CFMOTO
CF500-5B Service
CF500-5C Manual
WWW.CFMOTO.COM
WWW.CFMOTO.COM
All rights reserved
Zhejiang CFMOTO Power Co., Ltd.
Aug. 2009
FORWARD
CONTENTS
Maintenance information
1
Vehicle body!Muffler
2
shooting and technical specifications. There are
Checking&Adjustment
3
illustrations, drawing to guide your operations.
Cooling&Lubricating system
4
Engine disassembly&assembly
5
Engine disassembly,check&assembly
6
Fuel supply&Air intake system
7
Front wheel!
Brake!
Suspension!
Steering system
8
Rear wheel!Brake!Suspension system
9
Front & rear axle
10
Electric system
11
Lighting!Odometer!Switch
12
Troubleshooting
13
This manual introduces X5 EFI version (CF5005B/5C) maintenance information, disassembly
procedure, check & adjustment methods, trouble-
Chapter 1 mainly introduces general operation
information, tools, vehicle structure and basic
specifications.
Chapter 2 mainly introduces check & adjustment
methods and how to do vehicle maintenance.
Chapter 3 mainly introduces disassembly,
installation, adjustment, maintenance and troubleshooting 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
Conversion table
Item
Example
Pressure 200 kPa"2.00kgf / cm2 )
Conversion
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
1. Maintenance Informat ion
C a uti o n! !! !! ! !! !! 1- 1
Tightening Torque!!!!!!!!1-13
Main Parameters Table!!!!!1-4
Wiring, Pipe & Cables Layout!!!1-19
Numbers Marking Locations!!!!!1-3
Maintenance Parameters Table!!!1-6
Grease & Seasant!!!!!!!!1-18
1
Failure I ndicator!!!!!!!!1-23
Cautions
Safety Cautions
1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly ventilated place for long time.
2. Do not touch the engine or muffler with bare hands after the engine has just stopped to avoid scalding. Wear longsleeve work clothes and gloves for operation.
3.Battery liquid (dilute sulfuric acid) is highly caustic and may cause burns to skin and eyes. Flush with water if
splashed to skin and get immediate medical attention. Flush with water if splashed to clothes to avoid burns. Keep
battery and liquid away from reach of children
4.Coolant is poisonous. Do not drink or splash to skin, eyes or clothes. Flush with plenty of soap water if splashed to
skin. If splashed into eyes, flush with water and consult the doctor. If drinking the coolant, induce vomit and consult the
doctor. Keep coolant away from reach of children.
5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and mask.
6. Gasoline is highly flammable. No smoking or fire. Also keep against sparks. Vaporized
gasoline is also explosive. Operate in a well-ventilated place.
7.When charged, Battery may generate hydrogen which is explosive. Charge the battery in a well-ventilated place.
8. Be careful not to get clamped by the turning parts like wheels and clutch.
9. When more 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 distorted after disassembled. Do not use the loosened retainers.
6. Clean and blow off the detergent after disassembling the parts. Apply lubricants on the surface of moving parts.
Measure the data during disassembly for correct assembling.
7.If you do not know the length of screws, install the screws one by one and make sure they are screwed in with same
depth.
8.Check if the disassembled rubber parts are aged and replace if necessary. Keep the
rubber parts away from grease.
9.Pre-tighten the bolts, nuts and screws, then tighten according to the specified torque,
from big to small and from inner side to outer side.
10Replace aged latex parts before assembling. Do not mix volatile oil and grease on the surface,due to aggressivness
of fuel and oil.
11Apply or inject recommended lubricant to the specified parts
12Use special tools wherever necessary.
13 When ball bearing disassembled by pressing ball ring, it can not be reused.
1-1
CFMOTO
14 . Turn the i nner and outer r i ngs of ba l l bear i ng to make sure the bear i ng w i l l turn
smooth l y .
"Rep l ace i f the ax i a l or rad i a l p l ay i s too b i g .
"I f the surface is uneven, clean wi th oi l and replace i f the clean ing does not help.When
press i ng the bear i ng i nto the mach i ne or to the shaf t .
15. Instal l the one- s ide dust - proof bear i ng in the r i ght di rect ion . When assemb l i ng the open
type or doub l e- s i de dustproof bear i ng , i nsta l l w i th manufacturer#s mark outward .
16. Keep the bear ing b l ock st i l l when bl owi ng dry the bear i ng af ter washi ng clean. App ly oi l
or l ubr i cant before assemb l i ng .
17 . Instal l the el ast i c ci rc l i p proper l y . Turn the ci rcl i p af ter assemb l i ng to make sure i s
has been i nstal l ed i nto the s l ot .
18 . Af ter assemb l i ng , check i f a l l the t i ghtened parts are proper l y t i ghtened and can move
smooth l y .
19 . Brake f l u i d and coo l ant may damage coat i ng , p l ast i c and rubber parts . Fl ush these parts
w i th water i f sp l ashed .
20 . Instal l o i l seal w i th the s i de of manufacturer#s mark outward .
"Do not fo l d or scratch the o i l seal l i p .
"App l y grease to the o i l seal l i p before assemb l i ng
21. When i nstal l ing p i pes, insert the pi pe t i l l the end of j o int . Fi t the p ipe cl ip , i f any ,
i nto the groove. Rep l ace the p i pes or hoses that cannot be t i ghtened .
22 . Do not m i x mud or dust i nto eng i ne and / or the hydrau l i c brake system .
23 . C l ean the gaskets and washers o f the eng i ne cas i ng be f ore assemb l i ng . Remove the
scratches on the j o i nt faces by po l i sh i ng even l y w i th an o i l stone.
24 . Do not tw i st or bend the cab l es too much . D i storted or damaged cab l es may cause poor
25 . When assemb l i ng the parts of protect i on caps , i nsert the caps to the grooves , i f any .
1-2
1. Maintenance Informat ion
Numbe r s Ma r k i ng L ocat i on
CF500 - 5B / CF500 - 5C
1
V I N Number!
! LCELDTS5"
" / LCELDTS6
"
Eng i ne Numbe r !CF188 - B"
1-3
CFMOTO
Ma i n Dat a Tab l e
Model
Length
Width
Height
Wheel base
Engine type
Displacement
Fuel type
Dry weight
Item
Parameter
CF500-5B/CF500-5C
CF500-5B: 2100mm CF500-5C: 2300mm
1180mm
1230mm
CF500-5B: 1290mm CF500-5C: 1490mm
CF188
493C m 3
Unleaded gasoline RQ-90or above
CF500-5B: 344 kg
Number of Passengers
Max. Load
Front Tire
Tire
Rear Tire
Min. Ground Clearance
Turning Diameter
Starting
Engine Type
Engine
1-4
Combustion Chamber Type
Valve Driving Type
Bore !Stroke
Compression Rati o
Lubrication Type
Oil Pump Type
Lubricant Filter Type
Oil Type
Cooling Type
Coolant Type
CF500-5C: 358 kg
CF500-5B:2 $ Include driver%
210 kg
25!8-12 40J
185/80-12 40J
25!10-12 47J
270/60-12 47J
275mm
Turning Diameter
Electrical starting, Manual Starting
Single cylinder, 4-stroke, Liquid-cooled, 4
valves, OHC
Triangle
SOH C /Chain Drive
87.5mm!82.0mm
10.2:1
Pressure & Splash
Rotor
Full flow filter screen
SA E15W-40/SF
Closed coolant circulati on
-35& anti-rust coolant
1. Maintenance Informat ion
Fuel
Devic e
Item
Air Filter type
Valve
Type
Diameter of mixing
valve
W et, A uto-Centrifugal
Parameter
Sponge element filter
Type: CF188-B-173000
36mm
1
Clutch
Operation
Automatic$ CVT% +P arking & Gear S hi fting
Mode
Gears Shift Low Gear, High Gear & Reverse Gear
Shift
Manual /L-H-N -R
Mode/order
$ CV T %
Transmis sio 2.88' 0.70
n Ratio
Final Ratio
1.333$ 24/18( Bevel Gear%
Secondary
1.952$ 41/21%
Ratio
Gearing
Low Gear ) 2.25(36/16) * H igh Gear )
Gear
Gears
1.350(27/20) * R ev erse
Gear )
Ratio
1.471(25/17)
Low Gear5.857 * High Gear ) 3.514 *
Total
Reverse Gear) 3.828
Front
33 / 9 = 3.667
Axle
Axle Ratio
Rear
33 / 9 = 3.667
Axle
Engine Output Mode
Front/Rear Shaft
Direction of Output
Clockwise on forward shift
Rotation
Steering
Steering
Inner
31º
Devic e
Angle
Outer
31º
Front
Hydraulic D isc
Brak e Type
R ear
Hydraulic D isc
Bumper
Suspension Swing Arm
Devic e
Frame Type
W elded Steel Tube and Plate
1-5
CFMOTO
Maintenance Parameters Table
L ub r i ca t i on Sys t em
Engine Oil
Capacity
Item
Volume
when
replacing
Volume
when
replacing filter
Recommended Oil$See Original%
1900mL
Standard
Service Limit
+
2200mL
+
·Specially for 4-stroke motorcycle
SAE-15W-40
Substitutes must be used in the
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
Gap
between
Outer rotor and
body
Oil pressure
0.03'0.1mm
0.15mm
0.03'0.1mm
0.12mm
3000r / min , 130-170KPa
A i r I n l e t Sys tem
Item
Fuel Tank Capacity
Full capacity
Valve
Inlet Pressure Sensor
Inlet Temperature Sensor
Air Bypass Valve
Injector
Idle Speed
1-6
Standard
18L
CF188-B-173000
CF188-B-175000
CF188-B-177000
CF188-B-172000
CF188-B-171000
1400±100r / min
1. Maintenance Informat ion
Coo l i ng Sys t em
1
It em
Standard/ Par amet er
Ful l Capacit y
2000ml
Reservoir t ank capacit y
300ml
Standard Densi ty
50%
Opening pr essur e of radiator
cap
Init ial
Temper ature
Thermostat
Full opening
Temper ature
Ful l opening lift
range
Temperat ur e
and
Resist ance of
Wat er
88&
3.5' 4.5mm/95?
End B
End A C
Resistance(k")
-20
----
13.71-16.94
25
-----
1.825-2.155
50
176-280
----
Sensor
80
110
63.4-81.4
24.6-30.6
0.303-0.326
0.138-0.145
Close -Open
88& Round
88& Round
Open-Close
82& Round
82& Round
of
Thermostat
Coolant Type
Remar k
71±3&
Temperat ur e
Temperat ur e
Li mit
108kpa(1.1kgf/ cm2 )
Resi stance(")
Temper at ur e(& )
Ser vice
-35& ant i-frozen, ant isepsi s, hi gh -boil coolant
1-7
CFMOTO
F r on t Whee l
Ite m
F ront W he e l
Pl ay o f whe e l
rim
Tire
Stand ar d
Ve rtica l
H orizo nta l
Groove
P ressu r e
1. 0mm
1. 0mm
+
35kP a$0 .35kgf- cm 2 %
Opera tio n
L im it
2.0mm
2.0mm
3.0mm
+
Rea r Whee l
Item
Re ar W h eel
Pl ay o f whe e l
rim
Tire
Stan d ard
Ve rtica l
H orizo nta
l
Groove
P ressu r e
1. 0mm
1. 0mm
+
30kP a$ 0. 30kgf- c m2 %
Oper ati on
Lim it
2.0mm
2.0mm
3.0mm
+
B r ake Sys t em
Ite m
Front B ra ke
Rea r Br ake
1-8
Brake
Brake
Brake
Brake
Brake
Stan da r d
End P la y
Disc T hickn ess
End P la y
Ped al P lay
Disc T hickn ess
0mm
3. 5mm
5-10 mm
0mm
7. 5mm
Op eration
L im it
+
2 .5mm
+
+
6 .5mm
1. Maintenance Informat ion
Bat te r y , Cha r g i ng Dev i ce , P i ckup Co i l
1
AC
Magneto
Motor
Item
Model
Output
Chargi ng Coil Resistance$ 20? %
Pickup Coil Resis tance
Magneto without Load Voltage/(Idle
Speed)
Max. Output Power
Rated Voltage
Peak Voltage of Pickup Coil
Terminal
Vol tage
Battery
Poi nt
Chargi ng
Current/time
I gn i t i on Dev i ce
Fully
Charged
Insufficient
Charged
Standard
Quick
Item
Ignition Timing
Ignition
Coil
Resistance
/100V$AC%(5000r/min
300W(5000r/min
13.5V-15.0V, 5000r/min
Three-phase
annular
rectification,
Silicon controlled parallel-connected
regulated voltage
Capacity
12.8V
<11.8V
0.9A-5'10H
4A-1H
Standard
Ignition
Spark Plug
3-phas e AC
0.2"-0.3"
110"-140"
/120V
Rectifier
Capacity
Standard
Permanentmagnet AC Type
ECU Ignition
Type
Standard
Optional
Spark plug gap
Spark
Characteristic
Resistance Spark plug
DPR7EA-9(NGK)
DR8EA .D7RTC
0.8-0.9mm
/8mm(1mpa
BTDC10ºCA 1500r/min
Initial
Secondary
Ignition Coil
Peak Voltage
Pulse
Generator
Starter Relay Coi l Res istance
Secondary Starter Relay Coil
Resistance
0.740-0.780
10.1k0-11.1 k0
/150V
2V
3"-5"
90"-100"
L i ghts , I nst rument , Sw i tches
Fuse
Light, Bulb
Fuse
Item
Main
Auxiliary
Head Light$Hi-Lo%
Brak e Light/ Tail Light
Turning Light
Dashboard Indicator Light
Indicators
Main
Standard
20A
10A!2
15A!2
12V—35W/35W !2
12V—5W !2
12V—21W/5W
12V—10W!4
#5 LED
LCD
1-9
CFMOTO
(mm)
Air Inl et Device+ Cyl i nder Head
Item
Valve Diameter
Valve Clearance( Idle Speed)
Fit Clearance between Valve
Guide and Valve Stem
Internal dia. of Valve Guide
Exterior dia. of Valve Stem
Standard
Operation Limit
Intake
30.6
Exhaust
27.0
Intake
0.05-0.10
Exhaust
0.17-0.22
Intake
0.010-0.037
Exhaust
0.030-0.057
Intake & Exhaust
5.000-5.012
Intake
4.975-4.990
Exhaust
4.955-4.970
Valve Stem Run-out
Intake & Exhaust
Length of Valve Stem End
Intake & Exhaust
Thick ness of Valve Head
Intake & Exhaust
0.5
Valve 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
Valve Spring Tension
Intake & Exhaust
Cam Height
Fit Clearance between
Camshaft Exterior dia. &Bore.
Camshaft Exterior dia.
Camshaft Bore Internal dia.
0.05
2.9-3.1
/Length31.5mm
Intake
33.430-33.490
33.130
Exhaust
33.500-33.560
33.200
#22
0.032-0.066
0.150
#17.5
0.028-0.059
0.150
#22
21.959-21.980
#17.5
17.466-17.484
#22
22.012-22.025
#17.5
17.512-17.525
0.10
Rocker Arm Internal dia.
Intake & Exhaust
12.000-12.018
Rocker Arm Shaft Exterior dia.
Intake & Exhaust
11.973-11.984
Adjoining Plant
Plainness of Cylinder Head
Cover Adjoining Plant
1-10
38.8
Tension182-210N
Camshaft Run-out
Plainness of Cylinder Head
2.3
0.03
0.05
0.03
0.05
1. Maintenance Informat ion
Cy l i n der + P i sto n + P ist on R ing
(m m )
+ Cran ksh af t
Item
Standard
C ylinder Pressure
1000kPa
F it C learance betw een
Operation
Limi t
0.030-0.051
P iston and C ylinder
R emark
1
0.15
87.460-87.480
Piston Sk irt dia.
Tes ting the point aw ay skirt end
87.380
10m m
Internal dia. of C ylinder
87.500-87.522
Plainness of Cylinder
0.015
Adjoining Plant
Piston Ring Free Gap
Pis ton R ing C losed Gap
Piston Annular F it
C learance
Thickness Pis ton R ing
Piston Annular Width
Internal dia. of Pis ton Pin
Top R ing
2
nd
R ing
0.05
R
11.7 round
8.9
R
12 round
9.5
Top R ing
0.15-0.30
0.60
R ing
0.15-0.30
0.60
Top R ing
0.04-0.08
0.180
R ing
0.0 3- 0.07
0.150
Top R ing
0.9 7- 0.99
2 nd R ing
1.1 7- 1.19
Top R ing
1.03-1.05
2
2
2
nd
nd
nd
R ing
1.2 2- 1.24
Oil R ing
2.51-2.53
23.002-23.008
2 3.0 30
Exterior dia. Piston Pin
22.995-23.000
2 2.9 80
Rod Sm all End Inner dia.
23.006-23.014
2 3.0 40
R od Big End Gap
0.10-0.55
1.0
Rod Big End Thi ckness
24.95-25.00
Crank shaft R un-out
0.03
Bore
0 .0 8
1-11
CFMOTO
Clutch + Transmission
Item
(mm)
Standard
Limit
Clutch Friction plate inner dia.
140.00-140.15
140.50
Clutch 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
0.10-0.40
0.50
Shifter and fit flute gap
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
1-12
Remark
1. Maintenance Informat ion
Tightening Torque
Item
Torque N·m(kgf·m)
5mm Bolt, nut
6mm Bolt, nut
8mm Bolt, nut
10mm Bolt, nut
12mm Bolt, nut
5(0.5)
10(1.0)
22(2.2)
34(3.5)
54(5.5)
Item
Torque N·m(kgf·m)
5mm Screw
4(0.4)
6mm Screw
9(0.9)
6mmSH Bolt with flange,
10(1.0)
6mm Bolt with flange, nut
12(1.2)
8mm Bolt with flange, nut
26(2.7)
10mm Bolt with flange, nut
39(4.0)
For o thers not listed in the chart, refe r to the standard tightening torque.
Notes: Apply some engine oil on the part of screw thre ad and adjo ining surface
Torque
Thread Dia.
Quantity
Item
Remark
N·m(kgf·m)
(mm)
Upper Front Mounting Bolt, Engine
M8!60
1
16'20
Upper Rear Mounting Bolt, Engine
Upper Rear Mounting Bracket Bolt,
Engine
Upper Front Mounting Bracket Bolt,
Engine
M10!1.25!110
1
40'50
M8!14
1
16'20
M8!14
1
16'20
Low Mounting Bolt, Engine
M12!1.25!140
2
50'60
Bolt, Swing Arm
M10!1.25!70
16
40'50
Bolt, 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
Mounting Screw, Rear Brake
Caliper
901-07.00.03 M10
4
110'130
M6!25
2
18'22
M10!1.25!20
2
40'50
901-08.00.03 M8!
8
25'30
Bolt, Front Brake Caliper
M8!14
4
16'20
Locknut, Steering Stem
M8!55
4
16'20
Nut, Steering Stem
M10!1.25
4
40'50
Locknut, Steering Shaft
M14!1.5
1
100'120
Rear Mounting Bolt, Muffler
M8!30
1
16'20
Bolt, Exhaust Pipe
M8!14
1
16'20
Mounting Bolt, Exhaust Pipe
M8!40
1
16'20
Mounting Bolt, Rear Axle
M10!1.25!110
2
40'50
Mounting Bolt, Front Axle
M10!1.25!90
1
40'50
Mounting Bolt, Front Axle
Back End Bolt, Rear Trans Shaft
M10!1.25!25
901-30.00.01
2
6
40'50
40'50
Front End Bolt, Rear Trans Shaft
901-29.00.01
4
35'45
901-29.00.01
CF250T-420500
M8!14
M6!12
M8!14
8
1
2
2
4
35'45
9'12
35'45
25'30
16'20
Bolt, Rear Brake Caliper
Bolt, Front Brake Disc
Bolt, Front Trans Shaft
Thermo Switch
Mounting Bolt 1, Front Rack
Mounting Bolt 2, Front Rack
Mounting Bolt , Rear Rack
1
1-13
CFMOTO
Engine Tightening Torque Table
Item
Q’ty
Screw dia.$mm%
Torque
Remark
$N.m%
Sensor, Reverse Gear
1
M10!1.25
20
Spark Plug
1
M12!1.25
18
Water Temperature Sensor
1
Rc1/8
8
Valve Clearance Adjusting Nut
4
M5
10
Drive Disc Nut
1
M20!1.5
115
Driven Disc Nut
1
M20!1.5
115
Circle Nut, Driving Disc
1
M30!1
100
Nut, Front Output Shaft
1
M14!1.5
97
Nut, Drive Bevel Gear
1
M22!1
145
Nut, Driven Bevel Gear
1
M16!1.5
150
Fixing Nut, Clutch
1
M18!1.5
70
Left handed
Limiting Nut, Driven Bevel Gear Shaft
1
M60
110
Apply screw thread sealant
Limiting Nut, Front Output Shaft
1
M55
80
Bolt, Swing Arm Shaft
2
M14!1.25
28
Drain Bolt
1
M12!1.5
30
Mounting Bolt, Overriding Clutch
6
M8
26
Apply screw thread sealant
Mounting Bolt, Magneto Stator
3
M6
10
Apply screw thread sealant
Bolt, CVT Windshield
3
M6
10
Apply screw thread sealant
Link Bolt, Oil Pipe
2
M14!1.5
18
Mounting, Oil Pump
3
M6
10
Mounting Bolt, Pressure Limiting Valve
2
M6
10
Bolt, Drive Bevel Gear Cover
4
M8
32
Bolt, Driven Bevel Gear Cover
4
M8
25
Locating Bolt, Shift
1
M14!1.5
18
Flange Bolt, Fan
1
M10!1.25
55
1-14
Apply screw thread sealant
Apply
screw
thread
sealant, left handed
1. Maintenance Informat ion
To be continued
Item
Torque
Quantity
Diameter$mm%
14
M6
10
3
M8
25
Bolt, Driven Sector Gear
1
M6
12
Mounting Bolt, Oil Filter
1
M20!1.5
63
Oil Filter
1
3 / 4 ?$ 1 6 / i n
18'20
Bolt, Starting 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
M5
4.5-6
M6
8-12
M8
18-25
Bolt, Crankcase
Bolt without remarks
$N.m%
1
Remark
Apply screw thread sealant
1-15
CFMOTO
Engine Tools
Measuring Tools
No
Name
Type
Function
1
Vernier Calipers
0-150mm
Measure length and thickness
2
Micrometers
0-25mm
3
Dial gauge
25-50mm
Measure max. lift range of camshaft
4
Dial gauge
75-100mm
Measure piston skirt
5
Inner dia. Gauge, Cylinder
6
Inner dia. Gauge,
10-34mm
7
Dial Test Indicator
1/100
8
Knife Straight Edge
plainness
9
Feeler Gauge
Plainness, adjusting valve clearance
10
Fuel Level Gauge
Fuel level length of carburetor
11
Plastic gauge
Fit clearance
12
pull tension gauge
Spring bounce
13
Tachometer
Engine rotation rate
14
Cylinder Pressure Meter
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
Torque Tester
Measure the outer diameters of swing
arm, valve rod and camshaft
Measure inner dia. of cylinder head
Inner dia. of swing arm, piston pin hole,
and rod head hole
Run-out
pressure in cyclinder
One Set
Tightening torque
Auxiliary Measuring Instrument
22
Alcohol Burner
Warming up
23
Magnet Stand
Install dialgauge
24
Slab
Auxiliary measure supplementary
25
V-Block
Run-out supplementary
26
Forcep
Install valve clip
27
Plier
Disassemble and install circlip
28
Joint Plier
Disassemble and install flange
29
Impact Driver
Disassemble cross recessed bolt
30
Slot Type Driver
31
Cross Type Driver
1-16
Remark
1. Maintenance Informat ion
Special Purpose Tools
No
Name
Type
Function
1
Spark Plug Wrench
2
CVT Wrench
3
Oil Filter Wrench
CF188-011300-922-001
Disassemble/ install oil filter
4
Piston Pin Remover
CF188-040004-922-002
Disassemble piston pin
CF188-031000-922-001
Disassemble magneto stator
5
Magneto stator
Remover
6
Crankcase Dissociator
7
Crank Remover
8
Crank Tool
9
Valve Spring
Compressor
172MM-022400-922-004
Disassemble/ install spark plug
CF188-051000-922-001
Disassemble/install CVT
CF188-052000-922-001
Remark
1
drive/driven disc nut
Divide L/R crank case
Disassemble crank shaft from
left crankcase
Install crank shaft on left
crankcase
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
CF188-062204-922-001
15
Bearing Tool
One full set
Install bearing and oil ring
16
Bearing Remover
One full set
Disassemble bearing
17
Oil Ring Remover
18
Limiting Nut Wrench
19
PDA
20
Oetiker Clamp Catcher
Disassemble driven bevel gear
bearing limiting nut
Disassemble bearing
CF188-060008-922-001
Disassemble front output shaft
bearing limiting nut
Diagnose failures of EFI
system
Disassemble/ install fuel Pipe
21
22
23
24
25
1-17
CFMOTO
Lubr icant Grease, Sealant
Coated Section
Turning Bearings
Throttle Cable Connecting Portion
Throttle Pedal Movable Parts
Brak e Pedal Movable Parts
Swing Arm Movable Parts
Steering Inner Circle Surfac e
Seat Lock Movable Parts
Transmission Movabl e Parts
Attention
Grease
Multi-purpos e
grease
Opera tion Material and Installment Supplementary of Engine
Engine operation materials include lubricant (oil), grease (lubricant grease) and coolant, installment
supplementary includes plane sealant and screw thread sealant.
Na me
Type
Sp ecially
for
P arts
4 -stroke
mot orcycle
lubrican t
SAE -10W -40.2 0W-50
Substitute s mu st be u se d
/o il
in t he fo llowin g rang e.
API type: S E or SG grade
Rem ark
Rota tin g sect ion and ca rriage in cylinder,
Rota tin g sect ion and ca rriage in crankcase
Rota tin g sect ion and carriag e in cylinde r
capacit y
2200 m L $replace oil%
hea d
2 300 m L$ replace oil filt er%
S ee L ubrication S yst ems Diagram$ 5-14%
2 600 m L$ eng ine ove rh aul%
$ Replaceme nt see 1-3 %
Lubrica nt with
P iston pin, valve rod pa rt, valve ring, cam
m olybde num
shaft
Gre ase/lubrican t
grea se
Coolant
# 3 MoS 2 l ith ium ba se d
Oil seal lip, O rin g an d oth er late x sea ling,
g re ase
bea ring with seals, and C VT bea ring/h ousin g
-35 & an ti-frozen, an ti-rust,
Ca pacit y based on ra diator
Coo ling syste m, wa ter seals
h igh –bo iled coolant
Plane sea la nt
p ipe system
Cou pling surfaces of ca ses,
ca se s and
cylin der, cylind er hea d an d cylin der h ead
cover
Screw
se ala nt
1-18
th re ad
Some screw threa d
1. Maintenance Informat ion
W i r i ng , P i pes , Cab l e Layout
1
Picture 1
Picture 2
Picture 3
1-19
CFMOTO
1-20
1. Maintenance Informat ion
1
1-21
CFMOTO
1-22
1. Maintenance Informat ion
Fa i l u r e I nd i ca t o r
Fa i l ure Ind i actor i s l ocated on the
1
left top !"#of instrument .
Whi le the indicator f lashing is faulty,
fai lure uses 4-digi t f lashing.
For example$0650%
!0#f lashes 10 t imes,
!6#f lashes 6 t imes,
!5#f lashes 5 t imes,
!0#f lashes 10 t imes,
See (Page 11 - 27) for the mean i ng of
Diagnost ic Trouble Code.
Whi le fai lure appears, use PDA to diagnose i t .
Connect PDA wi th PDA connector , the locat ion of PDA connector (see Page 1-19)
Picture 3. the use of PDA (see Page 1126) .
1-23
2 Vehicle Body and Muf f ler
Overhaul Info !!!!!!!!!!!!!!2 - 1
Footrest Board (LH, RH)!!!!!!!!!!2-10
Troubleshooting!!!!!!!!!!!!!!2 - 1
Rear Fender, Engine Skid Plate (Front, Center, Rear),
Front Rack, Bolt Cap!!!!!!!!!!!!2-2
Double Seat, Protection Plate!!!!!!!!2-11
Seat, Seat Support & Rear Rack!!!!!!!!2-3
Front Inner Fender (R&H), Front Protector (RH, LH) !2 -13
Front Top cover, Dashboard Cover!!!!!!!2-4
Rear Protector (RH,LH), Bumper, Bumper Protector!2 - 14
Side Support(LH&RH)!!!!!!!!2 - 5
Bumper Cap !!!!!!!!!!!!!!2 - 15
Rear Top Cover!!!!!!!!!!!!!!2-6
Front Vent Grille, Fuel Tank!!!!!!!!!2-16
Left Side Panel!!!!!!!!!!!!!!2 - 7
Bottom Plate, Fuel Tank !!!!!!!!!!2-17
Right Side Panel!!!!!!!!!!!!!!2-8
Muffler!!!!!!!!!!!!!!!!!2 - 18
Fuel Tank Top Cover, Front Fender!!!!!!!2-9
Description of Visible Parts!!!!!!!!!2-19
Overhaul Information
Operation Cautions
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,
muffler and fuel tank.
l
l
l
Hoses, cables and wiring should be routed properly.
Replace the gasket with a new one after muffler is removed.
After muffler is installed, check if there is any exhaust leakage.
Tightening torque
Muffler Rear Fixing Bolt: 35-45N.m
Muffler Exhaust Pipe Bolt: 35-45N.m
Muffler Body Fixing Bolt: 35-45N.m
Troubleshooting
Loud exhaust noise
Broken muffler
Exhaust leakage
Insufficient power
Distorted muffler
Exhaust leakage
Muffler clogged
2-1
2
CFMOTO
Front Rack, Bolt Cap
Remove:
Upward l y remove Bo l t cap hard ; two assemb l y
bo l ts of f ront rack shal l be seen .
Remove fixing Bolt 1
(one for each on theleft and right)
Romove f i x i ng Bo l t 2
Remove f ront rack
Installation:
Reverse the removal procedure for installation
Tightening Torque:
Fixing Bolt 1, Bolt 2
35 N.m -45N.m
Fixing Bolt 3, Bolt 4
25 N.m -30N.m
2-2
2 Vehicle Body and Muf f ler
Seat
Remove:
Pull upward seat buckle
2
Lift and push seat backward
Installation:
Press upward seat buckle
Press seat forward and down
Note:
Shake 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#
B o l t 1 #3 5 N $m - 4 5 N $m
B o l t 2 #3 5 N $m - 4 5 N $m
B o l t 3 #8 N $m - 1 2 N $m
2-3
CFMOTO
Fr on t Top Cove r
Remove
F r on t Rack %" 2 - 2&
6 nu t s'
Front Top Cover
Assemb l e
Reverse the remova l process and d i rect i on .
Dashboa r d Cove r
Remove
- -2 pieces Bol t 1
- -2 pieces bol t 2
- -Dashboard Cover
I nsta l l at i on
Reverse the remova l process and d i rect i on .
2-4
2 Vehicle Body and Muf f ler
F r on t S i de Suppo r t ( L e f t )
Remove
Bol t 1
Front Side Support
2
Assemb l e
Reverse the remova l process and d i rect i on .
F r on t S i de Suppo r t ( R i gh t )
Same as Left Side Support
2-5
CFMOTO
Rear Top Cover
Remove
Rea r Rack %" 2 - 3&
Seperate c l asps of rear top cover f rom rear
fender ;
Remove Rear Top Cover
I nsta l l at i on
Reverse the remove procedure and
d i rect i on for i nsta l l at i on .
Gear Sh i f t Un i t Fender
Remove
- -Bol t 1
- -Bol t 1
- -Bol t 2
Remove Gear Shi ft Uni t Fender
I nsta l l at i on
Reverse the remove procedure and
d i rect i on for i nsta l l at i on .
2-6
2 Vehicle Body and Muf f ler
L e f t S i de Cove r
Remove
- - S e a t %" 2 - 3 &
- - Lef t S i de Cover f i x i ng bo l t
2
- - Lef t S i de Cover
I nsta l l at i on
Reverse the remove procedure and
d i rect i on for i nsta l l at i on .
Rea r P r o t ec t o r
R em ov e
- - Rea r Rack%" 2 - 3&
- - Rear Top Cover%" 2 - 6&
- - Rear L i nk P l ate%" 2 - 7&
- - Rear Le f t S i de Suppor t%" 2 - 8&
- - Rear R i ght S i de Support%" 2 - 8&
- -Rear Turn i ng L i ght Connector
- - Bo l t 1 , 2 , 1
- - Rear Protector
I nsta l l at i on
Reverse the remove procedure and d i rect i on
for i nsta l l at i on .
Rear L i nk P l ate
Remove
- - Bo l t 3
Rear L i nk P l ate
I nsta l l at i on
Reverse the remove procedure and d i rect i on
for i nsta l l at i on .
2-7
CFMOTO
Rear S i de Pane l
Remove
- - S e a t %" 2 - 3 &
- - R i ght S i de Cover F i x i ng
Bo l t
Remove connect ing Bol t 1 between Right
Side Panel and Front Fender at bottom
of Front Fender
Remove R i ght S i de Panel
I nsta l l at i on
Reverse the remove procedure and
d i rect i on for i nsta l l at i on .
Rear R i gh t S i de Suppo r t
R em ov e
- - Bo l t 2
- - Remove Rear R i ght S i de Support
I ns t a l l a t i on
Reverse the remove procedure for i nstal lat i on
Remova l and I ns t a l l at i on and
Rear R i gh t S i de Suppo r t i s
same w i th L e f t s i de .
2-8
2 Vehicle Body and Muf f ler
Top Cover , Fue l Tank
Remove
- - S e a t %" 2 - 3 &
- - F r on t Rack%" 2 - 2&
2
- - Front Top Cover%" 2 - 4&
- - Le f t S i de Pane l %" 2 - 7&
- - R i ght S i de Pane l %" 2 - 8&
- - Bo l t 1 , 2
- - Bo l t 3 , 4
- - Fuel Tank Cap
Remove Fuel Tank Top Cover
I nsta l l at i on
Reverse the remove procedure and
d i rect i on for i nsta l l at i on .
Front Fender
Remove
- - F r on t Rack%" 2 - 2&
- - Front Top Cover%" 2 - 4&
- - L e f t , R i gh t S i de Pane l %" 2 - 7&%" 2 - 8&
- - Fue l Tank Top Cover%" 2 - 8&
- - Le f t , R i ght S i de Suppor t%" 2 - 5&
Loosen Cab l e Connector of Front Fender
Remove E l ectron i cs Parts of Front Fender
Remove 3 Front Fender bo l ts f i xed i n Frame
Remove 4 bo l ts f i xed w i th l ef t and r i ght
footrest
Remove Front Fender
I ns t a l l a t i on
Reverse the remove procedure for i nstal lat i on
2-9
CFMOTO
Foo t r es t , L e f t S i de
Remove
Le f t S i de Pane l %" 2 - 7&
Remove three Bo l t 1 and 3 nuts connect i ng
w i th Front Fender
Remove three Bo l t 2 and 3 nuts connect i ng
w i th Rear Fender
Remove Bo l t 1
Remove Lef t Footrest
I nsta l l at i on
Reverse the remove procedure for Instal lat ion.
Foo t r es t , R i gh t S i de
Removal and Instal lat ion same wi th Left side.
2-10
2 Vehicle Body and Muf f ler
Rear Fender
Remove
- - S e a t %" 2 - 3 &
- - Rea r Rack%" 2 - 3&
2
- - Rear Top Cover%" 2 - 6&
- - L e f t , R i gh t S i de Pane l %" 2 - 7&%" 2 - 8&
- - Le f , R i ghtS i de Suppor t%" 2 - 8&
- - Rea r Pro tec to r%" 2 - 7&
Remove Battery Bracket and F i x i ng P l ate%"
8 - 4&
Remove Bat t e ry%" 8 - 4&
Remove Bo l t 1
Remove Nut 1
Remove E l ecton i c Parts f rom Rear Fender
Loosen Cab l e Connector f rom Rear Fender
Upward i ng l y Remove Rear Fender
Eng i ne F r on t , M i dd l e and Rea r Sk i d
P l a t e ; P r o t ec t o r P l a t e o f Doub l e
Seat
2-11
CFMOTO
D i sasemb l y
NOTE : S i de sk i d P l ate ( Front , M i dd l e , Rear )
and Doub l e Sea t P r o t ec t i on a r e l oca t ed
a t bo t t om o f veh i c l e . The ma i n t eanace
pe r son shou l d wo r k unde r bo t t om o f ve h i c l e when d i sassemb l e the
above par ts .
Fo r sa f t y , make su r e t he veh i c l e i s
f i r m l y p a r ked .
Eng i ne Sk i d P l ate ( Front )
Remove Bo l t 1 , 2 , 3 , and 4 ;
Remove Eng i ne Front Sk i d P l ate
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
Eng i ne Sk i d P l ate ( M i dd l e )
Remove Bo l t 5 and 6 ;
Remove M i dd l e Eng i ne Ski d P l ate.
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
Doub l e - Seat Protect i on P l ate
Remove Bo l t 7 and 8 ;
Remove Doub l e- Seat Protect i on P l ate .
N OT E : N o P r o t ec t i o n P l a t e f o r s i n g l e sea t .
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
Eng i ne Sk i d P l ate ( Rear )
Remova l
Remove Bo l t 9 and 10 ;
Remove Rear Eng i ne Ski d P l ate.
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
2-12
2 Vehicle Body and Muf f ler
R i ght Front I nner Fender
Remova l
Remove Bo l t 1 , and remove R i ght Front Inner
Fender
2
Insta l l at i on
Reverse the remove procedure for Insta l l a t i on
NOTE : Hook Water Pump w i th C l i p o f R i ght
I nne r S i de Fende r du r i ng I ns t a l l a t i on .
Le f t Front I nner Fender
Remova l
Remove Bo l t 1 , and remove Lef t Front Inner
Fender
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
F r on t L e f t P r o t ec t o r
Remove
- - Bo l t 1
Pu l l backward and remove f ront Front
Lef t Protector
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
F r on t R i gh t Pr o t ect o r
Remova l and I nsta l l at i on
same w i th Le f t
S i de .
2-13
CFMOTO
Fr on t L e f t I nner Fender
Remova l
Remove Bo l t 1 and 2 ;
Remove Front Lef t Inner Fender
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
Fr on t R i gh t I nner Fender
Remova l and Instal l at i on same as Lef t S i de.
Bumpe r , Bumpe r P r o t ec t o r
Remove
Remove two Bo l ts of Eng i ne Front Ski d P l ate
f i xi ng i nto the Bumper .
Remove Bo l t 1 , 2 , 3 and 4 .
Remove Bumer and Bumper Protector
Remove Bo l t 5 connect i ng Bumper and Rack.
2-14
2 Vehicle Body and Muf f ler
Bumper Protector
Remove
- - Loosen Front Turn i ng L i ght Connector .
- - Remove Bumper and Bumper Protector .
2
Remove tapp i ng screw 1 f rom Bumper ;
Remove Bumper Protector .
I ns t a l l a t i on
Reverse the remove procedure for Insta l l a t i on
Bumpe r P r o t ec t o r Cap
Remove
Pu l l the two Caps f rom Bumper
(There are on l y 2 caps i n th i s veh i cl e)
I ns t a l l a t i on
Press Caps i nto Bumper P i pe
2-15
CFMOTO
F r on t Ven t Gr i l l
Remove
- - Loosen Connector of Front Head L i ght
- - Remove Front Fender%" 2 - 9&
- - Remove Bumpe r%" 2 - 14&
- - Remove Bo l t 1 , 2 and 3 ;
- - Remove Vent Gr i l l
No t e : Fo r r emova l o f f r on t ven t g r i l l e
on l y ,
Jus t r emove 2 f i x i ng bo l t s
o f bumpe r and 2 cen t e r f i x i ng bo l t s ,
t hen pu l l bumpe r down
I nsta l l at i on :
Reverse the remova l procedure f or
i nsta l l at i on
Warn i ng : Gaso l i ne i s h i gh l y
f l ammab l e , therefore smoke and f i re
are str i ct l y f orb i dden i n the work
p l ace .
Spec i a l a t t en t i on shou l d a l so be
pa i d to sparks .
Gaso l i ne may a l so be exp l os i ve when
i t i s vapor i zed ,
so ope rat i on shou l d be done i n a
we l l - vent i l ated p l ace .
Remove Lef t and R i ght S i de Pane l %" 2 - 7&
Remove Front Fender%" 2 - 9&
Remove Fue l Tank Top Cover%" 2 - 9&
Remove Bo l t 4
Loosen Fue l Sensor 3P Connector .
2-16
2 Vehicle Body and Muf f ler
2
Remove Fuel P i pe 1 and C i rcl i p
Remove Fuel Tank
I nsta l l at i on :
Reverse the remova l procedure f or
i nsta l l at i on
Note:
Be careful not to damage main cable,
pipes and hoses. Main cable, cables,
pipes and hoses should be routed proper ly
according to the rout ing drawing.
Take precaut ion against fuel leakage
when removing fuel Fuel Hose I
Remove :
- -Fuel tank (" 2-16)
- -Bol t 1
- -Bol t 2
- -Fuel tank top cover
I nsta l l at i on :
Reverse the remova l procedure f or
i nsta l l at i on .
No te :
Be carefu l not to damage ma i n cab l e ,
p i pes and hoses . Ma i n cab l e , cab l es ,
p i pes sh ou l d b e r ou t ed p r ope r l y
accord i ng to the rout i ng draw i ng
2-17
CFMOTO
Mu f f l e r
Caut i on : Per form d i sassemb l y
on l y
af ter the muf f l er i s coo l ed
down .
Remo ve :
- - Seat (2 - 3)
- - R i ght s i de pane l (2 - 8)
- - Nut1 , Nut 2 for exhaust p i pe
e l bow
Remove Bo l t
Remove Bo l t 2 , Bo l t 3
Remove muf f l er
I ns ta l l a t i on :
Reverse the removal procedure for
i nsta l l at i on .
Note :
Rep l ace seal i ng gasket when i nstal l i ng the
muf f l er .
2-18
2 Vehicle Body and Muf f ler
V i s i b l e Pa r t s
2
2-19
3 . Checks & Ad j ustment
Overhaul Info……………………… 3-1
Maintenance Interval………………..3-2
Inspection & Maintenance………… ………3-3
Steering Stem, Brake System……………...3-6
Wheels……………………………………….3-8
Suspension System………………. ………3-10
Gear Shifting, Fuel Device………………...3-11
Check the throttle………………................3-12
Cooling System..…………………………3-13
Lighting System...………………………...3-16
Valve Clearance…………………………..3-17
Engine Idle Speed & Spark plug…………3-18
Air Filter……………………………….3-19
Fuel Hose!&Drive Belt..
3-20
Inspection of Lubrication System…………3-22
Inspection of Cylinder Pressure…………..3-24
Inspection of Clutch Engagement and
Lock-up……………………………………..3-26
Overhaul info
Operat ion Caut ions
Note
-
DO NOT keep the eng i ne runn i ng for l ong t i me i n a poor l y vent i l ated or
enclosed place because of the harmful components l ike CO, etc, in the exhaust
gas.
-
The muf f ler and engine are st i l l very hot when the engine is just stopped.
Careless contact may cause ser ious burn. Be sure to wear fat igue dress wi th long
sleeves and gloves i f the work has to be done after the engine is just stopped.
-
Gaso l i ne i s h i gh l y f l ammab l e , smok i ng i s str i ct l y forb i dden i n the work
p l ace . Keep a l ert on the e l ectr i ca l sparks . Bes i des , vapor i zed gaso l i ne i s
highly explosive, so work should be done in a wel l -vent i lated place.
- Be carefu l that your hands or c l othes not get n i pped by the turn i ng or
movable parts of the dr iving system.
Note
The vehicle should be parked on hard and level ground.
3-1
3
CFMOTO
Maintenance Interval
T he table below lists the recommended interv als for all the required periodic maintenance
work nec es sary to k eep the engine at its best performanc e and economy. Maintenanc e
intervals are ex pressed in terms of k ilometer, miles and hours, whichever occurs firs t.
Note: Maintenance interval sh ould be sh ortened on eng ines that are used in severe conditions.
Interval
Km
Ho urs
Item
Valve Clearanc e
Initial
Every
Ev ery
500 k m
10 00 km
Initial
E very
Ev ery
2 0 hours
5 0 hours
100 hou rs
2 50km
I
!
I
IN: 0.05~0.10
EX:0.17~0.22
Idle Speed
I
I
!
1400±100r/Min
Spark Plug
I
!
I
No carbon deposit
Gap: 0.8~0.9mm
Replace
every
20000 Km
Replace every 4
years
Replace ev ery 6000Km
Air Filter
!
I
C
!
!
I
!
!
I
!
I
!
Engine Oil
R
!
R
Oil Filter
R
!
R
Coolant Level
I
I
!
Water Hos e & Pipes
I
!
I
High-Pressure Fuel Hose
Clutch
Drive Belt
Coolant
I= Inpectio n and adjust, or replace if necessary
R=Replace
C=Clean
3-2
Remark
Replace
2000Km
Replace every 2 years
every
3 . Checks & Ad j ustment
Inspection & Maintenance
!: Interval
Item
Part
Item
Handlebar
Steering
System
Steering
system
Brake lever
Brake
System
Connecting
rod, oil pipe
& Hose
Hydraulic
brake and
brake disc
Driving
System
Wheel
Operation agility
Damage
"
Installation condition of steering system
"
Sway of ball stud
"
Free play
"
"
Brake
Efficiency
"
"
Looseness,
Slack and damage
"
Front and rear brake fluid level
"
3
Shock
absorber
Front axle
Front: lever end 0mm
Rear : lever end 0mm
"
Brake fluid should
above LOWER limit
"
Brake disc damage and wear
"
"
Tire pressure
"
"
Chap and damage
"
"
"
Loosened wheel nut and axle
"
Sway of front wheel bearing
"
"
Sway of rear wheel bearing
"
"
"
"
"
"
Oil leakage and damage
be
Replace
when
the
thickness of front brake
disc is less than 2.5mm,
rear brake less than
6.5mm.
Front tire: 35kPa
(0.350kgf/# 2)
Rear tire:
30kPa
(0.30kgf/# 2)
Groove depth and abnormal wear
Sway of Joint parts, rocker arm
damage
Standard
"
Function
Drive
Train
Intervals
1/2
Annual
Year
"
Suspension
arm
Buffer
System
Daily
No wear indication on the
surface of tire (the
remained depth of groove
should not be less than
1.6mm)
"
"
Transmission, lubrication
"
"
Rear axle
Transmission, lubrication
"
"
Gear box
Transmission, lubrication
"
"
Final shaft
Looseness of joint parts
(Drive shaft)
Sway of Spline
Remove filling bolt, add oil
till oil level reaches edge
of filling hole.
3-3
CFMOTO
Item
Part
Drive train
Electrical
System
Item
Final
shaft
(Drive
shaft)
Ignition
Device
Battery
Wiring
Fuel device
Cooling system
3-4
Looseness of joint parts
Daily
O
Intervals
1/2
Annual
Year
O
Sway of Spline
O
Spark plug
O
Ignition timing
Terminal Joint
Looseness and damage of
joints
Fuel leakage
O
Spark plug gap:
0.8-0.9mm
O
O
O
Throttle
Coolant level
Coolant leakage
Standard
O
O
O
O
Throttle
clearance:
3~5mm
grip
3 . Checks & Ad j ustment
It e m
Pa rt
Lighting devi ce and
turning indic tors
Alarm and lock devic e
Instrum ents
Exhaus t pi pe and
m uffler
Frame
O thers
Abnormal parts whic h
can be determ ined
when driv ing
I tem
Function
Function
Function
Loosenes s or dam age
caused by im proper
ins tallation
Function of m uffler
Looseness and/or
dam age
Lubric ati on & grease of
fram e parts
M ake sure if there is any
abnorm al with relative
parts.
Daily
I n terv als
1/2
Annual
Year
"
"
Standard
"
"
3
"
"
"
"
"
3-5
CFMOTO
Steer i ng Stem
Park the veh i cl e on l evel p lace, ho l d steer i ng hand l ebar , and shake i n the di rect i on as
i l l ustrated on the r i ght and see i f there i s
any sway .
I n case o f any sway , check i f i t i s the
prob l em of the steer i ng stem or other parts
and then do the mai ntenance accord i ng l y .
In case of sway of the steer ing stem, t ighten
the l ocknut or d isassemb l e the steer i ng stem
for further check .
Park the veh i cl e on l evel p lace, s l owl y turn
the handlebar left and r ight to see i f i t can
turn f ree l y .
In case there i s any h i ndrance , check i f i t
i s f rom the ma i n cab l e assemb l y or other
cab l es .
I f no , check the steer i ng t i e - rod end , and
check i f the steer ing stem bear ing is damaged.
Note:
Make sure the steer ing can be operated freely.
An acc i dent may occur
i f the hand l ebar i s out of contro l .
Brake system
Front brake lever free play
Operate f ront brake l ever and check brake
ef f i ci ency and brake l ever funct i on .
Check f ree p l ay of f ront l ever end .
Free p l ay : 0mm
3-6
3 . Checks & Ad j ustment
Master Cy l i nder
<Fluid level>
Check the brake f luid level
When the brake f l u i d l eve l i s near to the
lower l imi t l ine, check master cyl inder , brake
3
hoses and jo i nts for l eakage. Remove the two
mount i ng screws on f l u i d reservo i r cap .
Remove the cap, add DOT3 or DOT4 brake l iquid
t i l l the upper l i m i t l i ne.
- Do not m i x w i th dust or water when add i ng
brake f l u i d .
- Use on l y the recommended of brake f l u i d
to avo i d chem i ca l react i on .
-Brake f luid may cause damages to the surface
of the
p l ast i c and rubber parts .
Keep the f l u i d away f rom these parts .
- S l i ght l y turn the hand l ebar l ef t and r i ght
t i l l the master cy l i nder i s i n hor i zonta l ,
then remove the f l u i d reservo i r cap .
Brake D i sc , Brake Pad
< Wear of brake pad>
Check the brake pad wears f rom the mark as
i nd i cated .
Replace the brake pad i f the wear has reached
pos i t i on of wear l i m i t trough .
Note The brake pad must be rep l aced w i th a
who l e set .
Checking and replacing the brake disc
Front brake d i sc th i ckness : " 2 . 5 mm # Re p l ace
Rear brake d i sc : " 6 . 5 mm # Rep l ace
M i n . l i m i ted th i ckness o f the f ront brake
d i sc: 2 . 5mm
M i n . l i m i ted th i ckness o f the rear brake
d i sc: 6 . 5mm
Change the Brake Fluid
< Changing Brake Fluid>
Change the brake f l u i d once every year .
3-7
CFMOTO
W he e l s
L i f t f ront whee l on l eve l p l ace , and make
sure there i s no l oad i ng on the wheel s .
Shake the front wheel left and r ight to check
whether the joint of front wheel is t ightened
and check whether i t sways .
Not t i ghten enough : # T i ghten i t
Sway : # Rep l ace the rocker arm
Front Toe - i n s i ze
Park the veh i cl e on l evel p lace, measure the
f ront toe - i n
Toe - i n : B - A=0 - 10mm
Toe- i n out of the range: # Adj ust the l ocknut of t i e- rod
No te :
Af ter the toe - i n has been ad j usted , s l ow l y
run the veh i cl e to check whether the d i rec t ion of vehicle can be control led by handlebar .
3-8
3 . Checks & Ad j ustment
T i r e P r essu r e
Check the pressure of the t i res
w i th a pressure gauge.
No t e
3
Check the t i re pressure af ter t i res
are coo l ed .
Dr i v i ng under i mproper t i re pressure
w i l l reduce the comfort of operat i on
and r i d i ng , and may cause def l ected
wear of the t i res .
Spec i f i ed pressure / t i re
Front wheel
Pressure
35kPa( . 035kgf / cm2)
T i re S i ze AT25 $ 8 - 12
Rear wheel
30kPa(0 . 30kgf / cm2)
AT25 $ 10 - 12
T i r e T r ead
Check the t i re t read .
Tread Hei ght : < 3mm # Rep l ace w i th new t i res
Note :
When the tread he i ght i s l ess than 3mm , the
t i re shou l d be rep l aced i mmed i atel y .
3-9
CFMOTO
Whee l Nu t and Whee l Ax l e
Check front and rear wheel axle nuts for looseness
Loosened ax l e nuts : # T i ghten
T i ghten i ng Torque :
Front wheel axl e nut :
110 - 130N . m(11 . 2kgf . m - 13 . 3kgf . m)
Rear wheel axl e nut :
110 - 130N . m(11 . 2kgf . m - 13 . 3kgf . m)
Sway o f Whee l Bear i ng
L i f t the f ront wheel
Make sure there i s no l oad i ng on the veh i c l e
Shake the wheel in axial di rect ion for any sway
In case of any sway ,
disassemble the front wheel and check the bear i ng
Suspens i on Sys t em
Park the veh i c l e on l ever p l ace , press the
veh i c l e Severa l t i mes up and down as i l l us trated on the r i ght .
In case of any rocking or abnormal noise, check
whether there is any oi l leakage from absorbers,
or any damage or looseness of t ightening parts.
3-10
3 . Checks & Ad j ustment
Ad j us t i ng t he Abso r be r
Use speci a l too l s to ad j ust the l ength of
absorber accord i ng to l oad i ng requ i rement
Turn cl ockw i se to ad j ust f rom h i gh to l ow
3
Gea r Sh i f t i ng
Sh i f t the gear to check for f l exi b i l i ty and
gear engagement
Ad j ust the gearsh i f t rod i f necessary
Re l ease the l ocknut to ad j ust the l ength of
gearsh i f t rod
Fue l Dev i ce
Status of the fuel system
Remove the seat (# 2 - 3)
Check the fue l hose for any ag i ng or damage.
Aged or damaged fuel hose: # Rep l ace
Check i f there i s cracks or bend i ng w i th the
vacuum tube .
Cracked or bended vacuum tube: # Rep l ace
3-11
CFMOTO
Check i ng t he Th r o t t l e L eve r
Check t he f r ee p l ay o f t h r o t t l e
l eve r
Free p l ay : 3 - 5mm
Out of range : # Ad j ust
Loosen l ocknut of thrott le cab l e
turn the regu l ator and ad j ust f ree p l ay of
thrott l e l ever
Af ter ad j ust i ng , t i ghten l ocknuts and i n stal l thrott le cab l e s l eeve
Rep l ace w i th a new thrott l e cab l e i f the
speci f ied free play could not be acqui red by
ad just ing the regul ator or i f there is st i l l
st i ck i ness w i th the thrott le .
Ad j us t i ng t he Speed L i m i te r
The speed l i mi ter i s to l imi t the openi ng of
thrott l e
Check the max i mum l ength of l i m i ter screw
thread
Max i mum screw thread : a=12mm
Ad j ust w i th a cross dr i ver .
No te :
For beg i nners , the speed l i m i t shou l d be
fu l l y t i ghtened .
Dr i vers w i th certai n sk i l l s may ad j ust
the thrott le w i th speed l i m i ter
Maxi mum l ength of screw thread i s 12mm .
It is recommended to adjust the thread length
to 3 - 5mm .
3-12
3 . Checks & Ad j ustment
Coo l i ng Sys t em
No t e
Check coo l ant l evel f rom reservo i r tank.
Do not check f rom rad i ator .
I f the rad i ator cap i s opened wh i l e the
3
eng i ne i s hot (over 100$) , the pressure of
the coo l i ng system w i l l drop down and the
coo l ant w i l l get bo i l ed rap i d l y .
DO NOT open the rad iator cap unt i l the coo l ant temperature drops down .
-Coolant is poisonous, DO NOT dr ink or splash
i t to ski n , eyes , and c l othes .
- In case the coo l ant gets to the sk i n and
cl othes , wash w i th soap i mmed i atel y .
- In case the coo l ant gets i nto eyes , r i nse
w i th p l enty of water and go to consu l t the
doctor
- In case of swa l l ow i ng the coo l ant , i nduce
vom i t and consu l t the doctor .
- Keep the coo l ant i n a safe p l ace and away
f rom reach of ch i l dren .
Coo l an t l eve l
Coo l ant m i ght r educe due to natu ra l
evaporat i on .
Check the coo l ant l eve l regu l ar l y .
No t e
- f reeze . Ord i nary water may cause eng i ne
rust or cracks i n w i nter due to f reez i ng .
-Park the vehicle on l evel ground for checki ng of the coo l ant .
Inc l i ned veh i c l e body w i l l cause i ncorrect
j udg i ng of the coo l ant l eve l .
-Check the coolant after the engine is warmed
up .
Start and warm up eng i ne.
Stop the eng i ne .
Remove l ef t s i de pane l (# 2 - 6)
Check i f the coo l ant l eve l i s between the
upper and l ower l i m i t .
3-13
CFMOTO
When the coo l ant l eve l i s be l ow the LOWER
l imit,
remove reservo i r tank cap and add coo l ant
t i l l upper l i m i t .
(Add coo l ant or d i l uted or i g i na l l i qu i d) .
Recommended coo l ant : CFMOTO coo l ant
S t anda r d dens i t y : 50%
( Freez i ng temperature o f coo l ant var i es
accord i ng to the d i f ferent m i xture rat i o .
Ad j ust the m i xture rat i o accord i ng to the
l owest temperature i n the p l ace where the
veh i c l e i s used . )
I f the coo l ant reduces very fast , check i f
there i s any l eakage.
The coo l i ng system may be m i xed w i th a i r
when there i s no
coo l ant i n the reservo i r tank and the a i r
shou l d be d i scharged
before add i ng coo l ant .
Coo l an t L eakage
Check radiator hose, water pump, water pipes
and j o i nts for l eakage.
In case of any l eakage , d i sassemb l e and do
further check .
(Refer to Chapter 4)
Check the rad i ator hose for ag i ng , damages
or cracks .
The rubber hose w i l l natura l l y get aged af ter a per i od of serv i ce t i me. The aged hose
may get cracked when the coo l i ng system i s
heated . N i p the hose w i th f i ngers and check
i f there are any t i ny cracks .
In case of any abnorma l , rep l ace w i th a new
hose .
Check the c l amps of the coo l ant p i pes and
hose .
T i ghten proper l y i n case of any l ooseness .
Check rad iator f ins for mud and dust cl og or
damage .
Correct the bent f i ns ; c l ean the mud w i th
water and compressed a i r . When the damaged
area of the rad i ator f i n i s over 20% , re p l ace w i th a new rad i ator .
3-14
3 . Checks & Ad j ustment
I nspect i on o f Coo l i ng System
Check ini t ial ly at 50 hours or 500km, replace
coo l ant every 2 years .
Check radiator, reservoi r tank and water hoses.
Leakage or Damage : # Rep l ace
Check coo l ant l eve l by observ i ng the upper
3
and the l ower l i m i t on the reservo i r tank.
I f the level is below lower l imi t , f i l l cool ant unt i l the l evel reaches the upper l i mi t .
Rep l ac i ng Coo l ant
- Remove rad i ator cap % and reservo i r tank
cap &.
- P l ace a pan be l ow water pump , and dra i n
coo l ant by remov i ng dra i n p l ug ' and water
hose (.
- Dra i n coo l ant f rom reservo i r tank.
Warn i ng !
-Do not open radiator cap when engine is hot ,
you may be i n jured by escap i ng hot l i qu i d or
vapor .
- Eng i ne coo l an t i s ha r m f u l . I f coo l an t
sp lashes i n your eyes or clothes, thorough l y
wash i t away wi th water and consul t a doctor .
I f coo l ant is swal l owed , i nduce vom i t i ng and
get i mmed i ate med i ca l attent i on .
- Keep coo l ant away f rom reach of ch i l dren
-Clean radiator with fresh water , i f necessary.
-Connect water hose ( and t i ghten drain bol t
' secure l y .
-Fi l l the speci f ied coolant into the radiator .
- Loosen b l eed bo l t ) on water pump , when
coo l ant f l ow f rom b l eed bo l t , t i ghten the
bo l t . Instal l rad i ator cap % secure l y af ter
f i l l i ng coo l ant .
- Start the eng i ne and keep i t runn i ng for
severa l m i nutes . Af ter warm up and coo l i ng
down the eng i ne, open rad i ator cap and check
coo l ant . F i l l the spec i f i ed coo l ant unt i l
the l eve l i s between the upper and l ower
l i nes on the reservo i r tank.
Caut i on :
Repeat the above procedures severa l t i mes
and make sure the rad i ator i s f i l l ed w i th
coo l ant and ai r i s d i scharged .
Inspect i on of Coo l i ng System
3-15
CFMOTO
Check Water Temperature Gauge
When eng i ne i s not work i ng , the water tem perature shou l d be i n the *0+ pos i t i on .
Start the eng i ne to check i f the i nd i cator
works . I f the i nd i cator i s not work i ng , do
the ma i ntenance i n t i me.
L i gh t i ng Sys t em
Ad j ust i ng head l i ght l i ght beam
Turn the head l i ght beam ad just i ng screw wi th
a cross screwdr i ver and ad j ust the h i gh / l ow
beam to meet the requ i rement .
3-16
3 . Checks & Ad j ustment
VA L VE C L EARANCE
Inspect i n i t i a l l y at 20 - hour break - i n and
every 100 hours or every 1000km thereaf ter .
Inspect the cl earance af ter remov i ng cy l i n der head .
3
Excess i ve va l ve c l earance resu l ts i n va l ve
no i se and i nsuf f i c i ent va l ve c l earance re su l ts i n va l ve damage and reduced power .
Check the valve clearance at the per iod indi cated above
and
ad j ust
the
va l ve
c l earance
to
speci f i cat i on , i f necessary .
- Remove cover p l ate %, reco i l starter &
- Remove i nspect i on cap ' on l ef t crankcase.
- Remove 2 va l ve ad j ust i ng cover (
- Turn the crankshaf t unt i l the l i ne ) of T .
D . C . on rotor i s a l i gned w i th mark , o f
i nspect i on ho l e on l ef t crankcase.
- Insert fee l er gauge to check the c l earance
between the va l ve stem end and the ad j ust
bo l t on the rocker arm .
Va l ve C l earance (When co l d)
IN : 0 . 05 - 0 . 10mm
EX : 0 . 17 - 0 . 22mm
No te :
- The va l ve c l earance must be ad j usted when
the eng i ne i s co l d .
- Ad j ust the val ve cl earance when the p i ston
i s at the Top Dead Center (T . D . C . ) on the
compress i on stroke .
I f the cl earance i s i ncorrect , br i ng i t into
the speci f i ed range us i ng the spec i al too l .
Loosen va l ve ad j ust bo l t and nut , i nsert a
fee l er gauge -IN : 0 . 1mm , EX : 0 . 2mm.between
the valve stem end and val ve ad j ust i ng bol t ,
t i ghten va l ve ad j ust bo l t , make sure i t
s l i ght l y contacts the fee l er gauge , t i ghten
bo l t and nut .
3-17
CFMOTO
Take ou t t he f ee l e r gauge , measu r e t he
c l earance .
I f the c l earance i s i ncorrect , repeat the
above steps unt i l the proper c l earance i s
obta i ned .
Locknut : 10 N . m
Caut i on :
Secure l y t i ghten the l ocknut af ter comp l et i ng ad j ustment
Insta l l :
2 va l ve ad j ust i ng cover ;
Inspect i on cap ;
Reco i l starter ;
Cover p l ate ;
App l y a sma l l quant i ty of THREAD LOCKER to
reco i l starter f i xi ng bo l ts .
Too l s :
Val ve ad j uster
Fee l er gauge
Mater i a l :
Thread Locker
ENG I NE I D L E SPEED
I nspect i n i t i a l l y at 20 hours run - i n and
every 50 hours or 500km thereaf ter .
Start the eng i ne and warm i t up for severa l
m i n u t e s , m e a s u r e en g i n e s p e e d w i t h a
tachometer . Set the eng i ne i d l e speed be tween 1300~1500 r / min by turning the thrott le
stop screw of carburetor .
Eng i ne i d l e speed : 1400r / m i n / 100r / m i n
Note :
Make th i s ad j ustment when the eng i ne i s hot
Too l : Tachometer
SPARK PLUG
I nspect i n i t i a l l y at 20 hours run - i n and
every 100 hours or 1000km thereaf ter . Re p l ace every 6000km .
Remove the spark p l ug w i th a speci al too l
Spec i f i cat i on : DER7EA - 9(NGK)
I f the el ectrode i s extremely worn or burnt ,
or spark plug has a broken insulator , damaged
thread , etc , rep l ace the spark p l ug w i th a
new one .
3-18
3 . Checks & Ad j ustment
I n case o f carbon depos i t , c l ean w i th a
proper too l .
SPARK PLUG GAP
Measure the spark p l ug gap w i th a fee l er
gauge .
Out of spec i f i cat i on : # Ad j ust
3
Spark p l ug gap : 0 . 8 - 0 . 9mm
Caut i on :
Check the thread size and reach when replaci ng the spark p l ug . I f the reach i s too
short , carbon wi l l be depos i ted on the screw
port i on of the spark p l ug ho l e and eng i ne
damage may resu l t .
Insta l l at i on :
Caut i on :
To avoid damag ing the cy l inder head threads;
f i rst , t i ghten the spark p l ug w i th f i ngers ,
and then t i ghten i t to the speci f i ed torque
us i ng the spark p l ug wrench .
T i ghten i ng Torque: 18 N . m
Too l : Spark P l ug Wrench ,
A i r F i l ter
Fee l er Gauge
Inspect every 50 hours or 500 km , c l ean i t
every 1000km i f necessary .
I f the a i r c l eaner i s c l ogged w i th dust ,
i ntake res i stance w i l l be i ncreased , w i th a
resu l tant decrease i n power output and an
increase in fuel consumpt ion. Check and clean
the ai r f i l ter as fo l l ow i ng :
Remove f i xi ng cl amp % and top cover &
No te :
Be carefu l not to drop the o - r i ng i nto the
a i r f i l ter box that i s attached to the a i r
f i l ter top cover .
Loosen screw ', remove f i l ter e l ement (,
separate support ), f i l ter e l ement , and
f i l ter el ement seat 0.
-Fi l l a wash pan of a proper size wi th a nonf l ammab l e c l ean i ng so l vent A . Immerse the
f i l ter el ement i n cl ean i ng so l vent and wash
it.
- Press the f i l ter el ement between the pal ms
of both hands to remove the excess so l vent .
Do not tw ist or wr i ng the element or i t wi l l
tear .
- Immerse the e l ement i n eng i ne o i l B , and
then squeeze out the excess o i l l eav i ng the
e l ement s l i ght l y wet .
3-19
CFMOTO
A - - Non - f l ammab l e cl ean i ng so l vent
B 1 Eng i ne o i l SAE#30 or SAE15W / 40 .
Never use w i th gaso l i ne or l ow f l ash po i nt
so l vents to c l ean the f i l ter e l ement
Inspect the f i l ter e l ement for tears .
torn e l ement must be rep l aced .
No te :
The surest way to accel erate eng i ne wear i s to
operate the eng i ne w i thout the e l ement or w i th
torn el ement . Make sure that the ai r f i l ter
el ement i s i n good cond i t i on at a l l t i mes .
I f dr i v i ng under dusty cond i t i ons , c l ean the
ai r f i l ter e l ement more f requent l y .
Remove the drai n p l ug 2 of ai r box to dra i n out any water .
Fue l Hose
Inspect every 100 hours or 1000 km ,
rep l ace every 4 years .
Inspect the fue l hose for damage and fuel
l eakage .
I f any damages are found , rep l ace the fuel hose
w i th a new one.
Dr i ve Be l t
Remova l :
Remove CVT cover
Ho l d the pr i mary sheave w i th speci al too l and
l oosen pr i mary sheave nut .
Speci al Too l : Rotor Ho l der
Remove pr i mary s l i d i ng sheave 1 ;
Ho l d the secondary sheave w i th speci a l too l
and l oosen secondary sheave nut .
Remove secondary sheave together w i th dr i ve bel t .
Speci al Too l : Rotor Ho l der
Remove dr i ve be l t f rom secondary sheave
3-20
3 . Checks & Ad j ustment
I nspect i on :
Inspect dr i ve bel t for wear and damage.
I f any cracks or damages are found ,
rep l ace dr i ve bel t w i th a new one.
3
Inspect dr i ve bel t for w i dth , i f w i dth i s
out of serv i ce l i m i t , rep l ace dr i ve be l t w i th a new one.
Serv i ce L i m i t : 33 . 5mm
Too l : Vern i er Ca l i per
I nsta l l at i on
Reverse the remova l procedure for i nstal l at i on .
Pay attent i on to the fo l l ow i ng :
Insert dr i ve bel t , as l ow as poss i b l e,
between secondary s l i d i ng sheave and pr i mary
f i xed sheave .
Ho l d secondary sheave w i th a speci al too l and
t i ghten the nut to the speci f i ed torque.
Nut , Secondary Sheave: 115 N . m
Instal l pr i mary sheave and nut . Ho l d the pr i mary
sheave w i th a spec i a l too l and t i ghten the nut
to the speci f i ed torque.
Nut , Pr i mary Sheave: 115N . m
Turn pr imary sheave , unt i l the dr i ve bel t i s
proper l y seated and both the pr i mary and
secondary sheaves rotate together smooth l y
and w i thout s l i pp i ng .
Caut i on :
- F i t the dr i ve bel t w i th the arrow on the dr i ve
be l t po i nts toward norma l turn i ng d i rect i on .
- The dr i ve bel t contact sur face of the dr i ven
face shou l d be thorough l y cl eaned .
Insta l l CVT cover
3-21
CFMOTO
I nspect i on o f Lubr i cat i on System
Rep l ace eng i ne o i l and o i l f i l ter i n i t i a l l y
at 20 hours or 250km and every 100 hours or
1000km thereaf ter .
Inspect the eng i ne o i l at every 10 hours .
Check Eng i ne O i l Leve l
- Keep the eng i ne i n a p l an pos i t i on .
-Remove the f ixture A, f ixture B, then remove
the l ef t s i de cover 1 .
- Remove o i l d i p rod 2
-Clean oi l dip rod, insert oi l dip rod but do
not t i ghten i t .
- Take out o i l d i p rod and check i f o i l i s
between upper and l ower l i m i t .
- I f the engine oi l is insuf f icient , f i l l more
o i l unt i l the suf f i ci ent o i l i s obtai ned .
Eng i ne O i l : SAE15W / 40 c l ass i f i cat i on SF or
SG
No te :
- Keep the eng i ne i n a p l an pos i t i on
- Do not t i ghten o i l d i p rod when measur i ng
o i l l eve l
Rep l ac i ng Eng i ne O i l
- Remove l ef t s i de cover 1 , o i l d i p rod 2 ,
drai n bo l t 3 and washer 4 .
-Drain out the engine oi l whi le the engine is
st i l l warm .
- C l ean o i l d i p rod , dra i n bo l t and washer
w i th so l vent .
- Insta l l washer and dra i n bo l t .
Drai n Bo l t :
30 N . m
- F i l l eng i ne o i l . ( about 1900m l )
3-22
3 . Checks & Ad j ustment
- Insta l l o i l d i p rod , start the eng i ne and
al low i t to run for several minutes at idl ing
speed .
- Turn of f the eng i ne and wa i t f or about 3
m inutes , and then check the o i l l evel on the
3
d i pst i ck .
Caut i on :
The eng i ne o i l shou l d be changed when the
eng i ne i s warm . I f the o i l f i l ter shou l d be
rep l aced , rep l ace eng i ne o i l at the same
t i me .
Rep l ac i ng O i l F i l ter
- Remove re l at i ve parts ( see Rep l ac i ng En g i ne O i l )
- Remove o i l f i l ter % w i th the spec i al too l
- Insta l l washer and drai n bo l t
- Instal l new oi l f i l ter wi th the special tool
- F i l l eng i ne o i l (about 2000m l ) and check
(see Rep l ac i ng Eng i ne O i l )
Too l :
O i l F i l ter Wrench
Eng i ne O i l Capac i ty
When rep l aci ng o i l : 1 . 9L
When rep l aci ng o i l f i l er : 2 . 0 L
Eng i ne overhau l : 2 . 2 L
I nspect i on o f Externa l O i l P i pe
Check external oi l pipe for leakage or damage.
Leakage or Damage : # Rep l ace
3-23
CFMOTO
I nspect i on o f cy l i nder pressure
Check cy l i nder pressure i s necessary .
Cy l i nder Pressure: 1000kpa
A l ower cy l i nder pressure may be caused by :
- Excess i ve wear of cy l i nder ;
- Wear of p i ston or p i ston r i ng ;
- P i ston r i ng j am i n groove;
- Poor cl osure of val ve seat ;
- Damaged cy l i nder gasket or other defects
Note : When cy l i nder pressure too l ow, check
the above i tems .
Test i ng Cy l i nder Pressure
Note : Before test i ng of cy l i nder pressure ,
make sure that cyl inder head bol ts are t ight ened to the speci f ied torque and valve clear ance has been proper l y ad j usted .
- Warm up the eng i ne before test i ng ;
- Make sure battery i s fu l l y charged ;
- Remove spark p l ug 1 ;
- Insta l l cy l i nder pressure gauge 2 i n spark
p l ug ho l e and t i ghten nut ;
- Keep thrott le fu l l open ;
- Press start button crank the eng i ne a few
seconds . Record the max i mum read i ng of cy l i nder pressure .
Too l s : Cy l i nder Pressure Gauge
Adaptor
3-24
3 . Checks & Ad j ustment
I nspect i on o f O i l P ressu r e
O i l Pressure : 1303170kpa at 3000r / m i n
Lower or h i gher o i l pressure may be caused
by :
! O i l p r essu r e i s t oo l ow
- C l ogged o i l f i l ter ;
3
- Leakage f rom o i l passage ;
- Damaged O - r i ng ;
- O i l pump fai l ure ;
- Comb i nat i on of above i tems ;
" O i l p r essu r e i s t oo h i gh
- O i l v i scos i ty i s too h i gh ;
- C l ogged o i l passage ;
- Comb i nat i on of above i tems ;
Test i ng O i l Pressure
- Remove bo l t %;
- Connect tachometer & w i th i gn i t i on co i l
- Instal l o i l pressure gauge ' and jo i nt seat
to mai n o i l
ga l l ery .
- Warm up eng i ne as per fo l l ow i ng :
Summer : 10 m i nutes at 2000r / m i n
W i nter :
20 m i nutes at 2000r / m i n
Af ter warm i ng up , i ncrease eng i ne speed to
3000r / m i n , and record read i ngs of o i l pres sure gauge .
- Af ter test i ng , app l y thread l ocker to the
thread i n the ho l e of ma i n o i l channel . In stal l bol t and t ighten to the speci f ied torque.
T i ghten torque423N . m
Too l s4O i l pressure gauge
Tachometer
3-25
CFMOTO
I nspect i on of C l utch Engagement and
Lock - up
CF188 - B eng i ne i s equ i pped w i th a centr i fu gal type automat i c cl utch .
Before check i ng the i n i t i a l engagement and
cl utch lock-up two i nspect ion checks must be
per formed to thorough l y check the operat i on
of the dr i ve trai n .
I I n i t i a l Engagemen t I nspec t i on
- Connect tachometer to i gn i t i on co i l
- Start eng i ne
- Sh i f t gear lever to *H igh+ posi t ion
- S l ow l y i ncrease thrott le and note down the
engi ne speed ( r / mi n) when the veh i cle starts
to move forward .
Engagement speed : 1800r / m i n32400r / m i n
I f the engagement speed i s out of the above
range, check the fo l l ow i ng :
- C l utch shoes
- C l utch shoe whee l
- Pr i mary and secondary sheave
Refer to Chapter 12 for inspect ion of clutch
I I C l u t ch L ock - up I nspec t i on
- Connect the tachometer to i gn i t i on co i l ;
- Start the eng i ne ;
- Sh i f t gear lever to *H igh+ pos i t i on ;
- App l y f ront and rear brakes as f i rm l y as
poss i b l e ;
- Fu l l y open the thrott l e for a br i ef per i od
and note the max i mum eng i ne speed obta i ned
dur i ng the test cycl e.
Lock - up Speed : 3300r / m i n33900r / m i n
Warn i ng :
Do not app l y f u l l power f or more than 5
seconds or damage to c l utch or eng i ne may
occur .
I f the l ock - up speed i s out o f the above
range, check the fo l l ow i ng :
- C l utch shoes
- C l utch whee l
- Pr i mary and secondary sheave
Refer to Chapter 12 for inspect ion of clutch
Too l : Tachometer
3-26
4 Coo l i ng and L i br i cat i on System
Overhaul Info !!!!!!!!!!4 - 1
Rad i ator and water hose check and c l ean!!4 - 9
Troub l e Shoot ing !!!!!!!!4 - 2
Coo l i ng fan check!!!!!!!!!!!!!4 -10
Per formance Overhau l !!!!!!4 - 3
Water temperature transducer check!!!!4 - 11
Reservo i r Tank !!!!!!!!!4 - 5
Water pump !!!!!!!!!!!!!!!! 4- 12
Addi ng Coo lant !!!!!!!!!4 - 6
Water pump check !!!!!!!!!!!!!4 -14
Coo l i ng system chart !!!!!!4 - 7
Water pump assemb l y and i nsta l l at i on!!!4 - 15
Engi ne Coo lant !!!!!!!!!4 - 8
Lubr icat i on system chart !!!!!!!!!4 - 19
O ve r h au l I n f o
Caut i on :
" I f the radiator cap is opened when the coolant temperature is above 100 #, the pressure of
coolant temperature wi l l go down and get bo i led rap idl y. The steam jet may cause danger and
injury. Cover the cap wi th a piece of cloth after the coolant temperature goes down and open
the cap .
"Inspect i on of coo l ant shou l d be done af ter the coo l ant i s fu l l y coo l ed .
" Coo l ant i s po i sonous . Do not dr i nk or sp l ash i t to ski n , eye or cl oth .
- I f coo l ant sp l ashes i n eyes , through l y wash your eyes w i th water and consu l t a docter .
- I f coolant splashes on your clothes, quickly wash i t away wi th water and then wi th soap and
water .
- I f coo l ant i s swa l l owed , vo i mt i mmed i ate l y and see a phys i c i an .
- Store the coo l ant proper l y and keep i t away f rom reach of the ch i l dren .
" Check radiator f ins for mud block and / or damage. Correct the bent f ins. Clean of f the mud
w i th water and compressed ai r . Rep l ace wi th a new one, i f the damaged f i n area reached 20%
"The overhau l i ng of the water pump can done w i thout remov i ng the eng i ne .
"Coo l ant f i l l i ng i s carr i ed through reservo i r tank. Do not open the rad i ator cap except
when d i sassemb l i ng the coo l i ng system for f i l l i ng or drai nage of coo l ant .
"Don$t stai n the pai nt i ng parts w i th coo l ant . In case of any coo l ant stai ns , f l ush w i th
water i mmed i ate l y .
" After di sassembly of the cool ing system, check the joints for leakage wi th a rad iator cap
tester (avai l ab l e i n the market ) .
" Refer to Chapter 10 for overhau l i ng of temperature transducer .
I ns p ec t i o n s t an d a r d
Standard
I tem
Coo l ant capaci ty
Fu l l capaci ty
1140m l
Reserv i or tank
300m l
Standard dens i ty
50'
Open i ng pressure of rad i ator cap
Thermostat
108kpa%1 . 1kg f / cm 2 &
Val ve open temperature
Fu l l open l i f t
71 ( 3#
under 95#)3 . 5 * 4 . 5mm
T i g h t en i n g t o r q ue :
Dra i nage bo l t , water pump :
8N"m%0 . 8kgf"m&
Water pump i mpe l l er :
10N"m%1 . 0kgf"m&
4-1
4
T r o ub l e sh o o t i n g
Wa t e r t empe r a t u r e r i ses t oo f as t
"Improper rad i ator cap
"A i r i n the coo l i ng system p i pe
"Mal funct i on of water pump
"Ma l funct i on of thermostat%thermostat i s
not open&
"C l ogged of rad i ator p i pe of coo l i ng p i pe
"Damaged or c l ogged rad i ator f i ns
"Coo l ant i s not enough
"Fau l ty or ma l funct i on of fan motor
No r i se or s l ow r i se o f water temperature
"Mal funct i on of thermostat%thermostat i sn$
t cl osed&
"Fau l ty c i rcu i t of water temperature d i s p l ay
W a t e r l eakag e
"Poor water sea l
"O - r i ngs are aged , damaged or i mproper l y
sea l ed
"Washers are aged , damaged or i mproper l y
sea l ed
"Improper i nsta l l at i on of p i pes
" Pipes are aged, damaged or improper ly sealed
4-2
4 Coo l i ng and L i br i cat i on System
P e r f o r m an ce O v e r h au l
I nspec t i on o f coo l an t dens i t y
Caut i on :
Be sure to open the radiator cap after coolant
i s coo l ed .
Remove :
Fron t top cover%+ 2 - 4&
Rad i ator cap(counter cl ockw i se)
4
Check w i th a dens i meter i f the dens i ty of
cool ant f i ts the temperature of us i ng p l ace;
Check coo l ant for stai ns
I nspec t i on o f t he r ad i a t o r cap
Caut i on
Be sure to open the rad i ator cap af ter cool ant i s coo l ed
Remove :
- Front top cover (+ 2 - 4)
- Rad i ator cap( + 4 - 3) ,
Caut i on
Appl y water on the seal ing sur face of radi ator cap , when at tach i ng the tester to the
rad i ator cap
App l y the spec i f i ed pressure( rad i ator cap
opening pressure) for 6 seconds and make sure
there i s no pressure drop .
Open i ng p r essu r e o f r ad i a t o r cap :
! 1 . 1 kg f / cm 2 "
1 0 8 kP a!
4-3
P r essu r e t es t i ng o f coo l i ng sys t em
App l y the spec i f i ed pressure( rad i ator cap
opening pressure) for 6 seconds and make sure
that there i s drop i n pressure
Caut i on
Do not app l y pressure over the spec i f i ed
pressure[108kPa(1 . 1 kgf / cm2 ) ] , or the coo l i ng
system may be damaged .
In case there i s any pressure l eakage , check
the p i pe , j o i nt par ts , j o i nts of water pump
and drai nage(+ 4 - 5)
Rep l ac i ng C oo l an t , A i r D i s ch a r ge
P r epa r a t i on o f coo l an t
Caut i on :
Coo l ant i s po i sonous , DO NOT dr i nk ot sp l ash
i t to ski n , eyes and c l othes
- I f coo l ant sp l ashed i n your eyes , through l y
wash your eyes w i th water and consu l t a doctor
- I f coo l ant spl ashed on your cl othes , qu i ckl y
wash i t away w i th water then w i th soap and
water
- I f coo l ant i s swa l l owed , i nduce vom i t i mme d i atel y and see a phys i ci an
- Store the coo l ant proper l y and keep i t away
f rom reach of ch i l dren
Caut i on :
M i x the coo l ant (und i l uted) w i th sof t
water accord i ng to the temperature 5#
l ower than the actua l l owest temperature i n
the operat i on area .
Coo l ant shou l d be made f rom und i l uted coo l ant w i th sof t water .
S t anda r d dens i t y o f coo l an t : 50%
Recommended coo l ant : CFMOTO coo l ant
(D i rect app l i cat i on w i thout hav i ng to be
d i l uted)
D r a i nage o f coo l an t
Remove t he r ad i a t o r cap
Caut i on
Open the rad i ator cap af ter the coo l ant
i s coo l ed down .
Remove :
- Front top cover (+ 2 - 8)
- Rad i ator Cap(+ 4 - 3)
4-4
4 Coo l i ng and L i br i cat i on System
Remove d r a i n bo l t
Remove drai n bo l t , seal gasket f rom water
pump , dra i n coo l ant .
Af ter drai nage, assemb l e new sea l gasket
and drai n bo l t and t i ghten .
4
R es e r v o i r T an k
Remove :
- Seat (+ 2 - 3)
- Lef t S i de Cover (+ 2 - 6)
- Two bo l ts of reservo i r tank
- Water hoses of reservo i r tank
Remove reservo i r tank
Drai n co l l ant of reservo i r tank
Wash c l ean the reservo i r tank
Insta l l :
- reservo i r tank
- water hoses of reservo i r tank
4-5
A dd i n g C o o l an t
Add coo l ant through f i l l i ng port
Start the engine and discharge ai r from cool i ng system . Check f rom f i l l ing port that ai r
i s fu l l y d i scharge f rom coo l i ng system and
i nstal l the rad i ator cap
Remove reservo i r tank cap and add coo l ant
t i l l the upper l i m i t
Caut i on :
Check coo l an t l eve l when the veh i c l e i s
on an even g r ound
D i s ch a r g e
D i scharge the a i r f rom coo l i ng system ac cord i ng to the fo l l ow i ng steps :
1 . Remove dra i n bo l t%+ 4 - 5&, d i scharge a i r
and i nsta l l i t
2.Start the engine and run i t several minutes
at i d l e speed
3.Quickly increase thrott le 3~4 t imes to discharge a i r f rom coo l i ng system
4 . Add coo l ant t i l l f i l l i ng port
5.Repeat step 2&3 t i l l no more coolant can be
ref i l l ed
6 . Check coo l ant l eve l i n reservo i r tank and
ref i l l t i l l upper l i m i t , i nsta l l reservo i r
tank cap
4-6
4 Coo l i ng and L i br i cat i on System
Coo l i ng Sys t em
4
4-7
- E ng i n e Co o l an t
The cool ing used in cool ing system is mixture
of 50% d i st i l l ed water and 50% ethy l ene gl y co l ant i f reeze . Th i s 50 : 50 m i xture prov i des
the opt i m i zed corros i on res i stance and f i ne
heat protect i on . The coo l ant w i l l protect the
coo l i ng system f rom f reez i ng at temperature
above -30#, the mixing rat io of coolant should
be i ncreased to 55% or 60% accord i ng to the
f i gure on the r i ght .
Note#
. Use h i gh qual i ty ethy l ene g l yco l base an t i freeze and mixed wi th dist i l led water .Never
m i x a l coho l base ant i f reeze and d i f ferent
brands of ant i f reeze
. The rat i o of ant i f reeze shou ld not be more
than 60% or l ess than 50%
. Do not use ant i - l eak add i t i ve
Warn i ng !
.DO NOT open radiator cap when the engine is
st i l l hot . Or you may be i n j ured by sca l d i ng
f l u i d or steam ;
. Coo lant i s harmfu l . DO NOT swal l ow or stai n
your sk i n or eyes w i th coo l ant . In case of
accidental swal low or stain, f lush wi th plenty
of water and consu l t the doctor immed i atel y ;
. Keep coo l ant away f rom reach of ch i l dren
- I nspec t i on o f C oo l i ng C i r cu i t
. Remove rad i ator cap / and connect tester
0 f i l l er
Warn i ng !
DOT NOT open the rad i ator when the engi ne i s
st i l l hot
. Gi ve a pressure of 105kPa and check i f the
cool i ng system can ho l d th i s pressure for 10
seconds .
. I f the pressure drops dur ing 10 seconds , i t
i nd i cates that there i s l eaakage w i th the
coo l i ng system . In th i s case , check the com plete system and replace the leaking parts or
components .
Warn i ng !
. When remov i ng the rad i ator cap tester , put
a rag on the f i l l er to prevent sp l ash o f
coo l ant
. DO NOT a l l ow a pressure to exceed the
rad i ator cap re l ease pressure
4-8
4 Coo l i ng and L i br i cat i on System
- I n s p ec t i o n an d C l ean i n g o f R ad i a t o r
and Wa t e r Hoses
R ad i a t o r Cap
. Remove rad i ator cap /
. Instal l rad i ator cap to cap tester 0
.Slowly increase pressure to 108kPa and check
i f the cap hol d the pressure for at l east 10
seconds
4
. I f t he cap can no t mee t t he p r essu r e
requ i rement , repal ce i t
Rad i a t o r Cap Va l ve Open i ng P r essu r e :
S t an d a r d : 1 0 8 kP a
To o l : Rad i a t o r C ap T es t e r
Rad i a t o r I ns pec t i on and C l ean i ng
. Remove d i rt or trash f rom rad i ator w i th
compressed ai r
. Cor rect the rad i ator f i ns w i th a sma l l
screwdr i ver
Rad i a t o r Hos e I nspec t i on
. Check rad i ator hoses l eakage or damage. I f
the hoses are l eakaged and damaged , rep l ace
them
. Check t i ghten i ng o f c l amps . Rep l ace the
c l amps i f necessary
. Af ter i nspect i on and c l ean i ng of rad i ator
and hoses , check coo l ant l eve l . F i l l coo l ant
i f necessary
4-9
I nspec t i on o f Fan Mo t o r
. Remove fan motor f rom rad i ator
. Turn the vanes and check i f they can turn
smooth l y
. Check fan motor .Make sure that the battery
app l i es 12 vo l ts to the motor and the motor
wi l l run at ful l speed whi le the ammeter wi l l
i nd i cate the ampere not more than 5A .
I f the motor does not work or the ampere
exceeds the l i m i t , rep l ace the motor
. Instal l at i on : App l y a l i tt l e thread l ocker
to the bo l ts and t i ghten to the spec i f i ed
torque .
Fan Mo t o r Bo l t T i gh t en i ng To r que : 10N . m
I n spec t i on o f T he r mos w i t ch
. Remove thermosw i tch
.Check the thermoswi tch for closing or opening by test ing i t at the bench as i l lustrated.
Connect the thermosw i tch / to the c i rcu i t
tester ,p l ace i t i n a vessel w i th eng ine oi l .
P l ace the vessel above a stove.
.Heat the oi l to raise the temperature slowly
and take the readi ng f rom thermostat 0 when
the thermosw i tch c l oses and opens .
Too l : amme te r
Th e r mo sw i t ch O pe r a t i ng T em pe r a t u r e :
S t an d a r d : ( O FF - O N ) : A p p r o x . 8 8 $
( ON - OFF ) : Appr ox . 82$
$
Note :
. Avo i d sharp i mpact on thermosw i tch
. Avo i d contact of thermosw i tch w i th ther mometer or vesse l
.Instal lat ion:Use a new O- r ing 1 and t ighten
the thermosw i tch to the speci f i ed torque:
Thermosw i tch T i ghten i ng T i rque: 17N . m
. Check coo l ant l evel af ter i nstal l at i on of
thermosw i tch . F i l l coo l ant i f necessary .
4-10
4 Coo l i ng and L i br i cat i on System
- Inspect i on of Water Temperature Sensor
. P lcae a rag under water temperature sensor
/ and remove i t f rom cyc l i nder head
. Check the res i stance of water temperature
sensor as i l l ustrated on ther i ght . Connect
the temperat ure sensor 0 to the c i rcu i t
tester ,p l ace i t i n a vessel w i th eng ine oi l .
P l ace the vessel above a stove.
To o l : oh mme t e r , t he r mo me t e r
.Heat the oi l to raise the temperature slowly
and take the read i ng f rom ohmmeter 2 and
4
thermometer 1.
B R es i s t an ce an d Wa t er T emp er at u re
T em pe ra tu re
50
80
100
154%
16
52%
4
27% 3
!" #
Re s i st an ce
!$ #
! C R es i st an ce an d W at er Temp er a tu re
A!
T em pe ra tu re
-20
25
13.7116.94
1.8252.155
!" #
Re s i st an ce
! k$#
80
110
0.3030.325
0.13830.1451
. Instal l at i on : App l y a l i tt l e thread l ocker
and instal l i t to the cyl inder head by t ight en i ng to the speci f i ed torque.
Water
Temper atu r e Senso r
T i ghten i ng
To r que : 10N . m
No t e :#
#
. Avo i d sharp i mpact on terperature sensor
. Avo i d contact of temperature sensor w i th
thermometer or vesse l
.After instal lat ion,check the coolant level .
F i l l coo l ant i f necessary .
% I n sp ec t i o n o f T he r mo s t a t
. Remove thermostat case
. Remove thermostat
4-11
. Check ther mos tat pe l l et f or cracks . I f
necessary , rep l ace i t .
. Test the thermostat accord i ng to the fo l l ow i ng steps :
3 Pass a str ing between thermostat f l ange as
i l l ustrated on the r i ght
3 Immerse the thermostat i n a beaker w i th
water .Make sure that the thermostat is in the
suspended pos i t i on w i thout contact to the
vessel . Heat the water by p l ac i ng the beaker
above a stove and observe the temperature
r i se on a thermometer
3 Take the temperature read ing f rom thermometer when the thermostat va l ve opens
The r mos t a t V a l ve Open i ng Tempe r a t u r e :
71 & 3 $
Too l : The rmomet er
3 Keep heat i ng the water to rai se the water
temperature.When the water temperature reaches
the spec i f i ed va l ve , the thermostat va l ve
shou l d have been l i f ted by 3 . 5 - 4 . 5mm
L i f t s t anda r d o f t he r mos t a t va l ve :
w a t e r t e m p e r a t u r e 9 5 $' l i f t s t a n d a r d
i s 3 . 5 - 4 . 5m m
3 I f thermotat va l ve open i ng temperature or
thermostat ve l ve l i f t does not reach the
standards , rep l ace i t .
. I nata l l thermostat : Reverse the remova l
procedure for i nstal l at i on
3 App l y coo l ant to the rubber seal of ther mostat
3 I nsta l l thermostat case . T i ghten to the
spec i f i ed torque :
T i g h t e n i n g T o r q u e s : 1 0 N (m
- Wa t e r Pu mp
Remova l an d D i sas semb l y
. Remove eng i ne l ef t s i de cover
. Dra i n coo l ant
Note#
#Before dra i n i ng coo l ant , check water
pump for o i l or coo l ant l eakage . In case of
o i l l eakage , check the water pump o i l sea l ,
O- r ing. In case of coolant leakage, check the
water sea l
4-12
4 Coo l i ng and L i br i cat i on System
. Remove c l amps and water hoses
. Re l ease bo l ts and remove water pump
. Remove O - r i ng
No t e : Do no t r euse t he O - r i ng
4
. Remove the over f l ow tube
. Rel ease water pump cover screws ,water pump
cover and gasket
. Remove r i ng and i mpe l l er
. Remove seal r i ng / and rubber sea l 0
4-13
. Remove mechan i cal sea l w i th spec i a l too l
Note#
#The mechan i ca l sea l does not need to
be moved , i f there i s no abnormal cond i t i on .
Note : Do not reuse a removed mechan i ca l sea l
. Put a rag on the water pump body
. Reomve o i l sea l
Note:The oi l seal does not need to be removed,
i f there i s no abnorma l cond i t i on
Note : Do not reuse a removed o i l sea l
. Remove bear i ng w i th spec i a l too l
Note :The bear ing does not need to be removed,
i f there i s no abnorma l no i se
Note : Do not reuse a removed bear i ng
I nspec t i on o f Wa t e r Pump
) Bea r i ng
. Check the bear i ng c l earance by hand , wh i l e
i t i s st i l l i n the water pump body
. Turn i nner race of bear i ng to check for
abnormal no i se and smooth rotat i on
. Rep l ace the bear i ng , i f there i s abnorma l
cond i t i on
) M ech an i ca l Sea l
. Check mechan i ca l sea l for damage , pay at tent i on to the seal face
. In case of l eakage or damage , rep l ace the
mechan i ca l sea l . I f nesessary , a l so rep l ace
the sea l r i ng .
4-14
4 Coo l i ng and L i br i cat i on System
) O i l S ea l
. Check o i l sea l for damaged . Pay attent i on
to the o i l seal l i p .
. In case of damage or l eakage, rep l ace the
o i l sea l
4
) Wa t e r Pump Body
. Chec l the mat i ng mace of water pump body
w i th bear i ng and mechan i ca l sea l . I f damage ,
rep l ace i t
) Wa t e r Pump I m pe l l e r
. Check the i mpe l l er and shaf t for damage.
. I f the i mpe l l er or shaf t are damaged , re p l ace a new part
Assemb l y and I ns ta l l a t i on o f Wat er Pump
. Instal l o i l sea l w i th speci al too l ;
T o o l #O i l
Sea l
I nsta l l er
Note : The stamped mark on the o i l seal faces
outs i de .
. App l y a l i tt l e grease to the o i l seal l i p
4-15
. Insta l l mechan i ca l sea l w i th a su i tab l e
socket wrench .
No t e : App l y sea l an t to s i de 4A5 o f me chan i ca l sea l
. Instal l bear i ng w i th spec i a l too l
T oo l : Bea r i n g I n s t a l l e r
Note : The stamped mark on the bear i ng faces
outs i de .
. Instal l seal r i ng to i mpe l l er
. Cl ean of f the oi l and grease f rom mechan i ca l sea l and i nstal l i nto the i mpe l l er
N o t e :4A5s i de o f mechan i ca l sea l f aces
i mpe l l er
. App l y grease to i mpe l l er shaf t
. Insta l l i mpel l er shaf t to water pump body
4-16
4 Coo l i ng and L i br i cat i on System
. Instal l r i ng to water pump shaf t
. Instal l new gasket to water pump body
4
. Insta l l water pump cover and t i ghten the
bo l ts and b l eed bo l t
Water
Pump
Cover
Bo l ts
T i ghten i ng
T o r q u e : 6 N (m
. Check i mpe l l er for smooth turn i ng
. Instal l the new O - r i ng
Note :
. Use the new O - r i ng to prevent l eakage
. App l y grease to O - r i ng
. Insta l l the over f l ow tubes
4-17
. Insta l l water pump and t i ghten the bo l ts
to the speci f i ed torque
Wa t e r pump bo l t s t i gh t en i ng t o r que :
10N(
(m
Note : Set the water pump shaf t s l ot end 4B5
to o i l pump sha f t f l at s i de 4A5.
. Connect water hoses
. Add coo l ant
. Instal l l ef t s i de cover
4-18
4 Coo l i ng and L i br i cat i on System
4
4-19
Add grease to the eng i ne parts(p i ston , cy l i n der body , camshaf t and so on) wh i ch run at
h i gh speed
Eng i ne l ubr i cat i on shou l d be spec i a l o i l .
Eng i ne o i l i s not on l y used as l ubr i cat i on ,
but also used to wash, rustproof ,seal and cool .
I nspect i on o f
L u b r i c a t i o n s y s t e m !*
3 - 22"
I nspect i on o f eng i ne o i l pump and l i m i t
pressure
4-20
v a l v e !* 6 - 4 1 "
5
Removal and Installation of Engine,Drive Traina and Gearshift Unit
Overhaul Info###############5-1
Remova l and Insta l l at i on of Front and Rear
Alex ##################5-5
R emo v a l an d I n s t a l l a t i o n o f G ea r s h i f t
Engi ne Removal and Instal l at ion##### 5-2
Uni t####################5-7
Overhau l Info
Operat i on Caut i ons
!Secure l y support the ATV w i th bracket when remov i ng or i nsta l l i ng eng i ne . Take
care not to damage f rame , eng i ne body , bo l ts and cab l es"
!Warp the f rame to avo i d anyy poss i b l e damage when remov i ng or i nsta l l i ng the
eng i ne"
!Fo l l ow i ng operat i on doesn#t requ i re remova l of eng i ne f rom the veh i c l e :
Oi l pump
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:
Engine front rear mounting bolt:
Bolt, engine front rear mounting bracket
Bolt, engine front upper mounting bracket
35N!45N"m
40!50N"m
35!45N"m
35!45N"m
5-1
5
CFMOTO
Engine Removal
Remove:
—Plastic( --Chapter 2)
—Air Filter( -Engine service 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.
5-2
5
Removal and Installation of Engine,Drive Traina and Gearshift Unit
Remove spark plug cap from cylinder
5
Remove protection sleeve of starter relay.
Remove Nut.
Disconnect positive wire of starter relay.
Remove nut.
Remove negative wire of starter relay.
5-3
CFMOTO
Remova l Bo l t (4 un i ts) of Eng i ne.
5-4
5
Removal and Installation of Engine,Drive Traina and Gearshift Unit
Eng i ne I nsta l l at i on
Put eng i ne onto the f rame , i nsta l l the two
l ower mount i ng bo l ts and nuts
Tightening torque:
!
Engine lower hanger bolt:50!60N"m
Install:
—Water outlet and inlet hoses to engine with proper
clamps.
—Positive and negative starting wires to engine.
—Connect all the connectors.
—Spark plug cap.
—Gearshift rod to engine.
5
—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:
P l ast i c par ts f or f ram $
( % Chapter 2&
Front and rear whee l s and arms$% Chapter
8 &
A i r f i l ter$% Chapter 7&
Ca rbure to r$% Chapt er 7&
Eng i ne
Rear brake Ca l i per$% Chapter 7&
5-5
CFMOTO
Remove nut and bolt of front axle from
frame.
Remove nut and bolt of rear axle from
frame.
5-6
5
Removal and Installation of Engine,Drive Traina and Gearshift Unit
Remove the 18 bo l ts f or dr i ve sha f ts and
f ront and rear ax l es$Refer to 5'bo l t 3)
Remove
Front and rear axl es , dr i ve shaf ts , rear brake
d i sc
I nsta l l at i on
Reverse the remova l procedure for Insta l l a t i on
T i ghten i ng torque :
Bo l t , f ront
Bo l t , rear
a x l e !4 0 - 5 0 N "m
a x l e !4 0 - 5 0 N "m
B o l t , f r o n t an d r e a r d r i v e s h a f t s !4 0 -
5
5 0 N "m
Gea r sh i f t Un i t
Remove
l e f t and r i ght s i de pane l $% 2 - 6&
Fue l tank top cover$% 2 - 8&
F r on t f ende r $% 2 - 8&
Bo l t 1
Gearsh i f t rod
Remove the 3 bo l ts
Remove gearsh i f t un i t
I nsta l l at i on :
Reverse the remova l procedure for i nsta l l a t i on
Make sure that gearsh i f t i s f l exi b l e.
In case of any inf lexibi l i ty,adjust the
gearsh i f t rod to ensure the gear en gagement
5-7
6
Engine Removal , Inspect ion & Instal lat ion
6 Engine Removal, Inspection and Installation
!Engine Removal/Installation Orders and the Relative Page Numbers
tem
DES
Water Hose/Pipe
gine
iphery Left Side Cover
Recoil Starter
gine
nt
Side
Spark Plug
Cylinder Head Cover
Tensioner
Camshaft
Cylinder Head/Tensioner Plate
Cylinder/Timing Chain Guide
Piston
Starting Motor
Oil Filter
ngine Sector Gear
ft side Water Pump
Sheave Drum
Left Crankcase Cover/ Magneto Stator
Magneto Rotor
Starting Driven Gear
Starting Dual Gear/Idle Gear
Oil Pump Sprocket and Chain
CVT Cover
Drive Belt
Primary Sheave/Secondary Sheave
ngine CVT Housing/Clutch Outer Face
ht side Clutch
Timing Chain
ngine
enter
Gear Position Bolt
Right Crankcase
Front Output Shaft Components
Driven Bevel Gear Components
Shift Cam
Guide Bar, Fork
Drive Bevel Gear Components
Main Transmission Shaft
Transmission Counter Shaft
Balancer Shaft
Crankshaft
Oil Pump, Pressure-limiting Valve
Left Crankcase
Disassembly
3-2
3-2
3-2
3-2
3-3
3-3
3-3
3-4
3-4
3-5
3-5
3-6
3-6
3-7
3-7
3-7
3-7
3-8
3-8
3-8
3-9
3-9
3-9
3-10
3-10
3-10
3-11
3-11
3-11
3-11
3-12
3-12
3-12
3-12
3-12
3-12
3-13
3-13
Inspection /
Maintenance
2-11
3-49
2-4
3-14
3-24
3-21
3-15/3-23
3-24/3-23
3-25
6-3
2-9
5-7
3-48
3-48
3-47
3-47
3-48
3-51
3-36
3-30
3-51
3-28
3-23
3-52
3-43
3-43
3-40
3-39
3-42
3-38
3-38
3-46
3-27
3-41
3-52
Assembly
Remarks
3-69
3-69
3-68
3-68
3-66
3-67
3-65
3-64
3-64
3-62
3-62
3-62
3-61
3-61
3-60
3-60
3-60
3-59
3-59
3-59
3-58
3-57
3-57
3-57
3-56
3-56
3-56
3-56
3-55
3-55
3-55
3-55
3-55
3-54
3-54
3-54
3-54
3-53
6
es: Arrowhead direction is for engine removal orders. Reverse the direction for assembly and
installation
6-1
" Eng i ne Remova l
! Preparat ion before engine removal
" Prepare a proper tray used for l oad of components
" Prepare necessary remova l and assemb l y too l s
" Dra i n up eng i ne o i l $3 - 22&
" Dra i n up coo l ant$3 - 15&
! Engine Periphery
Water Hose/Pipe
" Remove water hose clamp '()*Remove
water hose +
" Remove screw , and water hose Left Side Cover
"Remove 6 bolts(M6X20) of left side cover#
$M6 % 20&,Remove left side cover #
Recoil Starter
" Remove 4 bolts$M6 % 12&of recoil starter
Remove recoil starter.
Inspection Plug
"Remove inspection plug/wi th screwdr iver
!Engine Front Side
Spark Plug
" Remove spark plug 0 with special wrench
Tool: Spark Plug Wrench
" Turn crankshaft, align T.D.C. line A on magneto
rotor with mark B of left crankcase
(p i ston on T . D . C&
6-2
6
Engine Removal , Inspect ion & Instal lat ion
Cylinder Head Cover
"Remove valve adjusting cover
"Remove12 bolts of cylinder head cover
"Remove cylinder head cover
Timing Chain Tensioner
"Remove screw plug', insert a flat screwdriver into
slot of timing chain tensioner adjuster , turn it
6
clockwise to lock tensioner spring;
" Remove tensioner fix bolt
" Remove tensioner and gasket
Camshaft
" Loosen timing sprocket bolt;
"Remove timing sprocket bolt and lock;
6-3
"Remove C-ring'
"Remove timing sprocket from camshaft, remove
camshaft
Note: Take care not to drop spacer, bolt, bolt lock
and C-ring into crankcase.
"Remove tensioner plate
Cylinder Head
"Remove cylinder head bolt
"Remove cylinder head bolts diagonally;
"Remove cylinder head
Note : Take care not to drop dowe l
p i n i nto crankcase
Cylinder
"Remove dowel pin and cylinder head gasket
" Remove timing chain guide'
6-4
6
Engine Removal , Inspect ion & Instal lat ion
"Remove cylinder bolt
"Remove cylinder
Note#Take care not to drop dowel pin into
crankcase
"Remove dowel pin and cylinder gasket
Note#When performing above removal process,
be sure to hook up timing chain to
prevent it from falling into crankcase
Piston
" Remove piston pin circlip ' with long nosed pliers
Note#Put a clean rag under piston so as not to
drop piston pin circlip into crankcase
6
" Remove piston pin ) and piston +
Note#
" When installing piston, make sure 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 ,
Tool: Piston Pin Remover
!Engine Left Side
Starting Motor
"Remove 2 bolts of starting motor
"Remove starting motor
6-5
Oil Filter
"Remove oil filter with special tools
Tool: Oil filter Remover
Sector Gear
"Remove bolt 1 of gearshift rocker arm
"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
6-6
6
Engine Removal , Inspect ion & Instal lat ion
Water Pump
"Screw out bolt of water pump
"Remove water pump
Sheave 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
6
Magneto Rotor
"Install attachment 1 to crankshaft end
" Install special tool to rotor thread;
Remove rotor and woodruff key
Tool: Rotor Remover
6-7
Starting Motor Gear
"Remove driven gear 1 and needle bearing
"Remove spacer 2
"Remove dual gear and shaft 3
"Remove idle gear and shaft 4
Oil Pump Sprocket and Chain
"Remove drive sprocket nut 5
"Remove C-ring 6
"Remove oil pump drive and driven sprockets and
chain
6-8
6
Engine Removal , Inspect ion & Instal lat ion
! Engine Right Side
CVT Cover
"Remove bolt of CVT cover
"Remove CVT cover
"Remove 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
6
"Remove secondary sheave
"Remove drive belt
Tool: Sheave Holder
"Remove primary fixed sheave'
"Remove bolt for air guide plate,Remove air guide
plate
6-9
CVT Case
"Remove bolt 1 of CVT case
"Remove nut 2 of CVT case
"Remove outer clutch face and CVT case
"Remove dowel pin, front and rear gasket
Clutch
"Remove clutch shoe fixing nut with special tool
"Remove clutch shoe
Note#The clutch shoe nut has left-hand threads
Timing Chain
"Remove timing chain
6-10
6
Engine Removal , Inspect ion & Instal lat ion
! Engine Center
Gear position bolt
" Remove gear position bolt '
"Remove spring and steel ball
Right Crankcase
"Remove left crankcase bolts
"Remove right crankcase bolts
6
"Separate right crankcase with special tool
Caution
"The Crankcase separator 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 ,
6-11
" Remove Oil seal '(Bearing limit nut )
$l e f t ro l l &
"Remove Front Output Shaft,
Shift Cam, Fork/Shaft
" Remove Shift Cam -(Fork /Shaft #1
Drive Bevel Gear
"Remove left crankcase from driven bevel gear
Drive Shaft, Drive Shaft
"Remove drive shaft.and driven shaft/
Balancer Shaft
" Remove balancer shaft1
6-12
6
Engine Removal , Inspect ion & Instal lat ion
Crankshaft
"Separate crankshaft from left crankcase with special tool
Tool: Crankshaft Separator
Oil bump, Relief Valve
" Remove oil bump and relief valve1
6
6-13
$ Engine Components Inspection
Cylinder Head Cover
! Disassembly
Caution#Each removed part should be identified to its location, and the pars should be laid out
in groups designated as ¡°Exhaust¡±, ¡°Intake¡±, so
that each will be restored to the original location
during assembly.
"Remove rocker arm shaft bolts A
"Remove rocker arm shaft by using M6 bolts B
Cylinder Head Cover Distortion
Clean off sealant from the fitting surface of cylinder head cover, place cylinder head cover on a surface plate and measure distortion with a thickness
gauge.
Cylinder head Cover Distortion
Limit: 0.05mm
Tool: Thickness Gauge
Distortion out of range: --Replace
Note#Cylinder head cover and cylinder head
should be replaced together.
Rocker Arm Shaft
"Measure out diameter of rocker arm shaft with a
micrometer.
Rocker Arm Shaft O.D.: (IN, EX)
Limit: 11.973~11.984mm
Tool: Micrometer (0~25mm)
6-14
6
Engine Removal , Inspect ion & Instal lat ion
Rocker Arm
"When checking the rocker arm, check the inner
diameter of the valve rocker arm and wear of the
camshaft contact surface.
" Rocker Arm I.D. : .000~12.018mm
Tool: Dial Calipers
! Assembly
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
6
the specified torque:
Rocker Arm Shaft Bolt: 28N.m
Cylinder Had
! Disassembly
"Remove intake pipe
"Remove water temperature sensor'and
thermostat cover)
6-15
"Remove thermostat
"Compress the valve spring and remove valve cotter
with tweezers.
Tools: Valve Spring Compressor
Tweezers
"Remove valve spring upper seat and valve spring
"Remove valve from the other side.
"Remove valve stem seal ring and valve lower seat.
6-16
6
Engine Removal , Inspect ion & Instal lat ion
Cylinder Head Distortion
"Clean off carbon deposit from combustion chamber;
"Check the gasket surface of the cylinder head for
distortion with a straightedge and thickness gauge.
Take clearance readings from several places. If any
clearance reading is out of the service limit, replace
with a new cylinder head.
Cylinder Head Distortion Service Limit: 0.05mm
Tool: Thickness Gauge
Valve Seat Width
"Coat the valve seat with color uniformly. Fit the
valve and tap the coated seat with the valve face in
a rotating manner. To get a clear impression of the
seating contact, use a valve lapper to hold the valve
head.
"The ring-like dye impression on the valve face
should be continuous, without any break. The width
6
of the dye ring, which is the visualized seat width,
should be within the following range:
Valve Seat Width: 0.9-1.1mm
Tool: Valve Lapper
Valve Stem and Valve Guid
"Lift the valve about 10mm from valve seat. Check
the valve stem deflection in the directions of X and Y
perpendicular to each other, with a dial gauge. If the
deflection measured is out 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
6-17
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 Run-out
" Support valve stem with V block as illustrated on
the right. Check the run-out with a dial gauge.
Service Limit: 0.05mm
Tool: Magnetism Stand
Dial Gauge (1/100)
V block
Valve Head Radial Run-out
" Measure the val ve head radi a l run out as i l lustrated on the r ight .
Valve head Radial Run-out out of range:--Replace
Service Limit: 0.03mm
Tool: Dial Gauge (1/100)
Magnetism Stand
V Block
Valve Face 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 End
"Check valve stem end for pitting or wear. In case of
any pitting or wear, resurface the valve stem end. If
the length T is less than service limit, replace valve
with a new one.
Valve Stem End Length
Service Limit: 2.1mm
Tool: Vernier Caliper
6-18
6
Engine Removal , Inspect ion & Instal lat ion
Valve Spring
Valve Spring keeps valve and valve seat tight.
Weakened spring results in reduced engine power
output and chattering noise from valve mechanism.
"Measure the spring free length.
Spring free length out of range: --Replace
Service Limit: 38.8mm
Tool: Vernier Caliper.
" Measure the force to compress the spring to the
specified length.
Valve spring tension out of range: ---Replace
Service Limit: (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
6
! Assembly of Cylinder Head
"Install each valve spring seat;
"Apply moly oil to valve stem seal and fit into
position.
Mater ial : Moly oi l
Note: Do not reuse the valve stem seal.
" Insert the valves, with stems coated with moly oil
all around.
Note: When inserting the valve, be careful not to
damage the lip of the stem seal.
6-19
"Install valve spring with small-pitch end (b) facing
cylinder head. Big-pitch end (a) is marked.
"Put on the valve spring retainer. Use the valve
spring compressor to press down the spring. Fit the
two cotter halves to the stem end 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.
Tool: Valve Spring Compressor
Tweezers
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.
6-20
6
Engine Removal , Inspect ion & Instal lat ion
" Install thermostat
"Install thermostat cover
"Install water temperature sensor, apply thread
locker to the thread part, tighten it to the
specified torque.
Water temperature sensor
Tightening torque: 10 N.m
6
"Install intake pipe, apply lubricant to 0-ring.
Camshaft
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 symptoms could be caused by wear of camshaft.
Note: Do not try to disassemble the camshaft/auto-
matic decompression assembly. It is not serviceable
6-21
"Automatic Decompression
Move the automatic decompression weight with
hand and check if it is operating smoothly. If it is
not working smoothly, replace with a new camshaft/
automatic decompression assembly.
" Cam Wear
Worn cams can often cause mistimed valve
operation resulting in reduced power output. The
limit ofcam wear is specified for both IN and EX
cams in terms of cam height2a3Measure with
a micrometer the cam height.
Cam height service limit:
IN: 33.130mm
EX: 33.200mm
Tool : micrometer (25-50mm)
" Camshaft Journal Wear
Check whether each journal is worn to the limit
by measuring camshaft journal oil clearance with the
camshaft installed.
Camshaft journal oil clearance#0 . 15mm
Check according to the following steps:
4Clean off materials from cylinder head and cover;
4 Install camshaft with plastic gauge;
4Install cylinder head cover and tighten bolts evenly
and diagonally to the specified torque:
Tightening torque #10 N5m
4Remove cylinder head cover, read the width of the
compressed plastic gauge with envelop scale. The
reading should be taken from the widest part.
Tool: Plastid Gauge
Note: Do not turn the camshaft with plastic gauge
in place.
If the camshaft journal oil clearance exceeds the
limit,measure the outer diameter of camshaft;
Replace either cylinder head set or the camshaft if
theclearance is not correct.
6-22
6
Engine Removal , Inspect ion & Instal lat ion
" Camshaft Journal O.D.
Measure camshaft journal O.D. with a micrometer.
If the O.D. is out of range, replace camshaft with a
new one.
Camshaft journal O.D. service l imi t :
Sprocket end: 22.959 mm 6 21.980mm
Other end: 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.
Service limit: 0.10mm
Timing Sprocket and Chain
"Check timing sprocket and chain for wear or
damage.
Replace with new parts if abnormal wear or damageis
6
found.
" Tensioner and Chain Guide
Check contact surface of tensioner and chain
guide for wear and damage.
Replace with news parts if abnormal wear or
damage is found.
6-23
CFMOTO
Chain Tensioner
Inspect ion
#Check tensioner for any damage or poor function.
Damage, poor function:—Replace
inspect way of working stability
! Insert screw driver " into the slotted end of adjusting
screw, turn it clockwise to loosen the tension and
release the screwdriver.
!Check the push rod movement. If the push rod is
stuck or there is a failure with spring mechanism,
replace the chain tensioner with 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 Distortion Service Limit: 0.05mm
Tool: Straight edge
Thickness Gauge
Cylinder Bore
#Check cylinder wall for scratches, nicks or other
damage. Replace with a new one if any
#Measure cylinder bore diameter at three points
of upper, middle and lower.
Standard Cylinder Bore:
87 . 500 - 87 . 522mm
Tool: Cylinder Gauge Set
6-24
6Engine Removal , Inspect ion and Instal lat ion
Piston
Piston Diameter
Use a micrometer to measure the diameter at the
point 10mm above the piston end, as illustrated on
the right. If the measurement is less that the limit,
replace the piston
Standard : 87 . 460 - 87 . 480mm
Limit : 87 . 380mm
Tool:Micrometer (75-100mm)
Calculate the piston to cylinder clearance according
to the abovemeasurement.If the clearance is more than
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
6
piston and piston rings.
Service Limit:
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
Oil ring : 2 . 51 - 2 . 53mm
Standard thickness of piston ring
Top ring!0 . 970 - 0 . 990mm
2nd ring :
1 . 170 - 1 . 190mm
Tools: Thickness gauge
Micrometer (0-25mm)
6-25
CFMOTO
Piston Ring Free End Gap and End Gap
Before installing piston rings, use vernier caliper to
measure the free end gap of each ring, and then fit
ring into the cylinder.
Use thickness gauge to measure each ring end gap,
if any ring has an excess end gap, replace the
piston ring
Piston ring free end gap 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 outer
diameter at three points
Piston pin outer diameter limit: 22.980mm
Tools: Bore gauge (18-35mm)
Micrometer (0-25mm)
6-26
6Engine Removal , Inspect ion and Instal lat ion
ConnectingRod/Crankshaft
Connecting rod small end I.D.
# Use a dial gauge to measure the I.D. of connecting rod small end. If the measurement exceeds the
limit,replace the connecting rod.
Connecting rod small end I.D. : 23.040mm
Tool: Dial Gauge (18-35mm)
Connecting Rod Deflection
#Check the movement of the small end of the rod
and inspect the wear of the small end. Thismethod
is also applicable to check and inspection of big end
Connecting Rod Deflection: 3.0mm
Tools: Dial Gauge
Magnetic stand
V-block
6
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 blocks as illustrated.
Put the dial gauge, slowly turn the crankshaft and
measure run-out with a dial gauge.
If the run-out exceeds the limit, correct or replace
the crankshaft.
Run out limit: 0.08mm
Tools: dial gauge
Magnetic stand
V-block
6-27
CFMOTO
Clutch inspection
#Check clutch for chipping, scrape, uneven wear or
heat discoloration. At the same time check depth of
the grooves of clutch shoes. If any of the clutch
shoes has no groove, replace the clutch.
Note: clutch should be replaced as aset.
Clutch Wheel
#Check the inner 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 uneven wear. If any damage is found, replace the clutch
wheel with a new one.
!Use special tool to remove oil seal
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
Apply lubricant grease to oil seal when
assembling.
6-28
6Engine Removal , Inspect ion and Instal lat ion
Primary and Secondary Sheave
6
6-29
CFMOTO
Primary Sliding Sheave
Disassembl
# Remove spacer
# Remove Cam " rol ler $
Roller inspection
#Check each roller and sliding face for wear and
damage.
Wear and damage:—Replace
Note: rollers should be replaced as a set.
Oil Seal inspection
#Check oil seal lip for wear and damage.
Wearanddamage: —Replace
# Remove the oil seal
6-30
6Engine Removal , Inspect ion and Instal lat ion
Primary Sliding Sheave and Fixed Sheave
#Check the drive face for any abnormal conditions
such as damage or stepped wearing.Replace if
necessary.
# Install oil seal with special tool.
Tool: Bearing install set
Assembly
Reverse the removal procedure of primary sliding
and fixed sheave for installation.
Pay attention to the following:
#Apply grease to inner bore and oil seal lip.
6
Note: Wipe off any excessive grease
thoroughly;
Take care not to attach any lubricant
grease to contact surface of drive belt.
Material: Lubricant grease
#Position 8 rollers"on the primary sliding sheave
%
# Install 4 dampers $ to cam &%
#Install cam to primary sliding sheave.
%
Note: When inserting the spacer, press down the cam
so that the rollers will not come out of position.
6-31
CFMOTO
# Install spacer
Secondary Sheave
Disassembly
#Use special tool and holder to hold the secondary
sheave. Remove secondary sheave nut with special
tool%
Caution:Do not remove the ring nut before
attaching theclutch spring compressor.
Tool: Nut Wrench
Sheave Holder
#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.
% 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 abruptly
#Slowly loosen tool handle and remove the
special tool.
6-32
6Engine Removal , Inspect ion and Instal lat ion
# Remove spring "%
# Remove spring seat $%
# Remove guide pin and spacer%
# Remove secondary sliding sheave &%
6
O-ring and Oil Seal
Check the O-ring and oil seal for wear and
damage.
WearandDamage: —Replace
# Remove Oil Seal%
6-33
CFMOTO
# Install oil seal with special tool.
Tool: Bearing install set
#Use vernier caliper to check the spring free length.
If the length is shorter than the service limit, replace
with a new one.
Service Limit: 145.4mm
Secondary Sliding and Fixed Sheave:
#Check drive face for any abnormal condition such
as stepped wear or damage. Replace if necessary.
Assembly
#Install a new O-ring
#Apply lubricant grease to O-ring, oil seal lip and
guide pin groove.
Material: lubricant grease
6-34
6Engine Removal , Inspect ion and Instal lat ion
# Install guide pin and spacer "
Note: To avoid damage to the oil seal lip during
assembly, slide the 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.
6
# Compress spring with special tool.
#Align the secondary sheave end with spring
plate hole
Tool: Secondary sheave spring compressor
# Tighten ring nut temporarily%
#Remove the special tool from secondary sheave%
6-35
CFMOTO
# Tighten the ring nut with special tool to
the specified torque.%
Ring Nut Tightening Torque:
1 00 N"
"m
Tool: Ring nut wrench
Sheave holder
Drive belt
#Check bel t for any greasy substance.
# Check contact surface of bel t for
any cracks and damage;
# check bel t width wi th veni re cal iper
In casse of damage, width out of range,
replace with new one.
Bel t width service l imi t :33 .5mm
Tool : verni re cal iper
Warning: I f bel t surface is stained
wi th grease or oi l ,degrease the bel t
thoroughly.
6-36
6Engine Removal , Inspect ion and Instal lat ion
Transm i ss i on
D i sassemb l y
6
I tem
Qty
I tem
1
MAINSHAFT. GEARSHIFT
1
10
2
SHIFT CAM
1
11
3
RIGHTCRANKCASE
1
12
1
14
GUIDE BAR
1
1
15
DRIVEN SHAFT
1
1
16
SPRING, SHIFT FORK
1
4
5
6
7
8
9
Descr i pt i on
LEFT CRANKCASE
DRIVENSECTORGEAR
SPROCKET,
REVERSEGEAR
CHAIN, REVERSEGEAR
DRIVENOUTPUTGEAR
DRIVE SECTORGEAR
1
1
1
13
17
18
Descr i pt i on
DRIVENGEAR, HIGH RANG
DRIVENGEAR,
LOWRANGE
SPRING, SHIFT FORK
RIGHT SHIFT FORK
LEFT SHIFT FORK
SHIFT FORK ASSEMBLY
Qty
1
1
1
1
1
1
6-37
CFMOTO
Inspect ion
#Inspect dr ive bevel gear and sprocket
for stains, scratch or damage, replace i f necessary.
#Inspect reverse gear chain for damage,
wear , replace i f necessary.
# Disassemble counter
i l lustrat ion.
shaft
as
#Inspect bear ing surfaces for stains,
damage or wear and also for bear ing
gaskets. Replace i f necessary.
6-38
6Engine Removal , Inspect ion and Instal lat ion
# Check the shi ft fork clearance wi th
a thickness gauge in the groove of
i ts gear .Replace i f clearance
exceeds the l i m i t .%
Shi ftfork to Groove clearance
Standard'0 . 10 - 0 . 30mm
Servi ce L imi t : 0 . 50mm
# Measure shi ft fork groove width wi th
vern i er ca l i per %
Standard shift fork groove width:
'6 . 05 - 6 . 15mm
# Measure shi ft fork thickness wi th
vern i er ca l i pers%
6
Standard fork thickness'5 . 80 -5 . 90mm
#Check shi ft fork " and $ for damage
or bend, replace i f necessary.
# Instal l shi ft fork to guide bar and
move l e f t and r i ght . In case of any
unsmooth moving, replace with a new one.
6-39
CFMOTO
#Put the guide bar on a f lat place and
rol l i t . In case of any bend,
repl ace wi th a new one%
Note!
!DO NOT attempt to correct
a bent guide bar .
# Check shi ft fork spr ing for damage,
repal ce i f necessary%
#Check shi ft cam groove for scratches,
damage.Replace i f necessary;
Assembly
Reverse the removal
procedure for
assembly. Pay attent ion to the
fol lowing'
No te!
# Use new retainers. Pay attent ion
to the di rect ion of the retainers.
Fi t to the side where the thrust
i s as i l l ustrated%
# Coat the gears and shafts wi th
engine oi l before assembly .
Wa r n i ng!
!
# Do not reuse the reta iners%
# Do not expand of the gap end of new
retainers too wide when assembl ing.
%Make sure that al l the retainers are
#
proper ly f i tted.
6-40
6Engine Removal , Inspect ion and Instal lat ion
# When assembl ing the guide bar ,
take care not to assemble the
two shi ft forks and spr ings in
the opposi te di rect ion.
1 Guide bar ; 2
Retainer 12;
3 Left shi ft fork;
4 Shi ft fork spr ing(smal l ) ;
5 Right shi ft fork;
6 Shi ft fork spr ing(big) ;
7 Spr ing seat
Oi l pump
# Disasseble oi l pump as i l lustrated%
1 Oi l pump housing; 2 Dowel pin;
3 Oi l pump shaft ;
4 Straight pin;
6
5 Inner rotor , oi l pump;
6 Outer rotor , oi l pump;
7 Oi l pumper cover
#Check oi l pump housing and cover for
cracks and damage. Replace i f
necessary.
# Measure the top clearance a between
inner and outer rotors and side
clearance b between outer rotor and
oi l pump housing. I f the clearance
exceeds the l imi t , replace wi th new
one.
Top clearance!
!0 . 03 - 0 . 10mm
Serv i ce l i m i t!
!0 . 15mm
Side clearance'0 . 03 - 0 . 10mm
Serv i ce l i m i t'0 . 12mm
6-41
CFMOTO
Oi l strainer inspect ion
# Check o i l stra i ner " and O - r i ng $
for damage, replace i f necessary;
#Clean the surface of oil strainer
with engine oil.
Rel ief valve
# Check the va l ve body "(va l ve $(
sp r i ng &(0 - r i ng ) f o r damage o r
wear ing. Replace i f necessary;
Dr ive bevel gear
#Use a clean rag to protect the dr ive
bevel gear shaft , clamp i t to the
pl iers%
# Loosen dr ive bevel gear nut 3,
remove the dr ive bevel gear 4 and
ad j ust washer 5%
# Check the dr ive bevel gear 4 and
output dr iven gear 2 for rust ,
scratch, wear or damage. Replace i f
necessary.%
# Check i f the bear ing 8 turns
smoothly, replace wi th a new bear ing i f necessary.
1-Dr ive bevel gear cover
2-Output dr iven gear
6- -Dr ive bevel gear shaft
3-Dr ive bevel gear nut
7- Bear ing nut
4-Dr ive bevel gear
# Adjust Washer 5 i f any of r ight
crankcase, dr ive bevel gear 4, or
dr ive bevel gear cover 1 is replaced.
Refer to bevel gear adjustment for
detai ls%
#Apply engine oil to bearing 8 when
assembling and tighten nut 3 to the
specified torque.%
Drive bevel gear nut tightening torque
145N.m
6-42
5-Washer
8
8-Bear ing
6Engine Removal , Inspect ion and Instal lat ion
Front Output Shaft
# Check bear i ng 7 for smooth turn i ng
and abnorma l wear . Check o i l sea l 5
for damage . Rep l ace i f necessary ;
# App l y l ubr i cat i on o i l to bear i ng 7
and o i l sea l 5 l i p before assemb l y ;
# App l y thread l ocker to bear i ng l i m i t
nut 6 ( l ef t thread) and t i ghten to
the spec i f i ed torque . (80N . m)
T i ghten
torque ,
Nut 1 to the spec i f i ed
f ront output shaf t nut
t i ghten i ng torque : 97N . m
Dr i ven Beve l Gear
# Remove nut 19 , washer 18 , coup l er 17
and o i l sea l 16 .
# Protect end thread of dr i ven beve l
gear w i th proper dev i ce $ F i x beve l
gear cover 14 and press out dr i ven
beve l gear .
# P l ace a c l ean rag " under beve l
6
gear cover . Remove bear i ng l i m i t nut
10 w i th spec i a l too l $ and remove
bear i ng%
# Check dr i ven beve l gear 8 sur face
for scratches ,
wear . Scratch or wear ,
rep l ace%
# Check f ree turn i ng of bear i ng 9 and
11 . Rep l ace i f necessary %
# Use new o i l sea l 16 and O - r i ng 12
when assemb l i ng ;
# Ad j us t washe r 13 i f any o f r i gh t
crankcase , dr i ven beve l gear 8 or dr i ven
beve l gear cover 14 i s rep l aced . Refer
to beve l gear ad - j ustment for deta i l s%
# App l y l ubr i cat i on o i l to bear i ng 9
and 11 and o i l sea l 16 , O - r i ng . App l y
thread l ocker to nut 10 and t i ghten
"m )
to the spec i f i ed torque . ( 110N"
Too l : dr i ven beve l gear nut wrench
Dr i ven beve l gear nut t i ghten i ng
torque : 150N . m .
Beve l Gear Washer Ad j ustment
# Adjust washer " and $ when replacing
crankcase and / or bevel gear and / or
bevel gear cover .
6-43
CFMOTO
Bevel gear
Note!
!Proper bevel gear engagement
depends on that the gear backlash &
tooth contact are within the proper range.
$ Bevel gear backlash
# I nstal l dr ive and dr iven gears to the
crankcase. Wrap a ( - ) screwdr iver&with
a rag $ and i nsert i t i nto the speed
sensor hole" of left crankcase to f ix
the dr ive bevel gear%
# Instal l special tool & and
micr imeter )
Tool: level gear side clearance
dial gauge micrometer
a=46mm
# Turn the dr iven bevel gear in each
di rect ion and measure the backlash.
Note'Measure four poi nts i n the
mutual vert ical di rect ion;
# I f the backlash is not wi thin the
speci f icat ion,adjust the thickness of
the dr iven bevel gear adjust washer .
Re-check the backlash unt i l the backlash is correct .
Bevel gear backlash:0 . 1 - 0 . 2mm
Ad j ustment!
!
Backlash
* 0.1mm
Washer thickness
adjustment
Washer thickness
0.1,0.2mm
adjustment
OK
+ 0.2mm
6-44
Increase thickness
6Engine Removal , Inspect ion and Instal lat ion
$ Tooth contact inspect ion
After adjust ing the backlash, check
the tooth contact according to the
fo l l ow i ng procedures'
# Remove dr i ve and dr i ven beve l gear
shafts from crankcase;
# Clean and degrease every tooth of
dr ive and dr iven bevel gear%
# Co a t t h e d rive n b e ve l ge a r wit h
machenist’s layout dye or paster%
# Install drive and driven bevel gear%
#Rotate the dr iven bevel gear several
turns in both di rect ions;
#Remove drive and driven bevel gear
shafts and check the coated teeth of
the drive bevel gear;
Contact "
tooth top
Incorrect
Contact $
Middle
Correct
Contact &
Bottom
Incorrect
6
# I f tooth contact is correct-Contact
$./cont i nue next procedure%
# I f t oo t h con t ac t i s i n co r r ec t
-Contact " &Contact &./ad j ust the
thickness of washerof dr ive gear . Repeat above steps to check tooth contact
unt i l correct .
Adjustment
Tooth contact Thickness adjustment
Contact "
Decrease thickness
Contact &
Increase thickness
No te!
#After adjust ing the tooth contact ,
the backlash must be checked again;
# I f the backlash is adjusted
but tooth contact is st i l l out
of speci f icat ion, replace the
dr ive and dr iven bevel gears;
#Both tooth contact and backlashshould
be wi thin the requi red speci f icat ion.
6-45
CFMOTO
Ba l ance sha f t
# Remove the parts as i l lustrated on
the r ight .
Check each part for abnormal wear
or damage.
Replace i f necessary.
" Balance shaft gear
$ woodruf key & Balance shaft ;
) Balance shaft sprocket
1 Bol t
0 Washer
Magneto Rotor
# Remove starter clutch nut .
6-46
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
!Check starter clutch rol ler and holder
for abnormal wear or damage, replace i f
necessary.
! Rep l ace the starter c l utch i n the
r ight di rect ion.
No te!
When instal l the starter clutch to
the magneto rotor , make sure side
A is in the r ight di rect ion.
"Face arrow mark B to the engine side
" Apply engine oi l to starter clutch
" Apply thread locker to bol t and
t ighten to the speci f ied torque.
Tightening torque of starter clutch
bol t : 26N.m.
Mater ial : Thread locker
! Instal l the starter dr iven gear
! Make that the starter dr i ven gear
turns in the opposi te di rect ion of the
arrow mark B . The gear cannot turn i n
the di rect ion of the arrow.
6
! Check starter dr i ven gear bear ing .
In case of anyth i ng unusua l , rep l ace
the bear ing.
! Remove starter dr i ven gear bear i ng
wi th special tool .
! Instal l starter dr iven gear bear ing
wi th special tool .
Tool#Bear ing instal ler / Remover
6-47
CFMOTO
E l ect r i c Star ter Gear
! Check the gear surface for scrap or
damage, replace i f necessary$
Le f t crank case cover :
! Check magneto stator coi l 2, pickup
coi l 3 for damage, replace ci rcui t i f
necessary.$
! Check bear ing 4 for smooth turning.
I f i t is stuck, replace wi th a new one;
!Check oi l seal 5 for damage. Replace
i f i t is damaged.
!Apply thread locker to the bol t when
assembl ing$
Tightening torque for magneto
co i l bo l t#10N%m
! App l y l ubr icat i ng o i l to bear i ng 4
and lubr icant grease to l ip of oi l seal
5 when assembl ing.
Reco i l star ter d i sassemb l y :
1-Recoi l starter
2-Bol t
3-Washer
4-Starter pul ly
I nspect i on
Check sheave drum for burrs, cracks or
rust . In case of any abnormal , replace.
6-48
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
Reco i l Star ter
!Disassembly is unnecessary i f recoi l
starter wokrs wel l
/
& Cap, handle
' Handle
( Fr ict ion plate
) Spr ing clamp
* Pawl
+ Spr ing
6
, Sheave drum
- Rope
. Coi l spr ing
/ Nut
D i sassemb l y
!Remove nut 10 and the parts from the
starter housing.
Warning"
"!The coi l spr ing may quickly
unwind and cause injury when the sheave
drum i s opened . Wear proper hand and
eye protect ion beforehand.
I nspect i on
! Check al l parts for damage. Repalce
i f necessary.
6-49
CFMOTO
Assemb l y
Reverse the removal procedure for insta l l at i on and pay attent i on to the
fol lowing:
Insta l l sheave drum &0rope '0co i l
spr ing (0Damper )1
Wind the rope clockwise around the
sheave drum three t i mes and hook
the rope at 2a3of sheave drum .
Warning"
"!The coi l spr ing may quickly
unwind and cause injury when the sheave
drum i s opened . Wear proper hand and
eye protect ion beforehand.
Instal l coi l spr ing & and sheave
drum ';
Apply lubr icant grease to spr ing;
Hook coi l spr ing end 3 to the starter
housing, wind the coi l spr ing clockwise
Hook the other end * of coi l spr ing to
hook part ) of sheave drum.
Instal l spr ing clamp &0fr ict ion plate
' and bol t
Put the end of spring clamp in the groove
near the damper .
Turn sheave drum clockwise three t imes
to t ighten the coi l spr ing.
Instal l handle & and handle cap '
Lead the rope through the hole of the
starter hous i ng and t i e a knot ( so
that the rope would not be drawn back.
After making a t ie )0draw back previ ous one (1
6-50
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
CV T C OV ER
! Remove screw 5 , o i l sea l l i m i tator 4 .
Remove o i l sea l 3 w i th sepec i al too l ;
! Check bear i ng 2 for f ree turn i ng . In case
of any abnormal , remove wi th special tool and
rep l ace w i th a new bear i ng ;
! App l y l ubr i cat i on o i l to outer r i ng o f
bear ing and instal l bear ing wi th special tool .
Check bear i ng for smooth turn i ng .
! App l y grease to bear i ng i nner s i de
!Apply grease oi l seal l ip and instal l bearing
w i th speci a l too l . Check bear i ng for smooth
t u r n i ng#
Note!
!Use a new o i l sea l
!Instal l oi l seal l imi tator and t ighten screw
af ter app l y i ng thread l ocker .
Too l "Bear i ng remover
O i l seal remover
Bear i ng i nstal ler
6
CVT case
! Check bear i ng 5 f or smooth turn i ng . I n
case o f any abnorma l , remove screw 3 and
bear i ng reta i ner 4 and rep l ace w i th a new
bear i ng .
! Check o i l seal 7 . In case of any
damage,
rep l ace i t .
! App l y grease to o i l sea l l i p and i nsta l l
w i th spec i a l too l #
! App l y l ubr i cat i on o i l to bear i ng 5 and
i nstal l w i th speci al too l ; Check bear i ng for
smooth turn i ng . The sea l s i de of bear i ng 5
shou l d face bear i ng retai ner 4 .
! Instal l bear i ng reta i ner 4 and
screw 3#
! Insta l l o i l sea l 1 i nto c l utch hous i ng 2
w i th spec i a l too l #
Too l : O i l seal i nstal l er
Bear i ng i nstal l er
6-51
CFMOTO
Crankcase
1 - R i ght crankcase
4 - Bear i ng
2 - Bear i ng
5 - Bear i ng
3 - Bear i ng
6 - Bear i ng
7 - O i l sea l
l 8 - Washer , reverse gear sensor
9 - reverse gear sensor 10 -O - r i ng 11 -Gear sen sor 12- Left crankcase 13 -Screw
15 - L i nk bo l t
16 - Washer 17 - Bear i ng 18 - Bear i ng
19 - Bear i ng 20 - Bear i ng
21 - Bear i ng 22 - O i l d i p rod 23 - O - r i ng
24 - Speed sensor
25 - Bo l t
26 - Washer
27 - O i l drai nage bo l t
! C l ean and grease the bear i ngs , turn the
i nner race o f bear i ng and check the p l ay ,
no i se and smooth turn i ng . I n case o f any
abnorma l , remove bear i ng w i th spec i a l too l
and rep l ace ;
! Check al l the o i l sea l s for over wear or
damage. In case of any over wear or damage ,
remove w i th spec i a l too l and rep l ace w i th a
new o i l seal ;
! Remove gear sensor 11 and check for cont i nui ty w i th reverse gear sensor 9 wi th a mul t i meter
! Remove l i nk bol t and oi l pi pe 14 and check
o i l p i pe for crack or c l og . Rep l ace w i th a
new one i f any ;
! Remove dra i nange bo l t 27&c l ean i t#
! Use spec i a l too l s to assemb l e bearn i g or
o i l sel as . Lubr i cant o i l i s app l ied for bear i ng and o i l seal l i ps . Check bear i ng smooth
turn i ng af ter i nstal l at i on
Note: Check bear ing for smooth turn ing after
i nstal l i ng .
6-52
14 -Oi l p ipe
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
! Insta l l new o - r i ng and app l y grease#
! Insta l l gear seasor#
! Instal l reverse gear sensor 9 and t i ghten
to the speci f i ed torque
T i gh t en i ng t o r que"2 0N "m
! Insta l l speed sensor 24
! Instal l o i l pipe and t ighten the l ink bol t
to the speci f i ed torque:
T i ghten i ng torque"18N$m
! Instal l washer 26 and oi l drainage bol t 27
and t i ghten to the spec i f i ed torque;
T i ghten i ng torque"30N"
"m
Too l "Bear i ng remover
Bear i ng i nstal l er
Mu l t i meter
# Eng i ne
Assemb l y
6
Reverse the eng i ne removal procedure for
i nsta l l at i on :
No te!
% C l ean a l l the parts before assemb l y#
% Make sure that the parts are i n good con d i t i on w i thout any damage ;
% App l y eng i ne o i l to the mov i ng parts be fore assemb l y ;
% App l y grease to o i l sea l - l i p&O - r i ng
Caut i on : Make sure that dr i ve bel t , pr imary
and secondary sheaves are not sta i ned w i th
grease .
Eng i ne Center
O i l pump and re l i e f va l ve
! Instal l o i l pump and rel i ef val ve to l ef t
crankcase, as i l lustrated on the r ight . Tighten
to the speci f i ed torque:
1 - Lef t crankcase
2 - O i l p i pe
O i l pump bo l t"10N"
"m
3 - O i l p i pe washer
Re l i e f va l ve bo l t"10N"
"m
4 - Pressure str i p , rel i ef
5 - Rel i ef va l ve
6-53
CFMOTO
Connec t ed Rod
! Insta l l connect i ng rod to l ef t crankcase
w i th spec i al too l
No te!
% Do not hammer the conrod i nto crankcase
w i th p l ast i c ma l l et#
%Use special tool to avoid af fect of conrod
prec i s i on
Too l : contro l i nstal l er
Ba l ance Sha f t
! Insta l l bal ance shaf t
Caut ion: Balancer shaft dr iven gear should
be a l i gned to the mark as i l l ustrated .
Ma i n Sha f t , Counter Sha f t
! Insta l l ma i n shaf t and counter shaf t#
&45
'65
(78
6-54
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
1
Sh i f t Cam , Sh i f t Fo rk
! Instal l sh i f t cam & and sh i f t fork '
2
! Check each part for smooth turn i ng#
! Insta l l l ow range dr i ven gear to counter
shaf t (
! Spray adequate engi ne o i l to
each
par t#
Dr i ve Beve l Gear
! Insta l l dr i ve beve l gear and t i ghten to
the spec i f i ed torque#
D r i ve beve l gea r t i gh t en i ng
6
t o r q u e "3 2 N "m
R i gh t C r ankcase
Dr i ven Beve l Gear
! Insta l l dr i ven beve l gear and t i ghten to
the spec i f i ed torque#
D r i ven beve l gea r t i gh t en i ng
t o r q u e "2 5 N "m
! Check beve l gear backl ash
(Refer to 6 - 44)
Front Output Sha f t
! Instal l f ront output shaf t to
r i ght crankcase;
6-55
! Apply sealant & to the mat ing face of r ight
c r ankcase#
Note!
!App l y sea l ant even l y i n a
un i nterrupted th i n l i ne
! Insta l l 2 dowe l p i ns '#
! Assembl e crankcase and tap sl ight ly w i th a
rubber hammer for proper f i tt i ng#
! Insta l l bo l t and t i ghten to the spec i f i ed
torque :
M6"10N"
"m
M8"25N"
"m
No te : Crankcase bo l ts shou l d be t i ghtened
d i agona l l y i n several steps .
Gear Pos i t i on i ng Bo l t
! P l ace the steel bal l and i nstal l gear po s i t i oni ng bo l t 1 and t i ghten the bo l t to the
spec i f i ed torque
T i ghten i ng torque"18N"
"m
Eng i ne R i gh t
T i m i ng Cha i n
! Put on t i m i ng cha i n 2
C l ut ch
!Instal l clutch 1 and nut 2. Tighten the nut
to the spec i f i ed torque( l ef t thread)#
C l utch nut t i ghten i ng
t or que!7 0 N "m
! Inta l l new O - r i ng ) i n spacer *
! Insta l l spacer * onto the c l utch hous i ng
shaf t , then i nsta l l i nto CVT case +
Note : a l i gn o i l n i ck on spacer w i th o i l
ho l e on the shaf t
CVT Case
! I nsta l l dowe l p i n ,-gasket ' gasket ./
i ntal l CVT case assemb l y to the r i ght crankcase
! Insta l l bo l t 0 and nut (
Note!
# T i ghten bo l t / nut d i agona l l y
# Use a new gasket
! Instal l gu i de p l ate 1 and screw 2
P r i ma r y sheave , seconda r y sheave ,
dr i ve Be l t
! Instal l pr i mary f i xed sheave & as
i l l ustrated on the r i ght ;
! Instal l dr i ve bel t on secondary sheave and
tap wi th a plast ic hammer to keep the bel t as
l ow as poss i b l e#
Not e!
% Instal l the dr i ve be l t w i th
the arrow on the bel t turn i n
the c l ockw i se d i rect i on#
% Dr i ve bel t contact sur face shou l d
be f ree f rom any sta i ns
CFMOTO
! Insta l l secondary sheave#
! Insta l l pr i mary s l i d i ng sheave
! T i ghten pr i mary sheave nut w i th spec i a l
too l to the spec i f i ed torque#
P r i ma r y sheave nu t t i gh t en i ng
t o r q u e "1 1 5 N "m
Too l "CVT Ho l der
! T i ghten secondary sheave nut w i th speci al
too l to the spec i f i ed torque#
Seconda ry sheave t i ght en i ng
t o r q u e "1 1 5 N "m
Too l "Rotor ho l der
No t e!
!Tur n the p r i ma ry sheave un t i l the
bel t i s seated i n and both pr i mary and sec ondary sheaves move together smooth l y .
CVT case cover
! Insta l l the new gasket and dowe l p i ns#
6-58
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
! Insta l l CVT case cover bo l ts and t i ghten
d i agona l l y i n several steps .
Eng i ne l e f t
O i l pump sp r ocke t and cha i n
! Instal l o i l pump dr i ve sprocket ;
! Instal l o i l pump dr i ven sprocket ;
! Insta l l o i l pump dr i ve cha i n#
! T i ghten o i l pump sprocket bo l t#
!Instal l sprocket retainer wi th a long
nose
p l i e rs#
Too l "Long nose p l i ers
6
Dua l gear / i d l er gear
! I nsta l l dua l gear sha f t & and dua l gear
' #
! Insta l l i d l er gear shaf t (-i d l er gear ,
and bush .#
Star ter dr i ven gear
! Insta l l start i ng dr i ven gear bush )$
6-59
CFMOTO
! Insta l l start i ng dr i ven gear#
Magneto rotor
! I ns t a l l wood r u f f key i n t o c r anksha f t
g r o o v e#
! Inta l l magneto rotor 1#
No te!
!Degrease the tapered par t o f rotor
and crankshaf t .
Use nonf l ammab le sol vent to
clean of f the oi ly or greasy matter and ful ly
dry the sur faces .
Le f t crankcase cover
! Insta l l dowe l p i n 2 and gasket 3#
Note!
!Use a new gasket
! App l y l ubr i cant grease to o i l l i p#
! Insta l l l ef t crankcase cover#
! Instal l bo l ts
Reco i l star ter
! Insta l l reco i l starter 1#
! Insta l l O - r i ng 2#
Note!
!Use a new O - r i ng and app l y
l ubr i cant grease to the O - r i ng
! Insta l l washer 3 and bo l t 4 , t i ghten to
the spec i f i ed torque.
Reco i l s t a r t e r bo l t
t i g h t e n i n g t o r q u e "5 5 N "m
6-60
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
Water pump
! Insta l l water pump#
! Insta l l water pump f i x i ng bo l ts#
Note : Before t i ghten i ng the bo l ts , be sure
to insert oi l pump shaft into groove of water
pump shaf t
Sector gear
Insta l l the parts as i l l ustrated on the
r i ght
1 - Sector gear cover and gasket
2 - Dowe l p i n
3 - Dr i ve
sector gear
4 - Dr i ven sector gear
5 - Dr i ven sector gear bo l t
6
Note!
W h en t h e s h i f t cam i s i n t h e n e u t r a l
pos i t i on , the mar k o f dr i ve sect or gear
shou l d be be t ween t he t wo ma r ks o f t he
d r i ven sec t o r gea r
D r i v en s ec t o r gea r t i gh t en i ng t o r qu e"
1 4 N $m
! Insta l l gearsh i f t rocker arm 6#
! Insta l l rocker arm bo l t 7 and washer 8#
6-61
CFMOTO
O i l f i l ter
Insta l l o i l f i l ter bo l t and t i ghten to the
spec i f i ed torque .
T i ghten i ng torque"63N"
"m
! App l y eng i ne o i l to O - r i ng#
! Instal l o i l f i l ter , turn i t by hand unt i l
the f i l ter gasket contacts the mat ing surface.
T i ghten the bo l ts .
Too l "O i l f i l ter wrench
Star t i ng motor
! App l y eng i ne o i l to new O - r i ng#
! Insta l l start i ng motor#
! Instal l bo l t and t i ghten to the
spec i f i ed torque
Tightening torque: 10N.m
Eng i ne top s i de
P i st on
! Insta l l the p i ston r i ngs i n the order of
o i l r i ng , ' r i ng and & r i ng#
! The f i rst member to go to the o i l r i ng
groove is spacer &, after placing the spacer ,
f i t the two s i de ra i l s '#
Warn i ng!
!when i nsta l l i ng the spacer &,
do not over l ap i ts two ends i n the groove.
! Instal l the secong r i ng A and f i rst
r i ng B .
Note!
!1st r i ng and 2nd r i ng d i f fer
i n shape
6-62
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
! 1st and 2nd r i ngs have l etter R marked on
the side. Be sure to br ing the marked side to
the top when f i tt i ng them to the p i ston#
! Pos i t i on the gaps of the three r i ngs as
i l l ustrated on the r i ght . Before i nstal l i ng
the p i ston i nto the cy l inder , check that the
gaps are so l ocated#
! App l y a l i ght coat o f mo l y o i l to the
p i ston p i n ;
6
! Insta l l p i ston p i n i nto ho l es of p i ston
and conrod sma l l end#
Not e : When i nsta l l i ng the p i ston , the I N
mark on p i ston top i s l ocated to the i ntake
s i de
! P l ace a c l ean rag beneath p i ston and i n stal l p i ston p i n c i rc l i p &
Note : wh i l e rotat i ng crankshaf t , pu l l the
cam cha i n upward , or the chai n w i l l be caught
between sprocket and crankcase .
! Instal l the dowe l p i ns and the new cy l i n der gasket#
Note : Use a new cy l i nder gasket to prevent
o i l l eakage
6-63
CFMOTO
Cy l i nder
! App l y eng i ne o i l to p i ston sk i rt and cy l i nder wal l
!Hold each piston r ing wi th proper posi t ion,
i nsert p i ston i nto the cy l i nder#
! T i ghten
the
cy l i nder
base
bo l ts
temporar i l y#
Note : When i nsta l l i ng the cy l i nder and cy l inder head, pul l the cam chain upward, or the
cha i n w i l l be caught between sprocket and
crankcase .
! Insta l l cha i n gu i de &#
! F i t the dowe l p i n and new cy l i nder cover
g as k e t #
Note : Use a new cy l i nder cover gasket to
prevent o i l l eakage
Cy l i nder
! Insta l l the cy l i nder cover , t i ghten the
cy l i nder head bo l ts d iagonal l y to the speci f i ed torque#
Cy l i nde r head bo l t t i gh t en i ng t o r que
I n i t i a l "25N"
"m
F i na l "38N"
"m
!Tighten the cyl inder head nuts to the speci f i ed torque#
Cy l i nde r head nu t s t i gh t en i ng t o r que :
M6 :
10N"
"m
M8 : I n i t i a l 10N"
"m
F i na l
25N"
"m
! T ighten the cyl inder top nuts and cyl inder
base to the spec i f i ed torque#
T i g h t en i n g t o r q u e : 1 0 N "m
6-64
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
! Insta l l cha i n tens i oner#
Camsha f t
! A l i gn mark A on magneto rotor w i th
mark
B on crankcase#
Note!
!wh i l e rotat i ng cranksha f t , pu l l the
cam chain upward, or the chain wi l l be caught
6
between sprocket and crankcase .
! A l i gn the mark A on the camshaf t so that
they are paral l el w i th the mat i ng surface of
the cy l i nder head#
Note : Do not rotate the magneto rotor wh i l e
do i ng th i s . when the sprocket i s not pos i t i oned correct l y , turn the sprocket ;
! Engage the chai n on the sprocket w i th the
l ocat i ng p i n B as i l l ustrated on the r i ght#
! Recheck i f the posi t i on of mark A and C is
correct. If not, reassemble unti l it is correct.
6-65
CFMOTO
! Insta l l crankshaf t C - r i ng &#
! Instal l l ock washer so that i t covers the
l ocat i ng p i n#
! App l y thread l ocker to the bo l ts be fore
i nstal l i ng, and
t i ghten them to the speci -
f i ed torque#
Sp r ocke t bo l t t i gh t en i ng t o r que
"1 5 N " m
! Bend up the l ock washer to l ock
the bo l ts ;
Cy l i nder head cover
! C l ean the mat i ng sur face of cy l i nder head
and cy l i nder head cover
! Instal l dowe l p i n to the cy l i nder head
! Appl y seal ant to the mat ing surface of the
cy l i nder head cover ;
! Instal l cyl inder head cover bol ts , t i ghten
d i agonal l y to the speci f i ed torque.
Cy l i nde r head cove r bo l t t i gh t en i ng
t o r q u e "1 0 N "m
Note: When t ightening the cyl inder head cover
bol ts , the p i ston must be at top dead center
on the compress i on stroke .
6-66
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
Gasket seal ant app l y i ng p l ace
Cha i n tens i oner
6
! Insert ( - - ) screwdr i ver i nto s l otted end
of chain
tension adjuster , turn i t clockwise
to l ock the tens i oner spr i ng ;
! Insta l l the cha i n tens i oner and the new
washer 1 #
! I nsta l l the bo l t 2 , t i ghten i t to the
spec i f i ed torque .
Cha i n
tens i oner
bo l t
t i ghten i ng
t o r q u e "1 0 N "m
! Af ter cha i n tens i oner i s i nsta l l ed , turn
the ( - - ) screwdr i ver counter cl ockw i se. The
tens i oner rod w i l l be advanced under spr i ng
force and push tens i oner aga i nst chai n .
6-67
CFMOTO
! Insta l l the new gasket 3#
! Instal l chai n tens i oner screw , t i ghten i t
to the speci f i ed torque
Cha i n
tens i oner
screw
t i ghten i ng
t o r q u e "8 N "m
Va l ve ad j uster cover
! Refer to 2 - 3 for val ve cl earance
! Use new rubber gasket and app l y grease
! Insta l l Val ve Inspect i on Cap
! Insta l l va l ve i nspect i on cap bo l t#
Spark p l ug
! Insta l l spark p l ug w i th spec i a l too l and
t i ghten to the speci f i ed torque;
Note : To avo i d damage to the cy l i nder head
thread , screw i n the spark p l ug w i th hand
f i rst , then t ighten i t to the speci f ied torque
w i th spark p l ug wrench .
Spa r k p l ug t i gh t en i ng t or que : 18N . m
Too l : Spa r k P l ug W r ench
Eng i ne per i phery
R eco i l s t a r t e r
! Insta l l reco i l starter#
! App l y thread l ocker to the bo l ts and then
t i ghten ;
Va l ve i n spec t i on cap
! Insta l l va l ve i nspect i on cap#
6-68
6
Eng i ne Remova l , I nspect i on & Insta l l at i on
Le f t p l ast i c cover
! Instal l l ef t p l ast i c cover 6
Water p i pe and hose
! Insta l l water hose 5#
! Insta l l bo l t 4#
! Insta l l water hose 3#
! I nsta l l c l amp 1-2#
6
6-69
7
Fue l System , A i r Intake System
Overhaul info. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Troubleshoot ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
High pressure oi l pipe Disassembly /
Instal lat ion. . .7-4
Thrott le Valve Disassembly / Instal lat ion. . . . . . . . . . . . .7-5
Fuel Injector Assy Disassembly / Instal lat ion. . . . . . . . . .7-6
Fuel injector Assy Removal / Assembly. . . . . . . . . . . . . . . . .7-6
Idle Ai r control valve Disassembly / Instal lat ion. . . . .7-6
7-1
O ve r h au l
info
Caut i on
No te
Gaso l i ne i s h i gh l y f l ammab l e , t he r e f o r e smoke and f i r e a r e s t r i c t l y f o r b i dden
i n t he wo r k p l ace . Spec i a l a t ten t i on shou l d a l so be pa i d t o spa rks .
Gaso l i ne
may a l so be exp l os i ve when i t i s vapo r i zed , so ope r a t i on shou l d be done i n a
w e l l - ven t i l a t ed p l ace .
! Do not over tw i st or bend the cab l es . The tw i sted cab l es may cause poor operat i on .
! Loose the h i gh pressure o i l p i pe before d i sassemb l y , d i scharge the fue l i n the h i gh
pressure o i l p i pe and put i t i n a conta i ner .
! When the body of thrott le val ve i s d i sassemb l ed , the a i r i ntake
shal l be covered by
d i shcl oth or tape, for avo i d i ng the entry of other ob j ects i nto the eng i ne f rom the
ai r i ntake s i de of the eng i ne.
! When the veh i c l e w i l l be stored for more than one month , the gaso l i ne i n the h i gh
pressure o i l p i pe and cap of the fue l i n j ector must be d i scharged . Otherw i se , the
gaso l i ne w i l l age and form co l l o i da l e l ements wh i ch may b l ock the nozz l e of fue l
i n j ector , therefore the eng i ne cannot start or the rotate speed i s unstab l e.
Ove r ha i l I n f o
Eng i ne s ta r t i ng f a i l ur e
!Too much fue l i n the eng i ne
" A i l f i l ter cl ogged
" Id l e a i r p i pe c l ogged
!No fuel i n the i n j ector
" fue l f i l ter cl ogged
" h i gh pressure o i l p i pe c l ogged
" fue l i n j ector cl ogged
Hard start i ng / shut down af ter start i ng ,
Unst eady i d l e speed
!Id l e a i r p i pe c l ogged
!fue l system c l ogged
!Ign i t i on system not funct i on i ng proper l y
!Fue l tank cap c l ogged
No f i re when acce l e rat i ng
!i gn i t i on system not funct i on i ng proper l y
Incorrect Spark P l ug cl earance
7-2
7
Fue l System , A i r Intake System
H i gh pressure o i l p i pe D i sassemb l y
Loosen the spec i a l fue l p i pe c l amp on fue l
i n j ector cap , l oosen the spec i a l fue l p i pe
cl amp on fuel tank.
D i sassemb l e H i gh pressure o i l p i pe
No t e
Use conta i ner to keep the rema i n i ng fue l
from h igh pressure o i l pi pe, when looseni ng
the speci al fuel p i pe c l amp
H i gh p ressu re o i l p i pe I ns t a l l a t i on
Reve r se t h e d i s as s em b l y p r o cedu r e f o r
i nsta l l at i on .
Use OETI KER c l amp ca l l i per to i nsta l l the
spec i a l fuel p i pe cl amp .
Throt t l e va l ve body D i sassemb l y
Loosen the strap and remove thrott l e va l ve
connector .
Loosen locknut , remove ad j ust nut and remove
the t hr ot t l e cab l e f r om th rot t l e r oto ry
s l eeve .
D i sassemb l e i del ai r out let p i pe on thrott le
va l ve .
Loosen ai r intake connect cl amp , ai r cl eaner
connect clamp, and remove thrott le valve body.
No tes
Donot ad j ust the bo l t on throt t l e va l ve .
Donot remove the cap on thrott le valve body.
Throt t l e va l ve body I nsta l l at i on
R eve r s e t h e d i s as s em b l y p r o cedu r e f o r
i nsta l l at i on .
Fue l I n j ector Assy D i sassemb l y
D i sassemb l e the speci al h i gh pressure o i l
Remove the strap and fuel injector connector .
D i sassemb l e bo l ts and remove fue l i n j ector
cap and i n j ector .
Fue l I n j ector Assy I nsta l l at i on
Reverse the d i sassemb l y procedure f or i n sta l l at i on
7-3
Fue l I n j ector Assy . Remova l
Use thumbs of both hands to push two si de of
fue l i n j ector cap snap spr i ng , and then re move i t .
Seperate fuel injector cap and fuel injector .
Fue l I n j ector Assy . Assemb l y
Instal l fuel injector cap on the fuel injector ,
A l i gn the groove of fue l i n j ector cap snap
spr ing to edge of fuel injector cap;and press
the snap spr i ng i nto i t .
I d l e a i r contro l va l ve D i sassemb l y
D i sassemb l e i d l e i ntake p i pe and i d le out l et
p i pe .
Loosen the strap , d i sassemb l e i d l e ai r con trol valve and check idle ai r control valve.
Replace i t when there is abnormal noise or i t
doesnot work .
I d l e a i r cont r o l va l ve I ns t a l l a t i on
Reve r se t h e d i s as s em b l y p r o cedu r e f o r
i nsta l l at i on .
Pay at tent i on not to bend the i ntake and
out l et p i pe of i d l e a i r contro l va l ve.
7-4
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Overhaul &&&&&&&&&&&&8-1
Brake system&&&&&&&&8-4
Front wheel&&&&&&&&&&&8-3
Steering system&&&&&&&&8-12
Front suspention system&&&&&8-7
Fault diagnosis &&&&&&&&&8-2
Overhau l
Operat i on not i ce
At tent i on
!The f rame must be ho l d up f i rm l y when overhau l i ng f ront whee l , suspent i on system .
!L i ght , meter , sw i tch"s
overhau l or i nspect i on refers to sect i on10 .
!Donot overpower on the tyre , be carefu l not to destroy the tyre .
!When d i sassemb l e the tyre on the r i ms , to avo i d destroy the r i m , you requ i red to use
speci al tyre - l ever and r i m - protector .
Overhau l standard
Item
Standard
Portrait
Cross
Remain
groove
Tyre
Air pressure
Brake lever windage
0.8mm
0.8mm
Rim jump
Front disc
Tightening torque
!
35kPa"0.35kgf#cm2$
0mm
steer ing t ie- rod nut
40-50 N%m
steer i ng shaf t l ock nut
100 - 120N%m
f ront wheel shaf t nut
110 N%m
suspens i on f i xed bo l t / nut
40 - 50 N%m
r i m i nstal l nut
r i m shaf t nut
Service
limits
2.0mm
2.0mm
8
3.0mm
!
!
50 - 60 N%m
110 - 130 N%m
8-1
C FM OT O
Spec i a l too l s
Bearing d i sassemb l e too l i ng bar
Bear i ng d i sassemb l e too l i ng nod 10mm
Press i n too l i ng l everA
Press i n too l i ng coat28 ' 30
Gu i de too l (10mm
Lock nut spanner
Bear i ng d i sassemb l e too l s
Rotor pu l l er
D i sassemb l e too l i ng bar
D i sassemb l e heavy punch
Assemb l e too l i ng bar
Fau l t d i agnos i s
Hand l ebar heavy
%upper screw over tong i ng .
whee l rotat i on dumb
%whee l shaf t bad
%steer i ng shaf t destroy , worn .
%f ront whee l shaf t bend
%Bear i ng i nner , externa l race dest roy , worn ,
%brake drag
step .
Front suspens i on too so f t
%steer i ng co l umn deform.
%tyre l ower pressure
%tyre worn out
Hand l ebar shake
%steer i ng shaf t destroy , bad t i ghten i ng
%l ef t and r i ght absorber unmatch
%f ront suspens i on bounce weaken
%tyre a i r too l ower
Front suspens i on too hard
%f ront suspens i on bend
%tyre a i r too h i gh
%tyre def l ect i on
Front suspens i on abnorma l
no i se
%tyre destroy
%f ront suspens i on bad
%whee l shaf t shaf t
%suspension
%f rame deform
Front whee l j ump
tightening parts loosen
Brake ef fet poor
%r i m de f orm
%brake ad j ustment bad
%whee l shaf t bad
%brake d i sc sur face deface
%tyre bad
%brake b l ock destroy
%whee l ba l ance bad
%whee l shaf t round bad t i ghten i ng
8-2
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
F r on t whee l
D i sassemb l e
Set up f ront wheel wi th too l , ensure w i thout
any force on the f ront whee l .
remove steer cap
remove the four nuts i nstal l ed i n the f ront
whee l hub , remove f ront whee l .
I nspec t i on
Rim
Inspect i f the r i m destroy , deform , speck ,
rep l ace the r i m i f needed .
Turn the whee l s l ow l y , use cent i meter mea sure r i m j ump .
Se r v i ce l i m i t : ax i a l d i r ec t i o n : 2 . 0mm
Rad i a l d i r ec t i on!
!2 . 0mm
8
I ns t a l l i ng
Press the r im in the tyre on special matchin.
Fi x the r i m i n hub
Rim
i ns ta l l
n u t t o r q u e !5 0 - 6 0 N "m
F r on t whee l hub d i sassemb l e
D i sassemb l e
remove f ront whee l () 8 - 3)
remove f ront brake ca l i per () 8 - 4)
remove r i m shaf t nut
take away brake d i sc and hub together
remove f ront brake d i sc 4pcs brake bo l ts
remove f ront wheel hub
I nsta l l i ng
Insta l l i ng carry on accord i ng to the oppo s i te sequence .
8-3
C FM OT O
B r ake sys t em
Front brake ca l i per
D i sassemb l e
remove f ront whee l ") 8 - 3$
remove the 2pcs nuts i nsta l l ed on the arm
remove brake ca l i per
I nspect i on
Check i f the brake cal i per crack,
i f the t i ghten i ng area o i l l eakage,
rep l ace i f needed .
I nsta l l i ng
B r ake ca l i pe r ho l d i ng bo l t t o r que !40 5 0 N "m
8-4
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Brake d i sc
D i sassemb l e
remove f ront whee l ") 8 - 3$
remove brake ca l i per") 8 - 4$
take away brake d i sc together w i th f ront
whee l hub .
remove brake d i sc*s 4pcs nut i nsta l l ed i n
f ront wheel hub .
remove the brake d i sc.
I nspect i on :
brake d isc th i ckness : rep l ace when less than
2 . 5mm .
Insta l l i ng
Instal l the brake d i sc we l l
8
B r ake d i sc ho l d i ng bo l t t o r que : 25 - 30N"
"
m
Hand brake master cy l i nder , f ront
br ake
D i sassemb l e
remove bo l t
remove park i ng l ever
Seperate f ront hand brake master cy l i nder
handlebar , i t is not need to remove the front
hand brake master cyl inder i f not replace the
brake pump assemb l y .
At tent i on
Dono t use b rake t ube hang t he b r ake
pump , to p r even t f r on t hand br ake mas te r
cy l i nder backdat e , so keep
i nst a l l i ng
pos i t i o n , a t t h e same t i me , f i x i t i n
t he h and l eb a r .
O i l t u b e t r e n d ac co r d i n g t o S c t i o n 1
cab l e , w i r e t r aces .
Mus t keep t he o i l l i ne smoo t h .
Comp l et e t he b r ake sys tem i ns ta l l a t i on ,
b r ake e f f o r t mus t be checked .
8-5
C FM OT O
D i sassemb l e
remove f oot rest") 2 - 9$
remove f ront i nner f ender RH"2 - 12$
remove bo l t1 , bo l t2
seperate peda l brake master cy l i nder f rom
the body
Assemb l i ng
Assemb l i ng carry on accord i ng to the oppo s i te sequence of d i sassemb l e .
At tent i on
To avo i d a i r i n l et the br ake pump , thus
you mus t to keep the assemb l e pos i t i on ,
at t he same t i me , f i x i t i n t he veh i c l e
body .
O i l tube t rend re f ers to Sect i on1 cab l e ,
w i r e t r aces . I t mus t en su r e t he b r ake
oi l
l i ne smooth .
A f ter comp l ete the
b rake syst em i nst a l l a t i on , check i ng the
b r ake e f f o r t i s r equ i r ed .
Brake Y - j o i nt
D i sassemb l i ng
remove f ront i nner f ender RH"2 - 12$
remove bo l t 1 then the brake Y - j o i nt canbe
remove form the body .
Assemb l i ng
Assemb l ing carry on to the opposi te sequence
of d i sassemb l i ng .
A t t en t i on : O i l tube t r end re f e r s to sec t i on 1 , cab l e and w i re t races , the brake
o i l l i ne mus t be smoo t h .
B r ake f o r ce check i n g i s r eq u i r ed w hen
comp l et e t he b r ake sys tem i ns ta l l a t i on .
If
i t canno t gang con t ro l
t he b r ake
s ys t em , ch eck i f t h e s t em T - j u n c t i on ,
b r ake f o r ce check i ng i s r equ i r ed a f t e r
f i n i sh t he b r ake sys t em i ns t a l l a t i on .
Brake cross j o i nt p l ug
D i sassemb l i ng
remove f ront i nner fender RH"2 ) 12$
remove bo l t 1 , bo l t 2 , then the cross j o i nt
p l ug canbe remove f rom the body .
8-6
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Assemb l i ng
Assemb l ing carry on accord ing to the oppsi te
sequence of d i sassemb l i ng .
A t t en t i on : O i l tube t r end re f e r s to sec t i on 1 cab l e , w i r e l i ne t r aces , b r ake
o i l l i ne mus t be smoo t h .
B r ak e f o r c e ch e c k i n g i s n e e d e d a f t e r
f i n i s h t h e b r ake sy s t em i n s t a l l a t i o n ,
if
i t c a n n o t j o i n c o n t r o l , c h ec k t h e
c r os s p l ug .
F r on t suspens i on sys t em
F r o n t l e f t s u s p en s i o n
assemb l e
Attent i on : when repa i r i ng suspens i on , you
must not remove both LH and RH suspensi on at
one t i me , or e l se the body w i l l fa l l down
because l ack of ho l d i ng power .
D i sassemb l e
Put veh i c l e body i nto hor i zonta l pos i t i on ,
use j ack ho l d the wheel f ront f i rm l y .
remove f ront whee l () 8 - 3)
remove f ront r im hub() 8 - 3)
8
remove ca l i per () 8 - 4)
remove f ront left absorber bo l t 1 and t i ght en i ng nut 1 i nsta l l ed on the body .
remove front left upper arm bol t 1 and t ight eni ng bo l t 1 ,nut 1 ; bo l t 2 and bo l t 2 , nut 2
i nstal l ed i n the f rame.
remove front left lower arm bol t 3 and t ight eni ng bo l t 3*s nut 3 , bo l t 4 and t ighteni ng
bo l t 4*s nut4 i nsta l l ed i n the f rame .
remove steer i ng t i e - rod ba l l p i n s l ot nut ,
remove the steer i ng p i e- rod
pu l l up j o i nt knuck l e f rom the dr i veshaf t ,
remove f ront l ef t suspens i on assy .
8-7
C FM OT O
D i smant l i ng
F r o n t sh ock abso r be r
D i s m an t l i n g
A t t en t i on : You dono t need t o r emove any
other par ts
i f you on l y r ep l ace the
f r o n t su s pens i on .
Remove f ront l ef t absorber*s bo l t 1 , nut 1
i nsta l l ed i n arm .
Remove f ront r i ght shock absorber .
Inspect i on
Inspect i f the absorber oi l leakage, oi l seal
age, destroy , rep l ace i f needed .
8-8
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Assemb l i ng
Assemb l i ng carry on accord i ng to the oppo s i te sequence of d i sassemb l i ng .
Fr on t
l e f t ab s o r b e r *s d i s a s s em b l i n g ,
assembl ing, inspect ion as same as front r ight
absorber .
A r m assemb l e
At tent i on !There are 8 suspens i on ar ms
in
the
veh i c l e ,
they
d i smant l e ,
d i s co m p o s e , i n s p ec t i o n an d as s em b l e i n
the same way . So here on l y i nt r oduce t he
way t o d i s man t l e , d i scompo se , i nsp ec t i on
an d as semb l e t he f r on t l e f t u pp e r a r m
and t he f r on t r i gh t l owe r ar m . Ot he r
a r m assemb l e r e f e r s t o t he above .
Front r i ght arm assy
D i sassemb l e
Remove f ront r i ght absorber () 6 - 8)
Remove f ront r i ght upper arm*s bo l t 3 and
8
t i ghten i ng nut 7 , bo l t 1 , t i ghten i ng bo l t 1
and nut 7 .
Remove f ront r i ght l ower arm*s bo l t 3 and
t i ghten i ng bo l t 7*s nut 7 i nstal l ed i n the
f rame .
Before d i sassemb l i ng the absorber , you have
to remove the whee l s , brake cal i per and r i m
hub .
Before d i sassemb l i ng the bo l ts , you need to
remove the steer i ng t i e - rod .
Before d i sassemb l i ng f ront r i ght l ower arm
assy , you need to pu l l up the knuck l e f rom
the dr i veshaf t .
Remove f ront r i ght arm assy .
8-9
C FM OT O
I nspec t i on
Ba l l p i n
Inspect i f i t can rotate f lexible between top
bal l pin 9 and front r ight upper arm 6,bottom
bal l pin 17 and front r ight lower 12. Besides,
the gap between top bal l pin and bottom, i f i t
cannot move f reel y or the gap too b i g , bal l
p i n rep l acement i s needed .
R i gh t knuck l e
I nspect i f the r i ght knuck l e i s dest roy ,
rep l ace i t i f need .
Inspect i f the r im shaft inside r ight knuckle
move +,-./012345678.9:;<=
>?@.9ABC56=>DE?FGHI56
8-10
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Constant ve l oc i ty dr i ve sha f t
At tent i on : For
thi s
veh i c l e ,
i nspect i on , d i sassemb l i ng and assem b l i ng t h e f r on t & r ea r ax l e L H&RH
constant ve l oc i ty dr i ve sha f t are
i n the same way .
( 55 ) Constant ve l oc i ty dr i ve sha f t ,
LH . Front ax l e
D i sassemb l i ng
A t t en t i on : You dono t need t o r emove t he
f r on t suspens i on assy f r om t he veh i c l e
i f you on l y repa i r the f ront ax l e costant
ve l oc i t y d r i ve sha f t , L H .
remove f ront l ef t whee l () 8 - 3)
remove f ront l ef t brake cal i per () 8 - 4)
remove fornt lef t r im hub() 8 - 3)
Exam i ne duct boot , rep l ace w i th new ones i f
destroy .
cost ant ve l oc i ty dr i ve sha f t shake?
i nspect i f the un i versa l j o i nt move f ree l y ,
the bear i ng move f ree l y , i f there i s gap
between j o i nt and sp l i ne .
8
Replace wi th new ones i f dumb,abnormal sound,
gap .
A t t ent i on : Doub l e o f f se t un i ve r sa l j o i n t
mus t can be move f ree l y ,
or e l se , i t
canno t con t r o l t he t y r es and r esu l t i n
acc i dent .
A t t en t i o n : R ep l acem en t i s r eq u i r ed i f
the
r i ght& l ef t
arm
shake
after
i ns ta l l a t i on .
Assemb l i ng
Mount i ng torque : 40#
#50N"
"m
Use speci al too l to press the ba l l p i n i nto
the arm assy .
Assemb l i ng carry on accord i ng to the oppo s i te sequence of d i sassemb l i ng .
8-11
C FM OT O
S t ee r i ng sys t em
Hand l ebar
Dashboard cover
d i sassemb i ng
remove dashboard cover bo l t1
remove dashboard cover
Assemb l i ng
Assemb l ing carry on the oppos i te sequence of
d i sassemb l i ng .
RH hand l ebar sw i tch
D i sassemb l i ng
remove f ront top cover") 2 - 4$
remove RH hand l ebar sw i tch connector
remove the two bo l ts i nstal l ed i n hand l ebar
tube .
remove hand l ebar sw i tch , RH .
I nsta l l at i on
Insta l l the hand l ebar sw i tch , RH") 8 - 15$
8-12
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Hand l eba r sw i tch , L H
d i sassemb l i ng
remove 2 screws
remove LH hand l ebar sw i tch connector
remove hand l ebar sw i tch , LH
I nst a l l
Insta l l the LH hand l ebar sw i tch") 8 - 15$
Rea r v i ew m i r r o r
8
D i sassemb l i ng
loosen the nut in counter -clockwise di rect ion,
then turn the rear m i rror i n counter - c l ock w i se and you can take o f f the rear v i ew
m i rror .
A t t en t i on : L e f t hand r ea r v i ew m i r ror i s r i gh t hand sc rew thread ,
turn i t i n counter - c l ockw i se d i r e c t i on whe n d i sm an t l i n g .
Loosen the nut i n cl ockw i se d i rect i on , turn
the RH rear v i ew m i rror then you can take
down the RH rear v i ew m i rror .
A t t en t i o n : RH r ea r v i e w m i r r o r i s
l e f t han d t h r e ad , y ou r eq u i r ed t o
t ur n i t i n c l ockw i se d i r ec t i on when
t ake i t down .
I nsta l l at i on
Insta l l i ng carry on accord i ng to the oppo s i te sequence , d i rect i on of un i nsta l l at i on .
8-13
C FM OT O
Hand l eba r p i pe
D i sassemb l i ng
remove the dashboard cover") 8 - 12$
remove RH&LH hand l ebar sw i tch") 8 - 12$
Seperate the r ight and l ef t brake pump f rom the
han l ebar p i pe .
remove the four instal lat ion bol t , take down the
hand l ebar .
Assemb l i ng
Assemb l i ng carry on accord i ng to the oppos i te
sequence of d i sassemb l i ng .
T o r q u e : 20-30N"
"m$
$ 2.0-3.0kgf"
"m%
%
At tent i on
Ma i n cab l e assy , #thrott l e cab l e , brake
o i l p i pe , cab l e hut accord i ng to t he
draw i ng correct l y .
I nsta l l throt t l e cab l e
remove the three screws , remove RH hand l ebar sw i tch cover .
Insta l l thrott l e cab l e
i nstal l RH hand l ebar sw i tch cover
8-14
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
I nsta l l LH hand l ebar sw i tch
Pa i r the LH hand l ebar sw i tch stopped onto the
hand l ebar l ocat i on ho l e .
use bo l t 1 t i ghten i ng f rom the bottom .
I nser t the LH hand l ebar sw i tch*s connector
i nto the mai n cab l e.
8
I nsta l l RH hand l ebar sw i tch
Pa i r the RH hand l ebar sw i tch stopped onto the
hand l ebar l ocat i on ho le. T i ghten ing through the
bo l t 2 f rom the bottom .
I nser t the RH hand l ebar sw i tch*s connector
i nto ma i n cab l e .
8-15
C FM OT O
I ns t a l l RH& L H g r i p
remove d i rty i nner LH gr i p and dry i t .
coat
the connect i on w i th j o i nt cement between
handlebar and LH gr ip, put in the RH&LH gr ips.
Attent ion
The instal led RH&LH gr ips must be placed
for hours for dry the j o i nt cement .
I ns t a l l b r ake pump
upward the brake pump base JUPK mark, then
i nstal l the brake pump .
eyeba l l i ng the d i stance between brake pump
and hand l ebar sw i tch , hand l ebar under hood
to equal i ty .
Attent ion:
Ma i n cab l e assy , throt t l e cab l e , brake
o i l p i pe , cab l e hut sha l l accord i ng to
the draw i ng correct l y .
Insta l l the park i ng l ever
i nsta l l the rear v i ew m i r ror") 8 - 13$
i nstal l the dashboard") 8 - 10$
i nstal l the dashboard cover") 8 - 12$
8-16
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
S t ee r i ng sys t em
8
8-17
C FM OT O
Steer i ng stem
D i sassemb l i ng
remove dashboard f ront cover
") 8 - 1 2 $
remove f ront whee l ") 8 - 2$
take down handlebar swi tch connector
Use st ra i ght screwdr i ver and
hammer hammer out the lock pad.
remove bo l t1(bo l t2
remove steer ing stem seat , plate
and bush .
Remove cotter p i n
Remove steer ing t ie- rod instal l at i on nut , washer
Press and separate the steer i ng t i e - rod f rom the steer i ng
stem .
Remove steer i ng stem i nsta l l at i on bo l t
Rai se up the steer i ng stem and
the handlebar together , then you
can remove the steer i ng stem .
I nsta l l i ng
Insta l l i ng carry on accord i ng to the oppo s i te sequence of un i nstal l i ng .
At t ent i on : Check
af ter
f i n i sh the
Cab l e ,
i nhau l
8-18
maneuve rab i l i ty
i n s t a l l a t i o n .$ 3 - 3 %
cab l e t race re f ers to
sect i on 1 cab l e ,
draw i ng .
the
i nhau l
cab l e t race
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Steer i ng bear i ng , o i l sea l
D i smant l i ng
remove f ront whee l ") 8 - 2$
remove steer i ng stem") 8 - 18$
remove f ront ADWS arm assy") 8 - 9$
Use spec i a l too l separate the steer i ng stem
and the o i l seal f rom the body .
S pec i a l t o o l :
bea r i ng r em ove r comp onen t
rotor pu l l er
r em ov e r ax l e
r emove r h eavy bob
I nsta l l at i on
Instal l at i on carry on accord i ng to the oppo s i te sequence of un i nstal l at i on .
S pec i a l t o o l :
Bea r i ng r ace i ns t a l l a t i on t oo l A
Ass emb l i ng t oo l i ng ba r
A t t e n t i o n !S p e c i a l
too l
must be used
8
when i ns t a l l t he bea r i ng .
Steer i ng system instal l accord i ng to the op pos i te sequence of un i nstal l at i on .
At t ent i on : Check
the
maneuve rab i l i ty
a f t e r f i n i sh t h e i ns t a l l a t i on .
8-19
9 Rear Whee l , Rear Brake , Suspens i on
Overhaul Info!!!!!!!!!9 - 1
Rear Brake System!!!!!!9 - 4
Troub l eshoot ing!!!!!!!!9 - 2
Rear Suspens i on System!!!!9 - 5
Rear Wheel !!!!!!!!!!!9- 3
Overhau l I n f ormat i on
O pe r a t i n g N o t i ce
No te
"Secure l y support the veh i cl e when overhau l i ng the r i m and suspens i on system .
"Use genu i ne parts of bo l ts and nuts for rear r im and suspens i on .
"Do not overexert on the whee l s to avo i d poss i b l e damage to the wheel s .
"When remov i ng t i res from r i m , use speci al t i re l ever and r i m protector to avoi d damage to
the r i m .
O ve r h au l S t an d a r d
I tem
Rim
V i brat ion
Rear
Whee l
Rear
Brake
Ti re
Brake
Long i tud i na l
Hor i zonta l
Rema i ned
T i re Tread
Ti re
Pressure
Lever
Free
P lay
Standard
Limit
#
#
2 . 0mm
2 . 0mm
#
3 . 0mm
30kPa
#
10# 20mm
#
9
T i g h t en i n g To r qu e
Rear Wheel Ax l e Nut
110 - 130N"m
R i m Mount i ng Bo l t
50 - 60N"m
Upper Mount i ng Bo l t , Shock Absorber
40 - 50N"m
Lower Mount i ng Bo l t , Shock Absorber
40 - 50N"m
9-1
C FM OT O
Troub l eshoot i ng
Rea r Whee l Wo bb l es
"R i m Warpage
"Fau l ty T i re
"T i re Pressure Too Low
"Improper Whee l Ba l ance
"Improper T i ghten i ng of Whee l Ax l e Nut
"Loosened Whee l Nut
Rea r Shock Abso r be r i s Too So f t
"Weak Spr i ng
"O i l Leakage f rom Rear Shock Absorber
Rea r Shock Abso r be r i s Too Ha r d
"Bent Rear Shock Absorber
"T i re Pressure i s Too H i gh
Poo r B r ake E f f i c i ency
"Improper Brake Ad j ustment
"Sta i ned Brake Pad or Brake D i sk
"Worn or Damaged Brake Pad
9-2
9 Rear Whee l , Rear Brake , Suspens i on
Rear Whee l
Remova l
Ref er to Front Whee l Remova l $% 8 - 3&
I nspec t i on
Rim
Damage, warpage, ser i ous scrapes : % Rep l ace
S l ow l y turn the whee l , measure the r i m v i trat i on w i th a d i al gauge.
Se r v i ce L i m i t : Ax i a l : 2 . 0 mm
Rad i a l : 2 . 0mm
I ns t a l l a t i on
Re fer to Front Whee l I nsta l l at i on$% 8 - 3&
Wh ee l H ub
Remove :
9
- Rea r Whee l $% 9 - 3&
- R i m Axl e Nut
- Wheel Hub
I ns ta l l a t i on :
Reverse the remova l procedure for i nstal l at i on .
T i gh t en i ng To r que , R i m Ax l e Nu t :
1 1 0 - 1 3 0 N !m
9-3
C FM OT O
Rear Brake
Rea r B r ake Ca l i pe r
Remove :
- Rear Le f t Whee l $% 9 - 3&
- 2 Bo l ts f rom Arm
- Brake Cal i per
I nspec t i on
Brake Cal iper : Cracks , Oi l Leakage: % Rep l ace
I ns t a l l a t i on
Reverse
the
remova l
procedure
for
i nsta l l at i on .
Note: Refer to Chapter 1 for brake hose routing.
Rea r B r ake D i sc
Remove :
- Rear Le f t Whee l $% 9 - 3&
- Rear Dr i ve Shaf t
- Rear Brake Ca l i per$% 9 - 4&
- 6 Shear Bo l ts
- Pa r k i ng B r ake$% 9 - 4&
- Rear Brake D i sc$% 8 - 3&
I nspec t i on
Brake D i sc : Th i ckness<6 . 5mm % Rep l ace
I ns t a l l a t i on
Reverse
the
remova l
procedure
for
i nsta l l at i on .
Note: Refer to Chapter 1 for brake hose routing.
P a r k i ng B r ake
Remove :
- Rear Le f t Whee l $% 9 - 3&
- Rear Dr i ve Shaf t
- Rear Brake Ca l i per$% 8 - 4&
- 6 Shaf t Bo l ts
- Parki ng Brake
9-4
9 Rear Whee l , Rear Brake , Suspens i on
Rear Suspens i on System
Rea r R i g h t Su spens i on
No te : DO NOT r emove bo th l e f t and r i gh t suspens i on at t he same t i me to avo i d f a l l
down o f t he veh i c l e .
9
D i sassemb l y
S t ab i l i z e r Ba r
Remove :
Bo l t1( 6 ) , Bo l t2 ( 7) , Bo l t3 ( 10 ) , Bo l t4( 11) ,
Bracket (8)and(5) , Rubber Support (4)and(9) ,
Nut2(2) , Nut10(12) , Lef t Ba l l P i n(1) , R i ght
Bal l P i n(14)
Remove : Stab i l i zer Bar (3)
I ns t a l l a t i on
Reverse
the
remova l
procedure
for
i nsta l l at i on .
9-5
C FM OT O
Rear R i ght Absorber
Remova l
No t e : Secu r e l y suppo r t t he veh i c l e when
r emov i ng r ea r l e f t and r i gh t absor be rs .
Suspend whee l s f r om g r ound .
Ma i nt enance o f r ea r absor be rs on l y does
not r equ i r e remova l o f rear suspens i on .
Remove the fo l l ow i ng parts f rom rear r i ght
shock absorber :
- Bo l t10(25)
- Nut7(27)
- Bo l t7(19)
- Nut8(28)
Remove rear r i ght shock absorber
I ns t a l l a t i on
Reverse
the
remova l
procedure
for
i nsta l l at i on .
Rea r R i gh t A r m
Refer to Front Lef t Upper Arm i n Chapter13
for the removal , i nspect ion and i nstal l at i on
of Rear R i ght Arm .
Rea r L e f t Su spens i on
Refer to Rear Right Suspension for the removal ,
i nspect i on and i nsta l l at i on o f Rear Le f t
Suspens i on .
9-6
10 Front/Rear Axle
Overhau l i n f ormat i on
! Standards
Lubricating Period
Item
In i t i a l : 0 . 33L / Rep l ace :
SAE15W / 40 SF
Front axle
Rear axle
Interval
Ini t ial
Next
Capaci ty
Type
0 . 28L
"
350km
5000km
SAE80W / 90 GL -4 Ini t i al : 0 . 30L / Rep l ace :
0 . 25L
Tightening torque table
Item
Pcs
Speci f icat ion
Torque(N.m)
Front axle case bol t
6
M8 # 28
25
Front axl e motor screw
4
M8 # 20
13
1
M8 # 10
13
Front axle nut
1
M14 # 1.5
62
Di f f . gear bol t
6
M10 # 1.25 # 22
45
25
Pi ni on shaft screw
Oi l bol t , f ront axl e
1
M14 # 1.25 # 12
Drai n bol t , f ront axl e
1
M10 # 1.25
25
Retainer
1
M64 # 1.5 # 7
80
Rear axle case bol t
2
M10 # 1.25 # 25
40
Rear axle case bol t
6
M8 # 25
25
Nut , input shaft ,R / A 1
M12 # 1.25
70
Bol t , input shaft ,R / A 4
M8 # 30
25
Retainer , R / A
1
M65 # 1.5 # 10
70
Nut
1
M8
16
Oi l bol t , rear axl e
Drai n bol t , f ront axl e
1
M20 # 1.5 # 12
25
1
M14 # 1.25 # 12
25
Remark
Wi th fasten ing gl ue
10
10-1
CFMOTO
! I nspec t i on & Ove r hau l
Inspect i on and overhau l i s needed i f any of prob l ems be l ow happens to f ront and rear ax l e
Problem descr ipt ions
Causes
$ Unstable moving dur ing accelerat ing, A.Bear ing broken;
B.Gear clearance over / under size;
decerat ing or constant speed.
C.Gear severely worn;
% Abnormal sound in front rear axle;
D.Gear blocked
E.Dr ive shaft broken
& Engine power tranmission fai lure to F. lack of lubr icant
G.Foreiggn matter in front or rear gear
front or rear wheels.
Note!
!A!B!C probl ems are hard to di st ingui sh . Anal ysi s is needed based on
actual break-down catagor ies.Make sure engine works al l r ight before disassembly
of front or rear axle
Obsernvat i on and Judgement
1.Never ignore abnormal sound:
a. Abnormal sounds dur ing accelerat ing,decelerat ing have l i tt le
to do wi th engine working, but possibly wi th gear worn
b. Constant abnormal sounds dur ing accelerat ing or decelerat ing might be cause
by gear clearance wrongly adjusted dur ing 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 not iced dur ing low-speed dr iving, and
shound not be heard dur ing high-speed dr iving.This is caused by
gear bolck.
Note!
!In case of above ment i oned i tmes , stop the veh i c l e i mmed i ate l y for
inspect ion unt i l they are solved, or wi l l cause accident
2.Check lubr icat ion i f i t"s under normal condi t ion;
3.Chcek lubr icant leakage;
a. Rear axle surface oi l stain inspect ion before through inspect ion;
b. Oi l stain on ground on the parking lot#
c. Lubricant splash inspect ion.Check i f there is gear case or oi l seal leakage.
Replace broken parts i f necessary.
10-2
10 Front/Rear Axle
Front axle exploded view
22
23
24
21
9
8
7
25
12
Item
Part Name
Qty
Item
Part Name
Bear ing F1512
Qty
1
Bol t M8 # 28
6
17
2
Front axle case
1
18
3
O- r ing 141 # 2.4
1
19
Bear ing 6007
4
Bear ing 16007
1
20
Oi l seal 48 # 65 # 9
1
5
Ci rcl ip 62
1
21
Coupler
1
6
Dr ive clutch cover
1
22
O- r ing 14 # 6.8
1
7
Dr ive clutch
1
23
Nut washer
1
8
Adjust washer ' 83 # 71
1(2
24
Nut M14 # 1.5
1
9
Di f ferent ial . gear assy 1
25
Screw M8 # 20
4
10
11
Adjust washer ' 61 # 48
Bol t M10 # 1.25
2(4
1
26
27
Gear motor
O- r ing 81.2 # 1.9
1
1
12
Washer 10
1
28
Rack
1
13
Washer 14
1
29
Pinion shaft
1
14
Bol t M14 # 1.25
1
30
Screw M8 # 10
1
15
Oi l seal 24 # 38 # 8
2
31
Retainer M64#1.5#7
1
16
Front axle case cover
1
Dr ive pinion gear
1
1
1
10-3
10
CFMOTO
I nspect i on a f ter f ront ax l e d i sassemb l y
!Check i f there is damage or crack on the front di f frent ial gear casecover and
bear ing assembl ing hole is ok.Replace casecover i f necessary;
!Check i f front axle bear ing clearance ok or turning stable,and rol l way,steel
bal l ,needle and plate are ok. Replace bear ing i f necessary. (Using special tools)
! Check i f oi l seal l ips and O- r ing shape are ok. Replace i f necessary;
! Check cyl indr ial surface of front axle and oi l seal l ips, Replace broken
parts i f necessary.
!Check dr ive pinion gear and di f ferent ial gear , inspect worn surface. Replace
broken i f necessary;
!Check driven gears surface,gear(center)di fferential ,bracket di fferential wearing
si tuat ion on the di f ferent ial gear assembly. Replace parts i f necessary;
!Check inside and out side spl ine washer wear ing status in front axle. Replace
parts i f necessary;
! Check gear motor working status. Replace wi th new parts i f necessary;
Gear motor inspect ion must be carr ied out wi th special equipment or acted on the vehicle;
! Check other parts. Replace broken parts of necessary.
10-4
10 Front/Rear Axle
Front ax l e assemb l y and ad j ustment
! Front ax l e casecover asse l b l y
16
Item)31* Tightening torque 80Nm
I tem
)24*T i ghten i ng torque 62Nm
Note$Use eng i ne o i l for o i l sea l ,
bear ing and dr ive clutch assembly;
)24*Use screw thread fasten i ng g l ue
10
23 24
! Frong ax l e case assemb l y
Note :Use engine oi l for oi l seal or
bear ing assembly.
10
! Di f ferent ial gear assembly
Bo l t
M10 % 1 . 25 % 22 T i ghten i ng torque 45Nm
Note !Use engine for bear ing and di f ferential gear;Use proper washer to make
gear working freely;
Washer th i ckness
0.1 0.2 0.3
0.5 1.0
0.4
10-5
CFMOTO
! Front axle assembly and adjustment
1
8
As i l l ustrat ion shown+
Tightening torque
I tem)1*
25Nm
I tem)25*
13Nm
Item)30*
Bolt
13Nm
25Nm
Bol t
25Nm
7
28
29
30
27
25
26
Use fasten i ng g l ue for i tem&30'
assembly
a
Use proper washer 8 and 10 thick ness to
adjust gear side clearance between drive pinion
gear and d i f ferent i al gear
Dr i ve beve l gear c l earance measurement ; Insta l l
support tool s, t igheni ng bol ts(
M10X1 . 25X60 ) put
up d i a l i nd i cator , make sure 21 mm i s between
measur i ng po i nt and suppor t too l s . Turn suppor t
too l s counter - c l ock and read the data .
Standard+0. 10(0. 25
Washer
th i ckness
b
0.1 0.2 0.3
0.5 1.0
0.4
Shi ft fork and dr ive clutch assem-
b l y shou l d be aga i nst t i ght l y to the
arrow shape i l lustrat ion when assembly
of front axle motor .
10-6
3
10
10 Front/Rear Axle
c
Use spec i a l equ i pment or veh i c l e
control ci rcui t into 2WD posi t ion before gear motor assembly
d
Make sure b and c is assembled prop-
er ly and using i l lustrated posi t ionging
screw to assemble gear motor and front
ax l e,
10
10-7
CFMOTO
Rear axle exploded view
Item
1
Part Name
Qty
Item
Part Name
Qty
Bolt M10 #1.25 #25
2
18
O- r ing 64.5 # 3
1
2
Bol t M8 # 25
6
19
Bear ing 6305
1
3
Rear axle bearing housig
1
20
Bear ing reteiner
1
4
O- r ing 151 # 3
1
21
Dr ive gear , rear axle
1
5
Bear ing 16017 / C2
1
22
Bear ing inner race
1
6
Ad j ust washer-2.
1(2
23
Bear ing outer race
1
7
Dr iven gear , rear axle
1
24
Adjust gasket
Ad j ust washer-1.
1
25
Washer14.5 # 21 # 1.5
1
9
Needle bear ing
1
26
Bol t M14 # 1.25 # 12
1
10
Rear gear case
1
27
O- r ing 19 # 2.5
1
11
Oi l seal SD4 65 # 90 # 9 NS 2
28
Bol t M20 # 1.5 # 12
1
12
Nut M12#1.25
1
29
Screw M8 # 45
13
Washer 12.5 # 30 # 4
1
30
Washer 8.2 # 15 # 1.5
1
14
Coupler , rear axle
1
31
Nut M8
1
15
Bol t M8 # 35
4
16
Oil seal
8
17
10-8
Bevel gear bearing housing
1
1
1(3
1
10 Front/Rear Axle
Disassembly of bearing
a
Disassemble needle bear ing as left
draw ing shown when necessary,
b When make needle bearing replacement,
rear bear ing housing should be heated
to 1500, then disassemble i t .
Rear ax l e i nspect i on a f ter d i sas semb l y
!Check i f there is crack or damage in rear gear case, see mount ing hole is ok
. Replace gear case or r ight cover i f necessary;/
!Check i f bearing clearance is normal ,and turing stabi l i ty, rol lway, stel lbal l ,
neddle bearing as wel l . Replace bearing i f necessary. (Special tools are requi red)
! Check worn status of dr i ve bevel gear and r ing gear rear axl e. Rep lace i f
necessary;
! Check oi l seal l ips, o- r ing shape. Replace parts i f necessary;
!Check cylndr ical surface of rear axle and oi l seal l ips. Replace i f necessary;
! Check inner and outsider spl ine. Replace i f necessary;
! Check other parts. Replace i f necessary.
10-9
10
CFMOTO
Rear ax l e assemb l y and ad j ustment
! I l lustrat ion
T i ghten i ng torque
I tem)1*
Item)2*
40Nm
25Nm
I tem)12*
70Nm
I tem)15*
25Nm
I tem)20*
70Nm
I tem)31*
16Nm
Bol t
25Nm
Bol t
25Nm
Use g l ue for I tem&29' assemb l y
!Assembly and clearance adjustment of
,
dr ive gear of rear axle
a By choos ing )24* washer to adj ust
instal l ing clearance
b By choos i ng )6* washer to ad j ust
clearance
c By coat i ng co l or to check contact
surface i f i t1s ok for mat ing/
d Inspect instal l ing clearance by checki ng beve l gear c l earance/By us i ng
assistant measurement tool to check i ts
clearance
Standard+0 . 1(0 . 2
e Keep instal l ing point bear ing clear ance
0 . 1 (0 . 2
by
c h o o s i n g &8 '
washer . ,
Washer
)6*
Th ickness: 0 . 2
0.4
Washer
)8*
Th i ckness 1 . 0
Wahser
)24*
Thickness 0.4
10-10
0.3
1.2
1.4
1.6
1.8
0.5
0.6
10 Front/Rear Axle
f Adjust i tem 29 as i l lustrated, and
make sure i ts end and back clearance of
dr i ve gear i s 0 . 3(0 . 6 . T i ghten i tem
31.
10
10-11
11 ELECTRIC SYSTEM
! CHARG I NG SYSTEM!!!!!!! 11 - 1
" ELECTR I C START I NG SYSTEM!!!!!! 11 - 3
# ELECTR I C I TY - SPRAY I NG SYSTEM!!!!!!! 11 - 8
1 . ELECTR I C I TY - SPRAY I NG SYSTEM STRUCTURE!!!!! 11 - 8
2 . ELECTR I C I TY - SPRAY I NG SYSTEM D I AGRAM!!!! 11 - 9
3 . ELECTR I C I TY - SPRAY I NG SYSTEM MA I NTENANCE NOT I CE!! 11 - 9
4 . MAINTENANCE TOOL!!!!!!!!11 - 10
5 . E L ECTR I C I TY - SPRAY I NG SYSTEM COMPONENTSCOMPOS I T I ON&FUNCT I ON!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 OI L PUMP ASSEMBLY!!!!!!! 11 - 21
OI L ATOMI ZER!!!!!!!!! 11- 22
IDLE AIR CONTROL !!!!! 11 - 23
IGNITION COI L!!!!!!!! 11- 24
6 . E L ECTR I C I TY - SPRAY I NG SYSTEM SE L F - D I AGNOS I S!! 11 - 25
TROUBLE LIGHT!!!!!!!!! 11- 25
DIAGNOSTIC EQUIPMENT!!!!!!!!! 11 - 26
TROUBLE CODE!!!!!!!!! 11- 27
7 . VEHICLE SCHEMATIC CIRCUIT CIRCUIT DIAGRAM!!!!! 11 - 28
11-1
CFMOTO
$ CHARGING SYSTEM
CHARG I NG C I RCU I T D I AGRAM
MAGNETO CO I L RES I STANCE
! MEASURE TRIPHASE MAGNETOR STATOR COIL RESISTANCE
! IF THE RESISTANCE VALUE OUT OF PRESCRIBED VALUE,
REPLACE THE STATOR COIL .
! I NSPECT I F THE STATOR CO I L AND STATOR CORE
INSULATION.
TURN MULTIMETER TO 1X10 !
MAGNETO CO I L RES ISTANCE :
YEL LOW#
INSULATING RESISTANCE:
GROUND#
0 . 5 - 1 . 5 !"YEL LOW "!
"YELLOW -
MAGNETOR NON - L OADED 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:
5 00 0 r / m i n # 20 0V$
$ A L T ERNAT I NG CURRENT %
11-2
11 ELECTRIC SYSTEM
&' ( ) *
!USE MULTIMETER MEASURE THE RESISTANCE BETWEEN THE
TERMINALS,AS BELOW FORM SHOWS, IF THERE IS ONE DATA
OUT OF THE SETTING VALUE,REPLACE WITH A NEW ONE.
!AFTER ENGINE RUNNING, BATTERY FULL POWER, IF VOLTAGE BETWEEN RED LINE, GREEN LINE EXCEED 15V OR UNDER
12V,REPLACE WITH A NEW ONE.
ADJUST MULTIMETER TO DIODE
ATTENT I ON+
WHEN MU L T I METER PROBE UNCONNECTED , I F THE
MU L T I METER SHOWS BE L L OW 1 . 4V , THEN REP L ACE
I T ,S B A T T E R Y .
11-3
CFMOTO
$ STARTING
SYSTEM
TR I GGER C I RCU I T D I AGRAM
START I NG DYNAMO
11-4
11 ELECTRIC SYSTEM
E L ECTR I C BRUSH
!CHECK IF THE ELECTRIC BRUSH PERMANENT SEAT ABNORMAL,
CRACK,UNSMOOTH
!IF THERE IS ANY BROKEN, CHANGE THE WHOLE ELECTRIC
BRUSH ASSEMBLY
COMMUTAT OR
! CHECK IF THE COMMUTATOR CHANGE COLOR , ABNORMAL
DAMAGE OR OVER WEAR.
!IF THERE IS ABNORMAL DESTROY, REPLACE WITH A NEW
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 CO I L
USE MULTIMETER CHECKING IF IT IS INTERCOMMUNICATION
BETWEEN THE TERMINALS, BETWEEN TERMINALS AND ARMATURES
. IF THEY NOT COMMUNICATION, REPLACE WITH A NEW ARMATURE.
O I L SEAL
CHECKING IF OIL SEAL LIP DESTROY OR OIL LEAK.
IF THERE IS ANY DESTROY OR LEAKAGE, REPLACE WITH A
NEW STARTING DYNAMO.
11-5
CFMOTO
I N I T I AT I NG RE L AY
! LOAD 12V VOLTAGE TO I N I T I AT I NG%S ANODE AND
CATHODE ;MEASURING WITH MULTIMETER IF THE EXTREMES
MEET.
!IF THE START RELAY CONTACT SOUND TICKTOCK AND ALSO
CONNECT,
!WHEN COIL TWO TERMINALS NON - LOADED 12V VOLTAGE,
THE TWO CONTACTS UNCOMMUNICATE
! ABOVE TWO ITEMS BOTH OK , IT SHOWS THE RELAY IS
OKAY.
ADJUST MULTIMETER TO DIODE GRADE.
AT TENT I ON :
RELAY VOLTAGE LOADED CANNOT EXCEED 2MINS,OR ELSE,
IT WILL CAUSE THE RELAY OVERHEAT AND BURNT THE RELAY
COIL .
! USE MULT IMETER MEASURI NG STARTI NG RELAY CO I L
RESISTANCE , IF THE VALUE OUT OF THE SETTING RANGE,
REPLACE WITH A NEW ONE.
! ADJUST MULTIMETER TO 1X10 ! GRADE
START AUX I L I ARY RE L AY CO I L RES I STANCE : 3 - 5
!
START AUX I L I ARY RE L AY.
.FUL E PUMP RE L AY
!LOAD 12V VOLTAGE TO THE THE ANODE AND CATHODE OF THE
STARTING RELAY COI L .USE MULTIMETER MEASURE IF CON TACTS A,B IS MEET.
ADJUST MULTIMETER TO DIODE GRADE.
!IF THE STARTING RELAY SOUND TICK AND CONNECTION,
! WHEN NON - LOADED 12V VOLTAGE , THE TWO CONTACTS
UNCONNECTED
!EITHER OF THE ABOVE TWO ITEMS IS SHOWS THE RELAY IS
FINE.
! ADJUST MULTIMETER TO 1X100 ! , MEASURING THE COI L
RESISTANCE
AUX I L I ARY RE L AY CO I L RES I STANCE+
+90 - 100 !
AT TENT I ON :
AT THE BACK OF AUX I L I ARY RELAY , PARAL LEL TO
THE D I ODE D I RECT I ON , I T I S THE RE L AY CO I L ,S
ANODE .
11-6
11 ELECTRIC SYSTEM
START I NG ENG I NE NOT I CE
!JOINT LINES ACCORDING TO TRIGGER CIRCUIT.
!BEFORE STARTING, CHECK IF ALL THE PARTS ARE CORRECT JOINTED.ELECTRICITY SPRAYING JOINT SEE BELOW:
!CHECK IF GAS CIRCUIT NORMAL .
!CHECK IF OIL CHANNEL AT FAULT.
IF BLOCK,CLEAR BLOCK PART, SECURE OIL CHANNEL SMOOTH.
IF LEAKAGE,RELINK LEAK SECTION, SECURE THE OIL CHANNEL
NO LEAKAGE.
!USE OIL PRESSURE GAGE MEASURE OIL PRESSURE.
FU L E PU MP O UTP UT PO RT PR E S SU RE : 0 . 3 / 0 .
0 1 Ba r 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 ENGINE, WARM UP TO IDLE SPEED STABLE,
EXAMINE IDLING SPEED:
I D L I NG SPEED : 1400 / 10 0 r pm0
0
11-7
CFMOTO
$ ELECTRONIC SPRAYING SYSTEM
ELECTRON I C SPRAY I NG SYSTEM STRUC TURE
ENG I NE E L ECTRON I C SPRAT I NG SYSTEM I NCL UD I NG THREE PARTS :
( 1 ) SE NSOR :
TRANSFORM THE ENGINE NON -ELECTRICITY PHYSICAL
QUANTITY TO ELECTRICITY QUANTITY,AND PROVIDE ALL THE
INFORMATIONS TO THE ELECTRONIC CONTROL UNIT.
IT IS THE ELECTRONIC CONTROL %S SPY. INCLUDING THE
FOLLOWING SENSORS:
! I NLET PRESSURE SENSOR ( LOADING I NFORMATION#
! THROTTLE POSITION SENSOR ( LOADING INFORMATION&
! I N LET A I R TEMPERATURE SENSOR ( A I R DENS I TY
LOADING RANGE INFORMATION, ACCELERATION AND DECEL INFORMATION)
ERATION INFORMATION#
!TRIGGER (BENT AXLE PHASE POSITION INFORMATION)
! WATER TEMPERATURE SENSOR (ENGINE TEMPERATURE
INFORMATION)
!ODOMETER SENSOR (OUTPUT SHAFT SPEED INFORMATION)
! GEAR SENSOR"GEAR INFORMATION)
$ I NCL UD I NG GEAR SENSOR AND REVERSE GEAR
SENSOR )
! OXYGEN SENSOR(EXCESS AIR COEFFICIENT ABOVE 1 OR
LOWER THAN 1#
!FOUR WHEEL DEAD LOCK (4WD DEAD LOCK INFORMATION)
!ASSISTOR SWITCH
(RELIEF SPEED LIMIT INFORMATION)
( 2 ) E CU :
ELECTRONIC CONTROL UNIT, IT IS THE BRAIN OF THE
ENGINE MANAGEMENT SYSTEM. IT ANALYZE AND PROCESS KINDS
OF INFORMATIONS PROVIDE BY THE SENSORS , REACH A
CONCLUTION, AND THEN TRANSMIT THE CONCLUTION TO THE
ACTUATOR, SO AS TO ENSURE THE ENGINE OPERATION UNDER
OPTIMAL STATE.
11-8
( 3 ) ACTUAT OR :
EXECUTE THE ECU INSTRUCTION. THE ACTUATOR IS THE
HAND OF ECU, THE MAIN ACTUATORS ARE:
!OIL FUEL PUMP ASSY(SUPPLY HIGH PRESSURE FUEL)
! OI L ATOMI ZER(SPRAY QUOTAL FUEL , MAKE FUEL SPRAY
EXCELLENT)
!IGNITION COIL(PROVIDE HIGH PRESSURE IGNITION ENERGY TO SPARK PLUG)
! IDLE SPEED CONTROL VALVE(PROVIDE IDLE SPEED AIR
INPUT)
11 ELECTRIC SYSTEM
ELECTRON I C SPRAY I NG SYSTEM D I AGRAM
E L E CTRON I C SPRAY I NG SYSTEM MA I NTENANCE NO T!I USE
CE QUAL ITY COMPONENTS FOR SERVICE , OR ELSE IT
CANNOT GUARANTEE THE ELECTRONIC SPRAYING SYSTEM NORMAL OPERATION.
!IN THE COURSE OF MAINTENANCE, NEVER TRY TO BREAK
DOWN THE ELECTRONIC PARTS!
!IN THE COURSE OF MAINTENANCE, THE ELECTRONIC COMPONENTS
MUSTDOWN
BE HANDLED
CAREFULLY.
!
WHEN CUT
OR CONNECT
UP PLUG CONNECTOR, YOU
MUST TURN OFF THE IGNITION SWITCH, OR ELSE THE ELECTRONIC SPRAYING COMPONENTS WILL BE DESTROYED.
!WHEN TAKE DOWN THE ELECTRIC OIL FUEL PUMP, DONOT
ENERGI ZE THE OI L PUMP , IT CAN GENERATE SPARK AND
! OI L FUEL PUMP NOT PERMITTED DO OPERATION TEST
UNDER DRY STATE OR IN WATER.OR ELSE WILL SHORTEN IT%
S LIFE.BESIDES,THE OIL FUEL PUMP TWO EXTREMES CANNOT
REVERSE CONNECTION.
!ELECTRONIC SPRAYING SYSTEM OIL SUPPLY PRESSURE IS
HIGH("AROUND 300kPa) , THE FUEL PIPE ALL APPLY HIGH
PRESSURE RESISTANCE PIPE,SO DONOT DISMANTLE THE PIPE
EASILY.
WHEN THE FUEL SYSTEM NEED TO BE REPAIRE,YOU HAVE
TO DO OIL 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.
OI L PIPE%S DISMANTLE AND FUEL FI LTER%S RE -
! WHEN INSPECTING THE IGNITION SYSTEM , ONLY IF IN
NECESSARY,DO SPARKING TEST,AND SHOULD BE AS FAST AS
POSSIBLE, DONOT OPEN AIR SAMPER WHEN TESTING,OR ELSE
PLENTY OF UNBURNED OIL WILL ENTER THE VENT-PIPE AND
DAMAGE THE TRIPLET CATALYST.
!IDLE SPEED REGULATION COMPLETELY CARRY OUT BY ELECTRONIC SPRAYING SYSTEM,THROTTLE VALVE GUN LIMIT SCREW
ALREADY SETTED WHEN IT LEAVE THE FACTORY, IT INITIAL
POSITION CANNOT BE CHANGED EASILY.
!WHEN JOIN THE BATTERY, THE ANODE AND THE CATHODE
CANNOT BE WRONG JOINTED . THIS SYSTEM APPLY MINUS
EARTH.
!WHEN ENGINE RUNNING,PROHIBIT TO DISMANTLE THE BATTERY CABLE.
!BEFORE CARRY OUT ELECTRONIC WELDING ON THE VEHICLE,
YOU REQUIRED TO
DISMANTLE THE BATTERY POSI -
TIVE TERMINAL ,
NEGTIVE TERMINAL AND ECU
! DONOT USE METHOD IMPALE LEAD CUTICULAR TO TEST
COMPONENTS%S INPUT AND OUTPUT ELECTRICAL SIGNAL .
!SET UP ENVIRONMENTAL PROTECTION CONSCIOUSNESS.TREATING THE WASTE AFTER MAINTENANCE.
PLACEMENT SHOULD BE CARRY ON BY PROFESSIONAL PERSON
IN WELL -VENTILATED PLACE.
11-9
CFMOTO
SERV I CE TOOLS
TOO L NAME : D I AGNOST I C EQU I PMENT
FUNCT I ON :
READ CLEAR ELECTRONIC SPRAYING SYSTEM TROUBLE
CODE,OBSERVE DATA STREAM,COMPONENETS MOTION TESTS.
TOO L NAME : COMMUTATOR
FUNCT I ON :
INSPECT ECU EACH SUTURAL ELECTRICAL SIGNAL , INSPECT
CIRCUIT STATES ETC.
TOOL NAME : D I G I TAL MU L T I METER
FUNCT I ON :
INSPECT ELECTRONIC SPRAYING SYSTEM VOLTAGE ,
CURRENT, RESISTANCE ETC.
TOO L NAME : VACUUM METER
FUNCT I ON :
INSPECT INLET PIPE PRESSURE STATE.
11-10
11 ELECTRIC SYSTEM
TOO L NAME : E L ECTRON I C SPARK T I M I NG
FUNCT I ON :
INSPECT ENGINE ELECTRONIC SPARK TIMING
TOO L NAME : CYL I NDER PRESSURE GAUGE
FUNCT I ON :
INSPECT ENGINE CYLINDER PRESSURE STATE.
TOOL NAME : FUE L PRESSURE GAUGE
FUNCT I ON :
INSPECT FUEL SYSTEM PRESSURE STATE , JUDGE THE
FUEL SYSTEM FUEL PUMP AND FUEL PRESSURE REGULATING
VALVE WORK STATE.
TOOL NAME : O I L ATOM I Z ER WASH I NG ANAL YZ ER
FUNCT I ON :
WASHING ANS ANALYZING OIL ATOMIZER.
11-11
CFMOTO
E LECTRON I C SPRAY I NG PARTS STRUCTURE AND
FUNCT I ON
( 1 ) E CU :
ECU, IT IS THE BRAIN OF THE ENTIRE ELECTRONIC SPRAYING
SYSTEM. IT ANALYZE AND PROCESS THE INFORMATIONS PROVIDED BY THE SENSOR, REACH A CONCLUTION, THEN TRANSMIT THE CONCLUTION TO THE ACTUATOR AS INSTRUCTION,SO
AS TO MAKE THE ENGINE OPERATION IN OPTIMAL STATE.
ECU EACH ST I TCH FUNCT I ON :
1. IGNITION COIL CONTROL SIGNAL
2.EARTHING CONTACT
3.VEHICLE SPEED SIGNAL
4.TROUBLE LAMP
5. 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.AIR DAMPER POSITION SENSOR SIGNAL
21.SENSOR
22.OIL PUMP
23.BATTERY POWER+
24.OXYGEN SENSOR
25.ENGINE SPEED OUTPUT
26.KWIRE DIAGNOSIS
L I M I T DATA :
! D I SA L L OW TO ADD L OAD ON CRUST OR COVE R
BOARD .
1 HANDLED CAREFUL LY AND AVO I D TO DROP ON THE
F L OOR .
11-12
11 ELECTRIC SYSTEM
( 2 ) THROTT L E VAL VE ASSY :
JOIN THE AIR CLEANER AND ENGINE,CONTROL THROTTLE
VALVE OFF AND ON ANGLE THROUGH THROTTLE CABLE. AIR
DAMPER POSITION SNESOR TRANSMIT ANGLE SIGNAL TO ECU.
EACH P I N FUNT I ON :
1.CONNECT 5V POWER
2.GROUNDING
3.OUTPUT VOLTAGE SIGNAL
THE R I GHT DRAW I NG I S THE W I R I NG D I AGRAM W I TH
ECU
I D L E SPEED L I M I T SCREW NOT A L L OWED T O BE
ADJUSTME NT .
! ENGINE IDLE SPEED COMPLETELY DEPEND UPON ELEC TRONIC SPRAYING SYSTEM ADJUSTMENT. PROHIBIT MANUAL
ADJUST THE IDLE SPEED SCREW.
11-13
CFMOTO
( 3 ) I NL ET PRESSURE SENSOR :
MONITOR INLET PIPE PRESSURE, PROVIDE ENGINE LOAD
INFORMATION TO ECU.
EACH ST I TCH FUNCT I ON :
1.CONNECT 5V POWER
2.GROUNDING
3.OUTPUT VOLTAGE SIGNAL
THE R I GHT DRAW I NG I S THE CONNECT I ON DRAW I NG
FOR SENSOR&ECU .
THE RI GHT DRAW ING I S THE PERM I T FITT ING L I M IT ,
I N TH I S WAY CAN ENSURE THERE I S NO CONDENSED
WATER I NS I DE THE SENSOR , THE CONDENSED WATER
CAN DE ST ROY SE NSO R I NNER PRE S SU RE - SE N S I NG
DEV I CE .
THE P I CTURE BE L OW I S THE REC I PROCAL D I AGRAM
DRAW I NG FOR PRESSURE AND OUTPUT VOL TAGE .
MON I TOR PRESSURE RANGE : 10 - 115kPa
11-14
11 ELECTRIC SYSTEM
( 4 ) I NTAKE A I R TEMPERATURE SENSOR :
THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT
"
( 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 R I GHT DRAW I NG I S THE W I R I NG D I AGRAM FOR
SNE SOR&E CU .
THE R I GHT DRAW I NG I S FOR SENSOR TEMPERATURE RES I STANCE PROPERTY L I ST .
11-15
CFMOTO
( 5 ) WATER TEMPERATURE SENSOR :
THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT
"
( NTC) THERMISTANCE, IT %
S RESISTANCE VALUE DECREASE
WHEN THE COOLANT TEMPERATURE INCREASE,BUT IT IS NOT
L INEAR RELATION . ONE GROUP PROVIDE TO ECU , MONITOR
ENGINE HEAT CONDITION.THE OTHER GROUP PROVIDE TO THE
METER,MONITOR WATER TEMPERATURE.
A AND C I N ONE GROUP , THEY PROV I DE WATER
TEMPERATURE TO ECU .
B ANDTHREADED PORTION IN ONE GROUP ,THEY PROVIDE
WATER TEMPERATURE TO THE METER.
THE R I GHT DRAW I NG I S THE W I R I NG DRAW I NG FOR
SENSOR , ECU AND METER .
THE R I GHT DRAW I NG I S B END AND CRUST TEM PE RATURE PROPE RT Y L I ST , S I GNA L PASS T O T HE
ME TER .
THE R I GHT DRAW I NG I S END A , C AND THE TEMPERA TURE PROPERTY L I ST , S I GNAL PASS TO THE ECU .
11-16
11 ELECTRIC SYSTEM
( 6 ) OXYGEN SENSOR :
THIS SENSOR USED IN ELECTRONIC CONTROL FUEL INJECTION EQUIPMENT FEEDBACK SYSTEM,TO REALIZE CLOSEDLOOP CONTROL ,RAISE ECU CONTROL THE AIR-FUEL DELIVERY
RATIO.
IT INSTALLED IN THE VENT-PIPE,MEASURING WASTE GAS
OXYGEN CONTENT,DEFINITE IF THE GAS AND AIR COMPLETE
BURNT, SO AS TO ENSURE UNIT TRIPLET CATALYTIC CONVERTER HAVE MAXIMUM CONVERSION EFFICIENCY TO EXHAUST
HC,CO AND NO X
THE P I NS FUNCT I ON :
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 R I GHT DRAW I NG I S THE W I R I NG D I AGRAM FOR
SENSOR AND ECU
T HE BE L OW SHEE T I S THE SENSOR PE RFORMANCE
CHARACTER I ST I C VA L UE
11-17
CFMOTO
( 7 ) TR I GGER :
PROVIDE ENGINE ROTATE SPEED INFORMATION TO ECU,
ECU DETERMINE IGNITION ANGLE,OIL SPRAY ANGLE ACCORDING TO THIS INFORMATION.
THE R I GHT DRAW I NG I S THE W I R I NG D I AGRAM FOR
TR I GGER AND ECU .
TEST I NG THE THR I GGER RES I STANCE VAL UE .
! ADJUST MULTIMETER TO 1X100 ! ;
T R I G GE R W I ND I NG RE S I ST A NC E : 1 0 0 - 1 30 ! $ 2 0
2 %
! IF THE TRIGGER RESISTANCE DONOT IN ABOVE RANGE,
REPLACE WITH A NEW ONE.
MEASUR I NG TR I GGER PEAK VOL TAGE VAL UE
! CONNECT MULTIMETER AND PEAK VOLTAGE ADAPTER ACCORDING TO THE RIGHT DRAWING:
+ GREEN LEAD W I RE
+PROBE+
- PROBE+
+ BL UE LEAD W I RE
ATTENT I ON :
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 RUNNING FOR FEW SECONDS,THEN START TO MEASURE:
THRI IGER COIL PEAK VOLTAGE;
! IF THE TRIGGER PEAK VOTAGE DONOT IN THE ABOVE
! REPEATED TIMES MEASURE, GET THE HIGHEST TRIGGER
COIL PEAK VOLTAGE VALUE. ;
TR I GGER CO I L PEAK VOL TAGE : - 2V
11-18
$300 rpm%
%
11 ELECTRIC SYSTEM
( 8 ) ODOMETER SENSOR :
PROVIDE ENGINE OUTPUT SHAFT SPEED TO ECU , ECU
JUDGE VEHICLE SPEED ACCORDING TO THIS INFORMATION. IT
IS A KIND OF HALL SWITCH COMPONENTS, IT OUTPUT SQUARE
WAVE VIA INDUCTION FIELD.
P I NS FUNT I ON :
1.GROUNDING
2.OUTPUT SQUARE WAVE VOLTAGE SIGNAL")INPUT
,
POWER
VOLTAGE 80%#
3.POWER+DC12V
THE R I GH I S THE W I R I NG DRAW I NG OF SENSOR AND
ECU .
ODOMETER SENSOR TEST I NG
!GROUNDING FOOT 1,CONNECT FOOT 3+12V;
!FIXED ONE GEAR TO ODOMETER ACCORDING TO THE RIGHT
DIAGRAM D ISTANCE("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&1 2V ;
! IF NO CHANGES , THEN THE SENSOR HAS BROKEN, YOU
REQUIRED TO REPLACE WITH A NEW ONE.
11-19
CFMOTO
( 9 ) GEAR SENSOR
C L USTER :
PROV I DE GEAR INFORMAT I ON TO THE METER , SO AS TO
AT THE SAME TIME,COORDINATE WITH CABLE AS STARTING
PROTECTION.
FUNCT I ONS OF THE FOOTS :
YEL LOW / BLUE - L"UNDERDR I VE#
ORANGE / BLUE - H"HI GH POSI TION#
YELLOW / BLACK - P"PARK POSIT ION#
WHITE / YELLOW - N"NEUTRAL POSITION#
!WHEN EACH OF THE FOUR GEAR IN A CERTAIN POSITION,
GEAR CORRESPONDING FOOT CONDUCT TO THE ENGINE COVER,
OR ELSE IT NON-CONDUCTION WITH THE ENGINE COVER.
( 10 ) REVERSE GEAR ASSEMBL E :
PROVIDE GEAR REVERSE INFORMATION TO ECU AND METER,
THE ECU RESTRICT VEHICLE SPEED ACCORDING TO THIS
INFORMATION.
! NORMAL L Y , A&B PO I NT CONDUCT I ON , DONOT CON DUCT W I TH THE CASE ;
! NORMALLY, C LENGTH IS * 3. 5mm+IF C LENGTH
, 3mm+OR IF B SLIDE BLOCK,YOU HAVE TO CHANGE IT
TO A NEW ONE.
!WHEN ENGINE BACK GEAR, A POINT NON-CONDUCTION WITH
THE ENGINE CASE, OR ELSE IT IS CONDUCT WITH THE CASE.
11-20
11 ELECTRIC SYSTEM
( 11 ) O I L FUE L PUMP ASSY :
THE OIL FUEL PUMP ASSY COMBINED OF OIL FUEL PUMP,
PLASTIC BRACKET, PREFILTRATION ,PRESSURE REGULATING
VALVE. IT DELIVER THE FUEL TO THE ENGINE WITH A CERTAIN OIL PRESSURE AND FLOW.
FUNCT I ONS OF THE FOOT :
1.BLUE(GROUNDING)
2.RED(CONNECT THE OIL PUMP RELAY OUTPUT ENDING)
PERFORMANCE PARAMETER :
PRESSURE REGULATING VALVE OPENING PRESSURE : 0 . 3 /
0FLOW
. 01:MPa
35L / h
!THIS OIL PUMP ASSY ALL USED INSIDE THE OIL BOX:
!DONOT RUNNING THE OIL PUMP ASSY IN DRY;
!HANDLE GENTLY, DONOT DROP THE OIL PUMP ASSY ONTO
THE GROUND.
THE R I GHT D I AGRAM I S THE W I R I NG D I AGRAM OF
THE O I L PUMP ASSY , O I L PUMP RE LAY , ECU .
!BATTERY SUPPLY POWER VIA OIL PUMP RELAY,ELECTRIC
OIL FUEL PUMP CIRCUIT CLOSE ONLY WHEN STARTING AND
THE ENGINE RUNNING.
MEASUR I NG THE O I L 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;
!WHEN STOPED OPERATION,PRESSURE HOLDING AT LEAST 0.
2MPa
5 MINUTES,
NOT , REPLACE
THE
O
I L FUE
L P I PE IF
PRESSURE
RE L I EF
: OI L FUEL PUMP
ASSY.
BECAUSE OF THE HIGH PRESSURE OF OIL SUPPLY,THE FUEL
PIPES ARE ALL HIGH PRESSURE RESISTANCE PIPE.EVEN IF
THE ENGINE DOES NOT WORK,THERE IS STILL HIGH PRESSURE
ON THE OIL CHANNEL ,THEREFOR,DONOT DISMANTLE THE OIL
PIPE DURING SERVICING EASILY.
BEFORE SERVICE THE FUEL SYSTEM,YOU REQUIRED TO DO
OIL PRESSURE RELIEF,THE METHOD IS AS BELOW:
REMOVE O I L PUMP RE L AY , START THE ENG I NE AND
RUN ENG I NE ON I DL E UNT I L L THE ENG I NE GO OUT
I T SE L F .
11-21
CFMOTO
( 12 ) O I L ATOM I Z ER :
O I L ATOM I ZER ONE END I NSTAL LED I N SEAT , THE
OTHER END CONNECT W I TH THE O I L P I PE V I A O I L
ATOM I ZER CAP . ACCORDI NG TO THE ECU I NSTRUCT ION ,
IT SPRAY OI L IN FIXED TIME.SO AS TO SUPPLY OIL TO
THE ENGINE AND ATOMIZING.
THIS OIL ATOMIZER APPLY QUADRIPUNTAL ,DONOT TURN
AFTER FIXED THE CLAMP.
FUNCT I ON OF P I NS :
! ONE SIDE OF THE PLUG MARK+-CONNECT OI L PUMP
RELAY OUTPUT END,
WITHOUT MARK SIDE CONNECT ECU PIN 14.
O I L A T O M I Z E R R E S I ST A N C E : 1 2 / 1 ! $2 0 2 %
THE R I GHT I S THE W I R I NG D I AGRAM FOR O I L ATOM I Z ER AND ECU .
O I L ATOM I Z ER I NSTA L L AT I ON :
!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,DO PRESSURE RELIEF IN ADVANCE.
!DO LEAK TIGHTNESS AFTER INSTALLED THE OIL ATOMIZER
TO ENSURE NO LEAKAGE;
11-22
11 ELECTRIC SYSTEM
( 13 ) I DLE SPEED CONTROL VALVE ( CARBON TANK CON TROL VAL VE ) :
CONTROL PASS -BY AIR FLOW . ECU CONTROL THE IDLE
SPEED VALVE ACCORDING TO THE INFORMATION OF ENGINE
LOAD ,THE ELECTRICAL PULSE DURATION AND FREQUENCY :
(DUTY RATIO) .THE IDLE SPEED VALVE HAS DIFFERENT AIR
FLOW UNDER DIFFERENT ORESSURE DIFFERENCE,SO IT MUST
BE CONNECTED ACCORDING TO PRESCRIPTIVE METHOD , OR
ELSE WILL CAUSE INCORRECT IDLE SPEED, WHEN WITHOUT
ELECTRICAL PULSE, IDLE SPEED VALVE CLOSE.
FUNCT I ON OF P I NS :
1.CONNECT PIN 17;
2.CONNECT OIL PUMPRELAY OUTLET END;
T H E R I GH T I S T HE W I R I N G D I AG RA M FO R I D L E
SPEED VAL VE AND ECU .
!WHEN FIXING THE IDLE SPEED CONTROL VALVE, IT CANNOT
BE I NSTAL LED L I KE THE R I GHT D I AGRAM ( CONNECTOR
VERT I CA L L Y DOWNWARD ) TO AVO I D DE ST ROY T HE
E L ECTRON I C COMPONENT .
! TO AVOID SOLID -BORNE SOUND TRANSMISSION,YOU CAN
INSTALL THE IDLE AIR CONTROL VALVE SUSPENDED IN THE
TUBE,OR USE RUBBER BOOT TO FIX IT TO THE ENGINE OR THE
FRAME.
I DL E SPEED CONTROL VAL VE PARAMETER L I ST :
11-23
CFMOTO
( 14 ) I GN I T I ON SW I TCH CO I L :
IGNITION SWITCH COIL AHANGE THE PRIMARY WINDING
LOW VOLTAGE INTO SECONDARY WINDING HIGH VOLTAGE ,
THROUGH SPARK PLUG DISCHARGE TO CREAT SPARK,FIRING
THE FUEL AND GAS MIXTURE.
FUNCT I ON OF P I NS :
1.GROUNDING;
2 . CONNECT POWER+.
3.CONNECT ECU 1 POINT;
THE R I GHT I S THE CONNECT I ON C I RCU I T D I AGRAM
OF I GN I T I ON CO I L AND ECU .
MEASUR I NG SECONDARY I GN I T I ON VOL TAGE :
! CONNECT THE ENGINE ACCORDING TO THE ELECTRONICSPRAY ELEMENTARY DIAGRAM;
! CONNECT THE PEAK VOLTAGE GUAGE ACCORDING TO THE
RIGHT DIAGRAM;
!START THE ENGINE;
!AFTER STARTS,THE SECONDARY IGNITION VOLTAGE SHOULD
BE # 15000V ;
I GN I T I ON CO I L PARAMETER L I ST :
11-24
11 ELECTRIC SYSTEM
ELECTRONIC SPRAY SYSTEM FAULT SELF D IECU
AGNOS
IS
CONTINUOUSLY
MONITOR THE SENSOR,ACTUATOR,RELEVENT
CIRCUIT,TROUBLE LAMP,BATTERY VOLTAGE ETC,EVEN THE
ECU ITSELF.ALSO THE SENSOR OUTPUT,ACTUATOR DRIVING SIGNAL , INTERNAL SIGNAL(SUCH AS CLOSED- LOOP CONTROL &
COOLANT TEMPERATURE, IDLING SPEED CONTROL ,BATTERY VOLTAGE CONTROL ETC) ,DO THE RELIABILITY MEASUREMENT.ONCE
DISCOVER SOME WHERE BREAK DOWN,OR SOME SIGNAL VALVE UNTRUSTED,THE ECU WILL IMMEDIATELY SET UP FAULT RECORD
INFORMATION IN RAM TROUBLE MEMORY.THE FAULT INFORMATION STORE AS TROUBLE CODE,AND DISPLAY THE FAULT IN IT
%
S EMERGENCE SEQUENCE.
THE FAULT CANBE DIVIDED INTO TWO TYPES 'STEADY FAULT( AND 'RANDOM FAI LURE(ACCORDING TO IT%S
EMERGENCE FREQUENCY(SUCH AS CAUSED BY BRIEF WIRE TURNOFF OR BAD CONNECTION OF THE CONNECTOR. )
THROUGH DIAGNOSTIC EQUIPMENT AND THE TROUBLE LAMP YOU CAN FIND THE TROUBLE PART QUICKLY.
ELECTRON I C SPRAY SYSTEM FAULT D I AGNOS I S MA I NLY APPLY TROUBLE LAMP AND D I AGNOST I C EQU I PMENT .
$1 %T R O U B L E
TROUBLE LAMP
ADOPTING LED,BY
FOR THE TROUBLE
L A M P $ M I L L A M P %+
FIXED IN THE METER DESPLAY BOARD ,
MEANS OF DIFFERENT FREQUENCY STAND
CODE.
THE R I GHT I S THE W I R I NG D I AGRAM FOR TROUBL E
L A MP A ND E CU . C UR RE NT F L O W I N T O E CU 4 P I N
SHOU L D BE L ESS THAN 0 . 5A3
3
TROUBL E L AMP BL I NK PR I NC I PL E :
a+
+I N B L I NK CODE MODE , AND A L SO THE TROUB L E
MEMOY TROUBL E FREE :
IF ECU MONITOR THAT THE MI L LAMP IN BL INK CODE
MODE , THE TROUBLE L IGHT WI LL FL ICKER TO SHOW THE
TROUBLE CORRESPONDING Pcode CODE. SINCE IGNITE ECU,
MI L WI LL CONTINUE BL INK 4 SECONDS , THEN HAVE A 1
SECOND SPAN , MI L BL INK WITH 2 HZ FREQUENCY TO SAY
TROUBLE FREE .UNTILL START THE ENGINE, FIND OUT THE
ROTATE
SPEED.BL I NK MODE , AND THE TROUBL E MEMORY
b+
+I N CODE
SHOWS AT FAUL T .
IF ECU MONITOR THAT THE MI L LAMP IN CODE BL INK
MODE ,THE TROUBLE LAMP WILL BLINK TO SHOW THAT THE
TROUBLE MEMORY CORRESPONDING Pcode CODE.SINCE IGNITE
ECU INITIAL I ZATION , MI L WI LL L IGHT 4 SECONDS , THEN
HAVE A 1 SECOND SPAN,MIL SHOW THE MEMORY TROUBLE CODE
THROUGH BLINK CODE Pcode. IF ALL THE TROUBLES ENTERED
THE MEMORY SHOWED BY MIL LAMP VIA BLINK CODE MODE,MIL
EXTINGUISH,UNTILL EXIT BLINK CODE MODE.
BLINK CODE MODE REQUIRES K LINE GROUNDING.
C:READ TROUBLE INFORMATION THROUGH THE BLINK CODE
THRN ON THE IGNITION SWITCH,K LINE GROUND AFTER 2.
5 SECONDS, IF ECU TROUBLE MEMORY HAVE TROUBLE CODE,AT
THE MOMENT , ENGINE MI L TROUBLE LAMP OUTPUT P- CODE
VALUE . SUCH AS : P0203 BL INK MODE IS : BL INK 10 TIMES
CONTINUOUSLY- INTERMISSION-BLINK 3 TIMES CONTINUED.
11-25
CFMOTO
$2%
%D I AGNOST I C EQU I PMENT : I T HAVE THREE P I NS ,
POWER , GROUNDW I RE AND DATA K L I NE , CONNECT W I TH
THE CORRESPOND I NG P I NS I N ECU .
THE R I GHT I S THE D I AGNOST I C EQU I PMENT OPERA T I ON FU NCT I ON S I ND I CA T O R D I AG RA M . S PE C I F I C
OPERAT I ON AND I T,
,S FUNCT I ONS P L EASE REFERS
P
I ONS :I C EQU I PMENT OPERAT I NG MANUAL .
TOI NS
THEFUNCT
D I AGNOST
1.ECU 26PIN
2.GROUNDWIRE
3.+12V POWER
KEY - PRESS FUNCT I ONS :
LEFT - HAND BUTTON : UPWARD TURN OVER ;
UPPER KEY : MENU SELECT I ON , UPWARD ROL L I NG TEXT :
R I GHT - HAND BUTTON : BACKWARD TURN OVER ;
DOWN KEY : MENU SELECT I ON , DOWNWARD ROLL I NG TEXT ;
CONF I RMAT I ON KEY : ENTER OR START CURRENT
OPERATION;
SELECT CURRENT MENU SELECTION;
ESC ESCAPE : CANCE L OR STOP CURRENT OPERAT I ON ;
RETURN TO PREVIOUS PAGE;
D I AGNOST I C EQU I PMENT FUNCT I ON :
$1 %E D I T I O N I N F O R M A T I O N D E S P L A Y :
ENGINE INFORMATION,ECU HARDWARE,ECU SOFTWARE.
$2 % T R O U B L E D I S P L A Y
INLET PRESSURE SENSOR, INTAKE AIR TEMPERATURE SENSOR,ENGINE TEMPERATURE SENSOR,THROTTLE POSITION SENSOR,
OXYGEN SENSOR ,OXYGEN SENSOR HEATING CIRCUIT ,AIR -FUEL DEL IVERY RATIO, OI L ATOMIZER ,OIL FUEL PUMP RELAY ,
REVOLUTION SPEED SENSOR ,VEHICLE SPEED SIGNAL , IDL ING SPEED , IDLE AIR CONTROL , SYSTEM VOLTAGE, ECU, TROUBLE
LAMP.
$3 %E N G I N E P A R A M E T E R D I S P L A Y
BATTERY VOLTAGE,ENGINE SPEED, IDLE SPEED,VEHICLE SPEED,ENGINE TEMPERATURE,ENGINE TEMPERATURE SENSOR SIGNAL 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, IGNITION ADVANCE ANGLE,OXYGEN
SENSOR SHORT-TERM CORRECTION,OXYGEN SENSOR VOLTAGE,OXYGEN SENSOR LONG TERM CORRECTION,ENGINE RELATIVE LOAD,
CARBON TANK CONTROL RELATIVE FUEL DEL IVERY , CARBON PURIFYING, CARBON LOAD , IDL ING ACTUATOR TEV OPENING ,
AMBIENT PRESSURE,ELEVATION CORRECTION FACTOR,OIL SPOUT PHASE,RUNTIME.
$4 %E L E CTRO N I C SPRAY SY STE M ST ATUS D I SP L AY
IGNITION TERMINAL OPEN UP,MAIN RELAY OPERATION,OIL FUEL PUMP OPERATION,REACH IDLING ROTATE SPEED,REACH
ENGINE WORK TEMPERATURE,VEHICLE RUNNING, IDLE SPEED WORKING CONDITION,FULL LOAD WORKING CONDITION,ACTIVE
DECELERATE OIL REDUCTION,ACTIVATE ACCELERATION CROWDING,OIL SPOUT CLOSED- LOOP CONTROL ACTIVATION,DECELERATION OIL -BREAK, lambda CONTROL ACTIVATE,MIXTURE GAS SELF- LEARNING ACTIVATION,TROUBLE LAMP STATE,MIL BLINK.
$5 %A C T U A T O R E X P E R I M E N T F U N C T I O N
TROUBLE LAMP,OIL FUEL PUMP,MAGNETIC STEPPING MOTOR,CARBON TANK CONTROL VALVE, IGNITION,OIL SPOUT.
11-26
11 ELECTRIC SYSTEM
TROUBLE CODE L I ST :
REF
TROUBLE
INSTRUCTION
CODE
OXYGEN SENSOR HEATING CONTROL CIRCUITOPEN
1
P0030
CIRCUIT
OXYGEN SENSOR HEATING CONTROL CIRCUITSHORT TO
2
P0031
EARTH
OXYGEN SENSOR HEATING CONTROL CIRCUITSHORT
3
P0032
CIRCUIT TO POWER
OXYGEN SENSOR HEATING INTERNAL RESISTANCE
4
P0053
UNREASONABLE
5
P0105
INLET PRESSURE SENSOR SIGNAL NO CHANGE"ICE UP#
6
P0106
INLET PRESSURE SENSOR UNREASONABLE
7
P0107
INLET PRESSURE SENSOR SHORT CIRCUIT TO GROUND
8
P0108
INLET PRESSURE SENSOR SHORT CIRCUIT TO POWER
INLET AIR TEMPERATURE SENSOR SIGNAL VOLTAGE TOO
9
P0112
LOW
INLET AIR TEMPERATURE SENSOR SIGNAL VOLTAGE TOO
10
P0113
HIGH
ENIGNE COOLANT TEMPERATURE SENSOR
11
P0116
UNREASONABLE
ENIGNE COOLANT TEMPERATURE SENSOR CIRCUIT
12
P0117
13
P0118
VOLTAGE TOO LOW
ENIGNE COOLANT TEMPERATURE SENSOR CIRCUIT
VOLTAGE TOO HIGH
THROTTLE POSITION SENSOR CIRCUIT VOLTAGE UNDER
14
P0122
LIMINAL VALUE
THROTTLE POSITION SENSOR CIRCUIT VOLTAGE EXCEED
15
P0123
LIMINAL VALUE
16
P0130
OXYGEN SENSOR SIGNAL UNREASONABLE
17
P0131
OXYGEN SENSOR SIGNAL CIRCUIT VOLTAGETOO LOW
18
P0132
OXYGEN SENSOR SIGNAL CIRCUIT VOLTAGETOO HIGH
19
P0134
OXYGEN SENSOR CIRCUIT SIGNAL TROUBLE
1 CYLINDER OIL ATOMIZER CONTROL CIRCUIT OPEN
20
P0201
CIRCUIT
1 CYLINDER OIL ATOMIZER CONTROL CIRCUIT SHORT
21
P0261
CIRCUIT TO EARTH
1 CYLINDER OIL ATOMIZER CONTROL CIRCUIT SHORT
22
P0262
CIRCUIT TO POWER
23
P0321
TRANSIENT SPEED SIGNAL REFERENCE POINT TROUBLE
24
P0322
CIRCUIT OR SHORT CIRCUIT)
25
P0501
VEHICLE SPEED SENSOR SIGNAL UNREASONABLE
NO TRIGGER(VEHICLE SPEED) PULSE SIGNAL (OPEN
11-27
CFMOTO
11-28
COMP L ETE SCHEMAT I C C I RCU I T D I AGRAM
13 Lights,Instrument,Switches
Overhau l Info!!!! !!!!!!10 -1
Horn!!!!!!!!!!!!10- 8
Troub leshoot i ng!!!!!!!!! 10 - 2
Dashboard!!!!!!!!!!!!0- 9
Bul b rep l acement!!!!!!!!!10 - 3
Fuel Sensor!!!!!!!!!!10 -
Head l i ght!!!!!!!10 - 5
WaterTemperature sensor!!!!!!10- 12
Ign i t i on Swi tch!!!!!!!!!!10 - 6
Hand l ebar Sw i tch!!!!!!!!! 10 - 7
Brake L i ght Sw i tch . . . . . . . . . . . . . . . 10 - 8
O ve r hau l I n f o r ma t i o n
O pe r a t i o n i n s t r uc t i on s
Warning
"Head l i ght bul b wi l l be very hot when i t is turned on. Do not touch i t after i t i s just
turned of f . Operat i on shou l d be done when the bu l b i s coo l ed down .
"Inspect ion of water temperature alarm may use f i re source and l iquid of high temperature.
Do not put f l ammab l e matters nearby and take care not to get burnt .
"The temperature of head l i ght i s qu i te h i gh when turned on . Rep l aci ng w i th bare hand
or sta i ned g l ove w i l l cause o i l sta i ns on the g l ass face wh i ch may form hot spot and
cause deformat i on of g l ass face and damage to bu l b .
"Pay attent i on to the fo l l ow i ng when rep l ac i ng the bu l b .
#$ Do not rep lace the bu lb when i t is turned on. Keep igni t i on sw i tch i n the OFF pos i t ion,
and rep l ace af ter the bu l b i s coo l ed down .
$ Rep l ace the bu l b w i th hands i n c l ean g l oves to avo i d o i l sta i ns on the g l ass sur face.
$ Cl ean the gl ass w i th a clean rag d ipped in alcoho l or isoamyl acetate i n case of any o i l
stai ns on the g l ass sur face.
"I f the Inspect i on has to be done w i th battery , check i f the battery i s normal .
"I nspect i on of sw i tch cont i nu i ty can be done w i thout remov i ng the sw i tches f rom the
veh i c l e .
"Af ter the i nspect i ng and overhau l i ng of each part , cab l es and w i res shou l d be routed
proper l y (chapter 1)
"Refer to Chapter 2 for remova l and i nsta l l at i on of tai l l i ght and rear turn i ng l i ghts
Check standard
F u se
Li g h t& B u lb
It em
M ai n
S u b- fu se
H ead l ig h t" H i# Lo $
Br ake l ig h t # Tai l l ig h t
Tu rn i n g li g h t
D ash b o ar d i nd i ca to r
I n di cat o rs
St an d ard
2 0A
1 0 A !2 1 5 A!2
1 2V-3 5 /3 5 W
1 2V-2 1 /5 W
1 2 V-1 0 W! 4
% 5 LE D
LC D
13-1
13
CFMOTO
TROUBLESHOOTING
Head Light Cannot Turn On
"Broken f use
"Open c i rcu i t w i th ma i n cab l e
"Burnt Bu l b
"Fau l ty Sw i tch
13-2
13 Lights,Instrument,Switches
Rep l ac i ng Bu l b
Head l i ght Bu l b
Caut i ons
Head l i ght bu l b w i l l be very hot when i t i s turned on .
Do not touch i t af ter i t i s j ust turned of f .
Operat i on shou l d be done when the bu l b i s coo l ed
down .
Remove head l i ght
( % 13 - 5&
D i sconnect head l i ght .
Remove dust - proof cap , head l i ght connector , ci rc l i p
and rep l ace w i th a new bu l b .
Warning:
Wear c l ean g l oves when rep l aci ng bu l b .
O i l sta i ns on the g l ass sur face may cause
break of bu l b . C l ean the stai ned sur face w i th
al coho l or i soamy l acetate .
Make sure that the three p i ns of the bu l b shou l d
be i n l i ne w i th the three pos i t i on i ng ho l es i n the
socket when rep l aci ng the bu l b .
Bu l b spec i f i cat i on :#12V - 35 / 35W
Reverse the removal procedure for instal lat ion
After replacing the bulb, adjust headl ight beam
13
'% 3 - 1 4 &
Inspect i on of Head l i ght
Turn the i gn i t i on sw i tch to ON pos i t i on ,
turn l i ght sw i tch to the i l l um i nat i ng
pos i t i on and check i f the head l i ght i s on .
- ON : Norma l
- St i l l of f : short ci rcu i t of mai n cab l e or
broken ma i n cab l e
13-3
CFMOTO
Brake Light/Tail Light Bulb
Remove 2 tapp i ng screws
Remove tai l l i ght cover .
Turn brake l i ght / ta i l l i ght bu l b counter
cl ockw i se and remove i t .
Rep l ace brake l i ght / tai l l i ght bu l b
Bu l b Spec i f i cat i on#12V - 21 / 5W
Reverse the removal procedure for i nsta l l at i on
Front Turning Indicator Bulbs
Remove head l i ght (% 13 - 5&
Remove cover of f ront turn i ng l i ght
Rep l ace f ront turn i ng l i ght bu l bs
Bu l b Spec i f i cat i on#12V - 10W
Rear Turning Indicator Bulbs
Remove screw1(
Remove rear turn i ng i nd i cator cover .
Rep l ace rear turn i ng i nd i cator bu l bs .
Bu l b Spec i f i cat i on#12V - 10W)
Reverse the removal procedure for
i nsta l l at i on .
13-4
13 Lights,Instrument,Switches
No t e
Ma i n cab l e , w i r i ng and tube shou l d
be routed proper l y ( ! chapter 1 )
Dashboa r d L i gh t Bu l b
Remove dashboa rd'% 13 - 9&
Remove dashboard i nd i cator socket)
Dashboard i nd i cator#LCD
Note : I f dashboard has someth i ng wrong ,
i t*s recommended to rep l ace who l e dashboard .
Reverse the removal procedure for i nsta l l at i on
Head l i ght
Remove nuts as p i cture shown
D i sconnect head l i ght connector
D i sassemb l e head l i ght comp .
Reverse the remova l procedure for i nsta l l at i on
No te :
Be careful not to damage main cable when
13
assembling.
Af ter rep l ac i ng , ad j ust the head l i ght beam .
"' 3 - 1 4 $(
Note
Main cables and wires should be routed
properly.(
13-5
CFMOTO
Ignition Switch
Inspection
Remove f ront & rear top cover
'% 2 - 4 &
D i sconnect 4P connector of i gn i t i on sw i tch
13-6
13 Lights,Instrument,Switches
Check accord i ng to the fo l l ow i ng tab l e i f
the connector term i nal s are i n cont i nu i ty .
(
) - ) cont i nu i ty
Disassemble:
Remove front cover "' 2 - 4$
Disconnect 4P connector of ignition switch
Loosen bo l t and remove i gn i t i on sw i tch
Reverse the removal procedure for i nsta l l at i on
Hand l ebar sw i tch
Remove f ront cover "' 2-4$
D i sconnect l ef t and r i ght hand l ebar
sw i tch connector .
Check accord i ng to the fo l l ow i ng tab l e i f
the connector term i nal s are i n cont i nu i ty .
*) cont i nu i ty
L i ght i ng sw i tch
13
!" # $
%& ' # $
13-7
CFMOTO
Turn sw i tch
Horn sw i tch
Acce l erat i on sw i tch
2WD / 4WD sw i tch
I f someth i ng wrong , p l ease rep l ace
hand l ebar sw i tch)
'% 6 - 12&
Park i ng sw i tch
B rake l i gh t sw i tch
D i sconnect brake l i ght sw i tch connector and
check term i nators for cont i nu i ty .
Ho l d the brake l ever . . Cont i nu i ty
Re l ease the brake l ever . No cont i nu i ty
No continuity: Replace brake light switch
Horn
Inspection:
Remove f ront vent gr i l l e"' 2-15$
D i sconnect horn .
Connect w i th a fu l l y charged 12V battery
and check i f the horn sounds .
Fau l ty Horn :
13-8
Rep l ace
13 Lights,Instrument,Switches
D i sassemb l e
D i sconnect horn connector
Remove bo l t
Remove horn
Reverse the removal procedure for
i nsta l l at i on
Dashboa r d
Run the veh i c l e at l ow speed and check i f
the speed i nd i cator moves
Fau l ty speedometer : Rep l ace
Remova l and I ns t a l l at i on
Remove f ront top cover'% 2 - 4&
Remove f ront cover o f dashboard'% 2 - 4&
D i sconnect dashboard w i re connector
Remove f i xi ng nut and remove dashboard i n
the d i rect i on as i l l ustrated on the r i ght
Reverse the removal procedure for
i nsta l l at i on .
Note :
Ma i n cab l es and w i res shal l be routed
13
proper l y .
13-9
CFMOTO
Fue l Senso r
Remove :
Fue l tank top cover w i th key'% 2 - 9&+
4 f i x i ng bo l ts
Fue l sensor
D i sconnect 2P connector
Inspection
Remove fuel sensor (refer to above steps)
Connect 2P connector
Turn ignition switch to ON
Shake fuel sensor float with hand, locate the float
position and check if it conforms to the fuel gauge
reading.
Non-conformity: -check ma i n cab l e for dam age or short c i rcu i t
- Check fue l sensorandfuel gauge
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 /White-Green:
9 0 - 1 0 0 ,"2 0 -$
Faulty fuel sensor: Replace
13-10
13 Lights,Instrument,Switches
I nsta l l at i on
Put fue l sensor i nto i nsta l l at i on ho l e of fue l tank.
Fuel sensor shou l d be f i tted proper l y .
No fue l l eakage i s al l owed .
Connect 2P connector
I nspec t i on o f Fue l Gauge
Sw i tch on power supp l y and check i f fuel
l evel gauge funct i ons normal l y .
I f fue l gauge works norma l l y ,
Reverse the removal procedure for
i nstal l at i on of p l ast i c parts and seat .
13
13-11
CFMOTO
Wa t er Tempe ra t u r e Senso r
Warning:
Be careful not to get scalded and do not place
flammables nearby.
Warning:
"Coo l ant must reach the sw i tch thread ,
and the depth f rom vessel bottom to sensor
top shou l d be over 40mm .
"Keep l i qu i d temperature for three m i nutes
before measur i ng , and do not rai se temperature
sharp l y .
"The thermometer shou l d not contact the
vessel bottom .
D i sassemb l y :
Remove r i ght s i de pane l '% 2 - 8&
D i sconnect and remove temp . sensor
Put the sensor i nto a vesse l w i th coo l ant , s l ow l y
heat up the l i qu i d and measure the sensor
res i stance .
Temperature
50,
Res i stance
154 -. 16 -
80,
52 -. 4 -
100,
27 -. 3 -
120,
16 -. 4 -
Out of range: Rep l ace
Insta l l transducer
Connect water temperature transducer connector .
Fi l l coo l ant and d i scharge ai r .
Reverse the removal procedure for i nsta l l at i on of
p l ast i c parts and seat .
13-12
13 Troubleshooting
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
13
13-1
CFMOTO
1.Engine troubleshooting
Complaint
Engine will not start
or is hard to start
Symptom and Possible Causes
Remedy
Compression is Too Low
1.Worn cylinder
2.Worn piston ring
Replace
Replace
3.Leakage with cylinder gasket
4. Wear valve guide or improper valve seating
Replace
Repair or Replace
5.Loose spark plug
6.Slow cranking of starting motor
Tighten
Check electrical part
7.Faulty valve timing
8.Improper valve clearance
Adjust
Adjust
No Sparking from Spark Plug
1. Fouled spark plug
2. Wet spark plug
3. Defective ignition coil
Clean or Replace
Clean and dry or replace
Replace
4. Open or short circuit with pickup coil
5. Faulty generator
Replace
Replace
No Fuel Reach Into Carburetor
1. Clogged fuel tank vent tube
2. Clogged or faulty fuel valve
3. Faulty carburetor needle valve
Clean or Replace
Clean or Replace
Replace
4. Clogged fuel hose
5. Clogged fuel filter
Replace
Clean or Replace
Transfer is not in Neutral position
Engine stalls easily or
has unstable idle
speed
13-2
Set to Neutral position
1. Improper valve clearance
Adjust
2. Improper valve seating
3. Faulty valve guide
Replace or Correct
Replace
4. Worn rocker arm or rocker arm shaft
5. Fouled spark plug
6. Improper spark plug gap
Replace
Replace
Replace or Adjust
7. Faulty ignition coil
8. Clogged idle-vale inlet & exhaust pipe
Replace
Adjust Fuel level
9. Faulty magneto
Replace
13 Troubleshooting
Complaint
Poor engine
running in
high-speed
range.
Exhaust smoke
is dirty or thick
Engine lacks
power
Engine
overheats
Symptom and Possible Causes
1. Weak valve spring
2. Worn camshaft
3. Fouled spark plug
4. Insufficient spark plug gap
5. Improper valve timing
6. Faulty ignition coil
7. Weak high pressure oil pump,
resulting in poor fuel supply
8. Dirty air filter
1. Excessive engine oil
2. Worn piston ring
3. Worn valve guide
4. Scored or scuffed cylinder wall
5. Worn valve stem
6. Worn valve stem oil seal
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
1. Carbon deposit on piston top
2. Insufficient or excessive engine
oil
3. Faulty oil pump
4. Clogged oil passage
5. Air leakage from air intake pipe
6. Incorrect engine oil
7. Faulty cooling system(7-5)
Remedy
Replace
Replace
Clean or replace
Adjust or replace
Replace
Adjust
Adjust or replace
Clean or replace
Check oil level and drain
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Replace
Replace
Replace or Correct
Clean or replace
Clean or replace
Clean or replace
Adjust fuel level
Clean or replace
Replace
13
Tighten or replace
Check oil level and drain
Clean
Check level, add or drain
Replace
Clean
Tighten or replace
Change engine oil
13-3
CFMOTO
Complaint
Symptom and Possible Causes
Valve Chatter
1. Excessive valve clearance
2. Worn or broken valve spring
3. Worn rocker arm or camshaft
1.
2.
3.
4.
5.
Engine is
noisy
13-4
Adjust
Replace
Replace
Replace
Replace
Clean
Replace
Replace
Noise from Timing chain
1. Stretched chain
2. Worn sprocket wheel
3. Faulty chain tensioner
Replace chain & sprocket
Replace chain & sprocket
Repair or replace
Noise from Clutch
1. Worn or damaged crankshaft spline
2. Worn inner race spline
Replace crankshaft
Replace inner race
Noise from Crankshaft
1. Rattling bearing
2. Worn or burnt crank pin bearing
3. Excessive thrust clearance
Replace
Replace
Replace
Noise from CVT
1. Worn or slipping drive belt
2. Worn rollers in primary sheave
Replace
Replace
1.
2.
3.
4.
Slipping
Clutch
Noise from Piston
Worn piston
Worn cylinder
Carbon deposit in combustion chamber
Worn piston pin or pin hole
Worn piston ring or piston ring groove
Remedy
1.
2.
3.
4.
Noise from Transmission
Worn or damaged gear
Worn or damaged input or output shafts
Worn bearing
Worn bushing
Worn or damaged clutch shoes
Weakened clutch shoe spring
Worn clutch housing
Worn or slipping drive belt
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
13 Troubleshooting
2 Diagnosis troubles according to EFI system Trouble Code
Note:
1. Only start inspection and fixation when trouble is steady -state;otherwise
diagnosis would probably wrong
2.
The “multimeter”mentioned below are numerical mutimeter; it is forbidden to
use pointer type multimeter to make EFI system inspecting.
3. When Trouble Code tells “Low Voltage”, means probably it’s Short Circuit to
Ground or Broken Circuit;
When Trouble Code tells “High Voltage”,means probably it’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,
13
2.When making inspections ,do not ignore possible affect from vehicle
mantenance condition,cylinder pressure,machanisim timing.
3.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.
Following are implications of EFI System Trouble Code,Diagnosis
Measurements, Possible Reasons and their Solutions as references.
13-5
CFMOTO
Trouble Code: P0030 Oxygen Sensor Heating Control Circuit Broken
Note
Possible Troubles are as below
1!Circuit broken between ECU Pin and
Oxygen Sensor Pin 2.
2!Circuit broken between Oxygen Sensor
Pin 1 and Main Relay.
3!Circuit broken between Oxygen Sensor
Pin 1 and Pin 2.
Note
Inspect as below
1 ! Check if resistance between ECU
Connector Pin and Oxygen Sensor Pin 2 is
normal or not.
2!Check if resistance between Oxygen
Sensor Pin 1 and Main Relay is normal or
not.
3!Check if resistance between Oxygen
Sensor Pin 1 and Pin 2 is normal or not.
Trouble Code: P0031 Oxygen Sensor Heating Circuit Short to Ground.
Note
Possible Troubles are as below
1 ! Circuit connect to ECU Pin are
short-to-ground.
Note
Inspect as below
1!Check if resistance of ECU Pin to ground
is normal or not.
Trouble Code: P0032 Oxygen Sensor Heating Circuit Short to Power
Note
Possible Troubles are 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 Resistance to decide if
heating output is correct or not. In some conditions, Heated Oxygen Sensor would be
damaged by precipitate, especially while making cold start.
Note
Possible Troubles are as below
1!Oxygen Sensor Heatng function disable;
Replace Oxygen Sensor.
Note
Possible Troubles are as below
1) Check if resistance between Oxygen
Sensor Pin 1 and Pin 2 is normal or not.
Trouble Code" Air Inlet Pressure Sensor no signal variable
Note
Possible Troubles are as below
Note
Possible Troubles are as below
1 ! Air Inlet Pressure Sensor frozen or 1!Re-install the Air Inlet Pressure Sensor
jammed.
after ice melted with indoor temperature.
2) Air Inlet Pressure Sensor seriously
aging.
13-6
13 Troubleshooting
Trouble Code!
!P0106 Air Inlet Pressure Sensor Signal irrationally failure
Note
Possible Troubles are as below
1!Air leakage of Air Inlet Pressure Sensor.
2!Air Inlet Pressure Sensor broken.
3!Air leakage from assemble point.
4 ! Air
Inlet
Pressure
Sensor
characteristically defluxion.
Trouble Code!
!P0107 Low Voltage of Air Inlet Pressure Sensor Circuit
Note
Note
Possible Troubles are as below
Inspect as below
1!ECU found Air Inlet Pressure Sensor 1 ! Resistance between ECU Pin and
signal circuit short to ground.
Ground.
!P0108 High Voltage of Air Inlet Pressure Sensor Circuit
Trouble Code!
Note
Note
Possible Troubles are as below
Inspect as below
1!ECU found Air Inlet Pressure Sensor 1!Resistance of ECU Pin.
signal circuit short to power.
!P0112 Air Inlet Temperature Sensor Signal Voltage Low.
Trouble Code!
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.
Trouble Code!
!P0113 Air Inlet Temperature Sensor Signal Voltage High.
Note
Possible Troubles are as below
1!Circuit between ECU Pin and Air Inlet
Temperature Sensor Signal short to power.
Note
Inspect as below
1!Check if voltage of Sensor Signal of ECU
Pin is normal or not.
Trouble Code!
! Engine Water Temperature Sensor Indicated Temperature
irrationally failure
Note
Possible Troubles are as below
1 ! Water Temperature Sensor need
replacement
13-7
13
CFMOTO
Trouble Code!
!P0117 Engine Water Temperature Sensor Circuit Voltage low.
Note
Possible Troubles are as below
1!Circuit between ECU Pin and ground
short.
Note
Inspect as below
1) Check resistance between ECU Pin
and Ground.
Trouble Code!
!P0118 Engine Water Temperature Sensor Circuit Voltage high.
Note
Possible Troubles are as below
1!Short Circuit between ECU circuit and
other circuit.
Note
Inspect as below
1) Check if voltage connected to ECU pin
is normal or not.
Trouble Code!
!P0122 Voltage of Throttle Control Positioning Sensor Circuit lower
than the lower limit
Note
Possible Troubles are as below
1! ECU Pin short to ground.
Note
Inspect as below
1) Check resistance between ECU pin and
ground.
Trouble 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 Oxygen Sensor Signal irrationally failure
Oxygen Sensor Signal Circuit coupling with Heating Circuit.
Note
Possible Troubles are as below
1!Check if Oxygen Sensor Connector is
correct or not.
2!Check if Oxygen Sensor Signal Circuit
coupling with Heating Circuit.
Trouble Code!
!P0131 Oxygen Sensor Circuit Voltage Low
Note
Possible Troubles are as below
1) Signal Circuit connected with ECU Pin is
short circuit to ground.
13-8
Note
Inspect as below
1!Check resistance between Signal Circuit
connected with ECU Pin and ground.
13 Troubleshooting
Trouble Code!
!P0132 Oxygen Sensor Circuit Voltage High
Explanation" When engine starts, ECU check the Oxygen Sensor Circuit Voltage; When voltage is
continuously higher than 1.5 Volt, system decides Oxygen Sensor Circuit Voltage is short to power.
Note
Note
Possible Troubles are as below
Inspect as below
1!Short Circuit between Signal Circuit connect to
1 ! Check resistance between Signal Circuit
ECU Pin and Oxygen Sensor Oxygen Sensor Pin
connect to ECU Pin and Oxygen Sensor Oxygen
1.
Sensor Pin 1
2!Short Circuit between Signal Circuit connect to
2!Check resistance of Signal Circuit connect to
ECU Pin and other power circuit.
ECU Pin
Trouble Code!
!P0133 Oxygen Sensor Aging
Explanation: Normally Air Fuel Ratio of Fuel and Air is shifting between Dense and Dilute; accordingly
Oxygen Sensor signal variate among different values. When Oxygen Sensor is aging, it goes less
sensitive to Fuel-Air-Mixture, which makes signals variate lower. ECU makes average cycle calculations
to Signal Variation; when it finds cycling slower as set, it decides Oxygen Sensor Aging.
Note
Possible Troubles are as below
1!Oxygen Sensor Aging, need replacement.
Trouble Code!
!P0134 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.
13
Note
Note
Inspect as below
Possible Troubles are as below
1 ! Short
Circuit
between
Oxygen Sensor
Oxygen Sensor 4.
connected to ECU Pin.
2 ! Bad
connection
1!Check resistance between ECU connector and
of
Oxygen
Sensor
Connectors.(Socket Oxidized)
Trouble Code!
!P0170 Self Studying found Closing Loop control Air Fuel Ratio irrational when
making End of Line Testing.
Trouble Code!
!P0171 Self Studying found Closing Loop control Air Fuel Ratio too dulate when
making End of Line Testing.
Trouble Code!
!P0172 Self Studying found Closing Loop control Air Fuel Ratio too dense when
making End of Line Testing.
(Note: This Inspection Process is only suitable when Air Inlet Pressure Sensor, Canister Control Valve
and Oxygen Sensor and so on has not shown with Trouble Code; If there is any other Trouble Code,
solve other Troubles first and then inspect Fuel Route correct or not)
Trouble Code!
!P0201 Cylinder Injector Control Circuit Open
Note
Note
Possible Troubles are as below
Inspect as below
1! Injector Coil Open Circuit
1! Check resistance of Injector
2! Injector Connector Socket to ECU Pin bad connection
2)Check cable is connected or not
3! Injector
Connector Socket
to Main
Relay bad
connection
13-9
CFMOTO
Errors coding: P0261 Control circuit of single cylinder injector short to ground
Maintenance Tips"
The possible faults may exists as follow:
1!All drivers ECU pin connected short to
ground
Maintenance Tips"
Check the item as follow:
1!Measure ECU pin connected resistance
to ground
Errors coding: P0262 Control circuit of single cylinder injector short circuit
Maintenance Tips"
The possible faults may exists as follow:
1 ! Short circuit between circuit ECU
connected and other electrical source
circuits
Maintenance Tips"
Check the item as follow:
1!Measure the voltage of circuit ECU pin
connected
Errors coding: P0321 reference point of rotate speed sensor fault
Maintenance Tips"
The possible faults may exists as follow:
Maintenance Tips"
Check the items as follow:
1! Circuits connect intermittently short
circuit or intermittently open circuit.
1! Check the connection or breaking of
cable related connection.
2! Fixed position of crankshaft signal ring
deviation declination.
3! Fixed position of rotate speed sensor
declination.
2! Check the
flywheel.
quantity
of
magneto
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!Trigger rotate speed sensor ECU cable
connected open circuit
2 ! Trigger circuit ECU connected short
circuit.
3!Trigger coil open circuit.
Maintenance Tips"
1! Measure resistance between trigger
and ECU cable connected
2! Measure resistance of trigger
3! Measure trigger peak value voltage
Errors coding: P0444 Control circuit voltage of idle air control valve open circuit
Maintenance Tips"
The possible faults may exists as follow:
1 ! Open circuit between ECU circuit
connected and no.2 pin of idle air control
valve.
2!The circuit that no.1 pin of idle air control
valve connected to main relay open way.
3!Electromagnetism coil between no.1 pin
and no.2 pin open way.
13-10
Maintenance Tips"
1! Check the connection or breaking of
cable related connection.
2! Measure resistance of idle speed valve.
13 Troubleshooting
Errors coding: P0458 Control circuit voltage of idle air control valve too
low
Maintenance Tips"
The possible faults may exists as follow:
1! Circuit ECU connected is short circuit
Maintenance Tips"
C heck the item as follow:
1 ! Measure connected to the ECU
pin-to-ground resistance whether proper
or not
Errors coding: P0459 Control circuit voltage of idle air control valve too
high
Maintenance Tips"
The possible faults may exists as follow:
1 ! Short circuit between ECU circuit
connected and No.1 pin of idle air control
valve.
2 ! Short circuit between circuit ECU pin
connected and other electrical source
circuits
Maintenance Tips"
C heck the item as follow:
1!Measure the voltage of ECU pin whether
norm al or not
2! Measure resistance between ECU pin
and No.1 pin of idle air control valve
Errors coding: P0501Speed sensor signal im proper.
Explanation: W hen loose throttle and keep direct 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"
C heck the item as follow:
1) Check circuit resistance that connecter
of ECU joint to vehicle speed signal sensor.
2! Check resistance to ground of ECU pin.
Errors coding: P0506 Rotate speed of idle air control valve slower than target
idle speed
Explanation: Engine rotate speed of idle speed control valve works by closed-loop control.
And it indicates fault if ECU perform s idle speed controlling after a certain tim e, but the
actual engine speed still slower than target idle speed.
Maintenance Tips"
The possible faults may exists as follow:
1! Idle air control valve not work.
2! Check adjust bolt of throttle valve #
throttle cable # throttle operating
condition etc. whether are in condition
or not.
3! Too dirty inside of throttle valve body
13-11
13
CFMOTO
Errors coding: P0507
Rotate speed of idle speed control valve faster than target idle speed
Introduction of theory and fault reason: Engine rotate speed of idle speed works by
closed-loop control. And it indicates fault if ECU performs idle speed controlling after a
certain time, but the actual engine speed faster than target idle speed.
Maintenance Tips"
The possible faults may exists as follow:
1!Check adjust bolt of throttle valve#throttle
cable # throttle operating condition etc.
whether are in condition or not.
2!Too dirty inside of throttle valve body
3!Check crankcase enforced-air flue whether
breaks off or leaks
Errors coding: P0560 Voltage signal of system battery i l logical ity
Errors coding: P0562 Voltage signal of system battery is too low
Errors coding: P0563 Voltage signal of system battery is too high
Maintenance Tips"
The possible faults may exists as follow:
1!Magneto damaged and disable to starting
or battery electric leakage
2!Magneto stator coil open circuit
3!Regulator of Magneto 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 ci rcuit of oi l pump relay open ci rcui t
Errors coding: P0628 Control ci rcui t of oi l pump relay short to ground
Errors coding: P0629 Control ci rcuit of oi l pump relay short ci rcui t
Maintenance Tips"
The possible faults may exists as follow:
1!Open circuit/short to ground/short circuit
between control circuit of oil pump relay
connected to ECU and oil pump.
2!Open circuit between relay and main relay
3!Magnet coil of relay open circuit
Maintenance Tips"
Check the items as follow:
1!Measure resistance or voltage of oil pump
relay control circuit connected to ECU.
2!resistance between relay and main relay
3!resistance between the toes of relay
Errors coding: P0650 MIL lamp-dr iver ci rcui t fault
Maintenance Tips"
Maintenance Tips"
The possible faults may exists as follow:
Check the item as follow:
1!Open circuit/short to ground/short circuit on 1!Measure resistance or voltage of MIL
circuit of MIL lamp-driver connected to ECU.
lamp-driver control circuit connected to
ECU.
2!Open circuit between MIL and main relay.
3!MIL lamp burnout
13-12
13 Troubleshooting
Errors coding : P2177
Self-learning value of air-fuel ratio, closed-loop control exceeds upper limit
Errors coding : P2178
Self-learning value of air-fuel ratio, closed-loop control exceeds lower limit
Introduction of theory and fault reason: In order to make catalytic converters for HC, CO and
NOx to maximize conversion efficiency, the air-fuel ratio of mixture should be 14.7:1. When
the engine occurs, parts manufacturing deviation, deposition of fuel colloid on fuel injector,
intake or back of valve, gas leak of intake and exhaust system, will cause the air-fuel
ratio(14.7:1) 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 fuel charge constantly till Max), system
will judge that self-learning value transfinite fault.
Maintenance Tips"
13
The possible faults may exists as follow:
1!Injector clog needs cleaning
2!Intake and exhaust system leaks
3!Inlet or back of intake valve that fuel colloid accumulation of excessive need to be cleaned
4!Engine parts deviation
5!Valve clearance deviation
6!Fuel system pressure deviation
13-13
CFMOTO
3"
" Diagnosis troubles according to engine fault phenomena
Before start to diagnosis fault, please take the primary inspection first:
1#Engine failure indicator light works regularly.
2#Affirm that no errors Code have been found by Diagnosis Analyze.
3#Affirm the fault that user complaint is exist, and affirm the condition of fault happen ed.
Then, take external inspection:
$1! Check fuel pipe whether has oil leak phenomena or not.
$2! Check vacuum tube if rupture, kink or incorrect connect.
$3! Check air intake pipe whether clogged, leaked, been staved or damaged or not.
$4! Check ignition coil of ignition system whether rupture, aged or not, firing sequence
whether correct or not%
$5! Check ground pole of wiring harness whether clean or fast or not%
$6! Check joints of sensor or actuator whether loose or poor contacts or not.
Notice" Please maintain the faults as above in advance. If not, the further f ault diagnosis will
be affected.
Diagnosis help:
1#Engine has no fault records%
2#Affirm the complaint of fault happened%
3#Do not ignore vehicle maintenance working, cylinder pressure, mechanism
timing, fuel etc effect against system during overhaul
4#Replace ECU and test it.
If Trouble Code is cleared, it means defective on ECU;
If Trouble Code is not cleared, put back original ECU and repeat inspecting
procedure to start again overhaul inspections.
Troubleshooting"
Starting Failure/Hard Starting
Engine can rotate but starting failure
Hard Starting in heating engine
Hard Starting in cold engine
Regularly rotate speed, but engine starting hard at any time
Engine works regularly&but unsteady idle speed at any time
Engine works regularly&but unsteady idle speed when engine is in warming-up
Engine starting normally, but idle speed unsteady after warming-up.
Engine starting normally, but unsteady idle speed or power off when engine
partly loading(such as: opening head light)
Engine starting regularly, but idle speed is too high.
Rotate speed can not increase or engine power off when in acceleration.
Reaction slowly when in acceleration.
No power and poor performance when in acceleration
13-14
in
13 Troubleshooting
#1$
$Starting Failure/Hard Starting
Possible defective part"
1#
Battery%
2#
Starter motor%
3#
Wiring harness or ignition switch;4#
engine mechanism part.
Overhaul:
Ref No.
Operation
Test result
Check the voltage between the two poles of
battery by multimeter, the voltage whether
around 8-12V or not when engine starting.
yes
next
1
no
Replace battery
yes
next
2
Keep ignition switch in engine starting station.
Check positive pole of Starter motor by
multimeter, the voltage whether above 8V or
not.
no
Repair or replace
wiring harness
3
Remove starter motor and check its work
condition, if circuit break or starter motor
locked because of improper lubricate.
yes
Repair or replace
Starter Motor
no
next
yes
Replace appropriate
grade of lubricating oil
no
next
yes
Overhaul
the
resistance inside of
engine mechanism
no
Repeat above steps
4
5
Fault only happens on winter, please check
lubricating oil if is improper for engine which
caused high resistance of starter motor.
Check the resistance inside of engine
mechanism whether is high or not, which
makes starter motor stop rotates or rotate
slowly.
Next Steps
13
#2$
$Engine can rotate but starting failure
Possible defective part"1#no gasoline in tank%2#Fuel pump%3#Trigger%4#Ignition
coil%5#engine mechanism part.
Overhaul:
Ref no
Operation
1
Contact fuel pressure meter(contact front point of oil
input pipe of injector)&
open ignition switch and repeat it
if possible, or starting engine, check the fuel pressure
whether is around 300kPa or not
2
Contact Electronic injection diagnostic meter, observe
item of “engine rotate speed”, starting engine, and
observe the rotate speed signal if is normally output.
3
Pull out ignition coil, and contact with spark plug, keep
pole of spark plug 5mm with body of engine, starting
engine and check it whether has blue-white high
pressure fire or not.
Test result
Next Steps
yes
next
no
examine and repair
oil support system
Yes
next
no
examine and repair
sensor wiring of
rotate speed
yes
next
no
Examine and repair
ignition system.
13-15
CFMOTO
4
5
Check air pressure of cylinder and observe the
pressure if is discrepantly.
Contact EFI commutator, open ignition switch,
check ECU5##10##13# stitch, the power whether
supply normally or not, check 2##21# stitch whether
Put up iron or not.
yes
Eliminate engine
mechanism fault
no
next
yes
Diagnosis help
no
Examine and repair
relevant wiring
$3!Hard Starting in normal status
Possible defective part"
1#
fuel containing water%
2#
fuel pump%
3#
engine water temperature
sensor%4#ignition coil
Overhaul:
Ref no
Operation
Test result
Contact fuel pressure meter(contact front point of
oil input pipe of injector), starting engine, check the
fuel pressure whether is around 300kPa or not
yes
next
1
no
examine and repair
oil support system
yes
next
no
Examine and repair
ignition system.
Yes
Examine and repair
wiring or replace
sensor
No
Next
No
Next
2
3
4
5
Pull out ignition coil, and contact with spark plug,
keep pole of spark plug 5mm with body of engine,
starting engine and check it whether has blue-white
high pressure fire or not.
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
temperature sensor, observe engine whether
succeed starting or not at this moment.)
Check fuel and observe the fault if caused after
fueling
Contact EFI commutator, open ignition switch,
check ECU5##10##13# stitch the power whether
supply normally or not, check 2##21# stitch whether
Put up iron or not.
Next Steps
yes
Replace fuel
no
next
yes
Diagnosis help
no
Examine and repair
relevant wiring
$4!Hard Starting in cold status
Possible defective part"
1#
fuel containing water%
2#
fuel pump%
3#
engine water temperature
sensor%4#injector%5#ignition coil%6#throttle valve body and idle speed side air duct; 7#
engine mechanism part (
Overhaul:
13-16
13 Troubleshooting
Ref no
Operation
Test result
Contact fuel pressure meter(contact front point of
oil input pipe of injector), starting engine, check the
fuel pressure whether is around 300kPa or not
yes
next
1
no
examine and repair
oil support system
yes
next
no
Examine and repair
ignition system.
Yes
Examine and repair
wiring or replace
sensor
no
next
yes
Clean throttle valve
body and idle speed
air duct
no
next
2
3
4
Pull out ignition coil, and contact with spark plug,
keep pole of spark plug 5mm away of body of
engine, starting engine and check it whether has
blue-white high pressure fire or not.
Pull out connector of engine water temperature
sensor, starting engine, observe engine whether
succeed starting or not at this moment. (or in series
a 2500 ' resistant instead of engine water
temperature sensor, observe engine whether
succeed starting or not at this moment.)
Draw accelerograph gently, observe it whether
starting engine easily or not.
Next Steps
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks or clogs
yes
Replace
5
no
next
6
Check fuel and observe the fault if caused after
fueling
yes
Replace fuel
no
next
7
Check air pressure of cylinder and observe the
pressure if it is discrepantly.
yes
Eliminate
engine
mechanism fault
no
next
yes
Diagnosis help
no
Examine and repair
relevant wiring
8
Contact EFI commutator, open ignition switch,
check ECU5##10##13# stitch, the power whether
supply normally or not, check 2##21# stitch whether
Put up iron or not.
13
$Regularly rotate speed, but engine starting hard at any time
#5$
Possible defective part"
1#
fuel containing water%
2#
fuel pump%
3#
engine water temperature
sensor%4#injector%5#ignition coil%6#throttle valve body and idle speed side air duct;
7#input air duct%8#ignition timing%9#spark plug%10#engine mechanism part
Overhaul:"
Ref no
Operation
Test result
Next Steps
1
Check air cleaner and input air duct whether are
clogged or not
yes
Examine and repair
air input system
no
next
13-17
CFMOTO
2
3
Contact fuel pressure meter(contact front point of
oil input pipe of injector), starting engine, check the
fuel pressure whether is around 300kPa or not
Pull out ignition coil, and contact with spark plug,
keep pole of spark plug 5mm away with body of
engine, starting engine and check it whether has
blue-white high pressure fire or not.
4
Check spark plug, look its type and gap if accords
with standard.
5
Pull out connector of engine water temperature
sensor, starting engine, observe engine whether
succeed starting or not at this moment.
6
Draw accelerograph gently, observe it whether
starting engine easily or not.
yes
next
no
examine and repair
oil support system
yes
next
no
examine and repair
ignition system
yes
next
no
Adjust or replace
yes
Examine and repair
wiring or replace
sensor
no
next
yes
Clean throttle valve
body and idle speed
air duct
no
next
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks or clogs
yes
replace
7
no
next
8
Check fuel and observe the fault if caused after
fueling
yes
Replace fuel
no
next
9
Check air pressure of cylinder and observe the
pressure if is discrepantly.
yes
Eliminate
engine
mechanism fault
no
next
10
11
Check engine ignition timing if accords with
standard.
Contact EFI commutator, open ignition switch,
check ECU5##10##13# stitch the power whether
supply normal or not, check 2##21# stitch whether
Put up iron or not.
yes
next
no
examine and repair
ignition timing
yes
Diagnosis help
no
Examine and repair
relevant wiring
$Engine works regularly%
%but unsteady idle speed at any time
#6$
Possible defective part"1#fuel containing water%2#injector; 3#spark plug%4#throttle
valve body and idle speed side air duct%5#input air duct%6#idle speed valve; 7#ignition
timing%8#engine mechanism part
Overhaul:
Ref no
1
13-18
Operation
Check air cleaner and input air duct whether are
clogged or not
Test result
Next Steps
yes
Examine and repair
air input system
no
next
13 Troubleshooting
Yes
Clean or replace
no
next
Check spark plug, look its type and gap if accords
with standard.
Yes
next
no
Adjust or replace
4
Check throttle valve body and idle speed side air
duct whether have carbide accumulated or not.
Yes
Clean
no
next
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks, clogs or flux discrepantly.
Yes
Fault replacement
5
no
next
6
Check fuel and observe the fault if caused after
fueling
Yes
Replace fuel
no
next
7
Check air pressure of cylinder and observe the
pressure if is discrepantly.
yes
Eliminate
engine
mechanism fault
no
next
yes
next
no
examine and repair
ignition timing
yes
Diagnosis help
no
Examine and repair
relevant wiring
2
Check idle speed valve whether clogged or not.
3
8
9
Check engine ignition timing if accords with
standard.
Contact EFI commutator, open ignition switch,
check ECU5##10##13# stitch, the power whether
supply normal or not, check 2##21# stitch whether
Put up iron or not.
#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
13
Overhaul:"
Ref no
Operation
Test result
Next Steps
1
Check air cleaner and input air duct whether are
clogged or not
yes
Examine and repair
air input system
no
next
2
Check spark plug, look its type and gap if accords
with standard.
yes
next
no
Adjust or replace
yes
Clean related parts
3
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
4
Pull out connector of engine water temperature
sensor, starting engine, observe idle speed
whether is unsteady or not when engine is in
warming-up.
yes
Examine and repair
wiring or replace
sensor
no
next
yes
Fault replacement
no
next
5
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks, clogs or flux discrepantly.
13-19
CFMOTO
6
Check fuel and observe the fault if caused after
fueling
Yes
Replace fuel
no
next
7
Check air pressure of cylinder and observe the
pressure if it is discrepantly.
yes
Eliminate
engine
mechanism fault
no
next
yes
Diagnosis help
no
Examine and repair
relevant wiring
8
Contact EFI commutator, open ignition switch,
check ECU5##10##23# stitch, the power whether
supply normal or not, check 2##21# stitch whether
Put up iron or not.
$Engine starting normally, but idle speed unsteady after warming-up.
#8$
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
1
Check air cleaner and input air duct whether are
clogged or not
yes
Examine and repair air
input system
no
next
2
Check spark plug, look its type and gap if accords
with standard.
yes
next
no
Adjust or replace
yes
Clean related parts
3
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
4
Pull out connector of engine water temperature
sensor, starting engine, observe idle speed whether
is unsteady or not when engine is in warming-up.
yes
Examine and repair
wiring or replace sensor
no
next
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks, clogs or flux discrepantly.
yes
Fault replacement
5
no
next
6
Check fuel and observe the fault if caused after
fueling
Yes
Replace fuel
no
next
7
Check air pressure of cylinder and observe the
pressure if it is discrepantly.
yes
Eliminate
engine
mechanism fault
no
next
yes
Diagnosis help
no
Examine and
relevant wiring
8
Contact EFI commutator, open ignition switch,
check ECU5##10##23# stitch, the power whether
supply normal or not, check 2##21# stitch whether
Put up iron or not.
$Engine starting normally, but unsteady idle speed or power off when engine
#9$
in partly loading(such as: opening head light)
13-20
repair
13 Troubleshooting
Possible defective part"1#idle speed valve%2#injector
Overhaul:
Ref no
Operation
Test result
Next Steps
yes
Clean related parts
1
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
Turn step no.4
2
Observe output power whether is increasing or not
when begin loading work, namely observe the
movement of ignition advance angle#injection
pulse width and air intake flowrate by EFI diagnosis
instrument
no
next
no
Examine and repair
air condition system
yes
Fault replacement
3
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks, clogs or flux discrepantly.
no
next
yes
Diagnosis help
4
Contact EFI commutator, open ignition switch,
check ECU5##10##23# stitch, the power whether
supply normal or not, check 2##21# stitch whether
is puting up iron or not.
no
Examine and repair
relevant wiring
13
$Engine starting regularly, but idle speed is too high.
#10$
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
no
next
Check air intake system and connector of injector
seat, the air if is leaking.
yes
Examine and repair
air intake system
no
next
yes
Clean related parts
3
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
4
Pull out connector of engine water temperature
sensor, starting engine, observe idle speed whether
is unsteady or not when engine is in warming-up.
yes
Examine and repair
wiring or replace
sensor
no
next
yes
next
no
examine and repair
ignition timing
1
Check the throttle cable if is clipped or too tight.
2
5
Check engine ignition timing if accords with
standard.
13-21
CFMOTO
6
Contact with EFI commutator, open ignition switch,
check ECU5##10##23# stitch, the power whether
supply normal or not, check 2##21# stitch whether
is puting up iron or not.
yes
Diagnosis help
no
Examine and repair
relevant wiring
#11$
$Rotate speed can not increase or engine power off when in acceleration.
Possible defective part"1#fuel containing water%2#air intake pressure sensor and throttle
position sensor%3#spark plug%4#throttle valve body and idle speed side air duct%
5#input air duct%6#idle speed valve%7#fuel injector%8#ignition timing%9#muffler
Overhaul:
Test result
Next Steps
yes
Examine and repair
air input system
no
next
Contact fuel pressure meter(contact front point of
oil input pipe of injector), starting engine, check
the fuel pressure whether is around 300kPa or not
yes
next
no
examine and repair
oil support system
3
Check spark plug, look its type and gap if accords
with standard.
yes
next
no
Adjust or replace
yes
Clean related parts
4
Disassembly idle speed valve and check the
throttle valve body, idle speed valve and idle
speed side air duct whether have carbide
accumulated or not.
no
next
yes
next
5
Check air intake pressure sensor # throttle
position sensor and their wiring whether works
regularly or not.
no
examine and repair
wiring or replace
sensor
yes
Fault replacement
6
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks, clogs or flux discrepantly.
no
next
7
Check fuel and observe the fault if caused after
fueling
Yes
Replace fuel
Ref no
1
2
Operation
Check air cleaner if is clogged.
8
Check engine ignition timing if accords with
standard.
9
Check the exhaust gas from muffler if exhausts
smoothly
Contact with EFI commutator, open ignition
10
13-22
switch, check ECU5##10##23# stitch, the power
whether supply normal or not, check 2##21# stitch
whether is puting up iron or not.
no
next
yes
next
no
examine and repair
ignition timing
yes
next
no
Repair or replace
muffler
yes
Diagnosis help
no
Examine and repair
relevant wiring
13 Troubleshooting
#12$
$Reaction slowly when in acceleration.
Possible defective part"1#fuel containing water%2#air intake pressure sensor and throttle
position sensor%3#spark plug%4#throttle valve body and idle speed side air duct%5#
input air duct%6#idle speed valve%7#fuel injector%8#ignition timing%9#muffler
Overhaul"
Test result
Next Steps
yes
Examine and repair air
input system
no
next
Contact fuel pressure meter(contact front point of
oil input pipe of injector), starting engine, check the
fuel pressure whether is around 300kPa or not
yes
next
no
examine and repair oil
support system
3
Check spark plug, look its type and gap if accords
with standard.
yes
next
no
Adjust or replace
yes
Clean related parts
4
Disassembly idle speed valve and check the throttle
valve body, idle speed valve and idle speed side air
duct whether have carbide accumulated or not.
no
next
yes
next
5
Check air intake pressure sensor# throttle position
sensor and their wiring whether works regularly or
not.
no
examine and repair
wiring or replace sensor
yes
Fault replacement
6
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks, clogs or flux discrepantly.
no
next
7
Check fuel and observe the fault if caused after
fueling
Yes
Replace fuel
no
next
8
Check engine ignition timing if accords with
standard.
9
Check the exhaust gas from muffler if exhausts
smoothly
Ref no
1
2
Operation
Check air cleaner if is clogged.
Contact with EFI commutator, open ignition switch,
10
check ECU5##10##23# stitch, the power whether
supply normal or not, check 2##21# stitch whether
is puting up iron or not.
yes
next
no
examine and
ignition timing
yes
next
no
Repair
muffler
yes
Diagnosis help
no
Examine and
relevant wiring
or
repair
replace
repair
#13$
$No power and poor performance when in acceleration.
Possible defective part"1#fuel containing water%2#air intake pressure sensor and throttle
position sensor%3#spark plug%4#ignition coil; 5#throttle valve body and idle speed side
air duct%6#input air duct%7#idle speed valve%8#fuel injector%9#ignition timing%10#
muffler
13-23
13
CFMOTO
Overhaul"
Ref no
1
2
3
4
Operation
Test result
Check the faults if exist clutch skid, low tyre
yes
repair
no
next
yes
Examine and repair air
input system
no
next
yes
next
no
examine and repair oil
support system
yes
next
no
examine and
ignition system
pressure, lagged brake, improper tyre size etc .
Check air cleaner if is clogged.
Contact fuel pressure meter(contact front point of
oil input pipe of injector), starting engine, check the
fuel pressure whether is around 300kPa or not
Pull out ignition coil, and contact with spark plug,
keep pole of spark plug 5mm away with body of
engine, starting engine and check the high
pressure fire whether is normal or not.
Next Steps
repair
5
Check spark plug, look its type and gap if accords
with standard.
yes
next
no
Adjust or replace
yes
Clean 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
Disassembly injector, and check the injector by
special washing analysis instrument if exists the
phenomena of leaks and clogs.
yes
Fault replacement
8
no
next
9
Check fuel and observe the fault if caused after
fueling
Yes
Replace fuel
no
next
Check engine ignition timing if accords with
standard.
yes
next
10
no
examine and
ignition timing
yes
next
11
Check the exhaust gas from muffler if exhausts
smoothly
no
Repair
muffler
yes
Diagnosis help
12
Contact with EFI commutator, open ignition switch,
check ECU5##10##23# stitch, the power whether
supply normal or not, check 2##21# stitch whether
is puting up iron or not.
no
Examine and
relevant wiring
13-24
or
repair
replace
repair