Content .. 14 15 16

CFMoto ATV CF500/CF500-A. Service Manual - part 16

17. Cooling and Lubrication System

Inspection of Lubrication System (

→

11-8)

Inspection of Oil Pump and Relief Valve(

→

12-41)

17-15

18. Electrical System

Charging System……………..18-1

Electric Starting…………..…..18-3

Ignition System…………….…18-5

18-1

18. Electrical System

Charging System

Resistance of Generator Coil

Measure resistance between the three lead wires;

Replace a new stator coil if resistance not within

specified value,

Check that the generator core is insulated.

Set multimeter at 1×10

Ω

Generator Coil Resistance : 0.9-1.5

Ω

(Yellow-Yellow)

Insulate Resistance:

∞Ω

(Yellow-Earthing wire)

Generator Non-load Performance

Start engine run it at 5000r/min

Measure AC voltage between three lead wires of

generator with multimeter.

Replace the generator if the voltage is lower than

the specified value.

Set Multimeter to AC Position

Generator Non-load Performance:

﹥

200V (AC) at 5000r/min

18-2

18. Electrical System

Regulator/Rectifier

Measure the resistance between the terminals using a multimeter.

If any of the resistance is not within the specified value, replace the regulator/rectifier.

NOTE:

If the multimeter reads under 1.4V when the probes
are not connected, replace the multimeter battery.

18-3

18. Electrical System

Starting System

Starting Motor

18-4

18. Electrical System

Brushes

Check brushes for abnormal wear, cracks or

moothness in the brush holder.

Wear, cracks or non-smoothness:

→

Replace

Commutator

Check Commutator for discoloration, abnormal wear

or undercut.

Abnormal wear or Damage:

→

Replace

If the commutator is discolored, polish with a sand

paper and clean with a clean and dry cloth.

If there is undercut, scrape out insulator B and make

its distance between A as d

≥

1.5mm

Armature Coil

Check for continuity between each segment and

between each segment and armature shaft using a
multimeter.

If there is no continuity between the segments or

there is continuity between segments and shaft,
replace the armature with a new one.

Oil Seal

Check Oil Seal Lip for damage or leakage.

Damage or leakage:

→

Replace with a new

starting motor

18-5

18. Electrical System

Starter Relay

Apply 12V to the terminals and check for continuity

between the positive and negative terminals using a
multimeter.

If the starter relay clicks and continuity is found, the

starter relay is OK.

If there is no continuity when without the 12V, the

relay is OK.

Note:

Do not apply the battery voltage to the starter relay

for more than 2 seconds. This may cause overheat and
damage the relay coil.

Measure the coil resistance between the terminals

using a multimeter. If the resistance is out of the
specified value, replace the starter relay with a new
one.

Set multimeter to 1x10

Ω

position

Starter relay coil resistance: 3-5

Ω

Auxiliary Starter Relay

Apply 12V to starter relay positive and negative

terminals and check for continuity between A and B
using a multimeter.

If the starter relay clicks and continuity is found, the

starter relay is OK.

If there is no continuity when without the 12V, the

relay is OK.

Set multimeter to 1x100

Ω

position

Auxiliary starter relay coil resistance: 90-100

Ω

18-6

18. Electrical System

Ignition System

Ignition Coil
Ignition Coil Primary Peak Vaoltage

Remove spark plug cap, install a new spark plug

into cap and connect as illustrated on the right with
cylinder head as ground.

Connect

multimeter

and peak voltage adaptor as

under:

Probe: Green lead wire or Ground

Probe: Black/Yellow lead wire

Note:

Make sure battery voltage

≥

12V, ignition coil lead

wire is connected.

Refer to user’s manual when using multimeter and

peak voltage adaptor.

Shift the gear to neutral position and turn the ignition

switch to the “ON” position;

Press the starter button and crank the engine

several seconds, then measure the ignition coil
primary peak voltage;

Repeat above steps several times and take the

measured highest ignition coil primary peak voltage.

Set the multimeter to AC position

18-7

18. Electrical System

Ignition Coil Primary Peak Voltage:

≥

150V

Caution:

Do not touch the tester probes or the spark

plug to avoid electric shock.

If the voltage is lower than the standard value,

check ignition coil and pick-up coil.

Ignition Coil Resistance

Disconnect ignition coil lead wire and spark plug cap.

Remove ignition coil;

Measure the ignition coil resistance in both primary

and secondary windings using the multimeter. If
both the primary and secondary windings are close
to the specified value, the ignition coil is in good
condition.

Ignition Coil Resistance
Primary: 0.1-1.5

Ω

(Terminal—Ground)

Secondary: 12-22K

Ω

(Terminal—Spark Plug Cap)

Pickup Coil Peak Voltage

Measure the pickup coil peak voltage in the

following steps:

Connect

multimeter

and peak voltage adaptor as

illustrated on the right;

+Probe: Green lead wire
-Probe: Blue lead wire

Shift the gear to neutral position and turn the ignition

switch to the “ON” position;

Press the starter button and crank the engine

several seconds, then measure the pickup coil
primary peak voltage;

Repeat above steps several times and take the

measured highest pickup coil peak voltage.

Set the multimeter to AC V position

Pickup Coil Peak Voltage:

≥

If the voltage is lower than the standard value,

replace the pickup coil

Pickup Coil Resistance

Set the multimeter to 1x100

Ω

position

Pickup Coil Resistance: 120-130

Ω

Replace the pickup coil if the resistance is not within

the value.

18-8

19. Troubleshooting

1. Engine

Complaint

Symptom and Possible Causes

Remedy

Engine will not

start of is hard to

start

Compression is Too Low

1. Worn

cylinder

2. Worn piston ring
3. Leakage with cylinder gasket

Wear valve guide or improper valve
seating

4. Loose

spark

plug

5.  Slow cranking of starting motor
6.  Faulty valve timing
7.  Improper valve clearance

No Sparking from Spark Plug

1.  Fouled spark plug
2.  Wet spark plug
3.  Defective ignition coil
4.  Open or short circuit with pickup coil
5. Faulty

generator

6. Faulty

CDI

No Fuel Reach Into Carburetor

1.  Clogged fuel tank vent tube
2.  Clogged or faulty fuel valve
3.  Faulty carburetor needle valve
4.  Clogged fuel hose
5.  Clogged fuel filter

Transfer is not in Neutral position

Replace
Replace
Replace
Repair or Replace

Tighten
Check electrical part
Adjust
Adjust

Clean or Replace
Clean and dry or replace
Replace
Replace
Replace
Replace

Clean or Replace
Clean or Replace
Replace
Replace
Clean or Replace
Set to Neutral position

Engine stalls easily

or has unstable

idle speed

1.  Improper valve clearance
2.  Improper valve seating
3.  Faulty valve guide
4.  Worn rocker arm or rocker arm shaft
5.  Fouled spark plug
6.  Improper spark plug gap
7.  Faulty ignition coil
8. Faulty

CDI

9. Faulty

generator

10.  Improper fuel level in float chamber
11. Clogged carburetor jet
12.  Faulty fuel valve
13.  Improper adjustment or idle screw

Adjust
Replace or Correct
Replace
Replace
Replace
Replace or Adjust
Replace
Replace
Replace
Adjust Fuel level
Clean
Replace
Adjust

19-1

19. Troubleshooting

Complaint

Symptom and Possible Causes

Remedy

Poor engine

running in

high-speed range.

1. Week

valve

spring

2. Worn

camshaft

3.  Fouled spark plug
4.  Insufficient spark plug gap
5.  Improper valve timing
6.  Faulty ignition coil
7.  Low fuel level in float chamber
8.  Dirty air filter
9.  Clogged fuel hose, resulting in poor fuel

supply

10. Clogged fuel valve

Replace
Replace
Clean or replace
Adjust or replace
Replace
Adjust float chamber fuel level
Clean or replace
Clean
Clean

Clean

Exhaust smoke is

dirty or thick

1.  Excessive engine oil
2.  Worn piston ring
3.  Worn valve guide
4.  Scored or scuffed cylinder wall
5.  Worn valve stem
6.  Worn valve stem oil seal

Check oil level and drain
Replace
Replace
Replace
Replace
Replace

Engine lacks

power

1. Improper valve clearance
2. Weak

valve

spring

3. Improper valve timing
4. Worn

cylinder

5.  Worn piston ring
6.  Improper valve seating
7.  Fouled spark plug
8.  Improper spark plug gap
9. Clogged

carburetor

jet

10.  Improper fuel level in fuel chamber
11.  Dirty air filter
12.  Worn rocker arm or rocker arm shaft
13.  Air leakage from air intake pipe
14.  Excessive engine oil

Adjust
Adjust
Adjust
Replace
Replace
Replace or Correct
Clean or replace
Clean or replace
Clean or replace
Adjust fuel level
Clean or replace
Replace
Tighten or replace
Check oil level and drain

Engine

overheats

1.  Carbon deposit on piston top
2.  Insufficient or excessive engine oil
3.  Faulty oil pump
4.  Clogged oil passage
5.  Fuel level in float chamber is too low
6.  Air leakage from air intake pipe
7.  Incorrect engine oil
8.  Faulty cooling system (

→

16-5)

Clean
Check level, add or drain
Replace
Clean
Adjust fuel level
Tighten or replace
Change engine oil

19-2

19. Troubleshooting

Complaint

Symptom and Possible Causes

Remedy

Valve Chatter

1.  Excessive valve clearance
2.  Worn or broken valve spring
3.  Worn rocker arm or camshaft

Replace
Replace
Replace

Noise from Piston

1. Worn

piston

2. Worn

cylinder

3.  Carbon deposit in combustion chamber
4.  Worn piston pin or pin hole
5.  Worn piston ring or piston ring groove

Replace
Replace
Clean
Replace
Replace

Noise from Timing chain

1. Stretched

chain

2. Worn sprocket wheel
3. Faulty chain tensioner

Replace chain & sprocket
Replace chain & sprocket
Repair or replace

Noise from Clutch

1. Worn or damaged crankshaft spline
2. Worn inner race spline

Replace crankshaft
Replace inner race

Noise from Crankshaft

1. Rattling

bearing

2. Worn or burnt crank pin bearing
3. Excessive thrust clearance

Replace
Replace
Replace

Noise from CVT

1. Worn or slipping drive belt
2. Worn rollers in primary sheave

Replace
Replace

Engine is

noisy

Noise from Transmission

1. Worn or damaged gear
2. Worn or damaged input or output shafts
3. Worn

bearing

4. Worn

bushing

Replace
Replace
Replace
Replace

Slipping

Clutch

1. Worn or damaged clutch shoes
2. Weakened clutch shoe spring
3. Worn

clutch

housing

4. Worn or slipping drive belt

Replace
Replace
Replace
REplace

19-3

19. Troubleshooting

Complaint

Symptom and Possible Causes

Remedy

Difficulty or locked

gearshift

1. Broken drive or driven bevel gear teeth

2. Distorted shift fork

3. Worn shift cam

4. Improper gearshift rod

Replace

Adjust

2. Carburetor

Complaint

Symptom and Possible Causes

Remedy

Starting Difficulty

1.  Clogged starter jet
2.  Clogged starter jet passage
3.  Air leakage from joint between starter body

and carburetor

4. Faulty starting plunger

Clean
Clean
Clean, adjust or replace gasket

Adjust

Idling or

low-speed

trouble

1.  Clogged slow jet
2.  Clogged slow jet passage
3.  Clogged air intake
4.  Clogged bypass port
5.  Starter plunger not fully closed
6.  Improper set of idle screw
7.  Improper float height

Clean
Clean
Clean
Clean
Adjust
Adjust
Adjust

Medium or high

speed trouble

1.  Clogged main jet
2.  Clogged main air jet
3.  Clogged needle jet
4.  Faulty throttle valve
5.  Clogged fuel filter
6.  Improper float height
7.  Starter plunger not fully closed

Clean
Clean
Clean
Adjust
Clean
Adjust
Adjust

Overflow and fuel
level fluctuation

1. Worn or damaged needle valve
2. Damaged needle valve spring
3. Improper working float
4. Foreign matter in needle valve

Replace
Replace
Adjust or Replace
Clean

19-4

19. Troubleshooting

3. Cooling System/Radiator

Complaint

Symptom and Possible Causes

Remedy

Engine overheats

1. Clogged water passage or radiator
2. Air in the cooling system; insufficient

coolant

3. Faulty

water

pump

4. Incorrect

coolant

5. Faulty

thermostat

6. Faulty fan motor or thermoswitch

Clean
Discharge air and add coolant

Check and replace
Replace
Replace
Check and/or replace

Engine coolant

overcools

1. Faulty

thermoswitch

2. Extremely cold weather
3. Faulty

thermostat

Replace
Put on radiator cover
Replace

4. Ignition

System

Complaint

Symptom and Possible Causes

Remedy

No Sparking or

Weak Sparking

1. Faulty

CDI

2. Faulty

spark

plug

3. Faulty

Generator

4.  Insufficient battery voltage
5.  Faulty ignition coil
6.  Faulty pickup coil

Check and replace
Check and replace
Check and replace
Check and replace
Check and replace
Check and replace

19-5

Content .. 14 15 16