • Voltage measured: ~ 14. v.
  • Page 44 S I G N A L L I N G S Y S T E M Battery and/or 10 A fuse are interrupted • Key “ON” (engine off): indicator does not move (C-F.). • 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.4). • Key “OFF”: the indicator remains against the glass of the instrument board until the fuse and/or battery are replaced (D-F.4). F. 34 Battery is flat (V~0) • Key “ON” (engine off): indicator does not move (C-F.). • Key “ON” (engine started using the starter lever): in idling condition, after a few minutes, the indicator reaches the first notch (E-F.).

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