CFMoto motorcycle CF650NK. Service Manual

16-30 ELECTRICAL SYSTEM

Ignition System

Ignition Coil

Stick Coil Primary Peak Voltage

NOTE

Be sure the battery is fully charged.



Remove the ignition coils (see Ignition Coil (Ignition

Coil together with Spark Plug Cap) Removal), but
do not remove the spark plugs.



Measure the primary peak voltage as follows.



Install the new spark plug [A] into each ignition coil

[B], and ground them onto the engine.



Connect the peak voltage adapter [C] into the hand

tester [D] which is set to the x DC 250 V range.



Connect the adapter to the lead wire-peak

voltage adapter [E] which is connected between
the ignition coil connector and ignition coil.
Battery [G]
ECU [F]

WARNING

To avoid extremely high voltage shocks, do

not touch the spark plugs or tester connections.



Turn the ignition switch and the engine stop switch

ON.



Pushing the starter button, turn the engine 4~5 sec

onds with the transmission in neutral to measure
the primary peak voltage.



Repeat the measurements 5 times for one ignition

coil.

Stick Coil Primary Peak Voltage

Standard: 88 V or more



Repeat the test for the other stick coil.



If the reading is less than the specified value, check

the following.
Ignition Coils (see Ignition Coil (Ignition Coil together
with Spark Plug Cap) Inspection)
Crankshaft Position Sensor (see Crankshaft Sen
sor Inspection)
ECU (see ECU Power Supply Inspection in the EFI
chapter)

Spark Plug Removal



Refer to the Spark Plug Replacement in the Peri-

odic Maintenance chapter.

Spark Plug Installation



Refer to the Spark Plug Replacement in the Peri-

odic Maintenance chapter.

WARNING

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ELECTRICAL SYSTEM 16-31

Ignition System

Spark Plug Condition Inspection



Refer to the Spark Plug Condition Inspection in the

Periodic Maintenance chapter.

Interlock Operation Inspection



Raise the rear wheel off the ground with stand.

1st Check



Start the engine to the following conditions.

Condition

Transmission Gear

1st Position

Clutch Lever

Release

Sidestand

Down or Up



Turn the ignition switch ON and push the starter

button.



Then the starter motor should not turn when the

starter system circuit is normality.



If the engine is start, inspect the starter lockout

switch, neutral switch and relay box.



If their parts are normality replace the ECU.

2nd Check



Start the engine to the following conditions.

Condition

Transmission Gear

1st Position Clutch Le-

ver

Pulled in Sidestand



Turn the ignition switch ON and push the starter

button.



Then the starter motor should turn when the starter

system circuit is normality.



If the starter motor is not turn, inspect the clutch

switch, neutral switch and relay box.



If their parts are normality replace the ECU.

3rd Check



Inspect the engine for its secure stop after the fol-

lowing operations are completed.



Run the engine to the following conditions.

Condition

Transmission Gear

1st Position Clutch Le-

ver

Pulled in Sidestand



Set the sidestand on the ground, then the engine

will stop.



If whichever may not be stopped, inspect the neu-

tral switch, clutch switch, sidestand switch and re
lay box.



If their parts are normality, replace the ECU.

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ELECTRICAL SYSTEM 16-33

Ignition System

Ignition System Troubleshooting Chart

Faulty Ignition (No spark)

Battery inspection

Ignition system wiring and connector

inspection

Spark plug inspection

Ignition coil winding resistance inspection

Ignition coil primary peak voltage

inspection

I g n i t i o n c o i l i s

defective. Replace

the ignition coil.

Voltage is zero or

almost zero.

Inspect:

1 . A d a p t e r c o n n e c t i o n i s

incorrect, or adapter is

defective.

2. Ignition switch and engine

stop switch

3. Crankshaft position sensor

peak voltage

Replace bad parts.

Charge of replace battery.

Repair or replace damaged part.

Replace spark plug.

Replace ignition coil.

Voltage is less than the specified

value.

Inspect:

1. Crankshaft position sensor peak

voltage

ECU is defective. Replace ECU .

Replace bad parts or inspect them

with hand tester.

No good

Good

No good

Good

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16-34 ELECTRICAL SYSTEM

Ignition System
Ignition System Circuit

1. Fuel Pump Relay

2.Crankshaft Position Sensor

3. Ignition Switch

4.Fuse Box

5. Starter Button

6.Engine Stop Switch

7. Auxiliary Starter Relay

8.Starter Relay

9. Battery

10.Neutral Switch

11. ECU

12.Ignition Coil &Spark Plug # 1

13. Ignition Coil &Spark Plug #2

14.Oxygen Sensor # 1

15. Oxygen Sensor # 2

16.Air Temperature Sensor

17. Coolant Temperature Sensor

18.Roll-over Sensor

19. Throttle Position Sensor

20.Sideswitch

21. Fuel Pump

22.Fuel Injector # 1

23. Fuel Injector # 2

24.Clutch Swith

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ELECTRICAL SYSTEM 16-35

Electric Starter System

Starter Motor Removal

Do not tap the starter motor shaft or body.

Tapping the shaft or body could damage the

motor.



Remove the fuel tank (see Fuel Tank Removal in

the EFI chapter).



Slide back the rubber cap [A].



Remove the starter motor cable terminal nut [B].



Remove the mounting bolts [A].



Pull out the starter motor [B].

Starter Motor Installation



When installing the starter motor, clean the starter

motor legs [A] and crankcase [B] where the starter
motor is grounded.



Replace the O-ring [A] with a new one.



Apply grease to the O-ring.



Apply a non-permanent locking agent to the threads

of the bolts and tighten the bolts.

Torque - Starter Motor Mounting Bolts: 9.8 N

m (1.0 kgf

m, 87 in

lb)



Install the starter motor cable.



Tighten:

Torque - Starter Motor Cable Terminal Nut: 6.

0 N

m (0.60 kgf

m, 53 in

lb)

Starter Motor Test



Using a cable as thick as or thicker than starter

motor cable [A], connect the 2 terminals of starter
relay [B].
Starter Motor [C]
Battery [D]

NOTE

Be sure the battery is fully charged.



If the starter motor turns, that indicates it’s normal.

Otherwise, the starter motor is defective and needs
to be replaced.

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16-36 ELECTRICAL SYSTEM

Ignition System

Starter Relay

Starter Relay Removal



Remove the fuel tank.



Discennect the connector [A].



Disconnect the starter motor cable [B] and battery

positive (+) cable [C] from the starter relay [D].



Disconnect the starter relay [D]

Starter Relay Test



Connect the hand tester [A] and 12 V battery [B] to

the starter relay [C] as shown.

When battery is connected

When battery is disconnected

Starter Relay Resistance Measurement



Connect the hand tester [A] and starter relay [B] as

shown.
Starter Relay Resistance: 3~5 (20 )



If the reading is out of specification, the relay is

defective. Replace the relay.



Using the relay connection and disconnection test

is a more reliable way to determine the condition of
the starter relay than starter relay resistance
measurements.

The battery positive (+) cable with the rubber

cap is connected directly to the battery posi-

tive (+) terminal even when the ignition switch

off, so take care not to short the removed cable

to chassis ground.



If the relay does not work as specified, the relay is

defective. Replace the relay.

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Sidestand Switch

Gear Position

Clutch Switch

Starter Switch

Grounded

Neutral

Grounded

Released

Disconnected

Can be started

Grounded

Neutral

Grounded

Pulled

Grounded

Can be started

Grounded

In Gear

Disconnected

Released

Disconnected

Can not be started

Grounded

In Gear

Disconnected

Pulled

Grounded

Can be started

DOWN

Disconnected

Neutral

Grounded

Released

Disconnected

Can be started

DOWN

Disconnected

Neutral

Grounded

Pulled

Grounded

Can be started

DOWN

Disconnected

In Gear

Disconnected

Released

Disconnected

Can not be started

DOWN

Disconnected

In Gear

Disconnected

Pulled

Grounded

Can not be started

●

Start the engine according to the Starting Logic Table above, otherwise, the engine can not be started.

Starting logic is controlled by ECU.

If the engine can not be started in accordance with the logic table, check sidestand switch, gear position

sensor, clutch switch, engine stop switch, ignition switch, starter switch, ECU, fuse, starter relay, starter

motor clutch, double gear,etc.

Starting System

Starting Logic Table

16-38 ELECTRICAL SYSTEM

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Sidestand Switch

Gear Position

Clutch Switch

Starter Switch

Grounded

Neutral

Grounded

Released

Disconnected

Can be started

Grounded

Neutral

Grounded

Pulled

Grounded

Can be started

Grounded

In Gear

Disconnected

Released

Disconnected

Can not be started

Grounded

In Gear

Disconnected

Pulled

Grounded

Can be started

DOWN

Disconnected

Neutral

Grounded

Released

Disconnected

Can be started

DOWN

Disconnected

Neutral

Grounded

Pulled

Grounded

Can be started

DOWN

Disconnected

In Gear

Disconnected

Released

Disconnected

Can not be started

DOWN

Disconnected

In Gear

Disconnected

Pulled

Grounded

Can not be started

●

Start the engine according to the Starting Logic Table above, otherwise, the engine can not be started.

Starting logic is controlled by ECU.

If the engine can not be started in accordance with the logic table, check sidestand switch, gear position

sensor, clutch switch, engine stop switch, ignition switch, starter switch, ECU, fuse, starter relay, starter

motor clutch, double gear,etc.

Starting System

Starting Logic Table

16-38 ELECTRICAL SYSTEM

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ELECTRICAL SYSTEM 16-39

Starting System

Starting System Troubleshooting Chart

Start failure (according to Starting Logic
Table)

Main fuse and fuse box

Battery voltage inspection

Inspect starter motor (using a thick lead,
bypass the 2 terminals of the starter relay.
Check if the starter motor run.).

Inspect starter relay continuity.

Inspect starter switch, engine stop switch.

Inspect sidestand switch, clutch switch,
gear position sensor.

Inspect starting system wiring.

Inspect ECU ground and power.

Replace ECU and re-test.

Replace

Recharge if discharged. Replace if
defective.

Replace starter motor.

Replace starter relay.

Inspect auxiliary starter relay, engine stop
switch.

Replace auxiliary starter relay.

Mainten or replace

Mainten

No good

ELECTRICAL SYSTEM 16-39

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16-40 ELECTRICAL SYSTEM

Ignition System

Ignition System Circuit

1.Fuel Pump Relay

2.Crankshaft Position Sensor

3.Igniition Switch

4.Fuse Box

5.Starter Button

6.Engine Stop Switch

7.Auxiliary Starter Relay

8.Starter Relay

9.Battery

10.Neutral Switch

11.ECU

12.Ignition Coil & Spark Plug # 1

13.Ignition Coil & Spark Plug # 2

14.Oxygen Sensor # 1

15.Oxygen Sensor # 2

16.Air Temperature Sensor

17.Coolant Temperature Sensor

18.Roll-over Sensor

19.Throttle Position Sensor

20.Sidestand Switch

21.Fuel Pump

22.Fuel Injector # 1

23.Fuel Injector # 2

24.Clutch Switch

25.Starter Motor

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ELECTRICAL SYSTEM 16-41

Lighting System



The headlight goes on when the ignition switch and

the light switch are turned on. Meanwhile, the head
light beam can be switched between high beam
and low beam.

Headlight Bulb Replacement



Remove:

Headlight Assy (see Headlight Removal/Installation)
Hook [A]
Headlight Bulb [B].

When handling the quartz-halogen bulb,

never touch the glass portion with bare hands.

Always use a clean cloth. Oil contamination

from hands or dirty rags can reduce bulb life

or cause the bulb to explode.

NOTE

Clean off any contamination that inadvertently gets

on the bulb with alcohol or soap and water solution.



Replace the headlight bulb.



Fit the projection [A] of the bulb in the hollow [B] of

the headlight.



Install the hook [C].

Hi Beam

Lo Beam

Hi Beam

Lo Beam

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ELECTRICAL SYSTEM 16-43

Headlight Removal/Installation



Remove:

Mounting Bolts [A]

Lighting System

Headlight Removal/Installation



Disconnect the headlight connector [A].



Remove the headlight assy.



Remove the upper fairings (see Upper Fairing

Removalin the Frame chapter).



Installation is the reverse of removal.

Tail/Brake Light Removal



Remove:

Seat Covers (see Seat Cover Removal in the Frame
chapter)



Disconnect the connector [A].



Remove the left and right handrails.



Remove the tail/brake light [B].

Tail/Brake Light Installation



Installation is the reverse of removal.

Tail/Brake light bulb is unserviceable. Replace the

tail/brake light assy if necessary.

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ELECTRICAL SYSTEM 16-45

Lighting System

Headlight/Position Light Circuit

1.Headlight (Hi Beam)

2.Headlight (Lo Beam)

3.Hi Beam Indicator Light

4.Instrument Light

5.Position Light

6.Hi Beam Relay

7.Lo Beam Relay

8.Dimmer Switch

9.Light Switch

10.Front Brake Switch

11.Rear Brake Switch

12.Tail/Brake Light

13.License Plate Light

14.Battery

15.Starter Relay

16.Fuse Box

17.Ignition Switch

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CFMoto motorcycle CF650NK. Service Manual - part 34