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CF MOTO CF400-A 2017 Service Manual

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CF400-A/CF650-7B

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Page 1 Service manual CF400-A/CF650-7B WWW.CFMOTO.COM...
Page 2 WWW.CFMOTO.COM All right reserved ZHEJIANG CFMOTO POWER CO.,LTD. Sep/2017...
Page 3 FOREWORD Contents This manual introduces CF400-A(CF650-7B/ CF400-Amodel) maintenance information, disas- Maintenance Information sembly procedure, check & adjustment methods, troubleshooting and technical specifications. Periodic Maintenance There are illustrations, drawings to guide your operation. EFI system CFMOTO has final explanations to this manual Cooling system information.Without our prior written approval, Any part in this manual is not allowed to be...
Page 4 Units form Ampere Pounds After bottom dead center Meter ABDC Alternating current Minutes After top dead center Newton ATDC Before bottom dead center Pascal BBDC Bottom dead center Horsepower Before top dead center Pound/Square inches BTDC °C Celsius Rounds Direct current Rounds per minutes Farad Top dead center...
Page 5 Introduction This manual is designed primarily for use by well-trained mechanics in a properly equipped workshop. So the operator should have basic and necessary mechanical and electrical knowledge, as well as knowledge of proper use of tools. If you don’t have enough experience, it is better to ask qualifi ed operator to work.
Page 6 If you see the warning sig nal. Please pay more attention. And follow the safety hand le and service meth od. Danger This signal shows special indication. It may cause injury or death if the instruction not followed. Warnin g Th is sign al shows special indication .
Page 7 1 Maintenance information Serial number position……………………………1-8 Safty pre-cautions…………………………………1-1 General specification ……………………………1-9 Before servicing……………………………………1-3 Unit convertion table………………………………1-12 Safety Precautions When the engine just stops, the temperature of Exhaust contains toxic ingredients. Do not run the engine, muffler is still high; please do not touch engine in enclosed or poorly-ventilated areas.
Page 8 CFMTOTO The Battery may produce combustible and explosive The personnel shall make them be aware of each hydrogen when it is being charged. So it may other from time to time when operating, for safety explode if there is f ame or electric spark. So please conf rmation.
Page 9 1 Maintenance information Before Servicing Before starting to perform an inspection service or carry out disassembly and installation on a motorcycle, read the precautions given below. To facilitate acutal operations, notes, illustrations, photograghs, cautions and descriptions have been included in each chapter wherever necessary.This section explains the items that require particular attentions during removal and reassembly.
Page 10 CFMTOTO Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse.Arrange the parts according to the order of parts disas- sembled and clean the parts in order prior to installation. Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area, put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before...
Page 11 1 Maintenance information Tightening Sequence Generally, when installing a part with several bolts, nuts or screws, start them all in their holes and tighten them in snug fit. Then tighten them accord- ing to specified sequence to prevent case warpage or deformation which can lead to malfunction.
Page 12 CFMTOTO Press For items such as bearing or oil seals that must be pressed into place, apply small amount of oil on contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove ball or needle unless removal is absolutely necessary.
Page 13 1 Maintenance information Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out through- out this manual.Apply specific oil or grease as specified. Direction of Engine Rotation When rotating crankshaft by hand, the free play of amount of rotating direction will affect adjustment.
Page 14 CFMTOTO Marking Locations CF400-A ／ CF650-7B Model： LCEPESL4 ／ LCEPEVLB ：～～ VIN No. 268MQ ／ 283MT ～～ Engine serial No： ① V I N ： ② M et al ： ③ E n g i n e N o .：...
Page 15 1 Maintenance information Mainly specifications C F400-A／CF650-7B Item Dimensions: O verall length 2114 m m(83.2in.) O verall width 757mm (29.8in.) 1100 m m （43.3in.) O verall height W heelbase 1415m m (55.7in.) Road clearance 150mm (5.9in.) Seat height 815mm (32.1in) Dry m ass 206kg(454.14lb) Curb m ass...
Page 16 CFMTOTO Item CF400-A／CF650-7B Exhaust: Open 53°BBDC／50°BBDC Close 34°ATDC／30°ATDC Keeping time 267°／260° Lubrication Pressure, Splash(Half dry oil pan) Engine oil： Model ELF 10W-40/SJ JASO MA2 Standard SAE 10W-40 Capacity 2.6L(2.7USqt) Drive system Moderate level 1: Style Gear Moderate Ratio 2.146(88/41)／2.095(88/42) Clutch style Oil cool multidisc clutch Gear box: Style...
Page 17 1 Maintenance information Item CF400-A／CF650-7B Rear suspension： Style Rocker arm Wheel clearance 125mm(4.9 in.) Break caliper： Front Dual disc Rear Single disc Electrical equipment Battery 12V 10Ah Headlight： Style Semi-closed Bulb CF400 High beam：HS1 35W×1；Low beam：HS1 35W×1 Bulb CF650-7 High beam：LED×3 Low beam：LED×1 ；...
Page 18 CFMTOTO Unit calculation form Unit prefixion: Length: km × 0.6214 = mile Prefix Sign Counting ×1000000 Mega × 3.281 = ft ×1000 Kilo mm × 0.03937 = in ×0.01 Centi Torque: ×0.001 Mini N·m × 0.1020 = kgf·m µ ×0.000001 Micro N·m ×...
Page 19: Table Of Contents
2 Periodic maintenance Co nten ts Periodic Maintenance Chart………………………………………………………………………………………2-3 Torque Specifications………………………………………………………………………………………………2-6 Specifications and Service Limit…………………………………………………………………………………2-11 Special Tools………………………………………………………………………………………………………2-13 Fuel System (EFI) ………………………………………………………………………………………………2-14 Air Filter Element Cleaning……………………………………………………………………………………2-14 Throttle Control System Inspection …………………………………………………………………………2-15 Idle Speed Inspection …………………………………………………………………………………………2-16 Fuel Line Inspection (fuel leak, damage, installation condition) …………………………………………2-17 Cooling System……………………………………………………………………………………………………2-18 Coolant Level Inspection………………………………………………………………………………………2-18 Radiator Hose Damage and Installation Condition Inspection ……………………………………………2-18...
Page 20 CFMOTO Suspensions……………………………………………………………………………………………………2-34 Front Forks/Rear Shock Absorber Operation Inspection ………………………………………………2-34 Front Fork Oil Leak Inspection ……………………………………………………………………………2-34 Rear Shock Absorber Oil Leak Inspection ………………………………………………………………2-34 Steering System………………………………………………………………………………………………2-35 Steering Play Inspection……………………………………………………………………………………2-35 Steering Play Adjustment……………………………………………………………………………………2-33 Steering Stem Bearing Lubrication…………………………………………………………………………2-36 Electrical System………………………………………………………………………………………………2-36 Spark Plug Condition Inspection……………………………………………………………………………2-36 Lights and Switches Operation Inspection ………………………………………………………………2-37 Headlight Aiming Inspection…………………………………………………………………………………2-39 Sidestand Switch Operation Inspection……………………………………………………………………2-40...
Page 21: Periodic Maintenance Chart
2 Periodic maintenance Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. ■： This service must be performed by an authorized CFMOTO dealer. *：...
Page 22 CFMOTO Period What ever → which *Mileage comes Page km×1000 first ↓ Each Item Rim, Chain sprocket and bearing Tire pressure inspection 1 Year ● 2-25 ● ● ● Rim and tire damage ● 2-26 ● ● Tire wearing and abnormal wearing ●...
Page 23 2 Periodic maintenance 2. Periodic maintenance FREQUENCY Whichever comes →* ODOMETER READING first km×1000 Page ↓ Replacement attention Every Two years 2-14 ■ Air filter element Six months Every 3000 km/First time 500km 2-48 Engine oil Six months Every 6000 km 2-48 Oil filter Four years...
Page 24: Torque Specifications
CFMOTO Torque Specifications The following tables list the tightening torque for the major fasteners requiring use of a threadlocker. Letters used in "emarks" column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque; EO: Apply engine oil; L: Apply a threadlocker to the threads; Lh: Left-hand threads;...
Page 25 2 Periodic maintenance Torque Tighten parts Re mark N·m kgf· m ft· lb Muffler mounting bolt (rear) Heat insulator bolt 0.60 52in·lb See test Clutch Oil cap – – – By hand Clutch cover mounting bolt 106in·lb Clutch pressure spring bolt 87in·lb Clutch wheel nut 13.5...
Page 26 CFMOTO Torque Tighte n part Re mark N·m kgf· m ft· lb Shift drum bearing screw 0.50 43in·lb Connecting rod big end nut See test ← ← CP S disc mounting bolt Pressure lim it va lve Shift fork shaft bolt 106in·lb Shift spring locking pin Locking gear bolt...
Page 27 2 Periodic maintenance Torque Tighte n Re mark N·m kgf· m ft· lb Front fork low e r pane l locking bo lt Front fork up pe r pane l locking bo lt U ppe r pa ne l midd le loc k ing n ut Re a r shoc k absorber mount in g bo lt Re a r shoc k absorber mount in g bo lt Re a r fork a xel nut...
Page 28 CFMOTO Torque Tighten part Remark N·m kgf·m in·lb Start motor wire nut 0.60 Start motor mounting bolt Stator coil mounting bolt Timing rotor bolt Water temp sensor 12.0 The form below is the torque for bolt and nut. The form is only for unspecial bolt and nut. Usual tighten nut torque Torque Screw diameter...
Page 29 2 Periodic maintenance Standard and service limit Item Standard Service limit （EFI） 2～3mm（0.08～0.12in.） Throttle free clearance Idle speed 1450±145r/min（rpm） Air filter element Po ly urethan e foam in g plastic Cooling system Coolant： Style Permanent antifreeze coolant Color Green Mix ratio Pure water 50%，Coolant 50% Freeze temp.
Page 30 CFMOTO Item Standard Service limit Chain drive system 30~40mm (1.2~ 1.6in.) Chain looseness 317.5~318.2mm (12.5012.53in.) 323mm (12.7in.) Chain wearing - Chain RK or DID Made 520×S01 Style 118 （CF400）/114（CF650-7） Pieces Breaking cylinder Breaking fluid DOT4 Level Breaking pads Thickness Front 4mm (0.15in.) 1mm (0.04in.) Rear...
Page 31: Special Tools
2 Periodic maintenance Special tool 2-13...
Page 32: Air Filter Element Cleaning
CFMOTO Electronic Fuel Injection Air Filter Element Cleaning Note ○In dusty or humid area running .The filter element should be cleaned more often ○After running in rainy day or on the mud. The filter must be cleaned. Danger If the throttle body always into dust. It will cause the throttle jammed and finally cause the accident.
Page 33: Throttle Control System Inspection
2 Periodic maintenance Danger Clean the filter element and make sure there is no spark or flame. Because high-flammable liquid is dangerous. Do not use gasoline or high flammable liquid to clean the filter. Ÿ Clean the element element [A] in a bath of highflash point solvent, and then dry it with compressed air or by shaking it.
Page 34: Idle Speed Inspection
CFMOTO « If necessary,adjust the throttle cable as follows. Ÿ Loosen the locknut [1] at the upper end of the accelerate cable. Ÿ Turn the adjuster [2] in completely so as to give the throttle grip plenty of play. Ÿ Loosen the locknut [3] at the middle of the deceler- ate cable.
Page 35: Fuel Line Inspection (Fuel Leak, Damage, Installation Condition)
2 Periodic maintenance Fuel Line Inspection (fuel leak, damage, installation condition) ○ The fuel line is designed to be used throughout the motorcycle¡¯s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the line to burst.
Page 36: Cooling System
CFMOTO Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambient temperature). Ÿ Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). «...
Page 37: Cylinder Head
2 Periodic maintenance Cylinder head Valve Clearance Inspection Note Enging must be totally cool down before adjustment. ● Remove the cylinder head cover (see Cylinder Head Cover Removal in the Engine Top End chapter) ● Unscrew the upper [A] and lower [B] caps on the clutch cover.
Page 38 CFMOTO Valve Clearance Measuring Position #1 Piston TDC at End of Compression Stroke Intake valve clearances of #1 piston,and Exhaust valve clearances of #1 piston NOTE Check the valve clearance using this method only. Checking the clearance at any other cam position may result in improper valve clearance.
Page 39 2 Periodic maintenance Valve clearance form Intake valve clearance Thickness Mark Thickness 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 0～0.01 — — — —...
Page 40 CFMOTO Intake valve clearance adjusting Clearance valve clearance Thickness Sign Thickness 3.68 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18 0～0. 01 3. 58 3. 62 3.
Page 41 2 Periodic maintenance Exhaust clearance Thickness 实例 Sign Thickness 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 0～0.01 — — — — —...
Page 42 CFMOTO Exhaust clearance form Rod thickness S ign Thickness 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4.02 4.04 4.06 4.08 4.12 4.14 4.16 4.18 0～0.01 3.52 3.54 3.56 3.58 3.62 3.64 3.66 3.68 3.72 3.74 3.76...
Page 43: Clutch
2 Periodic maintenance Clutch Clutch Operation Inspection Ÿ Pull the clutch lever just enough to take up the free play [A]. Ÿ Measure the gap between the lever and the lever holder. « If the gap is too wide,the clutch may not release fully.
Page 44: Wheel/Tire Damage Inspection
CFMOTO Wheel/Tire Damage Inspection Ÿ Remove any imbedded stones [A] or other foreign particles [B] from tread. Ÿ Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. Ÿ...
Page 45: Wheel Bearing Damage Inspection
2 Periodic maintenance Wheel Bearing Damage Inspection Ÿ Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/Tires chapter). Ÿ Turn the handlebar all the way to the right or left. Ÿ Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel.
Page 46: Drive Chain Slack Inspection
CFMOTO Ÿ Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. Wipe off any excess oil. Ÿ...
Page 47: Wheel Alignment Inspection
2 Periodic maintenance Ÿ Turn the wheel, measure the chain slack again the tightest position, and readjust if necessary. Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.
Page 48: Drive Chain Wear Inspection
CFMOTO Drive Train Wear Inspection Ÿ Remove Chain Cover (see Swingarm Removal in the Suspension chapter) Ÿ Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links. « If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry.
Page 49: Brake System
2 Periodic maintenance Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection Ÿ Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], fittings [B] and [C] « If the brake fluid leaked from any position, inspect or replace the problem part.
Page 50: Brake Operation Inspection
CFMOTO Brake Operation Inspection Ÿ Inspect the operation of the front and rear brake by running the vehicle on the dry road. « If the brake operation is insufficient, inspect the brake system. Warning Make sure the transportation is safe when check on the way.
Page 51: Brake Pad Wear Inspection
2 Periodic maintenance Ÿ Follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand. Brake Pad Wear Inspection Ÿ Check the lining thickness [A] of the pads in each caliper.
Page 52: Suspensions
CFMOTO Suspensions Front Forks/Rear Shock Absorber Operation Inspection Ÿ Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke.If the forks do not work smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
Page 53: Steering System
2 Periodic maintenance Steering System Steering Play Inspection Ÿ Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/Tires chapter). Ÿ With the front wheel pointing straight ahead, al- ternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
Page 54: Steering Stem Bearing Lubrication
CFMOTO Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. Ÿ Hand tighten the stem locknut until it touches the claw washer. Ÿ Tighten the stem locknut clockwise until the claws are aligned with the grooves (ranging from 2nd to 4th) of stem nut [D], and bend the 2 claws down- ward [E].
Page 55: Lights And Switches Operation Inspection
2 Periodic maintenance Lights and switches operation inspec- tion First step Ÿ Turn the ignition switch on Ÿ The following light should be on according to below table. Position light[A] Tail light[B] Rear license light[C] Dashboard LCD[F] Neutral indicator（LED）[E] EFI trouble light（LED）[D] （About 5s）...
Page 56 CFMOTO Second step ŸTurn the ignition switch[A]on and turn the position light [B] on. ŸThe position light ,tail light and licence light should be on. «If the light does not on. Inspect or replace the item below. Ignition switch or RH switch or inspect the wire (See switch inspection in electrical system chapter) Third step ŸTurn the steering indicating light on[D](LH or RH).
Page 57 2 Periodic maintenance . Turn dimmer switch to highbeam. . Low beam [A] and high beam [B] headlight should be on. . Highbeam indicator(LED)[C] should be on. .If highbeam head light and/or indicator is not on. In- spect or replace the item below. Highbeam bulb of headlight (See headlight bulb re- placement in electrical system chapter) Dimmer switch(See switch inspection in electrical...
Page 58 CFMOTO N ot e ○For high beam headlight. When driver on the seat. The axis of headlight should be a little lower then horizontal point. Adjust the angel by following the local law. When the low beam on only left side on. When high beam on.
Page 59: Engine Stop Switch Operation Inspection
2 Periodic maintenance «If sidestand is normal but the engine still cannot work. Inspect or replace the item below. Battery (See charging inspection in electrical sys- tem chapter) Main fuse 20A (See fuse inspection in electrical system chapter) Fuel pump relay fuse 15A (See fuse inspection in electrical system chapter) Ignition switch (See switch inspection in electrical system chapter)
Page 60: Others
CFMOTO Others Chassis lubrication Ÿ Before lubricate the parts. Use the cleaning solu- tion to clean up the rustese, grease, oil, dust and dirt. Ÿ Use named lubricant to lubricate the point below. Note ○Use normal lubricant whenever the humit, rainy or washed.
Page 61: Bolts, Nuts And Fasteners Tightness Inspection
2 Periodic maintenance Bolts, Nuts and Fasteners Tightness Inspec- tion •Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
Page 62: Replacement Parts
CFMOTO Replacement Parts Air Filter Element Replacement ŸRefer to the Air Cleaner Element Cleaning Fuel Line Replacement Warning Wh en removing and installing the fuel line joint, do not app ly strong force to the o utlet pipe on the fuel pu mp and delivery pipe on the throttle body assy.
Page 63: Coolant Change
2 Periodic maintenance Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coo lant when the engin e is still hot. Wait until it cools down. Coolant on tires will make them slipp ery and can cause an accident and injury.
Page 64 CFMOTO ŸRemove the rediator cap [A] by 2 steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○The coolant will drain from the radiator and engine.
Page 65: Radiator Hose And O-Ring Replacement
2 Periodic maintenance ŸTemporarily install the reserve tank to the frame with two bolts. ŸFill the reserve tank up to the “F” (full) level line [A] with coolant and install the cap [B]. ŸStart the engine, warm it up thoroughly until the ra- diator fan turns on and then stop the engine.
Page 66: Oil Filter Replacement
CFMOTO Engine Oil Replacement ŸSituate the motorcycle so that it is vertical after warming up the engine. ŸUnscrew the oil filler plug [A]. ŸPlace on oil pan beneath the engine. ŸRemove the engine oil drain bolt [A] to drain the oil. ○The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
Page 67: Brake Hose And Pipe Replacement
2 Periodic maintenance ŸReplace the filter with a new one. ŸApply engine oil to the gasket [A] before installation. ŸTighten the filter with the oil filter wrench. Torque - Oil Filter: 17N·m（1.75kgf·m， 13ft·lb） NOTE ○Hand tightening of the oil filter can not be allowed since it does not reach to this tightening torque.
Page 68: Master Cylinder Rubber Parts Replacement
CFMOTO ŸChange the brake fluid. ○Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3. Close the bleed valve [C]. 4.
Page 69 2 Periodic maintenance Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal reguires brake position adjustment. Special Tool - Inside Circlip Pliers Pull out the push rod with the piston stop. ŸTake off the piston [A], secondary cup [B], primary cup [C] and return spring [D].
Page 70: Caliper Rubber Parts Replacement
CFMOTO Caliper Rubber Parts Replacement Front Caliper Disassembly ŸRemove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Padal (see Front Brake Pad Removal in the Brakes chapter) ŸUsing compressed air, remove the pistons. ○Cover the piston area with a clean, thick cloth [A]. ○Blow compressed air [B] into the hole for the banjo bolt to remove the piston.
Page 71 2 Periodic maintenance ŸApply brake fluid to the outside of the pistons, and push them into each cylinder by hand. ŸCheck the shaft rubber friction boot [A] and the dust cover [B] replace them with new ones if they are damaged.
Page 72: Spark Plug Replacement
CFMOTO ŸReplace the fluid seal [A] with a new one. ○ Apply brake fluid to the fluid seal, and install it into the cylinder by hand. ŸReplace the dust seal [B] with a new one if it is damaged. ○ Apply brake fluid to the dust seal, and install it into the cylinder by hand.
Page 73 3 EFI System Table of Contents Exploded View …………………………………………………………………………………………………… 3-2 ECU Pin Function………………………………………………………………………………………………… 3-4 EFI Specification …………………………………………………………………………………………… … … 3-6 Special Tools……………………………………………………………………………………………………… 3-8 EFI servicing precautions … …………………………………………………………………………………… 3-10 EFI trouble shooting……………………………………………………………………………………………… 3-11 General ………………………………………………………………………………………………………… 3-11 EFI Diagnose flow chart ……………………………………………………………………………………… 3-15 Diagnose sheet…………………………………………………………………………………………………...
Page 74: Exploded View
CFMOTO △ Exploded View...
Page 75 3 EFI System 1. Ignition Switch 2. Engine Stop Switch 3. Start relay 4. RPM meter 5. Trouble indicator light(LED) 6. Spark plug 7. Crankshaft position sensor 8. Injector 9. Throttle position sensor 10. Fuel hose and pipe 11. Throttle body 12.
Page 76: Ecu Pin Function
CFMOTO ECU Pin function ECU pin function 26(C2) Auxiliary relay 1(M1) Oxygen sensor 2 heating 27(B2) Step motor A 2(L1) Oxygen sensor 1 heating 28(A2) Step motor B 3(M2) Ignition coil 1 29(K3) MIL indicator 4(L2) None 30(J3) 5V power 5(M3) Ignition ground 31(H2) None 6(L3) None...
Page 77: Efi Specification
3 EFI System EFI Specification Item Standard EFI system Idle speed 1 450 ±100 r/min (rpm) Throttle body： Style Double pipes Ф38 mm Diameter Made in UAES Style Data controlling with electric system Can running in RPM 100 ~11 000 r/min (rpm) Fuel pressure: Ignition switch open 323 kPa (3.3 kgf/cm...
Page 78 CFMOTO EFI Specification Item Standard Oxygen sensor Output voltage(High) 0.7V or higher Output voltage(Low) 0.2V or lower Throttle handle bar and cable 2~3mm(0.08~0.12in. Throttle handle free clearance...
Page 79: Special Tools
3 EFI System Special tools Oil pressure gauge Needle Adaptor Set Hand Tester Throttle Sensor Setting Harness Fuel Hose Fuel Pressure Gauge Adaptor Peak Voltage Adapter...
Page 80: Efi Servicing Precautions
CFMOTO EFI Servicing Precautions There are a number of important precautions that should be followed servicing the EFI system. ● This EFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
Page 81 3 EFI System EFI Servicing Precautions ● When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage. ● When any fuel hose is disconnected, do not turn on the ignition switch.
Page 82: Efi Trouble Shooting
CFMOTO EFI trouble shooting General information When an abnormality in the system occurs, the FI indicator light (LED) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
Page 83 3 EFI System EFI trouble shooting ● The DFI part connectors [A] have seals [B], in- cluding the ECU. ● Join the connector and insert the needle adapt- ers [C] inside the seals [B] from behind the connec- tor until the adapter reaches the terminal. CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short-...
Page 84 CFMOTO EFI trouble shooting ● Measure the coil resistance after EFI parts cool down. ● Make sure the connectors are clean and tight, and see if it got burned, wore or any other damage. Damaged wire or bad connection will cause the trouble often comes out and make the EFI system running unstable.
Page 85 3 EFI System EFI trouble shooting ● Wire color code ： B: Black L: Blue Gr: Grey Br: Brown G: Green Lg: Light green Sb: Light blue O:Orange R:Red P: Purple W: White Y: Yellow EFI trouble shooting method There are two ways to inspect the EFI system. One is voltage Check Method and the other is Resis- tance Check Method.
Page 86: Efi Diagnose Flow Chart
CFMOTO EFI trouble shooting EFI Diagnosis Flow Chart Trouble comes Confirm trouble Get the trouble information from driver Ignition on with trouble indicated No blinking Blinking Use self-diagnosing Use assistance diagnose Use normal fuel system inspection (Normal fuel system includes :Throttle body、...
Page 87: Diagnose Sheet
3 EFI System EFI trouble shooting Diagnose sheet：：： Rider name Registration No. (license plate No.) ：： Year of initial registration Model ： VIN： Engine No ：： Date problem occu rred Mileage Environment when problem occurred □fi ne, □cloudy, □rain, □snow, □always, □other: Weather □hot, □warm, □cold, □very cold, □always Temperature...
Page 88 CFMOTO EFI trouble shooting Diagnose sheet □clutch slipping □others Poor running or Spark plug getting loose no power at high Spark plug dirt, broken or clearance not fit speed Spark model wrong Engine knocking Breaking dragging Clutch sliding Engine overheat Too much engine oil High viscocity engine oil Other...
Page 89: Efi System Trouble Shooting Form
3 EFI System EFI system trouble shooting form NOTE ● This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common diffi culties. ●...
Page 90 CFMOTO EFI system trouble shooting form Trouble or reason Solution (Chapter) Hold the clutch or set the gear in neutral When the side stand up or down. The clutch lever not hold .And the gear is not in Neutral Hold the clutch with side stand down. Gear Side stand up with clutch lever hold not in neutral Roll over sensor dropped...
Page 91 3 EFI System EFI system trouble shooting diagram Trouble and reson Solution(Chapter) Cylinder head wrap Inspect and replace(See chapter 5) No valve clearance Adjust (See chapter 2) Valve conductor wearing Inspect and replace (See chapter 5) Valve spring damaged or wearing Inspect or replace(See chapter 5) Inspect repair or replace(See chapter 5) Valve is not in position(Valve bent,...
Page 92 CFMOTO EFI system trouble shooting diagram Trouble and Reason Solution(Chapter) TPS problem Trouble(Chapter 3) TPS not adapted or wrong adapted See PDA chapter Engine easy stop： Fuel pump trouble Inspect(See Chapter 3) Injector problem Inspect(See Chapter 3) TPS problem Inspect(See Chapter 3) TPS not adapted or wrong adapted See PDA chapter Fuel pressure too low or too high...
Page 93 3 EFI System EFI system trouble shooting diagram Trouble and reason Solution(Chapter) Ignition time late Inspect the CPS and Ignition control part of ECU(See chapter 16) Bad accelerate： Fuel pressure too low Inspect (See chapter 3) There is water in fuel or other liquid Replace the fuel.
Page 94 CFMOTO EFI system trouble shooting diagram Trouble and reason Solution(Chapter) Inspect and repairing(See chapter 16) Battery or ECU ground wire loose Valve seat carbon covered Repairing (See chapter 5) Engine overheat (See chapter 17) Others： Engine oil viscosity too high Replace(See chapter 2) Transmission system problem Inspect driving chain(See chapter 2) and...
Page 95 3 EFI System EFI system trouble shooting diagram Trouble and reason Solution(Chapter) Cylinder head not total tighten Tight up(See chapter 5) No valve clearance Adjust(See chapter 2) Cylinder and piston wearing Inspect and replace( See chapter 5) Bad piston ring(Wearing, weak, Damage) Inspect and replace ( See chapter 5) Piston and grove clearance too large Inspect and replace ( See chapter 5) Cylinder head gasket damaged...
Page 96 CFMOTO EFI system trouble shooting diagram Trouble and reason Solution (Chapter) Black smoke Air filter jammed Clean(See chapter 3) Fuel pressure too high Inspect(See chapter 3) Injector open Inspect (See chapter 3) Water temp. sensor problem Inspect and replace(See chapter 3) Intake temp sensor problem Inspect and replace (See chapter 3) 3-24...
Page 97: Self Diagnose
3 EFI System Self diagnose General ECU constantly monitor sensors, actuators and circuits, FI indicator light and battery voltage, etc, even ECU itself and inspect the sensor output signal, ac- tuator drive signal and internal signal (such as close loop control, coolant temperature, idle speed control and battery voltage control, etc.) for reliablity.
Page 98 CFMOTO Self diagnose Trouble blinking control Blinking function needs special situation to become real. Before the engine start(Speed 0, Engine RPM 0) . Full throttle open( Or larger then 65.1) . Keep the throttle full open. Then turn the ignition switch on. If the EMS cannot get the trouble.
Page 99 3 EFI System Self diagnose How to Erase Trouble Codes ● Even if ignition switch is turned off, the battery or the ECU is disconnected or the problem is solved, all trouble codes remain in ECU. ● For trouble appeared. If the trouble still on. The trouble code cannot be erased. Restart the vehicle after the trouble solved.
Page 100: Trouble Code List
CFMOTO Self diagnose Trouble code list Pco de De cription (UAES) P 0 0 3 0 O 2 Se n so r 1 H e a te r Co n tr. C irc. H ig h P 0 0 3 1 O 2 Se n so r 1 H e a te r Co n tr.
Page 101 3 EFI System Self diagnose Note ● If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU. ● When no trouble code is displayed, the electrical parts of the EFI system has no fault, and the mechani- cal parts of the EFI system and the engine are suspect.
Page 102: Efi Trouble Back Up
CFMOTO Self diagnose EFI trouble back up ECU has the back up solution below to protect the engine when EFI part got trouble. Trouble Signal not stable or out Parts ECU settings code of standard Intake intake temp sensor trouble temp disconnected，ECU temp is -40°C ；...
Page 103: Efi Parts Service
3 EFI System EFI parts service Throttle body CAUTION Do not remove or adjust the throttle position sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can damage it.
Page 104 CFMOTO Throttle body Input voltage connection inspection. ● Turn the ignition switch OFF. ● Disconnect ECU connector and throttle position sensor connector. ● Test the continuity of the 2 lead wires. ECU Connector [A]←→ Throttle Body Connec- tor [B] Throttle Body Connector Gr/R ←→ ECU pin 18 Throttle Body Connector Lg/Y ←→...
Page 105 3 EFI System Throttle body Throttle Position Sensor Output Voltage Connections to Adapter Meter (+)→ Br/R (sensor output) lead Meter (+)→ Lg/Y( sensor ground) lead ： Stand ard Idle speed：0 . 3 4 ～0 . 6 4 V D C Full open：≥...
Page 106 CFMOTO Throttle body T hr ot tl e po si ti on se nsor r esista nc e inspection. ● Turn the ignition switch OFF. ● Disconnect ECU connector and throttle position sensor connector. ● Connect a hand tester [A] to the throttle position sensor connector [B].
Page 107: Intake Temp And Pressure Sensor
3 EFI System Intake temp and pressure sensor CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage Intake temp and pressure sensor output volt- age inspection. ● Make sure the battery get fully charged ●...
Page 108 CFMOTO Intake temp and pressure sensor Resistance inspection ● Remove the intake temp sensor. ● Suspend the sensor [A] in a container of ma- chine oil so that the heat-sensitive portion issubmerged. ● Suspend a t herm om et er [ B] wi t h t he heatsensitive portion [C] located in almost the same depth with the sensor.
Page 109 3 EFI System Intake temp and pressure sensor Wiring diagram 1. ECU 2. Intake temp and pressure sensor 3-37...
Page 110: Water Temp Sensor
CFMOTO Water temp sensor Water Temp Sensor Removal/Installation CAUTION Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can damage it. ● Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). ●...
Page 111 3 EFI System Water Temp Sensor NOTE ● Coolant temperature sensor output voltage varies with the coolant temperature change. ● Turn the ignition switch off. « If the output voltage is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection).
Page 112: Crankshaft Position Sensor
CFMOTO Crankshaft Position Sensor Crankshaft Position Sensor Removal/Installa- tion ● Refer to the Crankshaft Sensor Removal/Installa- tion in the Electrical System chapter. Crankshaft Position Sensor Inspection ● The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no signals ●...
Page 113: Speed Sensor
3 EFI System Speed sensor Speed Sensor Removal/ Installation ● Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Inspection ● Refer to the Speed Sensor Inspection in the Elec- trical System chapter Speed Sensor Input Voltage Inspection NOTE ●...
Page 114 CFMOTO Speed Sensor ● Measure the sensor output voltage with the en- gine stopped, and with the connector joined. ● Turn the ignition switch ON. Speed Sensor Output Voltage at Sensor Connections to Adapter (+)→ P(Sensor)[C] Meter (-)→ G/B(Sensor)[D] Meter Standard：About 0.05～1.0VDC Speed Sensor Circuit 1.
Page 115 3 EFI System Roll-over Sensor Caution Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can damage it. Roll-over sensor removal： ● Disconnect connector [B].Remove the roll-over sensor [A] Roll-over sensor Installation： ●...
Page 116: Roll Over Sensor
CFMOTO Roll-over Sensor ● Turn the ignition switch on and measure roll-over sensor power source voltage. ： Roll-over Sensor Output Voltage Standard:12V DC (Battery voltage) ● Turn the ignition switch OFF « If the reading of input voltage is less than the standard, check the ECU for its ground, power sup- ply and wiring shorted.
Page 117: Oxygen Sensor
3 EFI System Oxygen Sensor WARNING Never drop the sensor [B], especially on a hard surface. Such a shock to the part can damage it. Do not touch the portion [A] of the sensor, otherwise, the oil residue on your hand may contaminate the sensor and cause performance degeneration.
Page 118 CFMOTO Oxygen Sensor Oxygen Sensor Inspection ● Disconnect the oxygen sensor connector [A] of one cylinder. ● Place the transmission in neutral. ● Start the engine and throughly warm it up, then have the engine run at more than 8000rpm. ●...
Page 119 3 EFI System Oxygen Sensor ● Remove the hose [B]. ● Measure oxygen sensor output voltage with hand tester [B]. Oxygen Sensor Output Voltage: Cylinder 1: Meter(+)→ Pin 3 [C] Meter (-)→ Pin 4 [D] Cylinder 2: Meter (+)→ Pin 3 [C] Meter (-)→...
Page 120: Ignition Coil
CFMOTO Ignition Coil WARNING Never drop the sensor, especially on a hard surface. Such a shock to the part can damage Ignition Coil Input Voltage Inspection NOTE ● Be sure the battery is fully charged ● Turn the iignition switch OFF ●...
Page 121 3 EFI System Ignition Coil Ignition Coil Circuit 1. Main Fuse 2. Battery 3. ECU 4. Ignition Switch 5. Fuse Box 6. Engine Stop Switch 7. Main relay 8. Ignition Coil 2 9. Ignition Coil 1 3-49...
Page 122: Trouble Indicating Light
CFMOTO Trouble indicating light Checking steps form Replace the Ignition on dashboard or cable Trouble See the indicator Trouble indicator and cable Light up Normal Y es Then indicator off Indicator and EFI after 4s light up are normal Indicator light still EFI tested on after 4s historical trouble...
Page 123 3 EFI System Trouble indicating light Indicator Light Inspection ● Remove the meter unit (see Meter Unit Removal in the Electrical System chapter). ● Using two auxiliary leads, supply battery power to the FI indicator light (LED) [A]. ● Battery [B] 12 V. Positive pole(+)→...
Page 124 CFMOTO E C U CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. ECU Removal ● Remove rear seat ● Pick out ECU [A] and the harness. ● Disconnect the ECU lead connectors ECU Installation ●...
Page 125: Ecu
3 EFI System ECU Power Source Inspection F G H ● Check the ECU power source voltage with a hand tester [A]. ● Use the drawings in this chapter to see the ECU connector [B] numbers and position the pins. Battery [C] Meter Connections ：...
Page 126 CFMOTO E C U ECU wiring diagram A B C D E F G H J K L M 1. Fuse 2.Battery 3. ECU 4. Ignition switch 5. Main fuse 6. Engine stop switch 7. Main relay 3-54...
Page 127: High Pressure Fuel Pipe
3 EFI System High pressure fuel pipe Fuel Pressure Inspection NOTE ● This inspection can determine which trouble the EFI system has, mechanical or electrical trouble. ● It is preferable to measure the fuel pressure while running the motorcycle just when trouble occurred in order to know symptom well.
Page 128 CFMOTO High pressure fuel pipe Fuel Pressure Inspection ● Measure the fuel pressure with the engine stopped. Fuel Pressure Right after Ignition Switch ON, with pump ： running Standard : 330kPa(0.33MPa) After 3 seconds from Ignition Switch ON, with pump stopped Standard: 265kPa(0.265MPa) The system should hold the residual pressure about 30 seconds.
Page 129: Fuel Pump
3 EFI System Fuel pump Fuel pump flow rate NOTE ● Be sure the battery is fully charged. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Page 130 CFMOTO Fuel pump Flow rate inspection WARNING Do not drive the fuel pump without the fuel in the fuel tank. ● Measure the discharge for 3 seconds with the plastic hose filled with fuel. ● Repeat this operation several times ：...
Page 131 3 EFI System Fuel Pump Fuel Pump Removal WARNING Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
Page 132 CFMOTO Fuel Pump Fuel Pump Installation ● Clean dirt or dust from the fuel pump [B] by lightly applying compressed air. ● Replace the fuel pump gasket [C] with a new one if damaged. ● Tighten the fuel pump bolts to a snug fit, tighten them in a crisscross pattern.
Page 133 3 EFI System Fuel Pump « If the reading stays on battery voltage, and never shows 0 V. Check the ECU and fuel pump relay. « If the voltage is in specification, but the pump doesn’t work, replace the pump (see Fuel Pump Removal/ Installation).
Page 134 CFMOTO Fuel pump Fuel Pump Circuit 1. Fuse 2. Battery 3. ECU 4. Ignition switch 5. Fuse box 6. Engine stop switch 7. Main relay 8. Fuel pump relay 9. Fuel pump 3-62...
Page 135: Injector
3 EFI System Injector Injector Removal/Installation ● Refer to the Throttle Body Assy Disassembly/ Assembly. Sound inspection ● Start the engine ● Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
Page 136 CFMOTO Injector ● Turn the ignition switch ON. Fuel fump input voltage is the battery voltage in first 3 seconds, then 0 V. « If the output voltage is normal, perform “Injector Signal Test”. « If the meter does not read as specified, check the following: ●...
Page 137 3 EFI System I n j e c t o r Injector Signal Test ● Prepare two test light sets with male terminals as shown. ● Rating of Bulb [A] : 12V Į3~3.4W Terminal Width [B] : 1.8mm Terminal Thickness [C] : 0.8mm CAUTION Do not use larger terminals than specified above.
Page 138 CFMOTO Injector Injector Resistance Inspection ● Remove the fuel tank(see Fuel Tank Removal). ● Remove the air filter housing ● Disconnect the connector from the connector [A]. ● Measure the injector resistance with the hand tester [B]. Injector Resistance ： St and ar d：1 2 . 5 ± 1 Ω（2 0 ℃） «...
Page 139 3 EFI System Injector Fuel Injector Circuit 1. Fuse 2. Battery 3. ECU 4. Ignition switch 5. Fuse box 6. Engine stop switch 7. main relay 8. Injector 2 9. Injector 1 3-67...
Page 140: Throttle Cable And Lever
CFMOTO Throttle Cable and lever Throttle Grip Free Play Inspection ● Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Throttle Grip Free Play Adjustment ● Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Throttle Cable Installation ●...
Page 141: Throttle Body
3 EFI System Throttle Body Idle Speed Inspection ● Refer to the Idle Speed Inspection in the Periodic Maintenance chapter. Engine Vacuum Synchronization Inspection/ Adjustment ● Refer to the Engine Vacuum Synchronization In- spection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions.
Page 142 CFMOTO Throttle Body ● After removing the throttle body assy, stuff pieces of lint-free, clean cloth into the throttle body holders. WARNING If dirt gets into the engine, excessive engine wear and possible engine damage will occur. Throttle Body Assy Installation ●...
Page 143: Trouble Code List
3 EFI System Trouble code list If the EFI system trouble. Follow this form to maintain the trouble. Please refer to related chapter to see the details. No Pcode Decription(UAES) P0030 O2 Sensor 1 Heater Contr. Circ. High P0031 O2 Sensor 1 Heater Contr. Circ. Low P0032 O2 Sensor 1 Heater Contr.
Page 144 CFMOTO No Pcode Decription(UAES) P0202 Cylinder 2- Injector Circuit P0264 Cylinder 2- Injector Circuit Low P0265 Cylinder 2- Injector Circuit High P0321 Ign./Distributor Eng.Speed Inp.Circ. Range/Performance P0322 Ign./Distributor Eng.Speed Inp.Circ. No Signal P0480 cooling fan control Circuit Open P0508 Idle Air Control Circuit Low P0509 Idle Air Control Circuit Low High P0511...
Page 145 3 EFI System ABS Fault Code C1D90 Fault of front wheel speed sensor (sensor, replace sensor) C1D91 Physical fault of front wheel speed sensor (signal problems, check front ring gear, wheel speed sensor, clearance is too big, wrong number of teeth, electromagnetic interference, ring gear、sensor may be missing) C1D92 Periodic fault of front wheel speed sensor (inspect ring gear deformation, ring gear deformation caused by wheel deformation)
Page 146 CFMOTO C1DD3 OSEK deadly fault (operation system is wrong, MAB is broken, High frequency interference [rarely]) C1DF0 Pump fault (MAB broken) C1DF1 Pump connection fault (MAB broken) C1DF2 hardware fault (MAB broken) C1DF5 inner hardware fault (main power, valve…..) (MAB broken, wrong software version [rarely]) C1DF3 Low voltage-Long-term tests (Battery losing power, Rectifier fault) C1DF4 Voltage is too low (Battery losing power, Rectifier fault, problem occurs when start)
Page 147 4 Cooling system Contents Exploded View ………………………………………………………………………………………………………4-2 Coolant Flow Chart …………………………………………………………………………………………………4-4 Specifications ………………………………………………………………………………………………………4-6 Special Tools…………………………………………………………………………………………………………4-7 Coolant ………………………………………………………………………………………………………………4-8 Coolant Deterioration Inspection ……………………………………………………………………………4-8 Coolant Level Inspection………………………………………………………………………………………4-8 Coolant Draining ………………………………………………………………………………………………4-8 Coolant Filling …………………………………………………………………………………………………4-8 Pressure Testing ………………………………………………………………………………………………4-8 Cooling System Flushing………………………………………………………………………………………4-9 Coolant Reserve Tank Removal/Installation …………………………………………………………………4-9 Water Pump …………………………………………………………………………………………………………4-10 Water Pump Removal……………………………………………………………………………………………4-10 Water Pump Installation…………………………………………………………………………………………4-10...
Page 148: Exploded View
Exploded view...
Page 149 4 Cooling system Torque Tighte n parts Re mark N· m kgf·m ft· lb Radiator pipe locking bolt 0.25 17in·lb Water pump peller bolt 87in·lb Water pump cover bolt 87in·lb Water pump draining bolt 0.70 62in·lb Thermostat housing bolt 87in·lb Water temp sensor 106in·lb Wind plate bolt...
Page 150: Coolant Flow Chart
Coolant flow chart Cool 1、Water cover for cylinder head 2、Thermostat 3、Cylinder sleeve 4、Reservior pipe 5、Reservior 6、Rediator 7、Fan 8、Radiator cap 9、Reservior pipe 10、 Water pump...
Page 151 4 Cooling system Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
Page 152 Item Standard Coolant P erma nent type of anti fr eeze (s oft water and ethylene Model（Recomm end） glycol plus corrosion an d rust inhibitor che micals for aluminum engines and radiators) Color Green Mix ratio Water 50%，Coolant 50% Freezing point -35°C(-31°F) Capacity 1.8L (Reservoir F le vel，Including radiator and the...
Page 153: Special Tools
4 Cooling system Special tool Bearing pressor Oil seal pressor...
Page 154: Coolant
Coolant Coolant Deterioration Inspection ŸRemove the right center fairing (see Center Fairing Removal in the Frame chapter). ŸVisually inspect the coolant [A] in the reserve tank. «If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the cool- ant is brown, iron or steel parts are rusting.
Page 155: Cooling System Flushing
4 Cooling system Cooling System Flushing Over a period of time, the cooling system accumu- lates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumu- lation is not removed, it will clog up the water passage and considerable reduce the effi ciency of the cooling system.
Page 156: Water Pump
Water Pump Water Pump Removal ŸDrain the coolant (see Coolant Change in the Periodic Maintenance chapter). ŸLoosen the clamp and remove the radiator hose [A] from the water pump cover [B]. ŸRemove the water pump cover bolts [C]. Ÿ Shift the transmission into 1st gear. ŸWhile applying the rear brake, remove the water pump impeller bolt [A].
Page 157: Mechanical Seal Inspection
4 Cooling system ŸInstall the water pump cover, being careful of the two dowel pins [A]. Torque - Water Pump Cover Bolts：10N·m(1. 0kgf·m,87in·lb) Mechanical Seal Inspection ŸVisually inspect the mechanical seal. «If any one of the parts is damaged, replace the mechanical seal as a unit.
Page 158: Impeller Assembly
Impeller Assembly ŸClean the sliding surface of the mechanical seal with a high-fl ash point solvent, and apply a little coolant to the sliding surface to give the mechani- cal seal initial lubrication. ŸApply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the...
Page 159: Radiator
4 Cooling system Radiator Radiator and Radiator Fan Removal ŸDrain the coolant (see Coolant Change in the Peri- odic Maintenance chapter) ŸRemove: Center Fairings (see Center Fairing in the Frame chapter) Reserve Tank (see Coolant Change in the PeriodicMaintenance chapter) Radiator Fan Motor Connector [A] (Disconnect) Radiator Hose Clamp Screw [B] (Loosen) ŸLoosen: Radiator Hose Clamp Screw [A]...
Page 160: Radiator And Radiator Fan Installation
Radiator and Radiator Fan Installation ŸInstall the grommets [A] so that its large side faces the front. ŸInstall the radiator [B] to the frame. ŸAlign [C] the projection on the frame with the hole on the radiator. ŸTighten the radiator bolt [D] ŸNote the baffl e plate on the cylinder head cover when installing the radiator ŸPosition the radiator hose clamp screws [E] as...
Page 161: Radiator Filler Neck Inspection
4 Cooling system Install the cap [A] on a cooling system pressure tester [B]. NOTE ○Wet the cap sealing surfaces with water or cool- ant to prevent pressure leaks. ŸWatching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle fl icks downward.
Page 162: Thermostat
Thermostat Thermostat Removal Ÿ Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). Ÿ Remove： Left Center Fairing (see Center Fairing Removal in the Frame chapter) Thermostat Hosing Bolts [A] Thermostat Hosing [B] ŸPull the thermostat [A] out of the cylinder head. Thermostat Installation ŸInstall the thermostat [A] in the cylinder head so that the air bleeder hole [B] is on top.
Page 163 4 Cooling system •To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of the water. ○The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.
Page 164: Hose And Pipes
Hose and Pipes Hose Installation ŸInstall the hoses and pipes, being careful to follow bending direction. Avoid sharp bending, kinking, fl attening or twisting. ŸRun the hoses (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). ŸInstall the clamp [A] as near as possible to the hose end to clear the raised rib of the fi tting.
Page 165: Coolant Temperature Sensor
4 Cooling system Coolant Temperature Sensor CAUTION The coolant temperature sensor should never be allowed to fall on a hard surface. Such a shock to the water temperature sensor can 。 damage it. Coolant Temperature Sensor Removal/ Installation ŸRefer to the Water Temperature Sensor Removal/ Installation in the Fuel System (EFI) chapter.
Page 166 5 Engine top Contents Exploded view………………………………………………………………………………………………………5-3 ……………………………………………………………………………………………………5-7 Specifications Special tools and sealant…………………………………………………………………………………………5-9 Cylinder head cover………………………………………………………………………………………………5-11 Cylinder head cover removal…………………………………………………………………………………5-11 Cylinder head cover installation ……………………………………………………………………………5-11 …………………………………………………………………………………………5-13 Timing chain tensioner Timing chain tensioner removal ……………………………………………………………………………5-13 Timing chain tensioner installation…………………………………………………………………………5-13 Camshaft/Timing chain…………………………………………………………………………………………5-15 …… 5-15 Camshaft removal………………………………………………………………………………………...
Page 167 CFMOTO Piston removal…………………………………………………………………………………………………5-30 Piston installation ……………………………………………………………………………………………5-31 Cylinder wear …………………………………………………………………………………………………5-32 Piston ring/Piston ring groove wear…………………………………………………………………………5-32 Piston ring groove width………………………………………………………………………………………5-33 Piston ring thickness…………………………………………………………………………………………5-34 Piston ring cut clearance ……………………………………………………………………………………5-35 Intake manifold……………………………………………………………………………………………………5-36 Intake manifold installation……………………………………………………………………………………5-36...
Page 168: Exploded View
5 Engine top Exploded view...
Page 169 CFMOTO Exploded view Torque Note Tighten parts Remark N·m kgf·m ft·lb Cable clamp bolt 7.2645 Cylinder head cover bolt 7.2645 Camshaft cover bolt 8.851 Cylinder head bolt(M10 New) MO,S Cylinder head bolt(M10 old) MO,S Cylinder head bolt(M6) 8.851 Intake pipe bolt 8.851 Chain conductor bolt Chain conductor bolt (283MT)
Page 170 5 Engine top Exploded view...
Page 171 CFMOTO Exploded view Torque Tighten parts Remark N·m kgf·m ft·lb 1 Cylinder body bolt(M8) 27.5 MO,S 2 Cylinder body nut (M10) MO,S 3 Cylinder head bolt (M6) 8.851 4 Exhaust pipe mounting nut 5 Muffler body mounting 6 Muffler body mounting bolt 7: “A1”marked side faces up...
Page 172 5 Engine top Specification Item Standard Service limit Cams haft Cam height： Exhaust 34.743 34.857 mm(1.36 78 ～ 1.372 3in.) 34 .6 4mm(1.3638in.) Exhaust (283MT) 35.843 35.957 mm(1.4111 1 .41 56in.) 35.74mm(1.4071in.) ～ Intake 35 .74 3~3 5.8 57 mm(1.4 072 1.4 117 in.) 3 5.6 4mm(1.4031in.) ～...
Page 173: Specifications
CFMOTO Specification Ite m Standard Service limit Valve spring free le ngth： Exhaust 39.9m m(1.571in.) 38.4mm(1.512in.) Exhaust(283M T) 41.6m m(1.638in.) 40mm( 1.575in.) Intake 39.9m m(1.571in.) 38.4mm(1.512in.) Intake( 283MT) 41.6m m(1.638in.) 40mm( 1.575in.) Cylinder、Piston Cylinder inner diam eter 68.4~68.418mm( 2.692 9～2.6936 in.) 68.50mm(2.6969in.) Cylinder inner...
Page 174: Special Tools And Sealant
5 Engine top Special tool and sealant...
Page 175 CFMOTO Special tool and sealant Piston pin puller Pressure gauge adapter Valve seat knife bracket Piston pin puller seat Valve conductor axle Silicon sealant glue Valve conducting pipe knife 5-10...
Page 176: Cylinder Head Cover
5 Engine top Cylinder head cover Cylinder Head Ccover Removal ● Remove Fuel Tank (see Fuel Tank Removal in the EFI chapter) Housing of air fi lter (see Air fi lter Housing Removal in the EFI chapter) Ignition coil[C] Baffle plate[D] Throttle cables[E] Clutch Cable Holder [F] with Bolt [G] Cylinder Head Cover Bolts [H]...
Page 177 CFMOTO Cylinder Head Cover ● Install the baffle plate [A]. Put the insulators [B] under the baffl e plate and the washers [C] on the baffl e plate. Apply a non-permanent locking agent to the baffl e plate bolts and tighten them. Torque - Baffl e Plate Bolts 6 N·ｍ...
Page 178 5 Engine top Camshaft Chain Tensioner Camshaft Chain Tensioner Removal ： ● Remove Cap Bolt [A] Washer[B] Spring [C] Camshaft Chain Tensioner Installation ● Release the stopper [A] and push the push rod [B] into the tensioner [C]. ● Install the bolt [A] and washer[B]. ●...
Page 179: Timing Chain Tensioner
CFMOTO Timing chain tensioner ● Remove: Spring seat bolt[A]. Washer[B]. Spring[C]. ● Remove tensioner bolt[D] and remove the tensioner. Timing chain tensioner installation(283MT). ● Loose the locker [A] and push the rack [B] into the tensioner body [C] ● The locker side should be up when install the tensioner.
Page 180 5 Engine top Camshaft/Timingchain CAUTION The crankshaft maybe tured while the crankshafts are removed.Aways pull the chain taut while turning the crankshaft.This avoids kinking the chain on the lower(crankshaft) sprocket.A kinked chain could damage both the chain and the sprocket. Camshaft removal ●...
Page 181: Camshaft/Timing Chain
CFMOTO Camshaft/Timing Chain Camshaft Installation ●Be sure to install the following parts. Plug Hole Gaskets [A] ● Apply molybdenum disulfide oil solution to all Į cams [A] journals [B] and thrust blocks [C] with marks. ★ If a new camshaft is to be used, apply a thin coat of molyb-denum disulfide grease to the cam surfaces.
Page 182 5 Engine top Camshaft/Timing Chain ● Pull the tension side (exhaust side) of the chain taut to install the chain. ● Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown. Using a wrench on the crankshaft rotation bolt, turn thecrankshaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge...
Page 183 CFMOTO Camshaft/Timing Chain NOTE The exhaust cap has a “EX” mark [A] and the inlet cap has a “IN” mark [B]. Be careful not to mix up these caps. ●Install the camshaft cap bolts. First tighten all the camshaft cap bolts evenly to seat the camshaft in place, then tighten all bolts following the specifi ed tightening sequence.
Page 184: Camshaft/Camshaft Cap Wear
5 Engine top Camshaft/Timing chain Camshaft, Camshaft Cap Wear ● Measure camshaft journal diameter ● Remove: Camshaft Caps (see Camshaft Diameter of Camshaft Journal Standard : 23. Removal) 950~23.972mm ● Retighten camshaft cap and measure hole diam- Service Limit : 23.920mm eter of camshaft cap <A>,<B>,<C>.
Page 185: Timing Chain Removal
CFMOTO Camshaft/Timing chain ● Set the camshaft in a camshaft alignment jig or on V blocks. ● Measure runout with a dial gauge at the specified place as shown. Camshaft Runout Standard: Less than 0.02mm Service limit: 0.04mm Camshaft wear ●...
Page 186: Cylinder Head
5 Engine top Cylinder head Cylinder Compression Measurement NOTE:Use the battery which is fully charged. ● Warm up the engine thoroughly. ● Stop the engine. ： ● Remove Fuel Tank (see Fuel Tank Removal in the Fuel System (EFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (EFI) chapter) Ignition Coils (see Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chapter) Spark Plugs (see Spark Plug...
Page 187: Cylinder Head Removal
CFMOTO Cylinder head Question Solution Diagnose Cylinder Clean the carbon and replace the damaged Too much carbon on piston and pressure too pars ifned conbuxtionroom much Gasket thickness is wrong Replace the gasket into standard Gasket leaking Replace the gasket and check the flatness Valve seat leaking Repair the valve seat Cylinder...
Page 188: Cylinder Head Installation
5 Engine top Cylinder head Cylinder head installation NOTE The camshaft cap is machined with the cylinder head,so if a new cylinder head is installed, use the cap that is supplied with the new head. ● Install a new cylinder head gasket [A] and dowel pins [B] ●...
Page 189: Cylinder Head Wear
CFMOTO Cylinder Head ● Tighten the M6 cylinder head bolts and M6 cylin- der bolts [A]. Torque - Cylinder Head Bolts (M6): 12 N·m(1.2 kgf·m, 106 in·Ib) Cylinder Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·Ib) ● Install the front camshaft chain guide [A]. Insert the end [B] of front camshaft chain guide into the hollow on the lower crankcase half.
Page 190: Valves
5 Engine top Valve Valve Clearance Inspection ● Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment ● Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal ● Remove cylinder head (see Cylinder Head Removal).
Page 191: Valve Guide Removal
CFMOTO Valves Valve Guide Removal ： ● Remove Valve (see Valve Removal) Oil Seal Spring Seat ● Heat the area around the valve guide to 120 < C (248< 302 F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
Page 192: Valve-To-Guide Clearance Measurement
5 Engine top Valves Turn the reamer in a clockwise direction until the reamer turns freely in the guide. Never turn the reamer counter-clockwise or it will be dulled. Once the guides are reamed they must be cleaned thoroughly. φ 4.5 Special tool - Valve Guide Reamer Valve-to-Guide Clearance Measurement (Wobble Method)
Page 193: Valve Seat Inspection
CFMOTO Valve Valve Seat Inspection ● Remove the valve (see Valve Removal). ● Check the valve seating surface [A] between the valve [B] and valve seat [C] Measure the outside diameter [D] ★ If the outside diameter is too large or too small, repair the seat (see Valve Seat Repair).
Page 194: Cylinder/Piston
5 Engine top Cylinder/Piston Cylinder Removal ● Remove: Cylinder Head (see Cylinder Head Removal) Front Engine Mounting Bolts (Both Side) [A] (see Engine Removal in the Engine Removal/ Installation chapter) Front Engine Brackets (Both Side) [B] (see Engine Removal in the Engine Removal/ Installation chapter) Cylinder [C] ●...
Page 195: Piston Removal
CFMOTO Cylinder/Piston ● Apply molybdenum disulfi de oil solution to the cylinder bore, piston rings and piston. ● Prepare two auxiliary head bolts with their head cut. ● Install the two bolts [A] diagonally in the crankcase. ● Position the crankshaft so that all the piston heads are almost same level.
Page 196: Piston Installation
5 Engine top Cylinder/Piston Piston installation ● Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. ● Install the oil ring steel rails, one above the ex- pander and one below it. NOTE Do not mix up the top [A] and second [C] ring...
Page 197: Cylinder Wear
CFMOTO Cylinder/Pistons Cylinder Wear ● Since there is a difference in cylinder wear in differ- ent directions, take a side-to-side and a front-to-back mea- surement at each of the two locations (total of four mea- sure- ments) shown in the fi gure. 10mm [A] 60mm [B] Cylinder Inside Diameter...
Page 198: Piston Ring Groove Width
5 Engine top Cylinder/Pistons The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. ● With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance.
Page 199: Piston Ring Thickness
CFMOTO Cylinder/Piston Second Piston Ring Groove Width [B] Standard: 1.01mm ～1.03mm Service limit: 1.11mm ★ If the one of grooves are out or limit.Re- place the piston. Piston ring thickness Use the micrometer to measure at several points around the ring. Top Piston Ring Thickness [A] Standard 0.97mm～0.99mm...
Page 200: Piston Ring Cut Clearance
5 Engine top Cylinder/Piston Piston ring cut clearance ● Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low ●...
Page 201: Intake Manifold
CFMOTO Intake manifold Intake manifold installation ● Install the clamps [B] as shown and so that their projections fi t [C] on the holes of intake manifold. Be sure that the clamp bolt heads [D] face outwards. ● Tighten screw [E]. Torque - Intake manifold screw 12N·m 5-36...
Page 202 6 Clutch Contents Exploded View………………………………………………………………………………………………………6-2 Specifications ………………………………………………………………………………………………………6-4 Special Tool and Sealant …………………………………………………………………………………………6-5 Clutch Cover…………………………………………………………………………………………………………6-6 Clutch Cover Removal……………………………………………………………………………………………6-6 Clutch Cover Installation…………………………………………………………………………………………6-7 Release Shaft Removal …………………………………………………………………………………………6-8 Release Shaft Installation ………………………………………………………………………………………6-8 Clutch Cover Disassembly………………………………………………………………………………………6-9 Clutch Cover Assembly…………………………………………………………………………………………6-10 Clutch ………………………………………………………………………………………………………………6-11 Clutch Removal …………………………………………………………………………………………………6-11 Clutch Installation ………………………………………………………………………………………………6-12 Clutch Plate, Wear, Damage Inspection………………………………………………………………………6-16 Clutch Plate Warp Inspection …………………………………………………………………………………6-16 Clutch Spring Free Length Measurement ……………………………………………………………………6-16...
Page 203: Exploded View
CFMOTO Exploded view...
Page 204 6 Clutch Exploded view Torque Tighten pa rts Re mark N· m kgf ·m ft· lb – – – Timing checking cap Hand tight CPS checking cap Hand tight （25）（2.5）（18） – – – Oil cap Hand tight 8.851 Right side cover bolt 7.2645 Clutch spring bolt...
Page 205: Specifications
CFMOTO Specification I tem Stan dar d S erv ice lim it Clutch le ver clearan ce 3m m(0.08 0.12in.) ––– ～～ Clut ch 2. 7 2.9mm (0. 106 0. 114i n. ) 2.6mm( 0. 102in.) ～～ Disc thickness Disc wearing 0.
Page 206: Special Tool And Sealant
6 Clutch Special tool and sealant Clutch holder Sealant...
Page 207: Clutch Cover
CFMOTO Clutch Cover Clutch Cover Removal ●Removal: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Right Frame Cover (see Frame Cover Removal in the Frame chapter) Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B] ●...
Page 208: Clutch Cover Installation
6 Clutch Clutch Cover Clutch Cover Installation ● Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket and to the crankshaft sensor lead grommet [B]. ●Be sure that the dowel pins [C] are in position. ●Replace the clutch cover gasket [D] with a new one.
Page 209: Release Shaft Removal
CFMOTO Clutch Cover Release Shaft Removal Caution Do not remove the release shaft assy if unnecessary. If the shaft removed. Please replase the oil seal together. ● Remove the clutch cover (see Clutch Cover Removal). ● Pull the lever and shaft assembly straight out of the clutch cover Release Shaft Installation ●...
Page 210: Clutch Cover Disassembly
6 Clutch Clutch Cover Clutch Cover Disassembly ● Remove: Oil Seal [A] Needle Bearings [B] ● Remove the oil level gauge [A].
Page 211: Clutch Cover Assembly
CFMOTO Clutch Cover Clutch cover assembly ● Replace the needle bearings and oil seal with new ones. NOTE Install the needle bearings so that the manufacture’s mark face out. ● Install the needle bearings [A] and oil seal [B] position as shown. Press [C] the bearing so that the bearing surface [D] is fl ush with the housing end of clutch cover [E].
Page 212: Clutch
6 Clutch Clutch Clutch removal ● Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) ●...
Page 213: Clutch Installation
CFMOTO Clutch ● Remove the oil pump sprocket bolt [A]. NOTE The oil pump sprocket bolt has a counterclock- wise threads. ●Using the hole [B], pull out the sleeve [C]. ● Remove the following as a set. Clutch Housing [D] Oil Pump Chain [E] Oil Pump Sprocket [F] ●...
Page 214 6 Clutch Clutch ●Be sure that the spacer [A] is in position ● Insert the following on the drive shaft. Clutch Housing [A] with Chain [B] and Sprocket [C] ● Align [E] the hole on the oil pump sprocket with the oil pump shaft.
Page 215 CFMOTO Clutch ● Install the following parts on the drive shaft. Spacer [A] Clutch Hub [B] Washer [C] Elastic washer[D] Nut [E] Install the washer so that the OUTSIDE mark [A] faces outward. Replace the clutch hub nut with a new one and apply screw fastening grease.
Page 216 6 Clutch Clutch ● Install the friction plates and steel plates, start- ing with a friction plate and alternating them. CAUTION If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. For the first and second steel plate [A], its thickness is 2 mm The others are 2.5 mm Install the last friction plate [A] fitting the tangs in...
Page 217: Clutch Plate, Wear, Damage Inspection
CFMOTO Clutch Clutch Plate, Wear, Damage Inspection ● Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. ● Measure the thickness of each friction plate [A] at several points. ★ If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
Page 218: Clutch Housing Finger Inspection
6 Clutch Clutch Clutch Housing Finger Inspection ● Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them. ★ If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.
Page 219 7 Engine Lubrication system Contents Exploded View………………………………………………………………………………………………………7-2 Engine Oil Flow Chart………………………………………………………………………………………………7-4 Specifications ………………………………………………………………………………………………………7-6 Special Tools and Sealant…………………………………………………………………………………………7-7 Engine Oil and Oil Filter……………………………………………………………………………………………7-8 Oil Level Inspection………………………………………………………………………………………………7-9 Engine Oil Change ………………………………………………………………………………………………7-9 Oil Filter Replacement …………………………………………………………………………………………7-9 Oil Pan………………………………………………………………………………………………………………7-10 Oil Pan Removal…………………………………………………………………………………………………7-10 Oil Pan Installation………………………………………………………………………………………………7-11 Oil Pressure Relief Valve …………………………………………………………………………………………7-13 Oil Pressure Relief Valve Removal ……………………………………………………………………………7-13 Oil Pressure Relief Valve Installation …………………………………………………………………………7-13...
Page 220: Exploded View
CFMOTO Exploded view...
Page 221 7 Engine Lubrication system Exploded view Torque No . Tighten pa rt Remark N ·m kgf·m ft·lb Oil draining bolt Oil strainer plate bolt 7.2645 Oil filter 1.75 EO,R Oil filter mounting bolt Oil pan bolt 8.851 Oil pipe I plate bolt 5.9285 Oil pressure limit valve Oil pressure warning switch （15）...
Page 222: Engine Oil Flow Chart
CFMOTO Engine Oil Flow Chart...
Page 223 7 Engine Lubrication system Engine Oil Flow Chart...
Page 224: Specifications
CFMOTO Specifications Item Standard Engine oil Style ELF 10W-40/SJJASO MA2 Viscosity 10W-40 Capacity 2.0L(2.1US qt)(Without replace the filter 2.2L(2.3US qt)(With filter replace together 2.6L(2.7US qt)(Total dry Lever Between upper and lower line 216～294kPa(2.2～3.0kgf/cm 2 ,31～43 psi) at 4000(rpm) 90℃(194°F) Oil pressure...
Page 225: Special Tools And Sealant
7 Engine Lubrication system Special Tools and Sealant Oil Pressure Gauge ,10kgf/cm Oil Filter Wrench Oil Pressure Gauge Adapter,PT3/8 Silicone Sealant...
Page 226: Engine Oil And Oil Filter
CFMOTO Engine Oil and Oil Filter 告 WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection ● Check that the engine oil level is between the upper [A] and lower [B] levels in the engine.
Page 227: Engine Oil Change
7 Engine Lubrication system Engine Oil and Oil Filter ★ If the oil level is too high, remove the excess oil, using a syring or some other suitable device. ★ If the oil level is too low, add the correct acmount of oil through the oil fi lter opening.
Page 228: Oil Pan
CFMOTO Oil Pan Oil Pan Removal ●Remove Engine oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhause Pipe Removal in the Engine Top End chapter) Muffler body (see Muffler Body Removal in the Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] Gasket [C]...
Page 229: Oil Pan Installation
7 Engine Lubrication system Oil Pan Oil Pan Installation ● Apply grease to the O-rings on the oil pipes [A] ● Install the oil pipe plate [B] so that its guide portion [C] fits the breather pipe [D] as shown. ●...
Page 230 CFMOTO Oil Pan ● Replace the oil pan gasket with a new one. ● When installing the oil pan, align [A] the damper [B] on the breather pipe with the hollow [C] on the oil pan. ● Tighten Oil Pan Bolts Torque: Oil Pan Bolts 12N·m 7-12...
Page 231: Oil Pressure Relief Valve
7 Engine Lubrication system Oil Pressure Relief Valve Oil Pressure Relief Valve Removal ● Refer to the Oil Pan Removal. Oil Pressure Relief Valve Installation ● Refer to the Oil Pan Installation Oil Pressure Relief Valve Inspection ● Check to see if the valve [A] slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
Page 232: Oil Pump
CFMOTO Oil Pump Oil Pump Removal ● Drain: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) ● Remove Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] Oil Pump Cover [B] ●Remove: Inner Rotor [A] for Scavenge Pump Outer Rotor [B] for Scavenge Pump ●Remove: Dowel Pin [A]...
Page 233: Oil Pump Installation
7 Engine Lubrication system Oil Pump Oil Pump Installation ● Apply molybdenum disulfi de grease to the portion [A] of the oil pump shaft as shown. ● Install: Outer Rotor [B] for Feed Pump Inner Rotor [C] for Feed Pump Oil Pump Shaft [D] and Pin [E] Dowel Pin [F] Oil Pump Body [G]...
Page 234: Oil Pressure Measurement
CFMOTO Oil Pressure Measurement Oil Pressure Measurement ● Remove the lower fairing (see Lower Fairing Removal in the Frame chapter) ●Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools: Oil Pressure Gauge 10kgf/cm2 Oil Pressure Gauge Adapter, PT3/8 ●...
Page 235: Oil Pressure Switch
7 Engine Lubrication system Oil Pressure Switch Oil Pressure Switch Removal ● Remove Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation ●...
Page 236 8 Engine removal and installation Contents Exploded View………………………………………………………………………………………………………8-2 Engine removal/installation ……………………………………………………………………………………… 8-4 Engine removal……………………………………………………………………………………………………8-4 Engine installation ………………………………………………………………………………………………8-7...
Page 237: Exploded View
CFMOTO Exploded view...
Page 238 8 Engine removal and installation Torque Tighten part Remark N· m kgf· m ft· lb Engine rear mounting nut Engine front mounting bolt Engine bracket bolt 4：Engine bra cket 5 ：Engine moun tin g sle eve S： Follow the special tighten order...
Page 239: Engine Removal/Installation
CFMOTO Engine Removal/Installation Engine Removal ŸSupport the rear part of the swingarm with a stand. ŸSqueeze the brake lever slowly and hold it with a band [A] D a n g e r Hold the front br eak lever when rem ov ing the engine.
Page 240 8 Engine removal and installation ŸDisconnect the crankshaft sensor lead connector [A]. ŸRemove Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (EFI) chapter) Air Filter Housing (see Air Filter Housing Removal in the Fuel System (EFI) chapter)
Page 241 CFMOTO ŸRemove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). Ÿ Remove the shift pedal[E] (see Shift Pedal Re- moval in the Crankshaft/Transmission chapter). Ÿ Disconnect: Oxygen Sensor Lead Connector [B] Neutral Switch Lead Terminal [C] Ÿ...
Page 242: Engine Installation
8 Engine removal and installation Engine Installation ŸFirstly, insert the rear engine mounting bolts [A] from the left side of the engine. ŸSecondly, temporally tighten the right engine mounting bracket bolts [B] and then the right front engine mounting bolt [C]. ○...
Page 243 9 Crankshaft /Transmission Contents Exploded View………………………………………………………………………………………………………9-3 Specification…………………………………………………………………………………………………………9-7 Crankcase Splitting…………………………………………………………………………………………………9-10 Crankcase Splitting………………………………………………………………………………………………9-10 Crankcase Assembly……………………………………………………………………………………………9-12 Crankshaft and Connecting Rods…………………………………………………………………………………9-18 Crankshaft Removal ……………………………………………………………………………………………9-18 Crankshaft Installation …………………………………………………………………………………………9-18 Connecting Rod Removal………………………………………………………………………………………9-19 Connecting Rod Installation……………………………………………………………………………………9-19 Connecting Rod Bend …………………………………………………………………………………………9-22 ……………………………………………………………………………………………9-22 Connecting Rod Twist Connecting Rod Big End Side Clearance ……………………………………………………………………9-22 Connecting Rod Big End Bearing Insert/ Crankpin Wear …………………………………………………...
Page 244 CFMOTO Shift Fork/Gear Groove Wear…………………………………………………………………………………9-39 Shift Fork Guide Pin/Drum Groove Wear……………………………………………………………………9-39 Gear Dog and Gear Dog Hole Damage………………………………………………………………………9-40 Ball and Needle Bearing Replacement………………………………………………………………………9-40 Ball and Needle Bearing Wear…………………………………………………………………………………9-40...
Page 245: Exploded View
9 Crankshaft /Transmission Exploded view...
Page 246 CFMOTO Exploded view Torque T ighten p arts R emark N· m k gf· m f t·lb Connecting rod nut See test CPS disc Oil separ ator plate bolt 7.2645 Oil separ ator bolt 5.0935 Shift spring locking pin Oil pipe bolt 7.2645 Crankcase bolt...
Page 247 9 Crankshaft /Transmission Exploded view...
Page 248 CFMOTO Exploded View Torqu e T ighten pa rt Remark N·m kgf· m ft·lb Locking rocker a rm screw 8.8 51 Shifting room co ver bolt Locking gea r bo lt 8.8 51 Shifting drum bearing 0.50 3.5905 Shifting fork plate 7.2645 Neutral sen sor screw...
Page 249: Specification
9 Crankshaft /Transmission Specification Item Standard Service limit Crankshaft/upper crankcase 0.10～0.30mm 0.40mm locking clearance Crankshaft radial run out 0.02mm 0.05mm Main joint/Main joint 0.025～0.04mm 0.07mm clearance Main joint/Main joint 0.020～0.035mm 0.07mm clearance (283MT) Main joint diameter 37.984～38.00mm 37.96mm Mark: 3 7. 98 4～37.992m m –––...
Page 250 CFMOTO Specification Crankcase balance shaft clearance: 31.000～31.016 mm ––– Mark: Yellow 31.000～31.008 mm ––– Green 31.009～31.016 mm ––– Balance bearing thickness: Mark： Brown 1.490～1.494mm ––– Black 1.494～1.498mm ––– Blue 1.498～1.502mm ––– Balance hole/shaft diameter/Bearing fitnes s Balance hole Shaft diameter Bearing Yellow Brown...
Page 251 9 Crankshaft /Transmission Specification Crankcase balance shaft clearance: 31.000～31.016 mm ––– Mark: Yellow 31.000～31.008 mm ––– Green 31.009～31.016 mm ––– Balance bearing thickness: Mark： Brown 1.490～1.494mm ––– Black 1.494～1.498mm ––– Blue 1.498～1.502mm ––– Balance hole/shaft diameter/Bearing fitnes s Balance hole Shaft diameter Bearing Yellow...
Page 252: Crankcase Splitting
CFMOTO Crankcase Splitting ● Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Cylinder (see Cylinder Removal in the Engine Top End chapter) Pistons (see Piston Removal in the Engine Top End chapter) Stater Motor (see Starter Motor Removal in the Electrical System chapter) Clutch (see Clutch Removal in the Clutch chapter)
Page 253 9 Crankshaft /Transmission Crankcase Splitting ● Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase. ★ If the oil pipe is to be removed, follow the next procedure.
Page 254: Crankcase Assembly
CFMOTO Crankcase Splitting Crankcase Assembly CAUTION The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. ● With a high-flash point solvent, clean off the mating surfaces of the crankcases halves and wipe dry.
Page 255 9 Crankshaft /Transmission Crankcase Splitting NOTE Make the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied. ●Apply a non-permanent locking agent to the threads and tighten the bolts [A]. Torque - Breather Plate Bolts 10N·m ●Install the breather pipe [A].Align the white mark [B] on the pipe with the white mark [C] on the breather...
Page 256 CFMOTO Crankcase Splitting ● Install the crankshaft assembly and the balancer shaft assembly on the upper crankcase half. Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crankshaft ●...
Page 257 9 Crankshaft /Transmission Crankcase Splitting ● Apply liquid gasket [A] to the mating surface of the lower crankcase half. NOTE Apply the sealant evenly on the mating surfcae without cutting. CAUTION Do not apply liquid gasket around the crank shaft main bearing inserts, and oil passage holes.
Page 258 CFMOTO Crankcase Splitting ● Fit the lower crankcase half to the upper crank- case half. Insert [A] the breather pipe [B] on the upper crankcase half through the hole [C] NOTE Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied.
Page 259 9 Crankshaft /Transmission Crankcase Splitting ● Tighten the lower crankcase bolts using the followwing steps. Tighten the M9 bolts [1, 2] L= 113 mm (4.45 in.) with washers. Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb) Tighten the M9 bolts [3, 4] L= 83 mm (3.27 in.) with washers.
Page 260: Crankshaft And Connecting Rods
CFMOTO Crankshaft and Connecting Rods Crankshaft Removal ● Split the crankcase (see Crankcase Splitting). ●Remove the crankshaft [A] Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
Page 261: Connecting Rod Removal
9 Crankshaft /Transmission Crankshaft and Connecting Rods Connecting Rod Removal ●Split the crankcase (see Crankcase Splitting). ●Remove the connecting rod nuts [A]. ●Remove the connecting rod. ●Remove the connecting rod bolts. CAUTION To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins.
Page 262 CFMOTO Crankshaft and Connecting Rods ● Install the 2 connecting rod bolts. ● Apply molybdenum disulfide grease [B] to the outer surface of the upper insert and the inner surface of the connecting rod big end. The molybdenum disulfi de oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1).
Page 263 9 Crankshaft /Transmission Crankshaft and Connecting Rods ● Apply molybdenum disulfi de oil solution [MO] to the threads and seating surfaces of the big end nuts and bolts. ● Install the crankshaft (see Crankshaft Installation). ●Install each connecting rod on its original crankpin.
Page 264: Connecting Rod Bend
CFMOTO Crankshaft and Connecting Rods Connecting Rod Bend ● Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. ● Insert the arbor [A] through the connecting rod big end. ●Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [B] through the connecting rod small end.
Page 265 9 Crankshaft /Transmission Crankshaft and Connecting Rods If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again. If clearance is too large after connecting rod replacement, the crankshaft also must be replaced. Crankpin/Connecting Rod Big End Bearing Insert Wear ●...
Page 266: Crankshaft Side Clearance
CFMOTO Crankshaft and Connecting Rods Match Mark[A] Connecting Rod body[B] Diameter Mark[C] Weight Mark[D] Connecting rod big end cover[E] ● Select the proper bearing insert [A] according to the crankpin diameter mark and the big end inside diameter mark. Size Color [B] Big end hole/Connecting joint/Bearing Big end hole C onnecting Bearing...
Page 267: Crankshaft Runout
9 Crankshaft /Transmission Crankshaft and Connecting Rods Crankshaft Runout ●Measure the crankshaft runout : 0.02mm Crankshaft Runout Standard Service limit: 0.05mm ★ If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Main Bearing Insert/Journal Wear ●Using a micrometer, measure the diameter of the main bearing journal [A].
Page 268 CFMOTO Crankshaft and Connecting Rods ● Select the proper bearing insert [A] in accor- dance with the combination of the crankcase and crankshaft coding. Size Color [B] 9-26...
Page 269: Balancer
9 Crankshaft /Transmission Balancer Balance shaft removal ● Disassemble the crankcase(Refer to crankcase assemble) ● Take the balance shaft out from crankcase. Balance shaft installation ● Pre-lubricate the balance shaft bearing. ● Aline [A] balance shaft mark [B]and crank shaft mark[C].
Page 270 CFMOTO Balancer ● Measuer the balancer hole diameter on crankcase. The diameter should be fit the mark. Or mark again to the truth. ： Crankcase Bearing Bore Diameter Marking 1 :31.000~31.008mm 2 :31.009~31.016mm ● Select the proper bearing insert [A] in accor dance with the combination of the crankcase and the balancer shaft coding.
Page 271: Transmission
9 Crankshaft /Transmission Transmission Shift Pedal Removal ● Remove: Shift Lever Bolt [A] Shift Lever [B] Shift Pedal Installation ● Align the mark [A] on the shift shaft with the slit [B] on the shift lever. ● Tighten the shift lever bolt securely External Shift Mechanism Removal ●Remove Engine Oil (Drain, see Engine Oil Change in the...
Page 272: Shift Mechanism Installation
CFMOTO Transmission Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Spacer, Washer and Spring. External Shift Mechanism Installation ●Install the gear positioning lever [A] as shown. Spring [B], Washer [C], Spacer [D], Bolt [E] Hook the spring at gear positioning lever, push- ing up [F] the hook portion, as shown.
Page 273: Shift Mechanism Inspection
9 Crankshaft /Transmission Transmission ● When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing until it is bottomed. Special Tool - Bearing Driver Set ●When the new oil seal [C] is installed in the shift cover, press and insert the new oil seal so that its surface is fl ush with the end of the hole.
Page 274: Transmission Assy Removal
CFMOTO Transmission ●Check the return spring pin [A] is not loose. ★ If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return Spring Pin · :29N ● Check the gear positioning lever [A] and its spring for breaks or distortion.
Page 275: Transmission Assy Disassembly
9 Crankshaft /Transmission Transmission ●Remove: Clutch (see Clutch Removal in the Clutch chapter) Transmission Case Bolts [A] If the transmission assy is to be disassembed, remove the following. Shift Rod Plate Bolt [B] Shift Rod Plate [C] Gear Positioning Lever Bolt [D] Gear Positioning Lever [E] with Spring, Washer and Spacer.
Page 276: Transmission Assy Assembly
CFMOTO Transmission Transmission Assy Assembly ● When the new ball bearings [A] are installed in the trans- mission case [B], press and insert them until they are bottomed. Special Tool - Bearing Driver Set ●Install the following on the transmission case [A]. Shift Drum [B] Pin [C] Shift Drum Cam [D]...
Page 277 9 Crankshaft /Transmission Transmission Transmission Assy Installation ● Assemble the transmission assy (see Transmis- sion Assy Assembly). ●Be sure that the dowel pins [A] are in position. ●Apply grease to the O-ring [B] on the oil pipe. ● Install the transmission assy on the crankcase. ●...
Page 278: Transmission Shaft Disassembly
CFMOTO Transmission Transmission Shaft Disassembly ●Remove the transmission assy (see Transmis- sion Assy Removal). ●Remove: Shift Rods [A],Shift Forks [B] Drive Shaft [C],Output Shaft [D] ● Remove the circlips, disassemble the transmis- sion shafts. ● Remove the fifth 5th gear Transmission Shaft Assembly ●Apply engine oil to the collar, needle bearing and the shaft.
Page 279 9 Crankshaft /Transmission Transmission ● The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place.
Page 280 CFMOTO Transmission 17.Washer 25.Toothed washer 1.1st gear 9.Toothed washer 18.Nut 26.Washer¦Õ28 2.2nd gear 10.Circlip 28 19.O-ring 27.Circlip¦Õ30 3.3re gear 11.Bushing 20.Ball bearing 28.Washer¦Õ25 4.4th gear 12.Washer¦Õ30 21.Washer¦Õ39 5.5th gear 13.Needle bearing 22.Positioning ring 6.6th gear 14.Circlip 23.Washer¦Õ38.5 7.Ball Bearing 15.Oil seal 24.Bushing 8.Bushing 16.Collar...
Page 281: Shift Fork Bending
9 Crankshaft /Transmission Transmission Shift Fork Bending ● Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause diffi culty in shifting, or allow the transmission to jump out of gear when under power. 90 degree [A] Shift Fork/Gear Groove Wear ●...
Page 282: Gear Dog And Gear Dog Hole Damage
CFMOTO Transmission Shift fork drum diameter Standard： φ 6.9~ φ 7.0mm Service limit ：φ 6.8mm Shift Drum Groove Width Standard： 7.10~7.17mm Service limit：7.30mm Gear Dog and Gear Dog Hole Damage ● Visually inspect the gear dogs [A] and gear dog holes [B].Replace any damaged gears or gears with excessively worn dogs or dog holes.
Page 283 10 Tire and rim Contents Explode View………………………………………………………………………………………………………10-2 Specifications and service limit…………………………………………………………………………………10-4 Special Tools………………………………………………………………………………………………………10-5 Wheel (Rims)………………………………………………………………………………………………………10-6 Front Wheel Removal …………………………………………………………………………………………10-6 Front Wheel Installation ………………………………………………………………………………………10-6 Rear Wheel Removal …………………………………………………………………………………………10-8 Rear Wheel Installation ………………………………………………………………………………………10-8 Wheel Inspection…………………………………………………………………………………………………10-10 Axle Inspection…………………………………………………………………………………………………10-10 Balance Inspection ……………………………………………………………………………………………10-11 Balance Adjustment……………………………………………………………………………………………10-11 Balance Weight Removal ……………………………………………………………………………………10-11 Balance Weight Installation …………………………………………………………………………………10-11 Tire pressure inspection and adjustment………………………………………………………………………10-13...
Page 284 CFMOTO Exploded view 10-2...
Page 285 10 Tire and rim Torque Tighten parts Remark N·m kgf·m ft·lb Front wheel axel 11.0 Front axel locking screw Rear Axel nut 11.0 G：Use grease HG：Use high heat grease R：Replace the parts WL：Use soapy water or special rubber washing liquid. 10-3...
Page 286: Specifications And Service Limit
CFMOTO Specifications and service limit Item Standard S ervice l imit Rim run out Axial TIR0. 5mm（0.02in.）or smaller TIR1.0mm（0. 04in.） Radial TIR0. 8mm（0.03in.）or smaller TIR1.0mm（0. 04in.） TIR0. 03mm （ 0.0012in. ） or W heel axle twisting angle TIR0.2mm（0. 008in.） /100m m （ 3.94in. ） Wheel smaller ――...
Page 287 10 Tire and rim Special tool Bearing pressing tool Screw driver Jack Jack accesesories Bearing remover 10-5...
Page 288: Special Tools
CFMOTO Wheel (Rim) Front wheel removal Ÿ Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] Ÿ Loosen Axle Clamp Bolt[C] Ÿ Remove the front axle [D] Ÿ Remove the lower fairing (see Lower Fairing Removal in the Frame chapter). Ÿ...
Page 289 10 Tire and rim Wheel (Rim) Ÿ Apply high-temperature grease to the grease seal lips. Ÿ Fit the collars [A] on the both sides of the hub. Ÿ Insert the front axle, and tighten the axle. Ÿ Torque - Front Axle :108N·m(11.0kgf·m,80ft·lb) Ÿ...
Page 290: Rear Wheel Removal
CFMOTO Rear Wheel Removal Ÿ Raise the rear wheel off the ground with stand [A]. Ÿ Remove Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] with Washer Ÿ Remove the drive chain [A] from the rear sprocket toward the left Ÿ...
Page 291 10 Tire and rim Wheel (Rim) Ÿ Engage the drive chain with the rear sprocket. Install the caliper bracket [A] onto the swing-arm stop [B]. Ÿ Insert the axle from the right side of the wheel, and tighten the axle nut. Torque - Rear Axle Nut:108N·m(11.0kgf·m,80ft·lb) Ÿ...
Page 292: Wheel Inspection
CFMOTO Wheel Inspection Ÿ Raise the front/rear wheel off the ground with jack. Special Tools – Jack, Jack Attachment Ÿ Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearingWheel Inspection Ÿ...
Page 293: Balance Inspection
10 Tire and rim Balance Inspection Ÿ Remove the front and rear wheels (see Front/ Rear Wheel Removal). Ÿ Support the wheel so that it can be spun freely. Ÿ Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
Page 294 CFMOTO Balance Weight Balance weight 10g (0.35oz.) 20g (0.71oz.) 30g (1.06oz.) NOTE ○ Balance weights are available from cfmoto dealers in 10, 20, and 30 grams (0.35, 0.71, and 1. 06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
Page 295: Tire Removal
10 Tire and rim Tire Pressure Inspection/Adjustment Ÿ Refer to the Air Pressure Inspection in the Periodic Maintenance chapter. Ÿ Refer to the Wheel/Tire Damage Inspection in the Periodic Maintenance chapter. Tire Removal Ÿ Remove Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) Ÿ...
Page 296 CFMOTO Ÿ Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place. W arn in g Do not u se t he oil or pet ro e le m e nt to lubrica te the va lv e rod.
Page 297: Tire Repair
10 Tire and rim Ÿ Check to see that the rim lines [A] on both sides of the tire sidewalls are parallel with the rim flanges. « If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. Ÿ...
Page 298: Hub Bearing
CFMOTO Hub Bearing Removal Ÿ Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Ÿ Sleeve Collars Coupling (Out of rear hub) Grease Seals Ÿ Use the bearing remover to remove the hub bearings [A]. :20x22 Special Tools :Bearing Remover Head Bearing Remover Shaft, 13 W arning Do not let the wheel disc dow n to the...
Page 299 11 Chain drive system Contents Exploded View………………………………………………………………………………………………………11-2 Specifications ………………………………………………………………………………………………………11-4 Special Tools ………………………………………………………………………………………………………11-4 Drive Chain …………………………………………………………………………………………………………11-5 Drive Chain Slack Inspection……………………………………………………………………………………11-5 Drive Chain Slack Adjustment …………………………………………………………………………………11-5 Wheel Alignment Inspection/Adjustment………………………………………………………………………11-5 Drive Chain Wear Inspection……………………………………………………………………………………11-5 Drive Chain Lubrication …………………………………………………………………………………………11-5 Drive Chain Removal ……………………………………………………………………………………………11-5 Drive Chain Installation …………………………………………………………………………………………11-6 Sprocket, Coupling…………………………………………………………………………………………………11-9 Engine Sprocket Removal………………………………………………………………………………………11-9 Engine Sprocket Installation……………………………………………………………………………………11-10...
Page 300: Exploded View
CFMOTO Exploded view 11-2...
Page 301 11 Chain drive system Tighten part Torque Remark N·m kgf·m ft·lb Engine sprocket nut 12.7 Rear axel nut 11.0 Chain sprocket nut Speed sensor bolt 0.80 5.7615 Speed sensor bracket bolt 7.2645 G：Use grease HG：Use high heat grease HO：Use heavy oil L：Use permanent thread locker MO：Use molybdenum disulfide lubricant （Mix with engine oil in ratio 10:1）...
Page 302: Special Tools
CFMOTO Chain specification and service limit Item Standard Service limit Drive chain ―― Cha in loosene ss 30～40mm（1.2～1 .6in.） Cha in wearing （20 pieces）in 317.5～318.2mm（12.5 0～12.53in . 323mm（12.7in. ）） standard ―― S uppliers RK or DID ―― S tyle 520×S01 ――...
Page 303: Drive Chain
11 Chain drive system Drive Chain Drive Chain Slack Inspection ŸRefer to the Drive Chain Slack Inspection in the Peri- odic Maintenance chapter Drive Chain Slack Adjustment ŸRefer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment ŸRefer to the Wheel Alignment Inspection in the Peri- odic Maintenance chapter.
Page 304: Drive Chain Installation
CFMOTO Ÿ Screw the pin holder until it touches chain pin Ÿ Be sure that the cutting pin hits center of chain pin. Ÿ Screw the handlebar [A] into body. Ÿ Turn the pin holder with wrench [B] clockwise to extract chain pin.
Page 305 11 Chain drive system Ÿ Fit the plate holder (a) to link plate Ÿ Turn the pin holder by hand until plate holder (b) touches the other link plate. Ÿ Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a). Ÿ...
Page 306 CFMOTO Ÿ After staking, check the staked area of the link pin for cracks. Ÿ Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter Standard:5.45～5.55mm Link Plates Outside Width S t a n d a r d : 1 7 . 2 5 ～ 1 7 . 4 5 m m( 0 . 6 7 9 ～ 0 . 687in.) «...
Page 307: Sprocket, Coupling
11 Chain drive system Sprocket, Coupling Engine Sprocket Removal Ÿ Remove Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Ÿ ： Remove Speed Sensor Bracket Bolts [A] Speed Sensor Bracket [B] Ÿ Flatten out the bended washer [A]. Ÿ Remove the engine sprocket nut [B] and washer.
Page 308: Engine Sprocket Installation
CFMOTO Engine Sprocket Installation Ÿ Replace the sprocket washer and axle cotter pin. Ÿ Install the engine sprocket [A] so that “OUTSIDE” letters face outward. Ÿ Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine sprocket nut.
Page 309: Coupling Installation
11 Chain drive system Coupling Installation Ÿ Apply high-temperature grease to the coupling grease seal lips [A]. Ÿ Apply grease to the coupling internal surface [B]. Ÿ Grease the following Wheel Flange Portion O-ring Install the collar Coupling Bearing Removal Ÿ...
Page 310: Coupling Bearing Inspection
CFMOTO Ÿ Replace the grease seal with a new one. Ÿ Press in the grease seal so that the seal surface is fl ush with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set Coupling Bearing Inspection «...
Page 311: Rear Sprocket Warp Inspection
11 Chain drive system R e a r Sp r o c k e t W a r p In s p e c tio n Ÿ R ai s e t h e re a r w h e e l of f t he g ro u n d w it h s t an d s o t ha t i t w i ll tu rn f re e ly .
Page 312 12 Breakingsystem Contents Exploded View (Front Brake)………………………………………………………………………………………12-3 Exploded View (Rear Brake) ………………………………………………………………………………………12-5 Specifications…………………………………………………………………………………………………………12-7 Special Tools…………………………………………………………………………………………………………12-8 Brake Lever, Brake Pedal …………………………………………………………………………………………12-9 Brake Lever Position Adjustment ………………………………………………………………………………12-9 Brake Pedal Position Inspection…………………………………………………………………………………12-9 Brake Pedal Position Adjustment ………………………………………………………………………………12-9 Brake Pedal Removal……………………………………………………………………………………………12-10 Brake Pedal Installation…………………………………………………………………………………………12-10 Caliper ………………………………………………………………………………………………………………12-12 Front Caliper Removal……………………………………………………………………………………………12-12 Rear Caliper Removal……………………………………………………………………………………………12-12...
Page 313 CFMOTO Master Cylinder Inspection ………………………………………………………………………………………12-18 Brake Disc …………………………………………………………………………………………………………12-19 Brake Disc Removal………………………………………………………………………………………………12-19 Brake Disc Installation……………………………………………………………………………………………12-19 Brake Disc Wear…………………………………………………………………………………………………12-19 Brake Disc Warp…………………………………………………………………………………………………12-19 Brake Fluid……………………………………………………………………………………………………………12-20 Brake Fluid Level Inspection ……………………………………………………………………………………12-20 Brake Line Bleeding………………………………………………………………………………………………12-20 Drain out the air in breaking system………………………………………………………………………………12-21 Brake Hose……………………………………………………………………………………………………………12-21 Brake Hose Removal/Installation ………………………………………………………………………………12-22 Brake Hose Inspection……………………………………………………………………………………………12-22 12-2...
Page 314: Exploded View (Front Brake)
12 Breakingsystem Exploded view(Front break) 12-3...
Page 315 CFMOTO Torque Tighten parts Remark N·m kgf·m ft·lb Drain valve 0.80 5.76 15 Breaking hose pipe Breaking lever holding bolt 0.10 0.75 15 Breaking lever holding nut 0.60 4.34 2 Fro nt breaking disc mounting Fro nt breaking switch screw 0.10 0.75 15 Breaking f luid reservoir screw...
Page 316: Exploded View (Rear Brake)
12 Breakingsystem Exploded view(Rear break) 12-5...
Page 317 CFMOTO Torque Tighten part Remark N·m kgf·m ft·lb Leaking valve 0.80 5.7615 Breaking pipe bolt Breaking pedal bolt 0.90 6.513 Rear breaking disc mounting Rear caliper mounting bolt Rear breaking master cylinder Rear breaking push rod locking B：Use breaking fluid； G：Use grease；...
Page 318: Specifications
12 Breakingsystem Specifications Item Sta ndard Service l imit Break lever and pedal 5 point a djustment （ For Breaking lever position Breaking lever clearance driver） ――― Breaking p edal adjustment Cannot adjust Ped al adjustm ent Cannot adjust Lower than top ab out 40mm（1.6in.）...
Page 319: Special Tools
CFMOTO Special tool Retainer plier Hand tester Jack Jack accessories 12-8...
Page 320: Brake Lever Position Adjustment
12 Breakingsystem Brake Lever , Break padel Brake Lever Position Adjustment Ÿ The brake lever adjuster can be adjusted to suit the operator’s hand ○ The distance from the grip to the lever is minimum at 103mm and maximum at 118mm. Brake Pedal Position Inspection Ÿ...
Page 321: Brake Pedal Removal
CFMOTO Brake Pedal Removal Ÿ Remove: Frame Cover (see Frame Cover Removal in the Frame chapter) Bolts Right Footpeg Stay Ÿ Remove: Cotter Pin Joint Pin Rear Brake Light Switch Spring Return Spring Ÿ Remove the mounting bolt [E] and take out the brake pedal.
Page 322 12 Breakingsystem Ÿ Install the foot rest bracket and tight up to stan- dard torque :30N·m Torque - Footpeg Rest Bolts (3.1kgf·m,22ft·lb) ○ Depress the brake pedal [A] and then align the bolts holes of the master cylinder [B]. Torque - Rear Master Cylinder Mounting Bolts 25N·m(2.5kgf·m,18ft·lb) Ÿ...
Page 323: Front Caliper Removal
CFMOTO Breaking Caliper Front Caliper Removal Ÿ Loose the front caliper LH mounting bolt [A] and remove the caliper from break disc [B] Ÿ Loose the front caliper RH mounting bolt remove the caliper from break disc CAUTION Immediately wash away any brake fluid that spills Rear Caliper Removal Ÿ...
Page 324: Front Caliper Disassembly
12 Breakingsystem Front Caliper Disassembly Ÿ Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter Front Caliper Assembly Ÿ Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Caliper Disassembly Ÿ Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.
Page 325: Caliper Piston And Cylinder Damage
CFMOTO Caliper Piston and Cylinder Damage Ÿ Visually inspect the pistons [A] and cylinder surfaces [B]. « Replace the caliper if the cylinder and piston are badly scores or rusty. Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A].
Page 326: Brake Pads
12 Breakingsystem Brake Pad Front Brake Pad Removal ŸRemove the front caliper with the hose installed (see Front Caliper Removal). ŸDraw out the holder shaft pin [A], and take off the holder shaft [B]. Ÿ Remove the pad [C] on the piston side. Ÿ...
Page 327: Master Cylinder
CFMOTO Master Cylinder Front Master Cylinder Removal Ÿ Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose Removal/Installation). Ÿ Disconnect the front brake light switch connectors [A]. Ÿ Unscrew the clamp bolts [B], and take off the mas- ter cylinder as an assembly with the reservoir, brake lever and brake switch installed.
Page 328: Rear Master Cylinder Removal
12 Breakingsystem Rear Master Cylinder Removal Ÿ Unscrew the brake hose banjo bolt [A] on themaster cylinder (see Brake Hose Removal/ Installation). Ÿ Unscrew the master cylinder mounting bolts [A]. Ÿ Remove the cotter pin [B]. NOTE ○ Pull off the joint pin while pressing down the brake pedal.
Page 329: Master Cylinder Inspection
CFMOTO Master Cylinder Inspection Front master cylinder[J] Ÿ Remove the master cylinders (see Front/Rear Mas- ter Cylinder Removal). Ÿ Disassemble the front and rear master cylinders Ÿ Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
Page 330: Brake Disc
12 Breakingsystem Brake Disc Brake Disc Removal Ÿ Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). Ÿ Unscrew the mounting bolts, and take off the disc. Ÿ Remove the gaskets Brake Disc Installation Ÿ Replace the gaskets with new ones. Ÿ...
Page 331: Brake Fluid
CFMOTO Brake Fluid Brake Fluid Level Inspection Ÿ Refer to the Brake Fluid Level Inspection in the Pe- riodic Maintenance chapter Brake Fluid Replacement Ÿ Refer to the Brake Fluid Change in the Periodic Main- tenance chapter. Brake Line Bleeding The brake fluid has a very low compression coeffi- cient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper...
Page 332 12 Breakingsystem Drain out the air in breaking line ○ Repeat this operation until no more air can be seen coming out into the plastic hose. 1.Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2.Quickly open and close [B] the bleed valve while holding the brake applied.
Page 333: Brake Hose Removal/Installation
CFMOTO Danger ： When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake f uid. 2. Do not use f uid from a container that has been left unsealed or that has been open for a long tim e.
Page 334 13 Suspension Contents Front shock exploded View…………………………………………………………………………………………13-2 Rear shock exploded View…………………………………………………………………………………………13-4 Specifications…………………………………………………………………………………………………………13-6 Special Tools…………………………………………………………………………………………………………13-7 Front Shockabsorber ………………………………………………………………………………………………13-8 Front shockabsorber removal……………………………………………………………………………………13-8 Front shockabsorber Installation ………………………………………………………………………………13-8 Rear shockabsorber ………………………………………………………………………………………………13-10 Spring Preload Adjustment ……………………………………………………………………………………13-10 Rear Shock Absorber Removal…………………………………………………………………………………13-10 Rear Shock Absorber Installation………………………………………………………………………………13-11 Rear Shock Absorber Inspection ………………………………………………………………………………13-11 Swingarm……………………………………………………………………………………………………………13-12 Swingarm Removal………………………………………………………………………………………………13-12 Swingarm Installation……………………………………………………………………………………………13-12...
Page 335 CFMOTO Front fork exploded view 13-2...
Page 336 13 Suspension Torque Tighten parts Remark N·m kgf·m ft·lb Front wheel axel tighten screw Front shockabsorber locking Front shockabsorber locking 13-3...
Page 337 CFMOTO Rear swing arm exploded view 13-4...
Page 338 13 Suspension Torque Tighten parts Remark N·m kgf·m ft·lb Rear shockabsorber bolt Rear shockabsorber Rear swing arm nut 18.0 G：Use grease R：Replace parts 13-5...
Page 339: Specifications
CFMOTO Specifications N ame Ite m S tandard Inner Tube O uts ide Φ41m m D iam eter O il s tyle TO P 46# or s am e level Front shock O il only ： 400m L±3 m L C apac ity absorbe r Total dry：...
Page 340: Special Tools
13 Suspension Special tool Retainer plier Jack Front shock absorber handle Front shock absorber oil seal remover Shock absorver cylinder head adjuster Shock absorber oil gauge Oil seal bearing remover Jack accessories Bearing pressor Valve rod bearing pressor Washer 13-7...
Page 341: Front Shockabsorber
CFMOTO Front Shockabsorber Front Shockabsorber removal Ÿ Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) « If you want to remove the shockabsorber, Remove the locking bolts [A] first and turn the shock absorber and pull it out.
Page 342 13 Suspension Compress [A] the fork [B] upside down to draw out the oil into the suitable container [C]. Ÿ Pour in the specified amount of oil. Shockabsorber oil viscosity: KAYABAKHL34-G10 or equivalent Amount (Per Side) Replace the oil only: About 390mL(13.2US oz) Total dry: 458±4mL(15.5±0.14USoz)
Page 343: Rear Shockabsorber
CFMOTO Rear shockabsorber Spring Preload Adjustment Ÿ Using the hook wrench [A], turn the adjusting nut [B] to adjust the spring preload. ○ Riders in average level 68kg(150lb) with no passen- ger and no accessories is 3rd position. Spring Preload Setting Standard Position: 3rd position Adjustable Range: 1st to 7th position Ÿ...
Page 344: Rear Shock Absorber Installation
13 Suspension Ÿ Remove Upper Shock Absorber Bolt [A] Lower Shock Absorber Nut and Washer Lower Shock Absorber Bolt[C] Ÿ Remove shockabsorber [B] from backward. Rear Shock Absorber Installation Ÿ Installation is the reverse of removal. Ÿ Apply grease to the lip of oil seals ○...
Page 345: Swingarm
CFMOTO Swingarm Swingarm Removal Ÿ Remove Chain Cover Bolts [A] and Cover [B] Ÿ Remove: Left, right side cover (see Side Cover Removal in the Frame chapter) Left, right foost rest bracket (see Foot Rest Bracket Remobal in Frame chapter) Ÿ...
Page 346: Swingarm Bearing Removal
13 Suspension Swingarm Bearing Removal Ÿ Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] Special Tool - Inside Circlip Pliers Ÿ Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A] Swingarm Bearing Installation Ÿ...
Page 347: Swingarm Bearing, Sleeve Inspection
CFMOTO Ÿ Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown. 25mm(0.98in.)[E] 17mm(0.67in.)[F] 1mm(0.04in.)[G] 0.5mm(0.02in.)[H] 1mm(0.04in.)[I] 23.5mm(0.93in.)[J] 6mm(0.24in.)[K] Swingarm Bearing, Sleeve Inspection CAUTIO N Do not remove the bearing fo r inspection. R emoval may d amag e them.
Page 348: Swingarm Bearing Lubrication
13 Suspension Ÿ Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. « If the bearing play, roughness, or binding is found, replace the bearing. Ÿ Examine the bearing seal [B] for tears or leakage.
Page 349 14 Steering system Contents Exploded View …………………………………………………………………………………………………14-2 Special Tools……………………………………………………………………………………………………14-4 Steering bearing removal……………………………………………………………………………………14-5 Steering bearing installation ………………………………………………………………………………14-6 Steering bearing lubrication ………………………………………………………………………………14-7 Steering Stem Warp……………………………………………………………………………………………14-8 Handlebar ………………………………………………………………………………………………………14-9 Handlebar Removal…………………………………………………………………………………………14-9 Handlebar Installation………………………………………………………………………………………14-9 Clutch lever assy installation………………………………………………………………………………14-10 14-1...
Page 350: Exploded View
CFMOTO Exploded view 14-2...
Page 351 14 Steering system Torque Tighten parts Remark N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Holder Bolts 0.36 2.5885 Left Switch Housing Screws 0.36 2.5885 Right Switch Housing Screws 11.0 Steering Stem Head Bolt Steering Stem Nut AD：...
Page 352: Special Tools
CFMOTO Special tool Steering rod tighten wrench Steering rod bearing remover Steering bearing removin adapter Bearing pressor 14-4...
Page 353: Steering Bearing Removal
14 Steering system Steering bearing removal Ÿ Remove Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Headlight Assy (see Headlight Removal/ Installation in the Electrical System chapter) Handlebar (see Handlebar Removal) Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] and Washer Front Fork Clamp Bolts (Upper) [C] (Loosen) Steering Stem Head [D]...
Page 354: Steering Bearing Installation
CFMOTO Ÿ Remove the lower bearing inner race [A] which is pressed onto the steering stem with a suitable com- mercially available chisel [B]. Steering bearing installation Ÿ Replace the bearing outer races with new ones Ÿ Apply grease to the outer races, and drive them into the head pipe at the same time Special Tool - Bearing Driver Set [A] Ÿ...
Page 355 14 Steering system Ÿ Settle the inner races in place as follows. ○ Tighten the steering stem nut with 39 N•m (4.0 kgf•m, 29ft•lb) of torque fi rst, and loosen it a fraction of a turn untilit turns lightly. Afterward tighten it again withspecifi ed torque using a stem nut wrench [A] in the direction shown.
Page 356: Steering Stem Warp
CFMOTO Steering Stem Warp • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. « If the steering stem [A] is bent, replace the steering stem. Steering parts damaged «...
Page 357: Handlebar
14 Steering system Handlebar Handlebar Removal Ÿ Remove: Clutch Lever Assembly Left Switch Housing Left Handlebar Weight [C] Ÿ Remove: Front Brake Master Cylinder (see Front Master Cylinder Removal in the Brakes chapter) Right Switch Housing Right Handlebar Weight Throttle Grip Ÿ...
Page 358: Clutch Lever Assy Installation
CFMOTO Clutch lever assy installation (see Clutch Lever Installation in the Clutch chapter) Ÿ Apply adhesive cement to the inside of the left handle- bar grip. Ÿ Apply a non-permanent locking agent to the left handlebar weight bolt. Ÿ Install the left switch housing. Fit the projection [A] i nt o a s m a l l ho l e [ B ] i n t he ha nd l e b a r .
Page 359 15 Vehicle body Contents Seat removal and installation…………………………………………………………………………15-2 Panels removal and installation………………………………………………………………………… 15-3 Side cover removal and installation …………………………………………………………………… 15-3 Tank cover plate removal and installation……………………………………………………………… 15-4 Tank front panel removal and installation ……………………………………………………………… 15-4 Tank removal and installation…………………………………………………………………………… 15-5 Front fender removal and installation……………………………………………………………………...
Page 360 CFMOTO Seats removal Rear Seat Removal Like photo shows. Press the seat by the left hand like? .Then insert the ignition key? . Turn clockwise? Then pull out the seat from rear? Front Seat Removal Like photo shows. Use wrenches to loose up Two bolts then pull the seat out from rear direction Front seat installation...
Page 361 15 Vehicle body Panels and side cover removal Panels removal Ÿ Remove assemble screw Ÿ Pull out the plastic clip[B] Ÿ Pull out the plastic clip[C] Side cover removal Ÿ Remove assemble bolt [D] Ÿ Pull out the plastic clip [F] Ÿ...
Page 362 CFMOTO Tank cover plates removal Ÿ Remove the seat (Refer to 15-2) 15-3) Ÿ Remove the panels and side covers Refer to [A] [D] Ÿ Remove the mounting bolt Ÿ Remove assemble screw Ÿ Remove plastic screw Ÿ Pull out the left tank cover plate let the clip [E] and plastic clip [F] out of position.
Page 363 15 Vehicle body Fuel tank removal Ÿ Remove front and rear seat (See 15-2) Ÿ Remove body covering parts(See 15-3,15-4) Ÿ Remove the screw[A] [B] Ÿ Loose fuel sensor connector Ÿ Loose fuel pump connector. Ÿ Disconnet the high pressure fuel pipe. Ÿ...
Page 364 CFMOTO Head cover side plate removal Ÿ Remove the screws [A](2 on each side) Ÿ Pull out the plastic clip [B](2 for each side) Ÿ Pull out the plastic locker[C](2 for each side) Head cover side plate Installation Ÿ Reverse the removal procedure for installation Head cover removal Ÿ...
Page 365 15 Vehicle body Head cover bottom plate removal Ÿ Remove the head cover(See 15-6) Ÿ Remove the screw[B] Head cover bottom plate installation Ÿ Reverse the removal procedure for installation Steering light removal Ÿ Remove the head cover(See 15-6) Ÿ Remove the nut [A](1 for each side) Ÿ...
Page 366 CFMOTO Tail cover and rear plate removal Ÿ Remove the seat(See 15-2) Ÿ Remove panels and side cover(See 15-3) Ÿ Remove screw [A] [C] (4 on each side) Ÿ Remove the screws [B] Ÿ Remove the rear plate screw Ÿ Remove the 6 plastic clips[E] [F] Ÿ...
Page 367 15 Vehicle body Licence bracket removal Ÿ Remove the seat(See 15-2) Ÿ Unplug the steering light and licence light connectors. Ÿ Remove 4 bolts [A] Ÿ Pull out the cables to remove the licence bracket. You can maintenance the rear steering light licence light and rear baffle-boards.
Page 368 CFMOTO Frame inspection • Inspect the frame to see cracks, sunks, bents or wraps. ○ If any damaged inspected. 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. 15-10...
Page 369 16 Electrical system Contents Specifications…………………………………………………………………………………………………… 16-2 Special tools………………………………………………………………………………………………………16-3 Parts Location…………………………………………………………………………………………………… 16-4 Wiring Diagram ………………………………………………………………………………………………… 16-6 Precautions……………………………………………………………………………………………………… 16-8 Electrical Wiring………………………………………………………………………………………………… 16-9 Battery…………………………………………………………………………………………………………… 16-10 Charging System ……………………………………………………………………………………………… 16-16 Overriding clutch………………………………………………………………………………………………… 16-23 Ignition System ………………………………………………………………………………………………… 16-26 Electric Starter System………………………………………………………………………………………… 16-35 Lighting System………………………………………………………………………………………………… 16-41 Radiator Fan System……………………………………………………………………………………………...
Page 370: Specifications
CFMOTO Specifications Item Standard Battery Style Sealed battery Model YTX12-BS Capacity 12V10Ah Voltage 12.8V or higher Charging system Type 3 phase AC Magneto output voltage 4000r/min (rpm) 42V or higher Stator coil resistance 0.18~0.27Ω Charging voltage 14.2~15.2V Ignition system CPS resistance 376~564Ω...
Page 371: Special Tools
16 Electrical system Special tool AVO meter Testing auxilary line Magneto rotor puller Adapter Peak volatage adapter Magneto rotor locker 16-3...
Page 372: Parts Location
CFMOTO Parts location 9 10 11 12 2 3 4 5 15 16 17 18 19 16-4...
Page 373 16 Electrical system Parts location 1. Dashboard 14.Roll-over sensor 2. Fan motor 15.Fuel pump£ØIn the tank£© 3. Magneto 16.Oil pressure switch 4. Water temp. sensor 17.Crankshaft position sensor 5. Neutral sensor 18.Throttle body 6. Speed sensor 19.Oxygen sensor 7. Side stand switch 20.Ignition coil 8.
Page 374: Wiring Diagram
CFMOTO Wiring diagram 13 14 22 23 24 25 17 18 19 20 26 27 MODE 12V6Ah 35 36 37 B/Br 闪烁器 Gr/R Br/B 起动电机 Br/G Br/W Br/G Br/G B/Br B/Br Gr/W Gr/W Lg/R Lg/R Lg/R Lg/R Lg/LR B/Br Lg/LR B/Br B/Br S(E)
Page 375 16 Electrical system Wiring diagram 1. Front position light 35. CPS 2. Front position light 36. Magneto 3. Low beam light 37. Rectifier 4. High beam light 38. Start relay 5. Front steering light LH 39. Battery 6. Front steering light RH 40.
Page 376: Precautions
CFMOTO Precaution There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. Always check battery condition before condemning other parts of an electrical system.
Page 377 16 Electrical system Eletric wire Female Connectors [A] 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.
Page 378: Battery
CFMOTO Battery Battery Removal ● Remove Seat. ● Disconnect the negative (-) cable [A]. ● Slide out the positive (+) terminal cap [B] and then disconnect the positive (+) cable. CAUTION Be sure to disconnect the negative (-) cable first. ●...
Page 379 16 Electrical system Battery NOTE oThe 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 oDo not pierce or otherwise open the sealed cells...
Page 380 CFMOTO Battery Initial Charge ● Place the strip [A] of caps loosely over the filler ports. ● Newly activated sealed batteries require an initial charge . :1.2A X5-10h Standard Charge Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used.
Page 381 16 Electrical system Battery Precautions 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. Refreshing charge. If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged.
Page 382 CFMOTO Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. ： ● Remove Seat (see Seat Removal in the Frame chapter) Battery Cable Cap (see Battery Removal) ● Disconnect the battery terminals. CAUTION Be sure to disconnect the negative (-) cable first.
Page 383 16 Electrical system Battery Charge :11.5~12.8V Terminal Voltage :1.2A X5-10h(See form Standard Charge below) :5Ax1h Quick Charge If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later 11.5V Terminal Voltage less than Charging 1.2Ax20h Method NOTE Increase the charging voltage to a maximum voltage...
Page 384: Charging System
CFMOTO Charging System Alternator Cover Removal ● Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) Alternator Lead Connector [A] ● Place a suitable container under the alternator cover [A], and remove the cover bolts [B]. ● Pull the alternator cover outside. Alternator Cover Installation ●...
Page 385 16 Electrical system Charging system Stator Coil Installation ● Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. :12N·m Torque - Stator Coil Bolts ● Secure the alternator lead with a holding plate, and tighten the bolt.
Page 386 CFMOTO Charging System ● Install the starter gear [A] and washer [B]. ● Again, clean the crankshaft tapered portion [C] and dry there. ● Install the alternator rotor [A] while turning [B] it counter- clockwise. ● Install the washer [A]. NOTE Confirm the alternator rotor fit or not to the crank- shaft before tightening it with specified torque.
Page 387 16 Electrical system Charging System ● Install the starter double gear [B] and starter idle gear [C]. ● Install the alternator cover. Magneto inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
Page 388 CFMOTO Charging System Check the stator coil resistance as follows. ● Stop the engine. ● Connect the hand tester as shown in the table 2. ● Note the readings (total 3 measurement). Connecting pin AVO meter Meter standard （+）（-） Black line Another black...
Page 389 16 Electrical system Charging System Regulator/Rectifier Regulator/Rectifier Removal ● Remove Bolts [A] ● Disconnect the connector [A]. ● Remove the regulator/rectifier [B]. 16-21...
Page 390 CFMOTO Charging System ● ● Using a hand tester, measure the resistance be After is the engine is running(at 5000 rpm), when tween the following pair of terminals. If any reading is the magneto is normal and the battery is fully charged, out of the specifi cation, replace the regulator/rectifi er if the voltage between the red and green terminals is with a new one...
Page 391: Overriding Clutch
16 Electrical system Charging System Overriding clutch Overriding Clutch Removal/Installation ● Refer to the Alternator Rotor Removal/Installation. Overriding Clutch inspection ● Remove alternator cover ● Remove starter idle gear and starter double gear. ● Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].
Page 392 CFMOTO Charging System Charging System Troubleshooting Chart Charging system trouble Main fuse Replace 1． Clean terminal Battery 2． Recharge. Charging voltage Charging system OK Start the engine and keep it at the speed of 5000rpm ， The voltage should be in 13.5V～15V Note：Battery must be fully charged ﹥15V Replace rectifier...
Page 393 16 Electrical system Charging system Charging wiring diagram 1. Battery 2. Start relay 3. Start motor 4. Rectifier 5. Magneto 6. Ignition switch 7. Fuse box 16-25...
Page 394 CFMOTO Ignition system WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. WARNING Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
Page 395 16 Electrical system Ignition system Crankshaft Position Sensor Resistance Inspection Remove: ● Right Frame Cover (see Frame Cover Removal inthe Frame chapter) ● Crankshaft Sensor Lead Connector [A]. ● Set the meter [B]on x 100 ohm position Meter(+)→ Black line Meter(-)→...
Page 396 CFMOTO Ignition system Crankshaft Sensor Peak Voltage Inspec- NOTE tion ● Be sure the battery is fully charged. ● Using the peak voltage adapter [A] is a more reli- able way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements Remove: ●...
Page 397 16 Electrical system Ignition system Ignition coil Ignition Coil Removal ● Remove body covering parts ● Remove the tank and air filter ● Disconnect the ignition coil connectors [A] . ● Pull the ignition coils [B] off the spark plugs. CAUTION Do not pry the connector part of the coil while removing the coil.
Page 398 CFMOTO Ignition system Ignition coil Ignition Coil Primary Peak Voltage Be sure the battery is fully charged ● Remove the ignition coils, but without sparkplug. ： Measure the primary peak voltage as follows. ● Install the new spark plug [A] into each ignition coil [B], and ground them onto the engine.
Page 399 16 Electrical system Ignition System Interlock Operation Inspection ● Raise the rear wheel off the ground with stand. 1st Check ● Start the engine to the following conditions. Condition Transmission Gear：Not neutral Clutch Lever: Release Side stand: Down or up ●...
Page 400 CFMOTO Ignition System ● The IC igniter is built in the ECU [A]. ● Refer to the Interlock Operation Inspection, Igni- tion System Troubleshooting chart and EFI chapter for ECU Power Supply Inspection. 16-32...
Page 401: Ignition System
16 Electrical system Ignition System Ignition System Troubleshooting Chart Ignition trouble shooting Ignition trouble(No spark) Battery inspection Charge or replace Maintain the wiring Ignition system wiring replace damaged parts connection Replace the spark plug Spark plug inspection Ignition coil inspection Replace ignition coil Ignition coil peak voltage V oltage lower than standard...
Page 402 CFMOTO Ignition System Ignition system wiring diagram 16-34...
Page 403 16 Electrical system 18. Ignition coil and spark plug 1 1. Dashboard 19. Ignition coil and spark plug 2 2.Clutch switch 20. Oxygen sensor 1 3. EFI mode switch 21. Oxygen sensor 2 4. Start switch 22. Idle step motor 5.
Page 404 CFMOTO Starting system Start motor CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. Start motor removal ● Slide out the rubber sleeve [A] . ● Remove start motor cable nut [B]. ●...
Page 405 16 Electrical system Starting system Start relay Start relay removal ● Remove left side cover. ● Disconnect the connectors [A]. ● Disconnect the start motor cable[C] on start relay [D]and battery (+) cable [B]. Start relay test ● Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown.
Page 406 CFMOTO Starting system Start auxilary relay Start auxilary removal ● Remove the tank. ● Take out the auxilary relay[A] with rubber sleeve [B] from the frame. ● Disconnect the connector [C]. Start auxilary relay test ● Connect the hand tester [A] and 12 V battery [B] to the starter auxilary relay [C] as shown.
Page 407 16 Electrical system Starting system Starting Logic Table S i d e s t a n d S t a r t o r G e a r p o s i t io n C l u t c h s w i t c h c a n n o t T o g r o u n d...
Page 408 CFMOTO Starting system Starting system trouble shooting Start failure (according to Starting Logic Main fuse and fuse box Replace Charge or replace. Battery voltage inspection Inspect starter motor (using a thick lead, bypass the 2 terminals of the Replace the motor starter relay.
Page 409 16 Electrical system Starting system Starting system wiring 16-41...
Page 410 CFMOTO 1. Dashboard 2.Clutch switch 3. EFI mode switch 4. Start switch 5. Engine stop switch 6. Start auxilary relay 7. Fuel pump relay 8. Main relay 9. Fuse box 10. Ignition switch 11. CPS 12. Magneto 13. Rectifier 14. Start auxilary relay 15.
Page 411: Lighting System
16 Electrical system 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 horizontal adjustment ● Refer to headlight inspection in maintenance chapter.
Page 412 CFMOTO Lighting System Headlight Removal/Installation Loose the body covering parts on headlight each side. ● Remove 6 bolts around the headlight ● Disconnect the connectors H eadl i ght st yl e: LED 12V20W × 2 (High beam and low beam) 12V3W Front position light: LED ●...
Page 413 16 Electrical system Lighting system Licence light replacement ● Remove the screw [A] ● Remove [B] ● Remove 4 screws under the licence light[C ]。 ● Replace the licence light Installation is the reverse of removal. 16-45...
Page 414 CFMOTO Lightening system Headlight and position light wiring diagram 1.Headlight(High beam) 2.Headlight (Low beam) 3.High beam indicator 4.Dashboard indicator 5.Position light 6.High beam relay 7.Low beam relay 8.Dimmer switch 9.Light switch 10.Front breaking switch 11.Rear breaking switch 12.Taillight/breaking light 13.Rear licence light 14.Battery 15.Start relay 16.Fuse box...
Page 415 16 Electrical system Lighting System Turn Signal Light Front Turn Signal Light Assy RH Replace- ment ● Remove the headlight assy ● Disconnect the connectors[A] [B] [C] ● Remove the screw[D]. ● Remove front turn signal light RH ● Replace front turn signal light RH ●...
Page 416 CFMOTO Lighting System Turn Signal Light Flasher Flasher removal ● Remove the middle fairing LH(Refer to Middle Fairing Removal.) ● Remove the flasher[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.
Page 417 16 Electrical system Light system Steering light Steering wiring diagram 1. Front turn signal light LH 2. Turn indicating light LH 3. Front turn signal light RH 4. Turn indicating light RH 5. Flasher 6. Turn signal switch 7. Indicating switch 8.
Page 418 CFMOTO Radiator fan cooling system Fan motor Fan motor inspection ● Disconnect the connectors [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. Fan Relay Fan Relay Inspection ●...
Page 419 16 Electrical system Radiator fan cooling system Radiator fan cooling system wiring diagram 1. Battery 2. Start relay 3. Ignition switch 4. Fuse box 5. Fan motor 6. Fan relay 8. Engine stop switch 7. Main relay 9. ECU 16-51...
Page 420 CFMOTO Dashboard Dashboard removal ● Remove Headlight Assy (see Headlight Removal/ Installation) ● Disconnect the connector [A]. ● Remove the screw[B],Remove the dashboard. CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or side- ways for any length of time, it will malfunction.
Page 421 16 Electrical system Dashboard LCD inspection ● Using the auxiliary wires, connect the 12 V battery to the meter unit connector as follows. ● Connect the battery positive pole to [10][12]. ● Connect the battery nagetive pole to [7]. ● Speed raise up, the fuel and water temp. shows 1 cube.
Page 422 CFMOTO Dashboard Speedo meter check ● Use ”LCD inspection ” to connect the battery and connector. ● If cubical wave signal into pin [10] The frequency will shows up on oscillator [A]. ● If the frequency nearly 133Hz, the speed is al- most 60km/h.
Page 423 16 Electrical system Dashboard RPM meter ● Use the same way in ”LCD inspection”. con- nect the battery and connector. ● If cubical wave signal into pin [3]. ● The RPM data will shows on oscillator « If input frequency nearly 100Hz.The indicator shows almost 6000rpm If you don’t have oscillator, Inspect the speedometer in this way.
Page 424: Dashboard
CFMOTO Dashboard Highbeam indicator ● Battery positive(+) pole to pin [6]. « If battery positive (+) pole connect to dashboard pin [17]. High beam indicator shoudl be on.If battery positive (+) pole disconnect to pin [17]High beam in- dicator should be off. If function is wrong.Replace the dashboard.
Page 425 16 Electrical system Dashboard Trouble indicator ● Battery Negative (-) pole to pin [11]. « If battery (-)pole connect to pin[11].Neutral indica- tor should be on. If the battery(-)pole disconnect to pin [7].The neutral indicator should be off. If function is wrong, replace the dashboard Parking indicator ●...
Page 426 CFMOTO Dashboard Dashboard wiring diagram 1. Dashboard 2. EFI mode switch 3. Engine stop switch 4. Main relay 5. Fuse box 6. Ignition switch 7. Oil pressure switch 8. Start relay 9. Battery 10. Neutral switch 11. ECU 12. Sidestand switch Speed sensor 16-58...
Page 427: Switches And Sensors
16 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 ●...
Page 428 CFMOTO Switches and Sensors Water temp sensor Water temp sensor inspection ● Remove the water temp sensor(See EFI chapter removal and installation). ● Suspend the sensor [A] in a container of coolant so hat the temperature-sensing projection [C] and threaded portion [C] are submerged. ●...
Page 429 16 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 ●...
Page 430 CFMOTO 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]. High beam relay installation ● Installation is the reverse of the removal. High beam relay inspection ●...
Page 431 16 Electrical system Relay and Fuse Main fuse Main fuse removal ● Remove left side cover ● Remove starter relay [A]. ● Disconnect the leads connector[B] ● Pull out the main fuse[C] Main Fuse Installation ● Installation is the reverse of removal. Fuse removal ●...
Page 432 17 PDA PDA connections： Open the seat connect the PDA and diag- nose cable [A]. Note Turn off the ignition switch when connecting. And turn the ignition switch on after connected. Button functions: Power[H]:PDA power button Up[C]:Move the arrow up side. Down[F]:Move the arrow down side.
Page 433 CFMOTO PDA functions Connect the PDA turn the ignition switch on. Then turn the PDA on. It will shows the CFMOTO sign（FIG1）； A f te r 3s w il l sh o w s “ 按确定键换下一步操作 ” （ F I G 2 ）； Press OK button to choose function slection.Choose “春风摩托”...
Page 434 17 PDA LANGUAGE Press up and down arrow to move the arrow.Choose” 语言（L A N G U A G E ）（FIG5）” Then press OK button to choose languages. The screen will shows like below(FIG6): 1.中文（Ch ines e） 2.英文（English） Press up and down button to move the arrow to choose “...
Page 435 CFMOTO Press up and down arrow to choose UAES ME6.0 SYSTEM to read the ECU. Press OK button to enter the function list. The screen will shows up like below: READ ECU ID READ DTC CLEAR DATASTREAM ACTUATOR TEST ECU RESET READ DTC Press up and down to move the arrow to READ DTC.
Page 436 17 PDA Press EXI button to back to the trouble code list. Then press the EXIT button again to enter the testing date. After entered the date the screen will shows the tested date. Without entering work. Press EXIT button to back the upper level.
Page 437 CFMOTO After you pressed the OK button the screen will shows “Clear DTC command has sent! Read DTC again?” Press OK button the screen will shows ”Syetem is O K” （FIG18） Press the EXIT button to enter the tested date. （F I G 1 9 ）...
Page 438 17 PDA Ater pressed the OK button. The datastream will be show up.Like right side. Press left or right button to turn pages.. Datastream contents 1.BATT VOLT 2.ENG SPD 3.TARGET IDLE 4.DYNAMIC TARGET IDLE 5.VHL SPD 6.ENG TEMP SEN VOLT 7.ENG TEMP 8.IAT SEN VOLT 9.IAT...
Page 439 CFMOTO CF_MOTO_ABS Press up and down button to move the arrow. Choose CF_MOTO_ABS. Then press the OK button to see t he f unct i on sl ect i on （FIG32） FIG32 After press the OK button the screen will shows like FIG 33.
Page 440 17 PDA Press the EXIT button to return the code list. Then press the EXIT button again to enter the tested date. The screen shows the date Without entering. Press the EXIT button to upper level list（FIG37） FIG37 CLEAR DTC Press up and down button to move the arrow .
Page 441 CFMOTO ”System is OK ” Press OK button shows （FIG40） FIG40 Press the EXIT button to return the code list. Then press the EXIT button again to enter the tested date. The screen shows the date （FIG41） Without entering. Press the EXIT button to upper level. FIG41 DATASTREAM Press up and down button to move the arrow.
Page 442 17 PDA ACTUATOR TEST Press the up and down button to move the arrow. Choose ACTUATOR TEST and press the OK button. （FIG44） FIG44 After pressed the OK button the screen will shows the testing items for choose like FIG 45. FIG45 Lamp OFF Press up and down button to move the arrow.
Page 443 CFMOTO READ ECU ID Press the up and down button to move the arrow. Choose READ ECU ID. （FIG48） FIG48 Press the OK button to see the ECU version informa- tion that the screen will shows. （FIG49） Press EXIT button to upper level. FIG49 ECU RESET Press up and down arrow to move the arrow.

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