Content .. 5 6 7 8 ..

CFMoto ATV CF500/CF500-A. Service Manual - part 7

8. Battery, Charging System

Inspection of AC magneto

Remove left side panel (

→

2-6)

Disconnect connectors of AC magneto (yellow, yellow,
yellow) and pickup coil (black/white/green).

Measure the resistance between the yellow terminals of
the AC magneto 3P connector.

Resistance: 0.2-0.3

Ω

( at 20

℃

)

Make sure the yellow terminal of AC magneto 3P
connector is not connected with frame body earth wire.

Replace with a new AC magneto in case of any faults
found in above check. (

→

Engine maintenance manual)

8-8

8. Battery, Charging System

8-9

9. Ignition System

Overhaul Info……………………………………..9-1
Troubleshooting……………………….…………9-3
Inspection of Ignition System…………………...9-4

  Pickup Coil ………………..………… .…... 9-6
  Ignition Coil ……………………... ……….. 9-6
  Ignition System Diagram ………………….9-7

Overhaul information

Note:

Exhaust gas contains toxicant, DO NOT keep the engine run for a long time in a

closed or poorly ventilated place.

Inspect ignition system in the order of the content in troubleshooting table

Refer to (9-7) for ignition system diagram

Ignition advancer is integrated in the CDI, so the ignition system will automatically adjust

ignition time.

Be careful with CDI overhaul. Dropping or strong impact may cause damage to CDI. In

addition, overvoltage may be generated on CDI and cause damage to return circuit when
removing or joining the connectors and terminals with switch ON .Always shut the ignition
switch when overhauling.

Most of the failures of ignition system are caused by faulty contacts between connectors and

terminals. Check all the connections for any faults before overhauling.

Select spark plug of proper heat value. Improper spark plug may cause malfunction or

damage of engine.

Refer to Chapter 10 for inspection of switches

9-1

9. Ignition System

Overhaul standard

Item Standard

Ignition

CDI, battery DC digital ignition

Standard DPR7EA-9(NGK)

Optional DR8EA,

D7RTC

Spark Plug

Spark plug gap

0.8-0.9mm

Ignition timing

Maximum advance

angle

34° CA

Ignition coil

>200V

Peak voltage

Impulse generator

Special tool

Peak voltage oscillograph 07HGJ-0020100

(Use together with digital muitimeter available in the market with input resistance over
10M

Ω

/DCV)

9-2

9. Ignition System

Troubleshooting

Engine cannot be started.

Check fuel and air channels for any faults; If the fuel and air channels are normal, check the

ignition system.

Inspect ignition system for the following items:

1. Spark inspection:

Check in the following steps:

Remove spark plug
Remove spark plug cap

Set high tension flexible cable end to earth
Check spark arc

It is normal if spark arc is more than 8mm

，

while it is weak if it is less than 5 mm.

If the spark is normal, check the spark plug.
A faulty spark plug may be caused by the following reasons:

(1) Spark plug is too wet and drowned. This is because the gas mixture is too thick. Cut the

fuel and start the engine several times..

(2) Carbon deposit on spark plug---Mixture too thick or oil combustion in the combustion

chamber. Clean and burnish the spark plug.

(3) Cracks with spark plug insulator.
(4) Spark plug electrodes have short circuit or it is obstructed between negative pole and

thread or positive pole and input end.

2. Faulty spark includes: no spark and weak spark.

Inspect the following aspects if there is no spark.
(1). Inspect ignition coil with multimeter or measurement in the following steps:

1) Measure primary bobbin resistance, usually it is about 1

Ω

2) Measure secondary bobbin resistance, usually it is about 4.2K.
3) Measure damp resistance, usually it is about 5K.

      (2). Check CDI if it is out of service.
   (3). Check ignition circuit. Usually the voltage between black wire and earth wire (green)
should be 12V. If there is no voltage, check from the battery positive terminal to the end of black
wire.
      (4). Check the cable: check if there are any faults from the input of trigger signal (output of
magneto pickup) to output (CDI terminal) and ignition output wire (black/yellow).
      (5). Check stop switch. When switch is at the ignition position, black/white wire should be cut

with green wire.

In case of weak spark, check the following:
(1). Check CDI .
(2). Check ignition coil and secondary coil whether there is short circuit, or fault with the damp

resistance.

9-3

9. Ignition System

Inspection of Ignition System

Note:

If the spark plug generates no spark, check first if

there is come-off, loosening or poor contact with
the wiring, then measure the peak voltage.

Different multimeter has different input resistance

and shows different readings. Measure with digital
multimeter with input impedance over10M

Ω

/DCV ).

Connect peak voltage oscillograph with digital
multimeter.

Special tools
Peak voltage oscillograph 519-922-150000

(Use together with digital multimeter available from

the market with input impedance over 10M

Ω

/DCV)

Ignition Coil Primary Voltage

Note:

Measure after all the wires are correctly
connected.

Inspection should be done when the spark plug
and spark plug cap are properly installed. If the

spark plug is removed, the peak voltage will
rise.
Remove left side panel. (

→

2-6)

Keep spark plug in the cylinder head, install qualified
spark plug on the spark plug cap and earth the engine.
Open rubber cover of ignition coil, keep the ignition wire
connected, and connect peak voltage oscillograph
between primary wire terminal and frame body earth
wire.

Special tool
Peak voltage oscillograph

(Use together with digital multimeter available

from the market with input impedance over 10M

Ω

/DCV)

Connecting terminals: black/yellow (+) –frame earth
wire (-)

Turn ignition switch to the ON position, and start
engine.

Peak voltage: above 150V

9-4

9. Ignition System

Pickup Coil
Note:

Measure after all the wires are correctly connected.

Inspect with compression pressure in the cylinder,

spark plug and spark plug cap are properly
installed. If the spark plug is removed and then do
the measurement, the peak voltage will rise.

Remove left side panel (

→

2-3)

Disconnect CDI unit connector.

Connect peak voltage oscillograph terminal with the
following terminal of main cable.

Special tools

Peak voltage oscillograph 07HGJ-0020100

(Use together with digital multimeter available from the
market with input impedance over 10M

Ω

/DCV)

Connecting terminal: blue/yellow (+) –green (-)

Turn ignition switch to the ON position, and start
engine.

Peak voltage: over 0.8V

Note:

When measuring the voltage, do not touch the
terminal with finger to avoid electric shock.

If peak voltage obtained from CDI unit connector is
improper, measure again the peak voltage on the AC
magneto 2P connector.

9-5

9. Ignition System

Pickup

Remove:

-- AC magneto connector
--Water pump inlet hose and outlet hose, and drain

coolant. (

→

Chapter 4)

--Crankcase breather hose. (

→

Engine Service)

--Muffler. (

→

Chapter 2)

-- Engine right side cover. (

→

Engine Service)

Note:

Stator is installed on the right side cover and is attached
by the magnet of rotor. Be careful not to hurt the fingers
when removing.
Disconnect primary terminal of ignition coil

Loosen bolt, remove AC magneto stator and pickup.

Installation

Reverse the removal procedure for installation.

Ignition Coil

Remove left side panel (

→

2-6)

Remove spark plug cap from spark plug (

→

Engine

Service)

Loosen bolt, and remove ignition coil.

Installation

Reverse the removal procedure for installation.

Note:
Wires, cables and hoses should be routed properly

(

→

Chapter 1).

9-6

9. Ignition System

Ignition System Diagram

9-7

10. Lighting, Instruments, Switches

Overhaul Info……………….…………..10-1
Troubleshooting ………………….…….10-2
Replacing bulbs.. ………………………10-3
Head Light ……….………….………….10-5

Dashboard ……………………...…….10-9
Fuel Sensor ……………………..……10-10
WaterTemperature Transducer.. …...10-12

Ignition Switch………….…….…………10-6
Handlebar Switch ………………………10-7
Brake Light Switch……………………...10-8
Horn………………………………………10-8

Overhaul Information

Warning

Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off.

Operation should be done when the bulb is cooled down.

Inspection of water temperature alarm may use fire source and liquid of high temperature.

Do not put flammable matters nearby and take care not to get burnt.

The temperature of headlight is quite high when turned on. Replacing with bare hand or

stained glove will cause oil stains on the glass face which may form hot spot and cause
deformation of glass face and damage to bulb.

Pay attention to the following when replacing the bulb.

---Do not replace the bulb when it is turned on. Keep ignition switch in the OFF position, and

replace after the bulb is cooled down.

---Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface.

---Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil

stains on the glass surface.

If the Inspection has to be done with battery, check if the battery is normal.

Inspection of switch continuity can be done without removing the switches from the vehicle.

After the inspecting and overhauling of each part, cables and wires should be routed properly

(

→

chapter 1)

Refer to Chapter 2 for removal and installation of taillight and rear turning lights

Overhaul Standard

Item Standard

Main 20A

Fuse

Sub-fuse

10A 15A

Headlight (Hi/Lo) 12V-35/35W

Brake light / Tail light

12V-21/5W

Turning light

12V-10W

Dashboard indicator

12V-1.7W

Light, bulb

Indicators 12V-3.4W

10-1

10. Lighting, Instruments, Switches

Troubleshooting

Head Light Cannot Turn On

Broken

fuse

Open circuit with main cable

Burnt

Bulb

Faulty

Switch

10-2

10. Lighting, Instruments, Switches

Replacing Bulb

Headlight Bulb

Warning
Headlight bulb will be very hot when it is turned on.
Do not touch it after it is just turned off.
Operation should be done when the bulb is cooled
down.

Remove headlight. (

→

10-5)

Disconnect headlight


Remove dust-proof cap, headlight connector, circlip
and replace with a new bulb.

Warning:

Wear clean gloves when replacing bulb.

Oil stains on the glass surface may cause
break of bulb. Clean the stained surface with
alcohol or isoamyl acetate.

Make sure that the three pins of the bulb
should be in line with the three positioning
holes in the socket when replacing the bulb.

Bulb specification: 12V-35/35W

Reverse the removal procedure for installation.

After replacing the bulb, adjust headlight beam.
(

→

3-14)

Inspection of Headlight

Turn the ignition switch to ON position, turn light switch
to the illuminating position and check if the headlight is
on.

—

ON: Normal

—

Still off: short circuit of main cable or broken

main cable

10-3

10. Lighting, Instruments, Switches

Brake Light/Tail Light Bulb

Remove 2 tapping screws,
Remove tail light cover.
Turn brake light/tail light bulb counter clockwise and
remove it.
Replace brake light/tail light bulb

Bulb Specification: 12V-21/5W

Reverse the removal procedure for installation.

Front Turning Indicator Bulbs

Remove headlight(

→

10-5)

Remove cover of front turning light
Replace front turning light bulbs

Bulb Specification: 12V-10W

Rear Turning Indicator Bulbs

Remove screw

Remove rear turning indicator cover.
Replace rear turning indicator bulbs.

Bulb Specification: 12V-10W

Reverse the removal procedure for installation.

10-4

10. Lighting, Instruments, Switches

Dashboard Lighter Bulb

Remove dashboard (

→

10-9)

Remove bulb socket and replace with a new bulb.

Bulb specification: 12V-1.7W

Note:

Main cable and wires should be routed properly

(

→

chapter 1

)

Reverse the removal procedure for installation.

Dashboard Indicator Bulb

Remove dashboard (

→

10-9)

Remove dashboard indicator socket.
Remove indicating light bulb and replace with new one.

Bulb specification: 12V-3.4W

Reverse the removal procedure for installation.

Headlight

Remove:

--Front fender(

→

2-8)

--3 fixing bolts of headlight cover.
--Headlight cover
--Fixing bolt of headlight, headlight connector
--Headlight.

10-5

10. Lighting, Instruments, Switches

Disconnect headlight connector.

Reverse the removal procedure for installation.

Note:

Be careful not to damage main cable when
assembling.

After replacing, adjust the headlight beam. (

→

3-14)

Note
Main cables and wires should be routed properly.

Ignition Switch
Inspection

Remove front top cover

Disconnect 4P connector of ignition switch

10-6

10. Lighting, Instruments, Switches

Check according to the following table if the
connector terminals are in continuity.

● ----●means proper continuity

Remove:

Remove front cover of dashboard (

→

6-12)

Remove rear cover of dashboard (

→

6-14)

Disconnect 4P connector of ignition switch

Remove bolt and ignition switch

Reverse the removal procedure for

Handlebar Switch

Remove front top cover

(

→

2-4)

Disconnect left and right handlebar switches

heck

according to the following table the continuity of the
terminals.

Lighting Switch

Start Switch

OFF
ON

●

B/Br Gr/R

Dip Switch

OFF

●

W/L W L

10-7

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