CFMoto motorcycle CF650NK. Service Manual - part 13

FUEL SYSTEM (EFI) 3-1

FUEL SYSTEM (EFI)

Table of Contents

Exploded View............................................................................................................................. 3-2

EFI System Wiring....................................................................................................................... 3-4

ECU Pin Function......................................................................................................................... 3-6
EFI Parts Location........................................................................................................................ 3-7

Specifications...............................................................................................................................

3-9

Special Tools................................................................................................................................ 3-11
EFI Servicing Precautions............................................................................................................ 3-12
EFI Troubleshooting..................................................................................................................... 3-14

Outline..................................................................................................................................... 3-14

EFI System Troubleshooting Table............................................................................................... 3-18
EFI System Troubleshooting Guide............................................................................................. 3-19
Self-diagnosis Outline.................................................................................................................. 3-29

Service Code Table................................................................................................................. 3-32

Backups..................................................................................................................................... 3-34

Backups.................................................................................................................................. 3-34

Throttle Position Sensor (Service Code 11)................................................................................ 3-35

Throttle Position Sensor Removal/Adjustment........................................................................ 3-35
Throttle Position Sensor Input Voltage Inspection................................................................... 3-35
Throttle Position Sensor Output Voltage Inspection ............................................................... 3-36
Throttle Position Sensor Resistance Inspection...................................................................... 3-38

Inlet Air Pressure Sensor (Service Code 12)............................................................................... 3-39

Inlet Air Pressure Sensor Removal.......................................................................................... 3-39
Inlet Air Pressure Sensor Installation....................................................................................... 3-39
Inlet Air Pressure Sensor Input Voltage Inspection.................................................................. 3-39

Inlet Air Temperature Sensor (Service Code 13)......................................................................... 3-40

Inlet Air Temperature Sensor Resistance Inspection............................................................... 3-40

Water Temperature Sensor (Service Code 14)............................................................................ 3-42

Water Temperature Sensor Removal/Installation.................................................................... 3-42
Water Temperature Sensor Output Voltage Inspection............................................................ 3-42

ECU............................................................................................................................................. 3-57

Fuel Line...................................................................................................................................... 3-60

Fuel Pump................................................................................................................................... 3-62

Fuel Injectors............................................................................................................................... 3-68
Throttle Cable.............................................................................................................................. 3-73
Throttle Body Assy....................................................................................................................... 3-74

Error Code Troubleshooting......................................................................................................... 3-77

3-2 FUEL SYSTEM (EFI)

Exploded View

FUEL SYSTEM (EFI) 3-3

a

. Ignition 

Switch

b

.  Engine Stop Switch

c

. Starter 

Switch

d

. Tachometer

e

.  FI Indicator Light(LED)

f

. Spark 

Plug

g

.   Crankshaft Position Sensor

h

. Fuel 

Injector

i

.  Throttle Position Sensor

j

. Fuel 

Rail

k

. Throttle 

Body

l

. Fuel 

Pump

m

. Pressure 

Regulator

n

. Fuel 

Tank

o

.  Air Filter Element

p

. Inlet 

Air 

Temperature 

Sensor

q

.  Air Filter Housing

r

. Neutral 

Switch

s

. Speed 

Sensor

t

. Roll-over 

Sensor

u

. Oxygen 

Sensor

v

. Battery

w

. ECU

x

. Inlet 

Air

fl

 ow Direction

w

.  Pressurized Fuel Direction

z

. Coolant 

Temperature 

Sensor

 

3-4 FUEL SYSTEM (EFI)

EFI Wiring Diagram

FUEL SYSTEM (EFI) 3-5

a

.  Front Position Light

b

.   Rear Position Light

c

.   Headlight

d

.   Front left turn light

e

.   Auxiliary Starter Relay

f

.   Speedometer

g

.   Fuel Meter

h

.   Coolant Temperature Sensor

i

.   FI Indicator Light

j

.   Tachometer

k

. Meter 

Unit

l

.   Horn

m

. Horn 

Switch

n

. Dimmer 

Switch

o

.   Turn Switch

p

.   Clutch Lever Switch

q

.   High Beam Relay

r

.   Low  Beam Relay

s

.   Starter Switch

t

.   Light Switch

u

.   Engine Stop Switch

v

.   Front Brake Switch

w

.   Fuel Pump Relay

x

.   Fan Relay

y

.   Auxiliary Starter Relay

z

.   Fuse Box

@7

. Ignition 

Switch

@8

.    Oil Pressurre Switch

@9

.  Crankshaft Position Sensor

#0

. Magneto 

Assembly

#1

. Regulator/Recti

fi

 er

#2

. Starter 

Relay

#3

. Starter 

Motor

#4

. Battery

#5

. Neutral 

Switch

#6

.  Rear Right Turn Light

#7

. Tail/btake 

Light

#8

.  License Plate Light

#9

.  Rear Left Turn Light

$0

. Fuel 

Pump

$1

.  Fuel Injector 1

$2

.  Fuel Injector 2

$3

.  Ignition Coil & Spark Plug 1

$4

.  Ignition Coil & Spark Plug 2

$5

.  Oxygen Sensor 1

$6

.  Oxygen Sensor 2

$7

. Diagnosis 

Connector

$8

. Inlet 

Air 

Temperature 

sensor

$9

. Coolant 

Temperature 

Sensor

%0

.  Throttle Position Sensor

%1

. Tip-over 

Sensor

%2

. ECU

%3

. Sidestand 

Switch

%4

.  Rear Brake Switch

3-6 FUEL SYSTEM (EFI)

ECU Pin and Function

a

.  Power Supply to ECU (from Battery Positive 

        Terminal)

b

.  Ground to ECU (from Battery Negative  

        Terminal)

c

.  Fuel Pump Relay

d

. Fan 

Relay

e

.  Auxiliary Starter Relay

f

.  FI Indicator Light

g

.  Fuel Injector 1

h

.  Fuel Injector 2

i

. Unused

j

. Unused

k

.  Ignition Coil 1

l

.  Ignition Coil 1

m

. Clutch 

Switch

n

. Unused

o

.  RPM Output (0-12V)

p

. Unused

q

.  Ground to ECU (Battery Negative Terminal)

r

.  ECU Power (Ignition Switch or Starter Switch)

s

.  Crankshaft Position Sensor Signal A

t

.  Crankshaft Position Sensor SignalB

u

.  Ground to Oxygen

v

.  Oxygen Sensor 1 Signal

w

.  Oxygen Sensor 2 Signal

x

.  Cable K Diagnosis  

y

. Neutral 

Switch

z

. Sidestand 

Switch

@7

.  Ground to Sensors

@8

.  Inlet Air Temperature Sensor Signal

@9

.  Coolant Temperature Sensor Signal

#0

. TPS 

Signal

#1

.  Roll-over Sensor Signal

#2

.  +5V Power Supply

#3

. Unused

#4

. Unused

FUEL SYSTEM (EFI) 3-7

EFI Parts Location

3-8 FUEL SYSTEM (EFI)

EFI Parts Location

a 

Ignition Coil

b

.  Clutch Lever Sensor

c

.  Throttle Position Sensor

d

.  Fuel Sensor

`e

.  Coolant Temperature Sensor

f

.  Fuel Pump

g

.  Fuel Pump Relay

h

.  Fuse Box

i

. Battery

j

. ECU

k

.  Sidestand Switch

l

.  Speed Sensor

m

.  Neutral Switch

n

.  Spark Plug

o

.  Oxygen Sensor

p

.  Ignition Coil

q

.  Diagnosis Connector

r

.  Inlet Air Temperature Sensor

s

.  Throttle Body

t

.  Engine Stop Switch

u

.  FI Indicator

v

.  Roll-over Sensor

FUEL SYSTEM (EFI) 3-9

Item

Standard

EFI:
Idle Speed

1300±50 r/min(rpm)

Thrttle Body Assy:
Type

Two barrel type

Bore

Ø 38 mm

ECU:
Make

Ducati

Type

Digital memory type, with bult in IC igniter, sealed with resin

Usable Engine Speed

100-11000 r/min (rpm)

Fuel Pressure (High Pressure Line):
Right After Ignition Switch ON

323 kPa (3.3 kgf/cm

2

, 47 psi ) with fuel pump running

After 3 Seconds from Ignition Switch ON 265 kPa (2.7 kgf/cm

2

, 38 psi ) with fuel pump stopped

With Engine Idling

333 kPa (3.4 kgf/cm

2

, 48 psi ) with fuel pump running

Fuel Pump:
Type

In-tank friction pump

Fuel Injectors:
Type

IWP 156

Nozzle Type

One spray with 5 holes

Resistance

About 13.5-15.5 

Ω

 at 20 °C (68 °F )

Throttle Position Sensor

Non-adjustable and non-movable

Input Voltage

4.75~5.25 V DC between L/G and Gr/R

Output Voltage at Idle Throttle Opening

0.4~0.7 V DC between L/G and Br/R

Output Voltage at Full Throttle Opening

2.9~3.4 V DC between L/G and Br/R

Resistance

1.1~1.4 k

Ω

 

Inlet Air Temperature Sensor:
Resistance

See text in Inlet Air Temperature Sensor Section

Output Voltage at ECU

About 2.5~3.50 V at 20 20 °C (68 °F )

Coolant Temperature Sensor:
Resistance

See Electrical System chapter

Output Voltage at ECU

About 2.5-3.50 V at 20 20 °C (68 °F )

Speed Sensor:
Input Voltage at Sensor

About 9~11 V DC at Ignition Switch ON

Output Voltage at Sensor

About 0.05~1 V DC at Ignition Switch ON and 0 km/h

Tip-over Sensor:
Detection Method

Resistance detection method

Detection Angle

More than 40 °~50 ° for each bank

Resistance

More than 40 °~50 ° : 

≤

 0.5 

Ω

 

Less than 40 °: 60~63 k

Ω

Oxygen Sensor:
Outout Voltage (rich)

0.7 V or more

Outout Voltage (lean)

o.2 V or less

Throttle Grip and Cables:
Throttle Grip Free Play

2~3 mm (0.08~0.12 in.)

Specifi cations

3-10 FUEL SYSTEM (EFI)

Specifi cations

Item

Standard

Oxygen Sensor:
Outout Voltage (rich)

0.7 V or more

Outout Voltage (lean)

0.2 V or less

Throttle Grip and Cables:
Throttle Grip Free Play

2~3 mm (0.08~0.12 in.)

                  

FUEL SYSTEM (EFI) 3-11

Oil Pressure Gauge

 Needle Adaptor Set

Throttle Sensor Setting Harness

Hand Tester

Fuel Pressure Gauge Adaptor

Fuel Hose

Peak Voltage Adapter

Special Tools

3-12 FUEL SYSTEM (EFI)

EFI Servicing Precautions

There are a number of important precautions that should
be followed servicing the EFI system.



 This EFI system is designed to be used with a 12 V

   sealed battery as its power source. Do not use any
   other battery except for a 12 V sealed battery as a
   power source.



 Do not reverse the battery cable connections.  This

   will damage the ECU.



 To prevent damage to the EFI parts, do not discon-

   nect the battery cables or any other electrical con-
   nections when the ignition switch is on or while the
   engine is running.



 Take care not to short the leads that are directly

   connected to the battery positive (+) terminal to the
   chassis ground.



 When charging, remove the battery from the

   motorcycle. This is to prevent ECU damage by ex-
   cessive voltage.



 Do not turn the ignition switch ON while any of the

   EFI electrical connectors are disconnected. The
   ECU memorizes service codes.



 Do not spray water on the electrical parts, EFI parts,

   connectors, leads, and wiring.



 Whenever the EFI electrical connections are to be

   disconnected, first turn off the ignition switch, and
   disconnect the battery (-) terminal. Do not pull the
   lead, only the con- nector. Conversely, make sure
   that all the EFI electrical connections are firmly re-
   connected before starting the engine.



 Connect these connectors until they click [A].



 If a transceiver is installed on the motorcycle, make

  sure that the operation of the EFI system is not
  influenced by electric wave radiated from the
  antenna. Check operation of the system with the
  engine at idle. Locate the antenna as far as pos
  sible away from the ECU.

FUEL SYSTEM (EFI) 3-13



 To maintain the correct fuel/air mixture (F/A), there

   must be no inlet air leaks in the EFI system. Be
   sure to install the oil filler plug [A] after filling the
   engine oil.
   Clutch Cover [B]
  

 Torque-Oil Filler Plug: Hand-tighten



 Do not operate the fuel pump if the pump is com

   pletely dry. This is to prevent pump seizure.



 Before removing the fuel system parts, blow the outer

  surfaces of these parts clean with compressed air.



 To prevent corrosion and deposits in the fuel system,

   do not add to fuel any fuel antifreeze chemicals.

EFI Servicing Precautions



 When any fuel hose is disconnected, fuel may spout

  out by residual pressure in the fuel line. Cover the
  hose joint with a piece of clean cloth to prevent fuel
  spillage.



 When any fuel hose is disconnected, do not turn on

   the ignition switch. Otherwise, the fuel pump will
   operate and fuel will spout from the fuel hose.

3-14 FUEL SYSTEM (EFI)

EFI Servicing Precautions

Outline

When an abnormality in the system occurs, the FI
indicator light (LED) goes on to alert the rider on the
meter panel.  In addition, the condition of the problem
is stored in the memory of the ECU (electronic control
unit). With the engine stopped and turned in the self-
diagnosis mode, the service code [A] is indicated by
the number of times the FI indicator light (LED) blinks.
When due to a malfunction, the FI indicator light (LED)
remains lit, ask the rider about the conditions [B] un-
der which the problem occurred and try to determine
the cause [C].



 First, conduct a self-diagnosis inspection and then

   a non-self-diagnosis inspection. The non-self-diag-
   nosis items are not indicated by the FI indicator light
  (LED). Don't rely solely on the EFI self-diagnosis
  function, use common sense.

Even when the EFI system is operating normally, the
FI indicator light (LED) [A] may light up under strong
electrical interference.  No repair needed.  Turn the
ignition switch OFF to stop the indicator light.
When the FI indicator light (LED) goes on and the
motorcycle is brought in for repair, check the service
codes. When the repair has been done, the light (LED)
doesn't go on. But the service codes stored in memory
are not erased to preserve the problem history, and
the light (LED) can display the codes in the self-diag-
nosis mode. The problem history is referred when solv-
ing unstable problems.
When the motorcycle is down, the vehicle-down sen-
sor is turned OFF and the ECU shuts off the fuel injec-
tors and ignition system. The FI indicator light (LED)
blinks but the service code cannot be displayed. The
ignition switch is left ON. If the starter button is pushed,
the electric starter turns but the engine doesn't start.
To start the engine again, raise the motorcycle, turn
the ignition switch OFF, and then ON. The vehicle-
down sensor is turned ON and the light (LED) goes
OFF.

FUEL SYSTEM (EFI) 3-15

EFI Servicing Precautions

O

 The DFI part connectors [A] have seals [B], includ-

    ing the ECU.



 Join the connector and insert the needle adapters

   [C] inside the seals [B] from behind the connector
   until the adapter reaches the terminal.
   

Special Tool - Needle Adapter Set



 Make sure that measuring points are correct in the

   connector, noting the position of the lock [D] and
   the lead color before measurement. Do not reverse
   connections of the hand tester or a digital meter.



 Be careful not to short-circuit the leads of the EFI

  or electrical system parts by contact between
   adapters.



 Turn the ignition switch ON and measure the volt-

   age with the connector joined.



 After measurement, remove the needle adapters and

  apply silicone sealant to the seals [A] of the con-
  nector [B] for waterproofing.



 Always check battery condition before replacing the

  EFI parts.  A fully charged battery is a must for con-
  ducting accurate tests of the DFI system.

Insert the needle adapter straight along the ter-

minal in the connector to prevent short-circuit

between terminals.

N

O

I

T

U

A

C

N

O

I

T

U

A

C

Incorrect, reverse connection or short circuit by

needle adapters could damage the DFI or elec-

trical system parts.



 Trouble may involve one or in some cases all items.

   Never replace a defective part without determining
   what CAUSED the problem.  If the problem was
   caused by some other item or items, they too must
   be repaired or replaced, or the new replacement part
   will soon fail again.

FUEL SYSTEM (EFI) 3-15

EFI Troubleshooting

O

 The EFI part connectors [A] have seals [B], includ-

    ing the ECU.



 Join the connector and insert the needle adapters

   [C] inside the seals [B] from behind the connector
   until the adapter reaches the terminal.
   

Special Tool - Needle Adapter Set



 Make sure that measuring points are correct in the

   connector, noting the position of the lock [D] and
   the lead color before measurement. Do not reverse
   connections of the hand tester or a digital meter.



 Be careful not to short-circuit the leads of the EFI

  or electrical system parts by contact between
   adapters.



 Turn the ignition switch ON and measure the volt-

   age with the connector joined.



 After measurement, remove the needle adapters and

  apply silicone sealant to the seals [A] of the con-
  nector [B] for waterproofing.



 Always check battery condition before replacing the

  EFI parts.  A fully charged battery is a must for con-
  ducting accurate tests of the EFI system.

Insert the needle adapter straight along the ter-

minal in the connector to prevent short-circuit

between terminals.

N

O

I

T

U

A

C

N

O

I

T

U

A

C

Incorrect, reverse connection or short circuit by

needle adapters could damage the EFI or elec-

trical system parts.



 Trouble may involve one or in some cases all items.

   Never replace a defective part without determining
   what CAUSED the problem.  If the problem was
   caused by some other item or items, they also must
   be repaired or replaced, or the new replacement part
   will soon fail again.