f12r LC 50 CC

B
TROUBLESHOOTING
electrical and ignition system
F12R L.C. 50 cc. - Euro 2
WORKSHOP MANUAL
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B Chapter Introduction F12R L.C. 50 cc.
Table of contents
Sez. Pag.
INTRODUCTION 1 3
Manual updates 1 3
Notes for easy consultation 1 4
Page layout 1 4
Modified pages 1 4
Additional pages 1 4
Editing symbols 1 4
Abbreviations 1 6
ELECTRICAL COMPONENTS 2 7
GENERAL WIRING 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
CHARGING SYSTEM 2 21
LIGHTING SYSTEM 2 23
SIGNALLING SYSTEM 2 28
PAGE ISSUE 02.07

F12R L.C. 50 cc. Introduction B Chapter
• 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. Malaguti reserves
all rights over this publication. Reasons must be given for any request for permission (written) thereto.
FIRST ISSUE : 02/07
INTRODUCTION
• This publication describes all necessary steps for troubleshooting concerning the electrical system (Elec-
tronic 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 con-
sultation 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.
02.07 ISSUE PAGE

NOTES FOR EASY CONSULTATION
PAGE LAYOUT
Y Chapter
X Y
X Section title
W Page N°
Z Date of issue
Z W
(RIGHT HAND PAGE)
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.
• 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 new date of issue.
Editing symbols
• Symbols have been provided 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 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.
PAGE ISSUE 02.07

F12R L.C. 50 cc. Introduction B Chapter
A) CAUTION! Recommendations and precautions

regarding rider safety and motor vehicle integrity. A
B) WARNING! Situations entailing the risk of personal

injury to maintenance or repair mechanics, other
workshop personnel or third parties, or damage to B
environment, vehicle or equipment.
C) FIRE HAZARD
Indicates operations which may constitute a fire
C
hazard.
D) RISK OF EXPLOSION
Indicates operations which may constitute a risk of D
explosion.
E) TOXIC FUMES
E
Indicates a possibility of intoxication or inflammation
of the upper respiratory tract.
F) MECHANICAL MAINTENANCE F
Operations to be performed only by an expert
mechanic.
G) ELECTRICAL MAINTENANCE G
Operations be performed only by an expert electrical/
electronic technician
H
H) NO! Operations to be absolutely avoided
I) ENGINE SERVICE MANUAL I

Indicates information which may be obtained by M
referring to said manual.
L
L) SPARE PARTS CATALOGUE
Indicates information which may be obtained by
R
referring to said catalogue
02.07 ISSUE PAGE

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.
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.
PAGE ISSUE 02.07

F12R L.C. 50 cc. Electrical Components B Chapter
ELECTRICAL COMPONENTS
1) AMBIENT TEMPERATURE PROBE 9) STARTING RELAY

2) KEY SWITCH 10) grounding wire terminals
3) RECHARGING SOCKET 11) H2O TEMPERATURE SENSOR
4) OIL INDICATOR SWITCH 12) BATTERY
5) HORN 13) FUEL RESERVE SWITCH
6) FLASHLIGHT 14) CHOKE CONTROL
7) VOLTAGE REGULATOR 15) FUEL LEVEL SENSOR
8) “CDI” CONTROL UNIT
02.07 ISSUE PAGE

02.07 ISSUE PAGE
31
4
10
32
VL
1
30
N
2
W
+
M
-
R
N
29
BL
BL
BL
M-N
BL-R
N
GL
N
N-R
+ AR
R
N
N-R
BL-R 10 A BL-R
5
AZ
R
BL 5A
GL
6
GL
L
R-VR 7.5 A RS VR VR
GL-R
VL VL
7
VL
TURN
M-N M-N M-N

AR AR VR
R B-R AZ AZ
28
BL R
ON
0FF
AZ
HORN
AR
BL
9
N
RS RS
35
VL VL
VR VR RS
H8
A B
N N N
VL 10
W
10
W
27
N
VL
VR
35
N
ALLARME
VL RS
H8
A B
R
RS N
PREDISPOSIZIONE
W
11
R
RS
N
VR
N
N N
26
Pick UP
N-R N-R
N 10
N-R
12
>
VL
Uscita ricarica / luci
> VR
W VR
BL-VR
>
>
>
RS
BL
> RS
BL
25
>
13
RS
Interruttore spia olio mix. BL-R
B-VL B-VL B-VL
B-VL
Alim. 12V sotto chiave. > BL GL-BL B-VR
> BL GR
N N N
N-R N
14
Interruttore riserva carburante RS VL
VR BL-VR BL-VR
RS
Alim. 5V
>
Signal rinvio
GL-BL VR GR-R
N
>
12 11 10 9 8 7 6 5 4 3 2 1
B
24 23 22 21 20 19 18 17 16 15 14 13
Sensore temperatura acqua. RS B

B-VR
Sonda livello carburante
MODE
GR
> GR-R
Alim. 12V V.bat. > BL-R
15
B-VR
N
24
BL-R
OFF
ON
23
BL-N
Alim. Centralina VR-N N
> BL-R GL-B
> BL-R
BL-N
GL-B GL-B VR-N
N N > N
16
> N BL
VR GR AZ BL
BL-R
Run STOP
<
Imp. Luci / starter <

>
<
>
>
ON
0FF
GR-R GR-R GR-R

MODE
BL BL BL
22
B-R B-R
N N
ON
0FF
N
START
< B
N
GL-BL
B-R
B
N
BL
18
17
R
21
BL
10
N 20
VR
19
Chapter
F12R L.C. 50 cc. General Wiring Diagram B
F12R L.C. 50 cc. General Wiring Diagram B Chapter
GENERAL WIRING DIAGRAM
COLOUR KEY
AR ORANGE GL-B YELLOW/WHITE

AR-BL ORANGE/BLUE GL-V YELLOW/GREEN
R-VR RED/GREEN GL-R YELLOW/RED
AZ LIGHT BLUE GR GREY
B WHITE M BROWN
B-VL WHITE/PURPLE M-N BROWN/BLACK
B-VR WHITE/GREEN M-B BROWN/WHITE
B-VL WHITE/PURPLE N BLACK
B-BL WHITE/BLUE N-R BLACK/RED
B-R WHITE/RED R RED
BL BLUE R-VR RED/GREEN
BL-R BLUE/RED RS PINK
BL-VR BLUE/GREEN VL PURPLE
GL YELLOW VR GREEN
GL-BL YELLOW/BLUE
KEY TO GENERAL WIRING DIAGRAM
1) FLYWHEEL MAGNETO
17) VOLTAGE REGULATOR
2) CHOKE CONTROL
18) “CDI” CONTROL UNIT
3) ELECTRICAL STARTER
19) SENSOR TRANSMISSION
4) BATTERY
20) FRONT LEFT TURN INDICATOR
5) FUSE, 10 A
21) FRONT STOP SWITCH
6) FUSE, 5 A
22) RIGHT HAND SWITCH
7) FUSE, 7.5 A
23) KEY SWITCH
8) STARTING RELAY
24) RECHARGING SOCKET
9) STARTER MOTOR
25) INSTRUMENT BOARD
10) REAR LEFT TURN INDICATOR
26) AMBIENT TEMPERATURE PROBE
11) 5W PARKING LIGHT / 10W STOP LIGHT
27) DOUBLE HEADLIGHT
12) REAR RIGHT TURN INDICATOR
28) LEFT SWITCH
13) OIL INDICATOR SWITCH
29) REAR STOP SWITCH
14) FUEL RESERVE SWITCH
30) FRONT LEFT TURN INDICATOR
15) H2O TEMPERATURE SENSOR
31) FLASHLIGHT
16) FUEL LEVEL SENSOR
32) HORN
02.07 ISSUE PAGE

B Chapter Checking Switches F12R L.C. 50 cc.
INSTRUMENT BOARD CONNECTOR CONFIGURATION
1) RPM RS 13) HALL SENSOR SIGNAL B
2) RIGHT TURN INDICATOR VR 14) MODE BUTTON GR-R
3) LIGHT INDICATOR RS 15) - -
4) BACKLIGHTING RS 16) LEFT TURN INDICATOR VL
5) AMBIENT TEMPERATURE N-R 17) GND (-) N
6) KEY ACTIVATION (+12V) BL 18) FUEL PROBE GR
7) VDC HALL SENSOR (+5V) GL-BL 19) WTEMP RESIST. PROBE B/VR
8) MIXTURE OIL B-VL 20) - -
9) BATTERY POSITIVE BL-R 21) - -
10) - - 22) - -
11) - - 23) - -
12) - - 24) FUEL RES. WARNING LIGHT BL-VR
24 PIN
10 PAGE ISSUE 02.07

F12R L.C. 50 cc. Checking Switches B Chapter
CHECKING SWITCHES
CHECKING PROCEDURES
- Using a Tester (code n°08609500), check switches. In particular, check continuity between terminals to
make sure they are correctly connected.
- Replace the switch, even if only one of the possible combinations does not give the requested result.
Set the tester to function Ω.
F. 1
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 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” there is continuous contact when the switch is “ON”.
F. 2
02.07 ISSUE PAGE 11

B Chapter Checking Switches F12R L.C. 50 cc.
POSITION OF SWITCHES AND CONNECTION OF CONNECTORS
1) REAR STOP SWITCH 5) “MODE” BUTTON SWITCH

2) TURN INDICATOR SWITCH 6) START SWITCH
3) HORN CONTROL 7) KEY SWITCH
4) FRONT STOP SWITCH
5 1 2 3
M-N
VR
VL
L
BL
R
R
GR-R
BL
0FF
AZ
AR
0FF
1 4 ON
ON
2 5
6 4
3 6
B-R
N
7
0FF
BL
R
ON
7
VR-N
BL-N
GL-B
BL-R
BL
N
OFF
ON
NOTE: the start switch is closed when the START button is pressed.
The STOP switch is closed when the brake lever is operated.
12 PAGE ISSUE 02.07

F12R L.C. 50 cc. Fuses B Chapter
FUSES
CHECKING FUSES
CAUTION: when checking fuses, always turn the main switch “OFF” or short-circuits may occur.
Checking procedure:
- Connect Tester (code n°08609500) to fuse and check continuity.
NOTE: 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 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 materials.
An unsuitable fuse can cause extensive damage to the electrical system, malfunctioning of the ignition
and light systems and even fires to break out.
F. 3
C
A) 10A Main / Recharging
B) 5A Stop / Turn indicators / Horn
F. 4 C) 7.5A Lights / Starter
02.07 ISSUE PAGE 13

B Chapter Starting System F12R L.C. 50 cc.
IGNITION SYSTEM
If the ignition system is not working, check:
1) Condition of SPARK PLUG
2) SPARK PLUG CAP RESISTANCE
3) RESISTANCE OF “CDI” CONTROL UNIT
4) RESISTANCE OF START PICK-UP
5) CONTINUITY OF KEY SWITCH
6) CONNECTIONS OF IGNITION SYSTEM
1. Condition of spark plug

- Check condition of spark plug.
- See Engine Workshop Manual.
- Not compliant: replace spark plug.
F. 5
2. Spark plug cap resistance

- Remove spark plug 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 spark plug cap.
2 Tester (kW)
F. 6
14 PAGE ISSUE 02.07

F12R L.C. 50 cc. Starting System B Chapter
3. Resistance of “CDI” control unit (red)

- Connect Tester (2kΩ) to “CDI”, as follows:
- Terminal (+) of Tester HV screw (V).
- Terminal (-) of Tester PIN 1 (GND).
- Resistance: 525 ÷ 640 Ω at 20°C (F.7a).
- Terminal (+) of Tester 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).
Tester (2kW) Tester (2kW)

1
1
V 2
F. 7a F. 7b
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.
Tester (W)
V 1
R 2
GL
F. 8
02.07 ISSUE PAGE 15

B Chapter Starting System F12R L.C. 50 cc.
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
VR-N
BL-N
GL-B
BL-R
BL
Tester (W)
N
OFF
ON
2 1
F. 9
6. Connections of ignition system

- Check connections of ignition system.
- NOTE: pay attention to correctly insert cables into connector (C) of “CD1” control unit.
- Not compliant: resume connections of ignition system.
See "Wiring Diagram”.
C 1 POS. CABLE DESTINATION
2 1 GND (N)
2 PICK-UP (GL/R)
3 3 ENGINE STOP (GL/B)
4 4 REGULATOR (B)
F. 10
16 PAGE ISSUE 02.07

F12R L.C. 50 cc. Ignition System B Chapter
STARTING SYSTEM
If the starting system is not working, check:
1) CONTINUITY OF 10A / 5A FUSE
2) CONDITION OF BATTERY
3) OPERATION OF STARTER MOTOR
4) OPERATION OF STARTING 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.
Tester (W)
F. 11
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.
BATTERIA
-
+
12 V
5Ah
F. 12
02.07 ISSUE PAGE 17

B Chapter Ignition System F12R L.C. 50 cc.
3. Starter motor
- Use a bridge cable (3) to connect the positive battery terminal (1) to the cable of the starter motor (2), as
shown in the figure.
WARNING: for the bridge, use a cable that can withstand the power draw of the starter motor otherwise
it would burn out.
- Check operation of the starter motor.
- Not compliant: replace starter motor.
2 1
BL R
B-R
R
F. 13
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 terminals.
- Check operation of the starter motor.
- Not compliant: replace starting relay.
BL R
R
B-R
4
1
F. 14
18 PAGE ISSUE 02.07

F12R L.C. 50 cc. Ignition System B Chapter
5. Key switch
- Connect Tester (Ω) as follows:
- Terminal (+) of Tester Blue/Red cable (1).
- Terminal (-) of Tester Blue cable (2).
- Turn key “OFF” and then “ON”.
see “Checking switches” on page 11
VR-N
BL-N
GL-B
BL-R
BL
Tester (W)
N
OFF
ON
2 1
F. 15
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
T.1 T.2
Tester (W)
1
2
A
1) Front or rear brake lever
pulled
not pulled
F. 16
02.07 ISSUE PAGE 19

B Chapter Ignition System F12R L.C. 50 cc.
7. Start switch (Start)

- Detach four-way connector of right hand switch.
- Connect Tester (Ω) to connector, as follows:
- Terminal (+) of Tester White/red cable (1).
- Press “START” button.
- Check continuity.
- Not compliant: replace right hand switch.
GR-R
B-R
BL
N
0FF 0FF
ON ON
MODE START Tester (W)

GR-R
B-R
BL
1 2
F. 17
8. Connections of starting system

- Check connections of starting system.
- Not compliant: resume connections of starting system.
See “Wiring Diagram”.
20 PAGE ISSUE 02.07

F12R L.C. 50 cc. Charging System B Chapter
CHARGING SYSTEM
If the charging system is not working, check:
1) CONTINUITY OF 10A FUSE
2) BATTERY CHARGING VOLTAGE
3) CHARGING COIL RESISTANCE
4) CONNECTIONS OF RECHARGING SYSTEM
1. Continuity of 10A fuse

- Remove fuse.
Tester (W)
F. 18
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: use a fully charged battery.
Tester (DC 20 V)
BATTERIA
-
+
12 V
5Ah
1 2
F. 19
02.07 ISSUE PAGE 21

B Chapter Charging System F12R L.C. 50 cc.
3. Charging coil resistance

- Detach connector of flywheel magneto.
- Connect Tester (Ω), as follows:
- Terminal (+) of Tester Yellow cable (1).
- Charging coil resistance: 1 ÷ 1.2 Ω at 20°C.
Tester (W)
2
R
GL
F. 20
4. Connections of recharging system

- Check connections of recharging system.
- Compliant: replace voltage regulator (code n° 02602600).
- Not compliant: resume connections of recharging system.
22 PAGE ISSUE 02.07

F12R L.C. 50 cc. Lighting System B Chapter
LIGHTING SYSTEM
If the lighting system is not working, check:
1) CONTINUITY OF 7.5A FUSE
2) RESISTANCE OF LIGHTING SYSTEM COIL
3) CONTINUITY OF YELLOW CABLE
4) VOLTAGE REGULATOR
5) CONNECTION OF LIGHTING SYSTEM
1. Continuity of 7.5A fuse

- Remove fuse.
Tester (W)
F. 21
2. Lighting system coil resistance

- Detach connector of flywheel magneto.
- Lighting system coil resistance: 1 ÷ 1.2 Ω at 20°C.
- Compliant: continue searching.
Tester (W)
R 2
GL
F. 22
02.07 ISSUE PAGE 23

B Chapter Lighting System F12R L.C. 50 cc.
3. Continuity of yellow cable

- Connect connector of flywheel.
- Disconnect regulator connector.
- Resistance: 1 ÷ 1.2 Ω at 20°C.
- Not compliant: yellow cable interrupted between flywheel connector and regulator connector. Repair.
2 Tester (W)
R-VR
N
BL-R
GL
B
F. 23
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).
- Run engine at 5000 RPM.
- Voltage: > 12 V.
- Not compliant: replace voltage regulator (code n° 02602600).
1
Tester (AC 20 V)
R-VR
N
BL-R
GL 2
B
F. 24
5. Connections of lighting system

- Check connections of lighting system.
- Not compliant: resume connections of lighting system.
24 PAGE ISSUE 02.07

If the headlight is not working, check:

1) CONTINUITY OF LIGHT BULB AND RELATIVE COUPLING
2) VOLTAGE DELIVERED TO LAMP SOCKET
1. Continuity of light bulb and relative coupling

- Remove light bulb.
- Connect Tester (Ω) to light bulb.
- Check continuity of light bulb.
- Not compliant: replace light bulb.
2. Voltage delivered to lamp socket

- Connect Tester (20 V AC) to connector of headlight, as follows:
- Terminal (+) of Tester Pink cable (1).
- Voltage delivered to lamp socket: > 12 V.
- Not compliant: pink cable is interrupted. Repair.
Tester (AC 20 V)
35 W 35 W
H8 H8
A B A B
RS
RS
N
1 2
F. 25
02.07 ISSUE PAGE 25

B Chapter Lighting System F12R L.C. 50 cc.
If the instrument board indicator lights are not working, check:

1) VOLTAGE DELIVERED TO INSTRUMENT BOARD
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).
- Voltage delivered to instrument board: > 12 V.
- Compliant: replace instrument board.
- NOTE: if the indicator light does not come on during the “CHECK”, replace the instrument board.
12 24 BL-VR
11 23 Tester (AC 20 V)
10 22
BL-R 9 21
B-VL 8 20
PIN 3 GL-BL 7 19 B-VR PIN 17
BL 6 18 GR
N-R 5 17 N
RS 4 16 VL
RS 3 15
VR 2 14 GR-R
RS 1 13 B
F. 26
26 PAGE ISSUE 02.07

If the rear light is not working, check:

1) CONTINUITY OF LAMP
2) VOLTAGE DELIVERED TO LAMP SOCKET
1. Continuity of lamp
- 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).
Tester (AC 20 V)
F. 27
02.07 ISSUE PAGE 27

B Chapter Signalling System F12R L.C. 50 cc.
SIGNALLING SYSTEM
If the signalling system is not working, check:
1) CONTINUITY OF 10 A FUSE
2) CONDITION OF BATTERY
3) KEY SWITCH
4) CONNECTIONS OF SIGNALLING SYSTEM

- Remove fuse.
Tester (W)
F. 28
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.
BATTERIA
-
+
12 V
5Ah
F. 29
28 PAGE ISSUE 02.07

F12R L.C. 50 cc. Signalling System B Chapter
3. Key switch
- Turn key “ON”
- Terminal (+) of Tester Blue/Red cable (1).
- Terminal (-) of Tester Blue cable (2).
VR-N
BL-N
GL-B
BL-R
BL
N
Tester (W)
OFF
ON
2 1
F. 30
4. Connections of signalling system

- Check connections of signalling system.
- Not compliant: resume connections of signalling system.
02.07 ISSUE PAGE 29

If the horn is not working, check:

1) HORN SWITCH
2) VOLTAGE DELIVERED TO HORN
3) GROUNDING OF HORN
1. Horn switch
- Disconnect six-way connector of left hand switch.
- Press Horn button to activate horn.
- Terminal (+) of Tester Orange cable (1).
- Terminal (-) of Tester Light blue cable (2).
- Check continuity of switch (with button pressed).
- Not compliant: replace left hand switch.
M-N
VR
VL
0FF
Tester (W)
AZ
AR
L
ON
R
TURN HORN
M-N
VL
VR
AR
AZ
1 2
F. 31
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).
- Press Horn button.
- Voltage delivered to horn: > 12 V.
- Not compliant: resume connections of horn power supply circuit.
Tester (DC 20 V)
N 2
+ AR
1
F. 32
30 PAGE ISSUE 02.07

3. Grounding of horn
- Disconnect black cable from terminal of horn.
- Connect a bridge cable (1) between terminal (2) and grounding point of chassis (3).
- Press Horn button to activate horn.
- Compliant: resume connection between black cable and chassis grounding.
- Not compliant: replace horn.
2 3
N
+ AR
F. 33
IIf stop light is not working, check:

3) FRONT AND REAR BRAKE SWITCH
4) VOLTAGE DELIVERED TO LIGHT BULB COUPLING
- Remove fuse.
- Not compliant: replace fuse
- NOTE: if 5A fuse is not compliant, the flashlight will not be working.2.
Tester (W)
F. 34
02.07 ISSUE PAGE 31


- Check continuity of light bulb and its coupling.
- Not compliant: replace light bulb or coupling.
3. Front and rear brake switch

- Disconnect switch cables (A).
- Connect Tester (Ω) to terminals (T1-T2).
- Check continuity between terminals.
- Not compliant: replace stop switch.
T.1 T.2
Tester (W)
1
2
A
pulled
not pulled
F. 35
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).
- Pull front or rear brake lever
- Voltage delivered to light bulb coupling: > 12 V.
- Not compliant: red cable interrupted. Resume connection.
- NOTE: if the grounding connection is interrupted, the rear light will not be working.
Tester (DC 20 V)
1
F. 36
32 PAGE ISSUE 02.07

If the turn indicators and the relative indicator lights are not working, check:
2) TURN INDICATOR SWITCH
3) VOLTAGE DELIVERED TO FLASHLIGHT
4) CONTINUITY OF BROWN/BLACK CABLE
1. 5 A fuse
- Remove fuse.
Tester (W)
F. 37
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.
Tester (W) Tester (W)
M-N
M-N
VR
VR
VL
VL
0FF 0FF
AZ
AR
AZ
AR
L L
ON ON
R R
TURN HORN TURN HORN
M-N
M-N
VL
VL
VR
VR
AR
AR
AZ
AZ
2 1 3 1
F. 38a F. 38b
02.07 ISSUE PAGE 33

3. Voltage delivered to flashlight

- Detach flashlight connector.
- Connect Tester (20 V DC), as follows:
- Terminal (+) of Tester Blue cable (1).
- Voltage delivered to flashlight: > 12 V.
- Not compliant: blue cable interrupted. Repair.
Tester (DC 20 V)
1
M-N
M
BL
2
F. 39
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.
M-N
VR
VL
0FF
AZ
AR
L
ON
Tester (W)
R
TURN HORN
M-N
M
BL
M-N
VL
VR
AR
AZ
F. 40
34 PAGE ISSUE 02.07

If right or left turn indicators are not working, check:

2) VOLTAGE DELIVERED TO RIGHT OR LEFT LAMP SOCKET

- Check continuity of light bulb.
- Not compliant: replace light bulb.
2. Voltage delivered to 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).
- Right turn indicator (B):
- Terminal (+) of Tester Green cable (3).
- Operate switch to activate left turn indicators (A)
- Operate switch to activate right turn indicators (B)
- Not compliant: resume connection between switch of turn indicators and connector of light bulb coupling.
Tester (DC 20 V) Tester (DC 20 V)
A B
10 W 10 W
2 4
VR
N
VL
1 3
F. 41a F. 41b
02.07 ISSUE PAGE 35

If “MODE” button is not working, check:

1) CONTINUITY OF “MODE” BUTTON
2) VOLTAGE DELIVERED TO “MODE” BUTTON
3) CONTINUITY OF GREY/RED CABLE
1. Continuity of “Mode” button

- Disconnect four-way connector of right hand switch.
- Terminal (-) of Tester Grey/red cable (2).
- Press “MODE” button.
- Check continuity.
- Not compliant: replace right hand switch.
GR-R
B-R
BL
0FF 0FF
ON ON
MODE START Tester (W)

GR-R
B-R
BL
1
2
F. 42
36 PAGE ISSUE 02.07

2. Voltage delivered to “Mode” button

- Connect Tester (20 V DC) to connector (system side), as follows:
- Voltage delivered to right hand switch: > 12 V.
GR-R
B-R
BL
N
0FF 0FF
ON ON
MODE START Tester (DC 20 V)
2
GR-R
B-R
BL
F. 43
3. Continuity of grey/red cable

- Terminal (+) of Tester Grey/red cable (right hand switch) (1).
- Terminal (-) of Tester Grey/red cable (PIN 14 of instrument board) (2).
- Compliant: replace digital instrument.
- Not compliant: grey/red cable is interrupted. Repair.
GR-R
B-R
BL
12 24 BL-VR 0FF 0FF

Tester (W)
11 23 ON ON
10 22 MODE START
BL-R 9 21
B-VL 8 20
GL-BL 7 19 B-VR
BL 6 18 GR
N-R 5 17 N
RS 4 16 VL 2
RS 3 15
VR 2 14 GR-R
RS 1 13 B
GR-R
B-R
BL
1
F. 44
02.07 ISSUE PAGE 37

If H2O temperature indicator is not working, check:

1) RESISTANCE OF H2O TEMPERATURE PROBE
- NOTE: the LED and relative icon on the display will start flashing to signal that the probe is not
connected.
F. 45
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.
H
L
F. 46
1. Resistance of H2O temperature probe
- Measurement of H2O temperature is performed in accordance to the following table:

°C Resistance (W) Segments
≤ 30 >2060 0
30 ÷ 39 2059 ÷ 1249 1
40 ÷ 49 1250 ÷ 891 2
50 ÷ 59 890 ÷ 591 3
60 ÷ 79 590 ÷ 281 4
80 ÷ 94 280 ÷ 161 5
95 ÷ 99 160 ÷ 151 6
100 ÷ 104 150 ÷ 134 7
>105 ≤ 133 8
38 PAGE ISSUE 02.07

If the mixture oil signal is not correct, check:

1) OIL PROBE
2) VOLTAGE LEVEL CHECK
1. Oil probe
- Detach connector of oil probe and take it out of tank.
- Terminal (+) of Tester Coupling (1).
- Terminal (-) of Tester Coupling (2).
- Check continuity of float (A). In there is continuity, the float will move freely and position itself at the base
of the probe.
- Not compliant: replace oil probe.
Tester (W)
1 2
A
F. 47
2. Check voltage level

- Connect Tester (20 V DC) to connector (system side), as follows:
- Voltage delivered to oil probe: > 12 V.
- Compliant: white/purple cable interrupted between probe and digital instrument (PIN 8). Repair.
Tester (DC 20 V)
BL B/VL
F. 48
02.07 ISSUE PAGE 39

NOTE: every time the sensor closes (V dc), the system activates the alarm procedure, which consists
in the oil icon lighting up on the display along with the relative red warning light. The system
will in any case remain fully operative. To avoid false alarms, 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
- NOTE: the information is displayed in graphic form by means of a bar graph with eight segments
located on the bottom right of the display and accompanied by the “fuel” icon.
F. 50
- CAUTION: the relative icon will start flashing if the probe is not connected.
F. 51
40 PAGE ISSUE 02.07

1. Resistance of fuel probe
- Probe readings take place in accordance to the following table:
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
- Detach the connector of the fuel probe (S).

- Provide a jumper (1) between grey cable and black cable of connector (system side).
- Turn key “ON” and wait a few seconds (THE INDICATOR/WARNING LIGHT CHECK IS PERFORMED).
- Bar graph with 0 segments: continue searching.
- Bar graph with 8 segments: replace fuel probe.
~ ~
1 GR N
F. 52
02.07 ISSUE PAGE 41

2. Continuity of grey cable

- Connect Tester (Ω).
- Check continuity of grey cable between fuel probe connector (1) and instrument board connector (PIN 18) (2).
- Compliant: black cable interrupted (probe connector). Repair.
- Not compliant: grey cable interrupted. Repair.
12 24 BL-VR 1
Tester (W)
11 23
10 22
BL-R 9 21
B-VL 8 20 2 GR N
GL-BL 7 19 B-VR
BL 6 18 GR
N-R 5 17 N
RS 4 16 VL
RS 3 15
VR 2 14 GR-R
RS 1 13 B
F. 53
42 PAGE ISSUE 02.07

Fuel level alarm

This alarm is activated by a switch located in the front section of the tank.
When the level of fuel in the tank drops to its minimum threshold (less than 2.5 litres), the first segment
of the relative bar graph will start flashing 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, this alarm is activated only if the contact remains grounded for a
period of more than ten seconds.
F. 55
02.07 ISSUE PAGE 43

If the instrument board (speedometer function) is not functioning correctly, check:

1) VOLTAGE DELIVERED TO REV COUNTER SENSOR
2) SIGNAL SENT TO INSTRUMENT BOARD
3) CONTINUITY OF WHITE CABLE
1. Voltage 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).
- 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 digital instrument board.
Tester (DC 20 V)
BL
N
B
GL-BL
N
B
2 1
F. 56
44 PAGE ISSUE 02.07

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).
12 24 BL-VR
11 23 Tester (DC 20 V)
10 22
BL-R 9 21
B-VL 8 20
GL-BL 7 19 B-VR
BL 6 18 GR
2
N-R 5 17 N
RS 4 16 VL
RS 3 15
VR 2 14 GR-R
RS 1 13 B
1
F. 57a
- Let wheel run in riding direction and check power as follows:
- Sensor (3) Slot on disc (4).
- Voltage: 5±0.5 V.
- Sensor (3) Disc body (5).
- Voltage: 0.20±0.15 V.
- Not compliant: continue searching.
Tester (DC 20 V) Tester (DC 20 V)
4 3 5 3
F. 57b F. 57c
02.07 ISSUE PAGE 45

3. Continuity of white cable

- Check continuity of white cable between connector of rev counter sensor (1) and instrument board connector
(PIN 13) (2).
- No continuity: white cable interrupted. Repair.
12 24 BL-VR Tester (W)

11 23
10 22
BL-R 9 21
B-VL 8 20
GL-BL 7 19 B-VR
BL 6 18 GR
BL
N
B
N-R 5 17 N
RS 4 16 VL
GL-BL
N
B
RS 3 15
2
VR 2 14 GR-R
RS 1 13 B
1
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 on operation of the instrument: all functions are there-
fore available.
The alarm condition ends when temperature rises above 5°C.
F. 59
46 PAGE ISSUE 02.07

f12r LC 50 CC

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F12R L.C. 50 cc. - Euro 2

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GENERAL WIRING DIAGRAM 2 8

 PAGE ISSUE 02.07

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FIRST ISSUE : 02/07

• IMPORTANT! The Electrical System Troubleshooting Manual is to be considered as an essential tool to be

02.07 ISSUE PAGE 

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NOTES FOR EASY CONSULTATION

(RIGHT HAND PAGE)

 PAGE ISSUE 02.07

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A) CAUTION! Recommendations and precautions

B) WARNING! Situations entailing the risk of personal

I) ENGINE SERVICE MANUAL I

02.07 ISSUE PAGE 

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 PAGE ISSUE 02.07

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1) AMBIENT TEMPERATURE PROBE 9) STARTING RELAY

02.07 ISSUE PAGE 

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M-N M-N M-N

Sensore temperatura acqua. RS B

Imp. Luci / starter <

GR-R GR-R GR-R

GENERAL WIRING DIAGRAM

AR ORANGE GL-B YELLOW/WHITE

KEY TO GENERAL WIRING DIAGRAM

02.07 ISSUE PAGE 

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INSTRUMENT BOARD CONNECTOR CONFIGURATION

1) RPM RS 13) HALL SENSOR SIGNAL B

2) RIGHT TURN INDICATOR VR 14) MODE BUTTON GR-R

3) LIGHT INDICATOR RS 15) - -

4) BACKLIGHTING RS 16) LEFT TURN INDICATOR VL

5) AMBIENT TEMPERATURE N-R 17) GND (-) N

6) KEY ACTIVATION (+12V) BL 18) FUEL PROBE GR

8) MIXTURE OIL B-VL 20) - -

9) BATTERY POSITIVE BL-R 21) - -

12) - - 24) FUEL RES. WARNING LIGHT BL-VR

10 PAGE ISSUE 02.07

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Set the tester to function Ω.

CONNECTION OF SWITCHES DESCRIBED IN THIS MANUAL

02.07 ISSUE PAGE 11

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POSITION OF SWITCHES AND CONNECTION OF CONNECTORS

1) REAR STOP SWITCH 5) “MODE” BUTTON SWITCH

12 PAGE ISSUE 02.07

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NOTE: put the Tester on “Ω” (sound-emitting function).

02.07 ISSUE PAGE 13

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1. Condition of spark plug

2. Spark plug cap resistance

14 PAGE ISSUE 02.07

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3. Resistance of “CDI” control unit (red)

Tester (2kW) Tester (2kW)

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