CFMoto motorcycle CF650NK. Service Manual - part 35

 

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CFMoto motorcycle CF650NK. Service Manual - part 35

 

 

16-46 ELECTRICAL SYSTEM

Lighting System

Turn Signal Light

Front Right Turn Signal Light Assy Replacement

 

Remove the fuel tank right side panel.

 

Disconnect the connector [A].

 

Remove the screw [B].

 

Remove the front right turn signal light assy.

 

Installation is the reverse of the removal.

 

Remove the rear fender assy.

 

Remove the nut [B].

 

Remove the rear right turn signal light assy.

 

Install a new rear right turn signal light assy.

 

Installation is the reverse of the removal.

Rear Left Turn Signal Light Assy Replacement

 

Refer to rear right signal light assy replacement.

Front Left Turn Signal Light Assy Replacement

 

Refer to the front right turn signal light assy

    replacement.

Rear Right Turn Signal Light Assy Replacement

 

Disconnect the connector [A].

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ELECTRICAL SYSTEM 16-47

Lighting System

Turn Signal Light
Flasher

Flasher Removal

 Remove the middle fairing(Refer to Middle 

   Fairing Removal.)

 Remove the 

fl

 asher [A].

Flasher Inspection

 Connect a 12 V battery and turn signal light as  

   shown and count how many times the 

fl

 asher 

    blinks in one minute.
    Flasher [A]
    Turn Signal Light [B]
    12 V Battery [C]
    If the 

fl

 asher does not blink as speci

fi

  ed,  replace   

    the 

fl

 asher.

Flasher Test

The Number of Turn

Signal Lights

Flashing Times

(c/m*)

1**

over 150

2

60 - 120

(*): Cycle(s) per minute
(**): Corrected to “one light burned out”.

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16-48 ELECTRICAL SYSTEM

Lighting System

Turn Signal Light

Turn Signal Circuit

   1.Front Left Turn Signal Light

 2.Left Turn Signal Indicator Light

   3.Right Turn Signal Indicator Light

 4.Front Right Turn Signal Light

   5.Flasher

 6.Turn Switch

   7.Hazard Switch

 8.Rear Right Turn Signal Light

   9.Rear Left Turn Signal Light

10.Battery

  11.Starter Relay

12.Fuse Box

  13.Ignition Switch

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ELECTRICAL SYSTEM 16-49

Fan Relay

Fan Relay Inspection

 

Remove the fuel tank.

 

Slide out the auxiliary starter relay [A] together with

    rubber ring [B] from the frame.

 

Disconnect the connector [C].

Fan Relay Test

 

Refer to Auxiliary Starter Relay Test.

Fan Relay Resistance Measurement

 

Refer to Auxiliary Starter Relay Resistance

   Measurement.

Fan relay and fan motor can be tested with PDA.

   Using active diagnosis/fan relay test to control fan
   operation, if it runs, that indicates fan relay and
   motor , along with the circuit are normal.

Radiator Fan System

Fan Motor

Fan Motor Inspection

 

Disconnect the connector [A].

 

Using an auxiliary leads, supply battery power to

   the fan motor.

If the fan does not rotate, the fan motor is defective

   and must be replaced.

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16-50 ELECTRICAL SYSTEM

Radiator Fan

Radiator Fan Circuit

  1.Engine Stop Switch

2.ECU

  3.Battery

4.Starter Relay

  5.Fan Motor

6.Fan Relay

  7.Fuse Box

8.Ignition Switch

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ELECTRICAL SYSTEM 16-51

Meter Unit

Meter Unit Removal

 Remove:

    Headlight Assy (see Headlight Removal/Installation)
   Dust Cover [A] and Cover [B]

 

Slide the dust cover [A] and remove the connector

   [B].

 

Remove the meter unit by taking off the mounting

   screws [C] with the washers.

Meter Unit Inspection



Remove meter unit [A]  (Refer to Meter Unit

     Removal).

[1]

Tachometer Signal

[2]

Dash Light (+)

[3]

Neutral Indicator Light (LED) (+)

[4]

Unused

[5]

Ground (-)

[6]

Ignition (+)

[7]

Unused

[8]

Hi Beam Indicator Light (LED) (+)

[9]

Left Turn Signal Indicator Light (LED) (+)

[10]    Oil Pressure Warning Indicator Light (LED) (-)
[11]    FI Indicator Light (LED) (-)
[12]    Right Turn Signal Indicator Light (LED) (+)
[13]    Parking Indicator Light (-)
[14]    Speed Sensor Signal
[15]    Coolant Temperature Sensor Signal
[16]    Fuel Level Sensor Signal

Place the meter unit so that the face is up. If a

meter unit is left upside down or sideways for

any length of time, it will malfunction.

N

O

I

T

U

A

C

Do not drop the meter unit. Place the meter

unit so that it faces upward. If the meter unit

is left upside down or sideways for a long time

or dropped, it will malfunction. Do not short

each terminals.

N

O

I

T

U

A

C

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16-52 ELECTRICAL SYSTEM

Meter Unit

Liquid Crystal Display (LCD) Segment Check

 

Using the auxiliary wires, connect the 12 V battery

   to the meter unit connector as follows.

 

Connect the battery negative terminal to the termi-

   nal [5].

 

Connect the battery positive terminal to the termi-

   nal [6].

 

When the terminals are connected, the needle [A]

  rotates and LCD warning lights [B] appear,
   meanwhile, fuel level signal and coolant tempera-
   ture signal flash.

 

Connect the terminal [2] to the terminal [6].

 When the connectors are connected, LCD segment

   backlight and dash light appear.

If  LCD segment backlight and dash light do not

   appear, replace the meter unit.

 Disconnect the terminal [2].

 LCD segment backlight and dash light disappear.

If LCD segment backlight and dash light do not

   disappear, replace the meter unit.

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ELECTRICAL SYSTEM 16-53

Meter Unit

Speedometer Check

 Connect the 12 V battery and terminals in the same

    manner as specified in the "Liquid Crystal Display
   (LCD) Segments Check".

 The speed equivalent to the input frequency is indi

   cated in the oscillator [A], if the square wave
    (illustrated as shown) would be input into the termi-
    nal [14].

Odometer Check

 Indicates approximately 60 km/h in case the input

    frequency would be approximately 105.6 Hz.

 

If the oscillator is not available, the speedometer

   can be checked as follows.

Install the meter unit.

Raise the rear wheel off the ground with stand.

Turn on the ignition switch.

Rotate the rear wheel by hand.

Check that the speedometer shows the speed.

If the speedometer does not work, check the speed

   sensor electric source voltage and speed sensor.

The electric source voltage and speed sensor are

   normal, replace the meter assembly.

 Check the odometer with the speedometer in the

   

same way.

 If value indicated in the odometer is not added, re-

   place the meter assembly.

Fuel Gauge Check

 Connect the 12 V battery and terminals in the same

    manner as specified in the "Liquid Crystal Display
    (LCD) Segments Check".

 Connect a resistance (0-1 k ) between the battery

    negative terminal and terminal [16].

 When the resistance is 0 

fuel gauge displays all

    8 lights.

 When the resistance is 1k 

fuel gauge displays

    one light and fuel signal appears.

Coolant Temperature Gauge Check

 Connect the 12 V battery and terminals in the same

    manner as specified in the "Liquid Crystal Display
    (LCD) Segments Check".

 Connect a resistance (0-1 k ) between the battery

    negative terminal and terminal [15].

 

When the resistance is 0 

fuel gauge displays all

    8 lights and coolant temperature signal appears.

 When the resistance is 1

k , 

fuel gauge displays

    one light.

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16-54 ELECTRICAL SYSTEM

Meter Unit

Tachometer Check

 Connect the 12 V battery and terminals in the same

    manner as specified in the "Liquid Crystal Display

    (LCD) Segments Check".

 The revolutions per minute (rpm) equivalent to the

    input frequency is indicated in the oscillator [A] if

    the square wave (illustrated as shown) would be

    input into the terminal [1].

 Indicates approximately 6 000 rpm in case the in-

    put frequency would be approximately 100 Hz.

 If the oscillator is not available, the tachometer can

    be checked as follows.

 Connect the 12 V battery and terminals in the same

    manner as specified in the "Liquid Crystal Display

    (LCD) Segments Check".

 Using an auxiliary wire, quick open and connect

    the terminal [2] to the terminal [6] repeatedly.

 Then the tachometer needle [A] should flick [B].

If the needle does not flick, replace the meter

   assembly.

Indicator Lights Inspection

 Connect the 12 V battery and terminals in the same

   manner as specified in the "Liquid Crystal Display

   (LCD) Segments check".

   Neutral Indicator Light (LED) [A]

    FI Indicator Light (LED) [B]

   Oil Pressure/Water Temperature Warning Indicator

    Light (LED) [C]

    Right Turn Signal Indicator Light (LED) [D]

    Left Turn Signal Indicator Light (LED) [E]

    High  Beam Indicator Light (LED) [F]

    Fuel Level Warning Indicator Light (LED) [G]

 

 Using the auxiliary leads, connect a 12 V battery

    to the meter unit connector as follows.

Neutral Indicator Light (LED)

 Battery Negative (-) Terminal to Terminal [3].

When the battery (-) terminal is connected to ter-

     minal [3], neutral indicator light should go on. When

    the battery (-) terminal is disconnected, neutral in-

    dicator light should go off. If neutral indicator light

    does not work as given above, replace the meter

    unit.

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ELECTRICAL SYSTEM 16-55

Meter Unit

High Beam Indicator Light (LED)

Battery Positive (+) Terminal to Terminal [8].

When the battery (+) terminal is connected to ter-

   minal [3], Hi beam indicator light should go on.
    When the battery (-) terminal is disconnected, neu-
    tral indicator light should go off. If Hi beam indicator
   light does not work as given above, replace the
    meter unit.

Right and Left Turn Signal Indicator Light

(LED)

Left Turn Signal Indicator Light (LED)
Battery Positive (+) Terminal to Terminal [9]
Right Turn Signal Indicator Light (LED)
Battery Positive (+) Terminal to Terminal [12]

When the battery (+) terminal is connected to ter-

   minal [9] or [12], left or light turn signal indicator
    light should go on. When the battery (-) terminal is
    disconnected, left or light turn signal indicator  light
   should go off.left or light turn signal indicator
   light does not work as given above, replace the
    meter unit.

Oil Pressure Warning Indicator Light (LED)

 Connect the 12 V battery and terminals in the same

   manner as specified in the "Tachometer Check".

 When rpm exceeds 1000 and the battery (-) termi-

    nal is connected to terminal [10], the indicator light
    does not go on.

 When rpm exceeds 1000 and the battery (-) termi-

    nal is disconnected from terminal [10], the indica-
    tor light goes on.

If oil pressure warning indicator light does not work

   as specified, replace the meter unit.

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16-56 ELECTRICAL SYSTEM

Meter Unit

FI Indicator Light

Battery Negative (-) Terminal to Terminal [11].

When the battery (-) terminal is connected to ter-

   minal [11], neutral indicator light should go on.
    When the battery (-) terminal is disconnected, neu-
    tral indicator light should go off. If Hi beam indicator
   light does not work as given above, replace the
    meter unit.

Parking Indicator Light

Battery Negative (-) Terminal to Terminal [13].

When the battery (-) terminal is connected to ter-

   minal [13], neutral indicator light should go on.
    When the battery (-) terminal is disconnected, neu-
    tral indicator light should go off. If Hi beam indicator
   light does not work as given above, replace the
    meter unit.

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ELECTRICAL SYSTEM 16-57

Meter Unit

Meter Unit Circuit

  1.Meter Unit

 2.Fuse Box

  3.Ignition Switch

 4.Oil Pressure Warning Light

  5.Main Fuse

 6.Starter Relay

  7.Battery

 8.Coolant Temperature Sensor

  9.ECU

10.Sidestand Switch

 11.Fuel Level Sensor

12.Speed Sensor

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16-58 ELECTRICAL SYSTEM 

Switches and Sensors

Brake Light Timing Inspection

 Refer to the Brake Light Switch Operation 

    Inspection in the Periodic Maintenance chapter.

Brake Light Timing Adjustment

 Refer to the Brake Light Switch Operation 

    Inspection in the Periodic Maintenance chapter.

Switch Inspection

 Using a hand tester, check to see that only the 

   connections shown in the table have continuity 
    (about zero ohms).

 

 

For the switch connections and continuity, 

    refer to the tables given below.
   If the switch has an open or short, repair it or 
    replace it with a new one.

Front/Rear Brake Light Switch Connections

Front/Rear Brake Light Switch Connections

Color

W/G

G/Y

When brake pedal is pushed down (ON)
When brake pedal is released (OFF)

Sidestand Switch Connectons

Sidestand Switch Connectons

Color

Br/B

W/G

Y/B

When sidestand is up
When sidestand is down

Neutral Switch Connectiions

Neutral Switch Connectiions

Color

SW. Terminal

Ground

When transmission is in neutral
When transmission is not in 
neutral

Oil Pressure Switch Connections

Oil Pressure Switch Connections (When engine lubrication is in good condition)

Color

SW. Terminal

Ground

When engine is stopped
When engine is running

Clutch Switch Connections

Clutch Switch Connections

Color

R/G

L/G

When clutch is pulled (ON)
When clutch is released (OFF)

16-58 ELECTRICAL SYSTEM 

16-58 ELECTRICAL SYSTEM 

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ELECTRICAL SYSTEM 16-59

Switches and Sensors
Coolant Temperature Sensor

Coolant Temperature Sensor Inspection

 Remove the coolant temperature sensor (see 

    Removal/Installation in the EFI chapter).

 Suspend the sensor [A] in a container of coolant 

   so hat the temperature-sensing projection [C] 
    and threaded portion [C] are submerged.

 Suspend an accurate thermometer [B] with 

    temperature-sensing projection located in almost 
    the same depth.

NOTE

o

 

The sensor and thermometer must not touch the 

    container side or bottom.

 Place the container over a source of heat and 

   gradually raise the temperature of the coolant 
    while stirring the coolant gently.

 Using the hand tester, measure the internal 

    resistance of the sensor.

 If the hand tester does not show the specified 

    values, replace the sensor.

Water Temperature Sensor Resistance

 

See the right table.

Resistance betwen Terminal A and 
Terminal C

Temperature (

o

C)

Resistance (K

Ω

)

-20

12-18

0

5-7

20

2-3

80

0.3-0.35

100

0.12-0.18

Resistance betwen Terminal B and 
Chassis Ground

Temperature (

o

C)

Resistance (

Ω

)

50

135-220

120

16-20

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16-60 ELECTRICAL SYSTEM

Switches and Sensors

Speed Sensor

Speed Sensor Removal

 

Disconnect the speed sensor lead connector [A].

 Remove the engine sprocket cover (see Engine

    Sprocket Removal in the Final Drive chapter).

 Remove: Bolt [A]

   Speed Sensor [B]

Speed Sensor Installation

 Installation is the reverse of removal.

 Apply a non-permanent locking agent to the sensor

   bolt, and tighten it.
   

Torque - Speed Sensor Bolt: 7.0 N

m

Speed Sensor Inspection

 Remove the speed sensor (see Speed Sensor

    Removal).

 Connect the speed sensor connector [A] with the

    battery [B], 10 k? resistor [C] and hand tester [D]
    as shown.

 

Set the tester to the DC 25 V range.

 

Trace [A] each side of the speed sensor surface

    with the screw driver.

 

Then the tester indicator should flick [B].

If the tester indicator does not flick, replace the speed

   sensor.

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ELECTRICAL SYSTEM 16-61

Relay and Fuse

Hi Beam Relay & Lo Beam Relay

Hi Beam Relay Removal

 

Remove the fuel tank.

 

Remove the bolt [A].

 

Disconnect the connector [B].

Hi Beam Relay Installation

Installation is the reverse of the removal.

Hi Beam Relay Circuit Inspection

 Connect the hand tester [A] and 12V battery as

    shown to test the Hi beam relay.

 When the battery is connected, the reading of

    resistance: 0

 

When the battery is disconnected, the reading of

    resistance: 

Hi Beam Relay Resistance Inspection

 Connect the hand tester[A] and A Hi beam relay

    [B].
    Hi beam relay resistance: 90~105

(20 )

If the hand tester does not show specified values,

    the relay is defective. Replace the relay.

 Using the Hi beam relay circuit inspection is a more

   reliable way to determine the Hi beam relay condi-
   tion than the Hi beam relay resistance inspection.

Lo Beam Relay

 

Refer to Hi beam relay.

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