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CF MOTO CF500-5B 2009, Service Manual, Page: 48 / 272

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CF MOTO CF500-5B 2009 Service Manual Download Page 48

3

-

2

C

F

MOTO

Maintenance Interval 

   

The table below lists the recommended intervals for all the required periodic maintenance 

work  necessary  to  keep  the  engine  at  its  best  performance  and  economy.  Maintenance 

intervals are expressed in terms of kilometer, miles and hours, whichever occurs first. 

Note: Maintenance interval should be shortened on engines that are used in severe conditions.

 

Km 

Initial 

250km 

Every 

500 km 

Every 

1000 km 

        Interval          
   

Item

 

Hours 

Initial   

20 hours 

Every 

50 hours 

Every 

100 hours 

Remark 

Valve Clearance 

I 

!

 

I 

IN: 0.05~0.10 
EX:0.17~0.22 

Idle Speed 

I 

I 

!

 

1400±100r/Min 

I 

!

 

I 

Spark Plug 

Replace every 6000Km

 

No carbon deposit 
Gap: 0.8~0.9mm 

Air Filter 

!

 

I 

C 

Replace 

every 

20000 Km 

High-Pressure Fuel Hose 

!

 

!

 

I 

Replace  every  4 
years 

Clutch 

!

 

!

 

I 

 

Drive Belt 

!

 

I 

!

 

Replace 

every 

2000Km 

Engine Oil 

R 

!

 

R 

 

Oil Filter 

R 

!

 

R 

 

Coolant Level 

I 

I 

!

 

 

Water Hose & Pipes 

I 

!

 

I 

 

Coolant 

Replace every 2 years

 

    

I=Inpection and adjust, or replace if necessary 
R=Replace 

C=Clean        

                                       

 

 

Summary of Contents for CF500-5B 2009

Page 1: ...WWW CFMOTO COM CF500 5B CF500 5C Service Manual CFMOTO ...

Page 2: ...All rights reserved Zhejiang CFMOTO Power Co Ltd Aug 2009 WWW CFMOTO COM ...

Page 3: ...ssembly installation adjustment maintenance and trouble shooting information CFMOTO reserves right to make improve ments and modifications to the products without prior notice Overhaul and mainte nance should be done according to actual condition of vehicle Zhejiang CFMOTO Power Co Ltd Aug 2009 CONTENTS Maintenanceinformation 1 V ehiclebody Muffler 2 Checking Adjustment 3 Cooling Lubricatingsystem...

Page 4: ...mple Conversion Pressure 200 kPa 2 00kgf cm2 1kgf cm2 98 0665kPa 1kpa 1000Pa 33kPa 250mmHg 1mmHg 133 322Pa 0 133322kPs Torque 18N m 1 8kgf m 1kgf m 9 80665N m Volume 419ml 1ml 1cm3 1cc 1l 1000cm3 Force 12N 1 2kgf 1kgf 9 80665N ...

Page 5: ...than two people are operating keep reminding each other for safety purpose Cautions for Disassembling and Assembling 1 Use genuine CFMOTO parts lubricants and grease 3 Clean the mud dust before overhauling 2 Store the disassembled parts separately in order for correct assemble 4 Replace the disassembled washers o rings piston pin retainer cotter pin with new ones 5 Elastic retainers might get dist...

Page 6: ...ter assembl ing check i f al l the tightened parts are properly tightened and can move smoothly 19 Brake f luid and coolant may damage coating plastic and rubber parts Flush these parts with water i f splashed 20 Instal l oi l seal with the side of manufacturer s mark outward Do not fold or scratch the oi l seal l ip Apply grease to the oi l seal l ip before assembl ing 21 When instal l ing pipes ...

Page 7: ...1 3 1 Maintenance Information 1 Numbers Mark i ng Locat i on CF500 5B CF500 5C VIN Number LCELDTS5 LCELDTS6 Eng i ne Number CF188 B ...

Page 8: ...re Front Tire 25 8 12 40J 185 80 12 40J Rear Tire 25 10 12 47J 270 60 12 47J Min Ground Clearance 275mm Turning Diameter Turning Diameter Engine Starting Electrical starting Manual Starting Engine Type Single cylinder 4 stroke Liquid cooled 4 valves OHC Combustion Chamber Type Triangle Valve Driving Type SOHC Chain Drive Bore Stroke 87 5mm 82 0mm Compression Ratio 10 2 1 Lubrication Type Pressure ...

Page 9: ...Ratio 2 88 0 70 Gear Ratio Final Ratio 1 333 24 18 Bevel Gear Secondary Ratio 1 952 41 21 Gears Low Gear 2 25 36 16 High Gear 1 350 27 20 Reverse Gear 1 471 25 17 Total Low Gear5 857 High Gear 3 514 Reverse Gear 3 828 Axle Ratio Front Axle 33 9 3 667 Rear Axle 33 9 3 667 Engine Output Mode Front Rear Shaft Direction of Output Rotation Clockwise on forward shift Steering Device Steering Angle Inner...

Page 10: ...e following range API type SE or SF grade SAE type Choose from the left chart according to the environmental temperature Oil Pump Rotor Gap between Inner and Outer Rotors 0 03 0 1mm 0 15mm Gap between Outer rotor and body 0 03 0 1mm 0 12mm Oil pressure 3000r min 130 170KPa Item Standard Fuel Tank Capacity Full capacity 18L Valve CF188 B 173000 Inlet Pressure Sensor CF188 B 175000 Inlet Temperature...

Page 11: ...Init ial Temperature 71 3 Full opening Temperature 88 Full opening lift range 3 5 4 5mm 95 Temperat ure and Resist ance of Water Temperat ure Sensor Temperat ure End B Resistance End A C Resistance k 20 13 71 16 94 25 1 825 2 155 50 176 280 80 63 4 81 4 0 303 0 326 110 24 6 30 6 0 138 0 145 Temperat ure of Thermostat Close Open 88 Round 88 Round Open Close 82 Round 82 Round Coolant Type 35 ant i f...

Page 12: ...e 3 0mm Pressure 35kPa 0 35kgf cm2 Item Standard Operation Limit Rear Wheel Play of wheel rim Vertical 1 0mm 2 0mm H orizonta l 1 0mm 2 0mm Tire Groove 3 0mm Pressure 30kPa 0 30kgf cm2 Item Standard Operation Limit Front Brake Brake End Play 0mm Brake Disc Thickness 3 5mm 2 5mm Rear Brake Brake End Play 5 10 mm Brake Pedal Play 0mm Brake Disc Thickness 7 5mm 6 5mm ...

Page 13: ...A 2 Light Bulb Fuse Head Light Hi Lo 12V 35W 35W 2 Brake Light Tail Light 12V 5W 2 Turning Light 12V 21W 5W Dashboard Indicator Light 12V 10W 4 Indicators 5 LED Main LCD Item Standard AC Magneto Motor Model Permanentmagnet AC Type Output 3 phase AC Charging Coil Resistance 20 0 2 0 3 Pickup Coil Resistance 110 140 Magneto without Load Voltage Idle Speed 100V AC 5000r min Max Output Power 300W 5000...

Page 14: ...e Head Seal Run out Intake Exhaust 0 03 Width of Valve Seats Seal Intake Exhaust 0 9 1 1 Length of Valve Spring Intake Exhaust 40 38 8 Valve Spring Tension Intake Exhaust Tension182 210N Length31 5mm Intake 33 430 33 490 33 130 Cam Height Exhaust 33 500 33 560 33 200 22 0 032 0 066 0 150 Fit Clearance between Camshaft Exterior dia Bore 17 5 0 028 0 059 0 150 22 21 959 21 980 Camshaft Exterior dia ...

Page 15: ... 7 round 8 9 Piston Ring Free Gap 2nd Ring R 12 round 9 5 Top Ring 0 15 0 30 0 60 Piston Ring Closed Gap 2 nd Ring 0 15 0 30 0 60 Top Ring 0 04 0 08 0 180 Piston Annular Fit Clearance 2nd Ring 0 03 0 07 0 150 Top Ring 0 97 0 99 Thickness Piston Ring 2nd Ring 1 17 1 19 Top Ring 1 03 1 05 2nd Ring 1 22 1 24 Piston Annular Width Oil Ring 2 51 2 53 Internal dia of Piston Pin Bore 23 002 23 008 23 030 ...

Page 16: ...Joint Rotation 1800 2400r min Clutch lock up Rotation 3300 3900r min Drive Belt Width 35 2 33 5 Driven Disc Spring Free Length 168 160 Shifter and fit flute gap 0 10 0 40 0 50 Left Shifter Sliding Thickness 5 8 5 9 Right Shifter Sliding Thickness 5 8 5 9 Plunging Flute Width 6 0 6 2 Driven Output Gear Sliding Width 6 0 6 2 ...

Page 17: ...olt Rear Absorber M10 1 25 50 4 40 50 Bolt Front Absorber M10 1 25 50 4 40 50 Bolt Rear Wheel Shaft Holder M10 1 25 100 4 40 50 Mounting Nut Rim 901 07 00 02 M20 16 50 60 Nut Rim Shaft 901 07 00 03 M10 4 110 130 Mounting Screw Rear Brake Caliper M6 25 2 18 22 Bolt Rear Brake Caliper M10 1 25 20 2 40 50 Bolt Front Brake Disc 901 08 00 03 M8 8 25 30 Bolt Front Brake Caliper M8 14 4 16 20 Locknut Ste...

Page 18: ...1 M18 1 5 70 Left handed Limiting Nut Driven Bevel Gear Shaft 1 M60 110 Apply screw thread sealant Limiting Nut Front Output Shaft 1 M55 80 Apply screw thread sealant left handed Bolt Swing Arm Shaft 2 M14 1 25 28 Drain Bolt 1 M12 1 5 30 Mounting Bolt Overriding Clutch 6 M8 26 Apply screw thread sealant Mounting Bolt Magneto Stator 3 M6 10 Apply screw thread sealant Bolt CVTWindshield 3 M6 10 Appl...

Page 19: ...ing Motor 2 M6 10 Bolt Cylinder Head 4 M10 38 Bolt Cylinder Head 2 sides 2 M6 10 1 M8 25 Upper and Lower Bolt Cylinder 4 M6 10 Bolt Cylinder Head Cover 12 M6 10 Bolt Chain Tensioner 2 M6 10 Nut Chain Tensioner 1 M8 8 Bolt Radiator Fan 3 M6 10 Thermostat Bolt 2 M6 10 Bolt Water Pump Cover 3 M6 6 Mounting Bolt Water Pump 2 M6 10 Fixed Bolt Timing Sprocket 2 M6 15 Apply screw thread sealant Bolt with...

Page 20: ...th of carburetor 11 Plastic gauge Fit clearance 12 pull tension gauge Spring bounce 13 Tachometer Engine rotation rate 14 Cylinder Pressure Meter pressure in cyclinder 15 Oil Pressure Gage Oil pressure 16 Barometer Opening pressure of radiator cover 17 Ohmmeter Resistance and voltage 18 Amperemeter Opening of currency switch 19 Thermometer Liquid temperature 20 Timing Lights Test spark timing 21 T...

Page 21: ...on left crankcase 9 Valve Spring Compressor CF188 022006 922 001 Disassemble install valve spring 10 Valve Former CF188 022004 922 001 Grind valve 11 Circle Nut Wrench CF188 052000 922 003 Disassemble CVT driven disc 12 Driven Disc Clamp CF188 052000 922 004 Disassemble CVT driven disc 13 Driven Disc Former CF188 052000 922 002 Disassemble CVT driven disc 14 Limiting nut Wrench CF188 062204 922 00...

Page 22: ...2300 m L replace oil filter 2600 m L engine overhaul Lubricant with molybdenum Piston pin valve rod part valve ring cam shaft Grease lubricant grease 3 MoS2 l ithium based grease Oil seal lip O ring and other latex sealing bearing with seals and CVT bearing housing Coolant 35 anti frozen anti rust high boiled coolant Cooling system water seals Capacity based on radiator pipe system Plane sealant C...

Page 23: ...1 19 1 Maintenance Information 1 Wir ing Pipes Cable Layout Picture 2 Picture 3 Picture 1 ...

Page 24: ...1 20 CFMOTO ...

Page 25: ...1 21 1 Maintenance Information 1 ...

Page 26: ...1 22 CFMOTO ...

Page 27: ...faulty fai lure uses 4 digit flashing For example 0650 0 flashes 10 times 6 flashes 6 times 5 flashes 5 times 0 flashes 10 times See Page 11 27 for the meaning of Diagnostic Trouble Code Whi le fai lure appears use PDA to diag nose it Connect PDA with PDA connector the lo cation of PDA connector see Page 1 19 Picture 3 the use of PDA see Page 11 26 ...

Page 28: ... Warning Gasoline is highly flammable therefore smoke and fire are strictly forbidden in the work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove and Install muffler after it is fully cold l This chapter is on the disassembly and installation of rack visible parts exhaust pipe mu...

Page 29: ...bly bolts of front rack shal l be seen Remove fixing Bolt 1 one for each on theleft and right Romove f ixing Bolt 2 Remove front rack Installation Reverse the removal procedure for installation TighteningTorque Fixing Bolt 1 Bolt 2 35 N m 45N m Fixing Bolt 3 Bolt 4 25 N m 30N m ...

Page 30: ...ake seat left right front and back to make sure that the seat is firmly installed Remove Seat 2 3 Bolt 1 bolt 2 Remove seat support Remove Bolt 3 for rear rack and rear fender from rear fender bottom Remove Bolt 1 Remove Rear Rack Installation Reverse the removal procedure for installation Tightening Torque Bo l t 1 35N m 45N m Bo l t 2 35N m 45N m Bo l t 3 8N m 1 2N m ...

Page 31: ... Remove Front Rack 2 2 6 nuts Front Top Cover Assemb l e Reverse the removal process and direction Dashboard Cover Remove 2 pieces Bolt 1 2 pieces bolt 2 Dashboard Cover Insta l l at ion Reverse the removal process and direction ...

Page 32: ...2 5 2 Vehicle Body and Muffler 2 Front S i de Support Lef t Remove Bolt 1 Front Side Support Assemb l e Reverse the removal process and direction Front S i de Support R i ght Same as Left Side Support ...

Page 33: ... from rear fender Remove Rear Top Cover Insta l l at ion Reverse the remove procedure and direction for instal lation Gear Sh i f t Un i t Fender Remove Bolt 1 Bolt 1 Bolt 2 Remove Gear Shift Unit Fender Insta l l at ion Reverse the remove procedure and direction for instal lation ...

Page 34: ...on Rear Protector Remove Rear Rack 2 3 Rear Top Cover 2 6 Rear L ink Plate 2 7 Rear Left Side Support 2 8 Rear Right Side Support 2 8 Rear Turning Light Connector Bolt 1 2 1 Rear Protector Insta l l at ion Reverse the remove procedure and direction for instal lation Rear L ink Plate Remove Bolt 3 Rear Link Plate Insta l l at ion Reverse the remove procedure and direction for instal lation ...

Page 35: ...om of Front Fender Remove Right Side Panel Insta l l at ion Reverse the remove procedure and direction for instal lation Rear R i ght S i de Support Remove Bolt 2 Remove Rear Right Side Support I nsta l l at i on Reverse the remove procedure for instal lation Remova l and Insta l l at i on and Rear R i ght S i de Support i s same w i th Lef t s i de ...

Page 36: ...rocedure and direction for instal lation Front Fender Remove Front Rack 2 2 Front Top Cover 2 4 Lef t R i ght S i de Pane l 2 7 2 8 Fuel Tank Top Cover 2 8 Left Right Side Support 2 5 Loosen Cable Connector of Front Fender Remove Electronics Parts of Front Fender Remove 3 Front Fender bolts f ixed in Frame Remove 4 bolts f ixed with left and right footrest Remove Front Fender I nsta l l at i on Re...

Page 37: ... Bolt 1 and 3 nuts connecting with Front Fender Remove three Bolt 2 and 3 nuts connecting with Rear Fender Remove Bolt 1 Remove Left Footrest Insta l l at ion Reverse the remove procedure for Instal lation Footrest R i ght S i de Removal and Instal lation same with Left side ...

Page 38: ... Lef RightSide Support 2 8 Rear Protector 2 7 Remove Battery Bracket and Fixing Plate 8 4 Remove Battery 8 4 Remove Bolt 1 Remove Nut 1 Remove Electonic Parts from Rear Fender Loosen Cable Connector from Rear Fender Upwardingly Remove Rear Fender Eng i ne Front M i dd l e and Rear Sk i d P l ate Protector P l ate of Doub l e Sea t ...

Page 39: ...late I nsta l l at i on Reverse the remove procedure for Instal la tion Engine Skid Plate Middle Remove Bolt 5 and 6 Remove Middle Engine Skid Plate I nsta l l at i on Reverse the remove procedure for Instal la tion Double Seat Protect ion Plate Remove Bolt 7 and 8 Remove Double Seat Protection Plate NOTE No Protect i on P l ate f or s i ng l e seat I nsta l l at i on Reverse the remove procedure ...

Page 40: ...Inner S i de Fender dur i ng Insta l l at i on Left Front Inner Fender Remova l Remove Bolt 1 and remove Left Front Inner Fender I nsta l l at i on Reverse the remove procedure for Instal la tion Front Lef t Protector Remove Bolt 1 Pul l backward and remove front Front Left Protector I nsta l l at i on Reverse the remove procedure for Instal la tion Front R i ght Protector Removal and Instal lat i...

Page 41: ... Reverse the remove procedure for Instal la tion Front R i ght Inner Fender Removal and Instal lation same as Left Side Bumper Bumper Protector Remove Remove two Bolts of Engine Front Skid Plate f ixing into the Bumper Remove Bolt 1 2 3 and 4 Remove Bumer and Bumper Protector Remove Bolt 5 connecting Bumper and Rack ...

Page 42: ...ve Bumper and Bumper Protector Remove tapping screw 1 from Bumper Remove Bumper Protector I nsta l l at i on Reverse the remove procedure for Instal la tion Bumper Protector Cap Remove Pul l the two Caps from Bumper There are only 2 caps in this vehicle I nsta l l at i on Press Caps into Bumper Pipe ...

Page 43: ...n Instal l at i on Reverse the removal procedure for i nsta l l at ion W a r n i n g G a s o l i n e i s h i g h l y f lammable therefore smoke and f ire are str ict ly forbidden in the work p l ace Spec i a l attent i on shou l d a l so be paid to sparks Gasol ine may also be explosive when i t is vapor ized so operat i on shou l d be done i n a wel l vent i lated place Remove Left and Right Side...

Page 44: ...cables pipes and hoses should be routed prop erly according to the routing drawing Take precaution against fuel leakage when removing fuel Fuel Hose I Remove Fuel tank 2 16 Bolt 1 Bolt 2 Fuel tank top cover Instal l at i on Reverse the removal procedure for i nstal l at i on Note Be careful not to damage main cable pipes and hoses Main cable cables p i pes shou l d be routed proper l y according t...

Page 45: ...uff ler is cooled down Remove Seat 2 3 Right side panel 2 8 Nut1 Nut 2 for exhaust pipe elbow Remove Bolt Remove Bolt 2 Bolt 3 Remove muff ler I nsta l l at i on Reverse the removal procedure for instal lation Not e Replace seal ing gasket when instal l ing the muff ler ...

Page 46: ...2 19 2 Vehicle Body and Muffler 2 V i s i b l e Parts ...

Page 47: ...ert on the electrical sparks Besides vaporized gasol ine is highly explosive so work should be done in a wel l venti lated place Be careful that your hands or clothes not get nipped by the turning or movable parts of the driving system Note The vehicle should be parked on hard and level ground Overhaul Info 3 1 Maintenance Interval 3 2 Inspection Maintenance 3 3 Steering S tem BrakeSystem 3 6 Whee...

Page 48: ...re conditions Km Initial 250km Every 500 km Every 1000 km Interval Item Hours Initial 20 hours Every 50 hours Every 100 hours Remark Valve Clearance I I IN 0 05 0 10 EX 0 17 0 22 Idle Speed I I 1400 100r Min I I Spark Plug Replace every 6000Km No carbon deposit Gap 0 8 0 9mm Air Filter I C Replace every 20000 Km High Pressure Fuel Hose I Replace every 4 years Clutch I Drive Belt I Replace every 20...

Page 49: ... front brake disc is less than 2 5mm rear brake less than 6 5mm Tire pressure Front tire 35kPa 0 350kgf 2 Rear tire 30kPa 0 30kgf 2 Chap and damage Groove depth and abnormal wear No wear indication on the surface of tire the remained depth of groove should not be less than 1 6mm Loosened wheel nut and axle Sway of front wheel bearing Driving System Wheel Sway of rear wheel bearing Suspension arm S...

Page 50: ...nal shaft Drive shaft Sway of Spline O Spark plug O Spark plug gap 0 8 0 9mm Ignition Device Ignition timing O Battery Terminal Joint O Electrical System Wiring Looseness and damage of joints O Fuel leakage O Fuel device Throttle O Throttle grip clearance 3 5mm Coolant level O O Cooling system Coolant leakage O ...

Page 51: ...ion Alarm and lock device Function Instruments Function Looseness or damage caused by improper installation Exhaust pipe and muffler Function of muffler Frame Looseness and or damage O thers Lubrication grease of frame parts Abnormal parts which can be determined when driving Make sure if there is any abnormal with relative parts ...

Page 52: ...em for further check Park the vehicle on level place slowly turn the handlebar left and right to see if it can turn freely In case there is any hindrance check i f it is f rom the main cable assembly or other cables If no check the steer ing t ie rod end and check if the steering stem bearing is damaged Note Make sure the steering can be operated freely An accident may occur i f the handlebar is o...

Page 53: ...astic and rubber parts Keep the f luid away from these parts Sl ightly turn the handlebar left and right ti l l the master cyl inder is in hor izontal then remove the f luid reservoir cap Brake Disc Brake Pad Wear of brake pad Check the brake pad wears from the mark as indicated Replace the brake pad if the wear has reached position of wear l imit trough Note The brake pad must be replaced with a ...

Page 54: ...is tightened and check whether it sways Not tighten enough Tighten it Sway Replace the rocker arm Front Toe in size Park the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in out of the range Adjust the lock nut of tie rod Note After the toe in has been adjusted slowly run the vehicle to check whether the direc tion of vehicle can be controlled by handlebar ...

Page 55: ...ure wi l l reduce the comfort of operation and riding and may cause def lected wear of the tires T i re Tread Check the t i re tread Tread Height 3mm Replace with new tires Note When the tread height is less than 3mm the tire should be replaced immediately Front wheel Rear wheel Pressure 35kPa 035kgf cm2 30kPa 0 30kgf cm2 Tire Size AT25 8 12 AT25 10 12 Speci f ied pressure t i re ...

Page 56: ... i ng Li ft the front wheel Make sure there is no loading on the vehicle Shake the wheel in axial direction for any sway In case of any sway disassemble the front wheel and check the bear ing Suspens i on System Park the vehicle on lever place press the vehicle Several t imes up and down as i l lus trated on the right In case of any rocking or abnormal noise check whether there is any oi l leakage...

Page 57: ...g Shi ft the gear to check for f lexibi l ity and gear engagement Adjust the gearshi ft rod i f necessary Release the locknut to adjust the length of gearshi ft rod Fue l Dev i ce Status of the fuel system Remove the seat 2 3 Check the fuel hose for any aging or damage Aged or damaged fuel hose Replace Check i f there is cracks or bending with the vacuum tube Cracked or bended vacuum tube Replace ...

Page 58: ...d free play could not be acquired by adjusting the regulator or if there is sti l l stickiness with the throttle Ad j ust i ng the Speed L i m i ter The speed l imiter is to l imit the opening of throttle Check the maximum length of l imiter screw thread Maximum screw thread a 12mm Adjust with a cross driver Note For beginners the speed l imi t should be ful ly tightened Drivers with certain ski l...

Page 59: ... gets into eyes rinse with plenty of water and go to consult the doctor In case of swal lowing the coolant induce vomit and consult the doctor Keep the coolant in a safe place and away from reach of chi ldren Coo l ant l eve l Coo l ant m i ght r educe due to natu ra l evaporation Check the coolant level regularly Note freeze Ordinary water may cause engine rust or cracks in winter due to freezing...

Page 60: ...scharged before adding coolant Coo l ant Leakage Check radiator hose water pump water pipes and joints for leakage In case of any leakage disassemble and do further check Refer to Chapter 4 Check the radiator hose for aging damages or cracks The rubber hose wi l l natural ly get aged af ter a period of service time The aged hose may get cracked when the cool ing system is heated Nip the hose with ...

Page 61: ...l ant splashes in your eyes or clothes thoroughly wash it away with water and consult a doctor If coolant is swal lowed induce vomiting and get immediate medical attention Keep coolant away from reach of chi ldren Clean radiator with fresh water if necessary Connect water hose and tighten drain bolt securely Fi l l the specified coolant into the radiator Loosen bleed bol t on water pump when coola...

Page 62: ... in the 0 posi t ion Start the engine to check i f the indicator works If the indicator is not working do the maintenance in time L i ght i ng System Adjust ing headl ight l ight beam Turn the headl ight beam adjusting screw with a cross screwdriver and adjust the high low beam to meet the requirement ...

Page 63: ...Turn the crankshaft unti l the l ine of T D C on rotor is al igned wi th mark of inspection hole on left crankcase Insert feeler gauge to check the clearance between the valve stem end and the adjust bolt on the rocker arm Valve Clearance When cold IN 0 05 0 10mm EX 0 17 0 22mm Note The valve clearance must be adjusted when the engine is cold Adjust the valve clearance when the piston is at the To...

Page 64: ...l ly at 20 hours run in and every 50 hours or 500km thereafter Start the engine and warm it up for several m i nutes measure eng i ne speed w i th a tachometer Set the engine idle speed be tween 1300 1500 r min by turning the throttle stop screw of carburetor Engine idle speed 1400r min 100r min Note Make this adjustment when the engine is hot Tool Tachometer SPARK PLUG Inspect in i t ial ly at 20...

Page 65: ... or 500 km clean it every 1000km i f necessary I f the ai r cleaner is clogged wi th dust intake resistance wi l l be increased with a resul tant decrease in power output and an increase in fuel consumption Check and clean the air f i lter as fol lowing Remove f ixing clamp and top cover Note Be careful not to drop the o ring into the air f i lter box that is attached to the air f i lter top cover...

Page 66: ...tions clean the air f i lter element more frequently Remove the drain plug 2 of air box to drain out any water Fue l Hose Inspect every 100 hours or 1000 km replace every 4 years Inspect the fuel hose for damage and fuel leakage If any damages are found replace the fuel hose with a new one Dr ive Bel t Remova l Remove CVT cover Hold the primary sheave with special tool and loosen primary sheave nu...

Page 67: ...g sheave and primary f ixed sheave Hold secondary sheave with a special tool and tighten the nut to the speci f ied torque Nut Secondary Sheave 115 N m Instal l primary sheave and nut Hold the primary sheave with a special tool and tighten the nut to the speci f ied torque Nut Primary Sheave 115N m Turn primary sheave unti l the drive belt is properly seated and both the primary and secondary shea...

Page 68: ...hten it Take out oi l dip rod and check i f oi l is between upper and lower l imit If the engine oi l is insufficient fi l l more oi l unti l the suff icient oi l is obtained Engine Oi l SAE15W 40 classi f icat ion SF or SG Note Keep the engine in a plan position Do not t ighten oi l dip rod when measuring oi l level Replacing Engine Oi l Remove left side cover 1 oi l dip rod 2 drain bolt 3 and wa...

Page 69: ...lace engine oi l at the same time Replacing Oi l Fi l ter Remove relat ive parts see Replacing En gine Oi l Remove oi l f i lter with the special tool Instal l washer and drain bolt Instal l new oi l fi lter with the special tool Fi l l engine oi l about 2000ml and check see Replacing Engine Oi l Tool Oi l Fi lter Wrench Engine Oi l Capaci ty When replacing oi l 1 9L When replacing oi l f i ler 2 ...

Page 70: ...low check the above items Test ing Cyl inder Pressure Note Before testing of cyl inder pressure make sure that cyl inder head bolts are tight ened to the specified torque and valve clear ance has been properly adjusted Warm up the engine before testing Make sure battery is ful ly charged Remove spark plug 1 Instal l cyl inder pressure gauge 2 in spark plug hole and tighten nut Keep throttle ful l ...

Page 71: ...ssage Combination of above items Testing Oi l Pressure Remove bolt Connect tachometer with ignition coi l Instal l oi l pressure gauge and joint seat to main oi l gal lery Warm up engine as per fol lowing Summer 10 minutes at 2000r min Winter 20 minutes at 2000r min After warming up increase engine speed to 3000r min and record readings of oi l pres sure gauge After test ing apply thread locker to...

Page 72: ...speed is out of the above range check the fol lowing Clutch shoes Clutch shoe wheel Primary and secondary sheave Refer to Chapter 12 for inspection of clutch I I C l utch Lock up Inspect i on Connect the tachometer to ignition coi l Start the engine Shift gear lever to High position Apply front and rear brakes as f i rmly as possible Ful ly open the throttle for a brief period and note the maximum...

Page 73: ...and then with soap and water If coolant is swal lowed voimt immediately and see a physician Store the coolant properly and keep it away from reach of the chi ldren Check radiator fins for mud block and or damage Correct the bent fins Clean off the mud with water and compressed air Replace with a new one i f the damaged fin area reached 20 The overhaul ing of the water pump can done without removin...

Page 74: ...Damaged or clogged radiator f ins Coolant is not enough Faulty or mal function of fan motor No r ise or slow r ise of water temperature Mal function of thermostat thermostat isn t closed Faulty ci rcui t of water temperature dis play Water l eakage Poor water seal O r ings are aged damaged or improper ly sealed Washers are aged damaged or improper ly sealed Improper instal lat ion of pipes Pipes a...

Page 75: ...s the temperature of using place Check coolant for stains Inspect i on of the rad i ator cap Caut i on Be sure to open the radiator cap after cool ant is cooled Remove Front top cover 2 4 Radiator cap 4 3 Caut i on Apply water on the seal ing surface of radia tor cap when attaching the tester to the radiator cap Apply the speci f ied pressure radiator cap opening pressure for 6 seconds and make su...

Page 76: ...ghly wash your eyes with water and consult a doc tor If coolant splashed on your clothes quickly wash it away wi th water then with soap and water If coolant is swal lowed induce vomit imme diately and see a physician Store the coolant properly and keep it away from reach of chi ldren Caut i on Mix the coolant undi luted with soft water according to the temperature 5 lower than the actual lowest t...

Page 77: ...ant After drainage assemble new seal gasket and drain bolt and tighten Reservo i r Tank Remove Seat 2 3 Left Side Cover 2 6 Two bolts of reservoir tank Water hoses of reservoir tank Remove reservoir tank Drain col lant of reservoir tank Wash clean the reservoir tank Instal l reservoir tank water hoses of reservoir tank ...

Page 78: ...when the veh icl e is on an even ground D i scharge Discharge the ai r from cool ing system ac cording to the fol lowing steps 1 Remove drain bol t 4 5 discharge ai r and instal l it 2 Start the engine and run it several minutes at idle speed 3 Quickly increase throttle 3 4 times to dis charge air from cool ing system 4 Add coolant ti l l f i l l ing port 5 Repeat step 2 3 ti l l no more coolant c...

Page 79: ...4 7 4 Cool ing and Libr ication System 4 Coo l i ng System ...

Page 80: ...the engine is sti l l hot Or you may be injured by scalding f luid or steam Coolant is harmful DO NOT swal low or stain your skin or eyes wi th coolant In case of accidental swal low or stain flush with plenty of water and consult the doctor immediately Keep coolant away from reach of chi ldren Inspect i on of Coo l i ng C i rcu i t Remove radiator cap and connect tester 0 f i l ler Warn i ng DOT ...

Page 81: ...palce it Rad i ator Cap Va l ve Open i ng Pressure Standard 108kPa Too l Rad i ator Cap Tester Rad i ator Inspect i on and C l ean i ng Remove di rt or trash from radiator wi th compressed air Correct the radiator f ins wi th a smal l screwdriver Rad i ator Hose I nspect i on Check radiator hoses leakage or damage If the hoses are leakaged and damaged replace them Check t ightening of clamps Repla...

Page 82: ...thermoswitch Check the thermoswitch for closing or open ing by testing it at the bench as i l lustrated Connect the thermoswi tch to the ci rcui t tester place it in a vessel with engine oi l Place the vessel above a stove Heat the oi l to raise the temperature slowly and take the reading from thermostat 0 when the thermoswitch closes and opens Too l ammeter Thermosw i tch Operat i ng Temperature ...

Page 83: ...2 and thermometer 1 Instal lation Apply a l ittle thread locker and instal l it to the cyl inder head by tight ening to the speci f ied torque Wa t e r Tempe r a t u r e Senso r T i gh t en i ng Torque 10N m Note Avoid sharp impact on terperature sensor Avoid contact of temperature sensor wi th thermometer or vessel After instal lation check the coolant level Fi l l coolant i f necessary Inspect i...

Page 84: ...he water temperature When the water temperature reaches the speci f ied valve the thermostat valve should have been l i fted by 3 5 4 5mm L i f t standard of thermostat va l ve water temperature 95 l i f t standard i s 3 5 4 5mm 3 If thermotat valve opening temperature or thermostat velve l i ft does not reach the standards replace it Inatal l thermostat Reverse the removal procedure for instal la...

Page 85: ...clamps and water hoses Release bolts and remove water pump Remove O ring Note Do not reuse the O r i ng Remove the overf low tube Release water pump cover screws water pump cover and gasket Remove ring and impel ler Remove seal ring and rubber seal 0 ...

Page 86: ...g with special tool Note The bearing does not need to be removed i f there is no abnormal noise Note Do not reuse a removed bearing Inspect i on of Water Pump Bea r i ng Check the bearing clearance by hand whi le it is sti l l in the water pump body Turn inner race of bear ing to check for abnormal noise and smooth rotation Replace the bearing i f there is abnormal condition Mechan i ca l Sea l Ch...

Page 87: ...of water pump body with bearing and mechanical seal If damage replace it Water Pump Impe l l er Check the impel ler and shaft for damage If the impel ler or shaft are damaged re place a new part Assemb l y and Insta l l at i on of Water Pump Instal l oi l seal with special tool Too l O i l Sea l I nsta l l er Note The stamped mark on the oi l seal faces outside Apply a l ittle grease to the oi l s...

Page 88: ...special tool Too l Bear i ng I nsta l l er Note The stamped mark on the bearing faces outside Instal l seal ring to impel ler Clean off the oi l and grease from mechani cal seal and instal l into the impel ler Note 4A5s i de of mechan i ca l sea l faces impel ler Apply grease to impel ler shaft Instal l impel ler shaft to water pump body ...

Page 89: ...r pump body Instal l water pump cover and tighten the bolts and bleed bolt W a t e r P u m p C o v e r B o l t s T i g h t e n i n g T o r q u e 6 N m Check impel ler for smooth turning Instal l the new O ring Not e Use the new O ring to preventleakage Apply grease to O ring Instal l the overf low tubes ...

Page 90: ...nd t ighten the bolts to the speci f ied torque Water pump bo l ts t i ghten i ng torque 10N m Note Set the water pump shaft slot end 4B5 to oi l pump shaft f lat side 4A5 Connect water hoses Add coolant Instal l left side cover ...

Page 91: ...4 19 4 Cool ing and Libr ication System 4 ...

Page 92: ...h run at high speed Engine lubr icat ion should be special oi l Engine oi l is not only used as lubrication but also used to wash rustproof seal and cool I nspec t i on o f L ub r i ca t i on sys t em 3 2 2 Inspect ion of eng ine o i l pump and l im i t p r es s u r e v a l v e 6 4 1 ...

Page 93: ...mp Carburetor air filter Cylinder head cover cylinder head cylinder body camshaft CVT system CVT cover Gearbox Right side cover AC magneto water pump Piston piston ring piston pin Following operation require removal of engine from vehicle Crankshaft Tightening torque Engine front upper mounting bolt 35N 45N m Engine front rear mounting bolt 40 50N m Bolt engine front rear mounting bracket 35 45N m...

Page 94: ... chapter Carburetor Engine service chapter Clamp Water Inlet Hose Remove screw Remove gearshift rod Remove clamp Remove water outlet hose Remove Sleeve Remove connectors of magneto enriching device lead pickup water temperature transducer gear sensor as illustrated on the right ...

Page 95: ...tion of Engine Drive Traina and Gearshift Unit 5 Remove spark plug cap from cylinder Remove protection sleeve of starter relay Remove Nut Disconnect positive wire of starter relay Remove nut Remove negative wire of starter relay ...

Page 96: ...5 4 CFMOTO Removal Bolt 4 units of Engine ...

Page 97: ...to engine with proper clamps Positive and negative starting wires to engine Connect all the connectors Spark plug cap Gearshift rod to engine Air filter carburetor and removed parts Removal and Installation of Front and Rear Axle Support the vehicle with jack make sure the vehicle will not fall Remove Plast ic parts for fram Chapter 2 Front and rear wheels and arms Chapter 8 Ai r f i l ter Chapter...

Page 98: ...5 6 CFMOTO Remove nut and bolt of front axle from frame Remove nut and bolt of rear axle from frame ...

Page 99: ...ening torque Bo l t f r o n t ax l e 4 0 5 0N m Bo l t r ea r a x l e 4 0 5 0N m Bo l t f ront and rear dr i ve sha f ts 40 5 0 N m Gearsh i f t Un i t Remove left and r ight side panel 2 6 Fuel tank top cover 2 8 Front fender 2 8 Bolt 1 Gearshi ft rod Remove the 3 bolts Remove gearshi ft unit Instal l at i on Reverse the removal procedure for instal la tion Make sure that gearshi ft is f lexible ...

Page 100: ...agneto Rotor 3 7 3 47 3 60 StartingDriven Gear 3 8 3 47 3 59 StartingDual Gear Idle Gear 3 8 3 48 3 59 ngine ft side Oil Pump Sprocket and Chain 3 8 3 59 CVT Cover 3 9 3 51 3 58 DriveBelt 3 9 3 36 3 57 Primary Sheave Secondary Sheave 3 9 3 30 3 57 CVT Housing Clutch Outer Face 3 10 3 51 3 57 Clutch 3 10 3 28 3 56 ngine ht side Timing Chain 3 10 3 23 3 56 Gear PositionBolt 3 11 3 56 Right Crankcase...

Page 101: ...Drain up engine oi l 3 22 Drain up coolant 3 15 Remove water hose clamp Remove water hose Water Hose Pipe Remove screw and water hose Recoil Starter Remove 4 bolts M6 12 of recoil starter Remove recoil starter Inspection Plug Remove inspection plug with screwdriver Engine Front Side Spark Plug Remove spark plug0with special wrench Tool Spark Plug Wrench Turn crankshaft align T D C line A on magnet...

Page 102: ... insert a flat screwdriver into slot of timing chain tensioner adjuster turn it clockwise to lock tensioner spring Remove tensioner fix bolt Remove tensioner and gasket Loosen timing sprocket bolt Cylinder Head Cover Timing Chain Tensioner Camshaft Remove timing sprocket bolt and lock Remove12 bolts of cylinder head cover ...

Page 103: ...ove cylinder head bolt Cylinder Head Remove cylinder head bolts diagonally Remove cylinder head Remove dowel pin and cylinder head gasket Cylinder Remove timing chain guide Note Take care not to drop dowel pin into crankcase Note Take care not to drop spacer bolt bolt lock and C ring into crankcase ...

Page 104: ...e its identification conforms to that of cylinder When removing piston pin clean off burrs of piston pin hole and groove If it is difficult to remove the piston DO NOT hammer use a special remover Remove piston pin and piston Engine Left Side Starting Motor Remove 2 bolts of starting motor Remove starting motor Tool Piston Pin Remover Note When performing above removal process be sure to hook up t...

Page 105: ...of gearshift rocker arm Sector Gear Remove gasket 2 and gearshift rocker arm 3 Remove bolt of sector gear housin cover Remove wire clip and sector gear housing cover Remove dowel pin and gasket Remove drive sector gear 4 Remove bolt 5 of driven sector gear Remove washer 6 and driven sector 7 ...

Page 106: ...e Drum Remove the sheave drum by using a suitable bar Remove washer and sheave drum Left Crankcase Cover Remove bolts Remove left crankcase cover Remove dowel pin and gasket Magneto Rotor Install attachment 1 to crankshaft end Install special tool to rotor thread Remove rotor and woodruff key Tool Rotor Remover ...

Page 107: ...eedle bearing Starting Motor Gear Remove idle gear and shaft 4 Remove dual gear and shaft 3 Oil Pump Sprocket and Chain Remove spacer 2 Remove drive sprocket nut 5 Remove C ring 6 Remove oil pump drive and driven sprockets and chain ...

Page 108: ... gasket and dowel pin CVT Continuously Variable Transmission Remove primary sheave nut with special tool Remove primary sliding sheave Remove secondary sheave nut with special tools Remove secondary sheave Tool Sheave Holder Remove drive belt Remove primary fixed sheave Remove bolt for air guide plate Remove air guide plate ...

Page 109: ...outer clutch face and CVT case Clutch Remove clutch shoe fixing nut with special tool Remove dowel pin front and rear gasket Remove clutch shoe Note The clutch shoe nut has left hand threads Timing Chain Remove timing chain Remove nut 2 of CVT case ...

Page 110: ...ator plate should be parallel with the end face of crankcase Crankshaft should remain in the left crankcase half Tool Crankcase separator Driven Bevel Gear Front Output Shaft Remove bevel gear cover bolt Remove driven bevel gear Remove front output shaft nut Engine Center Gear position bolt Remove gear position bolt Remove spring and steel ball Caution Right Crankcase ...

Page 111: ... gear Shift Cam Fork Shaft Drive Bevel Gear Remove Shift Cam Fork Shaft 1 Balancer Shaft Remove balancer shaft1 Drive Shaft Drive Shaft Remove Oil seal Bearing limit nut l ef t ro l l Remove Front Output Shaft Remove drive shaft and driven shaft ...

Page 112: ...6 13 6 Engine Removal Inspection Instal lation 6 Remove oil bump and relief valve1 Oil bump Relief Valve Separate crankshaft from left crankcase with spe cial tool Crankshaft Tool Crankshaft Separator ...

Page 113: ...t by using M6 bolts B Cylinder Head Cover Distortion Clean off sealant from the fitting surface of cylin der head cover place cylinder head cover on a sur face plate and measure distortion with a thickness gauge Cylinder head Cover Distortion Limit 0 05mm Tool Thickness Gauge Distortion out of range Replace Rocker Arm Shaft Measure out diameter of rocker arm shaft with a micrometer Rocker Arm Shaf...

Page 114: ...aft contact surface Rocker Arm I D 000 12 018mm Tool Dial Calipers Assembly Cylinder Had Note Intake rocker arm shaft A has oil holes Apply engine oil to rocker arms and shafts Install rocker arms and tighten rocker arm shaft to the specified torque Rocker Arm Shaft Bolt 28N m Disassembly Remove intake pipe Remove water temperature sensor and thermostat cover ...

Page 115: ...ress the valve spring and remove valve cotter with tweezers Remove valve spring upper seat and valve spring Tools Valve Spring Compressor Tweezers Remove valve from the other side Remove valve stem seal ring and valve lower seat ...

Page 116: ...ut of the limit replace either the valve or the valve guide If the valve stem is worn to the limit and the clearance is found to be in excess of the limit replace the valve If the valve stem is within the limit replace the valve guide Double check the clearance after replacing the valve stem or the guide Valve Stem Deflection IN EX 0 35mm Tool Micrometer Magnetic Stand Valve Seat Width Coat the va...

Page 117: ... Wear Check each valve face for wear or damage Replace valve with a new one if it is found to have abnormal wear Measure valve head thickness T Valve head thickness T out of range Replace Service Limit 0 5mm Tool Vernier Cal iper Valve Stem O D Measure valve stem O D with a micrometer Service Limit IN 4 975 4 990mm EX 4 955 4 970mm Tool Micrometer 0 25mm Valve Stem End Check valve stem end for pit...

Page 118: ...e spring tension out of range Replace ServiceLimit IN EX 182N 210N 31 5mm Tool Spring Scale Measure valve spring incline Spring incline out of range Replace Valve Spring Incline Limit 2 5o 1 7mm Assembly of Cylinder Head Service Limit 38 8mm Tool Vernier Caliper Install each valve spring seat Apply moly oil to valve stem seal and fit into position Material Moly oi l Note Do not reuse the valve ste...

Page 119: ... and release compressor to allow the cotter to wedge in between seat and stem Make sure that the rounded lip of the cotter fits into the groove in the stem end NOTE Knock the valve end with rubber hammer Make sure valve cotter is fit into groove Check the sealing effectiveness of cylinder head Dip clean solution into valve IN EX and check for any leakage of valve seat after a few minutes Tool Valv...

Page 120: ...que Install intake pipe apply lubricant to 0 ring Camshaft Water temperature sensor Tightening torque 10 N m Check camshaft for wear and run out of cams and journals if the engines produces abnormal noise or vibration or lacks power output Any of these symp toms could be caused by wear of camshaft Note Do not try to disassemble the camshaft auto matic decompression assembly It is not serviceable ...

Page 121: ...earance with the camshaft installed Camshaft journal oil clearance 0 15mm 4Install cylinder head cover and tighten bolts evenly and diagonally to the specified torque Check according to the following steps 4Clean off materials from cylinder head and cover 4Install camshaft with plastic gauge Tightening torque 10N5m 4Remove cylinder head cover read the width of the compressed plastic gauge with env...

Page 122: ...17 466mm 6 17 484mm Tool micrometer 0 25mm Camshaft Run out Measure the run out with a micrometer Replace camshaft is the run out is out of range Check timing sprocket and chain for wear or damage Service limit 0 10mm Timing Sprocket and Chain Replace with new parts if abnormal wear or damageis found Tensioner and Chain Guide Check contact surface of tensioner and chain guide for wear and damage R...

Page 123: ...ith a new one Clyinder Cylinder Distortion Check the gasket face of cylinder for distortion with a straightedge and thickness gauge and take clearance readings at 7 points as illustrated If the largest reading at any of the 7 points of the straightedge is out of the range replace the cylinder Cylinder Bore Check cylinder wall for scratches nicks or other damage Replace with a new one if any Cylind...

Page 124: ...ccording tothe abovemeasurement If the clearance is morethan 0 15mm replace the cylinder or piston or both Piston Ring to Groove Clearance Use a thickness gauge to measure the side clearance of topt ring and 2nd ring If the clearance exceeds the limit replace both piston and piston rings Top ring 0 18mm 2nd ring 0 15mm Standard width of piston ring groove Top ring 1 03 1 05mm 2nd ring 1 22 1 24mm ...

Page 125: ... limit Top ring 8 9mm 2nd ring 9 5mm Piston ring end gap limit Top Ring 0 60mm 2nd ring 0 60mm Tool Vernier caliper Thickness gauge Piston Pin and Pin Bore Use a bore gauge to measure the inner diameter of piston pin bore Use micrometer to measure outer diameter of piston pin If out of limit replace both piston and piston pin Piston pin bore limit 23 030mm Use micrometer to measure piston pin oute...

Page 126: ...ection of big end Connecting Rod Deflection Connecting Rod Deflection 3 0mm Tools Dial Gauge Magnetic stand V block Connecting Rod Big End Side Clearance Push the big end to one side and use thickness gauge to measure the other side clearance If out of limit replace with a new crankshaft Connecting Rod big end side clearance 1 0mm Tool Thickness Gauge Crankshaft Run out Support crankshaft with blo...

Page 127: ...clutch wheel for scratches scuffs or bluediscoloration or unevenwear If anydamageis found replace the clutch wheel with a newone for scratches scuffs or blue discoloration or un even wear If any damage is found replace the clutch wheel with a new one Tool Oil seal remover Use special tool to assemble oil seal Tool Oil seal installer set Check the turning of bearing Abnormal damage Replace Assembly...

Page 128: ...6 29 6Engine Removal Inspection and Instal lation 6 Primary and Secondary Sheave ...

Page 129: ...m rol ler Check each roller and sliding face for wear and damage Wear and damage Replace Check oil seal lip for wear and damage Wearanddamage Replace Note rollers should be replaced as a set Remove the oil seal Roller inspection Oil Seal inspection Disassembl ...

Page 130: ...ure of primary sliding and fixed sheave for installation Pay attention to the following Apply grease to inner bore and oil seal lip Position 8 rollers on the primary sliding sheave Install 4 dampers to cam Install cam to primary sliding sheave Material Lubricant grease Note When inserting the spacer press down the cam so that the rollers will not come out of position Note Wipe off any excessive gr...

Page 131: ...er Attach special tool to the secondary sliding sheave and compress it by turning in the tool handle Note Make sure that spring end A is inserted into slot B of the tool handle Remove ring nut Disassembly Tool Secondary sliding sheave spring compressor Note Since a high spring force applies to the secondary sliding sheave take special care that the secondary sliding sheave will not come off abrupt...

Page 132: ...ection and Instal lation 6 Remove spring Remove spring seat Remove guide pin and spacer Remove secondary sliding sheave O ring and Oil Seal Check the O ring and oil seal for wear and damage Remove Oil Seal WearandDamage Replace ...

Page 133: ...gth is shorter than the service limit replace with a new one Service Limit 145 4mm Assembly Check drive face for any abnormal condition such as stepped wear or damage Replace if necessary Install a new O ring Apply lubricant grease to O ring oil seal lip and guide pin groove Material lubricant grease Secondary Sliding and Fixed Sheave ...

Page 134: ...lip with a 0 1mm steel sheet as guide Install spring seat Align hole A with hole B Install spring and spring plate Insert spring end into the hole Compress spring with special tool Align the secondary sheave end with spring plate hole Tighten ring nut temporarily Tool Secondary sheave spring compressor Remove the special tool from secondary sheave ...

Page 135: ...der Drive belt Check belt for any greasy substance Check contact surface of belt for any cracks and damage check belt width with venire cal iper In casse of damage width out of range replace with new one Belt width service l imit 33 5mm Tool vernire cal iper Warning If belt surface is stained with grease or oi l degrease the belt thoroughly ...

Page 136: ...RIVENGEAR HIGH RANG 1 2 SHIFT CAM 1 11 DRIVENGEAR LOWRANGE 1 3 RIGHTCRANKCASE 1 12 SPRING SHIFT FORK 1 4 LEFT CRANKCASE 1 13 RIGHT SHIFT FORK 1 5 DRIVENSECTORGEAR 1 14 GUIDE BAR 1 6 SPROCKET REVERSEGEAR 1 15 DRIVEN SHAFT 1 7 CHAIN REVERSEGEAR 1 16 SPRING SHIFT FORK 1 8 DRIVENOUTPUTGEAR 1 17 LEFT SHIFT FORK 1 9 DRIVE SECTORGEAR 1 18 SHIFT FORK ASSEMBLY 1 ...

Page 137: ...t for stains scratch or damage re place if necessary Inspect reverse gear chain for damage wear replace if necessary Disassemble counter shaft as i l lustration Inspect bearing surfaces for stains damage or wear and also for bearing gaskets Replace if necessary ...

Page 138: ... Standard 0 10 0 30mm Service Limit 0 50mm Measure shift fork groove width with vernier cal iper Standard shift fork groove width 6 05 6 15mm Measure shift fork thickness with vernier cal ipers Standard fork thickness 5 80 5 90mm Check shift fork and for damage or bend replace if necessary Instal l shift fork to guide bar and move left and r ight In case of any unsmooth moving replace with a new o...

Page 139: ...Replace if necessary Assembly Reverse the removal procedure for assembly Pay attention to the fol lowing No t e Use new retainers Pay attention to the direction of the retainers Fit to the side where the thrust is as i l lustrated Coat the gears and shafts with engine oi l before assembly Warn i ng Do not reuse the retainers Do not expand of the gap end of new retainers too wide when assembl ing M...

Page 140: ...le oi l pump as i l lustrated Check oi l pump housing and cover for cracks and damage Replace if necessary Measure the top clearance a between inner and outer rotors and side clearance b between outer rotor and oi l pump housing If the clearance exceeds the l imit replace with new one Top clearance 0 03 0 10mm Side clearance 0 03 0 10mm Service l imit 0 12mm 1 Oi l pump housing 2 Dowel pin 3 Oi l ...

Page 141: ...pl iers 1 Drive bevel gear cover 5 Washer 2 Output driven gear 6 Drive bevel gear shaft 3 Drive bevel gear nut 7 Bearing nut 4 Drive bevel gear 8 Bearing 8 Check the drive bevel gear 4 and output driven gear 2 for rust scratch wear or damage Replace if necessary Check if the bearing 8 turns smoothly replace with a new bear ing if necessary Adjust Washer 5 if any of right crankcase drive bevel gear...

Page 142: ... for scratches wear Scratch or wear rep l ace Check free turning of bear ing 9 and 11 Replace i f necessary Use new oi l seal 16 and O ring 12 when assembl ing Apply lubr ication oi l to bearing 9 and 11 and oi l seal 16 O r ing Apply thread locker to nut 10 and tighten to the speci f ied torque 110N m Ad j ust washer 13 i f any of r i ght crankcase driven bevel gear 8 or driven bevel gear cover 1...

Page 143: ...nt Backlash Washer thickness adjustment 0 1mm Washer thickness adjustment 0 2mm Increase thickness 0 1 0 2mm OK Instal l special tool and micrimeter dial gauge micrometer a 46mm Turn the driven bevel gear in each direction and measure the backlash Note Measure four points in the mutual vertical direction If the backlash is not within the specification adjust the thickness of the driven bevel gear ...

Page 144: ...ck the coated teeth of the drive bevel gear Contact tooth top Incorrect Contact Middle Correct Contact Bottom Incorrect If tooth contact is correct Contact cont inue next procedure I f tooth contact i s i ncorrect Contact Contact adj ust the thickness of washerof drive gear Re peat above steps to check tooth contact unti l correct Adjustment Tooth contact Thickness adjustment Contact Decrease thic...

Page 145: ...ve starter clutch nut Magneto Rotor Remove the parts as i l lustrated on the right Check each part for abnormal wear or damage Replace if necessary Balance shaft gear woodruf key Balance shaft Balance shaft sprocket 0 Washer 1 Bolt ...

Page 146: ... l to starter clutch Apply thread locker to bolt and tighten to the specified torque Instal l the starter driven gear Tightening torque of starter clutch bolt 26N m Material Thread locker Make that the starter driven gear turns in the opposite direction of the arrow mark B The gear cannot turn in the direction of the arrow Check starter driven gear bearing In case of anything unusual replace the b...

Page 147: ...locker to the bolt when assembl ing Tightening torque for magneto co i l bo l t 10N m Check oi l seal 5 for damage Replace if it is damaged Apply lubricating oi l to bearing 4 and lubricant grease to l ip of oi l seal 5 when assembl ing Recoi l starter disassembly 1 Recoi l starter 2 Bolt 3 Washer 4 Starter pul ly Electr ic Starter Gear Left crank case cover Check sheave drum for burrs cracks or r...

Page 148: ...ut Recoi l Starter Disassembly Inspect i on Check al l parts for damage Repalce if necessary Remove nut 10 and the parts from the starter housing Disassembly is unnecessary if recoi l starter wokrs wel l Warning The coi l spring may quickly unwind and cause injury when the sheave drum is opened Wear proper hand and eye protection beforehand ...

Page 149: ...n beforehand Instal l coi l spring and sheave drum Apply lubricant grease to spring Hook coi l spring end 3 to the starter housing wind the coi l spring clockwise Hook the other end of coi l spring to hook part of sheave drum Instal l spring clamp 0friction plate and bolt Put the end of spring clamp in the groove near the damper Turn sheave drum clockwise three times to tighten the coi l spring In...

Page 150: ... wi th special tool Apply lubr icat ion oi l to bear ing 5 and instal l with special tool Check bearing for smooth turning The seal side of bear ing 5 should face bearing retainer 4 Apply lubr icat ion oi l to outer r ing of bearing and instal l bearing with special tool Check bearing for smooth turning Apply grease to bearing inner side Apply grease oi l seal l ip and instal l bearing with specia...

Page 151: ...ooth turning In case of any abnormal remove bearing with special tool and replace Check al l the oi l seals for over wear or damage In case of any over wear or damage remove with special tool and replace with a new oi l seal Remove l ink bolt and oi l pipe 14 and check oi l pipe for crack or clog Replace with a new one i f any Use special tools to assemble bearnig or oi l selas Lubricant oi l is a...

Page 152: ... for instal lation No te Clean al l the parts before assembly Make sure that the parts are in good con dition without any damage Apply engine oi l to the moving parts be fore assembly Apply grease to oi l seal l ip O ring Caution Make sure that drive belt primary and secondary sheaves are not stained wi th grease Engine Center Instal l oi l pump and rel ief valve to left crankcase as i l lustrated...

Page 153: ...nrod into crankcase wi th plast ic mal let Use special tool to avoid affect of conrod precision Ba lance Shaf t Instal l balance shaft Caution Balancer shaft driven gear should be al igned to the mark as i l lustrated Tool control instal ler Main Shaft Counter Shaft Instal l main shaft and counter shaft 45 65 78 ...

Page 154: ...e speci f ied torque Sh i f t Cam Sh i f t Fork Dr ive Bevel Gear R i ght Crankcase Dr iven Bevel Gear Front Output Shaft Spray adequate engine oi l to each pa r t Dr i ve beve l gear t i ghten i ng t o r q ue 3 2 N m Instal l driven bevel gear and tighten to the speci f ied torque Dr i ven beve l gear t i ghten i ng t o r que 25N m Check bevel gear backlash Refer to 6 44 Instal l front output sha...

Page 155: ...Posi t ioning Bol t Timing Chain C l utch Instal l clutch 1 and nut 2 Tighten the nut to the speci f ied torque left thread Clutch nut tightening t or que 7 0N m Note Crankcase bol ts shou ld be t ightened diagonal ly in several steps Eng i ne R i ght Instal l 2 dowel pins M6 10N m M8 25N m Place the steel bal l and instal l gear po sitioning bolt 1 and tighten the bolt to the speci f ied torque T...

Page 156: ...ket Intal l new O ring in spacer Instal l spacer onto the clutch housing shaft then instal l into CVT case Note al ign oi l nick on spacer wi th oi l hole on the shaft Instal l dowel pin gasket gasket intal l CVT case assembly to the right crank case Instal l bolt 0 and nut N o t e Tighten bolt nut diagonal ly Instal l guide plate 1 and screw 2 Instal l primary f ixed sheave as i l lustrated on th...

Page 157: ...ed torque Secondary sheave t ighten ing t o r q ue 115N m Tool Rotor holder Note Turn the pr i mary sheave unt i l the belt is seated in and both primary and sec ondary sheaves move together smoothly CVT case cover Instal l secondary sheave Instal l primary sl iding sheave Pr i mary sheave nut t i ghten i ng t o r q ue 115N m Instal l the new gasket and dowel pins ...

Page 158: ... steps O i l pump sprocket and cha i n Instal l oi l pump drive sprocket Instal l oi l pump driven sprocket Instal l oi l pump dr ive chain Tighten oi l pump sprocket bol t Instal l sprocket retainer with a long nose p l i ers Tool Long nose pl iers Instal l dual gear shaft and dual gear Instal l idler gear shaft idler gear and bush Instal l start ing dr iven gear bush ...

Page 159: ...ruf f key i nto crankshaf t groove Intal l magneto rotor 1 Note Degrease the tapered part of rotor and crankshaft Use nonf lammable solvent to clean off the oi ly or greasy matter and ful ly dry the surfaces Instal l dowel pin 2 and gasket 3 Apply lubricant grease to oi l l ip Instal l left crankcase cover Instal l bolts Instal l washer 3 and bolt 4 tighten to the speci f ied torque Reco i l start...

Page 160: ...mp shaft Instal l water pump f ixing bolts 1 Sector gear cover and gasket 2 Dowel pin 3 Drive sector gear 4 Driven sector gear 5 Driven sector gear bolt N o t e When the sh i f t cam i s i n the neut ra l pos i t ion the mark of dr i ve sector gear shou l d be between the two marks of the dr i ven sector gear Dr i ven sector gear t i ghten i ng torque 1 4 N m Instal l gearshi ft rocker arm 6 Insta...

Page 161: ...e 1st r ing and 2nd r ing di f fer in shape Instal l oi l f i l ter bol t and tighten to the speci f ied torque Apply engine oi l to O ring Instal l oi l f i lter turn it by hand unti l the fi lter gasket contacts the mating surface Tighten the bolts Apply engine oi l to new O ring Instal l bolt and tighten to the speci f ied torque Tightening torque 10N m Instal l the piston rings in the order of...

Page 162: ...the three r ings as i l lustrated on the right Before instal l ing the piston into the cyl inder check that the gaps are so located Note When instal l ing the piston the IN mark on piston top is located to the intake side Place a clean rag beneath piston and in stal l piston pin circl ip Note whi le rotating crankshaft pul l the cam chain upward or the chain wi l l be caught between sprocket and c...

Page 163: ... e n t h e c y l i n d e r b a s e b o l t s temporari ly Note When instal l ing the cyl inder and cyl inder head pul l the cam chain upward or the chain wi l l be caught between sprocket and crankcase Instal l chain guide Fit the dowel pin and new cyl inder cover gasket Instal l the cyl inder cover t ighten the cyl inder head bolts diagonal ly to the speci f ied torque Tighten the cyl inder head ...

Page 164: ... between sprocket and crankcase Al ign the mark A on the camshaft so that they are paral lel with the mating surface of the cyl inder head Note Do not rotate the magneto rotor whi le doing this when the sprocket is not posi tioned correctly turn the sprocket Engage the chain on the sprocket with the locating pin B as i l lustrated on the right Recheck if the position of mark A and C is correct If ...

Page 165: ...t it covers the locat ing pin Apply thread locker to the bol ts before instal l ing and tighten them to the speci f ied torque Sprocket bo l t t i ghten i ng torque 1 5 N m Bend up the lock washer to lock the bolts Clean the mating surface of cyl inder head and cyl inder head cover Instal l dowel pin to the cyl inder head Apply sealant to the mating surface of the cyl inder head cover Instal l cyl...

Page 166: ...Instal l the chain tensioner and the new washer 1 Instal l the bol t 2 t ighten i t to the speci f ied torque Gasket sealant applying place C h a i n t e n s i o n e r b o l t t i g h t en i n g t o r q u e 1 0 N m After chain tensioner is instal led turn the screwdriver counter clockwise The tensioner rod wi l l be advanced under spring force and push tensioner against chain ...

Page 167: ... it to the speci f ied torque Refer to 2 3 for valve clearance Use new rubber gasket and apply grease Instal l Valve Inspection Cap Instal l valve inspection cap bol t Instal l spark plug with special tool and tighten to the speci f ied torque Note To avoid damage to the cyl inder head thread screw in the spark plug wi th hand first then tighten it to the specified torque with spark plug wrench In...

Page 168: ...6 69 6 Engine Removal Inspect ion Instal lat ion 6 Instal l left plastic cover 6 Instal l water hose 5 Instal l water hose 3 Left plast ic cover Water pipe and hose Instal l bol t 4 Instal l clamp 1 2 ...

Page 169: ...oubleshooting 7 3 High pressure oi l pipe Disassembly Instal lation 7 4 Throttle Valve Disassembly Instal lation 7 5 FuelInjector Assy Disassembly Instal lation 7 6 Fuel injector Assy Removal Assembly 7 6 Idle Air control valve Disassembly Instal lation 7 6 ...

Page 170: ... of other objects into the engine from the air intake side of the engine When the vehicle wi l l be stored for more than one month the gasol ine in the high pressure oi l pipe and cap of the fuel injector must be discharged Otherwise the gasol ine wi l l age and form col loidal elements which may block the nozzle of fuel injector therefore the engine cannot start or the rotate speed is unstable Ov...

Page 171: ...Loosen the strap and remove thrott le valve connector Loosen locknut remove adjust nut and remove the thrott le cable f rom thrott le rotory sleeve Disassemble idel air outlet pipe on throttle valve Loosen air intake connect clamp air cleaner connect clamp and remove throttle valve body Notes Donot adjust the bol t on thrott le valve Donot remove the cap on throttle valve body Thrott le valve body...

Page 172: ...ap spring to edge of fuel injector cap and press the snap spring into it Idle ai r control valve Disassembly Disassemble idle intake pipe and idle outlet pipe Loosen the strap disassemble idle air con trol valve and check idle air control valve Replace it when there is abnormal noise or it doesnot work Id l e a i r contro l va l ve Insta l l a t i on Reverse the d i sassemb l y procedure f or inst...

Page 173: ...im you required to use special tyre lever and rim protector Overhaul standard Item Standard Service limits Portrait 0 8mm 2 0mm Rim jump Cross 0 8mm 2 0mm Remain groove 3 0mm Tyre Air pressure 35kPa 0 35kgf cm2 Front disc Brake lever windage 0mm Tighteningtorque steering tie rod nut 40 50 N m steering shaft lock nut 100 120N m front wheel shaft nut 110 N m suspension f ixed bolt nut 40 50 N m rim ...

Page 174: ...tat ion dumb wheel shaft bad front wheel shaft bend brake drag Front suspension too soft front suspension bounce weaken tyre ai r too lower Front suspension too hard front suspension bend tyre ai r too high Front suspension abnormal no i se front suspension bad suspension tightening parts loosen Brake ef fet poor brake adjustment bad brake disc surface deface brake block destroy Special tools Bear...

Page 175: ...wheel slowly use cent imeter mea sure rim jump Serv i ce l i m i t ax i a l d i rect i on 2 0mm Rad i a l d i rect i on 2 0mm I nsta l l i ng Press the rim in the tyre on special matchin Fix the rim in hub R i m i ns ta l l nu t to rque 50 60 N m Front whee l hub d i sassemb l e D i sassemb l e remove front wheel 8 3 remove front brake cal iper 8 4 remove rim shaft nut take away brake disc and hub...

Page 176: ... e remove front wheel 8 3 remove the 2pcs nuts instal led on the arm remove brake cal iper Inspect i on Check i f the brake cal iper crack i f the tightening area oi l leakage replace i f needed Instal l i ng Brake ca l i per ho l d i ng bo l t torque 40 50N m ...

Page 177: ...and brake master cy l inder front brake Disassemble remove bolt remove parking lever Seperate front hand brake master cyl inder handlebar it is not need to remove the front hand brake master cyl inder if not replace the brake pump assembly Attent i on Dono t use b rake t ube hang t he b r ake pump to prevent front hand brake master cy l i nder backdat e so keep i nst a l l i ng pos i t i on at the...

Page 178: ...e brake ef fort i s requ i red Brake Y joint D isassemb l ing remove front inner fender RH 2 12 remove bolt 1 then the brake Y joint canbe remove form the body Assemb l i ng Assembl ing carry on to the opposite sequence of disassembl ing Attent i on Oi l tube trend refers to sec t ion 1 cab le and wi re traces the brake o i l l i ne must be smooth Brake f orce check i ng i s requ i red when comp l...

Page 179: ... LH and RH suspension at one t ime or else the body wi l l fal l down because lack of holding power D i sassemb l e Put vehicle body into horizontal posi tion use jack hold the wheel front f irmly remove front wheel 8 3 remove front rim hub 8 3 remove cal iper 8 4 remove front left absorber bolt 1 and tight ening nut 1 instal led on the body remove front left upper arm bolt 1 and tight ening bolt ...

Page 180: ...You donot need to remove any o the r pa r t s i f you on l y r ep l ace the f ront suspens i on Remove front left absorber s bol t 1 nut 1 instal led in arm Remove front right shock absorber Inspection Inspect if the absorber oi l leakage oi l seal age destroy replace i f needed ...

Page 181: ...t i on and assemb l e the f ront l e f t upper arm and the f ront r i ght l ower arm Other arm assemb l e refers to the above Front r ight arm assy D i sassemb l e Remove front right absorber 6 8 Remove front right upper arm s bolt 3 and tightening nut 7 bolt 1 tightening bolt 1 and nut 7 Remove front right lower arm s bolt 3 and tightening bolt 7 s nut 7 instal led in the frame Before disassembl ...

Page 182: ...ottom bal l pin 17 and front right lower 12 Besides the gap between top bal l pin and bottom if it cannot move freely or the gap too big bal l pin replacement is needed R i ght knuck l e Inspect i f the r ight knuckle is destroy replace it i f need Inspect if the rim shaft inside right knuckle move 012345678 9 9ABC56 DE FGHI56 ...

Page 183: ...e cal iper 8 4 remove fornt left rim hub 8 3 Examine duct boot replace with new ones i f destroy cos t an t ve l oc i t y d r i ve sha f t shake inspect i f the universal joint move freely the bear ing move freely i f there is gap between joint and spl ine Replace with new ones if dumb abnormal sound gap Attent i on Doub le of fset un i versa l j o i nt mus t can be move f ree l y or e l se i t ca...

Page 184: ... cover Assemb l i ng Assembl ing carry on the opposite sequence of disassembl ing RH handlebar swi tch D isassemb l ing remove front top cover 2 4 remove RH handlebar switch connector remove the two bolts instal led in handlebar tube remove handlebar switch RH Insta l l at ion Instal l the handlebar swi tch RH 8 15 ...

Page 185: ... and you can take of f the rear view mirror At tent i on Lef t hand rear v i ew m i r r o r i s r i gh t hand sc r ew t h r ead turn i t i n counter c l ockw i se d i rect i on when d i smant l i ng Loosen the nut in clockwise direction turn the RH rear view mi rror then you can take down the RH rear view mirror At tent i on RH rear v i ew m i r ror i s l e f t hand thread you requ i red to turn i...

Page 186: ...tion bolt take down the handlebar Assemb l i ng Assembl ing carry on according to the opposi te sequence of disassembl ing T o r q u e 20 30N m 2 0 3 0kgf m Attent i on Main cable assy thrott le cable brake oi l pi pe cab le hut accordi ng to the drawing correctly Instal l thrott le cable remove the three screws remove RH handlebar switch cover Instal l throttle cable instal l RH handlebar switch ...

Page 187: ...handlebar location hole use bolt 1 tightening from the bottom Insert the LH handlebar swi tch s connector into the main cable Instal l RH handlebar swi tch Pai r the RH handlebar swi tch stopped onto the handlebar location hole Tightening through the bolt 2 from the bottom Insert the RH handlebar swi tch s connector into main cable ...

Page 188: ...he joint cement Insta l l brake pump upward the brake pump base JUPK mark then instal l the brake pump eyebal l ing the distance between brake pump and handlebar switch handlebar under hood to equal ity Attention Main cable assy thrott le cable brake oi l pipe cable hut shal l according to the drawing correct ly Instal l the parking lever instal l the rear view mi rror 8 13 instal l the dashboard ...

Page 189: ...8 FRONT WHEEL BRAKE SUSPENSION STEERING SYSTEM 8 8 17 Steer i ng system ...

Page 190: ...al lation nut washer Press and separate the steer ing t ie rod from the steering stem Remove steering stem instal la tion bolt Raise up the steering stem and the handlebar together then you can remove the steering stem Instal l i ng Instal l ing carry on according to the oppo site sequence of uninstal l ing A t t en t i o n Check t h e maneuve r ab i l i t y a f ter f i n i sh the i nsta l l at i ...

Page 191: ...r component rotor pu l l er remover ax l e remover heavy bob Insta l l at ion Instal lation carry on according to the oppo site sequence of uninstal lation Spec i a l too l Bear i ng race i nsta l l at i on too l A Assemb l i ng too l i ng bar A t t en t i on Spec i a l too l must be used when i nsta l l the bear i ng Steering system instal l according to the op posite sequence of uninstal lation ...

Page 192: ...age to the wheels When removing tires from rim use special tire lever and rim protector to avoid damage to the rim Overhau l Standard T i ghten i ng Torque Rear Wheel Axle Nut 110 130N m Rim Mounting Bolt 50 60N m Upper Mounting Bolt Shock Absorber 40 50N m Lower Mounting Bolt Shock Absorber 40 50N m I t e m S t a n d a r d L i m i t L o n g i t u d i n a l 2 0 m m R i m V i b r a t i o n H o r i ...

Page 193: ...r Tightening of Wheel Axle Nut Loosened Wheel Nut Rear Shock Absorber i s Too Sof t Weak Spr ing Oi l Leakage from Rear Shock Absorber Rear Shock Absorber i s Too Hard Bent Rear Shock Absorber Ti re Pressure is Too High Poor Brake Ef f i c i ency Improper Brake Adjustment Stained Brake Pad or Brake Disk Worn or Damaged Brake Pad ...

Page 194: ...ce Slowly turn the wheel measure the rim vitration with a dial gauge Serv i ce L i m i t Ax i a l 2 0mm Rad i al 2 0mm I nsta l l at i on Refer to Front Wheel Instal lat ion 8 3 Whee l Hub Remove Rear Whee l 9 3 Rim Axle Nut Wheel Hub I nsta l l at i on Reverse the removal procedure for instal lation T i ghten i ng Torque R i m Ax l e Nut 110 130N m ...

Page 195: ...apter 1 for brake hose routing Rear Brake D i sc Remove Rear Left Wheel 9 3 Rear Drive Shaft Rear Brake Cal iper 9 4 6 Shear Bolts Park ing Brake 9 4 Rear Brake Disc 8 3 I nspect i on Brake Disc Thickness 6 5mm Replace I nsta l l at i on R e v e r s e t h e r e m o v a l p r o c e d u r e f o r instal lation Note Refer to Chapter 1 for brake hose routing Park i ng Brake Remove Rear Left Wheel 9 3 ...

Page 196: ...t the same t ime to avo i d fa l l down of the veh i c l e Stab i l i zer Bar Remove Bol t1 6 Bol t2 7 Bol t3 10 Bol t4 11 Bracket 8 and 5 Rubber Support 4 and 9 Nut2 2 Nut10 12 Left Bal l Pin 1 Right Bal l Pin 14 Remove Stabi l izer Bar 3 I nsta l l at i on R e v e r s e t h e r e m o v a l p r o c e d u r e f o r instal lation D i sassemb l y ...

Page 197: ...fol lowing parts from rear r ight shock absorber Bolt10 25 Nut7 27 Bolt7 19 Nut8 28 Remove rear right shock absorber I nsta l l at i on R e v e r s e t h e r e m o v a l p r o c e d u r e f o r instal lation Rear R i ght Arm Refer to Front Left Upper Arm in Chapter13 for the removal inspection and instal lation of Rear Right Arm Rear Lef t Suspens i on Refer to Rear Right Suspension for the remova...

Page 198: ...e case bolt 6 M8 28 25 Front axle motor screw 4 M8 20 13 Pinion shaft screw 1 M8 10 13 With fastening glue Front axle nut 1 M14 1 5 62 Diff gear bolt 6 M10 1 25 22 45 Oi l bolt front axle 1 M14 1 25 12 25 Drain bolt front axle 1 M10 1 25 25 Rear axle case bolt 2 M10 1 25 25 40 Rear axle case bolt 6 M8 25 25 Nut input shaft R A 1 M12 1 25 70 Bolt input shaft R A 4 M8 30 25 Retainer R A 1 M65 1 5 10...

Page 199: ... Abnormal sounds during accelerating decelerating have l ittle to do with engine working but possibly with gear worn b Constant abnormal sounds during accelerating or decelerating might be cause by gear clearance wrongly adjusted during assembl ing Note Wrong assembly or adjustment of the front or rear axle wi l l aggravate gear worn and block c Sl ight sounds wi l l be noticed during low speed dr...

Page 200: ...t M14 1 25 1 30 Screw M8 10 1 1 Bolt M8 28 6 17 Bearing F1512 1 Front axle exploded view 4 Bearing 16007 1 20 Oi l seal 48 65 9 1 5 Circl ip 62 1 21 Coupler 1 6 Drive clutch cover 1 22 O ring 14 6 8 1 7 Drive clutch 1 23 Nut washer 1 8 Adjust washer 83 71 1 2 24 Nut M14 1 5 1 9 Differential gear assy 1 25 Screw M8 20 4 15 Oi l seal 24 38 8 2 31 Retainer M64 1 5 7 1 Item Part Name Qty Item Part Nam...

Page 201: ...if necessary Check driven gears surface gear center differential bracket differential wearing situation on the differential gear assembly Replace parts if necessary Check gear motor working status Replace with new parts if necessary Check if oi l seal l ips and O ring shape are ok Replace if necessary Check cyl indrial surface of front axle and oi l seal l ips Replace broken parts if necessary Che...

Page 202: ...clutch assembly 24 Use screw thread fastening glue Frong axle case assembly Note Use engine oi l for oi l seal or bearing assembly Differential gear assembly Bolt M10 1 25 22 Tightening torque 45Nm Note Use engine for bearing and dif ferential gear Use proper washer to make gear working freely Washer thickness 0 1 0 2 0 3 0 4 0 5 1 0 16 23 24 10 Item 31 Tightening torque 80Nm ...

Page 203: ...d drive clutch assem bly should be against tightly to the arrow shape i l lustration when assembly of front axle motor Washer thickness 0 1 0 2 0 3 0 4 0 5 1 0 Use fastening glue for item 30 assembly Dr ive bevel gear clearance measurement Instal l support tools tighening bolts M10X1 25X60 put up dial indicator make sure 21 mm is between measur ing point and support tools Turn support tools counte...

Page 204: ...le c Use special equipment or vehicle control circuit into 2WD position be fore gear motor assembly d Make sure b and c is assembled prop erly and using i l lustrated positionging screw to assemble gear motor and front ax l e ...

Page 205: ...1 Oi l seal SD4 65 90 9 NS 2 12 Nut M12 1 25 1 13 Washer 12 5 30 4 1 14 Coupler rear axle 1 15 Bolt M8 35 4 16 Oil seal 1 17 Bevel gear bearing housing 1 18 O ring 64 5 3 1 5 Bearing 16017 C2 1 19 Bearing 6305 1 20 Bearing reteiner 1 22 Bearing inner race 1 23 Bearing outer race 1 25 Washer14 5 21 1 5 1 26 Bolt M14 1 25 12 1 27 O ring 19 2 5 1 28 Bolt M20 1 5 12 1 29 Screw M8 45 1 30 Washer 8 2 15...

Page 206: ...l tools are required Check worn status of drive bevel gear and ring gear rear axle Replace if necessary Check oi l seal l ips o ring shape Replace parts if necessary Check cylndrical surface of rear axle and oi l seal l ips Replace if necessary Check inner and outsider spl ine Replace if necessary Check other parts Replace if necessary Disassembly of bearing a Disassemble needle bearing as left dr...

Page 207: ...ing 6 washer to adjust clearance c By coat ing color to check contact surface if it1s ok for mating d Inspect installing clearance by check ing bevel gear clearance By using assistant measurement tool to check its clearance Standard 0 1 0 2 Washer 8 Wahser 24 Washer 6 Thickness 0 2 0 3 0 4 Thickness 1 0 1 2 1 4 1 6 1 8 Thickness 0 4 0 5 0 6 e Keep instal l ing point bearing clear ance 0 1 0 2 by c...

Page 208: ...10 11 10 10 Front Rear Axle f Adjust item 29 as i l lustrated and make sure its end and back clearance of drive gear is 0 3 0 6 Tighten item 31 ...

Page 209: ...PONENTSCOMPOSITION FUNCTION 11 12 ECU 11 12 THROTTLE ASSEMBLY 11 13 INLET PRESSURE SENSOR 11 14 INTAKE AIR TEMPERATUR SENSOR 11 15 WATER TEMPERATURE SENSOR 11 16 OXYGEN SENSOR 11 17 TRIGGER 11 18 ODOMETER SENSOR 11 19 SHIFT LEVER POSITION SENSOR 11 20 FULE OIL PUMP ASSEMBLY 11 21 OIL ATOMIZER 11 22 IDLE AIR CONTROL 11 23 IGNITION COIL 11 24 6 ELECTRICITY SPRAYING SYSTEM SELF DIAGNOSIS 11 25 TROUBL...

Page 210: ...TANCE 0 5 1 5 YELLOW Y E L L O W INSULATING RESISTANCE YELLOW G R O U N D MAGNETOR NON LOADED PERFORMANCE START THE ENGINE LET IT GOES TO 5000r min USE MULTIMETER MEASURE MAGNETOR STATOR COIL THREE OUTPUT LINE VOLTAGE IT THE RESULT VALUE BELLOW THE SETTING VALUE CHANGE A NEW MAGNETOR ADJUST MULTIMETER TO ALTERNATING VOLTAGE GRADE MAGNETOR NON LOADED STATE COIL VOLTAGE VALUE 5000r m i n 200V ALTERN...

Page 211: ...E DATA OUT OF THE SETTING VALUE REPLACE WITH A NEW ONE ADJUST MULTIMETER TO DIODE A TT EN T I ON WHEN MULTIMETER PROBE UNCONNECTED IF THE MULTIMETER SHOWS BELLOW 1 4V THEN REPLACE I T S BATTERY AFTER ENGINE RUNNING BATTERY FULL POWER IF VOLT AGE BETWEEN RED LINE GREEN LINE EXCEED 15V OR UNDER 12V REPLACE WITH A NEW ONE ...

Page 212: ...11 4 CFMOTO STARTING SYSTEM TRIGGER CIRCUIT DIAGRAM STARTING DYNAMO ...

Page 213: ...W AMATURE IF THE COMMUTATOR SURFACE DISCOLOURATION POLISH WITH SEND PAPER AND WIPE UP WITH DRY CLOTH IF OVER WEAR CUT PART OF B INSULATOR WITH BLADE KAME THE DISTANCE BETWEEN A AND B TO d d 1 5mm ARMATURE COI L USE MULTIMETER CHECKING IF IT IS INTERCOMMUNICATION BETWEEN THE TERMINALS BETWEEN TERMINALS AND ARMATURES IF THEY NOT COMMUNICATION REPLACE WITH A NEW ARMATURE OI L SEAL CHECKING IF OIL SEA...

Page 214: ...IL RESISTANCE IF THE VALUE OUT OF THE SETTING RANGE REPLACE WITH A NEW ONE ADJUST MULTIMETER TO 1X10 GRADE START AUXI L IARY RELAY COI L RESISTANCE 3 5 START AUXI L IARY RELAY FULE PUMP RELAY LOAD 12V VOLTAGE TO THE THE ANODE AND CATHODE OF THE STARTING RELAY COIL USE MULTIMETER MEASURE IF CON TACTS A B IS MEET ADJUST MULTIMETER TO DIODE GRADE IF THE STARTING RELAY SOUND TICK AND CONNECTION WHEN N...

Page 215: ...ANNEL SMOOTH IF LEAKAGE RELINK LEAK SECTION SECURE THE OIL CHANNEL NO LEAKAGE USE OIL PRESSURE GAGE MEASURE OIL PRESSURE FULE PUMP OUTPUT PORT PRESSURE 0 3 0 01Bar0 0 CHANGE ENGINE SHIFT HAND LEVER TO NEUTRAL USE DIAGNOSTIC EQUIPMENT CHECK IF AT FAULT IF YES CLEARING OF FAULT ACCORDING TO DIAGNOSTIC TROUBLE CODE CLOSE THROTTLE TURN OFF THE IGNITION SWITCH PRESS START SWITCH 3 5 SECONDS START THE E...

Page 216: ...ODOMETER SENSOR OUTPUT SHAFT SPEED INFORMATION OXYGEN SENSOR EXCESS AIR COEFFICIENT ABOVE 1 OR LOWER THAN 1 GEAR SENSOR GEAR INFORMATION INCLUDING GEAR SENSOR AND REVERSE GEAR SENSOR 3 ACTUATOR EXECUTE THE ECU INSTRUCTION THE ACTUATOR IS THE HAND OF ECU THE MAIN ACTUATORS ARE OIL FUEL PUMP ASSY SUPPLY HIGH PRESSURE FUEL OIL ATOMIZER SPRAY QUOTAL FUEL MAKE FUEL SPRAY EXCELLENT IGNITION COIL PROVIDE...

Page 217: ... PIPE PRESSURE RELIEF BEFORE DISMANTLE THE OIL PIPE PRESSURE RELIEF METHOD IS AS FOLLOWING REMOVE OIL PUMP RELAY STARTING THE ENGINE AND LET IT IDLE RUNNING UNTILL THE ENGINE GO OUT ITSELF OIL PIPE S DISMANTLE AND FUEL FILTER S RE PLACEMENT SHOULD BE CARRY ON BY PROFESSIONAL PERSON IN WELL VENTILATED PLACE WHEN INSPECTING THE IGNITION SYSTEM ONLY IF IN NECESSARY DO SPARKING TEST AND SHOULD BE AS F...

Page 218: ...E OBSERVE DATA STREAM COMPONENETS MOTION TESTS TOOL NAME COMMUTATOR FUNCT ION INSPECT ECU EACH SUTURAL ELECTRICAL SIGNAL INSPECT CIRCUIT STATES ETC TOOL NAME DIGITAL MULTIMETER FUNCT ION INSPECT ELECTRONIC SPRAYING SYSTEM VOLTAGE CURRENT RESISTANCE ETC TOOL NAME VACUUM METER FUNCT ION INSPECT INLET PIPE PRESSURE STATE ...

Page 219: ...ME CYL INDER PRESSURE GAUGE FUNCT ION INSPECT ENGINE CYLINDER PRESSURE STATE TOOL NAME FUEL PRESSURE GAUGE FUNCT ION INSPECT FUEL SYSTEM PRESSURE STATE JUDGE THE FUEL SYSTEM FUEL PUMP AND FUEL PRESSURE REGULATING VALVE WORK STATE TOOL NAME OI L ATOMI ZER WASHING ANALYZER FUNCT ION WASHING ANS ANALYZING OIL ATOMIZER ...

Page 220: ...IGNITION SWITCH POWER 6 INTAKE AIR TEMPERATURE SENSOR SIGNAL 7 REVERSE GEAR 8 4WD DEAD LOCK SWITCH SIGNAL 9 ASSISTOR SWITCH SIGNAL 10 5VPOWER OUTPUT 11 IGNITION SWITCH POWER 12 TRIGGER SIGNALA 13 TRIGGER SIGNALB 14 OIL ATOMIZER 15 OXYGEN SENSOR HEATING 16 SUPPLEMENTARY RELAY 17 IDLE SPEED CONTROL VALVE CARBON TANK CONTROL VALVE 18 WATER TEMPERATURE SENSOR SIGNAL 19 INLET PRESSURE SENSOR SIGNAL 20 ...

Page 221: ...MPER POSITION SNESOR TRANSMIT ANGLE SIGNAL TO ECU EACH PIN FUNTION 1 CONNECT 5V POWER 2 GROUNDING 3 OUTPUT VOLTAGE SIGNAL THE RIGHT DRAWING IS THE WIRING DIAGRAM WITH ECU I DLE SPEED L IM IT SCREW NOT ALLOWED TO BE ADJUSTMENT ENGINE IDLE SPEED COMPLETELY DEPEND UPON ELEC TRONIC SPRAYING SYSTEM ADJUSTMENT PROHIBIT MANUAL ADJUST THE IDLE SPEED SCREW ...

Page 222: ...E SIGNAL THE RIGHT DRAWING IS THE CONNECTION DRAWING FOR SENSOR ECU THE RIGHT DRAWING IS THE PERMIT FITTING LIMIT IN THIS WAY CAN ENSURE THERE IS NO CONDENSED WATER INSIDE THE SENSOR THE CONDENSED WATER CAN DESTROY SENSOR I NNER PRESSURE SENS I NG DEVI CE THE PICTURE BELOW IS THE RECIPROCAL DIAGRAM DRAWING FOR PRESSURE AND OUTPUT VOLTAGE MONITOR PRESSURE RANGE 10 115kPa ...

Page 223: ...CIENT NTC THERMISTANCE IT S RESISTANCE VALUE DECREASE WHEN THE COOLANT TEMPERATURE INCREASE BUT IT IS NOT LINEAR RELATION THE SENSOR HAVE 2 PINS AND THEY CAN BE EXCHANGED USING THE RIGHT DRAWING IS THE WIRING DIAGRAM FOR SNESOR ECU THE RIGHT DRAWING IS FOR SENSOR TEMPERATURE RESISTANCE PROPERTY L IST ...

Page 224: ...NDITION THE OTHER GROUP PROVIDE TO THE METER MONITOR WATER TEMPERATURE A AND C IN ONE GROUP THEY PROVIDE WATER TEMPERATURE TO ECU B ANDTHREADED PORTION IN ONE GROUP THEY PROVIDE WATER TEMPERATURE TO THE METER THE RIGHT DRAWING IS THE WIRING DRAWING FOR SENSOR ECU AND METER THE RIGHT DRAWING IS B END AND CRUST TEM PERATURE PROPERTY L I ST S I GNAL PASS TO THE METER THE RIGHT DRAWING IS END A C AND ...

Page 225: ...CONTENT DEFINITE IF THE GAS AND AIR COMPLETE BURNT SO AS TO ENSURE UNIT TRIPLET CATALYTIC CON VERTER HAVE MAXIMUM CONVERSION EFFICIENCY TO EXHAUST HC CO AND NOX THE PINS FUNCTION 1 CONNECT HEATING POSITIVE SOURCE WHITE 2 CONNECT HEATING NEGATIVE SOURCE WHITE 3 OUTCOMING SIGNAL NEGATIVE POLE GRAY 4 OUTCOMING SIGNAL POSITIVE POLE BLACK THE RIGHT DRAWING IS THE WIRING DIAGRAM FOR SENSOR AND ECU THE B...

Page 226: ...LUE CONNECT MULTIMETER AND PEAK VOLTAGE ADAPTER AC CORDING TO THE RIGHT DRAWING PROBE GREEN LEAD WIRE PROBE BLUE LEAD WIRE ATTENTION WHEN USE PEAK VOLTAGE ADAPTER REFERS TO OPERATION MANUAL ADJUST MULTIMETER TO ALTERNATE V ADJUST THE GEAR TO NEUTRAL ADJUST IGNITION SWITCH T O O N PRESS ON STARTING BUTTON AND LET THE ENGINE RUN NING FOR FEW SECONDS THEN START TO MEASURE THRIIGER COIL PEAK VOLTAGE R...

Page 227: ...QUARE WAVE VOLTAGE SIGNAL INPUT POWER VOLTAGE 80 3 POWER DC12V THE RIGH IS THE WIRING DRAWING OF SENSOR AND ECU GROUNDING FOOT 1 CONNECT FOOT 3 12V ODOMETER SENSOR TESTING FIXED ONE GEAR TO ODOMETER ACCORDING TO THE RIGHT DIAGRAM DISTANCE 2 5mm ADJUST MULTIMETER TODCV ROTATE THE GEAR SLOWLY MEASURE THE VOLTAGE VALUE BETWEEN FOOT 2 AND FOOT 3 TO SEE IF IT IS VARY FROM 0V 12V IF NO CHANGES THEN THE ...

Page 228: ...NE COVER OR ELSE IT NON CONDUCTION WITH THE ENGINE COVER NORMALLY C LENGTH IS 3 5mm IF C LENGTH 3mm OR IF B SLIDE BLOCK YOU HAVE TO CHANGE IT TO A NEW ONE 10 REVERSE GEAR ASSEMBLE PROVIDE GEAR REVERSE INFORMATION TO ECU AND METER THE ECU RESTRICT VEHICLE SPEED ACCORDING TO THIS INFORMATION NORMALLY A B POINT CONDUCTION DONOT CON DUCT WITH THE CASE WHEN ENGINE BACK GEAR A POINT NON CONDUCTION WITH ...

Page 229: ... PRESSURE CONNECT OIL PRESSURE GATE TO THE OIL FUEL PUMP FUEL DISCHARGE PORT LOCK WITH CLAMP ENSURE THERE IS NO LEAKAGE IN CONNECT AREA LINK THE CIRCUIT ACCORDING TO THE ABOVE DIAGRAM TURN OFF THE IGNITION SWITCH FLAMEOUT SWITCH AT THIS MOMENT THE OIL FUEL PUMP WILL WORKING FOR 5 SECONDS WHEN IT STOP THE OIL PRESSURE SHALL REACH THE AUTHORIZED PRESSURE OR ELSE REPLACE THE ENTIRE OIL FUEL PUMP ASSY...

Page 230: ...LUG MARK CONNECT OIL PUMP RELAY OUTPUT END WITHOUT MARK SIDE CONNECT ECU PIN 14 FUNCTION OF PINS O I L ATOM I ZER RES I STANCE 12 1 202 2 THE RIGHT IS THE WIRING DIAGRAM FOR OIL ATOM I ZER AND ECU INSTALL THE OIL ATOMIZER WITH MANUL FORBID KNOCK WITH HAMMER OR SUCH KIND OF THINGS WHEN DISASSEMBLE AND ASSEMBLING THE OIL ATOMIZER YOU MUST REPLACE THE O RING WHEN DISMANTLE OIL ATOMIZER IF NECESSARY D...

Page 231: ...L CAUSE INCORRECT IDLE SPEED WHEN WITHOUT ELECTRICAL PULSE IDLE SPEED VALVE CLOSE FUNCTION OF PINS 1 CONNECT PIN 17 2 CONNECT OIL PUMPRELAY OUTLET END THE R I GHT I S THE W I R I NG D I AGRAM FOR I DLE SPEED VALVE AND ECU WHEN FIXING THE IDLE SPEED CONTROL VALVE IT CANNOT BE INSTALLED LIKE THE RIGHT DIAGRAM CONNECTOR VERT I CAL LY DOWNWARD TO AVO I D DESTROY THE ELECTRONIC COMPONENT TO AVOID SOLID...

Page 232: ...NCTION OF PINS 1 GROUNDING 2 CONNECT POWER 3 CONNECT ECU 1 POINT THE RIGHT IS THE CONNECTION CIRCUIT DIAGRAM OF IGNITION COI L AND ECU MEASURING SECONDARY IGNITION VOLTAGE CONNECT THE ENGINE ACCORDING TO THE ELECTRONIC SPRAY ELEMENTARY DIAGRAM CONNECT THE PEAK VOLTAGE GUAGE ACCORDING TO THE RIGHT DIAGRAM START THE ENGINE AFTER STARTS THE SECONDARY IGNITION VOLTAGE SHOULD BE 15000V IGNITION COI L P...

Page 233: ...BLE CODE THE RIGHT IS THE WIRING DIAGRAM FOR TROUBLE LAMP AND ECU CURRENT FLOW I NTO ECU 4 P I N SHOULD BE LESS THAN 0 5A3 3 a IN BL INK CODE MODE AND ALSO THE TROUBLE MEMOY TROUBLE FREE IF ECU MONITOR THAT THE MIL LAMP IN BLINK CODE MODE THE TROUBLE LIGHT WILL FLICKER TO SHOW THE TROUBLE CORRESPONDING Pcode CODE SINCE IGNITE ECU MIL WILL CONTINUE BLINK 4 SECONDS THEN HAVE A 1 SECOND SPAN MIL BLIN...

Page 234: ...R D I SPL AY BATTERY VOLTAGE ENGINE SPEED IDLE SPEED VEHICLE SPEED ENGINE TEMPERATURE ENGINE TEMPERATURE SENSOR SIG NAL VOLTAGE INLET TEMPERATURE INLET AIR TEMPERATURE SENSOR INLET PRESSURE AIR INPUT MAGNETIC STEPPING MOTOR TARGET LOCATION THROTTLE POSITION SENSOR SIGNAL PRESSURE THROTTLE OPENING RELATIVE THROTTLE POSITION CARBON TANK CONTROL VALVE DUTY RATIO CHARGING TIME OIL SPOUT PILSE WIDTH IG...

Page 235: ...RE SENSOR UNREASONABLE 12 P0117 ENIGNE COOLANT TEMPERATURE SENSOR CIRCUIT VOLTAGE TOO LOW 13 P0118 ENIGNE COOLANT TEMPERATURE SENSOR CIRCUIT VOLTAGE TOO HIGH 14 P0122 THROTTLE POSITION SENSOR CIRCUIT VOLTAGE UNDER LIMINAL VALUE 15 P0123 THROTTLE POSITION SENSOR CIRCUIT VOLTAGE EXCEED LIMINAL VALUE 16 P0130 OXYGEN SENSOR SIGNAL UNREASONABLE 17 P0131 OXYGEN SENSOR SIGNAL CIRCUIT VOLTAGETOO LOW 18 P0...

Page 236: ...11 28 CFMOTO COMPLETE SCHEMATIC CIRCUIT DIAGRAM ...

Page 237: ...e deformation of glass face and damage to bulb Pay attention to the fol lowing when replacing the bulb Do not replace the bulb when it is turned on Keep ignition switch in the OFF position and replace after the bulb is cooled down Replace the bulb with hands in clean gloves to avoid oi l stains on the glass surface Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of an...

Page 238: ...13 2 CFMOTO TROUBLESHOOTING Head Light Cannot Turn On Broken fuse Open circuit with main cable Burnt Bulb Faul ty Swi tch ...

Page 239: ...bulb Oi l stains on the glass surface may cause break of bulb Clean the stained surface with alcohol or isoamyl acetate Make sure that the three pins of the bulb should be in l ine with the three positioning holes in the socket when replacing the bulb Bulb speci f icat ion 12V 35 35W Reverse the removal procedure for instal lation After replacing the bulb adjust headl ight beam 3 1 4 Inspection of...

Page 240: ...at ion 12V 21 5W Reverse the removal procedure for instal lation Front Turning Indicator Bulbs Remove headl ight 13 5 Remove cover of front turning l ight Replace front turning l ight bulbs Bulb Speci f icat ion 12V 10W Rear Turning Indicator Bulbs Remove screw1 Remove rear turning indicator cover Replace rear turning indicator bulbs Bulb Speci f icat ion 12V 10W Reverse the removal procedure for ...

Page 241: ...hboard has something wrong it s recommended to replace whole dashboard Reverse the removal procedure for instal lation Headl ight Remove nuts as picture shown Disconnect headl ight connector Disassemble headl ight comp Note Be careful not to damage main cable when assembling After replacing adjust the headl ight beam 3 1 4 Note Main cables and wires should be routed properly Reverse the removal pr...

Page 242: ...13 6 CFMOTO Ignition Switch Inspection Remove front rear top cover 2 4 Disconnect 4P connector of ignition switch ...

Page 243: ...front cover 2 4 Disconnect 4P connector of ignition switch Loosen bolt and remove ignition switch Reverse the removal procedure for instal lation Handlebar swi tch Remove front cover 2 4 Disconnect left and right handlebar switch connector Check according to the fol lowing table i f the connector terminals are in continuity continuity L ight ing swi tch ...

Page 244: ...continuity Hold the brake lever Continuity Release the brake lever No continuity No continuity Replace brake light switch Horn Inspection Remove front vent gr i l le 2 15 Disconnect horn Connect with a ful ly charged 12V battery and check i f the horn sounds Faulty Horn Replace Turn swi tch 2WD 4WD swi tch Horn swi tch Acce lerat i on swi tch Parking swi tch ...

Page 245: ...eed and check i f the speed indicator moves Faulty speedometer Replace Remova l and Insta l l at i on Remove front top cover 2 4 Remove front cover of dashboard 2 4 Disconnect dashboard wire connector Remove f ixing nut and remove dashboard in the direction as i l lustrated on the right Reverse the removal procedure for instal lation Note Main cables and wires shal l be routed properly ...

Page 246: ... hand locate the float position and check if it conforms to the fuel gauge reading Non conformity check main cable for dam age or short circuit Check fuelsensorandfuelgauge Remove fuel sensor 2P connector Connect multimeter between 3P connector terminals Shake float with hand and measure the resistance of float at different positions Connection Terminal Upper Blue White Green 4 1 0 2 0 Lower Blue ...

Page 247: ...uel tank Fuel sensor should be f itted properly No fuel leakage is al lowed Connect 2P connector Inspect i on of Fue l Gauge Switch on power supply and check i f fuel level gauge functions normal ly If fuel gauge works normal ly Reverse the removal procedure for instal lation of plastic parts and seat ...

Page 248: ...perature sharply The thermometer should not contact the vessel bottom D i sassemb l y Remove r ight side panel 2 8 Disconnect and remove temp sensor Put the sensor into a vessel with coolant slowly heat up the l iquid and measure the sensor resistance Temperature Resistance 50 154 16 80 52 4 100 27 3 120 16 4 Out of range Replace Instal l transducer Connect water temperature transducer connector F...

Page 249: ...13 Troubleshooting 13 1 13 1 Engine troubleshooting 13 2 2 Diagnosis troubles according to EFI system Trouble Code 13 5 3 Diagnosis troubles according to engine fault phenomena 13 14 ...

Page 250: ...ion coil Replace 4 Open or short circuit with pickup coil Replace 5 Faulty generator Replace No Fuel Reach Into Carburetor 1 Clogged fuel tank vent tube Clean or Replace 2 Clogged or faulty fuel valve Clean or Replace 3 Faulty carburetor needle valve Replace 4 Clogged fuel hose Replace 5 Clogged fuel filter Clean or Replace Transfer is not in Neutral position Set to Neutral position Engine stalls ...

Page 251: ...gine lacks power 1 Improper valve clearance 2 Weak valve spring 3 Improper valve timing 4 Worn cylinder 5 Worn piston ring 6 Improper valve seating 7 Fouled spark plug 8 Improper spark plug gap 9 Clogged carburetor jet 10 Improper fuel level in fuel chamber 11 Dirty air filter 12 Worn rocker arm or rocker arm shaft 13 Air leakage from air intake pipe 14 Excessive engine oil Adjust Adjust Adjust Re...

Page 252: ... chain sprocket Repair or replace Noise from Clutch 1 Worn or damaged crankshaft spline 2 Worn inner race spline Replace crankshaft Replace inner race Noise from Crankshaft 1 Rattling bearing 2 Worn or burnt crank pin bearing 3 Excessive thrust clearance Replace Replace Replace Noise from CVT 1 Worn or slipping drive belt 2 Worn rollers in primary sheave Replace Replace Engine is noisy Noise from ...

Page 253: ...s Short Circuit to Power When Trouble Code tells Circuit Error means Circuit Broken or Various Errors Exist Diagnosis Help 1 Trouble Code cannot be cleared means trouble is steady state Focusing on the connector wires possible losen if trouble is incidental 2 When making inspections do not ignore possible affect from vehicle mantenance condition cylinder pressure machanisim timing 3 If Trouble Cod...

Page 254: ... as below 1 Short Circuit between ECU Pin and Oxygen Sensor Pin 1 2 Short Circuit between ECU Pin and other circuit Note Inspect as below 1 Check if resistance of ECU is normal or not 2 Check if resistance between ECU Pin and Oxygen Sensor Pin 1 circuit is normal or not Trouble Code P0053 Inner Resistance of Oxygen Sensor Heating not correct Explanation ECU system measure the Oxygen Sensor Heating...

Page 255: ...s below 1 ECU found Air Inlet Pressure Sensor signal circuit short to power Note Inspect as below 1 Resistance of ECU Pin Trouble Code P0112 Air Inlet Temperature Sensor Signal Voltage Low Note Possible Troubles are as below 1 Circuit between ECU Pin and Air Inlet Temperature Sensor Signal short to ground Note Inspect as below 1 Check Resistance of circuit between ECU Pin Sensor Signal and Ground ...

Page 256: ...Code P0123 Voltage of Throttle Control Positioning Sensor Circuit higher than the higher limit Note Possible Troubles are as below 1 Circuit between ECU Pin and other power circuit short Note Inspect as below 1 Check if ECU Pin voltage is normal or not Trouble Code P0130 Oxygen Sensor Signal irrationally failure Explanation When Oxygen Sensor Signal happens with situations as below System decide O...

Page 257: ...Oxygen Sensor Signal Failure Explanation When engine starts ECU check the Oxygen Sensor Circuit Voltage When ECU finds voltage stays between 0 4 0 6 volt it decides Oxygen Sensor Signal Circuit Short Note Possible Troubles are as below 1 Short Circuit between Oxygen Sensor connected to ECU Pin 2 Bad connection of Oxygen Sensor Connectors Socket Oxidized Note Inspect as below 1 Check resistance bet...

Page 258: ...connection or breaking of cable related connection 2 Check the quantity of magneto flywheel Errors coding P0322 Non rotate speed sensor pulse signal short circuit or open circuit Explanation After starting engine ECU will measure signal of trigger and other signals together judging the losing of trigger signal by signal rationality system Maintenance Tips The possible faults may exists as follow 1...

Page 259: ...ct to free wheel ECU measure engine rotate speed and vehicle speed together If engine lasting higher speed but vehicle speed display 0 or too low obviously system will judge that vehicle speed signal faults Maintenance Tips The possible faults may exists as follow 1 The signal circuit ECU connected and vehicle speed sensor short to ground or open to ground Maintenance Tips Check the item as follow...

Page 260: ...neto damaged Maintenance Tips Check the item as follow 1 Check the capability of generate electricity of Magneto measure voltage of Magneto after starting Errors coding P0627 Control circuit of oi l pump relay open circuit Errors coding P0628 Control circuit of oi l pump relay short to ground Errors coding P0629 Control circuit of oi l pump relay short circuit Maintenance Tips The possible faults ...

Page 261: ...1 deviation in various degrees partial dilute or partial concentration which will lead to emission deterioration and poor engine performance Engine control system will amend and self learning fuel charge based on the extent and characteristics of air fuel ratio deviation When self learning value reach the limit of system setting gas mixture partial dilute or partial concentration system amends the...

Page 262: ...lp 1 Engine has no fault records 2 Affirm the complaint of fault happened 3 Do not ignore vehicle maintenance working cylinder pressure mechanism timing fuel etc effect against system during overhaul 4 Replace ECU and test it If Trouble Code is cleared it means defective on ECU If Trouble Code is not cleared put back original ECU and repeat inspecting procedure to start again overhaul inspections ...

Page 263: ... no next yes Overhaul the resistance inside of enginemechanism 5 Check the resistance inside of engine mechanism whether is high or not which makes starter motor stop rotates or rotate slowly no Repeat abovesteps 2 Enginecanrotatebut startingfailure Possibledefectivepart 1 nogasolineintank 2 Fuel pump 3 Trigger 4 Ignition coil 5 enginemechanismpart Overhaul Ref no Operation Test result Next Steps ...

Page 264: ...f spark plug 5mm with body of engine starting engine and check it whether has blue white high pressure fire or not no Examine and repair ignition system Yes Examine and repair wiring or replace sensor No Next 3 Pull out connector of engine water temperature sensor starting engine observe engine whether succeed starting or not at this moment or in series a 300 resistant instead of engine water temp...

Page 265: ...ently observe it whether starting engine easily or not no next yes Replace 5 Disassembly injector and check the injector by special washing analysis instrument if exists the phenomena of leaks or clogs no next yes Replace fuel 6 Check fuel and observe the fault if caused after fueling no next yes Eliminate engine mechanism fault 7 Check air pressure of cylinder and observe the pressure if it is di...

Page 266: ...e 7 Disassembly injector and check the injector by special washing analysis instrument if exists the phenomena of leaks or clogs no next yes Replace fuel 8 Check fuel and observe the fault if caused after fueling no next yes Eliminate engine mechanism fault 9 Check air pressure of cylinder and observe the pressure if is discrepantly no next yes next 10 Check engine ignition timing if accords with ...

Page 267: ...t up iron or not no Examine and repair relevant wiring 7 Engine works regularly but unsteady idle speed when engine is in warming up Possible defective part 1 fuel containing water 2 engine water temperature sensor 3 spark plug 4 throttle valve body and idle speed side air duct 5 input air duct 6 idle speed valve 7 engine mechanism part Overhaul Ref no Operation Test result Next Steps yes Examine ...

Page 268: ...th standard no Adjust or replace yes Clean related parts 3 Disassemblyidle speed valve and check the throttle valve body idle speed valve and idle speed side air duct whether have carbide accumulated or not no next yes Examine and repair wiring or replace sensor 4 Pull out connector of engine water temperature sensor starting engine observe idle speed whether is unsteady or not when engine is in w...

Page 269: ...er supply normal or not check 2 21 stitch whether is puting up iron or not no Examine and repair relevant wiring 10 Engine starting regularly but idle speed is too high Possible defective part 1 throttle valve body and idle speed side air duct 2 injector seat 3 idle speed valve 4 engine water temperature sensor 5 ignition timing Overhaul Ref no Operation Test result Next Steps yes adjust 1 Check t...

Page 270: ...k spark plug look its type and gap if accords with standard no Adjust or replace yes Clean related parts 4 Disassembly idle speed valve and check the throttle valve body idle speed valve and idle speed side air duct whether have carbide accumulated or not no next yes next 5 Check air intake pressure sensor throttle position sensor and their wiring whether works regularly or not no examine and repa...

Page 271: ...air intake pressure sensor throttle position sensor and their wiring whether works regularly or not no examine and repair wiring or replace sensor yes Fault replacement 6 Disassembly injector and check the injector by special washing analysis instrument if exists the phenomena of leaks clogs or flux discrepantly no next Yes Replace fuel 7 Check fuel and observe the fault if caused after fueling no...

Page 272: ...n related parts 6 Disassembly idle speed valve and check the throttle valve body idle speed valve and idle speed side air duct whether have carbide accumulated or not no next yes next 7 Check air intake pressure sensor throttle position sensor and their wiring if works regularly no examine and repair wiring or replace sensor yes Fault replacement 8 Disassembly injector and check the injector by sp...

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