CFMoto motorcycle CF650NK. Service Manual - part 32

FRAME 15-11

Frame

Frame Inspection 

●

 Visually inspect the frame for cracks, dents, 

    bending or warp.

○

 If there is any damage to the frame, replace it.

WARNING

A repaired frame may fail in use, possibly 
causing an accident. If the frame is bent, 
dented, cracked, or warped, replace it.

!

15-12 FRAME

Footpeg

Left Footpeg Stay Removal

●

 Remove:

   Left Side Cover (see Left Side Cover Removal)
   Bolts [A]
   Footpeg Stay [B]

●

 Remove:

   Sidestand Switch Bolt [A] 

●

 Remove:

   Spring [A]
   Sidestand Nut [B]
   Sidestand [B]

Sidestand Installation

●

 Apply grease to the sliding area [A] of the 

   sidestand [B].

●

 Tighten the bolt and lock them with the nut.

   

Torque - Sidestand Bolt: 44 N·m (4.5 kgf·m, 33 

   ft·lb)

●

 Hook the spring. 

●

 Install the sidestand switch.

○

 Apply a non-permanent locking agent to the 

   thread of the switch bolt.

   Torque - Sidestand Switch Bolt: 8.8 N·m (0.90 
   kgf·m, 78 in·lb)

●

 Install the footpeg stay. 

●

 Tighten:

   Torque - Footpeg Stay Bolts: 34 N·m (3.5 
   kgf·m, 25 ft·lb)

Right Footpeg Removal

●

 Refer to Left Footpeg Removal.

FRAME 15-13

Rear View Mirrors

Rear View Mirrors Removal

●

 Loosen the lower hexagonal area [A] for 

   tightening to remove the rear view mirror from the 
   holder.

CAUTION

Do not force to tighten and/or loosen the 
rear view mirror stays, or the damage of the 
threads could happen.

Rear View Mirrors Installation

●

 Screw the mounting area of the rear view 

   mirror into the holder all the way, and tighten the 
   lower hexagonal area for tightening securely.
   Lower Hexagonal Area for Tightening [A]
   Rear View Mirror (Right) [C]

●

 Turn the stay [A] to assure the safe conditions of 

   the rear with the operator sat on the motorcycle. 

●

 Adjust the rear view mirror slightly with its mirror 

   [B].

○

 Installation and adjustment of the left side are 

   common with those of the right side. Follow the 
   procedure speci

fi

 ed at the right side.

ELECTRICAL SYSTEM 16-1

Electrical System

Table of Contents

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

16-2

Special Tools and Sealants..........................................................................................................

16-3

Parts Location..............................................................................................................................

16-4

Wiring Diagram............................................................................................................................

16-6

Precautions..................................................................................................................................

16-8

Electrical Wiring...........................................................................................................................

16-9

Battery.........................................................................................................................................

16-10

Charging System.........................................................................................................................

16-16

Starter Motor Clutch.....................................................................................................................

16-23

Ignition System............................................................................................................................

16-28

Electric Starter System................................................................................................................

16-35

Lighting System...........................................................................................................................

16-41

Radiator Fan System...................................................................................................................

16-49

Meter, Gauge, Indicator Unit........................................................................................................

16-51

Switches and Sensors.................................................................................................................

16-58

Relay and Fuse............................................................................................................................

16-61

16-2 ELECTRICALL SYSTEM

Specifi cations

Item

Standard

Battery

   Type
   Model Name
   Capacity

Sealed Battery 
YTX12-BS
12 V 10 Ah 

Voltage

12.8 V or more

Charging System

  Type
  Alternator Output Voltage
  Stator Coil Resistance
  Charging Voltage

Three-phase AC
42 V or more at 4 000 r/min (rpm) 
0.18~0.27 

Ω

14.2~15.2 V

Ignition System

  Crankshaft  Position Sensor Resistance
  Crankshaft Sensor Peak Voltage
  Primary Winding Resistance
  Secondary Winding Resistance
  Primary Peak Voltage

376~564 

Ω

1.9 V or more
1.1~1.5 

Ω

10.8 ~16.2 k

Ω

88 V or more

Spark Plug

Spark Plug Gap

0.8   0.9 mm (0.03   0.04 in.)

Switch and Sensors

Rear Brake Light Switch 
Engine Oil Pressure 
Switch Connections
Water Temperature Sensor Resistance

ON after about 10 mm (0.39 in.) pedal travel
When engine is stopped: ON 
When engine is running: OFF
in the text

ELECTRICAL SYSTEM 16-3

Electrical System

Special Tools

Hand Tester                                                                Lead W ire Adaptor

Magneto Rotor Puller                                                     Needle Adaptor Set

Peak Voltage Adapter                                                    Magneto Rotor Holder

16-4 ELECTRICAL SYSTEM

Electrical System

Parts Location

ELECTRICAL SYSTEM 16-5

 1. Alternator
 2. Battery 12V10Ah
 3. ECU
 4. Fan Motor
 5. Fuse Box with ECU Main Fuse
 6. Meter Unit
 7. Neutral Switch
 8. Starter Motor
 9. Coolant Temperature Sensor
10. Speed Sensor
11. Turn Signal Relay
12. Regulator/Rectifier
13. Side Stand Switch

Electrical System

Parts Location

14. Front Brake Switch
15. Oxygen Sensor
16. Crankshaft Position Senssor
17. Oil Pressure Sensor
18. Rear Brake Light Switch
19. Relay
20. Throttle Body
21. Ignition Coil
22. Ignition Switch
23. Fuel Fump (in the fuel tank)
24. Inlet Air Temperature Sensor
25. Roll-over Sensor

16-6 ELECTRICAL SYSTEM

Wiring Diagram

ELECTRICAL SYSTEM 16-7

 1. Front Position Light
 2. Rear Position Light
 3. Headlight
 4. Front Left Turn Light
 5. Auxiliary Relay
 6. Speed Meter
 7. Fuel Meter
 8. Coolant Temperature Meter
 9. FI Indicator Light
10. Tachometer
11. Meter Unit
12. Horn
13. Horn Switch
14. Dimmer Switch
15. Turn Switch
16. Clutch Switch
17. High Beam Relay
18. Low Beam Relay
19. Engine Start Switch
20. Light Switch
21. Engine Stop Switch
22. Front Brake Switch
23. Fuel Pump Relay
24. Fan Relay
25. Auxiliary Relay
26. Fuse Box
27. Ignition Switch
28. Oil Pressure Sensor
29. Crankshaft Position Sensor

Wiring Diagram

30. Alternator
31. Regulator/Rectifier
32. Starter Relay
33. Starter Motor
34. Battery
35. Neutral Switch
36. Rear Right Turn Light
37. Tail/Brake Light
38. License Plate Light
39. Rear Left Turn Light
40. Fuel Pump
41. Fuel Injector 1
42. Fuel Injector 2
43. Ignition Coil and Spark Plug 1
44. Ignition Coil and Spark Plug 2
45. Oxygen Sensor 1
46. Oxygen Sensor 2
47. Diagnostic Connector
48. Inlet Air Temperature Sensor
49. Coolant Temperature Sensor
50. Throttle Position Sensor
51. Roll-over Sensor
52. ECU
53. Sidestand Switch
54. Rear Brake Switch
55. Fuel Level Sensor
56. Fan Motor
57. Speed Sensor

16-8 ELECTRICAL SYSTEM

Electrical System

Precautions

There are a number of important precautions that are musts when servicing electrical systems.  Learn and ob-
serve all the rules below.

o

 

 Do not reverse the battery cable connections.  This will burn out the diodes on the electrical parts.

o

 

 Always check battery condition before condemning other parts of an electrical system. A fully charged

    battery is a must for conducting accurate electrical system tests.

o 

 

The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface.

    Such a shock to the parts can damage them.

o

  

To prevent damage to electrical parts, do not disconnect the battery cables or any other electrical connec-

    tions when the ignition switch is on, or while the engine is running.

o 

 

Because of  the large amount of current, never keep the starter button pushed when the starter motor will not

    turn over, or the current may burn out the starter motor windings.

o

  

Do not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram,

    as the meter or gauge panel could be warped by excessive heat radiated from the bulb.

o

  

Take care not to short the cables that are directly connected to the battery positive (+) terminal to the

    chassis ground.

o

  

Troubles may involve one or in some cases all items. Never replace a defective part without determining what

   CAUSED the failure. If the failure was caused by some other item or items, they must be repaired or
   replaced, or the new replacement will soon fail again.

o

  

Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying,

   etc. Poor wires and bad connections will affect electrical system operation.

o

  

Measure coil and winding resistance when the part is cold (at room temperature).

Color Codes:

R:   Red        R/W:   Red/White        R/G:   Red/Green        B:   Black        B/Y : Black/Yellow
B/Br:   Black/Brown        B/L:   Black/Blue        G:   Green        Gr:   Grey        Lg: Lght green
Lg/G:   Light green/Green        Lg/Y:   Light green/Yellow       Sb:   Sky blue        Sb/W: Sky blue/White
Y:   Yellow        O:   Orange        L:   Blue  P:   Purple        Br:   Brown        W :   White

ELECTRICAL SYSTEM 16-9

Female Connectors [A]

Electrical System

Male Connectors [B]

Wiring Inspection



 Visually inspect the wiring for signs of burning,

   fraying, etc.



If any wiring is poor, replace the damaged wiring.



 Pull each connector [A] apart and inspect it for

   corrosion, dirt, and damage.



If the connector is corroded or dirty, clean it carefully.

   If it is damaged, replace it.



 Check the wiring for continuity.

o

 

 Use the wiring diagram to find the ends of the lead

    which is suspected of being a problem.

o

 

 Connect the hand tester between the ends of the

    leads.

o

 

 Set the tester to the 

 range, and read the

    tester.



If the tester does not read 0 ?, the lead is defective.

  Replace the lead or the wiring harness [B] if
   necessary.

16-10 ELECTRICAL SYSTEM

Battery

Battery Removal



 

Remove:

   Seat (see Seat Removal in the Frame chapter)



 Disconnect the negative (-) cable [A].



 

Slide out the positive (+) terminal cap [B] and then

   disconnect the positive (+) cable.

N

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

 Remove the battery.

   Battery Installation



 Put the battery into the rear fender front.



 Apply a light coat of grease on the terminals to

   prevent corrosion.



 Install the positive (+) cable [A] first.



 Cover the positive (+) terminal with the cap [B].



 Install the negative (-) cable [C].

Battery Activation

Electrolyte Filling



 Make sure that the model name [A] of the electro-

   lyte container matches the model name [B] of the
   battery. These names must be the same.

   Battery Model Name for 650NK: YTX12-BS

Be sure to use the electrolyte container with

the same model name as the battery since the

electrolyte volume and specific gravity vary

with the battery type.  This is to prevent over-

filling of the electrolyte, shorting the battery

l i f e ,   a n d   d e t e r i o r a t i o n   o f   t h e   b a t t e r y

performance.

N

O

I

T

U

A

C

Do not remove the aluminum sealing sheet [A]

from the filler ports [B] until just prior to use.

Be sure to use the dedicated electrolyte con-

tainer for correct electrolyte volume.

N

O

I

T

U

A

C



 

 Place the battery on a level surface.



 

 Check to see that the sealing sheet has no peeling,

    tears, or holes in it.



  Remove the sealing sheet.

ELECTRICAL SYSTEM 16-11

Battery

   NOTE

o 

 

The battery is vacuum sealed. If the sealing sheet

    has leaked air into the battery, it may require a

    longer initial charge.



 Remove the electrolyte container from the vinyl bag.



 Detach the strip of caps [A] from the container and

  set aside, these will be used later to seal the
   battery.

NOTE

o 

 

Do not pierce or otherwise open the sealed cells

   [B] of the electrolyte container.  Do not attempt to

   separate individual cells.



 Place the electrolyte container upside down with

    the six sealed cells into the filler ports of the battery.
   Hold the container level, push down to break the
   seals of all six cells. You will see air bubbles rising
   into each cell as the ports fill.

NOTE

o 

 

 

Do not tilt the electrolyte container.



 Check the electrolyte flow.



 

If no air bubbles [A] are coming up from the filler

   ports, or if the container cells have not emptied
   completely, tap the container [B] a few times.



 

Keep the container in place for 20 minutes or more.

  Don't remove the container from the battery until
   it's empty, the battery requires all the electrolyte
   from the container for proper operation.

Removal of the container before it is com-

pletely empty can shorten the service life of

the battery. Do not remove the electrolyte con-

tainer until it is completely empty and 20 min-

utes have elapsed.

N

O

I

T

U

A

C



 Gently remove the container from the battery.



 Let the battery sit for 30 minutes prior to charging

   to allow the electrolyte to permeate into the plates
   for optimum performance.

NOTE

o 

 

Charging  the  battery  immediately  after  filling

   can shorten service life.  Let the battery sit for at

   least 30 minutes after filling.

16-12 ELECTRICAL SYSTEM

Battery

Initial Charge



 Place the strip [A] of caps loosely over the filler

   ports.



 Newly activated sealed batteries require an initial

   charge.
Standard Charge:    1.2 A x 5~10 hours

NOTE

o 

Charging rates will vary depending on how long the

   battery has been stored, temperature, and the type

   of charger used.   Let battery sit 30 minutes after

   initial charge, then check voltage using a voltmeter.

   If it is not at least 12.8 V, repeat charging cycle.



 After charging is completed, press down firmly with

   both hands to seat the strip of caps [A] into the
   battery (don't pound or hammer.). When properly
   installed, the strip of the caps will be level with the
   top of the battery.

Once the strip of the caps [A] is installed onto

the battery, never remove the caps, nor add

water or electrolyte to the battery.

N

O

I

T

U

A

C

NOTE

o 

To ensure maximum battery life and customer

    satisfaction, it is recommended the battery be load

   tested at three times its amp-hour rating for 15

   seconds. Recheck voltage and if less than 12.8 V

   repeat the charging cycle and load test.  If still be

   low 12.8 V the battery is defective.

ELECTRICAL SYSTEM 16-13

Battery

Precautions

1) No need of topping-up.
        No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the
        seal cap to add water is very dangerous. Never do that.
2) Refreshing charge.
       If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
       discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see
        Specifications).
        When a fast charge is inevitably required, do it following precisely the maximum charge current and time
        conditions indicated on the battery.

This battery is designed to sustain no unusual deterioration if refresh-charged according to the

method specified above. However, the battery's performance may be reduced noticeably if charged

under conditions other than given above.  Never remove the seal cap during refresh charge. If by

chance an excessive amount of gas is generated due to overcharging, the relief valve releases

the gas to keep the battery normal.

N

O

I

T

U

A

C

3)  When you do not use the motorcycle for months.
     Give a refresh charge before you store the motorcycle and store it with the negative cable re- moved. Give
     a refresh charge once a month during storage.
4)  Battery life.
     If the battery will not start the engine even after several refresh charges, the battery has exceeded its
     useful life. Replace it (Provided, however, the vehicle's starting system has no problem).
3)  When you do not use the motorcycle for months.
     Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give
     a refresh charge once a month during storage.
4)  Battery life.
     If the battery will not start the engine even after several refresh charges, the battery has ex- ceeded its
     useful life. Replace it (Provided, however, the vehicle's starting system has no problem).

Keep the battery away from sparks and open flames during charging, since the battery gives off

an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the

battery to the charger before turning on the charger.

This procedure prevents sparks at the battery terminals which could ignite any battery gases.

No fire should be drawn near the battery, or no terminals should have the tightening loos- ened.

The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If

touched, wash it off with liberal amount of water. Get medial attention if severe.

Interchange

     A sealed battery can fully display its performance only when combined with a proper vehicle electric system.
    Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed
    battery.
    Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
    equipment, the sealed battery's life will be shortened.

WARNING

!