CF MOTO CF400-A 2017 Service Manual Download

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9-2

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

Summary of Contents for CF400-A 2017

Page 1: ...WWW CFMOTO COM Service manual CF400 A CF650 7B ...

Page 3: ...e If any problems comes Please connect to your dealer to get the news for product The information in this manual refer to the newest product when comes out The pictures drawings and photos in this manual doesn tstand for the real model assy and parts This manual is compiled according to standard GB T9969 2008 and GB T19678 2005 CFMOTO reserves rights to make improve ments and modifications to the ...

Page 4: ...om deadcenter PS Horsepower BTDC Before topdead center psi Pound Square inches C Celsius r Rounds DC Direct current rpm Rounds per minutes F Farad TDC Top dead center F Fahrenheit TIR Times indicator record ft Feet V Volt g Gram W Watt h Hour Ω Ohm L liter in Inches US gal US gallon US qt US quart oz Ounce HP Horse power cm Hg Hg deepness in cm pint Pint cu in Cubical inches mL mililiter ...

Page 5: ... vehicle Follow the maintenance schedule in this manual Be alert for problems and non scheduled maintenance Use genuine CFMOTO parts and proper tools There are necessary information about genuine parts and special tools in our parts catalogue and special tools list Follow the service manual procedures step by step Do not take shortcuts Remember to keep complete records of maintenance and repair wi...

Page 6: ... not fallowed Note This signal shows information about highly efficiency working way This manual has also 3 signals below Except the warnings on top They will help you see different level sign Shows the job needs to be done Shows the job step or after step work It maybe before the caution note Shows the step s solution Depends on the step for testing or inspection result For most chapter after con...

Page 7: ... Uniform pilot uniform etc cap safety boots suit able for the operation must be worn and the safety articles such as dustproof goggles dustproof respirator and gloves shall be worn for protection when necessary When the engine just stops the temperature of engine muffler is still high please do not touch them with bare hands for avoiding burn Please wear uniform with long sleeves as well as gloves...

Page 8: ... Battery may produce combustible and explosive hydrogen when it is being charged So it may explode if there is f ame or electric spark So please charge it in the place with nice ventilation Do not touch the turning or movable pieces such as rear wheel clutch etc Pay attention not to get pinched when servicing CFMTOTO ...

Page 9: ...attery to prevent the engine from accidentally turning over Disconnect the ground cable first and then the positive When finishing the service first connect positive cable to the positive terminal of the battery and then the negative cable to the nega tive terminal Edges of Parts When service parts with edges wearing gloves to prevent injury Solvent Use a high flush point solvent when cleaning par...

Page 10: ...rn or damaged parts may lead to serious accidents Visually inspect removed parts for corrosion discoloration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part beyond the service limits Replacement Parts Replacement parts must be CFMOTO genuine or recommended by CFMOTO Gaskets O rings...

Page 11: ...ood quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening torque Porper Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair damage When necessary remove screws that have non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary G...

Page 12: ...g out Press bearing into place by putting pressure on the correct bearing race as shown Oil seal Grease Seal Do not remove pressed oil or grease seals unless removal is absolutely necessary Replace with new ones whenever removed Press new oil seals with manufacturer and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease to the lip of the seal before...

Page 13: ...haft by hand the free play of amount of rotating direction will affect adjustment Rotate the crankshaft to positive direction Clockwise viewed from output side Electrical Wires When connecting electrical wires first to check color of wires and unless special instruction same color of wires should be connected Instrument Use a meter that has enough accuracy for an accurate measurement Read the manu...

Page 14: ...1 8 Marking Locations Model CF400 A CF650 7B VIN No LCEPESL4 LCEPEVLB Engine serial No 268MQ 283MT V I N Metal Engine No CFMTOTO ...

Page 15: ...ystem liquid cooled Bore and stroke 68 4 54 5 2 7 2 1 in 83 60 3 3 2 4in Displacement 400 4 cm 24 434cu in 649 3 cm 39 60 cu in Compression ratio 11 1 11 3 1 Max power 29 5kW 40 12ps 9500r min 45 kW 61 2 PS 8750 r min rpm Max torque 32 N m 3 26 kgf m 23 6 ft lb 7750r min 56 N m 5 7 kgf m 41 3 ft lb 7 000 r min rpm Carburetion system EFI Starting system Electric starter Ignition system ECU Timing a...

Page 16: ...Style 6 gears International series gear Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear 2 5 2 353 1 8 1 714 1 333 1 111 0 966 0 852 Main moderate system Style Chain drive Ratio 3 857 3 067 Total ratio 7 052 Bottom gear 5 474 Top gear Frame Style Welding Steel pipes and plates Front fork angle 24 5 Drag distance 102mm 4 0in Front tire Style No inner tires Size 120 70 ZR17M C 58W Ri...

Page 17: ...l 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 Tail light Breaking light LED 13 AC magneto Style 3 phase AC Out put 24A 14V 5000r min As the order changes the specifications may different from the real vehicle This specifications do not stand for all models for all areas ...

Page 18: ...m 7 233 ft lb g 0 03527 oz kgf m 86 80 in lb Volume Pressure L 0 2642 gal US kPa 0 01020 kgf cm2 L 0 2200 gal imp kPa 0 1450 psi L 1 057 qt US kPa 0 7501 cmHg L 0 8799 qt imp kgf cm2 98 07 kPa L 2 113 pint US kgf cm2 14 22 psi L 1 816 pint imp cmHg 1 333 kPa mL 0 03381 oz US Velocity mL 0 02816 oz imp mL 0 06102 cu in km h 0 6214 mph Force Power N 0 1020 kg kW 1 360 PS N 0 2248 lb kW 1 341 HP kg 9...

Page 19: ...2 25 Clutch Operation Inspection 2 25 Wheels Tires 2 26 Air Pressure Inspection 2 26 Wheel Tire Damage Inspection 2 26 Tire Tread Wear Abnormal Wear Inspection 2 26 Wheel Bearing Damage Inspection 2 27 Drive chain 2 27 Drive Chain Lubrication Condition Inspection 2 27 Drive Chain Slack Inspection 2 28 Drive Chain Slack Adjustment 2 28 Wheel Alignment Inspection 2 29 Drive Chain Wear Inspection 2 3...

Page 20: ... 37 HeadlightAiming Inspection 2 39 Sidestand Switch Operation Inspection 2 40 Engine Stop Switch Operation Inspection 2 41 Others 2 42 Chassis Parts Lubrication 2 42 Bolts Nuts and Fasteners Tightness Inspection 2 43 ReplacementParts 2 44 Air Filter Element Replacement 2 44 Fuel Line Replacement 2 44 CoolantChange 2 45 Radiator Hose and O ring Replacement 2 47 Engine Oil Change 2 48 Oil Filter Re...

Page 21: ...d Item What ever which comes out first Total Mileage km 1000 See page Each 1 6 12 18 24 30 36 Filter element wash 2 14 Valve clearance inspection 42000k m 2 19 Throttle system Clearance Return Inspection 1 year 2 15 Idle speed inspection 2 16 Fuel leaking inspection 1 year 2 17 Fuel pipe damage 1 year 2 17 Fuel pipe installation 1 year 2 17 Throttle valve washing Coolant inspection 2 18 Coolant le...

Page 22: ...ection 1 Year 2 31 Break fluid level inspection 6 months 2 32 Breaking handle Breaking force Clearance Working smoothly inspection 1 Year 2 33 Breaking light control inspection 2 33 Suspension Front fork and rear shockabsorber action Smoothly inspection 2 34 Front fork and rear shockabsorber oil leaking inspection 1 Year 2 34 Handling system Steering clearance inspection 1 Year 2 35 Steering beari...

Page 23: ... 24 36 48 Air filter element Two years 2 14 Engine oil Six months Every 3000 km First time 500km 2 48 Oil filter Six months Every 6000 km 2 48 Fuel line Four years Coolant Two years 2 45 Radiator hose Two years Brake fluid and pipe Four years Brake fluid F R Two years 2 50 Rubber parts of master cylinder and caliper Four years Spark plug 2 54 Damper ...

Page 24: ...L Fuel pump bolt 5 0 5 L S Oxygen sensor 60 6 60 44 3 Cooling system Radiator hose locking bolt 2 5 0 25 Water pump peller bolt 10 1 0 87in lb Water pump cap bolt 10 1 0 87in lb Water pump draining bolt 7 0 0 70 62in lb Thermostat mounting bolt 10 1 0 87in lb Engine bottom plate mounting bolt 6 0 60 52in lb See test Cylinder head Cylinder head cover bolt 10 1 0 87in lb Camshaft cover bolt 12 1 2 1...

Page 25: ...Oil pump chain conductor bolt 12 1 2 106in lb L Oil strainer 10 1 0 87in lb L Oil pressure warning switch 15 1 5 11 SS Oil pump cap bolt 12 1 2 106in lb L Lower fairing bracket bolt 12 1 2 106in lb L Oil pump chain sprocket 12 1 2 106in lb L Lh Main oil line leaking bolt 20 2 0 15 L Engine removal and installation Engine rear mounting nut 45 4 6 32 S Engine assemble bracket bolt 25 2 5 18 S Engine...

Page 26: ...2 L Rear wheel axel nut 108 11 0 80 Rear chain wheel nut 59 6 0 44 Speed sensor mounting bolt 8 0 80 69in lb L Speed sensor bracket bolt 10 1 0 87in lb Breaking Leaking valve 7 8 0 80 69in lb Breaking hose bolt 25 2 5 18 Breaking lever mounting bolt 1 0 0 10 9in lb Si Breaking lever locking nut 5 9 0 60 52in lb Break pedal bolt 8 8 0 90 78in lb Break hose connecting nut 18 1 8 13 Front breaking di...

Page 27: ...lb L Front steering signa l light screw 1 2 0 12 11 in lb Handlebar mounting bolt 25 2 5 18 Lower fairing m ounting bolt 8 8 0 90 78in lb Seat locking screw 1 2 0 12 11 in lb Side stand bolt 44 4 5 32 Side stand bolt 8 8 0 90 78in lb L Electric system Left side cover bolt 12 1 2 106in lb Magneto stator locker bolt 10 1 0 87in lb L Magneto rotor bolt 155 15 8 114 L CP S bolt 6 0 0 60 53in lb L Engi...

Page 28: ...nsor 12 0 1 2 106 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 mm N m kgf m in lb 5 4 5 6 0 0 45 0 60 40 57 6 8 0 12 0 0 80 1 20 69 91 8 18 25 1 8 2 5 13 0 17 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33...

Page 29: ...ake 0 22 0 28mm 0 0087 0 0110in 0 08 0 13mm 0 0031 0 0051in Clutch Clutch handle bar clearance 2 3mm 0 08 0 12in Engine lubrication system Oil Type Viscosity level Capacity Oil level ELF 10W 40 SJ JASO MA2 10W 40 2 0L 1 8USqt With no filter 2 2L 2 0USqt With filter together 2 6L 2 5USqt Total dry Between upper and lower line At idle speed or on running Wheel and tire Tread dipness Front Rear Tire ...

Page 30: ...6in 317 5 318 2mm 12 5012 53in RK or DID 520 S01 118 CF400 114 CF650 7 323mm 12 7in Breaking cylinder Breaking fluid Level Breaking pads Thickness Front Rear Breaking light Front Rear DOT4 4mm 0 15in 5mm 0 196in on About10mm 0 39in Padel movement 1mm 0 04in 1mm 0 04in Electric systen Spark plug clearance 0 7 0 9mm 0 027 0 035in ...

Page 31: ...2 13 2 Periodic maintenance 2 Special tool ...

Page 32: ...move the net frame because the filter ele ment is glued 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 Warning If the dust into the cylinder The engine parts will be abnormal wearing an...

Page 33: ...y facing down Throttle Control System Inspection ŸCheck that the throttle grip moves smoothly from full open to close A and the throttle closes quickly and completely by the return spring in all steering positions If the throttle grip doesn t return properly check the throttle cable routing grip free play and cable damage Then lubricate the throttle cable ŸCheck the throttle grip free play A If th...

Page 34: ...ster until the proper amount of throttle grip free play is obtained ŸTighten the locknut Fuel system chapter mainly introduce the TPS voltage Idle Speed Inspection ŸStart the engine and warm it up thoroughly ŸWith the engine idling turn the handlebar to both sides A If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure ...

Page 35: ...led the high pressure inside the fuel line can cause fuel to leak A or the line to burst Remove the fuel tank see Fuel Tank Removal in the Fuel System chapter and check the fuel line Replace the fuel line if any fraying cracks B or bulges C are noticed Ÿ Check the line if it has been sharply bent or kinked Hose Joints A Fuel Line B ŸCheck that the hose joints are securely connected Push and pull A...

Page 36: ...t the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed ŸCheck that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 2 5 N m 0 2 5 k g f m Warning Use special coolant only when injecting the coolant If use wate...

Page 37: ...TDC Using a wrench A on the crankshaft rotation bolt turn the crankshaft clockwise until the 1 T mark on the timing rotor is aligned with the notch B in the edge of the upper hole in the clutch cover for 1 piston and 2 T mark for 2 piston 1 T Mark A 2 T Mark B Hole C of Upper Cap Notch D in Edge of Upper Hole Using the feeler gauge A measure the valve clearance between cam and valve lifter Valve C...

Page 38: ...djust it To change the valve clearance remove the cam shaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness Note Mark and record the valve lifter and shim location so they can be reinstalled in their original positions If there is no clearance select a shim which is several sizes smaller and then measure the clearance To select a new shim which brings...

Page 39: ... 3 54 3 56 3 58 3 6 3 62 3 64 3 66 3 68 3 7 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 0 46 0 47 3 54 3 56 3 58 3 6 3 62 3 64 3 66 3 68 3 7 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 0 48 0 49 3 56 3 58 3 6 3 62 3 64 3 66 3 68 3 7 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 4 02 0 50 0 51 3 58 3 6 3 62 3 64 3 66 3 68 3 7...

Page 40: ...4 1 4 12 4 14 4 16 4 18 0 22 0 23 3 78 3 8 3 82 3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 06 4 08 4 1 4 12 4 14 4 16 4 18 0 24 0 25 3 8 3 82 3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 06 4 08 4 1 4 12 4 14 4 16 4 18 0 26 0 27 3 82 3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 06 4 08 4 1 4 12 4 14 4 16 4 18 0 28 0 29 3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 ...

Page 41: ... 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 0 51 0 52 3 5 3 52 3 54 3 56 3 58 3 6 3 62 3 64 3 66 3 68 3 7 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 0 53 0 54 3 52 3 54 3 56 3 58 3 6 3 62 3 64 3 66 3 68 3 7 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 4 02 0 55 0 56 3 54 3 56 3 58 3 6 3 62 3 64 3 66 3 68 3 7 3 72 3 74 3 76 3 7...

Page 42: ...3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 06 4 08 4 1 4 12 4 14 4 16 0 20 0 26 Suitable clearance 0 27 0 28 3 78 3 8 3 82 3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 06 4 08 4 1 4 12 4 14 4 16 4 18 0 29 0 30 3 8 3 82 3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 06 4 08 4 1 4 12 4 14 4 16 4 18 0 31 0 32 3 82 3 84 3 86 3 88 3 9 3 92 3 94 3 96 3 98 4 4 02 4 04 4 06 4 08 4 ...

Page 43: ...adjustment nut C until the free play is correct After the adjustment tighten the locknut and start the engine and check that the clutch does not slip and that it releases properly Wheels Tires Air Pressure Inspection ŸRemove the air valve cap ŸMeasure the tire air pressure with an air pressure gauge A when the tires are cold that is when the motorcycle has not been ridden more than a mile during t...

Page 44: ...ur during the last 10 of tread life 90 worn So it is false economy and unsafe to use the tires until they are bald ŸMeasure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter Tread DepthStandard...

Page 45: ... A the wheel ŸSpin B the rear wheel lightly and check for smoothly turn roughness binding or noise If roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Removal Hub Bearing Inspection in the Wheels Tire chapter and coupling see Coupling Bearing Inspection in the Final Drive chapter Drive Train Drive Chain Lubrication Condition Inspection ŸIf a sp...

Page 46: ... 6in Drive Chain Slack Adjustment ŸRemove the cotter pin A and loosen the axle nut B ŸLoosen the both chain adjuster locknuts C If the chain is too loose turn in the left and right chain adjuster nuts D evenly If the chain is too tight turn out the left and right chainadjuster nutsevenly and kick the wheelforward ŸTurn both chain adjuster nuts evenly until the drive chain has the correct amount of...

Page 47: ...e nut B Wheel Alignment Inspection Check that the value A on the left wheel alignment adjuster B aligns with the same left or right edge C of inspection window on swingarm that the right wheel alignment adjuster value aligns with If they do not adjust the chain slack and align the wheel alignment see Drive Chian Slack djustment NOTE Wheel alignment can be also checked using the straightedge or str...

Page 48: ...laces If any measurements exceed the service limit replace the claim Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2mm 12 50 12 53in Service Limit 323mm 12 7in Standard Chain RK Japan or DID Type 520 S01 Links 118 CF400 114 CF650 7 Chain Guide Inspection ŸRemove Swingarm see Swingarm Removal in the Suspension chapter ŸVisua...

Page 49: ...rioration cracks and signs of leakage The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly maintained Bend and twist the rubber hose while examing it Replace the hose and pipe if any crack B bulge C of leakage is noticed Tighten any brake hose banjo bolts and brake pipe joint nuts Torque Brake Hose Banjo Bolts 25N m 2 5kgf m 18ft lb Bra...

Page 50: ...vel is lower than the lower level line fill the reservoir to the upper level line C in the reservoir ŸRemove the seat see Seat Removal in the Frame Chapter ŸCheck that the brake fluid level in the rear brake reservoir A is above the lower level line B If the fluid level is lower than the lower level line fill the reservoir to the upper level line C Recommended Disc Brake Fluid Grade DOT4 Warning M...

Page 51: ...n on the ignition switch The brake light A should go on when the brake lever is applied of after the brake pedal is depressed about 10 mm 0 39 in If not ŸInspect the connector A and the connector If it does not go on inspect or replace the follow ing items Battery see Charging Condition Inspection in the Electrical System chapter Brake Light see Tail Brake Light Removal in the Electrical System ch...

Page 52: ...k clamps see Front Fork Oil Change in the Suspension chapter ŸPump the seat down and up A 4 or 5 times and inspect the smooth stroke Front Fork Oil Leak Inspection ŸVisually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection ŸVisually inspect the shock absorber A for oil leakage If the oil leakage is found on it repl...

Page 53: ...ken into account Be sure the wires and cables are properly routed The bearings must be in good condition and prop erly lubricated in order for any test to be valid Steering Play Adjustment ŸRemove Handlebar see Handlebar Removal in the Steering chapter Handlebar midium cover See handlebar remobal in steering chaprer Loose the bolt 2 Remove the handle bar 1 Lock the bolt on front fork 3 Steering pl...

Page 54: ... bearings in the cages and wipe the upper and lower outer races ŸTheouter racesshould bepress fitted into the frame head pipe clean off grease and dirt Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage ŸPack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races Ÿ...

Page 55: ...hboard inspec tion on electrical system chapter EFI indicator LED See dashboard inspection on electrical system chapter ECU See ECU inspection on EFI system chapter Main fuse 20A and taillight fuse 10A See fuse in spection on electrical system chapter Ignition switch See switch inspection in electrical chapter Neutral switch See switch inspection in electrical chapter Wire See wiring inspection on...

Page 56: ...hapter Steering indicator switch See switch inspection in electrical system chapter Flash relay See flash relay inspection on electri cal system chapter Cable See cable inspection on electrical system chapter Ÿ Press steering indicator switch ŸSteering indicator and indicating light should be off If the light does not off Inspect or replace the item below Steering signal switch See switch inspecti...

Page 57: ...igh beam and low beam indicator goes off In spect or replace the item below Headlight relay See high beam and low beam re lay inspection in electrical system chapter Off the ignition switch High beam indicator LED should be off Headlight axis inspection ŸInspect the ray axis If the axis point to one side insdead of straight ahead Adjust the horizontal axis Headlight axis horizontal adjustment ŸUse...

Page 58: ...e Side stand switch inspection Inspect the side stand switch by following the form below Side stand running situation Side stand Gear Clutch Engine start Engine running Up Neutral Release Start On running Up Neutral Tight Start On running Up Not neutral Release Cannot start Stop Up Not neutral Tight Start On running Down Neutral Release Start On running Down Neutral Tight Start On running Down Not...

Page 59: ...apter Auxilary relay See start system inspection in elec trical system chapter Wire See wire inspection in electrical system chapter If all the parts are OK Replace the ECU See ECU replace ment on EFI chapter Engine stop switch inspection First step Ÿ Turn on the ignition switch Ÿ Set the vehicle on N gear Ÿ Set the engine stop switch to stop position A Ÿ Press the start button Ÿ Engine cannot sta...

Page 60: ...ease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables ŸLubricate the cables by seeping the oil between the cable and housing The cable may be lubricated by using a com mercially available pressure cable lubricator with an aerosol cable lubricant With the cable disconnected at both ends the in ner c...

Page 61: ...tandard Torque Table For each fastener first loosen it by 1 2 turn then tighten it If cotter pins are damaged replace them with new ones Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Nut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels Front Axle Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot ...

Page 62: ... fuel line correctly See the wires cables and pipe goes in attached chapter ŸInstall the removed parts see appropriat chapters ŸStart the engine and check the fuel line for leaks Warning When removing and installing the fuel line joint do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy The pipes made from resin could be damaged WARNING Be prep...

Page 63: ...nder the leaking bolt C Then remove the leaking bolt WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the ...

Page 64: ...hoose a suitable mix ture ratio by referring to the coolant manufacturer s directions Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 1 7L 1 8USqt ŸFill the radiator up to the filler neck A with coolant NOTE Pour in the coolant slowly so that it can expel the air from the engine and radiator ŸCheck the cooling system for leaks ŸTap the rad...

Page 65: ...coolant level is lower than the L level line add coolant to the F level line Radiator Hose and O ring Replacement ŸDrain the coolant see Coolant Change ŸRemove Thermostat Housing A see Water Pump Removal in the Cooling System chapter Water Pump Cover B see Water Pump Removal in the Cooling System chapter Hoses C O rings D ŸApply grease to the new O rings and install them Install ŸInstall the new h...

Page 66: ... 0kgf m 22ft lb ŸPour in the specified type and amount of oil Recommended Engine Oil Type ELF 10W 40 SJ level JASO MA2 Capacity 2 2 L 2 3 US qt when filter is removed 2 6 L 2 7 US qt when engine is completely dry NOTE Although 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area ŸCheck the oi...

Page 67: ...g the brake hoses C temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum ŸImmediately wash away any brake fluid that spills Brake Fluid Replacement NOTE The procedure to change the front brake fluid is as follows Changing the rear brake fluid is the same as for the front brake ŸLevel the brake fluid reservoir ŸRemove the reservoir cap and diaphragm ŸRemov...

Page 68: ...rque Front Brake Reservoir Cap Screws 1 0N m 0 10kgf m 9in lb ŸFollow the procedure below to install the rear brake fluid reservoir cap correctly Use criss cross screw driver C to tight the screw D Torque Bleed Valve 7 8N m 0 80kgf m 69in lb ŸAfter changing the fluid check the brake for good braking power no brake drag and no fluid leakage Bleed the air from the lines is a must ŸMaster Cylinder Ru...

Page 69: ...he piston or the inner wall of the cylinder ŸTighten the brake lever pivot bolt and locknut ŸApply silicone grease ŸBrake Lever Pivot Bolt ŸTighten Torque Brake Lever Pivot Bolt 1 0N m 0 10kgf m 9in lb Brake Lever Pivot Bolt Locknut 6 0N m 0 60kgf m 52in lb CAUTION Do not remove the secondary cup from the piston since removal will damage it CAUTION Except for the disc pads and disc use only disc b...

Page 70: ...ly the brake lever toremove the piston The remaining process is asdescribed above Front Caliper Assembly ŸClean the caliper parts except for the pads ŸInstall the bleed valve and rubber cap ŸTorque Bleed Valve 7 8N m 0 80kgf m 69in lb Replace the fluid seals A with new ones Apply brake fluid to the fluid seals and install them into the cylinders by hand ŸReplace the dust seals B with new ones if t...

Page 71: ...e spring see Rear Brake Pad Removal in the Brakes chapter ŸUsing compressed air remove the piston Cover the piston area with a clean thick cloth B Blow compressed air A into the hole for the banjo bolt to remove the piston ŸRemove the dust seal and fluid seal ŸRemove the bleed valve and rubber cap NOTE If compressed air is not available with the brake hose still attached apply the brake pedal to r...

Page 72: ... resistance grease ŸInstall the anti rattle spring A in the caliper as shown ŸInstall the pads see Rear Brake Pad Installation in the Brakes chapter ŸWipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement ŸRemove Ignition Coils see Ignition Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chapter ŸRemove the spark plugs using the 16 mm ...

Page 73: ...m 3 18 Self diagnose 3 26 General 3 26 Trouble code list 3 29 EFI trouble back up 3 31 EFI parts service 3 32 Throttle body 3 32 Intake temp and pressure sensor 3 36 Water temp sensor 3 39 Crankshaft position sensor 3 41 Speed sensor 3 42 Roll over sensor 3 44 Oxygen sensor 3 46 Ignition coil 3 49 Trouble indicating light 3 51 ECU 3 53 High pressure fuel pipe 3 56 Fuel pump 3 58 Injector 3 64 Thro...

Page 74: ...3 2 CFMOTO Exploded View ...

Page 75: ...ensor 8 Injector 9 Throttle position sensor 10 Fuel hose and pipe 11 Throttle body 12 Fuel pump 13 Pressure regulator 14 Tank 15 Air filter element 16 Intake temp sensor 17 Air filter body 18 Neutral switch 19 Speed sensor 20 Roll over sensor 21 Oxygen sensor 22 Battery 23 ECU 24 Intake air direction 25 Compressed fuel direction 26 Water temp sensor ...

Page 76: ...Step motor C 19 K2 Oxygen sensor 1 20 J2 Oxygen sensor 2 21 H2 Ignition diagnose 2 22 G2 None 23 F2 Side stand switch 24 E2 None 25 D2 None 26 C2 Auxiliary relay 27 B2 Step motor A 28 A2 Step motor B 29 K3 MIL indicator 30 J3 5V power 31 H2 None 32 G3 Ignition switch 33 F3 Continue power 34 E3 L_line 35 D3 Neutral switch 36 C3 Ignition diagnose 1 37 B3 Clutch switch 38 A3 Roll over switch 39 K4 Co...

Page 77: ...0M139 Injector model 4 way injedting Resistance In 20 C 68 F about 12 Ω TPS Cannot adjust and cannot move Input voltage In Lg Y and Gr R wire 4 75 5 25 V DC Idle speed output voltage In Lg Y and Br R wire 0 34 0 64V DC Full open output voltage In Lg Y and Br R wire larger than 4 V DC Intake temp sensor Resistance See chapter related ECU output voltage In 20 C about 2 5 3 50 V Water temp sensor Res...

Page 78: ... 6 CFMOTO Item Standard Oxygen sensor Output voltage High 0 7V or higher Output voltage Low 0 2V or lower Throttle handle bar and cable Throttle handle free clearance 2 3mm 0 08 0 12in EFI Specification ...

Page 79: ...3 EFI System 3 7 3 Special tools Oil pressure gauge NeedleAdaptor Set Throttle Sensor Setting Harness Hand Tester Fuel Pressure Gauge Adaptor Fuel Hose Peak Voltage Adapter ...

Page 80: ...tery from the motorcycle This is to prevent ECU damage by excessive voltage Do not turn the ignition switch ON while any of the EFI electrical connectors are disconnected The ECU memorizes service codes Do not spray water on the electrical parts EFI parts connectors leads and wiring Whenever the EFI electrical connections are to be disconnected first turn off the ignition switch and disconnect the...

Page 81: ... system parts blow the outer surfaces of these parts clean with compressed air To prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals 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 disco...

Page 82: ...system is operating normally the FI indicator light LED A may light up under strong electrical interference No repair needed Turn the ignition switch OFF to stop the indicator light When the FI indicator light LED goes on and the motorcycle is brought in for repair check the service codes When the repair has been done the light LED doesn t go on But the service codes stored in memory are not erase...

Page 83: ...of the EFI or electrical system parts by contact between adapters Turn the ignition switch ON and measure the volt age with the connector joined CAUTION Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts After measurement remove the needle adapters and apply silicone sealant to the seals A of the connector B for waterproofing Always che...

Page 84: ... end of line Set the hand tester on X1 Ω to see the resistance If the resistance is not 0 Ω Means the line has trouble Replace the main cable or auxilary cable If the cable A both side too far Use a connect ing line D connect C side to ground B and check another side D and E connection If the wire got trouble Repair or replace the wire When check the wire A short cutting open one side B to see ano...

Page 85: ...tail in this chapter Use a fully charged battery and a digital meter D which can be read two decimal places voltage or re sistance Resistance checking This method issimple No need for a fully charged battery and the needle adapter Just do the follow ing especially when a sensor A is suspect Turn the ignition switch OFF and disconnect the connectors Inspect the sensor resistance using a digital met...

Page 86: ...gnosis Flow Chart EFI Diagnosis Flow Chart Inquiries to Rider Each rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered Try to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem The following sample diagnosis sheet will help prevent y...

Page 87: ...nition switch ON but goes off after about unlights light LED ECU or its wiring fault sometimes lights up probably wiring fault Hard to start qStart motor not running qStart motor running but the engine not running qStart motor and the engine not running qNo fuel No fuel in tank Fuel pump not running qOil blow out Do not run the engine when throttle open or the oil will blow out more qNo spark qOth...

Page 88: ...lipping others Poor running or no power at high speed Spark plug getting loose Spark plug dirt broken or clearance not fit Spark model wrong Engine knocking Breaking dragging Clutch sliding Engine overheat Too much engine oil High viscocity engine oil Other ...

Page 89: ...epair or replace See chapter16 Main 20A or ECU fuse burnt Inspect or replace See chapter16 Start motor running but the engine not running Over riding clutch problem Inspect See chapter16 Dual clutch problem Inspect See chapter16 Engine not running Valve jammed Inspect or replace See chapter 5 Cylinder or piston jammed Inspect or replace See chapter 5 Camshaft jammed Inspect or replace See chapter ...

Page 90: ... Starting system open or shortcut Inspect repairing or replace See chapter16 Main 20A or fuel pump relay fuse 15A Inspect or replace See chapter16 Fuel air mixed ratio not true Air filter jammed Not sealed or lost Clean or install again See chapter3 Oil filter cap Crankcase breather or air filter water drainer leaking Inspect repairing or replace See chapter 3 There is water in fuel Replace the fu...

Page 91: ...ir mix ratio wrong Few fuel in the tank Supply the fuel See owner s manual Air filter jammed not sealed or loose Clean the filter or check the sealing See chapter2 3 Air filter pipe loose Reinstall See chapter 3 Throttle body loose Reinstall See chapter 3 TPS not adapted or wrong adapted Readapt See PDA chapter Intake pipe damaged or leaking Replace See chapter 3 Fuel filter or strainer jammed Ins...

Page 92: ... replace See chapter 5 Bad piston ring Wearing Weak Damage or hammed Inspect and replace See chapter 5 Piston ring and groove clearance too large Inspect and replace See chapter 5 Cylinder head gasket damaged Replace See chapter 5 Cylinder twisted Inspect and replace See chapter 5 Valve conductor wearing or rod sealing damag Inspect and replace See chapter 5 Valve spring damaged or weak Inspect an...

Page 93: ...spect See chapter 3 TPS problem Inspect See chapter 3 Water temp sensor problem Inspect See chapter 3 Vehicle Shaking Fuel pressure not stable Fuel pressure adaptor problem or fuel hose twisted See chapter 3 Injector jammed Inspect See chapter 3 Water temp sensor problem Inspect See chapter 3 Cut fire in deaccelerate Spark plug dirty damaged or clearance not fit Replace See chapter 2 Fuel pressure...

Page 94: ...e chapter 16 Ignition coil short cut or bad connection Reinstall or inspect the ignition coil See chapter 16 Wrong spark plug Use right spark plug See chapter 16 The ignition controlling mode in ECU provlem Inspect See chapter 16 CPS problem Inspect See chapter 16 Wrong fuel mix ratio Air filter jammed bad sealing or missing Clean the filter or check the sealing See chapter3 Air filter pipe loose ...

Page 95: ...o right one See chapter16 Ignition coil problem Inspect See chapter 16 Ignition control mode in ECU problem Inspect See chapter 16 Intake temp sensor problem Inspect See chapter 3 Other Throttle valve cannot full open Checkthe throttle cable and machenism Breaking jammed Inspect the sealant damage and pipe jamming See chapter 12 Clutch sliding Inspect the disc wearing see chapter 6 Engine over hea...

Page 96: ...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 ...

Page 97: ...d to improve the service efficiency and quality Self diagnosis Procedures When a problem occurs with the EFI system and ignition system the FI indicator light LED A goes on Note Use a fully charged battery when conducting self diagnosis Otherwise the light LED blinks very slowly or doesn t blink EFI Indicator Light Conditions Turn on the ignition switch and the engine does not work No trouble code...

Page 98: ...The trouble indicating light will be blinking in 2Hz Off and turn on the ignition switch again If the system tested the trouble recovered The indicating light keeps on until engine start If the system still test the trouble for now The trouble indicating light will on for 4s and stop for 1s Then keeps blinking in 2Hz Until the engine start How to Read Trouble Codes Trouble codes are shown by a ser...

Page 99: ... warm up means the water temperature lower then 51 degree before start And it goes higher than 71 degree after engine warmed See the trouble codes erase chapter on PDA to erase the code PDA diagnose advantages PDA has multifunctions It is much easier more accurate and straighter then see the indicating light blinking We recommend to use the PDA to diagnose the vehicle trouble The mainly functions ...

Page 100: ...Sens or C irc Bank1 Sens or2 20 P0137 O2 Sensor C irc Bank1 Sens or2 low 21 P0138 O2 Sens or C irc Bank1 Sensor2 High 22 P0140 O2 Sensor C irc Bank1 Sens or2 N o 23 P0201 C ylinder 1 Injector Circuit 24 P0261 C ylinder 1 Injector Circuit Low 25 P0262 C ylinder 1 Injector Circuit H igh 26 P0202 C ylinder 2 Injector Circuit 27 P0264 C ylinder 2 Injector Circuit Low 28 P0265 C ylinder 2 Injector Circ...

Page 101: ...t 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: ...er temp sensor Water temp Tw 40 C 129 C If water temp sensor trouble or disconnected ECU temp is 40 C If water temp sensor trouble or short circuit ECU temp is 129 C P0130 P0131 P0132 and P0134 Oxygen sensor 1 The oxygen sensor is active and sensor must send signals output voltage continuously to the ECU If the oxygen sensor is not activated the ECU stops oxygen sensor feedback mode P0136 P0137 P0...

Page 103: ... OFF Disconnect the throttle position sensor connector and connect the harness adapter A between these connectors Connect a digital meter to the harness adapter lead Engine stop Measure the sensor input voltage Turn the ignition switch on Throttle position sensor input voltage Connections to Adapter Meter Gr R C Meter Lg Y D Standard 4 75 5 25V DC Not connected Standard 4 0 4 5V DC Conne cted Turn...

Page 104: ...tout voltage inspection Measure the output voltage at the main throttle sensor in the same way as input voltage inspection Note the following Disconnect the main throttle sensor connector and connect the harness adapter A between these connectors Start the engine and warm it up thoroughly Higher than 80 degree Check idle speed to ensure the throttle opening is correct Idle speed standard 1450 100r...

Page 105: ... resistance If the output voltage is normal check the wiring for continuity Output voltage wire connection inspection Turn the ignition switch OFF Disconnect ECU connector and throttle position sensor connector Test the continuity of the lead wires ECU Connector A Throttle Body Connec tor B Thrrottle Body Connector Br R ECU pin 26 Thrrottle Body Connector Lg Y ECU pin 39 Standard 0 Ω If the wiring...

Page 106: ...ster A to the throttle position sensor connector B Measure the throttle position sensor resistance Throttle position sensor resistance Connections Gr R C Br R D Standard 1 1 1 4 k Ω 2 0 If the reading isout of the range replace the throttle body assy If the reading is within the range but the problem still exists replace the ECU see ECU Removal Installation 1 ECU 2 Throttle position ...

Page 107: ... Intake temp sensor output voltage Active line Meter W Br ECU pin 25 Meter L G ECU pin 40 Standard Output voltage when intake temp 20 About 2 5V 3 5V Intake pressure sensor output voltage Dotted line Meter L R ECU pin 19 Meter R B ECU pin 59 Standard Output voltage in normal atmosphere About 4V 4 7V Turn off the ignition switch If the output voltage is not in standard Remove the fuel tank and chec...

Page 108: ... still trouble on Replace the ECU 65 1 70 1 75 1 80 1 85 1 45 1 50 1 55 1 60 1 10 1 15 1 20 1 25 1 30 1 35 1 40 1 15 1 10 1 5 1 0 1 5 1 35 1 30 1 25 1 20 1 130 1 100 1 105 1 110 1 115 1 120 1 125 1 95 1 90 1 40 1 Temp C M i n R e s i s t a n O H M S ta nd ar d R e s i s ta nd O H M 42661 31810 23970 18258 14039 10895 8529 5 6733 5 5358 1 4295 9 48153 35763 26885 20376 15614 12078 9428 0 7419 0 588...

Page 109: ...3 EFI System 3 37 3 Intake temp and pressure sensor Wiring diagram 1 ECU 2 Intake temp and pressure sensor ...

Page 110: ...ure sensor Fill the engine with coolant and bleed the air from the cooling system see Coolant Change in the Pe riodic Maintenance chapter Water Temperature Sensor Output Voltage Inspection Be sure the battery is fully charged Remove the ECU see ECU Removal Do not disconnect the connectors Connect a hand tester A to the ECU connector B with the needle adapter set Measure the sensor output voltage w...

Page 111: ...age is out of the standard check the wiring And if the output voltage is 4 8 V the ECU is normal If the wiring is good check the water temperature sensor resistance Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Water temp wiring 1 ECU 2 Water temp sensor 3 Dashboard Water temp sensor resistance inspection Remove water temperature sensor re...

Page 112: ...ion The crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no signals Crank the engine and measure the peak voltage of the crankshaft position sensor see Crankshaft Sensor Inspection in the Electrical System in order to check the sensor Check the wiring for continuity using the following diagram Crankshaf Position Sensor Circuit 1 ECU 2 Crankshaft posit...

Page 113: ...sor input voltage with the engine stopped and with the connector joined Turn the ignition switch ON Speed Sensor Input Voltage Meter W G Sensor C Meter G B Sensor D Standard About 9 13VDC with ignition switch on If the reading is out of the range check the wiring see wiring diagram in this section If the reading is good check the output voltage Turn the ignition switch OFF Speed Sensor Output Volt...

Page 114: ...n gine stopped and with the connector joined Turn the ignition switch ON Speed Sensor Output Voltage at Sensor Connections to Adapter Meter P Sensor C Meter G B Sensor D Standard About 0 05 1 0VDC Speed Sensor Speed Sensor Circuit 1 Speed Sensor 2 Meter Unit ...

Page 115: ...over sensor can make the engine stop suddenly The rider will loose balance get injured or death in some situa tion such as turning Make sure the sensor can be hold in position by bracket Roll over Sensor Output Voltage Inspection when tilted Be sure the battery is fully charged Connect a hand tester A to the connector B of the roll over sensor C with the needle adapter set D Measure the sensor out...

Page 116: ...eter L G F Roll over Sensor Output Voltage Inspection when tilted Hold the sensor vertically Turn the ignition switch ON and measure the output voltage with the connector joined Tilt the sensor 40 50 degree or more C right or left then and measure the output voltage Sensor output voltage Standard 0 0 5 V Tilt the sensor right or left 55 75 degree or more NOTE If you need to test again turn the ign...

Page 117: ...rt 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 Oxygen Sensor Removal Disconnect connector A and remove oxygen sensor B Oxygen Sensor Installation Connect oxygen sensor B and connector A Torque 6 0 N m 2 N m ...

Page 118: ... then have the engine run at more than 8000rpm Measure oxygen sensor output volatage using hand tester B Oxygen Sensor Output Voltage Cylinder 1 Disconnect the oxygen sensor connector A of one cylinder Place the transmission in neutral Start the engine and let it idle Meter Pin 3 C Meter Pin 4 D Cylinder 2 Meter Pin 3 C Meter Pin 4 D Standard About 0 8V Oxygen Sensor Output Voltage ...

Page 119: ...er Pin 3 C Meter Pin 4 D Oxygen Sensor Standard about 0 1V Oxygen Sensor Output Voltage Cylinder 2 Meter Pin 3 C Meter Pin 4 D Remove the hose B Use the meter B to measure the sensor s resistance Sensor heat up resistance Cylinder 1 Meter Pin 2 C Meter Pin 1 D Cylinder 2 Meter Pin 2 C Meter Pin 1 D Standard About 1 Ohm ...

Page 120: ... hand tester B as shown Measure the input voltage to each primary wind ing of the ignition coils with the engine stopped and with the connectors joined Turn the ignition switch ON Measure the ignition coil input voltage during fuel pump working time Ignition Coil Input Voltage Meter W B C Meter Ground Standard about 12 V DC Ignition coil 1 Ignition coil 2 Meter W B C Meter Ground Standard about 12...

Page 121: ...ition 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 Q P N O A B C D E F G H J K L M 4 3 2 1 1 2 2 1 1 2 3 4 5 6 7 8 9 ...

Page 122: ...cator light up 4s then stop 1s and blinking in 2Hz Off the ignition switch turn to clear up the code Lightup See the indicator and cable Replace the dashboard or cable No Trouble Indicator and EFI are normal Normal EFI tested historical trouble Off the ignition switch turn to clear up the code Y es No No Yes Ask the driver if the trouble comes out EFI OK No Replace Yes ...

Page 123: ...e FI indicator light LED A Battery B 12 V Positive pole Meter Pin 1 and 2 Negative pole Meter pin 3 and 13 Criterion The light LED should light If the light does not go on replace the meter unit Indicator Light Circuit 1 Main Fuse 2 Battery 3 ECU 4 Ignition Switch 5 Fuse Box 6 Engine Stop Switch 7 Main relay 8 Meter 0 1 2 3 4 5 6 7 8 9 10 11 12 A Q P N O A B C D E F G H J K L M 4 3 2 1 1 2 3 4 5 6...

Page 124: ... blow it off with compressed air Replace the main harness if the terminals of the main harness connectors are cracked bent or oth erwise damaged Replace the ECU if the terminals of the ECU con nectors are cracked bent or otherwise damaged With the ECU connectors A connected check the following ground lead for continuity with the igni tion switch OFF using a tester and needle adapter set Battery B ...

Page 125: ...Switch ON Engine Stop Switch ON Pin 8 51 and Battery 0V If the meter does not read as specified check the following Main Fuse 20A see Fuse Inspection in the Elec trical System chapter ECU fuse 7 5A see Fuse Inspection in the Elec trical System chapter Power Source Wiring see wiring diagram below If the inspection checks good the ECU is damaged Replace the ECU see ECU Removal Installation The ECU i...

Page 126: ... CFMOTO E C U ECU wiring diagram 1 Fuse 2 Battery 3 ECU 4 Ignition switch 5 Main fuse 6 Engine stop switch 7 Main relay L R R G 2 0 A 1 5 A 1 5 A 2 1 7 6 5 3 4 7 5 A Q P N O A B C D E F G H J K L M 4 3 2 1 ...

Page 127: ... the fuel hose C Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connec tion with a piece of clean cloth to prevent fuel spillage WARNING Install the fuel pressure gauge adapter A and fuel hoses between the fuel pump outlet pipe B and the ...

Page 128: ...ssure at the average of the maximum and minimum indications If the fuel pressure is normal the fuel circulation system fuel pump pressure regulator and fuel passage is no faults Check the EFI electronic con trol system injectors sensors crankshaft sensor and ECU If the fuel pressure is much lower than specified check the following Fuel Line Leakage Fuel PumpOperation check the soundof the pump Amo...

Page 129: ... Remove thefuel tankbolt see FuelTankRemoval Open the fuel tank cap A to release pressure Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel WARNING Connect the plastic hose A to the fuel...

Page 130: ...s operation several times Amount of Fuel Flow Srandard 60mL in 3s If the fuel flowismuch lessthan the specified check the battery condition see Charging Condition In spection in the Electrical System chapter If the bat tery is good replace the fuel pump see Fuel Pump Removal Installation After inspection install the fuel tank see Fuel Tank Installation Start the engine and check for fuel leakage ...

Page 131: ...l spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately WARNING Draw the fuel out from the fuel tank with a com mercially available electric pump Remove the fuel tank see Fuel Tank Removal Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pu...

Page 132: ...n to the pump sound in the fuel tank to confirm pump operation Turn the ignition switch ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops Turn the ignition switch OFF If the pump does not work as described above inspect the operating voltage Fuel Pump Operation Inspection NOTE Be sure the battery is fully charged Connect the fuel pump power Turn the igniti...

Page 133: ...attery voltage Inspect the fuel pump relay Pressure Regulator Removal The pressure regulator A isbuilt into the fuel pump B and cannot be removed Fuel Filter Cleaning The fuel filter A is built into the pump and cannot be cleaned or checked If the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set If the fuel filter is suspected of clogging or being damage...

Page 134: ...TO Fuel Pump Circuit Fuel pump 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 Q P N O A B C D E F G H J K L M 4 3 2 1 1 2 3 4 5 6 7 8 1 2 M 9 ...

Page 135: ...are good The trouble may be related to the fuel line requiring fuel pressure inspection see Fuel Pressure Inspection The click interval becomes shorter as the engine speed rises If any injector s doesn t click the EFI circuit or the injector is suspect Perform Fuel Injector Power Source Voltage Inspection first Injector Power Source Voltage Inspection Turn the ignition coil OFF Remove the fuel tan...

Page 136: ...the Electrical System chapter Power Source Wiring see wiring diagram below Fuel fump input voltage is the battery voltage in first 3 seconds then 0 V Injector Wiring Inspection Cylinder 1 ECU pin 50 D Standard Connected ECU pin 49 E Cylinder 2 If the wiring is good inspect the resistance of the injectors see Injector Resistance Inspection Standard Connected Connect a hand tester A to check the con...

Page 137: ...test light set B to the injector sub harness connector C Turn the ignition switch ON While cranking the engine with the starter motor watch the test lights If the test lights flicker at regular intervals the in jector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection Injector signals can be also confirmed by connect ing the hand tester x10 V AC instead of the te...

Page 138: ...two leads A and the same test light set B as in Injector Signal Test Rating of Bulb C 12V 3 3 4W 12V battery D Be sure to connect the bulb in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current CAUTION Connect the test light set to the injector E as shown Open and connect F the end of the lead to the battery terminal repeatedly The injector sho...

Page 139: ...3 EFI System 3 67 3 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 ...

Page 140: ...hrottle cables in accordance with Cable Wire and Hose Routing section in the Appendix chapter Install the lower ends of the throttle cables in the cable bracket on the throttle body assy after installing the upper ends of the throttle cables in the lever After installation adjust each cable properly Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding co...

Page 141: ...nd free from any source of flame or sparks this includes any appliance with a pilot light Be prepared for fuel spillage any spilled fuel must be com pletely wiped up immediately WARNING Remove fuel tank see Fuel Tank Removal Removetheairfilter see AirFilterHousingRemoval Disconnect Throttle Body Sensor Connector A Disconnect Fuel Hose Lower End B Disconnect Evaporative emission control hose C of c...

Page 142: ...control hose throttle cable high pressure fuel line joint Operation with an incorrectly routed cable could result in an unsafe riding condition WARNING Do not remove disassemble or adjust the throttle position sensor A throttle link mechanism B and throttle pulley C because they are adjusted or set at the manufacturer Adjustment of these parts could result in poor performance requiring replacement...

Page 143: ... Circ Low Input 10 P0113 Intake Air Temp Circ High Input 11 P0117 Engine Coolant Temp Circ Low Input 12 P0118 Engine Coolant Temp Circ High Input 13 P0122 Throttle Pos Sensor Circ Low Input 14 P0123 Throttle Pos Sensor Circ High Input 15 P0130 O2 Sensor Circ Bank1 Sensor1 Malfunction 16 P0131 O2 Sensor Circ Bank1 Sensor1 low Voltage 17 P0132 O2 Sensor Circ Bank1 Sensor1 High Voltage 18 P0134 O2 Se...

Page 144: ...2 P0508 Idle Air Control Circuit Low 33 P0509 Idle Air Control Circuit Low High 34 P0511 Idle Air Control Circuit Open 35 P0560 System Voltage Malfunction 36 P0562 System Voltage Low Voltage 37 P0563 System Voltage High Voltage 38 P0627 Fuel Pump A Control Circuit Open 39 P0628 Fuel Pump A Control Circuit Low 40 P0629 Fuel Pump A Control Circuit High 41 P0650 Malfunction Indicator Lamp Control Cir...

Page 145: ...d sensor fault tire specification is wrong wheel speed sensor may be broken clearance is too big sensor position is wrong C1DA0 Fault of rear wheel speed sensor sensor replace sensor C1DA1 Physical fault of rear 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 C1DA2 Pe...

Page 146: ...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 C1DF7 Voltage is too high Rectifier fault battery voltage is too high C1E59 Vehicle code is wrong No activation pins errors disconnect 2 and 15 C1E5A ABS switch fault ABS switch fault ABS ...

Page 147: ...Inspection 4 11 Water Pump Housing Disassembly 4 11 Water Pump Housing Assembly 4 11 ImpellerAssembly 4 12 PumpImpeller Inspection 4 12 Radiator 4 13 Radiator and Radiator Fan Removal 4 13 Radiator and Radiator Fan Installation 4 14 Radiator Inspection 4 14 Radiator Cap Inspection 4 14 Radiator FillerNeck Inspection 4 15 Thermostat 4 16 Thermostat Removal 4 16 Thermostat Installation 4 16 Thermost...

Page 148: ...4 2 Exploded view ...

Page 149: ... Water pump draining bolt 7 0 0 70 62in lb 5 Thermostat housing bolt 10 1 0 87in lb 6 Water temp sensor 12 1 2 106in lb 7 Wind plate bolt 5 9 0 60 52in lb L 8 Reservoir mounting bolt 5 9 0 60 52in lb 9 Wind plate 10 Seal ribbon 11 Reservoir 12 Heat insulator 13 Cylinder head cover 14 Thermostat 15 Water pump pe ller 16 Seal G Use grease HG Use high heat grease L Use thread locker R Replace part ...

Page 150: ...4 4 Coolant flow chart 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 Hot Cool ...

Page 151: ...tor fan stops In this way this system controls the engine temperature within narrow limits where the engine operates most effi ciently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant fl o...

Page 152: ...or chemicals for aluminum engines and radiators Green Water 50 Coolant 50 35 C 31 F 1 8L Reservoir F level Including radiator and the Engine Rediator cap Release pressure 112 3 141 7kPa 1 15 1 45kgf cm2 16 3 20 5psi Thermo stat Valve open temp Valve open temp 283MT Full open clearance Full open clearance 283MT 80 84 176 183 70 74 158 165 95 203 8mm 0 31in 85 185 8mm 0 31in ...

Page 153: ...4 Cooling system 4 4 7 Special tool Bearing pressor Oil seal pressor ...

Page 154: ...Refer to the Coolant Change in the Periodic Mainte nance chapter Pressure Testing ŸRemove the reserve tank see Coolant Change in the Periodic Maintenance chapter ŸRemove the radiator cap and install a cooling sys tem pressure tester A on the fi ller neck B NOTE Wet the cap sealing surfaces with water or coolant to prevent pressure leaks ŸBuild up pressure in the system carefully until the pressure...

Page 155: ...a fl ushing compound ŸWarm up the engine and run it at normal operating temperature for about ten minutes ŸStop the engine and drain the cooling system ŸFill the system with fresh water ŸWarm up the engine and drain the system ŸRepeat the previous two steps once more ŸFill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Periodic Maintenance chap...

Page 156: ...eller B Water Pump Housing C Water pump installation ŸWhen installing the water pump impeller bolt shift the transmission into 1st gear and apply the rear brake ŸReplace the O rings A on the water pump hous ing with new ones and apply grease them ŸApply high temperature grease to the lips of the wa ter pump housing oil seal B ŸBe sure that the dowel pin A is in position ŸInstall the water pump hou...

Page 157: ...l Diaphragm C Water Pump Housing Disassembly ŸTake the oil seal A out of the housing B with a hook C ŸPress the mechanical seal A out of the housing with a bearing driver B Special Tool Bearing Driver Set Note Do not damaged the sealant surface Water Pump HousingAssembly Apply high temperature grease A to the new oil seal B Press the oil seal into the housing with a bearing driver so that the seal...

Page 158: ...l 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 hole Pump Impeller Inspection ŸVisually check the impeller A If the surface is corroded or if the blades are damaged replace the impeller see Water Pump Removal ...

Page 159: ...nge in the PeriodicMaintenance chapter Radiator Fan Motor Connector A Disconnect Radiator Hose Clamp Screw B Loosen ŸLoosen Radiator Hose Clamp Screw A ŸRemove Radiator Bolt B ŸPull A the radiator B toward the left noting the baffl e plate C on the cylinder head cover ŸIf necessary remove Radiator Fan Mounting Bolts A Radiator Fan B Warning Do not touch the cooling fin It can cause the fin damaged...

Page 160: ... straighten them ŸIf the air passages of the radiator core are blocked more than 20 byunremovable obstructionsor irrepa rably deformed fi ns replace the radiator with a new one RadiatorCap Inspection ŸRemove Reserve Tank see Coolant Change in the Periodic Maintenance chapter RadiatorCap ŸCheck the condition of the bottom A and top B valve seals and valve spring C If any one of them shows visible d...

Page 161: ...able below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 112 3 141 7kPa 1 15 1 45kgf cm2 16 3 20 5psi If the cap can not hold the specifi ed pressure or if it holds too much pressure replace it with a new one Radiator Filler Neck Inspection ŸRemove the reserve tank see Coolant Change in the Periodic Maintenance chapter ŸRemove the rad...

Page 162: ...ThermostatInstallation ŸInstall the thermostat A in the cylinder head so that the air bleeder hole B is on top ŸInstall a new O ring into the housing and apply grease it ŸTighten Torque Thermostat Hosing Bolts 10N m 1 0kgf m 87in lb Ÿ Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter ThermostatInspection Ÿ Remove the thermostat and inspect the thermo stat valve ...

Page 163: ...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 It must not touch the container either If the measurement is out of the specifi ed range replace the thermostat with a new one Thermostat valve open temp 80 84 C 176 183 F Thermostat valve open temp 283MT 70 74 C 158 165 F ...

Page 164: ...hapter ŸInstall the clamp A as near as possible to the hose end to clear the raised rib of the fi tting This will prevent the hoses from working loose The clamp screws should be positioned cor rectly to prevent the clamps from contacting the other parts Torque Radiator Hose Clamp Screws 2 5N m 0 25kgf m 17in lb HoseInspection Refer to the Radiator Hose Damage and Installation Condition Inspection ...

Page 165: ...l Installation in the Fuel System EFI chapter Coolant Temperature Sensor A CoolantTemperature Sensor Inspection ŸRefer to the Water Temperature Sensor Inspection in the Electrical System chapter 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 A ...

Page 166: ...g chain assembly 5 18 Camshaft Camshaft cap wear 5 19 Camshaft run out 5 19 Cam wear 5 20 Timing chain removal 5 20 Cylinder head 5 21 Cylinder compression measurement 5 21 Cylinder head removal 5 22 Cylinder head installation 5 23 Cylinder head wear 5 24 Valves 5 25 Valve clearance inspection 5 25 Valve clearance adjustment 5 25 Valve removal 5 25 Valve installation 5 25 Valve guide removal 5 26 ...

Page 167: ...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: ...5 3 5 Engine top 5 Exploded view ...

Page 169: ...ts N m kgf m ft lb Remark 1 Cable clamp bolt 10 1 0 7 2645 2 Cylinder head cover bolt 10 1 0 7 2645 3 Camshaft cover bolt 12 1 2 8 851 S Cylinder head bolt M10 New 54 55 40 MO S 4 Cylinder head bolt M10 old 49 50 36 MO S 5 Cylinder head bolt M6 12 1 2 8 851 S 6 Intake pipe bolt 12 1 2 8 851 7 Chain conductor bolt 20 2 0 15 L 8 Chain conductor bolt 283MT 10 1 0 7 2645 9 Tensionerbolt 28 2 9 21 9 Sp...

Page 170: ...5 5 5 Engine top 5 Exploded view ...

Page 171: ...e grease in a weight ratio 10 1 R Replacement Parts S Follow the specifi ed tightening sequence Exploded view Torque No Tighten parts N m kgf m ft lb Remark 1 Cylinder body bolt M8 27 5 2 8 20 MO S 2 Cylinder body nut M10 49 5 0 36 MO S 3 Cylinder head bolt M6 12 1 2 8 851 S 4 Exhaust pipe mounting nut 17 1 7 12 5 Muffler body mounting 20 2 0 15 6 Muffler body mounting bolt 20 2 0 15 ...

Page 172: ...der head flatness 0 05mm 0 002in Valve Valve clearance Exhaust 0 20 0 26mm 0 0078 0 0102in Exhaust 283MT 0 22 0 28mm 0 0087 0 0110in Intake 0 08 0 13mm 0 0031 0 0051in Valve rod straightness 0 01mm 0 0004in 0 05mm 0 002in Valve rod diameter Exhaust 4 455 4 470mm 0 1754 0 1760in 4 44mm 0 175in Intake 4 475 4 490mm 0 1762 0 1768in 4 46mm 0 176in Valve conducting pipe inner diameter Exhaust 4 500 4 5...

Page 173: ...nce 1 st air ring 0 02 0 0 6m m 0 0 00 8 0 0 02 4i n 0 16mm 0 0063in 1 st air ring 283MT 0 03 0 0 7m m 0 0 01 2 0 0 02 8i n 0 16mm 0 0063in 2 nd air ring 0 02 0 0 6m m 0 0 00 8 0 0 02 4i n 0 16mm 0 0063in Piston groove wideness 1 st air ring 1 01 1 0 3m m 0 03 98 0 0 40 6in 1 11mm 0 044in 1 st air ring 283MT 0 92 0 9 4m m 0 0 36 2 0 0 37 0i n 1 02mm 0 040in 2 nd air ring 1 01 1 03 mm 0 039 8 0 0 4...

Page 174: ...5 9 5 Engine top 5 Special tool and sealant ...

Page 175: ...5 10 CFMOTO Special tool and sealant Pressure gauge adapter Piston pin puller Valve seat knife bracket Piston pin puller seat Valve conductor axle Silicon sealant glue Valve conducting pipe knife ...

Page 176: ...able Holder F with Bolt G Cylinder Head Cover Bolts H Cylinder Head Cover I CylinderHead CoverInstallation Replace the head cover gasket A with a new one Apply silicone sealant B to the cylinder head as shown Install gaskets of spark plug hole C Instal Washers A Cylinder Head Cover Bolts B Install the washers with metal side C faces upward Tighten bolt of cylinder head cover Torque Cylinder Head C...

Page 177: ...e plate A o Put the insulators B under the baffl e plate and the washers C on the baffl e plate o Apply a non permanent locking agent to the baffl e plate bolts and tighten them Torque Baffl e Plate Bolts 6 N ｍ Cylinder Head Cover ...

Page 178: ...lts are loosened the tensioner must be removed and reset as described in Camshaft Chain Tensioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves Camshaft Chain Tensioner Remove Cap Bolt A Washer B Spring C Camshaft Chain Tensioner Installation Release the stopper A and push the push rod B into the tension...

Page 179: ...nkshaft clockwise for 2 rounds to let the tensioner getting tight And check the cam timing again 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: ...er Head Cover see Cylinder Head Cover Removal Position the crankshaft as follows o Remove the upper A and lower B caps on the clutch cover right side cover o Using a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the 2 T mark line A on the timing rotor is aligned with the notch B in the edge of the upper hole C in the clutch cover Remove Camshaft Chain Tensioner see Cam...

Page 181: ... oil solution to all cams A journals B and thrust blocks C with Į marks If a new camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces Note The exhaust camshaft has a EX mark D and the inlet camshaft has a 2 412 IN mark E Be careful not to mix up these shafts Camshaft Timing Chain ...

Page 182: ...ng rotor is aligned with the notch B in the edge of the upper hole C in the clutch cover If the clutch cover is removed perform the next procedure oUsing a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the 1 T mark line A on the timing rotor is aligned with the wating surface B of the crankcase halves The timing marks must be aligned with the cylinder head upper surfac...

Page 183: ...Cap Bolts 1 12 12N ｍ Installation Camshaft Chain Tensioner see Camshaft Chain Tensioner Installation Cylinder Head Cover see Cylinder Head Cover Installation Camshaft and SprocketAssembly o The inlet and exhaust sprockets are identical Install the sprockets so that the marked IN and EX side faces to the right side Intake cam position hole A Exhaust cam position hole B Apply a non permanent locking...

Page 184: ... out Remove the camshaft see Camshaft Removal If the runout exceeds the service limit replace the shaft Camshaft Timing chain Measure camshaft journal diameter Diameter of Camshaft Journal Standard 23 950 23 972mm Service Limit 23 920mm If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again If the clearance still remains ...

Page 185: ...A of each cam with a micrometer If the cams are worn down past the service limit replace the camshaft Camhight Exhaust 34 743 34 857mm Exhaust 283MT 35 843 35 957mm Intake 35 743 35 857mm Intake 283MT 36 543 36 657mm Service limit Exhaust 34 64mm Exhaust 283MT 35 74mm Intake 35 64mm Intake 283MT 36 44mm Timing chain removal Saperate the crankcase see Crankcase Splitting in the Crankshaft Transmiss...

Page 186: ...Periodic Maintenance chapter Owner s Tool Spark Plug Wrench 16mm Attach the compression gauge A and adapter B firmly into the spark plug hole Using the starter motor turn the engine over with the throttle fully open until the compres sion gauge stops rising the compression is the highest reading obtainable Special tools Compression Gauge 20kgf cm2 Compression gauge screw M10x1 0 Cylinder pressure ...

Page 187: ... nut C Remove the M10 bolts D Cylinder head Question Diagnose Solution Too much carbon on piston and conbuxtionroom Clean the carbon and replace the damaged pars ifned Cylinder pressure too 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 Valve clearance not right Adjust the valve clear...

Page 188: ... gasket A and dowel pins B Apply molybdenum disulfide oil solution A to both sides of washers and the threads of bolts and nut M10 Cylinder Head Bolts B M10 Cylinder Nut C M8 Cylinder Bolt D Follow the order to tight up the bolts and nuts 1 8 Torque Cylinder head bolt M10 First 25N m Final Used Cylinder Head Bolts 49 N m New Cylinder Head Bolts 54 N m Cylinder Nut M10 49 N m Cylinder body M8 27 5 ...

Page 189: ...s see appropriate hapters CylinderHead Wearing Clean the cylinder head Lay a straightedge across the lower surface of the cylinder head at several positions Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard 0 05mm If the cylinder head is warped more than the service limit replace it If the cylinder head is warped less than the service ...

Page 190: ...stalled in their original positions Using the valve spring compressor assembly removethevalve Special Tools Valve Spring Compressor Assem bly A Valve Spring Compressor Adapter B ValveInstallation Replace the oil seal with a new one Apply engine oil to the oil seal lip Apply a thin coat of molybdenum disulfi de grease to the valve stem before valve installation Install the springs so that the close...

Page 191: ...inder head in oil and heat the oil Special Tool Valve Guide Arbor Φ 4 5 ValveGuideInstallation Apply engine oil to the valve guide outer surface before installation Heat the area around the valve guide hole to about 120 150 C Drive the valve guide in from the top of the head using the valve guide arbor The fl ange stops the guide from going in too far Special Tool Valve Guide Arbor φ 4 5 Wait unti...

Page 192: ...nsert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface Move the stem back and forth C to measure valve valveguideclearance Repeat the measurement in a direction at a right angle to the first NOTE The reading is not actual valve valve guide clearance because the measuring point is above the guide Valve ...

Page 193: ...2 7mm Exhaust 283MT 27 6 27 7mm Intake 26 7 26 8mm Intake 283MT 32 6 32 7mm oMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Like F is OK If too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Exhaust 0 5 1 0 mm Intake 0 5 1 0 mm ValveSeatRepair Repair the valve seat w...

Page 194: ...re the ball A and spring B are in order like photo in upper crankcase oil line 283MT no steel ball and spring Cylinderinstallation NOTE If a new cylinder is used use new piston ring Install the dowel pins A and new cylinder gasket B The piston ring openings must be positioned as shown in the fi gure The openings of the oil ring steel rails must be about 30 40 degree of angle from the opening of th...

Page 195: ...rt the piston rings with your thumbs Piston Removal Remove the cylinder see Cylinder Removal Place a clean cloth under the pistons and remove the piston pin snap ring A from the outside of each piston Remove the piston pins Special tool Piston pin puller A Bolt B Piston C Piston Pin Puller Adapter D Remove pistons Carefully spread the ring opening with your thumbs and then push up on the opposite ...

Page 196: ... use new piston ring Install the piston with its marking hollow facing forward Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole Install piston pin Use same way to install the other piston pin ring oApply molybdenum disulfi de oil solution to the piston pins and piston journals When installing the piston p...

Page 197: ... 000mm 83 032mm Service limit 68 50mm Service limit 283MT 83 1mm Piston wear Measure the outside diameter A of each piston 10mm B up from the bottom of the piston at a right angle to the direction of the piston pin If themeasurement is under service limit replace the piston Piston diameter Standard 68 366mm 68 384mm Standard 283MT 82 988mm 82 970mm Service limit 68 24mm Service limit 283MT 82 83mm...

Page 198: ...n Ring Groove Clearance Standard 0 02mm 0 06mm Standard 283MT 0 03mm 0 07mm Service limit 0 16mm Service limit 283MT 0 16mm Secondary Piston Ring Groove Clearance Standard 0 02mm 0 06mm Service limit 0 16mm Piston Ring Groove Width Measure the piston ring groove width Use a vernier caliper at several points around thevpiston Top Piston Ring Groove Width A Standard 1 01mm 1 03mm Standard 283MT 0 92...

Page 199: ...Standard 0 97mm 0 99mm Service limit 0 90mm If any of the measurements is less than the service limit on either of the rings replace all the rings NOTE When using new rings in a used piston check for uneven groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Cylinder Piston Second Piston Ring Groove Width B Standard 1 01mm 1 03mm Service limit 1 11mm I...

Page 200: ...e all the rings 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 Measure the gap B between the ends of the ring with a thickness gauge Top Piston ring cut clearance Standard 0 15mm 0 30mm Standard 283MT 0 25mm 0 40mm Service limit 0 60mm S...

Page 201: ... 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 ...

Page 202: ...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 Clutch Housing Finger Inspection 6 17 Clutch Housing Spline Inspection 6 17 ...

Page 203: ...6 2 CFMOTO Exploded view ...

Page 204: ...al surface grease SS Apply Silicone sealant Exploded view Torque No Tighten parts N m kgf m ft lb Remark 1 Timing checking cap Hand tight 2 CPS checking cap 25 2 5 18 Hand tight 3 Oil cap Hand tight 4 Right side cover bolt 12 1 2 8 851 5 Clutch spring bolt 10 1 0 7 2645 6 Clutch nut 132 13 5 98 L R 7 Oil pump sprocket 12 1 2 8 851 L Lh 8 Clutch lever tighten 7 8 0 80 5 7615 S 9 Oil pump chain 10 1...

Page 205: ... Clutch lever clearance 2 3mm 0 08 0 12in Clutch Disc thickness Disc wearing Steel disc wearing Spring free length 2 7 2 9mm 0 106 0 114in 0 15mm 0 006in or less 0 15mm 0 006in or less 33 6mm 1 32in 2 6mm 0 102in 0 3mm 0 012in 0 3mm 0 012in 32 6mm 1 28in ...

Page 206: ...6 Clutch 6 5 6 Clutch holder Sealant Special tool and sealant ...

Page 207: ... 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 Turn the release lever A toward the rear as shown and remove the clutch cover B About 90 degree C Clutch Cover ...

Page 208: ...g 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 Tighten the clutch cover mounting bolts Torque Clutch Cover Mounting Bolts 1 2 N m Clutch Cover ...

Page 209: ...erature grease to the oil seal lips on the upper ridge of the clutch cover Apply engine oil to the needle bearings in the hole of the clutch cover Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft Install the washer B and spring C Insert the release shaft straight into the upper hole hole of theclutch cover CAUTION When inserting the release shaft be careful no...

Page 210: ...6 Clutch 6 9 6 Clutch Cover Disassembly Remove Oil Seal A Needle Bearings B Remove the oil level gauge A Clutch Cover ...

Page 211: ...earings 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 Apply grease to the rubber of the oil gauge A and press B it so that the ring C face outside Clutch Cover ...

Page 212: ...Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with thrust bearing and pusher C Remove Friction Plates Steel Plates Clutch Hub Nut A Holding the clutch hub B remove the nut and washer Special Tool Clutch Holder C Remove Clutch Hub Spacer Shaft sleeve washer Clutch ...

Page 213: ...lowing as a set Clutch Housing D Oil Pump Chain E Oil Pump Sprocket F Unscrew the bolts A and remove the oil pump chain guide B Clutch Installation Apply a non permanent locking agent to the oil pump chain guide bolts and tighten them Torque Oil Pump Chain Guide Bolts 1 0 N m Put the oil pump chain A on the clutch hous ing gear B and the oil pump sprocket C Clutch ...

Page 214: ...A with Chain B and Sprocket C Align E the hole on the oil pump sprocket with the oil pump shaft Apply engine oil on the sleeve D and insert to Clutch Housing A NOTE Insert the sleeve into the clutch housing noting its direction as shown Sleeve A Oil Holes B Long Distance C Short Distance D Clutch Housing E Clutch ...

Page 215: ...Washer C Elastic washer D Nut E oInstall the washer so that the OUTSIDE mark A faces outward Clutch oReplace the clutch hub nut with a new one and apply screw fastening grease oHolding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder Torque Clutch Hub Nut 132 Nm ...

Page 216: ...and second steel plate A its thickness is 2 mm The others are 2 5 mm oInstall the last friction plate A fitting the tangs in the grooves in the housing as shown Apply molybdenum disulfi de grease to the pusher ends A and install it in the clutch spring plate B oApply engine oil to the bearing C Install the clutch spring plate and springs D and tighten the clutch spring bolts E Torque Clutch Spring...

Page 217: ...nspection Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 15 mm or less Service Limit 0 3 mm Clutch Clutch ...

Page 218: ... are groove cuts where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged Clutch Housing Spline Inspection Visually inspect where the teeth A on the steel plates wear against the clutch hub splines B If there are notches worn into the splines replace the clutch hub Also replace the steel plates if their teeth are damaged Clutch ...

Page 219: ...er 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 Oil Pressure Relief Valve Inspection 7 13 Oil Pump 7 14 Oil Pump Removal 7 14 Oil Pump Installation 7 15 Oil Pressure Measurement 7 16 Oil Pressure Switch 7 17 Oil Pressure Switch Removal 7 17 Oil Pressure S...

Page 220: ...7 2 CFMOTO Exploded view ...

Page 221: ...1 Oil draining bolt 30 3 0 22 2 Oil strainer plate bolt 10 1 0 7 2645 L 3 Oil filter 17 1 75 13 EO R 4 Oil filter mounting bolt 25 2 5 18 L 5 Oil pan bolt 12 1 2 8 851 6 Oil pipe I plate bolt 8 0 8 5 9285 L 7 Oil pressure limit valve 15 1 5 11 L 8 Oil pressure warning switch 15 1 5 11 Tighten by hand 9 Oil pump covering bolt 12 1 2 8 851 L 10 Oil pump chain sprocket 12 1 2 8 851 L Lh 11 Main oil l...

Page 222: ...7 4 CFMOTO Engine Oil Flow Chart ...

Page 223: ...7 Engine Lubrication system 7 5 7 Engine Oil Flow Chart ...

Page 224: ...iscosity Capacity Lever ELF 10W 40 SJJASO MA2 10W 40 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 Between upper and lower line Oil pressure 216 294kPa 2 2 3 0kgf cm2 31 43 psi at 4000 rpm 90 194 F ...

Page 225: ...7 Engine Lubrication system 7 7 7 Special Tools and Sealant Oil Pressure Gauge 10kgf cm2 Oil Filter Wrench Oil Pressure Gauge Adapter PT3 8 Silicone Sealant ...

Page 226: ... has just been used wait several minutes for all the oil to drain down o If the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the o...

Page 227: ...me type and make of oil that is already in the engine NOTE o If the engine oil type and make are unknown use any brand of the specifi ed oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine OilChange Refer to the Engine Oil Change in the Periodic Maintenance chapter Oil Filter Replacement Refer to the...

Page 228: ...End chapter Muffler body see Muffler Body Removal in the Engine Top End chapter Oil Pan Bolts A Oil Pan B Gasket C Damper D Remove the following from the oil pan as necessary Filter Plate Bolts A Filter Plate B Filter C Remove the following from the lower crankcase half as necessary Oil Screen A Oil Pipe Plate Bolt B Oil Pipe Plate C Oil Pipes D Oil Pressure Relief Valve E ...

Page 229: ... Plate Bolt E 8N m If the oil pressure relief valve F was removed install it oApply a non permanent locking agent to the threads G of the oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15N m CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil passage Apply grease to the O ring A on the oil screen B and install it on the lower c...

Page 230: ...FMOTO 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 ...

Page 231: ...y may change the valve performance If any rough spots are found during above inspection wash the valve clean with a high fl ash point solvent and blow out any foreign particles that may be in the valve with com pressed air WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highl...

Page 232: ...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 Pin B Oil Pump Body C Remove Oil Pump Shaft C with Inner Rotor A and Pin for Feed Pump Outer Rotor B for Feed Pump ...

Page 233: ... for Feed Pump Inner Rotor C for Feed Pump Oil Pump Shaft D and Pin E Dowel Pin F Oil Pump Body G Pin H and Inner Rotor I for Scavenge Pump Outer Rotor J for Scavenge Pump Oil Pump Cover K NOTE o The scavenge pump rotors are wider than the feed pump rotors Apply a non permanent locking agent to the oil pump cover bolts and tighten them Torque Oil Pump Cover Bolts 12N m ...

Page 234: ...e If the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard At 4000r min rpm Oil temp 90 C 194 F 216 294kPa 2 2 3 0kgf cm2 31 43psi Stop the engine Remove the oil pressure gauge and adapter WARNING Take care against bu...

Page 235: ...ine Oil Change in the Periodic Maintenance chapter Switch Cover A Switch Terminal Bolt B Oil Pressure Switch C Oil Pressure Switch Installation Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Silicone Sealant Torque Oil Pressure Switch 15Nm Tighten the terminal bolt securely ...

Page 236: ...8 Engine removal and installation 8 8 1 Contents Exploded View 8 2 Engine removal installation 8 4 Engine removal 8 4 Engine installation 8 7 ...

Page 237: ...8 2 CFMOTO Exploded view ...

Page 238: ... 3 No Tighten part Torque Remark N m kgf m ft lb 1 Engine rear mounting nut 44 4 5 32 S 2 Engine front mounting bolt 44 4 5 32 S 3 Engine bracket bolt 25 2 5 18 S 4 Engine bracket 5 Engine mounting sleeve S Follow the special tighten order ...

Page 239: ...section in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Frame Covers see Frame Cover Removal in the Frame chapter Radiator and Hoses see Radiator and Radiator Fan Removal in the Cooling System chapter ŸUnscrew the lower fairing bracket bolts both sides B and remove the brackets both sides c ŸDisconnect the oil pressure switch terminal D D an g er Hold the front break l...

Page 240: ...EFI chapter Air Filter Housing see Air Filter Housing Removal in the Fuel System EFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System EFI chapter Clutch Cable see Clutch Cable Removal in the Clutch chapter ŸRemove Stick Coils A Baffl e Plate B ŸRemove or Disconnect Coolant Temperature Sensor Lead Connector A Starter Motor Cable B Engine Ground Cable Terminal Bolt C Alte...

Page 241: ... Connector B Neutral Switch Lead Terminal C Ÿ Remove the bracket D and the engine sprocket E see Engine Sprocket Removal in the Final Drive chapter Ÿ Remove Horn Leads A Disconnect Horn Bolt B Horn C Ÿ Support the engine with a stand or jack Put a wooden board K on the suitable stand Ÿ Remove the engine mounting bolts J Ÿ Remove the engine mounting bracket bolts both sides L Ÿ and remove the brack...

Page 242: ...5kgf m 32ft lb ŸEighthly tighten the left engine mounting bracket bolts Torque Engine Mounting Bracket Bolts 25N m 2 5kgf m 18ft lb ŸLastly tighten the left front engine mounting bolt Torque Front Engine Mounting Bolt 44N m 4 5kgf m 32ft lb ŸInstall the engine sprocket see Engine Sprocket In stallation in the Final Drive chapter ŸRun the leads cables and hoses correctly See the leads cables and ho...

Page 243: ...ring Insert Crankpin Wear 9 23 Crankshaft Side Clearance 9 24 Crankshaft Runout 9 25 Crankshaft Main Bearing Insert Journal Wear 9 25 Balancer 9 27 Balancer Removal 9 27 Balancer Installation 9 27 Insert Journal Clearance 9 27 Transmission 9 29 Shift Pedal Removal 9 29 Shift Pedal Installation 9 29 Shift Mechanism Removal 9 29 Shift Mechanism Installation 9 30 Shift Mechanism Inspection 9 31 Trans...

Page 244: ...9 2 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: ...9 3 9 Crankshaft Transmission 9 Exploded view ...

Page 246: ...Apply silicone sealant Torque No Tighten parts N m kgf m ft lb Remark 1 Connecting rod nut See test MO 2 CPS disc 40 4 1 30 3 Oil separator plate bolt 10 1 0 7 2645 L 4 Oil separator bolt 7 0 7 5 0935 L 5 Shift spring locking pin 29 2 9 22 L 6 Oil pipe bolt 10 1 0 7 2645 L 7 Crankcase bolt 44 4 5 32 MO S 8 Crankcase bolt M9 L 83mm 44 4 5 32 MO S 9 Crankcase bolt M8 L 73mm 35 3 6 26 MO S 10 Crankca...

Page 247: ...9 5 9 Crankshaft Transmission 9 Exploded view ...

Page 248: ...1 R Replacement Parts Torque No Tighten part N m kgf m ft lb Remark 1 Locking rocker arm screw 12 1 2 8 851 L 2 Shifting room cover bolt 20 2 0 15 L 3 Locking gear bolt 12 1 2 8 851 L 4 Shifting drum bearing 5 0 50 3 5905 L 5 Shifting fork plate 10 1 0 7 2645 6 Neutral sensor screw 5 0 50 3 5905 L 7 Neutral sensor 15 1 5 11 8 Shifting axel cover 12 1 2 8 851 9 Shifting axel cover bolt 5 0 50 3 590...

Page 249: ... hole diameter 41 000 41 016mm Mark Yellow 41 000 41 008mm Green 41 009 41 016mm Main bearing thickness Mark Brown 1 496 1 500mm Black 1 500 1 504mm Blue 1 504 1 508mm Crankcase main hole Main joint Main bearing Crankcase main hole mart Crankcase main joint diameter Main bearing color Yellow 1 Brown Yellow 2 Green 1 Black Green 2 Blue Balance bearing shaft clearance 0 025 0 04mm 0 07mm Balance bea...

Page 250: ...494mm Black 1 494 1 498mm Blue 1 498 1 502mm Balance hole shaft diameter Bearing fitness Balance hole Shaft diameter Bearing Yellow 2 Brown Yellow 1 Black Green 2 Green 1 Blue Transmission system Shift fork thickness 5 9 6 0mm 5 8mm Fork groove wideness 6 05 6 15mm 6 25mm Shift fork shaft diameter 6 90 7 0mm 6 8mm Shift drum groove wideness 7 1 7 17mm 7 3mm CFMOTO ...

Page 251: ...rk Brown 1 490 1 494mm Black 1 494 1 498mm Blue 1 498 1 502mm Balance hole shaft diameter Bearing fitness Balance hole Shaft diameter Bearing Yellow 2 Brown Yellow 1 Black Green 2 Green 1 Blue Transmission system Shift fork thickness 5 9 6 0mm 5 8mm Fork groove wideness 6 05 6 15mm 6 25mm Shift fork shaft diameter 6 90 7 0mm 6 8mm Shift drum groove wideness 7 1 7 17mm 7 3mm ...

Page 252: ...ch chapter Transmission Assy see Transmission Assy Removal Alternator Rotor see Alternator Rotor Re moval in the Electrical System chapter Remove the spring B and ball A in upper body 283MT has no spring and balls Remove the upper crankcase bolts A and the washers Remove the oil pan relief valve oil screen and oil pipes see Oil Pan Removal in the Engine Lubrication System chapter Remove the lower ...

Page 253: ...s to be removed follow the next procedure oUnscrew the bolts A and remove the oil pipe B oPrepare a 5 mm rod A and insert it to the hole of the upper crankcase half o Remove the oil pipe B tapping C the rod as shown If the breather plate A is to be removed follow the next procedure oRemove the oil pipe see above oCut the gasket around the plate B oRemove Breather Plate Bolts C Breather Plate with ...

Page 254: ...on the upper crankcase half was removed install it as shown Apply a non permanent locking agent to the oil plate bolts and torque them Torque Oil Plate Bolts B 10N m Press and insert A the new needle bearing B for the shift drum until it is bottomed Special Tool Bearing Driver Set Press and insert C the new needle bearing D for the shift shaft so that the bearing surface is flush with the end of t...

Page 255: ...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 fittling Install the oil pipe A so that its flange B touches to the surface C of the upper crankcase half Apply grease to the O ring D on the oil pipe ...

Page 256: ...he upper crankcase half o Align A the timing mark on the balancer gear B with the timing mark on the balancer drive gear C of the crankshaft Be sure to hang the camshaft chain A on the crankshaft Be sure that the dowel pins A are in position Set the bearing groove A on the positioning ring B as shown ...

Page 257: ...et 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 oDo not apply liquid gasket to the oil passage B ...

Page 258: ...asket to the mating surface of the lower crankcase half is applied oMoreover fi t the case and tighten the case bolts just after fi nishing the application of the liquid gasket Apply molybdenum disulfide oil solution to both sides A of the M9 bolts washers and the threads B of the M9 bolts Apply molybdenum disulfi de oil solution to fl ange A and the threads B of the M8 bolts which is tightening o...

Page 259: ...s 5 6 L 113 mm 4 45 in with washers Torque Crankcase Bolts M9 44 N m 4 5 kgf m 32 ft lb oTighten the M8 bolts 7 10 Torque Crankcase Bolts M8 35 N m 3 6 kgf m 26 ft lb oTighten the M8 bolts A Do not apply molybdenum oil solution Torque Crankcase Bolts M8 27 5 N m 2 8 kgf m 20 ft lb oTighten the M7 bolts B Torque Crankcase Bolts M6 20 N m 2 0 kgf m 15 ft lb oTighten the upper crankcase bolts A Torqu...

Page 260: ...d 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 Apply molybdenum disulfi de oil solution to the crankshaft main bearing inserts Align A the timing mark on the balancer gear B with the timing mark on the balancer drive gear C of the crankshaft Install the crankshaft with the ca...

Page 261: ...p against the crankpins Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Always use new connecting rod bolts and nuts Match Mark A Connecting Rod B Diameter Mark C Weight Mark D Connecting Rod Big End Cap E CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check...

Page 262: ...ot apply any grease or oil D to the cap inside cap insert outside connecting rod inner hole upper sur face and upper bearing surface B oAlign the bearing lip E to upper groove on connect ing rod CAUTION Wrong application of oil and grease could cause bearing damage oWhen installing the inserts A be careful not to damage the insert surface with the edge of the con necting rod B or the cap C oOne wa...

Page 263: ...gle way to tight up the connecting rod nut this can make the torque tight and accurate First tighten the 2 nuts of a connecting rod alter nately to 40 N m Loosen the 2 nuts completely Tighten them alternatly to 29 N m oAfter the connecting bolts are tightened to 29 N m the connecting rod can turn freely Turn the connecting rod nuts clockwise 100 degree The final torque should be between 65Nmand 90...

Page 264: ...e surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the connecting rod must be replaced Connecting Rod Bend Service Limit 0 2 mm Connecting Rod Twist With the big end arbor A still on V block C Hold the connecting rod horizontally Measure the arbor B hight different to see the twist Connecting Rod Twist limit ...

Page 265: ... Crankpin Diameter Standards 37 984 38 00mm Service Limit 37 97mm If any crankpin has worn past the service limit re place the crankshaft with a new one If the measured crankpin diameters are not less thanthe servicelimit butdonotcoincide withthe original diameter markingson the crankshaft make new marks on it Crankpin Diameter Marks 2 37 984 37 992mm 1 37 993 38 000mm Measure the connecting rod b...

Page 266: ... diameter mark Size Color B Crankshaft Side Clearance Insert a thickness gauge A between the crank case main bearing and the crank web at the No 2 journal B to determine clearance Crankshaft Side Clearance Standard 0 10 0 30mm Service Limit 0 40mm If the clearance exceeds the service limit replace the crankcase halves as a set Big end hole Connecting joint Bearing Big end hole Connecting joint Bea...

Page 267: ...andards 37 984 38 00mm Service limit 37 97mm If the main bearing journal has worn past the service limit replace the crankshaft with a new one If the measured main bearing journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Main Bearing Journal Diameter Marks 2 37 984 37 992mm 1 37 993 38 000mm Measure...

Page 268: ...9 26 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 ...

Page 269: ...eck Balance bearing wear ing Use micrometer to measure the diameter of balance shaft neck A Balance shaft neck standard 27 987 28 000mm Service limit 27 96mm If balance bearing is out of service limit Replace the balance shaft Note Balance shaft without oil hole cannot mixed with the balance shaft with oil hole If balance shaft diameter is out of service limit but balance shaft diameter sign is di...

Page 270: ... 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 Size Color B Balancer Balance shaft hole Balance shaft Balance bearing Balance shaft hole sign Balance shaft sign Balance shaft bearing color Yellow 2 Brown Yellow 1 Black Green 2 Green 1 Blue ...

Page 271: ...securely External Shift Mechanism Removal Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Shift Pedal see Shift Pedal Removal Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter Neutral Switch Lead Connector Disconnect Shift Shaft Cover Bolts A Shift Shaft Cover Screw B Shift Shaft Cover C Remove the shift shaft assembly A Remove Clutch see Clut...

Page 272: ... up F the hook portion as shown Apply a non permanent locking agent to the gear positioning lever bolt and tighten it Torque Gear Positioning Lever Bolt 12N m Install the shift shaft assembly oApply A molybdenum disulfi de oil solution to the rubbing surface between the lever B and pawl C and move them two or three times up and down to lubricate them oBe sure that the washer A is on the shaft oBe ...

Page 273: ...all the shift shaft cover o Be sure that the dowel pins A are in position oInstall the new gasket B Apply a non permanent locking agent to the shift shaft cover screw A oDo not apply a non permanent locking agent to the shift shaft cover bolts B C D E oInstall the auxilary ground wire F Tighten the cover screw lastly Torque Shift Shaft Cover Bolts 12N m Shift Shaft Cover Screw 5N m External Shift ...

Page 274: ...ositioning lever A and its spring for breaks or distortion If the lever or spring are damaged in any way replace them Visually inspect the shift drum cam B If they are badly worn or if they show any damage replace it TransmissionAssy Removal Remove Shift Shaft Assembly see External Shift Mecha nism Removal Neutral Switch Holder Bolt A Neutral Switch Holder B and Pin Shift Drum Holder C and Pin Rem...

Page 275: ...t B Shift Rod Plate C Gear Positioning Lever Bolt D Gear Positioning Lever E with Spring Washer and Spacer Pull the transmission assy A out of the crankcase Transmission Assy Disassembly Remove the transmission assy see Transmis sion Assy Removal Remove the following from the transmission case A Shift Rods B Shift Forks C Drive Shaft D Output Shaft E Remove Shift Drum Cam Bolt A Shift Drum B and P...

Page 276: ...cam bolt E and tighten it Torque Shift Drum Cam Bolt 10N m Install the Drive Shaft F and output shaft G Install the forks as shown oPosition the one H with shortest ears on the drive shaft and place the pin in the center groove in the shift drum oThe two forks J on the output shaft are identical install the shift rods noting the groove position Install the fork rods K and L Apply molybdenum disulf...

Page 277: ...smission Case Bolts 20N m Install the gear positioning lever see External Shift Mechanism Installation Install the locking gear Cover the threadlocker on the bolt and tight up Locking gear bolt torque 12N m Set the gear positioning lever to the neutral posi tion A Install Pin A Shift Drum Holder B Pin C Gear sensor D Gear sensor screw E oApply the thread locker on screw E and tight up Torque Neutr...

Page 278: ...s 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 Install the collar to the shaft Replace all the removed circlips Install the circlips A so that the opening B is aligned with a spline groove C ...

Page 279: ... holes aligned Install the 6th gear and the bushing onto the drive shaft with their oil holes aligned The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the smallest 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 Install the 3rd 4th gear and the bushings onto the output ...

Page 280: ...ushing 4 4th gear 12 Washer Õ30 5 5th gear 13 Needle bearing 6 6th gear 14 Circlip 7 Ball Bearing 15 Oil seal 8 Bushing 16 Collar 17 Washer 25 Toothed washer 18 Nut 26 Washer Õ28 19 O ring 27 Circlip Õ30 20 Ball bearing 28 Washer Õ25 21 Washer Õ39 22 Positioning ring 23 Washer Õ38 5 24 Bushing ...

Page 281: ... B of the gear grooves If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 5 9 6 0mm Service limit 5 8mm If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15mm Service limit 6 25mm Shift Fork Guide Pin Drum Groove Wear Measure the diameter of each shift fork...

Page 282: ...lace any damaged gears or gears with excessively worn dogs or dog holes Ball and Needle Bearing Replacement Using a press or puller remove the ball bearing and or needle bearings Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing Ball and Needle Bearing Wear Spin A the bearing by hand to check its condition If the bearing is noisy do...

Page 283: ...0 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 Tire Removal 10 13 Tire installation 10 13 Tire Repair 10 15 Hub Bearing 10 16 Hub Bearing Removal 10 16 Hub Bearing Installation 10 16 Hub Bearing Inspection 10 1...

Page 284: ...10 2 CFMOTO Exploded view ...

Page 285: ...rts Torque Remark N m kgf m ft lb 1 Front wheel axel 108 11 0 80 2 Front axel locking screw 34 3 5 25 3 Rear Axel nut 108 11 0 80 G Use grease HG Use high heat grease R Replace the parts WL Use soapy water or special rubber washing liquid ...

Page 286: ...30g 1 06oz 3 50 17 4 50 17 TIR1 0mm 0 04in TIR1 0mm 0 04in TIR0 2mm 0 008in Tire Tire pressure cold Front Rear Tire pattern deepness Front Rear 180kg 397lb 250kPa 2 50kgf cm 2 36 3psi 180kg 397lb 280kPa 2 80kgf cm 2 40 6psi 6 5mm 0 26in 9 0mm 0 35in 1mm 0 04in AT CH DE 1 6mm 0 06 in Upto130km h 80m ph 2mm 0 08in Over130km h 80m ph 3mm 0 12in Tire standard Front Rear Style Size DUNLOP SPORTMAX RADI...

Page 287: ...10 Tire and rim 10 10 5 Special tool Bearing pressing tool Screw driver Jack Jack accesesories Bearing remover ...

Page 288: ...heel off the ground with jack Special Tools Jack Jack Attachmen ŸPull out the axle to the right and drop the front wheel out of the forks Front Wheel Installation The direction of the wheel rotation is shown by an arrow E ŸCheck the wheel rotation mark on the front wheel and install it Warning Do not let the break disc down on the ground or the break disc will be damaged or wrapped Put a piece of ...

Page 289: ...nt fork leg to seat on the front axle NOTE Put a block in front of the front wheel to stop mov ing ŸTighten the axle clamp bolt B ŸTorque Front Axle Clamp Bolt 34N m 3 5kgf m 25ft lb ŸInstall the lower fairing see Lower Fairing Installa tion in the Frame chapter ŸInstall the front brake calipers see Caliper Installa tion in the Brakes chapter ŸCheck the front brake effectiveness see Brake Op erati...

Page 290: ...ove Cotter Pin A Axle Nut B Washer C Axle D with Washer ŸRemove the drive chain A from the rear sprocket toward the left ŸMove the rear wheel back and remove it Rear Wheel Installation ŸApply high temperature grease to the grease seal lips ŸFit the collars A on the both sides of the hub ...

Page 291: ...tighten th nut clockwise B up to next alignment It should be within 30 again and bend the cotter pin on ght nut ŸAdjust the drive chain slack after installation see Drive Chain Slack Inspection in the Periodic Main tenance chapter ŸInstall the rear brake caliper see Caliper Instal lation in the Brakes chapter ŸCheck the rear brake effectiveness see Brake Operation Inspection in the Periodic Mainte...

Page 292: ...in or less Radial TIR0 8mm 0 03in or less Service limit Axial TIR1 0mm 0 04in Radial TIR1 0mm 0 04in Axle Inspection ŸRemove the front and rear axles see Front Rear WheelRemoval ŸVisually inspect the front and rear axle for damages If the axle is damaged or bent replace it ŸPlace the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the ...

Page 293: ...nd the weight goes up replace the weight with the next heavier size If the wheel ro tates and the weight goes down replace the weight with the next lighter size ŸRotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced ŸPermanently install the balance weight Balance Weight Removal ŸInsert a regular tip screwdrivers A B between the rib C and the weight D...

Page 294: ...ht more than 90gram 3 17 oz If the wheel requires an excess balance weight disassemble the wheel to find the reason ŸSlip the balance weight A onto the rib B by push ing or lightly hammering C the clip D Left Side E Right Side F ŸBe sure to install the balance weight Check that the blade A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Left Side E Right Side F ...

Page 295: ...with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges ŸRemove the tire from the rim using a suitable commercially available tire changer NOTE The tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation ŸInspect the rim and tire and replace them if necessary ŸClean the sealing surfaces of the rim and tire and sm...

Page 296: ...ark B the chalk mark made during removal or the yellow paint mark on a new tire ŸInstall the tire bead over the rim fl ange using a suit able commercially available tire changer ŸLubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while infl ating the tire ŸCenter the rim in the tire beads and in...

Page 297: ...ee Balance Adjustment Tire Repair ŸCurrently two types of repair for tubeless tires have come into wide use One type is called a temporary external repair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by permanent internal repai...

Page 298: ...ight until they are bottomed Special Tool Bearing Driver Set B ŸReplace the grease seals with new ones ŸPress in the grease seals A so that the seal surface is fl ush B with the end of the hole Apply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C Hub Bearing Inspection Since the hub bearings are made to extremely close tolerances the clearance can not normally be...

Page 299: ...ication 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 Rear Sprocket Removal 11 10 Rear Sprocket Installation 11 10 Coupling Installation 11 11 Coupling Bearing Removal 11 11 Coupling Bearing Installation 11 11 Coupling Bearing Inspection 11 12 Coupling Bearing Oil Seal 11 12 Coupling Damper Inspect...

Page 300: ...11 2 CFMOTO Exploded view ...

Page 301: ... 2 Rear axel nut 108 11 0 80 3 Chain sprocket nut 59 6 0 44 4 Speed sensor bolt 7 8 0 80 5 7615 L 5 Speed sensor bracket bolt 9 8 1 0 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 R Replace the parts ...

Page 302: ...in Chain looseness Chain wearing 20 pieces in standard Suppliers Style Pcs 30 40mm 1 2 1 6in 317 5 318 2mm 12 50 12 53in RK or DID 520 S01 118 CF400 114 CF650 7 323mm 12 7in Sprocket Rear sprocket wearing 0 4mm 0 016in or less 0 5mm 0 02in Special tool Inner retainer pliers Bearing tools ...

Page 303: ...ter Drive Chain Lubrication ŸReferto theDrive ChainLubrication ConditionInspec tion in the Periodic Maintenance chapter Drive Chain Removal NOTE Since the drive chain is installed through the swingarm the chain cannot be removed other than by cutting it Prepare the new link pin link plate grease seals and tools for rejoining the chain ŸUsing a suitable tool cut the drive chain by removing the link...

Page 304: ...he old drive chain until they are changing the position ŸRemove the old drive chain from the new drive chain ŸApply grease to the link pins A and grease seals B C ŸEngage the drive chain on the rear sprocket ŸInsert the link pins in the drive chain ends ŸInstall the grease seals C ŸInstall the link plate so that the mark D faces out ŸPush the link plate by hand or plier to fix it ŸIn case of greas...

Page 305: ...e pin holder by wrench clockwise until two pins of link come into groove of plate holder a ŸTake off the plate holder a ŸSet the plate holder b A and cutting and riveting pin B as shown ŸTurn the pin holder until riveting pin touches link pin ŸTurn the wrench clockwise until tip of riveting pin hits of link pin ŸRivet it ŸSame work for the other link pin ...

Page 306: ... Link Pin Outside Diameter Standard 5 45 5 55mm Link Plates Outside Width S ta ndar d 1 7 2 5 17 4 5mm 0 67 9 0 687in If the reading exceedsthe specified length cut and rejoin the chain again ŸCheck Movement of the Rollers ŸAdjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter ...

Page 307: ... and washer NOTE When loosening the engine sprocket nut hold the rearbrake on ŸRaise the rear wheel off the ground with stand ŸRemove the axle cotter pin and loosen the rear axle nut ŸLoosen the drive chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter ŸRemove the drive chain from the rear sprocket toward the right ŸPull the engine sprocket A with drive chain B off the outpu...

Page 308: ...chain slack after installing the sprocket see Drive Chain Slack Adjustment in the Periodic Maintenance chapter ŸBend the end of axle cotter pin surely after tighten ing the axle nut see Rear Wheel Installation in the Wheels Tires chapter Rear Sprocket Removal ŸRemove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter ŸRemove the rear sprocket nuts A ŸRemove the rear sprocket B Rear ...

Page 309: ...nstall the collar C Coupling Bearing Removal ŸRemove Coupling Grease Seal Ci r cl i p A Special Tool Inside Circlip Pliers ŸRemove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B Coupling Bearing Installation ŸReplace the bearing with a new one ŸPress in the bearing A until it is bottomed Special Tool Bearing Driver Set B ŸReplace the circlip with a new one Special T...

Page 310: ...ness or binding is found replace the bearing ŸExamine the bearing seal B for tears or leakage If the seal is torn or is leaking replace the bearing NOTE Since the coupling bearing is packed with grease and sealed lubrication is not required Coupling DamperInspection ŸRemove the rear wheel coupling and inspect the rub ber dampers A ŸReplace the damper if it appears damaged or deteriorated Sprocket ...

Page 311: ... ea r th e te eth a s s ho w n a nd r ota te C the re ar w h ee l to m e as u re th e s p ro ck et run ou t w a rp T h e di ffe re nc e be tw e e n the hig he st a n d lo w es t d ial g au ge re ad ing s is th e a m o un t o f run ou t w a rp If the r un ou t e x c e ed s th e se rv ic e l im it rep la c e the rea r s p roc k et R e ar Sp ro ck et W arp S tan d ard 0 4 m m 0 0 16 in o r les s S er...

Page 312: ...er Disassembly 12 13 Rear CaliperAssembly 12 13 Caliper Fluid Seal Damage 12 13 Rear Caliper Dust Boot and Friction Boot Damage 12 13 Caliper Piston and Cylinder Damage 12 14 Rear Caliper Holder Shaft Wear 12 14 Brake Pads 12 15 Front Brake Pad Removal 12 15 Front Brake Pad Installation 12 15 Rear BrakePad Removal 12 15 Rear Brake Pad Installation 12 15 Brake Pad Wear Inspection 12 15 Master Cylin...

Page 313: ... 12 19 Brake Disc Installation 12 19 Brake Disc Wear 12 19 Brake Disc Warp 12 19 BrakeFluid 12 20 Brake Fluid Level Inspection 12 20 Brake Line Bleeding 12 20 Drain out the air in breaking system 12 21 BrakeHose 12 21 Brake Hose Removal Installation 12 22 BrakeHose Inspection 12 22 ...

Page 314: ...12 Breakingsystem 12 3 12 Exploded view Front break ...

Page 315: ...ever holding nut 5 9 0 60 4 342 5 Front breaking disc mounting 27 2 8 20 L 6 Front breaking switch screw 1 0 0 10 0 7515 7 Breaking fluid reservoir screw 1 0 0 10 0 715 8 Front breaking caliper bolt 34 3 5 25 9 Front breaking cylinder 8 8 0 90 6 513 S B Use breaking fluid L Use thread locker R Replace the parts S Follow the special orders T Si Use silicon grease Such as PBC grease ...

Page 316: ...12 Breakingsystem 12 5 12 Exploded view Rear break ...

Page 317: ... 18 3 Breaking pedal bolt 8 8 0 90 6 513 4 Rear breaking disc mounting 27 2 8 20 L 5 Rear caliper mounting bolt 25 2 5 18 6 Rear breaking master cylinder 25 2 5 18 7 Rear breaking push rod locking nut 18 1 8 13 B Use breaking fluid G Use grease L Use thread locker R Replace the part Si Use silicon oil Such as PBC oil ...

Page 318: ...dal adjustment Pedal adjustment 5 point adjustment For driver Cannot adjust Cannot adjust Lower than top about 40mm 1 6in Breaking pad Front Rear 4 0mm 0 16in 5 0mm 0 20in 1mm 0 04in 1mm 0 04in Breaking pad thickness Front Rear Runout 4 3 4 7mm 0 17 0 19in 4 8 5 2mm 0 19 0 20in 0 15mm 0 006in 4 0mm 0 16in 4 5mm 0 18in 0 3mm 0 01in Breaking fluid DOT4 ...

Page 319: ...12 8 CFMOTO Special tool Retainer plier Hand tester Jack Jack accessories ...

Page 320: ...the pedal position but always adjust it when the push rod lock nut has been loosened Brake Pedal Position Adjustment ŸRemove Frame Cover see Frame Cover Removal in the Frame chapter Bolts F Right footrest brecket G ŸLoosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position If the length C shouws 55 1mm 2 76 0 04in The rear breaking pedal position should b...

Page 321: ...ht Switch Spring C Return Spring D ŸRemove the mounting bolt E and take out the brake pedal Brake Pedal Installation ŸApply grease to the pivot shaft A and install the washer B ŸInstall Brake Pedal C Washer D Brake Pedal Bolt E Torque Brake Pedal Bolt 8 8N m 0 90kgf m 78in lb ŸInstall the spring F ŸReplace to new cottor pin ŸInsert the cottor pin G and bend up like H points ...

Page 322: ...n dard torque Torque Footpeg Rest Bolts 30N m 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 ŸCheck the brake pedal position see Brake Pedal Position Inspection ...

Page 323: ...caliper from rear breaking disc D ŸInstall rear caliper and breaking hose lower side Replase the washer on the hose each side into new ŸTighten torque Rear Caliper Mounting Bolts Front 34N m 3 5kgf m 25ft lb Rear 25N m 2 5kgf m 18ft lb Breaking hose bolt 25N m 2 5kgf m 18ft lb ŸCheck the oil level in breaking fluid reservior ŸDrain out the air of the breaking pipe See air draining chapter ŸInspect...

Page 324: ...ston to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the temperature of the discs or the brake fluid to increase Replace the fluid seal if it exhibits any of the condi tions listed below Brake fluid leakage around the pad Brakes overheat Considerable difference in inner and outer pa...

Page 325: ... does not slide smoothly one pad will wear more than the other pad wear will increase and constant drag on the disc will raise brake and brake fluid temperature ŸCheck to see that the caliper holder shafts are not badlywornor stepped andthatthe rubberfrictionboots are not damaged If the rubber friction boot is damaged replace the rubber friction boot To replace the friction boot re move the pads a...

Page 326: ...he front caliper see Caliper Installation Rear Brake Pad Removal ŸRemove the rear caliper with the hose installed see RearCaliper Removal ŸDraw out the holder shaft pin A and take off the holder shaft B ŸRemove the pad C and D Rear Brake Pad Installation ŸPush the caliper piston in by hand as far as it will go ŸInstall the anti rattle spring in its correct position ŸInstall the pad on the piston s...

Page 327: ...tch C Front Master Cylinder Installation ŸMake sure the mark A to the front when install the front master cylinder ŸTight up the upper tighten bolt B first then the lower one C The tighten place needs several clearance Torque Front Master Cylinder Clamp Bolts 8 8N m 0 90kgf m 78in lb ŸReplace the washers on each side of the hose fitting with new ones ŸTighten the brake hose banjo bolt Torque Brake...

Page 328: ... each side of hose fitting with new ones ŸTighten the following bolts Torque Rear Master Cylinder Mounting bolts 25N m 2 5kgf m 18ft lb Brake Hose BanjoBolt 25N m 2 5kgf m 18ft lb ŸDrain out the air in breaking system See breaking sys tem air draining way ŸCheck the brake for good braking power no brake drag and no fl uid leakage Front Master Cylinder Disassembly ŸRefer to the Master Cylinder Rubb...

Page 329: ...ry cup C and secondary cup D If acup isworn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups If fluid leakage is noted at the brake lever the pis ton assembly should be replaced to renew the cups Rear Master Cylinder K ŸCheck the dust covers E for damage If they are damaged replace them ŸCheck the piston return springs F for any damage If the springs are ...

Page 330: ...e the thickness of each disc A at the point where it has worn the most If the disc has worn past the service limit replace it Measuring Area B Brake Discs Thickness Standard Front 4 3 4 7mm 0 17 0 19i n Rear 4 8 5 2mm 0 19 0 20in Service limit Front 4 0mm 0 16in Rear 4 5mm 0 18in Brake Disc Warp ŸRaise the wheel off the ground with jack see Front Rear Wheel Removal in the Wheels Tires chapter Spec...

Page 331: ...ing power NOTE The procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake ŸRemove the reservoir cap A ŸFill the reservoir with fresh brake fluid to the MAX level line in the reservoir ŸSlowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir Ble...

Page 332: ...for more complete bleeding Front Brake First bleeding the right caliper then repeat the above steps for the left caliper ŸRemove the clear plastic hose ŸInstall the diaphragm and reservoir cap ŸTightentorque Front Brake Reservoir Cap Screws 1 0N m 0 10kgf m 9in lb ŸFollow the procedurebelow to installthe rearbrake fluid reservoir cap correctly First tighten the rear brake fluid reservoir cap B clo...

Page 333: ...oline engine oil or any otherpetroleumdistillatewillcausedeterioration of therubberparts Oil spilled onany part willbe diff cult to washoff completely and willeventually deterioratethe rubber used in thediscbrake 7 Whenhandling thediscpadsor disc be carefulthat nodisc brakef uidor anyoil gets onthem Clean off anyf uidor oilthat inadvertentlygetsonthepadsor discwith a high f ash point solvent Do no...

Page 334: ...allation 13 8 Rear shockabsorber 13 10 Spring PreloadAdjustment 13 10 Rear ShockAbsorber Removal 13 10 Rear Shock Absorber Installation 13 11 Rear ShockAbsorber Inspection 13 11 Swingarm 13 12 Swingarm Removal 13 12 Swingarm Installation 13 12 Swingarm Bearing Removal 13 13 Swingarm Bearing Installation 13 13 Swingarm Bearing Sleeve Inspection 13 14 Swingarm Bearing Lubrication 13 15 ChainGuideIns...

Page 335: ...13 2 CFMOTO Frontfork exploded view ...

Page 336: ...13 Suspension 13 3 13 No Tighten parts Torque Remark N m kgf m ft lb 1 Front wheel axel tighten screw 34 3 5 25 2 Front shockabsorber locking 20 2 0 15 AL 3 Front shockabsorber locking 20 2 0 15 ...

Page 337: ...13 4 CFMOTO Rearswing armexplodedview ...

Page 338: ...13 Suspension 13 5 13 No Tighten parts Torque Remark N m kgf m ft lb 1 Rear shockabsorber bolt 59 6 0 44 2 Rear shockabsorber 59 6 0 44 3 Rear swing arm nut 180 18 0 133 G Use grease R Replace parts ...

Page 339: ...only 400m L 3 m L Total dry 445m L 3m L Shock spring length 300m m Service lim it 295m m Spring and pre load Free length 165m m Continuously adjustable 4m m 5m m Pressure 1MPa No adjustable Recovering dam p Tolerant 4th Clockwise add dam p Counterclowise decrease dam p from level 1 to 7 Front shock absorbe r Rear shock absorbe r ...

Page 340: ...etainer 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 ...

Page 341: ...er tube flush A against the top surface of the stem head B ŸTighten torque Front Fork Clamp Bolt lower 20N m 2 0kgf m 15ft lb Front Fork Top Plug 25N m 2 5kgf m 18ft lb NOTE Tighten the top plug before tightening the upper Fork clamp bolt Tighten the two clamp bolts alternately two times to ensure even tightening torque ŸTighten torque Front Fork Clamp Bolt Upper 20N m 2 0kgf m 15ft lb ŸInstall th...

Page 342: ...Level Gauge Set the oil level gauge stopper B so that the dis tance C from the bottom of the stopper to the lower end of the pipe is the standard oil level distance A correct measurement can not be obtained un less the level gauge pipe is placed in the center of the inner tube Oil Level fully compressed without spring Standard 115 2mm 4 5 0 08in Place the stopper of the level gauge at the top D of...

Page 343: ...the table below Spring Preload Adjustment Rear ShockAbsorber Removal Remove Frame Covers see Frame Cover Removal in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End Chapter Raise the rear wheel off the ground with jack Special Tools Jack Jack Attachment ŸSqueeze the brake lever slowly and hold it with band A Adjuster Position Damping Force Shock Absorber Hardness Load ...

Page 344: ...tall the oil seals to the shock ab sorber ŸTighten torque Rear Shock Absorber Bolt 59N m 6 0kgf m 44ft lb Rear Shock Absorber Nut 59N m 6 0kgf m 44ft lb ŸInstall the removed parts see appropriate chapters Rear Shock Absorber Inspection ŸRemove the rear shock absorber see Rear Shock AbsorberRemoval ŸVisually inspect the following items Smooth Stroke Oil Leakage Crack or Dent If there is any damage ...

Page 345: ...ne Top End chapter Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter ŸRaise the rear wheel off the ground with jack Special Tools Jack Jack Attachment ŸRemove the lower shock absorber nut and bolt A ŸRemove the drive chain see Drive Chain Removal in the Final Drive chapter ŸUnscrew the swingarm pivot shaft nut A ŸPull off the pivot shaft B and remove the swingarm SwingarmInstallation Ÿ...

Page 346: ... Inside Circlip Pliers ŸRemove the ball bearing and needle bearings Special Tool Oil Seal Bearing Remover A SwingarmBearingInstallation ŸReplace the ball and needle bearings A with new ones ŸInstall the ball and needle bearings so that the manufacturer s marks face out Special Tools Bearing Driver Set Stem Bearing Driver 28 B Spacer φ 28 ...

Page 347: ...the needle bearings A and ball bearing installed in the swingarm The rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage If the needle bearing and sleeve B show any sings of abnormal wear discoloration or damage replace them as a set CAUTION Do not remove the bearing fo...

Page 348: ...binding is found replace the bearing ŸExamine the bearing seal B for tears or leakage If the seal is torn or is leaking replace the bearing Swingarm BearingLubrication NOTE Since the bearings are packed with grease and sealed lubrication is not required Chain Guide Inspection ŸRefer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter ...

Page 349: ...ew 14 2 SpecialTools 14 4 Steering bearing removal 14 5 Steering bearing installation 14 6 Steering bearing lubrication 14 7 SteeringStem Warp 14 8 Handlebar 14 9 Handlebar Removal 14 9 Handlebar Installation 14 9 Clutchlever assyinstallation 14 10 ...

Page 350: ...14 2 CFMOTO Exploded view ...

Page 351: ... S 4 Left Switch Housing Screws 3 5 0 36 2 5885 5 Right Switch Housing Screws 3 5 0 36 2 5885 6 Steering Stem Head Bolt 108 11 0 80 7 Steering Stem Nut 20 2 0 15 AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tighten torque G Apply grease L Apply a non permanent locking agent Replacement Parts R Rep la ce pa rts S Follow the specified tightening sequence ...

Page 352: ...14 4 CFMOTO Special tool Steering rod tighten wrench Steering rod bearing remover Bearing pressor Steering bearing removin adapter ...

Page 353: ...in the Suspension chapter ŸBend the claws of the claw washer straighten ŸRemove the steering stem locknut B and claw washer C ŸPushing up the stem base and remove the steering stem nut A with stem cap B Special Tool Steering Stem Nut Wrench C ŸRemove the steering stem D under side ŸRemove the upper stem bearing inner race and bearing ŸTo remove the bearing outer races A pressed into the head pipe ...

Page 354: ...er Set A ŸReplace the bearing inner races and oil seal with new ones ŸApply grease to the oil seal ŸDrive the lower ball bearing inner race applied the grease onto the stem Special Tools Steering Stem Bearing Driver Steering Stem Bearing Driver Adapter ŸApply grease to the lower ball bearing A and in stall it onto the stem ŸApply grease to the upper ball bearing B and inner race C ŸInstall the ste...

Page 355: ...kwise until the claws arealigned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E ŸInstall the stem head ŸInstall the washer and tighten the stem head bolt with specified torque ŸInstall the front forks see Front Fork Installation in the Suspension chapter NOTE Tighten the upper fork clamp bolts fi rst next the stem head bolt last the lower fork clamp bolts Ti...

Page 356: ...ring 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 Replace the stem cap if its oil seal A shows damage ...

Page 357: ...dlebar Weight C ŸRemove Front Brake Master Cylinder A see Front Master Cylinder Removal in the Brakes chapter Right Switch Housing B Right Handlebar Weight D Throttle Grip C ŸRemove the handlebar holder bolts B and then pull out the handlebar Handlebar Installation Torque Handlebar Holder Bolts 25N m 2 5kgf m 18ft lb ...

Page 358: ...the projection A into a small hole B in the handlebar Torque Left Switch Housing Screws 3 5N m 0 36kgf m 31in lb ŸInstall Throttle Grip Throttle Cable Tips A Right Switch Housing Fit the projection B into a small hole C in the handlebar Torque Right Switch Housing Screws 3 5N m 0 36kgf m 31in lb ŸApply a non permanent locking agent to the right handlebar weight bolt ŸInstall the front brake master...

Page 359: ...and installation 15 5 Rear foot rest removal and installation 15 5 Head cover side plate removal and installation 15 6 Head cover removal and installation 15 6 Head cover bottom plate removal and installation 15 6 Dashboard removal and installation 15 7 Steering light removal and installation 15 7 Headlight removal and installation 15 7 Rearview mirror removal and installation 15 7 Tail cover and ...

Page 360: ...ut from rear direction Front seat installation Put point into frame Each side Put point into frame Put point into frame Each side Make sure the front seat paste tightly to the tank Then tight up the bolts on rear side Rear seat installation Like picture shows Put point on the seat to hook the frame panel And push forward to use hook to align the lock Then press the seat down until a click comes ou...

Page 361: ... clip B ŸPull out the plastic clip C Side cover removal ŸRemove assemble bolt D ŸPull out the plastic clip F ŸPull out the plastic clip E ŸPull out the plastic clip G Panels and side cover installation ŸReverse the removal procedure for installation Note Photos shows the vehicle left side Right side is symmertrical ...

Page 362: ...clip F out of position Tank side cover installation ŸReverse the removal procedure for installation Note Point G into H first Then E and F Note It shows vehicle LH side The RH side is the same method Tank front panel removal ŸRemove the seat See 15 2 ŸRemove side plates and side covers See 15 3 ŸRemove the tank front panel See 15 4 ŸRemove the plastic clip A B ŸRemove the screw C Tank front panel ...

Page 363: ...oval ŸRemove the pipe clamp A ŸRemove the screws each side LH and RH B to remove thefront fender Front Fender Installation ŸReverse the removal procedure for installation Lower air delfectors removal ŸRemove the screws A B C Lower air delfectors installation ŸReverse the removal procedure for installation Note The photos shows the vehicle left side Right side is the same method Rear foot rest remo...

Page 364: ...er removal ŸRemove the head cover side plate See last chapter ŸRemove the screw A B ŸRemove the screw C ŸRemove the bolt D ŸRemove the head cover Unplug the steering indicating light and headlight connector Head cover installation ŸReverse the removal procedure for installation Dashboard removal ŸRemove the head cover See 15 6 ŸRemove the nut A ŸUnplug the connector to remove the dashboard Dashboa...

Page 365: ...ht side is the same method Head cover bottom plate removal ŸRemove the head cover See 15 6 ŸRemove the screw B Head cover bottom plate installation ŸReverse the removal procedure for installation Steering light removal ŸRemove the head cover See 15 6 ŸRemove the nut A 1 for each side ŸRemove the spring washer and flat washer to remove the steering light Steering light installation ŸReverse the rem...

Page 366: ...and seperate it from the locker seat ŸRemove the tail covers and rear plate together with seat locker cable from the vehicle Can remove rear plate first Tail cover and rear plate installation ŸReverse the removal procedure for installation Taillight removal ŸRemove the seat See 15 2 ŸRemove panels and side cover See 15 3 ŸRemove tail covers and rear plate See 15 10 ŸRemove tail light screws H ŸUnp...

Page 367: ...plug the steering light and licence light connectors ŸRemove 4 bolts A ŸPull out the cables to remove the licence bracket You can maintenance the rear steering light licence light and rear baffle boards Licence bracket installation ŸReverse the removal procedure for installation ...

Page 368: ...pection 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 ...

Page 369: ...n 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 16 49 Dashboard 16 51 Switches and sensors 16 58 Relays and fuses 16 61 ...

Page 370: ... winding resistance Secondary winding resistance Primary peak voltage 376 564Ω 1 9V or higher 1 1 1 5Ω 10 816kΩ 88V or higher Sparkplug Sparkplug clarance 0 8 0 9mm 0 03 0 04in Start system Start motor Brush length Commutator diameter 12mm 0 47in Service limit 6 0mm 0 24in 28mm 1 10in Service limit 27mm 1 06in Switches and sensors Rear breaking light switch Engine oil pressure switch Water temp se...

Page 371: ...16 Electrical system 16 3 16 Special tool AVO meter Testing auxilary line Magneto rotor puller Adapter Peak volatage adapter Magneto rotor locker ...

Page 372: ...16 4 CFMOTO Parts location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 21 ...

Page 373: ...l 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 Start motor 21 Front breaking switch 9 Recitifier 22 Ignition key 10 Fuse box 11 Battery 12V10Ah 12 Steering light relay 13 ECU Parts location ...

Page 374: ... W L B B r G Lg L g G Sb O G r W L L W B B r G R G B B r P W R W Y W Y W Lg Y B r W P P 3 0 A R Y Y Y G W B W Y B B Br B Y G 1 3 2 1 W G G Y L B B r MODE Gr W G 2 A D B R L O R C Y G r P B G R P B G r W G r W Y B O W D C B A R P P i 2 1 P i P R A C B R L P B B L S E G B r R G R W R W A C B B B r R L G r B W P B r B B r R L W L O B O B O B O B 1 13 9 11 3 5 7 39 41 43 45 47 12 10 2 4 6 8 48 40 42 4...

Page 375: ...t auxilary relay 30 Fuel pump relay 31 Main relay 32 Fuse box 33 Ignition switch 34 Oil pressure switch Wiring diagram 35 CPS 36 Magneto 37 Rectifier 38 Start relay 39 Battery 40 Start motor 41 Neutral switch 42 Rear steering light RH 43 Taillight 44 Rear Licence light 45 Rear steering light LH 46 Rear wheel speed sensor 47 Front wheel speed sensor 48 ABS 49 Ignition coil and spark plug 1 50 Ignit...

Page 376: ...6 Do not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb 7 Take care not to short the cables that are directly connected to the battery positive terminal to the chassis ground 8 Troubles may involve one or in some cases all items Never replace a defective part ...

Page 377: ...ect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity Use the wiring diagram to find the ends of the lead which is suspected of being a problem Connect the hand tester between the ends of the leads Set the tester on x1Ω and record the data If the tester does not read 0Ωthe lead is defective Replace ...

Page 378: ... container matches the model name B of the battery These names must be the same Battery Model Name for 650NK YTX12 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type This is to prevent overfill ing of the electrolyte shorting the battery life and deterioration of the battery perfor...

Page 379: ...trolyte flow If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation NOTE o Do not tilt the electrolyte container Removal...

Page 380: ...fter charging is completed pressdown firmly with both hands to seat the strip of caps A into the bat tery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery To ensure maximum battery life and customer satisfaction it...

Page 381: ... motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has exceeded its useful life Replace it Provided however the vehicle s starting system has no problem CAUTION Sealed battery...

Page 382: ...ltmeter which can be read one decimal place voltage If the reading is 12 8 V or more no refresh charge is required however if the read is below the specified refresh charge is required NOTE Battery Terminal Voltage Standard 12 8V or higher Terminal Voltage V A Battery Charge Rate B Good C Refresh charge is required D Refreshing Charge Remove the battery A see Battery Removal Do refresh charge by f...

Page 383: ...e increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D Determinethe batterycondition afterrefresh charge Determine ...

Page 384: ...outside Alternator Cover Installation Apply silicone sealant to the alternator lead grom met and crankcase halves mating surface A on the front and rear sides of the cover mount Check that dowel pins B are in place on the crankcase Install a new gasket and the alternator cover Tighten Torque Alternator Cover Bolts 9 8N m Stator Coil Removal RemoveAlternator Cover Remove the magneto rubber sleeve B...

Page 385: ...l Remove the alternator cover Remove the starter idle gear torque limiter and shafts Wipe oil off the outer circumference of the rotor Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B and washer Special Tool Rotor Locker Using the flywheel puller A remove the alterna tor rotor from the crankshaft Special Tool Flywheel Puller Assembly Do not attempt to strike the...

Page 386: ...orque Remove the rotor bolt and washer Check the tightening torque with flywheel puller If the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly If the rotor is pulled out with under 20 N m 2 0 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that...

Page 387: ... output To check the alternator output voltage do the fol lowing procedures Turn off the ignition switch Disconnect the alternator lead connector A Connect the hand tester as shown in the table 1 Run it at the rpm given in the table 1 Note the voltage readings total 3 measurements Table 1 Alternator Output Voltage AV O m e te r C o n n ec ting p in 4 0 0 0 rp m 2 5 0 V A C B la c k lin e A no th e...

Page 388: ...st be replaced If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity indicates a short necessitating st...

Page 389: ...16 Electrical system 16 21 16 Regulator Rectifier Regulator Rectifier Removal Remove Bolts A Charging System Disconnect the connector A Remove the regulator rectifier B B A ...

Page 390: ... the hand tester to Diode range mv NOTE If the hand tester displays less than 1 4 V when the probes are not connected replace the batteries Charging System After is the engine is running at 5000 rpm when the magneto is normal and the battery is fully charged if the voltage between the red and green terminals is more than 15V or less than 13 5V replace the regula tor rectifi er with a new one ...

Page 391: ...lockwise C If the starter motor clutch does not operate as it should or if it makes noise go to the next step Disassemble the starter motor clutch and visually inspect the clutch parts If there is any worn or damaged part replace it NOTE Examine the starter motor clutch gear as well Re place it if it worn or damaged Overriding clutch removal Remove magneto rotor clutch bolt A Remove the overriding...

Page 392: ... the engine and keep it at the speed of 5000rpm The voltage should be in 13 5V 15V Note Battery must be fully charged Stator resistance inspection Cable inspection Replace the rectifier Replace 1 Clean terminal 2 Recharge Charging system OK Replace the stator Repair or replace OK OK 13 5V OK No No No No OK Replace rectifier 15V OK ...

Page 393: ...16 Electrical system 16 25 16 1 Battery 2 Start relay 3 Start motor 4 Rectifier 5 Magneto 6 Ignition switch 7 Fuse box Charging wiring diagram Charging system ...

Page 394: ... not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent ECU Electric Control Unit damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the ECU WARNING Crankshaft Position Sensor Removal Remove Lower Fairing see Lower Fairing Removal in the Framechapter C...

Page 395: ...an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced CPS resistance 250 300 Ω In 20 Using the highest resistance range of the tester measure the resistance between the crankshaft sen sor leads A and chassis ground Any tester reading less than infinity indi catesa short necessitating replacement of the crank shaft sensor assembly Meter Blac...

Page 396: ...reen lead and connect the negative terminal of the adaper to black lead in the crankshaft sensor connector Turn the ignition switch and engine stop switch ON Pushing the starter button turn the engine 4 5 seconds with the transmission gear in neutral to mea sure the crankshaft sensor peak voltage Repeat the measurement 5 or more times Standard 1 9 V or higher If the tester reading is not specified...

Page 397: ...ap the coil head while installing the coil CAUTION Ignition Coil Inspection Remove the ignition coils see Ignition Coil Ignition Coil together with Spark Plug Cap Removal Measure the primary winding resistance A as follows Connect the AVO meter between the coil terminals Set the tester to the x 10 ohm range and read the tester Measure the secondary winding resistance B Connect the tester between t...

Page 398: ...gs or tester connections WARNING Turn the ignition switch and the engine stop switch ON Pushing the starter button turn the engine 4 5 sec onds with the transmission in neutral to mea sure the primary peak voltage Repeat the measurements 5 times for one igni tion coil Stick Coil Primary Peak Voltage Standard 88 V or more Repeat the test for the other stick coil If the reading is less than the spec...

Page 399: ...he ECU 2nd Check Start the engine to the following conditions Condition Transmission Gear Not neutral Clutch Lever Pulled in Sidestand Up Turn the ignition switch ON and push the starter button Then the starter motor should turn when the starter system circuit is normality If the engine start Inspect the neutral switch auxilary relay and start relay If their parts are normality replace the ECU 3rd...

Page 400: ...16 32 CFMOTO Ignition System ECU 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 ...

Page 401: ...ug inspection Ignition coil inspection Ignition coil peak voltage Replace ignition coil Inspection 1 Adaptor wrong connection or adaptor defective 2 Inspect the fuel pumprelay 3 CPS peak voltage Replace defective parts Replace ECU Charge or replace Maintain the wiring and replace damaged parts Replace the sparkplug Replace ignition coil V oltage lower thanstandard OK OK OK OK OK No No No No No No ...

Page 402: ...Ignition System Ignition system wiring diagram 16 34 CFMOTO ...

Page 403: ...ensor 27 Injector 2 28 Injector 1 29 Lgnition diagnostic resistor 2 30 Lgnition diagnostic resistor 1 31 ECU 32 Sidestand switch 33 Fuel pump 34 Diagnose connector 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 Start Batter...

Page 404: ...motor legs A and crankcase B where the starter motor is grounded Apply grease to the O ring Tight up the bolt Torque Starter Motor Mounting Bolts 9 8N m Install the start motor cable Torque Starter Motor Cable Terminal Nut 6 0 N m Starter Motor Test Using a cable as thick as or thicker than starter motor cable A connect the 2 terminals of starter relay B Starter Motor C Battery D Be sure the batte...

Page 405: ...d cable to chassis ground CAUTION If the relay does not work as specified the relay is defective Replace the relay Remove left side cover When battery is connected 0 Ω When battery is disconnected Ω Start relay test Start Relay Resistance Measurement Connect the hand tester A and starter relay B as shown Starter Relay Resistance 3 5 Ω 20 If the reading is out of specification the relay is defectiv...

Page 406: ...y Start Auxilary Relay Resistance Measure ment Connect the hand tester A and starter auxilary relay B as shown Starter Auxilary Relay Resistance 90 105 Ω 20 If the reading is out of specification the relay is defective Replace the relay Using the relay connection and disconnection test is a more reliable way to determine the condition of the starter relay than starter relay resistance measurements...

Page 407: ...t r a l D i s c o n n e c t t o g r o u n d S t a rt D o w n D i s c o n n e c t t o g ro u n d N e u t ra l T o g r o u n d H o l d T o g r o u n d S t a rt D o w n D i s c o n n e c t t o g ro u n d N o t N e u t ra l D i s c o n n e c t t o g r o u n d N e u t r a l D i s c o n n e c t t o g r o u n d C a n n o t D o w n D i s c o n n e c t t o g ro u n d N o t N e u t ra l D i s c o n n e c t ...

Page 408: ...spect starter relay continuity Replace Charge or replace Replace the motor Replace the start relay OK OK OK No No No No Inspect starter auxiliary relay continuity Replace the start auxiliary relay No OK Inspect auxiliary starter relay engine stop Maintain or replace No OK Inspect starting system wiring Maintain or replace No OK Inspect sidestand switch clutch switch Maintain or replace No OK Inspe...

Page 409: ...16 Electrical system 16 41 16 Starting system Starting system wiring ...

Page 410: ... Injector 1 29 Lgnition diagnostic resistor 2 30 Lgnition diagnostic resistor 1 31 ECU 32 Sidestand switch 33 Fuel pump 34 Diagnose connector 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 Start Battery 16 Start motor 17 Ne...

Page 411: ...eam and low beam Headlight horizontal adjustment Refer to headlight inspection in maintenance chapter Headlight vertical adjustment Refer to headlight inspection in maintenance chapter Headlight Bulb Replacement Headlight bulb cannot be replaced Please replace the whole headlight assy Position light bulb replacement Position light bulb cannot be replaced Replace the whole headlight assy ...

Page 412: ... 6 bolts around the headlight Disconnect the connectors Headl i ghtst yl e LED 12V20W 2 High beam and lowbeam Front position light LED 12V3W Remove rear seat Remove tail light mounting bolt A Disconnect the taillight connector B Tail Brake light model LED 12V3W 2W A B A Remove the bolt A Disconnect steering light connector Replace the steering light Installation is the reverse of removal Installat...

Page 413: ... Electrical system 16 45 16 Licence light replacement Lighting system Remove the screw A Remove B Remove 4 screws under the licence light C Replace the licence light Installation is the reverse of removal ...

Page 414: ...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 17 Ignition switch ...

Page 415: ...r Turn Signal Light Assy RH LH Re placement 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 Rear turn signal light are in taillight assy So it can not be replaced saperatly If needs maintenance It needs to replace the whole taillight assy That refers to the taillight assy replacement chapter...

Page 416: ... A Connect a 12 V battery and turn signal light as shown and count how many times the fl asher blinks in one minute Flasher A Turn Signal Light B 12 V Battery C Flasher inspection If the flasher does not blink as specifi ed replace the flasher Test the flasher Signal light QTY Frequency times MIN 1 150 or more 2 60 120 1 Means one light burned out A ...

Page 417: ...ram 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 Rear turn signal light RH 9 Rear turn signal light LH 10 Battery 11 Start relay 12 Fuse box 13 Ignition switch ...

Page 418: ...ion Remove the fuel tank Slide out the auxiliary starter relay A together with rubber ring B from the frame Disconnect the connector C Fan Relay Test Refer to Auxiliary Starter Relay Test Fan Relay Resistance Measurement Refer to Auxiliary Starter Relay Resistance Measurement Fan relay and fan motor can be tested with PDA Using active diagnosis fan relay test to control fan operation if it runs th...

Page 419: ...rical system 16 51 16 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 7 Main relay 8 Engine stop switch 9 ECU ...

Page 420: ... down or sideways for a long time or dropped it will malfunction Do not short each terminals CAUTION Pin1 Pin10 Pin9 Pin18 Pin Function Wire color Pin1 Mode LG G Pin2 Oil pressure Blue black Pin3 r min Purple Black Pin4 K LINE Green Blue Pin5 Key ON White Green Pin6 Battery Red Pin7 GND Green Black Pin8 ECU neutral Light green Red Pin9 ABS indicator Light green Pink Pin Function Wire color Pin10 S...

Page 421: ...e pole to 10 12 Connect the battery nagetive pole to 7 Connect the pin 5 to pin 17 After connector connected The LCD will be light up If LCD light cannot on Replace the dashboard Disconnect the connector 17 LCD light and dashboard light off If LCD light does not off replace the dashboard assy Speed raise up the fuel and water temp shows 1 cube 0 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 422: ...dometer shows the speed If the speedometer doesnot work check the speed sensor electric source voltage and speed sensor If powervoltageand speedsensorisnormal replace the dashboard Mileage meter test Use the same way as speedometer to inspect the mileage meter If mileage meter number cannot raise up replace the dashboard Fuel level gauge Use the same way in LCD inspection con nect the battery and ...

Page 423: ...es not move replace the dashboard Using the auxiliary leads connect a 12 V battery to the meter unit connector as follows Neutral indicator LED Negative pole to dashboard pin 7 If battery positive pole to pin 8 The neutral gear should be on If negative pole disconnect to pin 7 The neutral indicator shoule be off If the func tion is wrong Replace the dashboard Indicator Lights Inspection Use the sa...

Page 424: ...cator RH LED Battery pole connect to pin 18 If battery pole connect to pin 15 or 18 The left or right steering indicator should be on If battery pole disconnect to pin 15 or 18 The left or right steering indicator should be off If function is wrong Replace the dashboard Oil Pressure Warning Indicator Light Use RPM meter inspection Way to connect the battery and pole When the RPM is higher than 100...

Page 425: ...on If the battery pole disconnect to pin 7 The neutral indicator should be off If function is wrong replace the dashboard Parking indicator Battery Negative pole to pin 14 If battery pole connect to pin 14 Neutral indica tor should be on When battery pole disconnect to pin 14 Neutral indicator should be off If the function is wrong replace the dashboard ...

Page 426: ...ing 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 13 Speed sensor CFMOTO 16 58 ...

Page 427: ... in the table have continuity about zero ohms For the switch connections and continuity refer to the tables given below If the switch has an open or short repair it or replace it with a new one Front and rear breaking switch Color W G G Y Press the break pedal ON Release the break pedal OFF Side stand switch connection Color Br B W G Y B UP DOWN Neutral switch connection Color SW pin Ground In neu...

Page 428: ...most the same depth NOTE The sensor and thermometer must not touch the container side or bottom Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently Using the hand tester measure the internal resis tance of the sensor If the hand tester does not show the specified values replace the sensor Water Temperature Sensor Resistanc...

Page 429: ...Installation Installation is the reverse of removal Torque Speed Sensor Bolt 7N m Speed Sensor Inspection Remove the speed sensor see Speed Sensor Removal Connect the speed sensor connector A with the battery B 10kΩresistor C and hand tester D as shown Set the tester to the DC 25 V range Trace A each side of the speed sensor surface with the screw driver Then the tester indicator should flick B If...

Page 430: ...ay installation Installation is the reverse of the removal High beam relay inspection If the relay is not in standard Means the relay is in trouble Replace the relay Low beam relay Low beam relay is the same as high beam relay Refer to start auxilary relay testing chapter High beam relay resistane inspection Refer to start auxilary relay resistance chapter ...

Page 431: ...tion is the reverse of removal Fuse Inspection Remove the fuse Inspect the fuse element If it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the af fected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related com ponents for a short circuit Housing A Fuse Element B Terminals C Blown Element D When replacing a fuse...

Page 432: ...B Turn the page from the left side Right D See the items data Turn the page from the right OK button G Confirm EXIT E Cancel Back to upper level Back to main menu PDA connections Open the seat connect the PDA and diag nose cable A Note Turnofftheignitionswitchwhenconnecting And turn the ignition switch on after connected ...

Page 433: ...l shows 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 to next step The screen shows like FIG3 1 春风摩托 2 演示程序 Cannot be seted do not choose Press up or down arrow button to choose 语言 LANGUAGE Then press OK button to continue The screen shows like this FIG4 1 车辆诊断测试 2 语言 LANGUAGE 3 历史测试记录 4 系统参数设置 5 数据流参数维护 6 帮助 ...

Page 434: ...nglish Pressup and down button to move the arrowto choose 英文 English Then press OK button to back to upper level Auto diagnosis Pressup and down button to move the arrowto choose AUTO DIAGNOSIS item Then press the OK button to enter the item FIG7 The PDA screen will shows FIG8 1 UAES ME3 0 SYSTEM 2 DUCATISYSTEM 3 DELPHI SYSTEM 4 CF650 5 CF_MOTO_ABS 6 CF_MOTO_EPS 7 UAES ME6 0 SYSTEM FIG 8 ...

Page 435: ...on list The screen will shows up like below READ DTC Press up and down to move the arrow to READ DTC Then press the OK button Press left and right button to choose the trouble code Then press OK button to enter the trouble code to see trouble discriptions READ ECU ID READ DTC CLEAR DATASTREAM ACTUATOR TEST ECU RESET ...

Page 436: ...en press the EXIT button again to enter the testing date After entered the date the screen will showsthe tested date Without entering work Press EXIT button to back the upperlevel CLEARDTC Press up or down button to move the arrow to CLEAR DTC Then press the OK button ...

Page 437: ...mand has sent Read DTC again Press OK button the screen will shows Syetem is OK FIG18 Press the EXIT button to enter the tested date F I G 1 9 Without entering Pressthe EXIT button to upper level Press up and down to move the arrow to DATASTREAM Then press the OK button DATASTREAM ...

Page 438: ...LT 11 IAP 12 IAV 13 STEP MOTOR TARGET POSIT 14 TP VOLT SIG 15 TP ANGLE SIG 16 RELATIVE TP 17 CANI CNTRLVLV DUTY 18 CHARGING TIME 19 INJPW 20 CY1 SPK ADV 21 O2S SHORT MODIFY 22 O2S VOLT 23 O2S LONG MODIFY 24 MODULE IAT 25 ENG RELATIVE LOAD 26 CANISTER CENTRLRELATIVE IN 27 CANI PURGING RATE 28 CANI LOAD 29 AMBIENTPRESSURE 30 IDLE AEV ACTUATOR OPENING 31 ALTITUDE MODIFY EFFICIENCY 32 INJ PHASE 33 WOR...

Page 439: ... After press the OK button the screen will shows like FIG 33 FIG33 READ ECU ID READ DTC CLEAR DTC DATASTREAM ACTUATOR TEST ECU RESET READ DTC Pressup and down button to choose READ DTC Then press the OK button to see the DTC list FIG34 FIG34 Press left and right button to choose the trouble code and press OK button to see the trouble discription FIG12 FIG35 ...

Page 440: ...ted date The screen shows the date Without entering Press the EXIT button to upper level list FIG37 FIG37 CLEARDTC Press up and down button to move the arrow Choose the CLEAR DTC and press the OK button FIG38 FIG38 After press the OK button The screen shows Clear DTC command has sent Read DTC again FIG39 FIG39 ...

Page 441: ...sthe EXIT button to upper level FIG41 DATASTREAM Press up and down button to move the arrow Choose the DATASTREAM and press the OK button FIG42 FIG42 FIG43 After press the OK button The screen will shows the data stream The screen will shows like below F I G 4 3 Datastream item 1 ABS Switch raw signal 2 ABS Switch system status 3 Reference Voltage 4 Pump 5 Connector PIN 30 6 External Vcc 7 Front S...

Page 442: ...he screen will shows the testing items for choose like FIG 45 FIG45 FIG46 Lamp OFF Press up and down button to move the arrow Choose the Lamp OFF item Press OK button the screen shows on testing FIG46 After3s ThescreenshowsNOACTUATORCONTROL LIMIT Then press the EXIT button to upper level FIG47 Then Lamp on and Lamp blinking test are handle in the same way FIG47 ...

Page 443: ...ss the OK button to see the ECU version informa tion that the screen will shows FIG49 Press EXIT button to upper level After press the OK button The screen will shows Communicate with auto ECU error FIG51 Press EXIT button to upper level ECU RESET FIG50 FIG51 Press the up and down button to move the arrow Choose READ ECU ID FIG48 ...

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CF MOTO CF400-A 2017, Service Manual

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