Malaguti CNK 50 DRAKON Instruction manual

IDENTIFICATION OF ELECTRICAL SYSTEM FAILURES
WORKSHOP MANUALS
CNK 50 DRAKON
B

3 03/06
B
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 1
INDEX
1 - INDEX
1 - INDEX. .............................................................................................................................. 3
2 - ELECTRICAL SYSTEM. ................................................................................................... 4
ELECTRICAL SYSTEM CODE .................................................................................................... 5
3 - ELECTRICAL COMPONENTS. ........................................................................................ 6
4 - CHECKINGTHE CONNECTIONS. ................................................................................... 8
5 - CHECKINGTHE SWITCHES............................................................................................ 9
SWITCH CONNECTIONS AS SHOWN IN THIS MANUAL .......................................................... 9
6 - IGNITION SYSTEM........................................................................................................... 10
7 - ELECTRICAL STARTING SYSTEM . ............................................................................... 13
STARTING CIRCUIT OPERATION .............................................................................................. 13
8 - RECHARGE SYSTEM. ..................................................................................................... 18
TROUBLE SHOOTING................................................................................................................. 18
9 - LIGHTS SYSTEM.............................................................................................................. 20
TROUBLE SHOOTING................................................................................................................. 20
LIGHTING SYSTEM CHECK........................................................................................................ 22
10 -SIGNAL SYSTEM. ............................................................................................................ 24
TROUBLE SHOOTING................................................................................................................. 24
CHECKING THE SIGNAL SYSTEM............................................................................................. 26
CONFIGURATION OF THE DIGITAL INSTRUMENT CONNECTOR .......................................... 42

BDRAKON 50 NKD
2
4 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
ELECTRICAL SYSTEM
M
BL
AR
N
N
GR
B
B-N
B
VR
N
ON
ON
0FF
0FF
HORN
R
L
TURN
ON
ON
START
B-N
BL
N
FUSE 10A
KA
B
B/N
GL-VR
AZ-B
BL-B
B-N
+
-
R
BL
LOCK
LOCK
OFF
OFF
ON
ON
BL
VR
N
GR
VL
R-N
GL-R
B-MA
BL - R
R
GL-VR
BL - N
1
18
B-R
B-R
BL
BL
VR-N
VR-N
VR
VR
GL
GL
AR
AR
GL
RS
B-R
AR
BL
GL
GL
GL
N
VL-GL
VL-GL
VL
VR
N
N
VR-N
BL-R VR
R
N
R
BL
BL
OFF
OFF
GL
VL-GL
GL - R
GL -R
BL - N
BL -N
GL-V
GL-V
^
NEUTRAL
LO
LO
HI
HI
BL
BL
BL
BL
N
B-R
B-R
R
BL
ON
ON
MODE
OFF
OFF
RS RS
NN
RELAIS
B-VR
B-VR
VL
N
RS
R
N
N
VR
1Kohm
B/R
R
VR
R
VR
B-BL
B-N
B-BL
B-N
VR
R
VR
R
GL
BL
N
BL
B-R
G
B/BL
RS
BL
VR
M
VL
AR
AZ
R
B/BL
RS
B/N
VR
M
VL
AR
BL
RN
R
BL
BL
B/R
B-BL
N
N
N
RS
B-N
G
AZ
RS
B/BL
BL
AZ
AR
M
VR
VL
15
24
2
1
26
24
28
29
30
31
8
32
33
34
35
9
36
14
17
12
6
7
10
18
19
20
21
4
13
3
16
22
5
05188053
2 - ELECTRI-
11
23
25

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IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 2
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM CODE
1) Instrument panel
2) Main switch
3) Oil gauge indicator switch
4) Neutral gear switch
5) Regulator
6) Battery
7) Fuse 10A
8) Clutch switch
9) Flasher unit
10) Starting relay
11) Rear stop switch
12) “CDI” control unit
13) Water temperature probe
14) Horn
15) Front stop switch
16) Fuel reserve sensor
17) CDI magneto
18) Starter
19) Left rear flasher light
20) Tail brake and stop light
21) Right rear flasher light
22) Electrical earth of the engine
23) Tachometer counter
24) Right control unit
25) Starter button
26) Right front flasher light
27) High beam
28) Parking light
29) Low beam
30) Left front flasher light
31) Left control unit
32) Horn control
33) Flasher light control
34) Light control
35) MODE button
36) Chassis ground
COLOUR CODE
AR Orange
AZ Light blue
AZ-B Light blue-White
B White
B-N White - Black
B-MA White - Brown
B-R White - Red
B-VR White - Green
BL Blue
BL-B Blue - White
BL-N Blue - Black
BL-R Blue - Red
GL Yellow
GL-B Yellow - White
GL-N Yellow - Black
GL-R Yellow - Red
GL-VR Yellow - Green
GR Grey
M Brown
N Black
R Red
RS Pink
VL Purple
VR Green
VL-GL Purple - Yellow

BDRAKON 50 NKD
3
6 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
ELECTRICAL COMPONENTS
COMPONENTI ELETTRICI
1) Digital meter assembly
2) Main switch
3) Oil gauge indicator switch
4) Neutral gear switch
5) Regulator
6) Battery
7) Fuse 10A
8) Clutch switch
05188091
1
2
05188001
8
05188006 05188005
6
7
05188002 05188003 05188004
345
3 - ELECTRI-

7 03/06
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IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 3
ELECTRICAL COMPONENTS
9) Flasher unit
10) Starting relay
11) Rear stop switch
12) “CDI” control unit
13) Water temperature probe
14) Horn
15) Front stop switch
16) Fuel level gauge
05188090
9
05188007 05188012 05188006
15
05188008 05188009 05188010
11 13
10 16
12
14
05188011

BDRAKON 50 NKD
4
8 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
CHECKING THE CONNECTIONS
Check rust and moisture of connectors.
1) Disconnect
• Connectors
2) Dry each terminal with an air blower.
3) Connect and disconnect the connector twice or three
times.
4) Pull the connector to check that it will not come off.
5) If the terminal comes off, bend up pin (A) and reinsert
the terminal into the connector.
6) Connect
• Connectors
NOTE
The connector parts are assembled properly when they
“click”together.
7) Check for continuity with a Tester.
NOTE
• If there is no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 when checking the
electrical system.
• For a field remedy, use a contact revitalizer.
• Use theTester as shown in figure.
05188013
A
05188014
05188015
05188016
4 - CHECKING THE CONNECTIONS

9 03/06
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IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 5
CHECKING THE SWITCHES
ELECTRICAL SYSTEM
• Set theTester selector to “ ”.
• Insert the terminals of the tester in the connector
corresponding to the cables in question.
• Check continuity.
SWITCH CONNECTIONS AS SHOWN
INTHIS MANUAL
This manual contains the connection charts (as shown
left)showingthe switchterminals(e.g.,main switch, brake
switch, lighting switch, etc.)
The left column indicates the different switch positions;
the top line indicates the colours of the conductors con-
nected to the switch terminals.
“” indicates the continuity between terminals; i.e., a
closed circuit at the special switch positions.
In this chart, “BL”and “R”are continuous when the switch
is set to “ON”.
05188017
05188018
5 - CHECKING THE SWITCHES
RIGHT-HAND CONTROL

BDRAKON 50 NKD
6
10 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
IGNITION SYSTEM
THE IGNITION SYSTEM FAILSTO OPERATE
(NO SPARK OR INTERMITTENT SPARK)
Check
1) Spark plug
2) Spark plug cap resistance
3) ”CDI” control unit resistance
4) Main switch
5) Resistance of condenser charging coil
6) Pick-up resistance
7) Ignition system connections
1 Spark plug
• Check the spark plug conditions
• Check the spark plug type
• Check the electrode gap
Electrode gap:
0,7 mm
Standard spark plug:
NGK BR 9ES
INCORRECT
Faulty spark plug ➜
Replace or adjust the electrode gap
CORRECT
2 Spark plug cap resistance
• Remove the spark plug cap
NOTE
Removing the spark plug ➜ Rotate the cap anti-
clockwise
Installing the spark plug ➜ Turn the key clockwise.
• Connect Tester (k )as follows:
- Terminal (+) Tester ➜side 1
- Terminal (-) Tester ➜side 2
Cap resistance:
5K ± 20% a 20°C
INCORRECT
Faulty spark plug cap ➜ Replace
CORRECT
05188060
2
1
6 - IGNITION

11 03/06
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IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 6
IGNITION SYSTEM
3 ”CDI”control unit resistance
• Connect the Tester (k )to the control unit as
follows:
- Terminal (+) Tester ➜Cable A.T.(1)
- Terminal (-) Tester ➜cable terminal (2)
Secondary coil resistance:
5-6 K a 20 °C.
INCORRECT
“CDI” control unit faulty ➜ Replace
CORRECT
4 Main switch
• Disconnect the main switch from the system
• Connect the Tester ( )and check the continuity
between the following cables:
• Turn the main switch to“ON”
- Orange (1) ➜Green (2)
-Yellow (3) ➜Green - Black (4)
INCORRECT
Faulty main switch ➜ Replace
05188061
CORRECT
2
1
56 1 234
• Turn the main switch to“OFF”
• Check the continuity between the following cables:
- Blue - Red (5) ➜Blue (6)
See “Checking the switches” page 7

BDRAKON 50 NKD
6
12 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
IGNITION SYSTEM
5 Resistance of condenser charging coil
• Disconnect flywheel connectors
• Connect Tester ( )as follows:
- Terminal (+) Tester ➜Green cable (1)
- Terminal (-) Tester ➜White cable (2)
Charge coil resistance:
640-780 a 20 °C.
INCORRECT
Replace the yoke
CORRECT
6 Pick-up resistance
• Connect the Tester ( )to the flywheel as follows:
- Terminal (+) Tester ➜Red cable (1)
- Terminal (-) Tester ➜White cable (2)
Pick-up resistance
100-140 a 20 °C.
INCORRECT
Replace the yoke
CORRECT
7 Wiring connections
• Check the ignition system for connections
See“Electrical diagram” INCORRECT
05188060
1
2
1
2
Repair the system wiring

13 03/06
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IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 7
ELECTRICAL STARTING SYSTEM
STARTING CIRCUIT OPERATION
The starting circuit on this model consists of the starter
motor and the starter relay.
When the main switch is in “ON” position and the starting
button is pressed, the starter motor can operate only if:
THE CLUTCH HANDLE IS PULLED
If the above mentioned conditions are not met, the start-
ing relay cannot be energized.
1) Battery
2) Fuse 10A
3) Main switch
4) Starting switch (start)
5) Clutch switch
6) Starting relay
7) Starter
8) Chassis ground
05188024
23
4
5
8
7
6
BL B/R
BL
7 - ELECTRICAL STARTING SYSTEM
8
8
1

BDRAKON 50 NKD
7
14 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
ELECTRICAL STARTING SYSTEM
THE STARTER MOTOR FAILSTO OPERATE
Check
1) Fuse 10A
2) Battery
3) Starter
4) Starting relay
5) Main switch
6) Clutch switch
7) Starting switch (start)
8) Wiring connections
1 Fuse 10A
• Remove the fuse
• Connect Tester ( )to the fuse
• Check the fuse for continuity
Faulty fuse ➜ Replace
NO CONTINUITY
2 Battery
• Check the battery conditions
See“Charge voltage”on page 16
CONTINUITY
INCORRECT
Clean the terminals
Recharge or replace battery
CORRECT
05188063
Minimum voltage:12,5V
Specific gravity electrolyte level:
1.280 g/dm3

15 03/06
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IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 7
ELECTRICAL STARTING SYSTEM
3 Starter
• Connect battery positive terminal (1) and starter
motorcable(2)using ajumperlead(3) asshownin
figure.
(4) Starting relay
• Check the starter motor for operation.
WARNING
A wire for the jumper lead must have the equivalent
capacity as that of the battery lead or more, other-
wise it may cause the jumper lead to be burned.
THE STARTER MOTOR
FAILSTOTURN
Faulty starter motor ➜ Replace
THE STARTER MOTORTURNS
4 Starting relay
• Disconnect the starter relay
• Connectthebattery tothe startingrelaywith jumper
leads (1).
Battery cable (+) ➜ White - Red cable
Battery cable (-) ➜Black cable
• Check the starter motor for operation.
WARNING
• Take care not to reverse the battery connections
because the diode will be damaged.
• Take care to avoid shorting the positive and nega-
tive terminals when connecting the battery to the
relay.
THE STARTER MOTOR
FAILSTOTURN
Faulty starter motor ➜ Replace
THE STARTER MOTORTURNS
1
23
1
05188064
4

BDRAKON 50 NKD
7
16 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
ELECTRICAL STARTING SYSTEM
5 Main switch
• Disconnect the main switch
• Turn the main switch to“ON”
• Connect Tester ( )and check leads for continuity
Orange cable ➜Green cable
Yellow lead ➜Green-Black lead
See “Checking the switches” page 7 INCORRECT
Faulty main switch ➜ Replace
CORRECT
6 Clutch switch
• Disconnect clutch switch (1)
• Connect Tester ( )and check the terminals for
continuity.
Terminal (T1) ➜Terminal (T2)
See “Checking the switches”page 7
INCORRECT
CORRECT
1 Clutch lever not
pulled
2 Clutch lever pulled
Faulty clutch switch ➜ Replace
1
05188065

17 03/06
B
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 7
ELECTRICAL STARTING SYSTEM
7 Starting switch (start)
• Disconnect two-way connector (1)
• ConnecttheTester( )to theconnectorontheside
of the switch
Terminal (+) Tester ➜Red cable (2)
Terminal (-) Tester ➜Blue cable (3)
• Press the “START”button
NO CONTINUITY
CONTINUITY Faulty starting switch ➜ Replace
8 Wiring connections
• Check the ignition system for connections INCORRECT
Reset see “Electrical diagram”
12
3
05188066

BDRAKON 50 NKD
8
18 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
RECHARGE SYSTEM
TROUBLE SHOOTING
IFTHE BATTERY IS FLAT
Check
1) Fuse 10A
2) Charge voltage
3) Charge coil resistance
4) Recharge system connections
1 Fuse 10A
• Remove the fuse
• Connect Tester ( )to the fuse
• Check the fuse for continuity NO CONTINUITY
Faulty fuse ➜ Replace
CONTINUITY
2 Charge voltage
• Connecttheinductive revcounterto the spark plug
cable.
• Connect the Tester (DC 20V) to the battery
Terminal (+) ➜Terminal (+) of the battery
Terminal (-) ➜Terminal (-) of the battery
• Measure the battery voltage
• Start the engine and accelerate to 5000 rpm.
• Check the battery voltage
Charge voltage:
13,5 ~ 14,5V
NOTE
Use a completely charged battery.
CORRECT
The charging circuit operates properly
INCORRECT
05188067
8 - RE-

19 03/06
B
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
DRAKON 50 NKD 8
RECHARGE SYSTEM
3 Charge coil resistance
• Disconnect flywheel connectors
• Connect Tester ( )as follows:
Terminal (+) ➜Terminal of yellow cable (1)
Terminal (-) ➜Terminal of white cable (2)
Charge coil resistance:
0,2 ~0,7 a 20 °C
INCORRECT
CORRECT Replace the yoke
4 Recharge system connections
• Check the connections of the recharge system
See “Electrical diagram” INCORRECT
Repair the system wiring
CORRECT
Replace the voltage regulator
1
2
05188068

BDRAKON 50 NKD
9
20 03/06
IDENTIFICATION OF ELECTRICAL
SYSTEM FAILURES
LIGHTS SYSTEM
TROUBLE SHOOTING
LIGHTS SYSTEM FAULTY
Check
1) Lighting coil resistance
2) Voltage regulator
3) Main switch
4) Lighting system wiring
1 Lighting coil resistance
• Disconnect flywheel connectors.
• Connect Tester ( )as follows:
Terminal (+) ➜ Yellow lead terminal (1)
Terminal (-) ➜ White lead terminal (2)
Lighting coil resistance:
0,2~0,7 a 20 °C
INCORRECT
CORRECT Replace the yoke
2
1
05188069
9 - LIGHTS