SERVICE MANUAL

400GT
650GT
CF400-5
CF650-8

www.cfmoto.com
Edition Date: 20190226
Edition Item: CF400-5,CF650-8 (6NQ#-00WX01-6100) SM-20190226.pdf

Website: www.cfmoto.com
 INTRODUCTION INDEX
This manual introduces CF400-5/CF650-
General Information 1
8 maintenance information, including
Maintenance Information 2
disassembly procedure checking
Technical Information 3
&adjustment methods, troubleshooting and
Seat and Side Box 4
technical specifications. There are some
Headlight and Fuel Tank Assy 5
illustrations, drawing to guide your operation.
Lights, Dashboard and Switches 6
The first three chapters mainly introduce
general operation information, special Air Filter Assy 7
tool, vehicle structure, basic specification, Electrical System 8
inspection&maintenance methods etc,. Coiling System 9
The rest chapters introduce vehicle part Muffler Assy 10
removal, installation, adjustment, service, Wheels and Brake System 11
fault diagnosis and etc,. Shock Absorbers and Rear Fork 12
CFMOTO has the copyright and final Engine Assy (CF400-5) 13
interpretation of this manual. Do not copy, Engine Assy (CF650-8) 14
translation without CFMOTO permit. Any Handlebar Assy 15
transmission or recording is prohibited. Triple Clamps 16
This manual has been improved by using Ignition System 17
many ways to make it accuracy. But we are Cleaning and Conservation 18
no response for any difference and missing. Storage 19
CFMOTO reserves right to make Electrical Diagram Appendix A
improvements and modifications to the
products without prior notice. Overhaul and
maintenance should be done according to
actual condition of vehicle. And CFMOTO is
not responsible for production improvements
and modifications. This manual is only for
reference. If any objections, please ask the
nearest dealer to get the latest information.
The information in this manual are the latest
depends on latest productions on coming out.
The images in this manual may not stand for
real model assy and parts.
Production CF400-5/CF650-8 is
accordance with standard: Q/CFD 013.
The manual standard: GB/T9969-2008
and GB/T19678-2005.
C F M O TO r e s e r v e s r i g h t t o m a k e
improvements and modifications to
the products without prior notice.
Overhaul and maintenance should be
done according to actual condition of
vehicle.

CFMOTO CO.LTD
 Conversion table
A Ampere lb Pound
ABDC After bottom dead center m Meter
AC Alternating current min Minute
ATDC After top dead center N Newton
BBDC Before bottom dead center Pa Pascal
BDC Bottom dead center PS Metric horse power
BTDC BTDC Before top dead center Psi Pound/Square Inch
°C Centigrade r Revolutions
DC Direct current rpm Revolutions per minute
F Farad TDC Top dead center
°F Fahrenheit TIR Total indicator reading
ft Feet V Volt
g Gram W Watt
h Hour Ω Ohm
L Litre in Inch
US gal Gallon(US) US qt Quart(US)
oz Ounce HP British horsepower
cm Hg Centimeter of mercury pint Pint
cu in Cubic inch mL Milliliter
 Forward
This service manual is not only specially designed for professional machinist, but also
it is used to instruct the vehicle’s user how to do maintenance work. It is necessary to
know mechanical knowledge, tools proper usage and have a well understanding of
service procedure Conversion before you perfectly solve all service problems. If no,
you should get the service support by professional machinist. Please read this service
manual and understand it before operate for high efficiency work. And working in clean
area. For vehicle mechanical performance and safety works. No tools replaced or
use temporary tools since that we have been appointed the special service tools and
equipment. All service and scheduled maintenance should be executed base on the
instructions of service manual. Any consequences are responsible by the vehicle’s
owner resulted from any rule-breaking operations.

How to get Long Service Life:

●Follow scheduled maintenance and service operations base on service manual.
●Non-periodical maintenance in special situations.
●Use tools properly and use CFMOTO genuine parts.
●Special tools, dashboard and tester have been listed into this service manual for
necessary genuine parts.
●Strictly operated bas on the correct service procedures.
●Keep fully service records and specify the date of new parts replacement.

How to use this manual:

In this manual, the production will be separated as several systems. All the systems are
shows up in the contents. That will help you to lock the chapter. And each chapter has its
own contents. For example, If you wanna see ignition coil information, use the contents
to find our the electrical system and find the ignition coil in electrical system chapter.
Whenever you see the warning or warning symbol, you must keep attention and
comply with the safety operation and maintenance method
Danger: This symbol means it will cause serious injuries even death if you
don't follow the procedure.

Warning: This symbol means the special steps. It may cause the vehicle
damage if you don't follow the procedure.

Note: This symbol means the special steps for higher efficiency and easier
working.

The other three symbol as following in order to distinguish the different levels of warning
information in service manual.
●Procedure or operation should be acted.
○One step of procedure or how to operate after procedure finished. Probably it is the
guidance before attention matters.
★ To take actions based on the front steps or test results from the front procedures. It
shows detail illustration including torque, lubrication oil, and lubrication grease or tighten
glue during assembling instruction.
 01 General Information
1.1 Operation Caution����������������������������������������������������������������������������� 1-1
1.2 Disassembly&Assembly Attentions������������������������������������������������ 1-3
1.3 Location of VIN/EIN��������������������������������������������������������������������������� 1-7
1.4 Wire, Pipe and Cable Diagram���������������������������������������������������������� 1-8
1.1 Operation Caution
Note: Exhaust contains toxic Note: When the engine just stops,
ingredients. Never run the engine in the temperature of engine, muffler is
enclosed or poorly-ventilated areas. still high. Never touch them with bare
hands to avoid getting burnt. Wear a
uniform with long sleeves and gloves
during operation.

Note: The liquor (dilute sulfuric acid)

in Battery is strongly corrosive. It may
burn the skin and blind the eyes. If you
contact the liquor, wash it with plenty Note: The coolant is poisonous,
of clean water immediately, and seek Never drink it. Neither let it contact
for medical treatment. Besides, wash the skin, eyes or clothes. If it contacts
it with plenty of clean water when it skin or clothes, rinse it immediately.
contacts the clothes to avoid skin If it contacts eyes, wash it with plenty
burnt. The battery and battery liquor of clean water immediately and seek
must be stored strictly out of the reach for medical treatment. If accidental
of children. drinking of the coolant, attempt to spit
it out/gargle it, and seek for medical
treatment immediately. The coolant
must be stored strictly out of the reach
of children.

1-1
CFMOTO
Note: Must wear uniform (pilot Note: No smoking or naked fire
uniform etc), cap, safety boots during at the operation site, because the
operation. Wear safety articles such gasoline is combustible. Not only
as dust-proof goggles, dust proof flames, but electric sparks shall be
respirator and gloves when necessary. avoided. Besides, the vapored gasoline
is explosive. Operate in the place with
nice ventilation.

Note: The battery may produce

combustible and explosive hydrogen
when being charged. It may explode Note: The operators shall remind
if there is a flame or electric spark. each other from time to time for safety
Charge it in the place with nice purpose during operation.
ventilation.

Note: Never touch the rotating or

movable pieces such as wheels, clutch,
etc. Pay attention not to get pinched
during operation.

1-2
 01 General Information
1.2 Disassembly&Assembly
Attentions ■ Clean the mud, dust before
■ Use CFMOTO genuine or overhauling.
recommended parts, lubricants and
grease.

■ Replace t he removed washer s,

o-rings, piston pin circlips, cotter pins
■ Place and store the disassembled with new ones.
parts separately for correct assembly. ■ Elastic circlips might get distorted
after disassembly. Do not use the
loosened circlips.

■ Clean and blow off the detergent

after disassembling the parts. Apply
lubricant on the surface of moving ■ Measure the data during disassembly
parts. for correct assembly.

1-3
CFMOTO
■ If not know the length of screws, ■ Pre-tighten bolts, nuts and screws,
install the screws one by one and then tighten them according to the
tighten with same torque. specified torque, from big to small and
from inner side to outer side.

■ Check if the disassembled rubber

parts are aged. Replace it if necessary. ■ Apply or inject recommended
Keep the rubber parts away from the lubricant to the specified parts.
grease.

■ If remove the ball bearing by pressing

■ Use special tools when necessary. the balls, the removed bearings should
not be used again.

1-4
 01 General Information
■ Turn the ball bearing with hands ■ Install the one-side dust-proof
to make sure the bearing will turn bearing in the right direction. When
smoothly. assembling the open type or double-
Replace if the axial or radial play is too side dust-proof bearing, the side with
big. manufacturer ’s mark should face
If the surface is uneven, clean with oil outside.
and replace if the cleaning does not
work.
When pressing the bearing into the
machine or to the shaft, replace the
bearing if it could not be pressed
tightly.

■ The circlip with chamfering side

should be towards force direction.
Loosened circlips can not be used.
Turn the circlip after installation to
■ Keep the bearing block still when make sure it is has been installed into
blowing the bearing after washing. the slot.
Apply oil or lubricant before assembly.

■ Brake fluid and coolant may damage

■ After assembly, check if all the
coating, plastic and rubber parts. Flush
tightened pats are properly tightened
these parts with water if splashed.
and can move smoothly.

1-5
CFMOTO
■ Install oil seal with the side of ■ When installing pipes, insert the pipe
manufacturer’s mark facing outside. till the end. Fit the pipe clip, into the
·Do not fold or scratch the oil seal lip. rove. Replace the pipes or hoses that
·Apply grease to the oil seal lip before cannot be tightened.
assembly.

■ Clean the gaskets and washers of the

■ Do not mix mud or dust into engine engine cases before assembly. Remove
or the hydraulic brake system. the scratches on the contact surfaces
by polishing evenly with an oil stone.

■ Do not twist or bend the cables too

much. Distorted or damaged cables ■ When assembling the parts like
may cause poor operation. protection caps, insert the caps to the
grooves.

1-6
 01 General Information
1.3 Location of VIN/EIN
Model: CF400-5, CF650-8
VIN: CF400-5: ★ LCEPESL5 ××××××××× ★
CF650-8: ★ LCEPEVLG ××××××××× ★
EIN: CF400-5:268MQ-A
CF650-8:283MT

010701

EIN VIN

010702 010703

1-7
CFMOTO
1.4 Wire, Pipe and Cable Diagram

1 2 3 4

5
6
010801

1 Roll-over sensor 3 ECU 5 Fuse box

2 Diagnosis connector 4 Battery 6 Main cable

7
010802 010803

10
9

010804 010805

7 Ignition Coil 8 Rear brake pump 9 Horn 10 Regulator

1-8
 01 General Information
11

12

13

11

010901

11 Adjusting nut, throttle cable 12 Throttle valve body 13 Throttle cable

15 16

17
14

18

010902 010903

RH handlebar
14 Clutch cable 15 LH handlebar switches 16 Dashboard 17 18 Lock
switches

1-9
CFMOTO
Fuel evaporation system diagram

Fuel vapor hose VI

Fuel tank assy

Fuel vent
pipe

Anti-rollover valve Fuel vapor

hose I
Fuel vapor hose II
Engine Fuel vapor
hose IV Canister
Fuel vapor hose III

Fuel vapor hose II

Throttle body
011001

Attention: To fixed the anti roll-over valve as horizontal position. Don’t change
the fuel evaporation system. Tube connection should be well connected after
maintenance by disassembling without air leakage, blocking, squeezing, broken
and damage etc. Fuel steam will be released into carbon tank by absorption tube
from fuel tank. Absorbing fuel steam by active carbon when engine stop; Fuel
steam of carbon tank will follow into combustor for burning when engine work-
ing in order to avoid environment pollution if fuel stem released into air directly.
Meanwhile, Air pressure of fuel tank should be balanced by absorption tube. If in-
ner pressure of fuel tank is lower than outside, it is available to replenish air pres-
sure by air tube of carbon tank or absorption tube. So, All tube system should
be smooth running without blocking and squeezing, otherwise fuel pump will be
damaged, fuel tank will be deformed or broken.

1-10
 02 Maintenance Information
2.1 Maintenance before Operation��������������������������������������������������������� 2-1
2.2 Break-in Maintenance Schedule������������������������������������������������������ 2-2
2.3 Periodic Maintenance Schedule������������������������������������������������������ 2-3

Cautions:
► = Severe Use Item. Reduce interval by 50% on vehicles subjected to severe use.
■ = Have an authorized dealer perform repairs that involve this component or system.
♦ = Emissions related components. Have an authorized dealer perform repairs that
involve this component or system.

2.1 Maintenance before Operation

Maintenance before operation
Item
Hour Calendar km Remarks
Fuel system
Fuel hose - Daily - Inspect for aging
Electrical system
Switches - Daily -
Inspect
Lights and horns - Daily -

2-1
CFMOTO
2.2 Break-in Maintenance Schedule
Break-in Maintenance Interval
Item (Service whichever interval comes first)
Hour Calendar km Remarks
Engine
■ Engine oil and oil filter - - 1000 Replace
Idle - - 1000
■ Coolant - - 1000 Inspect
Throttle system - - 1000
Electrical system
■ Functions of electrical parts - - 1000
Battery - - 1000 Inspect
Fuses or circuit breakers - - 1000
Brake system
Brake discs - - 1000
Brake pads - - 1000 Inspect
Brake fluid level - - 1000
Inspect for free
Brake lever - - 1000
play
Inspect for damage
■ Brake hoses - - 1000
and sealing
Wheels
Tire condition - - 1000
Inspect
Tire pressure - - 1000
Suspension system
Inspect for leaking
Rear shock absorber and (maintain parts
■ - - 1000
front forks according to the
requirement)
Cooling system
Coolant level - - 1000
■ Coolant - - 1000
Inspect
■ Radiator fan function - - 1000
Coolant hoses - - 1000
Steering system
■ Steering bearings - - 1000 Inspect
Other parts
■ Diagnosis connector - - 1000 Read with PDA
Lubricate; inspect
■ Mobile parts - - 1000
for flexibility
■ Bolts and nuts - - 1000 Inspect for fastness
Inspect for damage,
■ Cables and wires - - 1000
bending and routing

2-2
 02 Maintenance Information
2.3 Periodic Maintenance Schedule
Periodic Maintenance Interval
Item (Service whichever interval comes first)
Hour Calendar km Remarks
Engine
Engine oil and oil filter - - 3000 Replace
■ Clutch - - 12000
Idle - - 1200 Inspect
- - 12000
■ Coolant
- 24M 36000 Replace
Throttle system - - 12000 Inspect
■ Throttle valve - - 6000 Clean
- - 12000 Inspect
► ■ Air filter element
- 24M -
Replace
■ Spark plug - - 12000
■ Valve clearance - 40000 Inspect
Electrical system
■ Functions of electrical parts - 12M 10000
Battery - 6M 5000 Inspect
Fuses or circuit breakers - 6M 5000
Inspect for damage,
■ Wires - 12M 10000
bending and routing
Brake system
- 12M 10000
Front and rear brake system
- 24M 20000
- 12M 10000
Brake discs
- 24M 20000
Inspect
- 12M 10000
► Brake pads
- 24M 20000
- 12M 10000
Brake fluid level
- - 20000
- 24M 20000 Inspect for free
Brake lever
- 12M 10000 play
- 24M 20000 Inspect for damage
■ Brake hoses
- 12M 10000 and sealing
■ Brake fluid 24M - Replace
Wheels
- 12M 10000
Tire condition
- 24M 20000
- 12M 10000
Tire pressure Inspect
- 24M 20000
- - 10000
■ Wheel bearings
- - 30000

2-3
CFMOTO
Periodic Maintenance Interval
Item (Service whichever interval comes first)
Hour Calendar km Remarks
Suspension system
- - 4000
■ Suspension system - - 8000 Inspect
- - 12000
Inspect for leaking
- 12M 10000
Rear shock absorber and (maintain parts
■
front forks according to the
- 24M 20000
requirement)
- - 10000
■ Swing arms Inspect
- - 30000
Cooling system
- 12M 10000
Coolant level
- 24M 20000
- 12M 10000
■ Coolant
- 24M 20000
Inspect
- 12M 10000
■ Radiator fan function
- 24M 20000
- 12M 10000
■ Coolant hoses
- 48M 30000
Frame system
Frame - - 30000 Inspect
Steering system
- 12M 10000
■ Steering bearings Inspect
- 24M 20000
Chain
Chain, rear sprocket and - 12M 10000
► Inspect
engine sprocket - 24M 20000
Other parts
- 12M 10000
■ Diagnosis connector Read with PDA
- 24M 20000
- 12M 10000 Lubricate; inspect
■ Mobile parts
- 48M 30000 for flexibility
- 12M 10000
■ Bolts and nuts Inspect for fastness
- 48M 30000
- 12M 7500 Inspect for damage,
■ Cables and wires
- 24M 15000 bending and routing
Pipes, ducts, hoses and - 12M 10000 Inspect for cracks,
■
sleeves - 48M 30000 sealing and routing

2-4
 03 Technical Information
3.1 General Specifications�������� 3-1 Ring and Connecting Rod����� 3-5
3.2 Engine Specification ���������� 3-2 3.4.4 Clutch and Transmission
3.3 Maintenance Specifications ������������������������������������������������� 3-6
���������������������������������������������������� 3-3 3.4.5 Cooling System������������� 3-6
3.3.1 Front Wheel������������������� 3-3 3.4.6 Air Inlet System������������� 3-6
3.3.2 Rear Wheel�������������������� 3-3 3.4.7 Electrical System���������� 3-6
3.3.3 Brake System���������������� 3-3 3.5 Tighten Torque��������������������� 3-7
3.3.4 Lighting, Dashboard and 3.5.1 Tighten Torque Table for
Switch������������������������������������� 3-3 Vehicle������������������������������������ 3-7
3.4 Service Specification���������� 3-4 3.5.2 Tighten Torque Table for
3.4.1 Valve Train&Cylinder Head Engine������������������������������������� 3-8
������������������������������������������������� 3-4 3.6 Consumption Materials &
3.4.2 Lubrication System������ 3-5 Assembling Materials������������� 3-11
3.4.3 Cylinder, Piston, Piston 3 . 6 . 1 Ve h i c l e C o n s u m p t i o n
Materials������������������������������� 3-11
3.1 General Specifications
Item Specifications
Model CF400-5 CF650-8
Length 2100mm
Width 784mm
Height 1300mm
Wheel base 1415mm
Engine model 268MQ-A 283MT
Displacement 400.4mL 659.3mL
Fuel grade RQ-95 or above
Gross weight 211kg
Passengers 2 people (including driver)
Load 361kg
Front 120/70 ZR17
Tire
Rear 160/60 ZR17
Min. ground clearance 150mm
Turning circle diameter 5.6m
Right 32°
Steering Steering angle
Left 32°
Front Hydraulic Disc
Brake system
Rear Hydraulic Disc
Front wheel Telescopic
Shock absorber Suspension
Rear wheel Cantilever type
Frame Steel tube
Item Standard
Fuel capacity 19L
Injector Type: F01R00M126
Voltage: DC13.5V
Fuel supplier
Pressure: 0.33MPa±0.01MPa
Fuel pump
Flow: ≥45L/h
Current: ≤2.80A

3-1
CFMOTO
3.2 Engine Specification
Type/Specification
NO. Item
CF400-5 CF650-8
Line Engine/duplex cylinder/four
1 Type
strokes/water-cooled
2 Bore × Stroke 68.4mm×54.5mm 83mm×60mm
3 Displacement 400.4mL 649.3mL
4 Compression ratio 11.1:1 10.3:1
5 Low idling speed (Idling) 1450r/min±145r/min
6 Starting Electric
Ignition type ECU
Spark plug/Electrode
7 Electrical system NGK CR7E/0.7mm~0.9mm
gap
Magneto type Out rotor, flywheel
Combustion chamber Triangular
8 Combustion system Air filter type Sponge filter
Gasoline RQ-95 and above
9 Valves system Valves type SOHC/chain drive
Lubrication type Pressure and splash
Oil pump type Rotor drive
10 Lubrication system
Oil filter type Paper type, replaceable
Engine oil type SAE10W~40/SG
C o o l i n g Cooling type Closed coolant circulation
11
system Coolant type -35°C anti-rust and anti-freeze fluid
Clutch Wet and multi-plate clutch
6 - g e a r, c o n s t a n t m e s h , s t e p
Transmission type
transmission
Reducer gear 6 gears
Mechanical reciprocating
Gearshift methods/orders
1-0-2-3-4-5-6-5-4-3-2-0-1
Drive train Primary ratio 2.147 2.095
12
system Final drive 3.857 3.067
1st 2.500 2.353
Secondary ratio

2nd 1.800 1.714

3rd 1.333 1.333
4th 1.111 1.111
5th 0.966 0.966
6th 0.852 0.852
L(mm)×W(mm)×H(mm):
13 Overall size
386mm×312.7mm×439mm
14 Dry weight 31kg
15 Output type Chain
When moving forward, counter
16 Rotation of engine output
clockwise(left view).

3-2
 03 Technical Information
3.3 Maintenance Specifications
3.3.1 Front Wheel
Item Standard Service limit
Front wheel shaft bending - 0.2mm
Longitudinal 0.8mm 2.0mm
Rim run-out
Front Horizontal 0.8mm 2.0mm
wheel Remaining
- 1.6mm
groove
Tire
225kPa±22.5kPa
Tire pressure -
(2.25kgf/cm2±0.225kgf/cm2)

3.3.2 Rear Wheel

Item Standard Service limit
Longitudinal 0.8mm 2.0mm
Rim run-out
R e a r Horizontal 0.8mm 2.0mm
wheel Remaining groove - 1.6mm
Tire 225kPa±22.5kPa
Tire pressure -
(2.25kgf/cm2±0.225kgf/cm2)

3.3.3 Brake System

Item Standard Service limit
Front (hand brake) free travel 10mm~20mm -
Front brake
Brake disc abrasion 4mm 3mm
Rear (foot brake) free travel 10mm~20mm -
Rear brake
Brake disc abrasion 4mm 3mm

3.3.4 Lighting, Dashboard and Switch

Item Standard
Primary 30A
Fuse
Subsidiary 1×7.5A 1×10A 5×15A
Headlight(Hi/Lo) 12V 14.4/13.3W
Position light LED
Light, bulb Tail light LED
Turn light LED
License light LED

3-3
CFMOTO
3.4 Service Specification
3.4.1 Valve Train&Cylinder Head
Service
Standard Remark
Item limit
CF400-5(268MQ-A) CF650-8(283MT)
Valve clearance IN 0.08mm~0.13mm -
(cold engine) EX 0.22mm~0.28mm
C l e a r a n c e , IN 0.02mm~0.08mm -
valve guide
b u s h i n g a n d EX 0.07mm~0.14mm -
valve stem
I . D o f v a l v e IN &
4.5mm~4.512mm -
guide bushing EX
O . D o f v a l v e IN 4.475mm~4.490mm -
stem EX 4.455mm~4.470mm
Free length,
39.5mm±0.68mm 41.6mm
valve spring
W h e n c o m p r e s s e d t o When compressed to
3 5 . 9 m m , e l a s t i c i t y i s 38.4mm, elasticity is
95.5N~111.5N 103N~121N
W h e n c o m p r e s s e d t o When compressed to
Va l v e s p r i n g
2 9 . 1 m m , e l a s t i c i t y i s 30.5mm, elasticity is
force
364.4N~402.4N 422N~466N
W h e n c o m p r e s s e d t o When compressed to
2 8 . 1 m m , e l a s t i c i t y i s 29.8mm, elasticity is
417.6N~461.6N 455N~503N
IN 35.743mm~35.857mm 36.543mm~36.657mm
Camshaft lift
EX 34.743mm~34.857mm 35.843mm~35.957mm -
Camshaft to
0.028mm~1.020mm 0.028mm~0.071mm
hole clearance
O.D of camshaft 223.950mm~23.972mm -
I.D of camshaft
24mm~24.052mm 24mm~24.021mm -
mating hole
Camshaft run-
0.02mm
out
Cylinder head
junction surface 0.05mm
flatness

3-4
 03 Technical Information

3.4.2 Lubrication System

Item Standard Service limit Remark
Outer rotor to inner rotor
0.08mm~0.15mm -
clearance
Outer rotor to pump body
0.15mm~0.193mm -
clearance
Oil pressure 3000r/min 10kPa~30kPa -
Oil type SAE10W-40,API SF or SG -
Change oil 1200mL -
Oil capacity Change filter 1250mL -
At overhaul 1450mL -

3.4.3 Cylinder, Piston, Piston Ring and Connecting Rod

Standard Service
Item Remark
CF400-5(268MQ-A) CF650-8(283MT) limit
Clearance
between piston 0.030mm~0.045mm 0.015mm~0.037mm
and cylinder
Dia. of piston
68.366mm~68.384mm 82.988mm~82.970mm -
skirt
I.D of cylinder 68.4mm~68.418mm 83mm~83.032mm -
Cylinder junction
0.03mm -
surface flatness
Piston ring 1 Ring 0.15mm~0.30mm 0.25mm~0.40mm -
closed gap 2 Ring 0.20mm~0.40mm 0.40mm~0.55mm -
Clearance 1 Ring 0.02mm~0.06mm 0.03mm~0.07mm
between piston
2 Ring 0.02mm~0.06mm 0.02mm~0.06mm -
ring and groove
Thickness of 1 Ring 0.97mm~0.99mm 0.87mm~0.89mm -
piston ring 2 Ring 0.97mm~0.99mm 0.97mm~0.99mm -
1 Ring 1.01mm~1.03mm 0.92mm~0.94mm -
Width of piston
2 Ring 1.01mm~1.03mm 1.01mm~1.03mm -
ring groove
Oil ring 1.5mm~1.52mm 1.510mm~1.525mm
O.D of piston
17.996mm~18mm 18.996mm~19mm -
pin
I.D of connecting
18.01mm~18.02mm 19.01mm~19.02mm -
rod small end
Connecting rod
big end side 41mm~41.016mm 41mm~41.016mm -
clearance
Connecting
rod big end 22.85mm~22.9mm 22.85mm~22.9mm -
thickness
Crankshaft run-
0.02mm 0.02mm -
out

3-5
CFMOTO
3.4.4 Clutch and Transmission
Item Standard Service limit Remark
Friction disc 2.95mm~3.05mm 2.8mm
Quantity 7
Steel plate A 1.92mm~2.02mm -
Quantity 1
Steel plate B 2.42~2.52
Quantity 5
Driven disc deformation 0.15mm 0.30mm
Free length of clutch spring 33.1mm~34.1mm 32.6mm
Quantity 5
Thickness of gearshift fork 5.9~6.0(268MQ-A) 4.8~5.0(283MT)
3.4.5 Cooling System
Item Standard/Specification Service limit Remark
CF400-5(268MQ-A) CF650-8(283MT)
Start temp. of thermostat 80°C~84°C 70°C~74°C -
Lift range of thermostat valve When 95°C, ≥8mm When 85°C, ≥8mm -
Open pressure of radiator cap 108kPa -
Temperature (°C) Resistance (kΩ) -
The relationship between
-20 15.04
the resistance of water
20 2.45
temp. sensor and
80 0.318
temperature
120 0.11
-35°C anti-rust and anti-freeze fluid with -
Coolant type
high boiling point
3.4.6 Air Inlet System
Item Specification Remark
CF400-5(268MQ-A) CF650-8(283MT)
Throttle model 0MQ0-173000 0700-173000-60000
Idle air control valve (canister
018B-172000
control valve)
Idle speed 1450r/min±145r/min
3.4.7 Electrical System
Item Specification Remark
Model NGK CR7E
Spark plug
Gap 0.7mm~0.9mm
Spark >8mm, 1MPa
Primary 740MΩ~780MΩ
Ignition coil resistance
Secondary 10.1kΩ~11.1kΩ
Magneto coil resistance Trigger 100Ω~160Ω
Magneto Voltage, unloading state
>50V(AC),5000r/min
(cold engine)
Max power 280W,6000 r/min
Stabilized voltage 13.5V~15.0V,5000r/min
Primary peak voltage, ignition coil 12V
Peak voltage, trigger coil >1.5V
Starter relay coil resistance 3Ω~5Ω
Starter auxiliary relay coil resistance 90Ω~100Ω

3-6
 03 Technical Information
3.5 Tighten Torque
3.5.1 Tighten Torque Table for Vehicle
Item Torque N•m(kgf•m) Item Torque N•m(kgf•m)
M5 screw
4(0.4)
M5 bolt, nut 5(0.5) M6 screw
9(0.9)
M6 bolt, nut 10(1.0) M6 SH flange bolt
10(1.0)
M8 bolt, nut 22(2.2) M6 flange bolt and nut
12(1.2)
M10 bolt, nut 34(3.5) M8 flange bolt and nut
26(2.7)
M12 bolt, nut 54(5.5) M10 flange bolt and
39(4.0)
nut
Please use standard torque if without torque value mentioned below table.
Note: 1. Lubrication oil should be applied on screw thread and contact surface
2. Replace with new ones if self-locking bolts are removed.
Thread dia. Torque N·m
Item Qty. Remark
(mm) (kgf·m)
Engine
Engine mounting bracket bolt 5 5 30(3.1)
Engine mounting shaft nut 1 14 100(10.1)
Front wheel, front suspension and steering system
Steering column lock nut 1 26 100(10.1)
Handlebar lock screw 4 8 20(2.1)
Front wheel shaft 1 12 65(6.6)
Upper lock bolt, shock absorber 2 8 20(2.1)
Lower lock bolt, shock absorber 4 8 20(2.1)
Rear wheel and rear suspension
Rear wheel shaft nut 1 14 100(10.1)
Upper lock bolt, shock absorber 1 10 40(4.1)
Lower lock bolt, shock absorber 1 10 40(4.1)
Brake system
Mounting bolt, front brake disc 5 8 30(3.1)
Mounting bolt, front brake caliper 2 10 40(4.1)
Muffler
Mounting nut, muffler front exhaust 2 8 26(2.7)
pipe
Mounting nut, muffler body 1 8 20(2.1)

3-7
CFMOTO
3.5.2 Tighten Torque Table for Engine

Thread dia.
Item Qty. Torque N·m Remark
(mm)
Bolt, crankcase 8 M7 20
Bolt, crankcase 6 M8 27.5
Flange, with engine oil and
Bolt, crankcase 4 M8 35
MoS2 grease (ratio 10:1)
With engine oil and MoS2
Bolt, crankcase 6 M9 44
grease (ratio 10:1)
Mounting bolt, breather
2 M6 10 With thread locker
guard
Long thread with thread locker
Hand-tighten,
Mounting stud, cylinder 1 M10 Short thread with engine oil
height limit
and MoS2 grease (ratio 10:1)
M o u n t i n g s c r e w, s h a f t
1 M6 Hand-tighten With thread locker
sleeve press plate (CF188)
Hand-tighten
Lock nut, cylinder 1 M10×1.25
(49)
Mounting bolt, oil pipe IV
2 M6 10 With thread locker
(152MI)
Mounting bolt, breather 4 M6 8 With thread locker
Mounting bolt, lower
6 M6 10 With thread locker
crankcase cover (152MI)
M o u n t i n g s c r e w, o i l
2 M6 8 With thread locker
shielding plate
Mounting bolt, trigger 2 M5 6 With thread locker
Low engine oil warning Hand-tighten
1 R1/8 With silicone sealant
switch (15)
Oil relief valve 1 M12×1.25 15 With thread locker
Screw plug, lower Hand-tighten,
1 M6 With thread locker
crankcase oil rail surface
Plug, main oil rail 1 R23/8 20 With thread locker
3/4″
Mounting bolt, oil filter 1 25 With thread locker
(16 thread/in)
Dowel pin, gearshift shaft
1 M8 29 With thread locker
spring
Mounting bolt, RH side
12 M6 12
cover (152MI)
Hole cap, timing inspection 1 M12×1.5 Hand-tighten
Filler plug 1 3/4″ Hand-tighten
Hand-tighten
Strainer cover (1P72MM) 1 M35×1.5 With engine oil
(25)
Mounting bolt, LH side
11 M6 12
cover (152MI)
Mounting bolt, LH side
1 M6 12
cover (1P52MI)
Bolt, engine oil strainer
2 M6 10 With thread locker
press plate (152MI)

3-8
 03 Technical Information
Thread dia. Torque N·m
Item Qty. Remark
(mm) (kgf·m)
Bolt with lip, cylinder
1 M6 10
head cover (152MI)
Bolt, clutch cable
1 M6 10 With thread locker
bracket (152MI)
New bolt 25→54 With engine oil and MoS2
Bolt, cylinder head 5 M10
Old bolt 25→49 grease (ratio 10:1)
New bolt 25→54 With engine oil and MoS2
Bolt, cylinder head 1 M10×1.25
Old bolt 25→49 grease (ratio 10:1)
Water temp. sensor
1 M12×1.5 12
(1P52MI-B)
Bolt, camshaft seat
8 M6 12
(CF188)
Bolt, camshaft press
4 M6 12
plate (CF188)
Plug 1/2, cylinder head 3 R21/2 Hand-tighten (40) With silicone sealant
With engine oil and MoS2
Bolt, cylinder 1 M8 27.5
grease (ratio 10:1)
I n n e r h e x s c r e w,
cylinder and cylinder 2 M6 Hand-tighten (12)
head (1P52MI-B)
Bolt, timing tensioner
2 M6 12
(172MM-B)
Bolt, timing sprocket 4 M6 15 With thread locker
Pin shaft 1 M8 20 With thread locker
Bolt, tensioner spring
1 M11×1 20
seat
Mounting bolt,
1 M12×1.25 155 With thread locker
magneto rotor
Bolt, crankshaft RPM
1 M8 40 With thread locker
trigger disc
With engine oil and MoS2
Bolt, connecting rod 4 M9×1
40→0→29N•m grease (ratio 10:1)
+30°+70° With engine oil and
Final torque: MoS2 grease on thread
Bolt, connecting rod 4 M9×1
65N•m~90N•m and junction surface
(ratio 10:1)
Bolt, gearshift drum
1 M6 12 With thread locker
cam (152MI)
Neutral gear sensor
Each
screw, gearshift cover M6 Hand-tighten (5) With thread locker
1
screw
S c r e w, g e a r c a s e
1 M6 Hand-tighten (10) With thread locker
bearing guard 1
Nozzle, gear case 1 M5 Hand-tighten, limit No glue

3-9
CFMOTO
Thread dia. Torque
Item Qty. Remark
(mm) N·m
Screw, countershaft fork shaft
1 M6 10 With thread locker
guard 2
Bolt, gear case 9 M7 20 With thread locker
Bolt, oil pipe I plate 1 M6 8 With thread locker
S c r e w, o i l p u m p c h a i n g u i d e
1 M6 10 With thread locker
(152MI)
Screw, oil pump chain guide 1 M6 10 With thread locker
Bolt, oil pump assy (152MI) 3 M6 12 With thread locker
M6 (Left-hand
Bolt, oil pump sprocket 1 12 With thread locker
thread)
Second gear 1 M20×1.5 80
Spark plug 2 M10×1 15
Oil filter 1 M20×1.5 17 With engine oil
Bolt, cylinder head cover 4 M6 10
Nut, counter pulse 1 M20×1.5 125 With thread locker
Nut, clutch 1 M20×1.5 132 With thread locker
Water pump impeller 1 M6 10 With thread locker
Bolt, isolator 3 M8 34 With thread locker
Bolt, magneto stator 3 M6 12 With thread locker
Bolt, position swing arm 1 M6 12 With thread locker
Neutral gear sensor 1 M10×1.25 15
Drain bolt 1 M12×1.5 30
Clutch press spring 5 M6 10
Tighten bolt, oil pan 10 M6 12
Speed sensor 1 M5 8 With thread locker
Drain bolt, water pump cover 1 M6 7
Bolt, starter motor (152MI) 2 M6 12 With silicone sealant
Bolt, clutch cable bracket (152MI) 2 M6 10 With silicone sealant
Screw, gearshift drum press plate 2 M6 5 With thread locker
M5 4.5~6
Other bolts M6 8~12
M8 18~25

3-10
 03 Technical Information
3.6 Consumption Materials&Assembling Materials
Consumption materials include lubricant oil (engine oil), lubricant grease (butter) and
coolant. Assembling materials include flange sealants, thread locker.
3.6.1 Vehicle Consumption Materials
Application areas Notes Type
Vehicle’s head pipe, bearing
races
Front wheel dust-proof seal lip
Rear brake cam movable
parts, cam
Junction, dashboard soft shaft
Shaft joint, throttle cable
Multi-purpose lithium base
Throttle handlebar part
lubrication oil
Pivot, rear pedal(LH),
Pivot, rear pedal(RH),
Pivot, side stand
Rear fork oil seal lip
Counter gear/small gear
surface and movable parts
Main bracket shaft
Thread of rear wheel axle
nut and joint Engine oil
Handle bar inner surface
Lower dust-proof seal lip of Absorber oil 5#
front shock absorber

3.6.2 Engine Consumption Materials&Assembling Materials

Item Specification Using parts Remark
Rotation and moving
Oil Capacity:
section in cylinder,
For 4-stroke motorcycle 1200mL (oil change)
crankcase and
Lubricant oil SAE15W-40, API SF or 1250mL(oil and filter
cylinder head.
SG change)
Details refer to
1400mL(at overhaul)
lubricant chart.
Piston pin, valve
Lubricant oil with
stem, valve oil seal,
molybdenum
camshaft
Oil seal, o-ring and
#3 MoS2 lithium
Lubricant grease rubber seal face,
grease
bearing with sealant
-35°C anti-rust and
C o o l i n g s y s t e m , Capacity depends on
Coolant anti-freeze fluid with
water seal installation radiator water pipes
high boiling point
Crankcase faying
face , crankcase and
Flange sealant cylinder joint cylinder
head and cylinder
head cover joint
Tread locker Parts of thread

3-11
 04 Seat and Side Box
4.1 Seat�������������������������������������������������������������������������������������������������������� 4-1
4.2 Side Box������������������������������������������������������������������������������������������������ 4-2

4.1 Seat

Removal
Insert the key into seat lock 1 . 2

Turn the key clockwise.

Remove rear seat 2 .
1

040101

Remove two M6 bolts 3 .

Remove front seat 4 from the rear side.

4
040102

Installation
Insert the seat limit hook 5 into the clasp 6
. 5

040103

040104

Install two M6 bolts 7 .

040105

4-1
CFMOTO

Insert rear seat limit hook 8 into the clasp

10 .

8
9

040201

Insert the seat lock hook 9 into the lock

seat 11 .
10

11

Installation
Reverse the removal procedures for 040202
installation.

4.2 Side Box

When the vehicle is equipped with side
boxes, please follow the procedures for
removal. 1

Removal
Insert the key into seat lock 1 .
Turn the key clockwise. 040203

Turn up side box handle 2 . 2

Turn up lock press cover 3 .
Push the side box from behind. 3
RH side box removal refers to LH side box
removal procedures.
040204

4-2
 04 Seat and Side Box
Remove four M8 inner hex bolts 4 .

4
4

040301

Remove two M8 inner hex bolts 5 .

Remove two M8 bolts 6 .

040302
Remove side box brackets 7 .

7
Installation
Reverse the removal procedures for
installation.
040303

4-3
 05 Headlight Assy and Fuel Tank Assy

5.1 Headlight Assy��������������������� 5-1 5.1.5 LH Panel and RH Panel5-2

5.1.1 Rear View Mirror����������� 5-1 5.1.6 Engine Guard���������������� 5-2
5.1.2 Windshield �������������������� 5-1 5.1.7 Reservoir LH Inner Plate
5.1.3 Headlight Upper Plate�� 5-1 ������������������������������������������������� 5-3
5.1.4 Reservoir LH Outer Plate 5.1.8 Headlight Assy�������������� 5-3
������������������������������������������������� 5-2 5.2 Fuel Tank������������������������������ 5-3

Danger:
In some situations, the gasoline is highly flammable and explosive.
Do not overfill the fuel tank. When the fuel reaches the neck of the oil filler, it is
the maximum capacity.
The engine must be stopped when refueling and must be refueled in a well-
ventilated area or outdoors
No smoking, open fire or sparkle in the refueling area or gasoline storage area.
If gasoline spills onto the skin or clothing, wash immediately with soap and water
or change the clothes.
Seek medical attention immediately if accidentally contact your eyes or swallow
gasoline.

5.1 Headlight Assy

5.1.1 Rear View Mirror 2

Removal
Remove four M6 inner hex bolts 1 . 1
Remove rear view mirrors 2 .
1

Installation 050101
Reverse the removal procedures for
installation.

5.1.2 Windshield
Removal 1
Remove four M6 inner hex bolts 1 .
Remove windshield 2 . 2

1 1
Installation
Reverse the removal procedures for
installation. 050102

5.1.3 Headlight Upper Plate

Removal 2
Remove two expansion screws 1 .
Remove headlight upper plate 2 .
1

Installation
Reverse the removal procedures for
installation. 050103

5-1
CFMOTO
5.1.4 Reservoir LH Outer Plate
Removal
Remove three expansion screws 1 .
Remove screw 2 . 2

050201

Remove screw 4 .
Remove reservoir LH outer plate 5 in the
direction of arrow.
Pull out turn light connectors 3 .
Reservoir RH outer plate removal refers to
3
LH outer plate removal.
4

Installation 5
Reverse the removal procedures for
installation.
050202

5.1.5 LH Panel and RH Panel

Removal 4
Remove two expansion screws 1 . 3
Remove bolt 2 .
Remove damp block 3 .
1
Remove LH panel 4 . 2
RH panel removal refers to LH panel 1
removal. 050203

Installation
Reverse the removal procedures for
installation.

5.1.6 Engine Guard

Removal 1
2
Remove two M6 inner hex bolts 1 . 1
Remove two expansion screws 2 . 2
Engine RH guard removal refers to LH
3
guard removal. 050204
Remove engine guard 3 .

5-2
 05 Headlight Assy and Fuel Tank Assy
5.1.7 Reservoir LH Inner Plate
Removal
Remove two M6 bolts 1 .
Remove expansion screw 2 .
Remove reservoir LH inner plate 3 .
2
Reservoir RH inner plate removal refers to 1 1
LH inner plate removal. 3

Installation
Reverse the removal procedures for 050301

installation.

5.1.8 Headlight Assy

Removal 1
Remove two M6 inner hex bolts 1 .
Remove two M6 bolts 2 .
Remove bolt 3 .
2 2

3
050302

6
Remove two expansion screws 4 . 4
Remove two expansion screws 5 .
Remove headlight assy 6 .
Disconnect connectors between headlight 5
and main cable.

Installation 050303
Reverse the removal procedures for
installation.

5.2 Fuel Tank 1

Note: Fuel tank inversion is forbid-

den. Otherwise, the fuel will leak from
fuel tank cover.
Removal 2
Remove two M6 bolts 1 . 050304

Remove seat hook 2 .

Lift the rear part of the fuel tank 3 .

Pull out high-pressure hose quick joint 4 . 7
5
Disconnect fuel pump connector 5 .
6
Remove fuel level sensor 7 .
Remove adsorption tube 6 . 050305
Remove fuel tank 3 .

5-3
CFMOTO
Inspection
If fuel tank and fuel hose has crack, age,
leakage or other deflective factors, replace
in time.

Installation
Reverse the removal procedures for
installation.

Note: When installing fuel tank, all

hoses, pipes and cables can not be ex-
truded.

5-4
 06 Lights, Dashboard and Switches
6.1 Maintenance Information���� 6-1 6.8 Ignition Switch��������������������� 6-4
6.1.1 Operation Caution�������� 6-1 6.9 Front Brake Light Switch���� 6-4
6.1.2 Inspection Standard����� 6-1 6.10 Rear Brake Switch������������� 6-5
6.2 Trouble Shooting����������������� 6-2 6.11 LH Handlebar Switch��������� 6-5
6.3 Dashboard ��������������������������� 6-2 6.12 RH Handlebar Switch�������� 6-6
6.4 Headlight Body�������������������� 6-2 6.13 Horn������������������������������������ 6-6
6.5 Turn Light����������������������������� 6-3 6.14 Fuel Level Sensor�������������� 6-7
6.6 Tail Light/Brake Light���������� 6-3 6.15 Battery�������������������������������� 6-8
6.7 Rear License Light�������������� 6-4

6.1 Maintenance Information

6.1.1 Operation Caution

Warning:
·Headlight bulb has big power and will be very hot when it is turned on. Do not
touch it after it is just turned off. Operation should be done when the bulb is
cooled down
·The temperature of headlight is quite high when turned on. Replacing with bare
hand or stained glove will cause oil stains on the glass face which may form hot
spot and cause deformation of glass face and damage to bulb.
·Pay attention to the followings when replacing the bulb:
-Do not replace the bulb when it is turned on. Keep ignition switch in the OFF
position, and replace after the bulb is cooled down.
-Replace the bulb with hands in clean gloves to avoid oil stains on the glass
surface.
-Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of
any oil stains on the glass surface.
·If the Inspection has to be done check if the battery is normal.
·Inspection of switch continuity can be done without removing the switches from
the vehicle.
·After the inspecting and overhauling of each part, cables and wires should be
routed properly.
6.1.2 Inspection Standard
Item Standard
Main fuse 30A
Fuse
Auxiliary fuse 1×7.5A 1×10A 5×15A
Headlight (Hi/Lo) 12V-14.4/13.3W
Position light LED
Light&Bulb Tail light LED
Turn light LED
License light LED

6-1
CFMOTO
6.2 Trouble Shooting
Head light cannot turn on, Hi/Lo switch
doesn’t work:
Fuse is blown
Switch is damaged
Bulb is burnt
Battery bad connection or no electricity
Wire connector loosen

6.3 Dashboard

Removal
Remove body covering parts first 1
according to the Chapter 5.
Disconnect dashboard connectors.
Remove dashboard lover cover 3 .
Remove two M6 nuts 2 .
Remove dashboard 1 . 3
2
Installation 060201
Reverse the removal procedures for
installation.

6.4 Headlight Body

Removal
Remove the headlight assy first according
to the Chapter 5.
1
Remove ten cross screws 1 on both
sides.
Remove headlight body 2 .
2
Installation
Reverse the removal procedures for 3
installation. 060202

Adjust the light angle and height of low-

beam and high-beam by LH low-beam
adjusting button 3 , RH low-beam adjusting
button 4 and high-beam adjusting button 1
5.

Note: When headlight damages,

replace the whole set.
5 4
060203

6-2
 06 Lights, Dashboard and Switches
6.5 Turn Light
Removal
Remove reservoir outer plate 3 . (See
Chapter 5 Reservoir Outer Plate removal) 1
Remove M5 nut 2 . 2
Remove turn light 1 .
Note: The turn light is consisted of 3
LED lights. When the light damages,
replace the whole set.
060301
Installation
Reverse the removal procedures for
installation.
All turn lights follow the same procedures
to remove and install.

6.6 Tail Light/Brake Light

Rear Armrest
Remove M8 bolts 1 . 1
Remove rear armrest 2 .

060302

Tail Light/Brake Light

Removal
Remove cross screws 1 .
Disconnect connectors with the main
cable.
Remove tail light 2 from behind.
1
Installation
Reverse the removal procedures for
installation. 2
Note: The tail light is consisted of
LED lights. When the light damages, 060303
replace the whole set.

6-3
CFMOTO
6.7 Rear License Light
Removal 1
Remove four M6 bolt 1 .
Remove rear fender 2 .

060401

Remove four cross screws 4 .

Disconnect connectors with the main
cable. 3
Remove rear license light 3 .
Note: The license light is consisted
of LED lights. When the light damages,
replace the whole set. 4

060402

6.8 Ignition Switch

Inspection
Pull out the connectors between ignition
switch 1 and main cable to check its
performance.
Action/Color G BW R B
● ● 1
● ●
● ●
060403

6.9 Front Brake Light Switch

Pull out the connectors between front
brake light switch 1 and main cable to
check its performance.
1) Grip front brake lever, the brake light is
on.
2) Loosen front brake lever, the brake light
is off.
1 060404

6-4
 06 Lights, Dashboard and Switches
6.10 Rear Brake Switch
Pull out the connectors between rear brake
light switch 1 and main cable. Inspect rear
brake switch for its performance. 1

1) Press rear brake pedal, the rear brake

light is on.
2) Loosen rear brake light is off.

060501

6.11 LH Handlebar Switch

Pull out the connectors between LH
handlebar switch 1 and main cable to
check its performance.
1 2
Dimmer switch 1
Color
W L Br W B W Br G
Action
3
● ● ● ●
● ● ● ●
4
060502
Mode Switch 2
Color
Lg/G G Br G
Action
MODE
● ● ● ●
（ON） 5
MODE
● ●
（OFF）
R

Horn switch 3
Color 060503
B Br Lg Br G
Action
● ● ● ●
R

Turn switch 4
Color
O Gr Sb Br G
Action
● ● ● ●
● ● ● ●
R

Override switch 5
Color
B Br Br W Br G
Action
● ● ● ●
R

6-5
CFMOTO

6.12 RH Handlebar Switch

Pull out the connectors between RH
handlebar switch 1 and main cable to 1
check its performance.
Stop switch slider 1
Color
Br B B Br Br G
Action
2
● ● 3
● ● ● ● 060601
R
CN
Start switch slider 1
Color
Br B Y R Br G
Action
● ● ● ●
R

1
Warning switch 2
Color
O Gr Sb Br G
Action
● ● ● ● ● 2
(ON)
● ●
(OFF)
R 060602

EU

Illumination switch slider 3

Color
Br W G W L Br G
Action
● ● ●
● ● ● ●
● ● ● ● ●
R

6.13 Horn
Pull out horn connector. Connect with 12V
battery to check If the horn works well and
the sound is loud and clear. Otherwise,
replace with a new horn.

060603

6-6
 06 Lights, Dashboard and Switches
6.14 Fuel Level Sensor
Removal
Remove four M6 mounting nuts 1 .
Remove fuel lever sensor 2 .
1
Note: Remove fuel level sensor
slowly, in case it deforms.
2

1
060701

Inspection
Inspect fuel level sensor seal ring 3 1
for deformation, damage or hardening.
Replace if it does.
Check the electrical resistance of the oil
level sensor at high and low poles.
Resistance:
2
High: 4~10 Ω
Low: 90~100 Ω 3

060702

1 High 2 Low

Connect fuel level sensor and main cable.

Turn on ignition switch, the floater of fuel
level sensor swings up and down slowly.
See the fuel gauge pointer on dashboard.
If the pointer can not reach F or E, it
means the fuel gauge is not qualified,
1
replace a new one.
If the pointer swings unsteadily, it means
the fuel gauge is not qualified, replace a 060703
new one.

Installation
Reverse the removal procedures for
installation.

Note: Check leakage after fuel level

sensor installation.

6-7
CFMOTO

6.15 Battery
Warning:
1. Battery acid and gas will produce serious corrosion, avoid contacting with
battery acid and gas.
2. Keep batteries out of reach of children.
3. When battery acid contacts skin, wash with plenty of water. If battery acid
enters the eye, flush with water for at least 15 minutes and seek for medical help.
Note:
1. Please wear protective clothing and goggles. Keep the battery away from
sparks and open fire. Only charge the battery in a well-ventilated room.
2. Do not mis-connect the positive and negative pole of battery. Remove the
negative wire first if disassembling battery, in case it damages electrical elements.
The system of this vehicle uses negative earth mode.
3. Battery wires are not allowed to be removed while the engine is working.
4. Battery positive/negative wires and electrical control units have to be removed
before welding on the vehicle.
5. It is forbidden to puncture the wire to test the input/output electrical signals.
6. Establish the awareness of environmental protection and effective disposal of
waste generated during maintenance.

Removal
Remove seat.
Remove battery negative wire fixing bolt.
Remove negative wire 1 from the battery. 3
Remove battery positive wire fixing bolt. 1 2
Remove positive wire 2 from the battery.
Remove battery 3 .

Warning: Negative wire must be

removed first. Otherwise, it will cause
battery short circuit. 060801

Installation
Reverse the removal procedures for
installation.
Note:
1. Even if the battery is not used, it also loses power every day.
2. Charging condition and charging mode are very important for the service life
of the battery. Using high charging current will have a negative impact on the
service life.
3. If the charging current, charging voltage and charging time are exceeded, the
battery will be damaged.
4. If the battery becomes empty due to repeated start of the vehicle, it needs to be
charged immediately.
5. When the battery is stored in the discharge condition for a long time, deep
discharge and sulfuric acid salination will occur, which damages the battery.
6. The battery does not need to be maintained, which means the acid level does
not need to be checked.

6-8
 06 Lights, Dashboard and Switches
Charge

Shut down all the electrical devices and

engine.
Remove battery.
Connect charger and battery.
After charging, remove the charger from
the battery.

Note: If the vehicle is not used,

recharge the battery every three
months.

Charging Voltage Inspection

The battery has proper performance and is
fully charged.
Start the vehicle and measure the voltage.
Measuring point is positive pole (+), the
other measuring point connects ground (-).
Charging Voltage
5000rpm 13.5V~15.0V

If less than specification:

Inspect the connectors between engine
and regulator.
Inspect the connectors between regulator
and cables.
Inspect engine electronic winding.
If more than specification:
Replace regulator.

6-9
 07 Air Filter Assy
7.1 Air Filter���������������������������������������������������������������������������������������������� 7-1

7.1 Air Filter

Note: Check air filter every 12,000km.

Clean or replace it if necessary. The
Air filter maintenance should be more
frequent when in severe environment.

Removal
Loose two clasps 1 .
1
Loose Clamp 2 . 3
Remove breather hose 3 .

Remove the air filter 5 in the direction of 2

070101
the arrow.

Inspection
If air filter has jams, less air input, lower
power, increasing fuel consumption,
inspect and clean air filter following the 2

procedures below:
•Loose screw 1 . 1
•Remove filter element assy 2 from air
filter.
•If there is too much dirty in filter element 070102
2 , use high-pressure air to clean it.
•Inspect air filter element for damage.
Replace if necessary.

Note: Keep filter element clean

during operation. Engine quickens
damaged if working without, or with
dirty or broken filter. Frequently clean
filter, if working in dirty situation.

•Check the air intake pipe 3 . If dust in it,

clean it by detergent.
•Check oil storage hose 4 if engine oil
remains. If it does, remove clamp 5 and 6
oil storage hose 4 and clean up the
engine oil in hose.
•Check if seal ring 6 of air filter breaks. If 5
3
it does, replace a new one.
Installation 4
Reverse the removal procedures for
070103
installation.
Note: Ensure all parts be fixed and
sealed reliably.

7-1
 08 Electrical System
8.1 Service Tool��������������������������������������������������������������������������������������� 8-2
8.2 Charging System������������������������������������������������������������������������������� 8-4
8.2.1 Charging Diagram����������������������������������������������������������������������� 8-4
8.2.2 Magneto Coil Resistance����������������������������������������������������������� 8-4
8.2.3 MAG Non-loaded Performance�������������������������������������������������� 8-4
8.2.4 Regulator������������������������������������������������������������������������������������� 8-5
8.3 EFI������������������������������������������������������������������������������������������������������� 8-6
8.3.1 EFI Structure������������������������������������������������������������������������������� 8-6
8.3.1.1 Sensors��������������������������������������������������������������������������������� 8-6
8.3.1.2 ECU���������������������������������������������������������������������������������������� 8-6
8.3.1.3 Actuators������������������������������������������������������������������������������� 8-6
8.3.2 EFI System Maintenance Notice������������������������������������������������ 8-7
8.3.3 Structure and Performance of EFI Parts���������������������������������� 8-8
8.3.3.1 ECU���������������������������������������������������������������������������������������� 8-8
8.3.3.2 Throttle Body������������������������������������������������������������������������ 8-9
8.3.3.3 T-MAP���������������������������������������������������������������������������������� 8-10
8.3.3.4 Water Temp. Sensor����������������������������������������������������������� 8-12
8.3.3.5 Oxygen Sensor������������������������������������������������������������������� 8-13
8.3.3.6 Trigger �������������������������������������������������������������������������������� 8-14
8.3.3.7 Speed Sensor��������������������������������������������������������������������� 8-15
8.3.3.8 Fuel Pump��������������������������������������������������������������������������� 8-16
8.3.3.9 Fuel Injector������������������������������������������������������������������������ 8-17
8.3.3.10 Idle Air Control valve������������������������������������������������������� 8-18
8.3.3.11 Ignition coil����������������������������������������������������������������������� 8-19
8.3.3.12 Roll-over Sensor�������������������������������������������������������������� 8-20
8.3.4 Self-diagnosis��������������������������������������������������������������������������� 8-21
8.3.4.1 Malfunction Indicating Lamp (MIL)����������������������������������� 8-21
8.3.4.2 PDA�������������������������������������������������������������������������������������� 8-22
8.3.4.3 Fault Code��������������������������������������������������������������������������� 8-23
8.4 Fault Diagnosis and Treatment������������������������������������������������������ 8-24
8.4.1 Engine Body������������������������������������������������������������������������������ 8-24
8.4.2 Fault Treatment������������������������������������������������������������������������� 8-27

8-1
CFMOTO

8.1 Service Tool

Tool: PDA

Function:
Read erase trouble code of EFI system,
observe data flow and accessories test
etc.

080201

Tool: Digital multimeter

Function:
Inspect the parameter of EFI system like
voltage, current and resistant etc.

080202

Tool : Vacuum gauge

Function:
Inspect the pressure of air inlet hose.

080203

8-2
 08 Electrical System

Tool: Ignition timing light

Function:
Inspect ignition timing of the engine.

080301

Tool: Cylinder compression gauge

Function:
Inspect the cylinder pressure of the engine

080302

Tool: Oil pressure gauge

Function :
Check the pressure of fuel system and
judge the working condition of fuel pump
and oil pressure regulating valve in fuel
system.

080303

Tool: Fuel injector cleaning analyzer

Function:
Analyze the cleaning of fuel injector.

080304

8-3
CFMOTO
8.2 Charging System
8.2.1 Charging Diagram

1
4 5

080401

1 Magneto 3 Fuse 5 Load

2 Stable Voltage 4 Battery 6 Regulator

8.2.2 Magneto Coil Resistance

●Measure 3-phase magneto stator coil
resistance.
●If the resistance is out of specification,
replace with a new stator.
●Check for the insulation between stator
coil and core.
Turn multimeter to 1×10Ω
MAG Coil Resistance:
0.5Ω~1.5Ω (Yellow-Yellow) 080402
Resistance between Stator Coil and Core:
∞Ω (Yellow-Ground)

8.2.3 MAG Non-loaded Performance

●Start the engine and allow it run at 5000r/
min. Use multimeter to measure the
voltage between 3 output lines.
●If the reading is below specification,
replace with a new magneto.
Turn Multimeter to V(AC).
Voltage between Output Lines When MAG
Non-loaded:
>50V(AC) at 5000r/min 080403

8-4
 08 Electrical System
8.2.4 Regulator

080501

1 IN3 2 IN2 3 IN1 4 OUT 5 NC 6 GND

After engine running and at the state of battery full charged, of which the RPM is about
5000r/min, if the voltage between positive and negative terminal exceeds 15V or is lower
13.5V, replace with a new regulator.

8-5
CFMOTO
8.3 EFI
8.3.1 EFI Structure

3
7

1
6 8

4
9

2
10

11

080601
1 Air filter 5 Roll-over sensor 9 Water temp. sensor
2 ECU 6 Injector 10 Trigger
3 Stepping motor 7 Ignition coil 11 Fuel pump assy
4 Throttle body 8 Oxygen sensor

parameters a engine needs to keep

8.3.1.1 Sensors running by calculating and analyzing
A sensor is a device that measures a values provided by sensors.
physical quantity and converts it into a
signal which can be read by an observer or 8.3.1.3 Actuators
by an instrument. Sensors in EFI system Actuators execute the EFI instruction. Main
include: actuators include:
Air pressure sensor (Air density and ●Fuel Pump (Provide high-press fuel)
pressure information) ●Fuel Injector (Inject the fuel to make it
Air temp. sensor (Air density information) spray better)
TPS (Load, load range, speed information) ●Ignition Coil (Provide high ignition
Trigger (crankshaft information) energy to spark plug)
Water temp. sensor (engine temp.) ●Idle Air Control Valve (Provide idle inlet
Speedometer sensor (Output shaft RPM air)
information)
Oxygen sensor (Air factor= λ >1 or <1)
Roll-over gear sensor (Output vehicle
gradient information)

8.3.1.2 ECU
Electronic Control Unit, the brain of EFI
system,which determines the amount of
fuel injection, ignition timing and other

8-6
 08 Electrical System

8.3.2 EFI System Maintenance Notice ●If possible, don’t do the spark test. If
●Always use genuine CFMOTO parts for spark test is done unavoidably, try to
maintenance. Otherwise it can not assure complete the test as soon as possible.
a normal performance to EFI system. Besides, don’t open the throttle, otherwise,
●During the maintenance procedure, never a large quantity of unburnt fuel would enter
try to break down the EFI components. muffler, causing the catalytic converter
●In the course of maintenance, EFI parts damage.
must be handled carefully. ●Idle speed is controlled by ECU, so it’s
●Ignition switch must be shut off before unadjustable. The throttle limiter screw
connecting or disconnecting connectors. has been adjusted by manufacturer before
Otherwise, it may cause the EFI parts sale. Therefore, it’s not recommended to
damage. adjust it by the user.
●When removing fuel pump from fuel tank, ●Don’t reverse the battery cable
do not energize the fuel pump. Otherwise, connections. This may damage electrical
a spark can cause a fire. components.
●Fuel pump is not allowed to operate ●Never remove the battery cables When
in a dry environment or under water. the engine is running.
Otherwise, its life would be shortened. ●Always remove cables and electrical
Besides, reverse connections between control units which are connected with
positive and negative terminal of fuel pump battery terminals.
is not permitted. ●Never test the component input and
●The fuel pressure in EFI fuel supply output electric signal by piercing the cable
system is very high (about 330kPa), plastic jacket.
accordingly, all fuel lines are high pressure ●Respect the environment and dispose of
resisting. Even if the engine is not running, the waste left during maintenance.
the fuel pressure is high. Therefore, do
not disassemble the fuel line unless it’s
necessary.
When the fuel line needs to be repaired,
release the fuel pressure as follow shows:
Remove fuel pump relay, start the
engine and allow it to idle until the
engine stalls automatically.
Fuel line removal and fuel filter replacement
should be practiced by a professional
person in a well-ventilated place.

8-7
CFMOTO
8.3.3 Structure and Performance of EFI ECU
Parts
8.3.3.1 ECU
Electronic control unit , is the brain of EFI
system. It analyzes and cope with the
information provided by sensors, and send
the conclusion in the form of instruction to
actuator, then make the engine run in the
optimal condition.
080801
ECU pin

080802
ECU pin function:
Oxygen sensor heated Stepping motor phase Uninterrupted battery
1(M1) 17(B1) 33(F3)
2 D (UBD)
Oxygen sensor heated Stepping motor phase
2(L1) 18(A1) 34(E3) K-line
1 C
Oxygen sensor signal
3(M2) Ignition 1 19(K2) 35(D3) Neutral switch
1
Oxygen sensor signal
4(L2) Unused 20(J2) 36(C3) Ignition diagnosis 1
2
5(M3) Ignition to ground 21(H2) Ignition diagnosis 2 37(B3) Clutch switch
6(L3) Unused 22(G2) Unused 38(A3) Roll-over switch
Touring/Sport mode
7(M4) Ignition 2 23(F2) Side stand switch 39(K4)
switch
Interruptible battery
8(L4) 24(E2) Unused 40(J4) RPM output
UBR1
Intake air pressure
9(K1) 25(D2) Unused 41(H4) Speed sensor
sensor 1 (DS)
10(J1) Sensor to ground 1 26(C2) Starter relay 42(G4) RPM sensor B
Intake air temp. sensor Stepping motor phase
11(H1) 27(B2) 43(F4) RPM sensor A
(TANS) A
Stepping motor phase
12(G1) TPS (DKG) 28(A2) 44(E4) Headlight relay
B
Engine temp. sensor
13(F1) 29(K3) MIL 45(D4) Fan relay
(TMOT)
14(E1) Main relay 30(J3) 5V output 1 46(C4) Fuel pump relay
15(D1) CANL 31(H2) Unused 47(B4) Fuel injector 2
16(C1) CANH 32(G3) Ignition switch KL15 48(A4) Fuel injector 1

8-8
 08 Electrical System
Limit Data:

Value
Item Unit
Min. Standard Max.
Normal 9 14±0.1 16 V
Battery voltage
Limit function 6.0~9.0 16.0~18.0 V
Limit and time
Keep part of function, can
of battery over 26.0V 5 min
diagnose the trouble
voltage
Working temperature -40 70 °C
Storage temperature -40 70 °C

Note: It is not allowed to load on

housing or cover. Gently handle it. Do
not drop it on the ground.

8.3.3.2 Throttle Body

Connect with air filter and the engine,
control the on-off angle of throttle by
throttle cable. Send out the angle signal
through TPS to ECU.
A
3
2
Pin Function:
1 connects ECU pin 10 (ground). 1

2 connects ECU pin 30 (5V power).

3 connects ECU pin 12 (output voltage
signal). 080901

A TPS

ECU connection circuit:

ECU

TPS 080902

8-9
CFMOTO

Note: Engine idle is completely

controlled by EFI system. Do not adjust 1
idle limit screw 1 manually.
It is not allowed to load on housing or
cover. Gently handle it. Do not drop it
on the ground.

081001
8.3.3.3 T-MAP A B C D
This sensor monitor inlet air pressure,
which provides the engine load signal to
ECU.

Pin Function:
A connects ECU pin 9 (inlet air pressure
signal).
B connects ECU pin 30 (5V voltage).
C connects ECU pin 11 (inlet air temp.
081002
signal).
D connects ECU pin 10 (sensor to ground
1).

Sensor connection circuit:

ECU
T-MAP 081003

The right picture shows the allowable

mounting range, which ensures that
condensation does not form inside the
sensor, as the condensation damages
pressure sensitive elements within the 60° 60° 60° 60°
sensor. 081004

8-10
 08 Electrical System

The relationship between output voltage and pressure.

Pressure range: 10~115kPa
5
4.65
Output Voltage Uout in V

0.4
0
0 10 115
Absolute Pressure Pabs in KPA 081101

The relationship between sensor temperature and resistance.

60000

50000

40000

30000

20000

10000

-10000
Temp. (°C) Resistance (OHM) 081102

8-11
CFMOTO
8.3.3.4 Water Temp. Sensor
This sensor is a NTC thermo resistance.
The resistance becomes lower when the
air temperature becomes higher, but it is
not a liner relationship.
One group of parameters is sent to ECU
to monitor engine temperature condition, 081201
One group is sent to dashboard to monitor
coolant temperature condition.
A and C are one group which provides Dashboard
water temperature signal to the ECU.
Through ECU, B sends the water
temperature signal to dashboard.

Sensor connection circuit:

ECU
Water temp. sensor
081202

Resistance between A and

Temp. °C
C (KΩ)
-20±0.1 13.71~16.94
The right table shows the relationship 25±0.1 1.825~2.155
between temperature and resistance. This 80±0.1 0.303~0.326
signal is sent to ECU. 110±0.1 0.1383~0.1451

8-12
 08 Electrical System
8.3.3.5 Oxygen Sensor
This sensor is used in closed-loop
feedback controlled fuel injection to
improve the air-to-fuel ratio accuracy and
control the emission. It’s located in the
exhaust stream to measure the amount
of oxygen in exhaust and send the signal
to ECU, which can revise the fuel injector
output, so as to reduce the amounts of 4
unburnt fuel and make catalytic converter
3
convert HC, CO and NO X of Nitrogen
efficiently. 2
1
Pin Function:
4 Output signal voltage +
3 Output signal voltage -
2 Heated ground -
1 Heated power +
081301

Sensor connection circuit:

ECU Oxygen sensor 2 Oxygen sensor 1

081302

8-13
CFMOTO
8.3.3.6 Trigger Trigger
The trigger transfers signal of engine
speed to ECU and by which ECU to
confirm engine speed ignition angle and
injecting phase.

081401

Trigger connection circuit:

Measure trigger resistance

Set multimeter to 1×100Ω range.
Trigger coil resistance: 100Ω~160Ω(20°C) Trigger
Replace a new one when resistance is not ECU
within above value range.
081402
Measure trigger peak voltage
Connect multimeter and peak voltage
adapter as shown as right picture
+Probe: Green (A) wire
-Probe: Blue (B) wire

Note: Refer to owner manual when Magneto

using peak value voltage adapter.
Trigger resistance
081403

Set multimeter to ACV range.

Set engine to Neutral gear, turn on ignition Peak voltage gauge
switch.
Press starter button and keep engine
running for seconds, then measure trigger
coil peak value voltage.
Repeat a few times and record the highest
value. Magneto
Trigger coil peak value voltage: ≥2V (300r/
min) Trigger peak voltage
Replace a new one when peak value 081404
voltage is not within above value range.

8-14
 08 Electrical System
8.3.3.7 Speed Sensor
This sensor provides engine output shaft Speed sensor
speed to ECU. Then ECU can calculate
1 2
the speed according to this signal. It is
a hall switch type device, which outputs
square wave by the change of the
magnetic field. 3

Pin Function:
1 Connecting ground
081501
2 Battery +DC 12V
3 Output voltage signal yellow (>80% of
input voltage)

Sensor connection circuit:

3 +12V voltage
ECU
1 2

Hall switch
Ground

Speed sensor
081502

Speed Sensor Inspection

Ground pin 1 and pin 2 with +12V power.
Fix the gear 1 2.5mm away from the
speed sensor as the picture shows.
Turn multimeter to DCV.
Slowly turn the gear and measure the
voltage between pin 2 and pin 3 to
determine that if the reading varies from
1
0V~12V
If the reading doesn’t vary, it indicates
the sensor is defective and needs to be
replaced.
081503

8-15
CFMOTO
8.3.3.8 Fuel Pump
The right picture shows the fuel pump
assy, fuel pump relay and ECU wiring
diagram.
This fuel pump assy consists of fuel pump,
plastic bracket, fuel strainer, fuel filter
element and pressure-regulating valve. It
delivers fuel from the tank to the engine at
a certain oil pressure and flow rate.

Pin function: 1 2
1 Blue (Ground)
2 Red (+12V)
Performance parameter: 081601
Pressure-regulating valve open pressure:
0.33MPa±0.01MPa
Flow rate: 45L/h When servicing EFI system, release the
Do not run the fuel pump assy when there pressure before removing the fuel hose.
is no fuel inside the fuel tank, in case of The release method is like:
fuel pump damage. Remove the fuel pump relay. Start the
Handle the fuel pump gently. Do not drop it engine and make it idle until the engine
on hard surfaces. stops automatically.
The battery supplies power to the fuel
pump through the relay. Only when starting
or running the engine can the circuit be
switched on.

Measure fuel pressure:

Connect oil pressure gauge and fuel pump
oil port, lock with clamp to ensure there is
no leak form the junction.
Connect the circuit as the picture shows.
Turn on ignition switch and stop switch.
The fuel pump will work for 5 seconds.
When stop working, the oil pressure should
reach the specified value. Otherwise,
replace with a new fuel pump.
After stopping working, the pressure
should maintain 0.2MPa for at least 5
minutes. Otherwise, replace fuel pump
assy.
Fuel hose pressure release method:
The fuel supply pressure in EFI system
is high, all fuel hoses are high-pressure
resistance. Even the engine does not
work, the pressure in fuel passage is
still high. So when in the maintenance
process, be careful not to remove the fuel
hose causally.

8-16
 08 Electrical System

8.3.3.9 Fuel Injector

One end of fuel injector mounts into fuel Injector cap
injector seat, and the other end attaches
to the injector cap, which connects with a
fuel line. Fuel injector is controlled by ECU 2 1

to inject fuel at stated time into the engine.

This injector nozzle is a 4-hole style. Don’t
turn injector after the joint between injector
and injector cap is installed.

Pin function:
2 Fuel pump relay output
1 Injector 1 connects ECU pin 48.
1 Injector 2 connects ECU pin 47. Connect fuel
injector sear 081701
Fuel injector resistance: 12.5Ω±1Ω ( 20°C)

Injector connection circuit:

Fuel pump relay

Fuel Injector Installation

Install fuel injector manually. Never knock
fuel injector with a hammer.
When removing and installing fuel
injector, the O-rings on both ends must be
replaced.
Perform pressure relief before fuel injector
removal if necessary.
Te s t t h e f u e l i n j e c t o r s e a l i n g a f t e r ECU
installation to ensure no leaks. Injector 1 Injector 2 081702

8-17
CFMOTO
8.3.3.10 Idle Air Control valve

IACV is used to control the air flow of by-

pass. ECU calculates the engine load
and controls IACV through electrical
pulse duration and frequency (commonly
known as duty ratio). IACV allows
different air flows passed through under
different pressure. Therefore, it should Idle air control valve
be connected properly. Otherwise, idle 081801
speed may be incorrect. When there is no
electrical pulse, IACV would be closed.

Idle air control valve circuit:

ECU
Idle air control valve
081802

Idle air control valve parameters

Value
Item Unit
Min Standard Max
Rated voltage 13.5 V
+20°C resistance 16 Ω
Rated current 0.85 A
Control pulse frequency 30 HZ
Standard control pulse width ≌8 ms
A i r F l o w ( W h e n p r e s s u r e d i ff e r e n c e =
5 m3/h
700mbar, duty ratio=100%)

8-18
 08 Electrical System
8.3.3.11 Ignition coil
Ignition coil transforms the low voltage of
primary coil to high voltage of secondary 1
coil needed to spark the spark plug and
ignite the mixture of air and fuel in cylinder.

Pin function: 2
1 connects power. 081901
2 connects signal.

Injector

Ignition coil connection circuit:

ECU

Ignition coil & Ignition coil &

spark plug 2 spark plug 1 081902

Secondary Ignition Voltage Test:

●Connect the engine according to EFI
wiring diagram.
●Connect the peak voltage tester according Peak voltage measurement
to the right diagram.
●Start the engine.
●Secondary ignition voltage should be
more than 15 kV.

Battery
ECU
Spark plug

081903
Ignition coil parameter chart table:

Item Value
Min Standard Max Unit
Stated Voltage 14 V
Operating Voltage 6 16.5 V
Primary 0.74 0.76 0.78 Ω
Resistance
(20°C~25°C) Secondary 10.1 10.6 11.1 kΩ
Primary Current 7 A

8-19
CFMOTO
8.3.3.12 Roll-over Sensor
1
Roll-over sensor is used for preventing
vehicle from tilting. When vehicle’s tilt 65°±10° 65°±10°
angle is larger than settled tilt angle, an
“OUT” signal will be transferred to ECU.
ECU will stop the engine.

082001
1 Tilt angle

The “UP” faces upward when installing as

picture shows.

082002

1 2
Connect the engine as EFI diagram shows:

082003

1 VCC 2 GND 3 OUT

8-20
 08 Electrical System
8.3.4 Self-diagnosis
ECU constantly monitor sensors, actuators and circuits, MIL and battery voltage, etc,
even ECU itself and inspect the sensor output signal, actuator drive signal and internal
signal (such as close loop control, coolant temperature, idle speed control and battery
voltage control, etc.) for reliability. If any process or signal is suspect, ECU records the
trouble code in the RAM memory.
Faulty information is recorded in the form of trouble code, and in the sequence of which
trouble comes first.
When servicing, using PDA and MIL, the defective parts can be promptly found to
improve the service efficiency and quality.

EFI system is mainly diagnosed by MIL

2
and PDA.

8.3.4.1 Malfunction Indicating Lamp

(MIL)
1
3
It indicates different fault codes through
the flashes in different frequency.
The right picture is the MIL connection ECU
circuit. The current in pin 29 to ECU should
be less than 0.5 A. 082101
MIL Flash Principles:

a: In flash code mode, and no fault in 1 +12V power 2 Resistant 3 LED

memory
When the ignition switch is on, but the
engine doesn’t start, MIL goes on.
MIL shows the yellow light when it is on.
After the engine starts, if OBD system
doesn't detect the fault, MIL goes off.
If any part connected with OBD system
and related to emission breaks down or
the OBD system breaks down with itself,
MIL activates and turns on to inform the
drive about the fault with visible signal.
After service and troubleshooting, restart
the vehicle.
The historical fault information can be
detected, and can be cleaned with PDA.

8-21
CFMOTO
8.3.4.2 PDA
PDA has 3 pins, power, ground wire and
data cable K. These pins are connected
with related ECU pins. The right photo 1
refers to operation panel of PDA. When it 1 2 3

comes to detailed keys function, refer to

PDA manual. 2 3

Pin function: 4 5

(1) connects ECU pin 34. 6

(2) connects ground.
(3) connects +12V battery. 7 082201
Key function: 1 UP Key 4 EXIT Key 7 Power switch
LH Key: Page up 2 LH Key 5 OK Key
UP Key: Scroll Up 3 RH Key 6 Down Key
RH Key: Page Down
Down Key: Scroll Down
OK Key: Entrance
EXIT Key: Exit

PDA Function:

(A) Version Information Display

PDA can display engine,ECU hardware
and soft ware information.
(B) Fault Display
PDA monitors IAP sensor, IAT sensor,coolant temperature sensor, TPS, O2S, O2S
heater circuit, air-to-fuel ratio revision, fuel injector, fuel pump relay, CPS, speed signal,
idle speed, idle air control valve, system voltage, ECU, FI indicator and displays the fault
code.
(C) Engine Data stream Display
PDA can display battery voltage, RPM, desired idle speed, vehicle speed, coolant
temperature, coolant temperature sensor signal voltage, inlet air temperature, IAT sensor
signal voltage, inlet air pressure, inlet air flow, IACV target position, TPS signal voltage,
throttle body position, throttle body relative position, canister duty, charging time, FI
pulse width, park advance angle, O2S voltage, engine relative load, canister load, IACV
position, atmospheric pressure, altitude multiplier, engine operation time.
(D) EFI Status Display
Starter switch, main relay, fuel pump relay, idle speed, idle speed, full load status,
deceleration activation, acceleration activation, FI close loop activation, lambda control
activation, canister control valve activation, MIL status.
(E) Actuator Test Function
MIL, fuel pump, IACV, canister control valve, ignition, fuel injection.

8-22
 08 Electrical System
8.3.4.3 Fault Code
No. Fault code Instruction(UAES)
1 P0030 First Cylinder Oxygen Sensor Heated Control Circuit Open (Bank 1 Sensor 1)
2 P0031 First Cylinder Oxygen Sensor Heated Control Circuit Low Voltage (Bank 1 Sensor 1)
3 P0032 First Cylinder Oxygen Sensor Heated Control Circuit High Voltage (Bank 1 Sensor 1)
4 P0050 Second Cylinder Oxygen Sensor Heated Control Circuit Open (Bank 1 Sensor 1)
Second Cylinder Oxygen Sensor Heated Control Circuit Low Voltage
5 P0051
(Bank 1 Sensor 1)
Second Cylinder Oxygen Sensor Heated Control Circuit High Voltage
6 P0052
(Bank 1 Sensor 1)
7 P0107 Intake Air Pressure Sensor Short to Ground
8 P0108 Intake Air Pressure Sensor Short to Power
9 P0112 Intake Air Temperature Sensor Low Voltage
10 P0113 Intake Air Temperature Sensor High Voltage
11 P0117 Water Temperature Sensor Circuit Low Voltage
12 P0118 Water Temperature Sensor Circuit High Voltage
13 P0122 Throttle Position Sensor Circuit Low Voltage
14 P0123 Throttle Position Sensor Circuit High Voltage
15 P0130 First Cylinder Oxygen Sensor Signal Abnormal (Bank 1 Sensor 1)
16 P0131 First Cylinder Oxygen Sensor Low Signal (Bank 1 Sensor 1)
17 P0132 First Cylinder Oxygen Sensor Signal Circuit Low Voltage (Bank 1 Sensor 1)
18 P0134 First Cylinder Oxygen Sensor Signal Circuit Error (Bank 1 Sensor 1)
19 P0150 Second Cylinder Oxygen Sensor Signal Abnormal (Bank 1 Sensor 1)
20 P0151 Second Cylinder Oxygen Sensor Low Signal (Bank 1 Sensor 1)
21 P0152 Second Cylinder Oxygen Sensor Signal Circuit High Voltage (Bank 1 Sensor 1)
22 P0154 Second Cylinder Oxygen Sensor Signal Circuit Error (Bank 1 Sensor 1)
23 P0201 First Cylinder Injector Control Circuit Open
24 P0261 First Cylinder Injector Control Circuit Short to Ground
25 P0262 First Cylinder Injector Control Circuit Short to Power
26 P0202 Second Cylinder Injector Control Circuit Open
27 P0264 Second Cylinder Injector Control Circuit Short to Ground
28 P0265 Second Cylinder Injector Control Circuit Short to Power
29 P0322 No Speed Sensor Signal (Open Circuit Or Short Circuit)
30 P0480 Fan Control Circuit Open
31 P0511 Idle Actuator Short Circuit
32 P0560 Battery Voltage Signal Abnormal
33 P0562 Battery Low Voltage
34 P0563 Battery High Voltage
35 P0627 Fuel Pump Relay Control Circuit Open
36 P0629 Fuel Pump Relay Control Circuit Short to Power
37 P0650 Mil Circuit Error
38 P0691 Fan Control Circuit Short to Ground
39 P0692 Fan Control Circuit Short to Power
40 P0501 Speed Signal Error
41 P1116 Engine High Temperature Over Range
42 P0602 Control Module Programming Error
43 P0116 Engine Water Temperature Sensor Circuit Error
44 P1098 Roll-Over Sensor Error

8-23
CFMOTO

8.4 Fault Diagnosis and Treatment

8.4.1 Engine Body

Troubles Possible Cause Countermeasures

Cylinder pressure too low
1. Cylinder worn Replace
2. Piston ring worn Replace
3. Air leakage of cylinder gasket Replace
4. Valve stem worn or unsuitable valve Repair or replace
seat
5. Spark plug loosen Tighten
6. Starting motor rotate too slowly Check electrical parts
7. Improper valve timing Adjust
8. Improper valve clearance Adjust
Spark plug cannot ignite or weak
Cannot start or
ignition
difficult to start
1. Improper spark plug clearance Adjust or replace
2. Spark plug dirty or wet Clean & dry or replace
3. Defect ignition coil Replace
4. Trigger short circuit or open circuit Replace
5. Magneto malfunction Replace
Insufficient fuel inside throttle body
1. Breather hole block Clean or replace
2. Injector blocked or failure Clean or replace
3. High Pressure oil pump failure Inspect or replace
4. Low pressure,oil pump Inspect or replace
5. Oil pump Filter net blocked Clean or replace

1. Improper valve clearance Adjust

2. Unsuitable valve seat Repair or replace
3. Defective valve Replace
4. Rocker or rocker arm wear Replace
No idle speed or 5. Dirty spark plug Replace
unstable speed 6. Incorrect valve clearance Replace or adjust
7. Ignition coil failure Replace
8. In & Ex a air hose blocked, idle Adjust or replace
valve
9. Magneto failure Replace

8-24
 08 Electrical System

Troubles Possible Cause Countermeasures

1. Valve spring getting worn Replace

2. Camshaft worn Replace
3. Spark plug dirty Clean or replace
4. Spark plug gap too narrow Adjust or replace
High RPM unstable
5. Valve timing incorrect Adjust
6. Ignition coil failure Replace
7. Low pressure,oil pump Adjust or replace
8. Air filter too dirty Clean or replace

1. Engine oil too much Check oil level and drain

2. Piston ring worn Replace
B l u e o r b l a c k 3. Valve worn Replace
exhaust gas 4. Cylinder worn or scraped Replace
5. Valve stem worn Replace
6. Oil seal of valve stem damaged Replace

Adjust
1. Valve clearance improper
Replace
2. Valve spring getting weak
Adjust
3. Valve timing incorrect
Replace
4. Cylinder worn
Replace
5. Piston ring worn
Replace or repair
6. Improper valve seat
Clean or replace
Engine Power not 7. Spark plug dirty
Clean or replace
enough 8. Improper spark plug gap
Clean or replace
9. Injector blocked
Adjust or replace
10. Insufficient pressure,oil pump
Clean or replace
11. Air filter too dirty
Replace
12. Rocker arm or camshaft worn
Tighten or replace
13. Air leakage of inlet pipe
Check oil level and
14. Engine oil too much
change

1. Carbon deposit on piston head

Clean
2. Engine oil too less or too much
Check and add or drain
3. Oil pump failure
Replace
Engine Overheating 4. Fuel hose blocked
Clean
5. Air leakage of inlet pipe
Tighten or replace
6. Unsuitable engine oil
Change oil
7. Cooling system failure(see7-5)

8-25
CFMOTO

Troubles Possible Cause Countermeasures

Valve abnormal noise
1. Valve clearance too big Adjust
2. Valve spring worn or broken Replace
3. Swing arm or camshaft worn Replace
Piston abnormal noise
1. Piston worn Replace
2. Cylinder worn Replace
3. Carbon deposit inside combustion Clean
chamber
4. Piston pin or pin hole worn Replace
5. Piston ring or groove worn Replace

Timing chain abnormal noise

1. Chain stretched out Replace chain and sprocket
2. Chain sprocket worn Replace chain and sprocket
Engine abnormal
3. Tensioner failure Repair or replace
noise

Clutch abnormal noise

1. Clutch gear worn or damaged Replace clutch gear
2. Cushion rubber aging or damaged Replace clutch gear

Crankshaft abnormal noise

1. Bearing noise Replace
2. Crankshaft pin bearing down Replace
3. Clearance too big Replace

Transmission abnormal noise

1. Gear worn or damaged Replace
2. Main shaft or counter shaft worn Replace
3. Bearing worn Replace
4. Bushing worn Replace

1. Clutch drive disc worn Replace

Clutch slippery 2. Clutch driven disc worn or damaged Replace
3. Clutch spring getting weak Replace

8-26
 08 Electrical System

8.4.2 Fault Treatment

When parts have faults in EFI system, the ECU applies the following procedures to
prevent the engine damage.

Unstable output
Fault
Part voltage range or Remark
code
standard
If inlet air temp. sensor breaks down
and open circuit, the ECU setting
Inlet air
P0112 or Inlet air temperature temperature is -40°C.
temperature
P0113 Ta=-40°C~+130°C If inlet air temp. sensor breaks down
sensor
and short circuit, the ECU setting
temperature is 130°C.
If water temp. sensor breaks down
and open circuit, the ECU setting
Water
P0117 or Water temperature temperature is -40°C.
temperature
P0118 Tw=-40°C~+130°C If water temp. sensor breaks down
sensor
and short circuit, the ECU setting
temperature is 129°C.
If oxygen sensor isn't activated, ECU
P0130, Oxygen sensor activates
stops oxygen sensor feedback mode.
P0131, Oxygen and continuously sends
If oxygen sensor outputs wrong
P0132 or sensor #1 signal (output voltage)
voltage signal, ECU stops oxygen
P0134 to ECU.
sensor feedback mode.
If oxygen sensor isn’t activated, ECU
P0150, Oxygen sensor activates
stops oxygen sensor feedback mode.
P0151, Oxygen and continuously sends
If oxygen sensor outputs wrong
P0152 sensor #2 signal (output voltage)
voltage signal, ECU stops oxygen
orP0154 to ECU.
sensor feedback mode.

8-27
 09 Cooling System Assy
9.1 Cooling System Diagram������������������������������������������������������������������ 9-1
9.1.1 400-5 (268MQ-A Engine) Cooling System��������������������������������� 9-1
9.1.2 CF650-8(283MT Engine) Cooling System (Status 1)���������������� 9-2
9.1.3 CF650-8(283MT Engine) Cooling System (Status 2)���������������� 9-3
9.2 Cooling System Assy Removal�������������������������������������������������������� 9-4
9.3 Engine Coolant���������������������������������������������������������������������������������� 9-5
9.4 Seal Inspection���������������������������������������������������������������������������������� 9-6
9.5 Radiator and Water Pipes Inspection and Clean���������������������������� 9-6
9.6 Fan Motor Inspection������������������������������������������������������������������������ 9-7

9.1 Cooling System Diagram

9.1.1 400-5 (268MQ-A Engine) Cooling System

090101

1 Reservoir 2 Radiator assy 3 Fan motor

4 Outlet pipe, radiator 5 Water pump assy 6 Inlet pipe, radiator
7 Engine assy

9-1
CFMOTO
9.1.2 CF650-8(283MT Engine) Cooling System (Status 1)

090201

1 Reservoir 2 Inlet pipe, radiator 3 Radiator assy

4 Fan motor 5 Outlet pipe, radiator 6 Water pump assy
7 Engine assy

9-2
 09 Cooling System Assy
9.1.3 CF650-8(283MT Engine) Cooling System (Status 2)

090301

1 Reservoir 2 Inlet pipe, radiator 3 Radiator assy

4 Fan motor 5 Outlet pipe, radiator 6 Water pump assy
7 Engine assy

9-3
CFMOTO
Warning:
Never open the radiator cap when the engine is still hot. Otherwise, the vapor or
hot coolant will cause injury.
Coolant is poisonous. Do not swallow or satin it on skin and eyes. If it happens,
flush with water immediately. Search for medical help if necessary.
Keep the coolant out of the reach of children.

9.2 Cooling System Assy Removal

Removal
Place a pan under the outlet pipe joint.
3
Remove drain bolt 1 .
Darin the coolant.
Note: After the outlet pipe removal, 2
there is still come coolant spilling.
Loose clamp 2 after coolant drain. 1
Remove outlet pipe 3 . 090401

Remove M6 bolts 4 .
Remove hose 5 . 5
Remove reservoir 6 .
6
4

090402

Remove M8 bolt 7 .

090403

9-4
 09 Cooling System Assy
Loose clamp 8 .
Remove radiator outlet pipe 9 .
8
9

090501

Push the radiator 10 in the direction of the

arrow.

10
Installation
Reverse the removal procedures for
installation. 090502

9.3 Engine Coolant

●Coolant in cooling system is a mixture Mixing ratio Freezing point
of 51.5% distilled water,46% ethylene
glycol antifreeze and 2.5% additive. This 50% 30°C
mixture ratio provides optimized corrosion 55% -40°C
resistance and fine heat production. The 60% -55°C
mixture has good anti-corrosion and
endothermic function, and its solidification
point is -30°C. If engine works under -30°C, (°C)
0
Freezing point

choose coolant of 55% or 60%.

Warning: -10
Use high quality ethylene glycol base -20
antifreeze mixed with distilled water. -30
Never mix alcohol base anti-freeze or -40
other different brands of antifreeze. -50
The ratio of mixture should not be -60
more than 60% or less than 50%. -70
Do not use anti-leak additive. Ratio 0 20 40 60 80 100
Warning:
Never open the radiator cap when the (°C)
engine is still hot. Otherwise, the vapor ×100Pa
150
Boiling point

or hot coolant will cause injury. 140 1.5

Pressure

Coolant is poisonous. Do not swallow 130 0.9

or satin it on skin and eyes. If it 120 0.5
happens, flush with water immediately. 110 0
Search for medical help if necessary. 100
Keep the coolant out of the reach of
children. 0 10 20 30 40 50 60
Ratio

9-5
CFMOTO
9.4 Seal Inspection
Radiator Cap Inspection
Remove radiator cap.
Measure the open pressure of radiator cap
with pressure gauge.
If the pressure is out of standard, replace a
new part.
Radiator Cap Open Pressure
Standard:
125 kPa~150 kPa
1.27 kgf/cm2~1.53 kgf/cm2
18.13 psi~21.76 psi 2

Seal Inspection
Connect the pressure gauge 2 with 1
reservoir joint 1 .

Warning: Never open the radiator

cap when the engine is still hot.
Otherwise, the vapor or hot coolant will 090601
cause injury.
Inflate to 120 kPa, and last for 10s.
If the pressure decreases within 10s, there
is leaking inside the system. Inspect the
whole system and replace the broken
parts.
Note: When remove the gauge, cover
radiator cap with cloth, in case the
coolant spills out.
Note: The testing pressure does not
exceed the open pressure.

9.5 Radiator and Water Pipes

Inspection and Clean
Radiator Inspection and Clean 090602
Remove dirt and dust from the radiator
with high-pressure air.

Repair radiator fins with a small

screwdriver.

090603

9-6
 09 Cooling System Assy
Radiator Water Pipes Inspection
Inspect radiator water pipes for leakage,
damage. Replace if necessary.

Inspect radiator water pipe clamps.

Replace if loose.

After radiator and water pipes inspection,

inspect the coolant. Add coolant if
necessary.

9.6 Fan Motor Inspection

Remove four M6 bolts 1 .
Remove fan 2 . 1

090701

Rotate the impeller with hands to inspect

its movement. Replace if the rotation isn’t
smooth or the impeller is broken.
Remove M6 nut 3 . 3
Remove impeller 4 . 4

090702

Connect 12V battery, the motor works and

the current is less than 5A. If the motor
doesn’t work or the current exceeds the
standard, replace a new motor.
Remove impeller.
Remove three M6 bolts 5 .
Remove motor 6 . 6

5
Installation
Reverse the removal procedures for
installation. 090703

9-7
 10 Muffler Assy
10.1 Muffler�������������������������������������������������������������������������������������������� 10-1

10.1 Muffler

Warning：Muffler is very hot when

running the vehicle. Never touch high-
temperature parts. Do operation when
the system cools down.

Removal
Remove two M6 inner bolts 1 . 1
Remove tail muffler deco cover 2 .

100101

3
Remove two M6 bolts 3 .
Remove tail muffler assy 4 .

100102

Remove M6 bolt 5 .

100103

Remove M8 bolt 6 .
6
Remove main muffler assy 7 .

100104

10-1
CFMOTO
Remove two oxygen sensors 8 counter
clockwise.

8
8

100201

9 9
Remove four 4 nuts 9 .
Remove exhaust pipe 10 .
10

100202

Inspection
Inspect the graphite seal ring 1 after
removal. Replace if rusty or cracked. 1

100203

Inspect the rubber sleeve of footrest

bracket mounting bolt 2 . Replace if 2
cracked.

Installation
Reverse the removal procedures for 100204
installation.

10-2
 11 Wheels and Brake System
11.1 Front Wheel Assy Removal���������������������������������������������������������� 11-1
11.2 Rear Wheel Assy Removal������������������������������������������������������������ 11-3
11.3 Hydraulic Brake Assy Removal���������������������������������������������������� 11-4
11.3.1 Front Shock Absorber������������������������������������������������������������ 11-4
11.3.2 Front Brake Removal�������������������������������������������������������������� 11-4
11.3.3 Rear Brake Removal��������������������������������������������������������������� 11-5
11.3.4 MAB Actuator Removal���������������������������������������������������������� 11-6
11.4 Front Brake Assy Inspection ������������������������������������������������������� 11-6
11.4.1 Brake Hose Inspection����������������������������������������������������������� 11-6
11.4.2 Brake Performance Inspection���������������������������������������������� 11-7
11.4.3 Front Brake Fluid Level Inspection��������������������������������������� 11-7
11.4.4 Brake Fluid Replacement ������������������������������������������������������ 11-7
11.4.5 Front Brake Lever Free Play ������������������������������������������������� 11-8
11.4.6 Front Brake Pad Inspection��������������������������������������������������� 11-8
11.5 Front/Rear Wheel, Brake Disc Inspection����������������������������������� 11-9
11.5.1 Tire Pressure Inspection�������������������������������������������������������� 11-9
11.5.2 Tire Inspection������������������������������������������������������������������������� 11-9
11.5.3 Wheel Bearing Inspection ��������������������������������������������������� 11-10
11.6 Rear Brake Assy Inspection������������������������������������������������������� 11-10
11.6.1 Rear Brake Fluid Inspection������������������������������������������������ 11-10
11.6.2 Brake Pedal Inspection���������������������������������������������������������11-11
11.6.3 Rear Brake Pad Inspection���������������������������������������������������11-11

11.1 Front Wheel Assy Removal

Removal
Remove three M6 inner hex bolts 1 on the
left side.
Remove three M6 inner hex bolts 1 on the 1
right side.

110101

Remove two screws 2 . 3

Remove front fender 3 in the front side of
the vehicle.
2

110102

11-1
CFMOTO
Place a jack under the engine. Load the
rear part of the vehicle to lift the front part
of the vehicle.
Remove speed sensor and wheel speed 4
sensor. 5
Remove two M8 bolts 4 on the left side.
Remove two M8 bolts 4 on the right side.
Remove RH brake caliper 5 .
110201
LH brake caliper removal refers to RH
brake caliper.

Loose M8 nut 6 . 7
Remove M20 front wheel shaft 7 .
Remove front wheel 8 .
8

110202

Note: Do not miss the front wheel

shaft sleeve 9 .

110203

12
10 11

Remove M6 bolts 10 . 10 10
Remove sensor disc 11 and RH front brake
disc 12 .
LH front brake disc removal refers to RH 10 10
brake disc.

Installation 110204
Reverse the removal procedures for
installation.

11-2
 11 Wheels and Brake System
11.2 Rear Wheel Assy Removal
Removal
Lift the rear wheel with bracket.
3
Remove speed sensor 1 .
Remove cotter pin 2 .
Remove M18 nut 3 .
Remove adjusting block 4 . 4 2

1
110301

Remove bolt 5 .
Remove adjusting block 6 .

5 6

110302

Remove rear brake caliper 7 .

Push the rear wheel towards the front part
of the vehicle.
9 7
Remove chain 8 .
Remove rear wheel 9 .

8
110303

Remove sprocket seat 10 .

Note: Lean the rear wheel rightward 10
during removal, in case the sprocket
seat falls down to cause injury.

110303

11
Note: Do not miss two rear wheel
shaft sleeves 11 .
110303

11-3
CFMOTO
Remove rubber damper 12 . Replace if
aged, damaged or harden.

12

110401
Remove four M6 bolts 13 .
Remove brake disc 14 .
14

13 13
Installation
Reverse the removal procedures for
installation. 110402

11 . 3 H y d r a u l i c B r a k e A s s y
Removal
2 3
11.3.1 Front Shock Absorber
1
Removal
Remove six M8 inner hex bolts 1 .
Remove front RH shock absorber 2 .
Remove front LH shock absorber 3 . 110403

Installation 5
Reverse the removal procedures for 4

installation.
Front shock absorber bolt tighten
torque: 20 N•m

When installing front shock absorbers,

the upper ends 4 of two shock absorber
inner pipes should be parallel and exceed 110404
1mm~2mm of the upper connecting plate
upper surface 5 .

11.3.2 Front Brake Removal

Remove M6 bolt 1 .
2
Remove front brake lever 2 .
1
Note: Never hang brake master
cylinder with brake hose. Never lean
brake master cylinder, in case the air 110405
gets into the system.
Note: Never grasp the front brake
lever after front brake assy removal.

11-4
 11 Wheels and Brake System
11.3.3 Rear Brake Removal
Removal
Remove M6 bolt 1 .
Remove frame RH panel 2 .
Frame LH panel removal refers to RH
2
panel.
3
1

110501

Remove six M6 inner hex bolts 3 .

Remove rear fender 4 .
4
3

110502

Remover rear deco plate 5 .

Remove rear brake 6 .
6

110503

Remove M6 bolt 7 .
Remove rear brake fluid reservoir 8 .
8
7

110504

Remove two M6 inner hex bolts 9 . 9

Remove RH footrest bracket 10 . 10

110505

11-5
CFMOTO
Remove cotter pun and washer 11 .
Remove two M6 bolts 12 .
Remove return spring 13 . 12 16
Remove pin shaft assy 14 .
Remove brake lever 15 . 11
13
Remove rear brake master cylinder 16 .

15 14
110601

11.3.4 MAB Actuator Removal

Removal
Remove two M6 bolts 1 .

110602

Remove M6 bolt 1 .
Remove MAB actuator 2 .
Remove whole ABS hydraulic brake assy.

2
1

110603

11.4 Front Brake Assy Inspection

11.4.1 Brake Hose Inspection
Inspect brake hose, connectors and pipes B

for damage, cracks or leaking. A

With improper maintenance, the high C
pressure inside the brake hose can cause
fluid leaking A or hose burst.
Inspect brake hose for bending or twist.
Replace with new hoses and pipes if crack
B , bulge C or leaking detected.
Tighten all the brake hose connecting bolts
and nuts. 110604
Inspect brake hose route. Reset the hose
route if not proper or correct.

11-6
 11 Wheels and Brake System
11.4.2 Brake Performance Inspection
Inspect the front&rear brake performance
on dry road.
If the brake performance is not good,
inspect the brake system for damage or
other defects.

11 . 4 . 3 F r o n t B r a k e F l u i d L e v e l
Inspection
Straighten the vehicle to make the front
brake fluid reservoir 1 parallel the ground. 2
Check if the brake fluid level is between
3 1
the UPPER 2 and LOWER 3 line.
Add or reduce the brake fluid until the level
is in between if not.
110701

11.4.4 Brake Fluid Replacement 1

Straighten the vehicle to make the brake 2
fluid reservoir parallel the ground.
Remove two crossing bolts 1 . 3
Remove brake reservoir cap 2 .
Remove brake reservoir gasket 3 .

110702

Remove rubber sleeve 4 of air-bleed bolt. 5

Connect a clean plastic hose with the air-
bleed bolt 5 .
Place the another end of the hose in a
container.
Add new brake fluid.

110703

11-7
CFMOTO
Repeatedly hold and loose brake lever
until it feels hard.
Hold the brake lever tightly.
Loose air-bleed bolt a little bit.
Tighten the bolt right after the old brake
fluid sprays out.
Repeat the above procedures until the new
brake fluid sprays out.
110801
Note: Keep the brake fluid level
between upper and lower line. Do not
spray brake fluid on plastic parts or
painted surface.
Pull out plastic hose.
Install air-bleed bolt rubber sleeve.
Install brake fluid reservoir.

11.4.5 Front Brake Lever Free Play

Front brake lever free play 1 : 3mm~6mm 1

110802

11.4.6 Front Brake Pad Inspection A

B
Front Brake Pad Wear Inspection
Remove brake caliper.
Inspect brake pad thickness of every brake
caliper.
Replace when the brake pad thickness A
reaches service limit B 3mm. A
B
Installation 110803
Reverse the removal procedures for A 制片磨擦层 B 1.5mm
installation.
Warning: Do not run the vehicle
right after replacing new brake discs
or pads. Do break-in on brake pads.
Operate the brake lever several times
until brake pad and brake caliper
engage well.

11-8
 11 Wheels and Brake System
11.5 Front/Rear Wheel, Brake Disc
Inspection A

11.5.1 Tire Pressure Inspection

Remove tire inflation valve cap.
Measure the tire pressure with air gauge
A when it is cool.
Install tire inflation valve cap.
Pressure kPa kgf/cm2 psi
Front 250±25 2.50 36.25
Rear 280±28 2.80 40.6
Adjust the tire pressure according to the 110901
standard if necessary.
B

11.5.2 Tire Inspection

Clean the embedded stone A or other A
inclusions B on tires.
Inspect the tire for cracks or damages by
watching it. Replace if necessary. If tire
expands or has bulges on it, replace a new
tire.

110902

When the tire thread wears to the block 1

height, replace a new tire.

110903

11-9
CFMOTO
11.5.3 Wheel Bearing Inspection
Front Wheel
Lift the front wheel with jack.
Inspect the front wheel bearing for damage
B
buy pushing or pulling the wheel A .
Rotate the front wheel B to inspect the for
the smooth movement and noise.
A
Replace if the movement is stuck or noise
occurs. 111001

Rear Wheel
Lift the rear wheel with jack.
Inspect the rear wheel bearing for damage
buy pushing or pulling the wheel A . B
Rotate the rear wheel B to inspect the for
the smooth movement and noise.
Replace if the movement is stuck or noise
occurs. A
111002

11.6 Rear Brake Assy Inspection

11.6.1 Rear Brake Fluid Inspection
Straighten the vehicle to make the front
brake fluid reservoir 1 parallel the ground. 2
Check if the brake fluid level is between 3
the UPPER 2 and LOWER 3 line. 1
Add or reduce the brake fluid until the level
is in between if not. 111003

4
4

Remove two crossing bolts 4 . 5

Remove brake reservoir cap 5 . 6
Remove brake reservoir gasket 6 .

111004

Remove rubber sleeve 7 of air-bleed bolt.

Connect a clean plastic hose with the air- 7

bleed bolt 8 .
8
Place the another end of the hose in a
container.
111005

11-10
 11 Wheels and Brake System
11.6.2 Brake Pedal Inspection
Brake pedal free play: 10mm
Inspect brake light performance (refer to
Chapter 06).
Add new brake fluid.
Repeatedly step brake pedal until it feels
hard.
Step the brake pedal.
Loose air-bleed bolt a little bit.
Tighten the bolt right after the old brake
fluid sprays out.
Repeat the above procedures until the new
brake fluid sprays out.
Note: Keep the brake fluid level
111102
between upper and lower line. Do not
spray brake fluid on plastic parts or
painted surface.
Pull out plastic hose.
Install air-bleed bolt rubber sleeve.
Install brake fluid reservoir.
1

11.6.3 Rear Brake Pad Inspection 2

Removal
Remove guide rod clasp 1 .
Remove guide rod 2 .
Remove rear brake pads 3 .

111103

A
B

Rear Brake Pad Wear Inspection

Inspect brake pad thickness of every brake
caliper.
Replace when the brake pad thickness A
reaches service limit B 3mm.
A
Installation
B
Reverse the removal procedures for
111104
installation.
Warning: Do not run the vehicle A 制片磨擦层 B 1.5mm
right after replacing new brake discs
or pads. Do break-in on brake pads.
Operate the brake lever several times
until brake pad and brake caliper
engage well.

11-11
CFMOTO

3
4

111201

Front brake fluid Front brake

1 2 Brake lever 3 Master cylinder 4
reservoir caliper
Rear brake
5 6 MAB actuator
caliper

11-12
 12 Shock Absorbers and Rear Fork
12.1 Gearshift Lever Assy������������������������������������������������������������������12-1
12.2 LH Footrest Bracket�������������������������������������������������������������������12-1
12.3 Side Stand�����������������������������������������������������������������������������������12-1
12.4 Rear Shock Absorber�����������������������������������������������������������������12-2
12.5 Chain�������������������������������������������������������������������������������������������12-2
12.6 Rear Fork�������������������������������������������������������������������������������������12-5

Note: Before operation, the vehicle

has to be fixed, in case it falls down to
cause injury.

12.1 Gearshift Lever Assy

Loose M6 bolt 1 . 3
2
Remove M6 inner hex bolt 2 .
Remove gearshift lever assy 3 . 1

Installation
Reverse the removal procedures for 120101
installation.

12.2 LH Footrest Bracket 1

Removal
Remove two M6 inner hex bolts 1 .
Remove LH footrest bracket 2 . 2

Installation
Reverse the removal procedures for 120102
installation.

12.3 Side Stand 1 2 4

Removal
3
Remove side stand switch connector 1 .
Remove side M6 bolt 2 .
Remove side spring 3 .
Remove side stand 4 .
120103
Installation
Reverse the removal procedures for
installation.

12-1
CFMOTO
12.4 Rear Shock Absorber
Removal
Remove three M6 inner hex bolts 1 . 1
Remove sprocket cover 2 .
Remove chain guard.

120201

Remove M15 bolt 3 .

Remove M15 bolt 4 .
3
Remove nut 5 .
Remove shock absorber 6 . 4
6

Note: After rear shock absorber

5
removed, the rear fork can be removed.

Installation 120202
Reverse the removal procedures for
installation.
Rear shock absorber nut tighten torque:
59N•m

12.5 Chain 1
2
Removal
Remove two M6 bolts 1 .
Remove small sprocket cover 2 .
Loose chain.
120203

Because the chain is installed through the 2

swing arm, it can only be cut rather then

removed. Prepare new chain pin, chain
board and pin seat to reconnect the chain. 1

Press hard 1 to make two pin heads

parallel.
Set the cutting and riveting pin 2 as 120204
picture shows.

Tighten the bolt to narrow the pin seat until

it touches chain pin.
Make sure the centers of cutting and
riveting pin and chain pin are aligned.

120205

12-2
 12 Shock Absorbers and Rear Fork
Rotate the pin seat with wrench 3
clockwise to remove the chain pin.
3

120301
Drive Chain Installation
Install new chain knots on chain to replace 1 2
the old ones. 3
Remove the chain boards of new drive
chain.
Apply grease on chain pin 2 and seal
1
rings 1 .
Engage the chain and rear chain sprocket.
Insert chain pins into chain knots.
Install seal rings 1 .
120302
Install chain boards and make the mark 3
face outside.
Fix the chain board with hand or plier.
Make sure the seal ring is installed 4
correctly in case of the chain grease
leaking.

Set the holder 4 and 5 .

5

120303

Align the holder and chain board.

Rotate the pin seat until it touches the
chain board.
120304

Rotate the pin seat with wrench clockwise

until two pins get into the grooves of
holder.
Remove holder 4 .
120304

12-3
CFMOTO
Set the holder 5 and cutting and riveting
pin 6 as picture shows. 6

120401

Rotate the pin seat until it touches chain

pin.

120402

Rotate the wrench clockwise until cutting

and riveting pin head touches chain pin to
rivet.
Other chain pins installation follows the
same procedures.

120403

Inspection
After installation, inspect riveting knots for 1
cracks. Measure chain pin outer diameter
1 and chain board width 2 .
Chain pin outer diameter
Standard: 5.45 mm~5.55 mm
Chain board width 2
Standard: 17.25 mm~17.45 mm
(0.679 in.~0.687 in.)
Cut and re-rivet the chain knots if out of
standard.
120404

Chain Looseness Adjustment

Chain sag standard: 30mm~40mm

12-4
 12 Shock Absorbers and Rear Fork
12.6 Rear Fork
Removal
Remove M20 nut 1 .
Remove rear fork shaft 2 .
Remove rear fork 3 . 1

Installation
2
Reverse the removal procedures for 3
installation. 120501
Rear fork shaft nut tighten torque: 180
N•m

12-5
 13 Engine Assy (CF400-5)
13.1 Engine Special Tool������������� 13-4 ������������������������������������������������� 13-25
13.2 Engine Removal������������������ 13-8 13.4.17 Oil Pipe IV Removal�� 13-26
13.2.1 Engine Inlet&Outlet Water 1 3 . 4 . 1 8 Tr a n s m i s s i o n A s s y
Pipe Removal �������������������������� 13-8 Removal���������������������������������� 13-26
13.2.2 Air Filter Loose������������� 13-9 13.4.19 Oil Pump Assy Removal
13.2.3 Clutch Cable Removal�� 13-9 ������������������������������������������������� 13-27
13.2.4 Gearshift Lever Assy 13.4.20 Oil Filter Removal����� 13-28
Removal������������������������������������ 13-9 13.4.21 Oil Pan Assy Removal....
13.2.5 Sprocket Removal������ 13-10 ������������������������������������������������� 13-28
13.2.6 Engine Assy Removal 13-10 13.4.22 Engine Case Removal....
13.3 Engine Air Intake System� 13-12 ������������������������������������������������� 13-29
1 3 . 3 . 1 T h r o t t l e Va l v e A s s y 13.4.23 Timing Chain Removal...
Disassembly��������������������������� 13-12 ������������������������������������������������� 13-30
1 3 . 3 . 2 T h r o t t l e Va l v e A s s y 13.4.24 Crankshaft and Balance
Inspection������������������������������� 13-13 Shaft Removal������������������������ 13-30
13.3.2.1 Throttle Valve Body� 13- 13.5 Engine Parts Inspection��� 13-30
13 13.5.1 Cylinder Head Cover
13.3.2.2 Fuel Rail Assy������ 13-13 Inspection������������������������������� 13-30
13.3.2.3 Air Intake Pipe ����� 13-14 13.5.2 Cylinder Head Inspection
1 3 . 3 . 3 T h r o t t l e Va l v e A s s y ������������������������������������������������� 13-31
Assembly�������������������������������� 13-14 13.5.3 Camshaft Cover Inspection
13.4 Engine Disassembly��������� 13-16 ������������������������������������������������� 13-32
13.4.1 Engine Oil Drain���������� 13-16 13.5.4 Camshaft Assy Inspection
13.4.2 Starter Motor Removal13-16 ������������������������������������������������� 13-32
13.4.3 Magneto Rotor Removal... 13.5.5 Cylinder Head Assy
������������������������������������������������� 13-16 Inspection������������������������������� 13-34
13.4.4 Ignition Coil and Spark Plug 13.5.6 Valve Guide Pipe Removal
Removal���������������������������������� 13-18 ������������������������������������������������� 13-36
13.4.5 Cylinder Head Cover 13.5.7 Cylinder Head Wear ��� 13-36
Removal���������������������������������� 13-18 13.5.8 Timing Tensioner Inspection
13.4.6 Tensioner Removal����� 13-19 ������������������������������������������������� 13-41
13.4.7 Camshaft Removal ���� 13-19 13.5.9 Cylinder Body Inspection
13.4.8 Cylinder Head Removal... ������������������������������������������������� 13-41
������������������������������������������������� 13-20 13.5.10 Piston Assy Inspection..
13.4.9 RH Side Cover Removal... ������������������������������������������������� 13-42
������������������������������������������������� 13-20 13.5.11 Camshaft Connecting Rod
13.4.10 Clutch Removal�������� 13-21 Assy Inspection��������������������� 13-44
13.4.11 Crankshaft Pulsing Rotor 13.5.12 Balance Shaft/Plain
Removal���������������������������������� 13-23 Bearing Wear ������������������������ 13-47
13.4.12 Cylinder Body Removal. 13.5.13 Overriding Clutch
������������������������������������������������� 13-23 Inspection������������������������������� 13-48
13.4.13 Piston Removal��������� 13-24 13.5.14 Magneto Rotor Inspection
13.4.14 Tensioner Plate Removal ������������������������������������������������� 13-49
������������������������������������������������� 13-24 13.5.15 Starter Driven Gear, Dual
13.4.15 Water Pump Removal13-25 Gear and Shaft Inspection���� 13-49
13.4.16 Gearshift Assy Removal 13.5.16 Magneto Stater���������� 13-50

13-1
CFMOTO
13.5.17 Clutch Assy Inspection.. Installation ����������������������������� 13-73
������������������������������������������������� 13-50 13.6.21 Magneto Rotor Installation
1 3 . 5 . 1 8 Tr a n s m i s s i o n C a s e ������������������������������������������������� 13-74
Inspection������������������������������� 13-51 13.6.22 Starter Motor Installation
13.5.19 Gearshift Assy Inspection ������������������������������������������������� 13-75
������������������������������������������������� 13-55 13.6.23 Drain Bolt Installation....
13.5.20 Gearshift Cover Inspection ������������������������������������������������� 13-75
������������������������������������������������� 13-56 13.7 Lubrication System����������� 13-76
13.5.21 Water Pump Assy 13.7.1 Engine Oil Inspection� 13-76
Inspection ������������������������������ 13-56 13.7.2 Engine Oil Change������ 13-76
13.5.22 Crankcase Inspection... 13.7.3 Relief Valve ����������������� 13-77
������������������������������������������������� 13-58 13.7.4 Engine Oil Pump��������� 13-78
13.6 Engine Assembly �������������� 13-61 13.7.5 Oil Pressure Measurement
13.6.1 Crankshaft and Balance ������������������������������������������������� 13-79
Shaft Installation�������������������� 13-61 1 3 . 7 . 6 O i l P r e s s u r e Wa r n i n g
13.6.2 Timing Chain Installation Switch������������������������������������� 13-79
������������������������������������������������� 13-61 13.8 Engine Installation������������ 13-81
13.6.3 Crankcase Installation13-61 13.8.1 Engine Installation������ 13-81
13.6.4 Oil Pan Assy Installation.. 13.8.2 Output Sprocket Installation
������������������������������������������������� 13-63 ������������������������������������������������� 13-82
13.6.5 Oil Filter Installation��� 13-63 13.8.3 Gearshift Lever Assy
13.6.6 Oil Pump Installation�� 13-64 Installation ����������������������������� 13-82
1 3 . 6 . 7 Tr a n s m i s s i o n C a s e 13.8.4 Clutch Cable Installation..
Installation ����������������������������� 13-64 ������������������������������������������������� 13-83
13.6.8 Oil Pipe IV Assy Installation 13.8.5 Air Filter Connection�� 13-83
������������������������������������������������� 13-65 13.8.6 Inlet/Outlet Pipe Installation
13.6.9 Gearshift Assy Installation ������������������������������������������������� 13-83
������������������������������������������������� 13-65
13.6.10 Water Pump Installation.
������������������������������������������������� 13-66
13.6.11 Tensioner Plate Installation
������������������������������������������������� 13-67
13.6.12 Piston Installation ���� 13-67
13.6.13 Crankshaft Pulsing Rotor
Installation������������������������������ 13-68
13.6.14 Cylinder Body Installation
������������������������������������������������� 13-68
13.6.15 Clutch Assy Installation.
������������������������������������������������� 13-69
13.6.16 Cylinder Head Installation
������������������������������������������������� 13-71
13.6.17 Camshaft Installation13-71
13.6.18 Tensioner Installation13-72
13.6.19 RH Side Cover Installation
������������������������������������������������� 13-72
13.6.20 Cylinder Head Cover

13-2
 13 Engine Assy (CF400-5)

13.1 Engine Special Tool

Magneto rotor removing tool (to remove magneto rotor)

0700-031000-922-00

130301
V-block

0800-060000-923-001

130302
Cylinder pressure gauge and connecting seat

Cylinder pressure standard: 0-2 MPa

130303
Water seal ring installing tool (puncher pin)

0700-080000-923-002

130304
120304

13-3
CFMOTO

Piston pin circlip installing tool (to install piston pin circlip)

0800-040005-922-001

130401
Feeler gauge (to measure the valve clearance)

130402

Spark plug sleeve

0700-170200-923-001

130403

Valve spring compressing tool

CF188-022006-922-001

130404

13-4
 13 Engine Assy (CF400-5)

Clutch stopping wrench (to remove/install clutch nuts, crankshaft RH nuts)

0700-051000-922-001

130501
Valve pipe guide shaft

φ4.5

130502
Water pump oil seal puncher

0700-081100-923-001

130503
Magneto rotor stopping wrench

0700-031000-922-001

130504

13-5
CFMOTO
Oil filter wrench

0700-070200-922-001

130601

13-6
 13 Engine Assy (CF400-5)
13.2 Engine Removal

Remove muffler.
Remove electrical connectors on engine.
Remove reservoir LH&RH outer protection
plates.
Remove reservoir LH&RH inner protection
plates.
Remove LH&RH panels.
Remove engine guards assy.
Remove frame LH&RH protection plates.

Note: Remove the engine until it

cools down or wear protection clothes
to avoid burnt injury.

13.2.1 Engine Inlet&Outlet Water Pipe

Removal
Open reservoir cap.
Straighten the vehicle. Place a pan under 1

the engine to store the drained coolant.

Remove M6 bolt 1 and washer to drain
the coolant.
130701

2
1

Loose clamp 1 .
Pull out inlet pipe 2 from the engine with
caliper. 130702

Loose clamp 1 .
Pull out outlet pipe 2 from the engine with
caliper.
130703

13-7
CFMOTO

13.2.2 Air Filter Loose

1
Loose clamp 1 .

130801

Loose clamp 1 .
2
Shake throttle valve body 2 until it looses.

130802

13.2.3 Clutch Cable Removal

Use tool to rotate clutch rod 2 .
Remove clutch cable 1 .

1 2

130803

13.2.4 Gearshift Lever Assy Removal

Remove M6 bolt 1 .
Remove gearshift lever assy 2 .
2

130804

13-8
 13 Engine Assy (CF400-5)
13.2.5 Sprocket Removal

Remove M6 bolt 1 .
1
Remove engine LH rear cover 2 .

130901

Remove M6 bolt 1 .
Remove bracket 2 .

Note: Pay attention there are two

1
dowel pins under the bracket 2 . After 2
bracket 2 removal, remove dowel pins 1
in case of getting lost.

130902

Knock and straighten the flanging of

1
retainer 1 .
3
Remove counter pulse M20 nut 2 .
Remove retainer 1 . 2
Remove output sprocket 3 .
130903

2
13.2.6 Engine Assy Removal
Place the jack with soft cushion under the
engine to support it.
Remove M10 nut 1 and bolt. 1
Remove M20 nut 2 and bolt.

Note: Fix the other side with wrench

during removal.
130904

13-9
CFMOTO

Remove M10 nut 1 and bolt.

1
Note: Fix the other side with wrench
during removal.

131001

2
Remove M10 bolt 1 and nut.
Remove M8 bolts 2 . 1
2

Note: Fix the other side with wrench

during removal.

131002

Remove M10 bolt 1 and nut. 2 1

Remove M8 bolts 2 .
Remove engine front mounting bracket 3

assy 3 . 2
Shake the engine and decline the jack
slowly to remove the engine. 131003

Note: Fix the other side with wrench

during removal.

13-10
 13 Engine Assy (CF400-5)
13.3 Engine Air Intake System
13.3.1 Throttle Valve Assy Disassembly
Air Filter Assy Removal (refer to Air
2
Filter chapter)

Loose clamps 1 .
Remove throttle valve assy 2 .
1 1

131101

1 1 1 1

Remove M6 inner hex screws 1 .

Remove air intake pipes 2 .
2
2

131102

1 1

Remove M6 bolts 1 .
Remove fuel rail assy 2 .

2 131103

Remove screws 1 . 2
Remove idle stepping motor 2 .

1 1

131104

13-11
CFMOTO

Remove screws 1 .
Remove TPS 2 . 1

131201

Remove screw 1 .
Remove T-MAP 2 .

2
13.3.2 Throttle Valve Assy Inspection
131202
13.3.2.1 Throttle Valve Body
Inspect throttle valve body for crack or
damage. Replace if it does. 1

Inspect electrical parts (refer to the

Inspection section of Electrical System
chapter).

Note: It is not allowed to remove the

idle position screw 1 . 131203

13.3.2.2 Fuel Rail Assy 2

Disassembly
Push both sides of injector spring 1 with
thumbs to remove the spring 1 .
Remove fuel injector caps 2 .
1 1
Details refer to Electrical System.
Assembly
Install injector 3 on injector caps 2 . Then 3 3
install injector cap spring 1 . Make sure the
edge of the injector cap 2 clip into the
groove of the spring 1 . 131204

13-12
 13 Engine Assy (CF400-5)

Idle stepping motor, TPS and T-MAP

inspection refer to Electrical System
chapter.

13.3.2.3 Air Intake Pipe 1 1

Inspection
Inspect air intake pipes 1 for cracks or
damage. Replace if they do.

Inspect rubber seal rings 2 for cracks,

hardening or damage. Replace if they do.

2 2
131301

13.3.3 Throttle Valve Assy Assembly

Install T-MAP 1 .
Install screw 2 .

131302

2
Install TPS 1 .
Install screws 2 . 1

131303

13-13
CFMOTO

Install idle stepping motor 1 .

Install screws 2 . 2 2

131401

2 2

Install fuel rail assy 1 .

Install M6 bolts 2 .

1 131402

2 2 2 2

Install air intake pipes assy 1 .

Install M6 inner hex screws 2 .

1
1

131403

Install throttle valve assy 1 .

Tighten clamps 2 .
2 2

131404

13-14
 13 Engine Assy (CF400-5)
13.4 Engine Disassembly

Put the engine on operating bench and fix

it.

Warning: Fix the engine firmly on the

bench, in case it falls down to cause
injury or engine damage.

Warning: Disassemble the engine

when the engine is cool. Otherwise,
wear protective clothes in case of
getting burnt.

13.4.1 Engine Oil Drain

Place a pan under the engine to store the
engine oil from the engine.
Remove M12×22 drain bolt 1 .
2
Remove washer 12 2 .
1
Drain the engine oil.
131501

13.4.2 Starter Motor Removal

Remove M6 bolts 1 . 2
Shake the starter motor 2 to remove it.
If it is too tight, knock the motor gently
with hammer to loose. Do not knock it very
1
hard.

131502

13.4.3 Magneto Rotor Removal

Remove M6 bolts 1 .
Remove cable clip 2 .
3 3
Remove LH front cover .
1

131503

13-15
CFMOTO

1
2
Remove seal gasket 1 .
Remove dowel pins 2 .

Note: Pay attention there are dowel

pins 2 in case of getting lost. Dowel
pins 2 may be on the LH front cover
when removing it.

2
131601

Remove middle gear shaft 1 . 3 4

Remove starter middle gear 2 .
Remove middle gear shaft 3 .
1
Remove dual gear assy 4 . 2

131602

1 2

Remove M12 bolt 1 .

Remove washer 2 .

131603

Use special tool: magneto rotator removing

1
tool 1 to remove the magneto rotor 2 . 2

131604

13-16
 13 Engine Assy (CF400-5)

13.4.4 Ignition Coil and Spark Plug

1 2 2 1
Removal
Remove M6 bolts 1 .
Remove press plate 2 .
Rotate the ignition coil 1 counter
clockwise until it gets loose.
3
Pull out ignition coil 1 .

131701

Use special tool: spark plug sleeve 1 to

2
remove spark plug 2 .

131702

13.4.5 Cylinder Head Cover Removal

1
Remove cylinder head cover M6 bolts and 3

seal rings 1 .
Remove cylinder head cover 2 .
Remove cylinder head cover seal gasket
3 . 2
131703
Note: After cylinder head cover
removal, the seal gasket may remain
on the cover. If the gasket is not
broken, it is not necessary to remove
it.

Remove spark plug hole seal ring 1 .

131704

13-17
CFMOTO

1 1
Remove timing inspection hole cap . 2
Remove o-ring 2 . 3

Remove oil filter cover 3 .

Remove o-ring 4 .
4

131801

2
Find a proper sleeve to install on M8 bolt 3
1 . Rotate it clockwise until X/T mark 2 is

aligned with the timing inspection mark 3 1

on RH side cover.

131802

13.4.6 Tensioner Removal

1 2 3
Remove M16X14 screw plug 1 .
Remove washer 2 .
Remove tensioner assy 3 .

131803
13.4.7 Camshaft Removal
Remove M6 bolt 1 .
Remove camshaft plate 2 .
Remove air inlet camshaft seat 3 . 1 3
Remove air exhaust camshaft seat 4 .
2

Note: Pay attention to dowel pins

in case of getting lost when removing 4
1
camshaft plate, air inlet&exhaust
camshaft seat. Do not knock parts hard
during removal, in case of damaging
dowel pins and parts. 131804

13-18
 13 Engine Assy (CF400-5)

Remove dowel pins 1 .

Remove camshaft assy 2 .
3 1 2

Note: During camshaft assy 2

removal, hook timing chain 3 in case
it falls down into the engine.

131901

13.4.8 Cylinder Head Removal

Remove M6 inner hex bolts 1 and
washers.
Remove cylinder head M10 bolts 2 and
washers. 3
2
Remove cylinder head 3 . 1

Note: Pay attention to the washers

in case of getting lost or falling into
the engine body when removing bolts. 131902
Cylinder head M10 bolts 2 can be
removed with magnet.

Note: Cylinder head can be removed

by shaking it. Pay attention to dowel
pins in case of getting lost. Hook 2
timing chain 3 in case it falls down
into the engine.
Remove chain guide 1 .
Remove dowel pins 2 . 1 3

Remove cylinder head gasket 3 . 131903

13.4.9 RH Side Cover Removal

Remove M6 bolts 1 . 2
1
Remove RH side cover 2 . (Rotate the
clutch rod 3 to the proper position to
remove the RH side cover.)

131904

13-19
CFMOTO

Remove seal gasket 1 . 1

Remove dowel pins 2 .

2 2
132001

13.4.10 Clutch Removal

Remove M6 bolts assy 1 .

132002

Remove clutch springs 1 .

1

132003

Pull the tie-rod 1 to remove clutch press

plate 2 along with tie-rod 1 .
Remove the tie-rod 1 from the press plate
2. 1

132004

13-20
 13 Engine Assy (CF400-5)

1 1 1 1 1 1 1

Remove frication disc assy 1 .

Remove steel plate B 2 . 1
Remove steel plate A 3 .
2

2 2 2 2 2 3
132101

Use special tool: clutch stopping wrench 1

to fix the clutch hub and remove M20 nut
2.
1 2
Remove washer 3 .
Remove central sleeve assy 4 . 4

132102

1 2

Remove washer 1 .
Insert into the holes 3 with needle-nose
pliers and pull out the clutch shaft sleeve 3
2.

132103

4
Remove M6 bolt 1 and washer. (Left-hand
thread)
Pull out oil pump sprocket 2 with needle-
nose pilers. (Oil pump sprocket is still on
the oil pump chain assy.) 1
Remove housing assy 4 , oil pump chain 2
3 and oil pump sprocket together. 3
132104

13-21
CFMOTO

Remove washer 1 .

132201

1 3 . 4 . 11 C ran ks h aft P u lsin g Rot or

Removal

Remove M5 bolt 1 .
Remove trigger assy 2 .

1
1

2 132202

Remove M8 bolt 1 and washer.

Remove crankshaft pulsing rotor 2 . 1

132203

2
3 4
13.4.12 Cylinder Body Removal

Remove M6 inner hex bolts 1 and

washers. 1
Remove M8 bolt 2 .
Loose M10 nut 3 . Loose the cylinder
body 4 by slightly shaking it. Remove M10
nut 3 and washer.
132204

13-22
 13 Engine Assy (CF400-5)

2 1
Lift and pull out cylinder body 1 .

Note: Hook timing chain 2 in case it

falls down into the engine.

132301

Remove dowel pins 1 .

Remove cylinder body gasket 2 .

13.4.13 Piston Removal

2
Rotate the crankshaft to the proper
situation. 132302
Use special tool: piston pin installing tool
4 to remove the circlip 1 from the gap.
Remove the piston pin 2 .
Remove piston 3 .

Note: When removing piston pin, 2

it is not necessary to remove the 1
4
circlip on both sides. One is enough.
The removed circlip can not be used
again. Replace with a new one when
3
installing.
132303
Rotate the crankshaft to proper position to
remove the other piston following the same
procedures.

13.4.14 Tensioner Plate Removal

2
Remove pin shaft 1 .
Remove tensioner plate 2 .
132304

13-23
CFMOTO

13.4.15 Water Pump Removal

Remove M6 bolts 1 .
Remove water pump cover 2 . The seal
gasket 3 may remain on the cover. 3
Remove it along with the water pump 1
cover. 2

132401

Remove dowel pins 1 . 3

Remove M6 bolt 2 . 1
Remove washer 3 .
Remove water pump impeller 4 . 2 4

132402

1
Remove water pump 1 .

132403

13.4.16 Gearshift Assy Removal

Remove M6 bolts 1 .
Remove screw 2 .
2
Remove gearshift cover 3 .
1

132404

13-24
 13 Engine Assy (CF400-5)

2
Remove gearshift cover gasket 1 .
Remove dowel pins 2 .

2
132501

Remove screw 1 .
Remove gear sensor 2 .
Remove shift location drum 3 .
Remove roller needle 4 .

1 2 3 4

132502

13.4.17 Oil Pipe IV Removal 3

Remove M6 bolts 1 .
Remove oil pipe IV assy 2 . 1 2
O-ring 3 remains on oil pipe IV assy 2 .
Remove o-ring 3 .
3

132503

13.4.18 Transmission Assy Removal

Remove M6 screw 1 .
Remove M6 screw 2 .
Remove oil pump chain guide 3 .
1

132504

13-25
CFMOTO

Remove M7 bolts 1.
Remove M7 bolts 2.

132601

Pull the main shaft 1 in the arrow direction

(by slightly shaking). 1
If shaking doesn't work, slightly knock the 2
countershaft 2 with rubber hammer in the
arrow direction, then pull out the whole
transmission assy.

132602

13.4.19 Oil Pump Assy Removal

1
Remove M6 bolts 1 .
Remove oil pump cover 2 .
Remove roller needle 3 .
Remove oil pump assy 4 with needle-
4 3
nose pliers.
132603

Remove oil pump outer rotor 1 .

132604

13-26
 13 Engine Assy (CF400-5)

13.4.20 Oil Filter Removal

Use special tool: oil filter wrench 1 to 2

1
remove the oil filter 2 .

Note: Cover a cloth or rubber

cushion when removing the oil filter, in
case the special tool damages the oil
filter.
132701

13.4.21 Oil Pan Assy Removal

Remove M6 bolts 1 .
1
Remove oil pan 2 . 2

132702

Remove seal gasket 1 .

Remove oil suction pan assy 2 .
Remove seal gasket 3 . 4
Remove oil return pipe rubber sleeve 4 .
3

132703

1
Remove M6 bolt 1 .
Remove oil pipe I press plate 2 .

132704

13-27
CFMOTO

1 1 1
13.4.22 Engine Case Removal
Remove M8 bolts 1 .
Remove washers 2 .
3
Remove spring 3 .
Remove steel ball 4 .

2 2 2

4 132801

Remove M7 bolts 1 .
1
1

132802

Remove M9 bolts 1 .
Remove washers 2 . 1 1
2 2
2

132803

Remove M8 bolts 1 .
Remove M8 bolts 2 .
1 1 2

132804

13-28
 13 Engine Assy (CF400-5)

Remove engine case 1 .

1
Remove dowel pins 2 .

Remove: Pay attention to dowel pins

2 during removal in case of getting 2
lost. 2

132901

1
13.4.23 Timing Chain Removal

Remove timing chain 1 .

132902

1
13.4.24 Crankshaft and Balance Shaft
Removal

Remove crankshaft 1 and balance shaft

2 together. 2

Note: Pay attention during

crankshaft and balance shaft removal 132903
in case of parts impact and damage.

3
13.5 Engine Parts Inspection
13.5.1 Cylinder Head Cover Inspection 1

Inspect cylinder head cover 1 for crack or

damage. Replace or repair if any defect
occurs.
Inspect seal gasket 2 for crack, hardening
or damage. Replace if any defect occurs. 2
Inspect ignition coil 3 for damage.
Replace if any defect occurs. 132904

13-29
CFMOTO

13.5.2 Cylinder Head Inspection

Va l v e C l e a r a n c e I n s p e c t i o n a n d
1
Adjustment
Note: Inspect and adjust when
engine is cool. 2

Adjust first cylinder timing.

Remove cylinder head cover. (Refer to
Engine Disassembly section)
Remove timing inspection hold cap 1 .
Remove oil strainer cover 2 . 133001

2
Rotate M8 bolt 1 with sleeve and watch B
its movement through timing inspection
hole 2 . Stop rotating when mark "1/T" on
1
pulsing rotor is aligned with mark B . This
is the TDC of first cylinder.

133002

Measurement
Use feeler gauge 1 to measure the
clearance of air inlet valve 2 and air
exhaust valve 3 . Record measurement
result. Transfer it to tappet thickness 1
according to data. If the valve is out of 2
standard, remove tensioner,
intake&exhaust camshafts and replace the
tappets of proper thickness. Inspect again
after installation.
3
133003
Valve Clearance Standard
Exhaust: 0.22 mm~0.28 mm
Intake: 0.08 mm~0.13 mm
Installation procedures refer to Installation
section. 2
B

Adjust second cylinder timing.

1
Rotate M8 bolt 1 with sleeve and watch
its movement through timing inspection
hole 2 . Stop rotating when mark "2/T" on
pulsing rotor is aligned with mark B . This
is the TDC of second cylinder. 133004

13-30
 13 Engine Assy (CF400-5)

Measurement
Use feeler gauge 1 to measure the
clearance of air inlet valve 2 and air
exhaust valve 3 . Record measurement
result. Transfer it to tappet thickness
1
according to data. If the valve is out of
standard, remove tensioner, 2

intake&exhaust camshafts and replace the

tappets of proper thickness. Inspect again
after installation.
Valve clearance standard 3
133101
Exhaust: 0.22 mm~0.28 mm
Intake: 0.08 mm~0.13 mm
Installation procedures refer to Installation
section.

13.5.3 Camshaft Cover Inspection

Removal/installation procedures refer to 1

engine disassembly/assembly sections.

Inspect camshaft covers 1 for wear,

cracks or damage. Replace camshaft and
1
cover together if any defect occurs.
Inspect camshaft holding strip 2 for wear, 2
cracks or damage. Replace if any defect
occurs. 133102

Camshaft cover hole diameter

Standard: 24.00 mm~24.021 mm
Service limit: 24.05 mm

Note: Replace with new cylinder

head assy if the camshaft cover hole
diameter is beyond service limit.

1 2 3

13.5.4 Camshaft Assy Inspection

Camshaft Disassembly
Remove M6 bolts 1 .
Remove retainer 2 .
Remove timing sprocket 3 .
Remove roller needle 4 .
1 4
133103

13-31
CFMOTO

Camshaft Neck Diameter Measurement

Measure camshaft neck 1 diameter. 1 1 1

Camshaft neck diameter

Standard: 23.950 mm~23.972 mm
Service limit: 23.920 mm

Note: Replace with new camshafts if

the diameter is beyond service limit.
133201
Clearance between camshaft neck and
camshaft cover
Standard: 0.028 mm~0.071 mm
Service limit: 0.13mm

Camshaft Deformation

Remove camshafts (refer to Camshaft

Removal section).
Replace with new camshafts if the
difference is beyond service limit.

Place camshafts on camshaft fixing tool or

V-block. 133202

Measure camshaft deformation value with

dial gauge as picture shows.

Cam Wear

Remove camshafts (refer to Camshaft

Removal section).
Measure each cam height A with dial
gauge.
Replace if cam wear is beyond service
limit. A

Cam height standard

Exhaust: 34.743 mm~34.857 mm
Intake: 35.743 mm~35.857 mm
Service limit
Exhaust: 34.64 mm 133203
Intake: 35.64 mm

13-32
 13 Engine Assy (CF400-5)

Inspect timing sprocket 1 for teeth break,

damage or wear. Replace if any defect
occurs.
Inspect retainer 2 for damage. Replace if
it does.
1

2
133301

Camshaft Assy Assembly 4 3 2 5

Put roller needle 1 on camshaft 5 .

Install timing sprocket 2 .
Install retainer 3 .
Install M6 bolts 4 .

4 1
133302

13.5.5 Cylinder Head Assy Inspection

Cylinder Head Assy Disassembly

Remove tappets 1 .
1
Note: Record every tappet place so
that it can be installed into the original
position.

133303

Put special tool: valve spring compressing

tool 1 in the center 2 of valves as picture
shows. 2

Wa rn i n g : We a r g o g g le s a ll t he
1
way during valve spring removal.
Be caution because the spring may
pop out due to high pressure when
removing it.

133304

13-33
CFMOTO

Install special tool: valve spring

compressing tool 1 on valve spring upper
seat 3 as picture shows. Tighten it to
compress the spring.
Remove valve clip 2 with tweezers. 2
1
Loose valve spring compressing tool 1 .
Remove valve spring upper seat 3 . 3

Note: The removed valve and related

parts should be marked and put 133401
together in case of getting mixed.
1
Remove spring 1 .
Remove valve stem seal ring assy 2 . 2
Remove valve spring lower seat 3 .
3

Note: Replace with new seal rings

after every removal. The removed seal
rings are sorted into waste.

Note: The removed valve and related 133402

parts should be marked and put
together in case of getting mixed. 2 2 2 2

Compress exhaust valves 1 . Remove

exhaust valves 1 from other side.
Compress intake valves 2 . Remove intake
valves 2 from other side. 1 1 1 1

Note: The removed valve and related 133403

parts should be marked and put
together in case of getting mixed.

1
Remove M6 bolts 1 .
Remove thermostat cover 2 .
Remove o-seal ring 3 .
Remove thermostat 4 .
4 3

133404

13-34
 13 Engine Assy (CF400-5)

13.5.6 Valve Guide Pipe Removal

Removal
Remove valve (refer to Valve Removal
section). A
Remove soil seal and spring seat.

Heat valve guide pipe nearby area to

120°C~150°C, slightly knock the valve
guide shaft head [A] to remove the valve
guide pipe.
133501
Warning: Do not heat the cylinder
head directly. Otherwise, it will cause
deformation. Soak the cylinder into the
oil and heat the oil, in order to heat the
cylinder head indirectly.
Special tool: valve pipe guide shaft φ4.5

13.5.7 Cylinder Head Wear

Cylinder Head Inspection
Put a parallel rule under the different
positions under cylinder head lower
surface 1 . Measure the clearance
between parallel rule and cylinder head
with feeler gauge.

Cylinder head flatness service limit: 0.05

mm

Replace a new cylinder head if beyond

service limit. 1
133502
If the flatness is less than service limit,
wipe cylinder head lower surface 1 for
service with sandpaper that is fixed on a
tablet (first use #200 sandpaper, then
#400).

Valve Clean

Rotate the reamer clockwise until it can

rotate freely in valve guide pipe. Never
rotate counter clockwise, or the reamer
may be dull.
Clean the valve guide pipe.
Tool: Valve guide pipe reamer φ4.5

13-35
CFMOTO
Valve/Valve Guide Pipe Clearance
Measurement (Swing Method)
A
Insert a new valve A into guide pipe B .
Place the dial gauge perpendicular to B
valve stem and close to cylinder head
connecting surface as much as possible.
Swing the valve forward and backward C
to measure the clearance between valve
and valve guide pipe.
Repeat several times to measure. Replace
valve guide pipes if beyond service limit.
Note: The measurement valve is C
not the exact clearance, because the
measuring point is on the valve stem.

Valve/valve guide pipe clearance standard

Exhaust: 0.07 mm~0.14 mm
Intake: 0.02 mm~0.08 mm
Service limit
Exhaust: 0.27 mm 133601
Intake: 0.22 mm

Valve Seat Ring Inspection

Remove valve (refer to Valve Removal
section).
Inspect valve B and the seal surface A of
B A C
valve seat ring C .
Measure the outer diameter of valve seat
ring D .
Service valve seat ring if outer diameter is E
too large or small.

Valve seat ring outer diameter standard D

Exhaust: 22.6 mm~22.7 mm
Intake: 26.7 mm~26.8 mm
Measure the valve seat seal surface width
E of no carbon deposition with slide
caliper.
F is proper. If it is too wide G , too narrow F G
H or uneven J , service valve seat ring.

Valve seat ring width standard

Exhaust: 0.5 mm~1.0 mm
Intake: 0.5 mm~1.0 mm H J

133602

13-36
 13 Engine Assy (CF400-5)

Valve Seat Ring Service B

Tool: valve seat ring knife A, Holding

shaft B and lever C A

133701
Valve Spring

Valve spring is used to strengthen the

seal effect between valve and valve seat.
Spring elasticity reduce will cause the
engine output power reduce and valve
noise.

Measure spring free length. Replace if less

than service limit.
1

Valve spring free length service limit 133702

(intake&exhaust): 39.5 mm±0.68 mm

Use spring scales 1 to measure the spring

2 elastic force when compressed to
specific length. Replace if beyond
standard. 2

Intake&Exhaust closed: 95.5 N~111.5 N

when compressed to 35.9 mm
1
Intake valve open: 364.4 N~402.4 N when
compressed to 29.1 mm 133703
Exhaust valve open: 417.6 N~461.6 N
when compressed to 28.1mm

Measure spring lean value. Replace if

beyond service limit.

Spring lean service limit: 2°

Thermostat Inspection
1
Remove thermostat 1 and inspect it at
room temperature.
Replace with a new thermostat if the valve 133704
opens.

13-37
CFMOTO
To inspect the valve open temperature,
soak the thermostat A into the container
full of water, and gradually heat the water.
The thermostat has to be immersed into
the water, but do not touch container wall
or bottom. Place a standard temperature
gauge B into the water at the same level
C with the thermostat. The gauge can not
touch the container neither. B
A

Replace if the value is beyond the

standard.

Thermostat valve open temperature

Initial open: 80°C~84°C
Full open: 93°C~97°C C

133801

Cylinder Head Assy Assembly

Install o-seal ring 1 on thermostat cover 2

2.
Install thermostat 3 . 4
Install M6 bolts 4 .

3 1

133802

Install air exhaust valves 1 according to

the records. 2 2 2 2
Install air intake valves 2 according to the
records.

1 1 1 1
133803

13-38
 13 Engine Assy (CF400-5)

According to records, install valve spring 3

lower seat 1 .
Install valve stem seal ring assy 2 . 2
Install valve spring 3 .
1

Note: Replace with new seal rings

after every removal. The removed seal
rings are sorted into waste.

133901

Put special tool: valve spring compressing

tool 1 in the center 2 of valves as picture 2
shows.
1
Wa rn i ng : We a r g o g g le s a ll t he
way during valve spring removal.
Be caution because the spring may
pop out due to high pressure when
removing it.

133902

According to records, install valve spring

upper seat 1 .
Install special tool: valve spring
compressing tool 2 on valve spring upper 3
2
seat 1 as picture shows. Tighten it to
compress the spring. 1
Install valve clip 3 with tweezers.
Loose valve spring compressing tool 2
after the clip is installed. 133904

Install tappets 1 into the original positions

according to records. 1

133904

13-39
CFMOTO

Cylinder head sealing inspection: Inject

cleaning agent into air intake/exhaust
passage 1 . Wait for a while to check
whether there is leaking from valve seat 2
.
2

13.5.8 Timing Tensioner Inspection 134001

Removal procedures refer to Engine

Disassembly section.
1 2 3
Inspect screw plug 1 and washer 2 for
damage. Replace if any defect occurs.
Inspect tensioner 3 for damage or smooth
movement. Replace if any defect occurs.
Press timing tensioner arm to inspect
whether it can return smoothly. Replace if
rough return or getting stuck.
134002
Installation procedures refer to Engine
Assembly chapter.

13.5.9 Cylinder Body Inspection

Cylinder body removal/installation

procedures refer to Engine Disassembly/
Assembly sections.
Cylinder head has different wear degree in
different directions. Measure at four points A
B
as picture show. Replace cylinder body
if any measuring point is beyond service
limit.
10 mm A
60 mm B
Cylinder body inner diameter
134003
Standard: 68.4 mm~68.418 mm
Service limit: 68.50 mm

13-40
 13 Engine Assy (CF400-5)

Cylinder Body Deformation

Measure the flatness of cylinder sealing
surface with straight edge knife and feeler
gauge at different measuring points.
Replace the cylinder body if any value is
beyond the service limit.

Cylinder body flatness service limit: 0.03

mm

Note: Replace with new piston rings 134101

when replacing cylinder body.

13.5.10 Piston Assy Inspection

Removal/Installation procedures refer to

Engine Disassembly/Assembly sections.
Measure piston outer diameter 2 at
different positions which are perpendicular
to piston pin and 10 mm 1 from the
bottom. Replace if the measuring value is
less than service limit.
Piston diameter
1
Standard: 68.366 mm~68.384 mm
Service limit: 68.24 mm 2
According to the above measurement,
figure out the fit clearance between piston 134102
and cylinder body. If the clearance is larger
than 0.10 mm, replace cylinder body and/
or piston.

Piston Ring/Groove Clearance

Piston rings have to be parallel to piston
ring groove. Replace piston and all piston
rings if not parallel.
Use feeler gauge 1 to measure the
clearance between piston ring and groove
for several times.
Clearance between first ring and groove
Standard: 0.02 mm~0.06 mm
Service limit: 0.16 mm 1
Clearance between second ring and groove
Standard: 0.02 mm~0.06 mm
Service limit: 0.16 mm
134103

13-41
CFMOTO

Piston Ring Groove Width

Measure piston ring groove width with

slide caliper at different points.
1
2
First piston ring groove width 1
Standard: 1.01 mm~1.03 mm
Service limit: 1.11 mm

Second piston ring groove width 2

Standard: 1.01 mm~1.03 mm
Service limit: 1.11 mm 134201

Replace piston if the width of any ring is

beyond service limit.

Piston Ring Thickness

1
Measure piston ring thickness with dial
gauge at different points.

First piston ring thickness 1

Standard: 0.97 mm~0.99 mm
Service limit: 0.90 mm 2

Second piston ring thickness 2 134202

Standard: 0.97 mm~0.99 mm
Service limit: 0.90 mm

Replace piston if the thickness of any ring

is beyond service limit.

Note: If new rings are used on old

piston, inspect the ring groove for wear
condition. If the groove surface is not
parallel, replace piston.

Piston Ring Cut Clearance

Put piston ring 1 into cylinder body and fix
it to the end, at which cylinder has
minimum wear.
Measure piston ring cut clearance 2 with
feeler gauge.
Replace all rings if clearance of any ring is
beyond service limit.

13-42
 13 Engine Assy (CF400-5)

First piston ring cut clearance

Standard: 0.15 mm~0.30 mm
Service limit: 0.60 mm

Second piston ring cut clearance

Standard: 0.20 mm~0.40 mm
Service limit: 0.70 mm

Piston Pin and Pin Hole

Measure piston pin hole inner diameter

and outer diameter with dial gauge.
Replace piston and piston pin together if
beyond standard.

Piston pin hole inner diameter standard: 134301

18.004 mm~18.01 mm
1

Measure piston pin outer diameter 1 at

three points.

Piston pin outer diameter standard: 17.996

mm~18 mm
134302

13.5.11 Camshaft Connecting Rod Assy

Inspection
(Status 1)
Connecting Rod Big Side Clearance
Measurement: Push the big end closely to
the shaft neck surface A . Insert the feeler
gauge 1 between surface B and rod to
measure the clearance. 1

Connecting Rod Bid Side Clearance

Standard:
Standard 0.15 mm~0.30 mm
Service limit 0.55 mm
Note: Replace with a new connecting A B
rod and measure the clearance if 134303
beyond service limit. If the clearance is
still out of standard, replace crankshaft.

13-43
CFMOTO
Disassembly
Remove connecting rod M9 nut 1 . 2
Remove connecting rod bolts 2 . 4
5
Remove connecting rod cap 3 . 2
Remove connecting rod body 4 . 5 4
Remove the plain bearing 5 from
connecting rod cap 3 and body 4 .
Wa r i n g : P a y a t t e n t i o n d u r i n g 3 2
connecting rod removal, in case it
breaks the shaft neck. 5

Note: Mark connecting rod cap and 1 5

3
body after removal. 134401
Note: If not worn or damaged, plain
bearings 3 are not necessary to 100cm
remove.

Connecting Rod Parallelism

2
Remove plain bearings and install
connecting rod cap. 1
3
Insert mandrel 1 into big end hole.
Insert mandrel 2 (100 mm long) into small
end hole.
Put connecting rod big end mandrel on
V-block 3 . Plumb it and measure mandrel 134402
2 height on both sides, the height
difference is the parallelism.
Note: Replace if parallelism is 1 2
beyond service limit.
Parallelism service limit: 0.2 mm

Connecting Rod Bend

3
Put connecting rod big end mandrel 1 on
V-block 3 .
Measure the mandrel 2 height difference,
which is the bend value.
134403
Bend service limit: 0.2 mm
N ot e : R e plac e if bend v a lue is
beyond service limit. 1 1

Crankshaft Rod Journal/Bearing Shell

Wear
Measure crankshaft rod journal diameter
1 with micrometer.
Specification:
Standard 37.984 mm~38.00 mm
Service limit 37.97 mm
Note: Replace if diameter is beyond 134404
service limit.
13-44
 13 Engine Assy (CF400-5)

Note: If measured diameter is not

less than service limit but coincide the
marks, re-mark signs.

Crankshaft rod journal diameter mark

2 37.984 mm~37.992 mm
1 37.993 mm~38.000 mm

Measure connecting rod big end hole

diameter 1 . It should coincide the mark.
Otherwise, re-mark.
1
Connecting rod big end hole diameter mark 134501
1 41.00 mm~41.008 mm
2 41.009 mm~41.016 mm

Crankshaft Runout Inspection

Measure crankshaft runout value.
Crankshaft runout standard
Standard 0.02mm
Service limit 0.05 mm

Note: Replace with a new crankshaft

if beyond service limit.

Crankshaft Main Journal 134502

Measure crankshaft main journal 1

diameter with micrometer.
Crankshaft main journal diameter
Standard 37.984 mm~38.00 mm
1 1 1
Service limit 37.97 mm

Note: Replace with a new crankshaft

if beyond service limit.

Note: If measured diameter is not

less than service limit but coincide the
marks, re-mark signs. 1 1 1

134503
Crankshaft main journal diameter mark
2 37.984 mm~37.992 mm
1 37.993 mm~38.000 mm

13-45
CFMOTO

Measure crankcase main shaft hole

diameter. It should coincide the mark.
Otherwise, re-mark.

Crankcase main shaft hole diameter mark

1 41.00 mm~41.008 mm
2 41.009 mm~41.016 mm

According to the crankshaft main journal

mark and crankcase main shaft hole,
choose main plain bearing 1 . Color mark
2.
1

Crankcase main shaft hole/main journal/

main plain bearing
Crankcase C r a n k s h a f t 2
Main plain
m a i n s h a f t main journal
bearing color
hole mark diameter mark
Yellow 1 Brown
Yellow 2 134601
Black
Green 1
Green 2 Blue

13.5.12 Balance Shaft/Plain Bearing

Wear
1 1

Measure balance shaft journal 1 diameter

with micrometer.

Balance shaft journal diameter

Standard 27.987 mm~28.000 mm
Service limit 27.96 mm

Note: Replace with a new balance 134602

shaft if beyond service limit.

Note: If measured diameter is not

less than service limit but coincide the
marks, re-mark signs.

Balance shaft journal diameter mark

1 27.987 mm~27.993 mm
2 27.994 mm~28.000 mm

13-46
 13 Engine Assy (CF400-5)

Balance Shaft

Measure balance shaft hole diameter. It

should coincide the mark. Otherwise, re-
mark.
Balance shaft hole diameter mark
1 31.000 mm~31.008 mm
2 31.009 mm~31.016 mm
1

According to the balance shaft journal

mark and balance shaft hole, choose main
plain bearing 1 . Color mark 2 . 2

Balance shaft hole/balance shaft journal/

balance shaft plain bearing
Balance shaft Balance shaft 134701
Balance shaft
journal diameter plain bearing
hole mark
mark color
Yellow 2 Brown
Yellow 1
Black
Green 2
5 4 3 1
Green 1 Blue

13.5.13 Overriding Clutch Inspection

Disassembly
Remove starter big gear assy 1 .
Remove M8 inner hex screws 2 .
Remove one-way clutch seat 3 .
Remove one-way clutch assy 4 . 2
Remove washer 5 . 134702

Note: Never try to knock the AC

generator rotor. Otherwise, magnet will
lose its magnetism.

Inspection
Turn overriding clutch assy gear 1 with
hand. It should rotate counterclockwise
freely, but not clockwise.

If overriding clutch assy can not work or 1

makes noise, disassemble and inspect
overriding clutch parts for damage.
Replace if necessary.

134703

13-47
CFMOTO

6 1 2 3 5
Assembly
Install one-way clutch assy 2 on seat 3 .
Make sure the counter-clockwise direction.
Put the washer 1 under magneto rotor
lower surface. Install one-way clutch assy
2 on rotor 6 . Install M8 inner hex screws
4 (with 243 thread locker).
Tighten torque: 34 N·m
Apply some grease on one-way clutch 4
assy 2 inner side and install starter big 134801
gear 5 .

13.5.14 Magneto Rotor Inspection

Inspect rotor 1 inside for scratch or other 1

damage.
Inspect rotor 1 key groove for skewness
or other damage.
Inspect rotor 1 outer ring teeth for lean or
other damage.
Inspect woodruff key and key groove on
crankshaft for wear or other damage.
Replace the parts above if severely
damaged. 134802

3
13.5.15 Starter Driven Gear, Dual Gear
and Shaft Inspection 2

Inspection
Inspect starter driven gear 1 for wear and 1
damage.
-Measure starter driven gear 1 inner
diameter and outer diameter.
Service limit:
Outer diameter 3 : 51.705 mm~51.718 mm 134803
Inner diameter 2 : 32.025 mm~32.05 mm
Replace starter driven gear 1 if beyond
service limit. 2

Inspect starter middle gear 3 and dual

gear assy 4 for wear and damage. 4
Replace if necessary. 1
Inspect middle gear shaft 1 and 2 for
wear and damage. Replace if necessary.
3

134804

13-48
 13 Engine Assy (CF400-5)

13.5.16 Magneto Stater

Disassembly
3
Remove M6 inner hex bolt 1 .
4
Remove stater assy 2 .
Remove M6 screws 3 .
Remove wire-press plate 4 . 1
Remove magneto stater 2 . 2

134901

Inspection
Inspect stater condition. Replace if broken.

Inspect coil for break, age or other

damage. Replace if necessary.

134902

Assembly
Install magneto stater 1 on engine LH
side cover 2 . 5
Install M6 inner hex bolt 3 . (With thread 4
locker)
Install wire-press plate . 3
Install M6 screw 5 . (With thread locker) 1

2
134903

13.5.17 Clutch Assy Inspection

Housing Assy
-If inner damping springs get worn, it will
cause waggle between gear and clutch 1
housing, which makes noise. Replace
primary driven gear assy 1 if the waggle
is severe.
-Replace two gears if worn or damaged.
-Replace two gears if the noise is too loud.

134904

13-49
CFMOTO

Friction Disc Assy

Inspect friction discs and steel plates for
blocking, overheating (color changed) and
other defects.
Measure friction disc 1 thickness at 1
different positions.
Replace if any disc gets broken or the
thickness is beyond service limit.

Friction disc thickness 135001

Standard 2.95 mm~3.05 mm
Service limit 2.8 mm

Put every friction disc or steel plate on

flatbed. Use feeler gauge 2 to measure 1
the clearance 1 between flatbed and 2

friction disc or steel plate. Such clearance

is the friction disc or steel plate
deformation value. Replace with new discs
or plates if beyond service limit. 135002
Friction disc and steel plate deformation
Standard 0.15 mm or less
Service limit 0.3 mm
1

Clutch Press Spring

Measure clutch press spring 1 free length.

Replace if less than service limit.

Clutch press spring free length

135003
Standard 33.6 mm±0.5 mm
Service limit 32.6 mm

1
3
4

13.5.18 Transmission Case Inspection 2

Disassembly 5
Remove main shaft fork shaft 1 .
Remove main shift fork 2 .
Remove countershaft fork shaft 3 .
Remove countershaft shift fork 3 and 5 .
135004

13-50
 13 Engine Assy (CF400-5)

6 7
Remove M6 inner hex screw .1
Remove gearshift swing arm bushing 2 .
Remove gearshift swing arm assy 3 . 8
Remove washer 4 .
Remove gearshift swing arm spring 5 .
Remove M6 bolt 6 .
Remove gearshift cam 7 .
Remove roller needle 8 . 1 2 3 4 5

135101

Remove shift drum hub 1 . 2

Remove countershaft assy 2 .
Remove main shaft assy 3 .

135102
Countershaft Assy

3 4 5 7 9 11

Retainer sharp
corner direction

1 2

13

15 16

8
10

Retainer sharp 12
14
corner direction
135103

13-51
CFMOTO

1 25×39×2 washer 7 Driven gear (4th gear) 13 Driven gear (1st gear)
2 Driven gear (2nd gear) 8 Driven gear (3rd gear) 14 20.4×28×1.2 washer
3 Driven gear (6th gear) 9 Washer, spline 15 20×26×13.8 needle bearing
4 Countershaft 10 30 retainer 16 20 retainer
5 30 washer 11 Driven gear (5th gear)
6 Bearing bushing 12 20.4×25×0.5 washer

Main Shaft Assy

6 7 9 10 11 12 13 14 15 16

1 2 3 4 5
8

Retainer sharp Retainer sharp

Retainer sharp Retainer sharp
corner direction corner direction
corner direction corner direction

135201
1 20 retainer 7 Drive gear (6th gear) 13 Washer, spline
2 Needle bearing 8 28×14.7 bearing bushing 14 Drive gear (5th gear)
3 20.5×30×1.5 washer 9 Washer, spline 15 28×14 bearing bushing
4 Drive gear (2nd gear) 10 28 retainer 16 Main shaft
5 28 retainer 11 Drive gear (3rd and 4th gear)
6 Washer, spline 12 28 retainer

Note: The removed retainers are

sorted into waste. Replace with new
retainers during installation.

Gear Inspection
Inspect every gear to see whether it
becomes blue, rusty or worn. Replace if it
does.
Inspect gear teeth if they become rounded,
misplace or have cracks. Replace if they
do.
Note: Replace gears in pairs. Use
new retainer during installation.

13-52
 13 Engine Assy (CF400-5)

Shift Fork Inspection

Inspect shift fork bulge 1 and paw 2 for 1
scratches, bend or damage. Replace if
yes.

2
135301

Shift Drum
Inspect shift drum groove and surface A for
wear or damage. Replace if necessary.

135302
Shift Fork Shaft Inspection
Inspect shift fork shaft 1 and 2 for
deformation, scratches, wear or damage. 1
Replace if necessary.

135303

According to the picture, slide/rotate shift

fork to check its action. Replace shift fork
or fork shaft if the action isn't smooth.

135304

13-53
CFMOTO

Measure shift fork joint thickness with

vernier caliper.
Shift fork thickness: 5.9 mm~6.0 mm

135401

Main Shaft and Countershaft

Inspect main shaft 1 and countershaft 2
for bending, wear or damage. Replace if 2
they do.

135402

1
13.5.19 Gearshift Assy Inspection
Gearshift Rod Inspection
Inspect gearshift rod 1 for bending, wear
or damage. Replace if it does. 2

Inspect gearshift spring 2 for damage or

severe deformation. Replace if it does.

135403

Gear sensor 1 inspection refers to

Electrical System chapter. 1 2
Inspect shift location drum 2 for damage
or deformation. Replace if it does.
Inspect gearshift swing arm return spring
3 for damage or deformation. Replace if it
does.
3

135404

13-54
 13 Engine Assy (CF400-5)

13.5.20 Gearshift Cover Inspection

Inspect gearshift cover 1 for cracks,
damage or severe deformation. Replace if
it does. 1

Rotate needle bearing 2 to inspect for

block or damage. Replace if it does.
Inspect oil seal for damage. Replace if it 2
does.
135501

13.5.21 Water Pump Assy Inspection

2
Inspect water pump cover 1 for cracks, 1
damage or severe deformation. Replace if
it does.
Inspect water pump cover seal ring 2 for
cracks, aging or damage. Replace if
necessary.
135502

Water Pump Impeller

Disassembly
Remove water seal moving ring 1 . 1

135503

Inspection
Inspect water pump impeller 1 for
damage. Replace if it does.
1

135504

13-55
CFMOTO

Assembly
Dip some ethyl alcohol with clean cloth to
clean water moving ring. Install the ring 1
into the mounting hole on water impeller.

2
135601

Water Pump Inspection

Inspect 34×2.5 o-seal ring 1 and water
pump seal ring 2 for cracks, hardening or 1
damage. Replace if necessary.
Inspect water pump 3 for cracks, damage 3
or severe deformation. Replace if it does.
2

135602

Water Seal Inspection 1

Watch the water seal to inspect. If any part

breaks, replace the whole water pump
2
assy. If the seal is good, it is not necessary
to remove it.

Removal
Remove oil seal 1 from water pump 2 .

Note: The removed oil seals are 135603

sorted into waste. Use new oil seals
during installation.
2

Use special tool: water seal puncher pin 1

to press out the static ring 2 from water
pump.
1

Note: The removed water seals are

sorted into waste. Use new water seals
during installation.
135604

13-56
 13 Engine Assy (CF400-5)

Assembly 2
Put the water pump on work bench as
picture shows. Apply some surface sealing
glue on 12×32×5.5 oil seal 2 , put the seal
on special tool: water pump oil seal 1
puncher pin. Align the seal with water
pump mounting hole. Knock puncher pin
1 with hammer to install the oil seal 2 .

135701

Apply 5699 sealing glue on water seal

static ring assy 2 . Install it into the water 1
pump mounting hole with special tool:
water seal puncher pin 1 .

135702

13.5.22 Crankcase Inspection

Inspect plain bearings on crankcase.

Replace if severely worn.

Inspect upper crankcase 1 for cracks or

damage. Replace in pairs if necessary. 1

135703

13-57
CFMOTO

Inspect lower crankcase 1 for cracks or

damage. Replace in pairs if necessary.
1

135801

1
Inspect LH rear cover 1 for cracks or
damage. Replace if necessary.

135802

Inspect oil pan 1 for cracks or damage.

Replace if necessary.
1

135803

Inspect LH side cover 1 for cracks or

damage. Replace in pairs if necessary.

135804

13-58
 13 Engine Assy (CF400-5)

Inspect RH crankcase cover 1 for cracks

or damage. Replace in pairs if necessary.

135901

13-59
CFMOTO
13.6 Engine Assembly

13.6.1 Crankshaft and Balance Shaft 1

Installation

Apply MoS2 on crankshaft 1 and balance

shaft 2 journal, then install them.
2

136001

Note: Align teeth marks 1 during

installation.
1

136002

13.6.2 Timing Chain Installation

Install timing chain 1 .

136003

13.6.3 Crankcase Installation

Install dowel pins 1 .
Apply sealing glue on joint surface evenly 1
and uninterruptedly. 1
Combine lower crankcase 2 with upper
crankcase 3 . 3
1

136004

13-60
 13 Engine Assy (CF400-5)

According to the number sequence, pre-

tighten the bolts 1 ~ 10 with 20 N·m torque
wrench. (Bolts 1 ~ 6 are M9, bolts 7 ~ 10 8 10
are M8.)
According to the number sequence, tighten 7 9
the bolts 1 ~ 10 with 35 N·m torque wrench.
3
(Bolts 1 ~ 6 are M9, bolts 7 ~ 10 are M8.) 1 5
According to the number sequence, tighten
the bolts 1 ~ 6 with 44 N·m torque wrench. 4
6
2
(Bolts 1 ~ 6 are M9, bolts 7 ~ 10 are M8.)
Note: Insert the bolts into holes 136101
before installation. The exposed height
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross
way.
Note: Apply engine oil on thread of
bolts 1 ~ 10 and both sides of washers. 1

Install M8 bolts 1 . Tighten torque: 27.5 N·m. 1

Note: Insert the bolts into holes 1
before installation. The exposed height
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross 136102
way.

Install M7 bolts 1 . Tighten torque: 20 N·m.

Note: Insert the bolts into holes 1
before installation. The exposed height
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross
way.
1

Put washers 1 on M8 bolts 2 and install 136103

the them on crankcase. Tighten torque:
27.5 N·m. 2 2 2

Note: Apply engine oil on thread of

bolts and both sides of washers.
4
Note: When tightening bolts 2 ,
tighten 2~3 times in criss-cross way,
from inside to outside.
1 1 1

3 136104

13-61
CFMOTO

13.6.4 Oil Pan Assy Installation

5

Install oil suction pan seal ring 1 . 2

3
Install oil suction pan assy 2 .
Put two 14x2.5 o-rings on oil pipe I 3 .
Apply some engine oil to the mounting
hose and install the pipe.
4
Install oil return hose damping rubber
sleeve 4 .
Install seal gasket 1 . 1

136201

Install oil pipe I press plate 1 .

Install M6 bolt 2 with 243 thread locker.
Tighten torque: 8 N·m
2

136202

Adjust oil return hose to make it fix into the

mounting groove. Then install oil pan assy
1.
Install M6×25 bolts 2 .
2
Tighten torque: 11~13 N·m 1

136203

13.6.5 Oil Filter Installation

Use special tool: oil filter wrench 1 to 2

install the oil filter 2 . Tighten torque: 1
16~18 N·m

Note: Wrap oil filter with a cloth or

rubber mat, in case the wrench breaks
the filter.
136204

13-62
 13 Engine Assy (CF400-5)

2 1
13.6.6 Oil Pump Installation
Install oil pump outer rotor 1 into the inner
rotor 2 .

136301

Install oil pump 1 .

Install roller pin 2 . 3
Install oil pump cover 3 .
Install M6 bolts 4 .
4

1 2
136302
13.6.7 Transmission Case Installation

Install pins 1 .
1

136303

Install the gearshift cover sub assy 1 to

the proper position in the direction of the
arrow.

136304

13-63
CFMOTO

Install M7×30 bolts 1 with 243 thread

locker.
Tighten torque: 19~21 N·m 1
Install M7×26 bolts 2 with 243 thread
locker. 2
Tighten torque: 20 N·m
Note: Tighten the bolts in criss-cross
way.
136401

Install oil pump chain guide 1 .

Install M6×12 screw 3 with 243 thread
3
locker.
Tighten torque: 10 N·m
1
Install M6×9 screw 2 with 243 thread
locker.
2
Tighten torque: 10 N·m

136402

13.6.8 Oil Pipe IV Assy Installation 1

Apply engine oil on o-seal ring 1 . Install
the ring on oil pipe IV assy 2 . 2
3
Insert the oil pipe IV assy 2 into the hole
on upper crankcase. After installing
position confirmed, knock with rubber
1
hammer to install the pipe.
Install M6 bolts 3 . (Along with a wire clip
for each bolt) 136403

13.6.9 Gearshift Assy Installation

Install roller needle 1 .

Install shift location drum 2 .
Install gear sensor 3 .
Install screw 4 with 243 thread locker.
4 3 2 1

136404

13-64
 13 Engine Assy (CF400-5)

Install dowel pins 1 .

Install seal gasket 2 . 2
Install shift shaft sub assy 3 . 4
Install washer 4 .

3
1

136501

Install gearshift cover 1 .

Install M6 bolts 2 . Tighten torque: 12 N·m
Install screw 3 . 3

Note: Insert the bolts into holes 2

before installation. The exposed height

1
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross
way.
136502

13.6.10 Water Pump Installation 3

Install roller needle 1 .

4 1
Apply engine oil on o-ring 2 .
Install seal ring 3 on water pump 4 . Do 5
not drop the seal ring.
Install water pump 4 .
Install roller needle 5 . 2

136503

2
Install water pump impeller 1 .
Put washer 2 on M6 bolt 3 .
Install M6 bolt 3 .
3 1
Note: Measure the clearance
between water pump and impeller
during installation. The clearance
should be 0.2~0.7. 136504

13-65
CFMOTO

Put seal ring 1 on water pump cover 2 .

Install water pump cover 2 .
Install M6 bolts 3 . 1

3
2

136601

13.6.11 Tensioner Plate Installation

2
Install tensioner plate assy 1 .
Install thread pin shaft 2 with 243 thread
locker.
Tighten torque: 20 N·m
1

136602

13.6.12 Piston Installation

Install piston circlip on one side in
advance.
Install piston 1 . 1
Install piston pin 2 . 2
Install piston circlip 3 on the other side.
Adjust the circlip position to make the
angle between circlip cut and piston cut
approximately 30°. 3

Note: Use new piston circlips after 136603

removal. Replace with new ones if
deformed.

Turn crankshaft to adjust the proper

position of the piston. Apply the same
procedures to install the other piston.

1
Install dowel pins 1 .
Install cylinder gasket 2 .
2

136604

13-66
 13 Engine Assy (CF400-5)

13.6.13 Crankshaft Pulsing Rotor

Installation
Install trigger assy 1 . 2
2
Install M5 bolts 2 .

136701

Install crankshaft pulsing rotor 1 .

Install M8 bolt 2 with 243 thread locker.
Tighten torque: 40 N·m
2

13.6.14 Cylinder Body Installation

136702
Rotate the crankshaft until first cylinder
and second cylinder are on the same level.
Apply engine oil inside the cylinder body.
Install cylinder body 1 . 2 1

Note: Hook the timing chain 2 in

case it falls into the engine.

Note: There three rings 2 3 4 on

piston. Make sure the top ring 3 cut
align with the mark “0” on piston. Make
180° angle between second ring 2 cut
136703
and the mark. Oil ring 4 upper and
lower rail cuts align with the top ring
and second ring respectively. Make 60°
2
angle between spacer and rails. 1 4
Compress the each ring into the
groove before installing into the
cylinder. Install the piston rings one by
one. 3
Install M10 nut 1 .
Install M8 bolt 2 and washer.
Install M6 bolts 3 and washer.
Install cylinder gasket 4 .
136704

13-67
CFMOTO

13.6.15 Clutch Assy Installation

Install washer 1 .

136801

Put oil pump chain 2 on clutch housing

sprocket 1 , then put the oil pump sprocket
3 on chain 2 . 1
Adjust oil pump shaft position, Install oil
pump sprocket, chain and drive hub assy.
Apply 243 thread locker on M6×20 bolt 4
(left-hand thread). Install the bolt with
6.3×16.3×1.2 washer to fix the oil pump 4
sprocket. 3
Tighten torque: 12 N·m 2
136802

Note: Align the sprocket and gear

2 1
during installation.

Apply engine oil on clutch sleeve 1 . Insert

it (the end with holes faces outside)
between main shaft and clutch housing.
Install washer 2 .
136803

2
Install central sleeve 1 .
Install washer 2 .
Use special tool: clutch stopping wrench 3
to fix the clutch housing. 4
Install M20 nut 4 with 243 thread locker. 3

Tighten torque: 132 N·m 1

Note: After tightening the nut, rotate
the housing. The movement should be
smooth, not blocked.
136804

13-68
 13 Engine Assy (CF400-5)

1 1 1 1 1 1 1

1
Install friction discs 1 .
Install steel plates A 2 . 2
Install steel plates B 3 .

Note: During installation, align

first 6 friction discs opening cut. The
outermost friction disc is dislocated. 3 3 3 3 3 2
136901

Install tie-rod 1 .
Install operating pad 2 .
1

136902

Install springs 1 .

136903

Install M6 bolts assy 1 .

136904

13-69
CFMOTO

13.6.16 Cylinder Head Installation

Install dowel pins 1 . 1

Install cylinder head gasket 2 .
Install chain guide 3 .

3 2
137001

Install cylinder head 1 .

Install M10 bolts 2 .
Tighten torque: 54 N·m (if the bolts are old
ones, tighten torque: 49 N·m) 1
Install M6 inner hex bolts 3 and washers. 2
3
Note: Apply engine oil on thread and
washers before installation.
Note: Hook the timing chain in case
it falls into the engine. 137002

1
13.6.17 Camshaft Installation 2 3

Install M8 bolt 1 with sleeve. Tighten until

the mark 2 on pulsing rotor aligns the
mark 3 on crankcase.

137003

Install dowel pins 1 .

Install intake camshaft assy 2 . (There is
"IN" mark on the intake camshaft.) 2
Install exhaust camshaft assy 3 . (There is
"EX" mark on the exhaust camshaft.) 4 1
Put the timing chain 4 on timing sprocket.
3

137004

13-70
 13 Engine Assy (CF400-5)
3
Note: During intake camshaft
installation, the “IN” mark line 2 on
timing sprocket should be parallel with
the cylinder edge 3 . During exhaust
camshaft installation, the “EX” mark 2 1
line 1 on timing sprocket should be
parallel with the cylinder edge 3 .
Note: The timing chain can not move
137101
during installation, the pulsing rotor
should be at the right position. After
timing chain installation, check if all 5
5 5
the marks are qualified or not. Reinstall
if not qualified.
3 2

Install dowel pins 1 . 4

Install intake camshaft seat 2 .
Install exhaust camshaft seat 3 . 1
Install camshaft position plate 4 . 1

Install M6 bolts 5 . 1
137102
Note: Tighten the bolts 5 for three
times. The tighten torque is 5 N·m, 8
N·m and 12 N·m respectively. Tighten 3 2 1
the bolts in criss-cross way.
Note: The exhaust camshaft cover
has “EX” mark on it while intake
camshaft cover has “IN” mark.

13.6.18 Tensioner Installation

Install tensioner assy 1 .

137104
Install washer 2 .
Install M16 inner hex screw plug 3 .
2

13.6.19 RH Side Cover Installation

Install dowel pins 1 .
Install seal gasket 2 .

1 1

137104

13-71
CFMOTO

Install RH side cover 2 .(During

installation, rotate the clutch tie-rod 3 to 1
2
proper position.)
Install M6 bolts 2 .

137201

13.6.20 Cylinder Head Cover Installation

1
Install spark plug seal rings 1 .

137202

Apply 5699 surface sealing glue on

cylinder head 1 .

137203

Put cylinder head seal ring 1 on cylinder

head cover 2 .
Install cylinder head cover 2 .
3
Install M6 cylinder head cover bolts and 1
washers 3 .
Tighten torque: 11~13 N·m

2
137204

13-72
 13 Engine Assy (CF400-5)

Use special tool: spark plug sleeve 1 to

install spark plugs 2 . 1
Tighten torque: 15 N·m
2

137301

3 2 2 3

Install ignition coils 1 .

Install press plates 2 .
Install M6 bolts 3 .
1

137302

13.6.21 Magneto Rotor Installation

Apply engine oil on crankshaft and 2 3
magneto rotor inner hole. Install magneto
rotor 1 . 1
Put washer 3 on M12 bolt 2 . Install M12
bolt 2 with 243 thread locker.
Tighten torque: 155 N·m 4

Note: Before tightening the bolt, pull

magneto with hand to make sure it
doesn’t move. Turn the starter big gear 137303
with hand, it can rotate in one direction.

Install middle gear shaft 3 . 3 2

Install dual gear assy 2 .
Install middle gear shaft 1 .
1
Install starter middle gear 4 . 4

137304

13-73
CFMOTO

2
1

Install dowel pins 1 .

Install seal gasket 2 .

1
137401

Install front LH cover 1 .

Install M6 bolts 2 and M6 bolt 3 . Before
installation, put wire clip 4 on M6 bolt,
then install it.
1
Note: Insert the bolts into holes 2
before installation. The exposed height
should be the same. Adjust the bolt if 4
not. Tighten the bolts in criss-cross
way.
3 137402

13.6.22 Starter Motor Installation 1

Install starter motor 1 . Use rubber

hammer to knock the motor slightly for 2
installation.
Install M6 bolts 2 .
Note: Apply engine oil on starter
motor o-ring before installation. The
o-ring can not be deformed.
137403

13.6.23 Drain Bolt Installation

Install washer 1 .
Install M12 magnetic drain bolt 2 .
Tighten torque: 28~32 N·m
2
1

137404

13-74
 13 Engine Assy (CF400-5)

13.7 Lubrication System

13.7.1 Engine Oil Inspection
Wa r n i n g : M o t o r c y c l e o p e r a t i o n w i t h
insufficient, deteriorated, or contaminated
engine oil will cause accelerated wear and
may result in engine or transmission seizure,
accident, and injury.

Oil Level Inspection

● Check that the engine oil level is between the
upper 1 and lower 2 level in the viewer.
Note: 1
Situate the motorcycle so that it is
perpendicular to the ground. 2
If the motorcycle has just been used, wait
several minutes for all the oil to drain down.
If the oil has just been changed, start the
engine and run it for several minutes at idle 137501
speed. This fills the oil filter with oil. Stop the
engine, then wait several minutes until the oil
settles.
Warning: Racing the engine before the oil
reaches every part can cause engine seizure.
If the engine oil gets extremely low or if the oil
pump or oil passages clog up or otherwise do
not function properly, the oil pressure warning
light will light. If this light stays on when the
engine is running above idle speed, stop the
engine immediately and find the cause.
If the oil level is too high, remove the excess oil,
using a syringe or some other suitable device.
If the oil level is too low, add the correct amount of
oil through the oil filter opening. Use the same type
and make of oil that is already in the engine.
Note: If the engine oil type and make are
unknown, use any brand of the specified oil
to top off the level in preference to running
the engine with the oil level low. Then at
your earliest convenience, change the oil
completely.

13.7.2 Engine Oil Change

Make sure the engine is on the horizontal position
before changing.
Change the engine oil and oil filter at the same
time. Change when the engine is warm.
Note: The engine temperature may
be very hot when changing. Wait until
the temperature is suitable.
Note: Engine oil filter removal/
installation and engine oil drain refer to
Engine Disassembly/Assembly section.

13-75
CFMOTO
Note: The drain oil can reflect some
conditions of the engine. Inspect
whether there is some metal debris in
the drain oil. The debris reflects the
engine internal problems. Inspect the
engine for trouble shooting.

Remove filler screw plug 1 . Add engine

oil.

137601

13.7.3 Relief Valve

Disassembly
Remove circlip 1 with plier. 1
Remove relief valve spring seat 2 .
2
Remove relief valve spring 3 .
Remove relief valve element 4 . 3
Remove relief valve 5 .
4

Oil Relief Valve Inspection

Inspect to see if the valve 1 slides 137602
smoothly when pushing it in with a wooden
or other soft rod, and see if it comes back
to its seat by spring 2 pressure.
1

Note: Inspect the valve in its

assembled state. Disassembly and 2
assembly may change the valve
performance. Usually, the relief valve
isn’t disassembled.
137603
If any rough spots are found during above
inspection, wash the valve clean with a
high-flash point solvent and blow out any Note: If cleaning does no solve the
foreign particles that may be in the valve problem, replace the oil pressure relief
with compressed air. valve as an accessory. The oil pressure
Warning: Clean the oil pressure relief valve is precision made with no
relief valve in a well ventilated area, allowance for replacement of individual
and take care that there is no spark parts.
or flame anywhere near the working
area. Because of the danger of highly
flammable liquids, do not use gasoline
or low flash point solvent.

13-76
 13 Engine Assy (CF400-5)
Assembly
Install relief valve 1 with wrench.
Tighten torque: 15 N·m 5
Install relief valve element 2 .
Install relief valve spring 3 . 4
Remove relief valve spring seat 4 . 3
Clamp circlip 5 with plier. Compress the
valve spring seat to install the circlip 5 . 2

137701

13.7.4 Engine Oil Pump

Disassembly 9 8 7 6
Remove auxiliary oil pump outer rotor 1 .
Remove auxiliary oil pump inner rotor 3 .
Remove roller needle 2 through hole 5 .
Remove main oil pump outer rotor 9 .
Push oil pump shaft 4 towards arrow
direction. Push the main oil pump inner 5 4 3 2 1
rotor 7 towards arrow negative direction
to remove roller needle 8 . 137702
Remove main oil pump inner rotor 7 from
pump shaft 4 .
Remove oil pump shaft 4 from the oil
pump 6 .

Inspection
Inspect oil pump each part for severe wear
and damage. Replace with new oil pump
assy.

Assembly
Install pump shaft 6 on oil pump 4 .
Install main oil pump inner rotor 3 .
Install roller needle 2 .
1 2 3 4
Install main oil pump outer rotor 1 .
Install roller needle 8 through hole 5 .
Install auxiliary oil pump inner rotor 7 .
Install auxiliary oil pump outer rotor 9 .

Note: The auxiliary oil pump rotors

are wider than main oil pump ones. 5 6 7 8 9

137703

13-77
CFMOTO

13.7.5 Oil Pressure Measurement

Remove engine guard.
Remove main oil passage plug 1 and 3
install the adapter 2 and dashboard 3
into the plug hole.
1
Tool: Oil pressure gauge 10kgf/cm2 2
Oil pressure gauge adapter PT3/8

Start and warm up the engine.

Run the engine at the specified speed, and 137801
read the oil pressure gauge

If the oil pressure is much lower than

the standard, check the oil pump, relief
valve, and/ or crankshaft bearing wear
immediately.

If the reading is much higher than the

standard, check the oil passages for
clogging.

Oil Pressure
Standard: At 4000r/min(rpm), the
temperature is 90°C (194°F) 216~294 kPa
(2.2~3.0 kgf/cm2 ,31~43 psi)

Stop engine.
Remove oil pressure gauge and adapter.

Warning: Take care against burns

form hot engine oil that will drain
through the oil passage when the
gauge adapter is removed.

Apply thread locker on main oil passage

plug. Install and tighten the oil passage
plug. 3 2 1
Tighten torque: 20 N·m

13.7.6 Oil Pressure Warning Switch

Removal
Drain engine oil (refer to Engine
Disassembly section).
Remove protection cover 1 .
Remove screw 2 . 137802
Remove oil pressure warning switch 3 .

13-78
 13 Engine Assy (CF400-5)

Inspection
Refer to Electrical System chapter.

Assembly
Apply silicone sealant to the threads of the 1 2 3
oil pressure switch 1 and tighten it.
Tighten torque: 15 N·m
Put the wire on screw 2 and then install
the screw 2 .
Install protection cover 3 on warning
switch 1 .

137901

13-79
CFMOTO
13.8 Engine Installation
13.8.1 Engine Installation
Put the engine on jack and lift up the
engine. Adjust it to the proper position.

Install engine mounting bracket assy 1 . 2

Install M8 bolts 2 .
1
Put the M10 bolt 3 through the hole and 2
install the nut. Fix the bolt with wrench and
then tighten the nut.
3
138001

Install M8 bolts 1 . 1
Put the M10 bolt 2 through the hole and
install the nut. Fix the bolt with wrench and
then tighten the nut. 1

138002

Put the bolt 1 through the hole and install

the M10 nut. Fix the bolt with wrench and
tighten the nut.
1

138003

Put the M10 bolt 1 and M20 bolt 2

2
through the holes and install the nuts. Fix
the bolts with wrench and tighten the nuts.

138004

13-80
 13 Engine Assy (CF400-5)

13.8.2 Output Sprocket Installation

Install output sprocket 1 .
Install washer 2 .
Install M20 pulsing nut 3 with 243 thread
locker. 3
Tighten torque: 125 N·m
1

138101

Install bracket 1 .
Install M6 bolts 2 .
2 1

Note: There are two dowel pins 2 2

under the bracket. Do not lose them
during installation.

138102

Install engine rear LH cover assy 1 .

Install bolts 2 . 1

138103

13.8.3 Gearshift Lever Assy Installation

1
Install gearshift lever assy 1 . 2
Install M6 bolt 2 .

138104

13-81
CFMOTO

13.8.4 Clutch Cable Installation

Rotate the clutch tie-rod 1 and install the
clutch cable 2 .

2 1

138201
13.8.5 Air Filter Connection

Install throttle valve body 2 properly.

Tighten clamp 1 . 2

138202

1
Tighten clamp 1 .

138203

13.8.6 Inlet/Outlet Pipe Installation

2
Install the outlet pipe 2 on engine.
Tighten clamp 1 .
1

138204

13-82
 13 Engine Assy (CF400-5)

Install the inlet pipe 2 on engine.

Tighten clamp 1 .

2
1

138301

Install M6 drain bolt 1 and washer.

138302

13-83
 14 Engine Assy (CF650-8)
14.1 Engine Special Tool ������������ 14-4 ������������������������������������������������� 14-25
14.2 Engine Removal������������������ 14-8 14.4.17 Oil Pipe IV Removal�� 14-27
14.2.1 Engine Inlet&Outlet Water 1 4 . 4 . 1 8 Tr a n s m i s s i o n A s s y
Pipe Removal �������������������������� 14-8 Removal���������������������������������� 14-27
14.2.2 Air Filter Loose������������� 14-9 14.4.19 Oil Pump Assy Removal
14.2.3 Clutch Cable Removal�� 14-9 ������������������������������������������������� 14-28
14.2.4 Gearshift Lever Assy 14.4.20 Oil Filter Removal����� 14-28
Removal������������������������������������ 14-9 14.4.21 Oil Pan Assy Removal......
14.2.5 Sprocket Removal������ 14-10 ������������������������������������������������� 14-29
14.2.6 Engine Assy Removal 14-10 14.4.22 Engine Case Removal......
14.3 Engine Air Intake System� 14-12 ������������������������������������������������� 14-29
1 4 . 3 . 1 T h r o t t l e Va l v e A s s y 14.4.23 Timing Chain Removal...
Disassembly��������������������������� 14-12 ������������������������������������������������� 14-31
1 4 . 3 . 2 T h r o t t l e Va l v e A s s y 14.4.24 Crankshaft and Balance
Inspection������������������������������� 14-13 Shaft Removal������������������������ 14-31
14.3.2.1 Throttle Valve Body... 14.5 Engine Parts Inspection��� 14-31
��������������������������������������������� 14-13 14.5.1 Cylinder Head Cover
14.3.2.2 Fuel Rail Assy������ 14-13 Inspection������������������������������� 14-31
14.3.2.3 Air Intake Pipe������ 14-14 14.5.2 Cylinder Head Inspection
1 4 . 3 . 3 T h r o t t l e Va l v e A s s y ������������������������������������������������� 14-31
Assembly�������������������������������� 14-14 14.5.3 Camshaft Cover Inspection
14.4 Engine Disassembly��������� 14-16 ������������������������������������������������� 14-33
14.4.1 Engine Oil Drain���������� 14-16 14.5.4 Camshaft Assy Inspection
14.4.2 Starter Motor Removal14-16 ������������������������������������������������� 14-33
14.4.3 Magneto Rotor Removal... 14.5.5 Cylinder Head Assy
������������������������������������������������� 14-16 Inspection������������������������������� 14-35
14.4.4 Ignition Coil and Spark Plug 14.5.6 Valve Guide Pipe Removal
Removal���������������������������������� 14-18 ������������������������������������������������� 14-36
14.4.5 Cylinder Head Cover 14.5.7 Cylinder Head Wear���� 14-37
Removal���������������������������������� 14-18 14.5.8 Timing Tensioner Inspection
14.4.6 Tensioner Removal����� 14-19 ������������������������������������������������� 14-42
14.4.7 Camshaft Removal ���� 14-19 14.5.9 Cylinder Body Inspection
14.4.8 Cylinder Head Removal... ������������������������������������������������� 14-42
������������������������������������������������� 14-20 14.5.10 Piston Assy Inspection...
14.4.9 RH Side Cover Removal... ������������������������������������������������� 14-43
������������������������������������������������� 14-20 14.5.11 Camshaft Connecting Rod
14.4.10 Clutch Removal�������� 14-21 Assy Inspection��������������������� 14-45
14.4.11 Crankshaft Pulsing Rotor 14.5.12 Balance Shaft/Plain
Removal���������������������������������� 14-23 Bearing Wear������������������������� 14-48
14.4.12 Cylinder Body Removal... 14.5.13 Balance Shaft/Plain
������������������������������������������������� 14-23 Bearing Wear������������������������� 14-52
14.4.13 Piston Removal��������� 14-24 14.5.14 Overriding Clutch
14.4.14 Tensioner Plate Removal Inspection������������������������������� 14-53
������������������������������������������������� 14-24 14.5.15 Magneto Rotor Inspection
14.4.15 Water Pump Removal14-25 ������������������������������������������������� 14-53
14.4.16 Gearshift Assy Removal 14.5.16 Starter Driven Gear, Dual

14-1
CFMOTO
Gear and Shaft Inspection���� 14-54 ������������������������������������������������� 14-77
14.5.17 Magneto Stater���������� 14-54 14.6.20 Cylinder Head Cover
14.5.18 Clutch Assy Inspection... Installation ����������������������������� 14-78
������������������������������������������������� 14-55 14.6.21 Magneto Rotor Installation
1 4 . 5 . 1 9 Tr a n s m i s s i o n C a s e ������������������������������������������������� 14-79
Inspection������������������������������� 14-56 14.6.22 Starter Motor Installation
14.5.20 Gearshift Assy Inspection ������������������������������������������������� 14-80
������������������������������������������������� 14-60 14.6.23 Drain Bolt Installation......
14.5.21 Gearshift Cover Inspection ������������������������������������������������� 14-80
������������������������������������������������� 14-60 14.7 Lubrication System���������� 14-81
14.5.22 Water Pump Assy 14.7.1 Engine Oil Inspection� 14-81
Inspection������������������������������� 14-60 14.7.2 Engine Oil Change������ 14-81
14.5.23 Crankcase Inspection...... 14.7.3 Relief Valve ����������������� 14-82
������������������������������������������������� 14-63 14.7.4 Engine Oil Pump��������� 14-83
14.6 Engine Assembly �������������� 14-65 14.7.5 Oil Pressure Measurement
14.6.1 Crankshaft and Balance ������������������������������������������������� 14-84
Shaft Installation�������������������� 14-65 1 4 . 7 . 6 O i l P r e s s u r e Wa r n i n g
14.6.2 Timing Chain Installation Switch������������������������������������� 14-84
������������������������������������������������� 14-65 14.8 Engine Installation������������ 14-86
14.6.3 Crankcase Installation14-65 14.8.1 Engine Installation������ 14-86
14.6.4 Oil Pan Assy Installation... 14.8.2 Output Sprocket Installation
������������������������������������������������� 14-67 ������������������������������������������������� 14-87
14.6.5 Oil Filter Installation��� 14-67 14.8.3 Gearshift Lever Assy
14.6.6 Oil Pump Installation�� 14-68 Installation������������������������������ 14-87
1 4 . 6 . 7 Tr a n s m i s s i o n C a s e 14.8.4 Clutch Cable Installation...
Installation������������������������������ 14-68 ������������������������������������������������� 14-88
14.6.8 Oil Pipe IV Assy Installation 14.8.5 Air Filter Connection�� 14-88
������������������������������������������������� 14-69 14.8.6 Inlet/Outlet Pipe Installation
14.6.9 Gearshift Assy Installation ������������������������������������������������� 14-88
������������������������������������������������� 14-69
14.6.10 Water Pump Installation...
������������������������������������������������� 14-71
14.6.11 Tensioner Plate Installation
������������������������������������������������� 14-72
14.6.12 Piston Installation ���� 14-72
14.6.13 Crankshaft Pulsing Rotor
Installation������������������������������ 14-72
14.6.14 Cylinder Body Installation
������������������������������������������������� 14-73
14.6.15 Clutch Assy Installation...
������������������������������������������������� 14-73
14.6.16 Cylinder Head Installation
������������������������������������������������� 14-75
14.6.17 Camshaft Installation14-76
14.6.18 Tensioner Installation14-77
14.6.19 RH Side Cover Installation

14-2
 14 Engine Assy (CF650-8)

14.1 Engine Special Tool

Magneto rotor removing tool (to remove magneto rotor)

0700-031000-922-00

140301
V-block

0800-060000-923-001

140302
Cylinder pressure gauge and connecting seat

Cylinder pressure standard: 0-2MPa

140303
Water seal ring installing tool (puncher pin)

0700-080000-923-002

140304
120304

14-3
CFMOTO

Piston pin circlip installing tool (to install piston pin circlip)

0800-040005-922-001

140401
Feeler gauge (to measure the valve clearance)

140402

Spark plug sleeve

0700-170200-923-001

140403

Valve spring compressing tool

CF188-022006-922-001

140404

14-4
 14 Engine Assy (CF650-8)

Clutch stopping wrench (to remove/install clutch nuts, crankshaft RH nuts)

0700-051000-922-001

130501
Valve pipe guide shaft

φ4.5

140502
Water pump oil seal puncher

0700-081100-923-001

140503
Magneto rotor stopping wrench

0700-031000-922-001

140504

14-5
CFMOTO

Oil filter wrench

0700-070200-922-001

140601

14-6
 14 Engine Assy (CF650-8)
14.2 Engine Removal

Remove muffler.
Remove electrical connectors on engine.
Remove reservoir LH&RH outer protection
plates.
Remove reservoir LH&RH inner protection
plates.
Remove LH&RH panels.
Remove engine guards assy.
Remove frame LH&RH protection plates.

Note: Remove the engine until it

cools down or wear protection clothes
to avoid burnt injury.

14.2.1 Engine Inlet&Outlet Water Pipe

Removal
Open reservoir cap.
Straighten the vehicle. Place a pan under 1
the engine to store the drained coolant.
Remove M6 bolt 1 and washer to drain
the coolant.
140701

Loose clamp 1 .
Pull out inlet pipe 2 from the engine with 2
caliper. 1

140702

Loose clamp 1 .
Pull out outlet pipe 2 from the engine with 2
caliper.

140703

14-7
CFMOTO

14.2.2 Air Filter Loose

1
Loose clamp 1 .

140801

Loose clamp 1 .
2
Shake throttle valve body 2 until it looses.

140802

14.2.3 Clutch Cable Removal

Use tool to rotate clutch rod 2 .

Remove clutch cable 1 .

1 2

140803

14.2.4 Gearshift Lever Assy Removal

Remove M6 bolt 1 . 2
Remove gearshift lever assy 2 . 1

140804

14-8
 14 Engine Assy (CF650-8)
14.2.5 Sprocket Removal

Remove M6 bolt 1 .
1
Remove engine LH rear cover 2 .

140901

Knock and straighten the flanging of

retainer 1 .
Remove counter pulse M20 nut 2 .
Remove retainer 1 . 1
Remove output sprocket 3 . 3

140903

2
14.2.6 Engine Assy Removal

Place the jack with soft cushion under the

engine to support it. 1

Remove M10 nut 1 and bolt.

Remove M20 nut 2 and bolt.

Note: Fix the other side with wrench

during removal.
140904

Remove M10 nut 1 and bolt. 1

Note: Fix the other side with wrench

during removal.

140904

14-9
CFMOTO

Remove M10 bolt 1 and nut.

Remove M8 bolts 2 . 2

1
Note: Fix the other side with wrench 2
during removal.

131002

Remove M10 bolt 1 and nut.

Remove M8 bolts 2 .
Remove engine front mounting bracket
assy 3 .
Shake the engine and decline the jack
slowly to remove the engine. 2 1

3
Note: Fix the other side with wrench
during removal. 2

131003

14-10
 14 Engine Assy (CF650-8)
14.3 Engine Air Intake System
14.3.1 Throttle Valve Assy Disassembly
Air Filter Assy Removal (refer to Air
2
Filter chapter)

Loose clamps 1 .
Remove throttle valve assy 2 .
1 1

141101

1 1 1 1

Remove M6 inner hex screws 1 .

Remove air intake pipes 2 .
2
2

141102

1 1

Remove M6 bolts 1 .
Remove fuel rail assy 2 .

2 141103

Remove screws 1 . 2
Remove idle stepping motor 2 .

1 1

141104

14-11
CFMOTO

Remove screws 1 .
Remove TPS 2 . 1

141201

Remove screw 1 .
Remove T-MAP 2 .

14.3.2 Throttle Valve Assy Inspection 2

14.3.2.1 Throttle Valve Body 141202

Inspect throttle valve body for crack or
damage. Replace if it does.
1

Inspect electrical parts (refer to the

Inspection section of Electrical System
chapter).

Note: It is not allowed to remove the

idle position screw 1 .
141203
14.3.2.2 Fuel Rail Assy
Disassembly 2

Push both sides of injector spring 1 with

thumbs to remove the spring 1 .
Remove fuel injector caps 2 .
Details refer to Electrical System.
1 1
Assembly
Install injector 3 on injector caps 2 . Then
install injector cap spring 1 . Make sure the 3 3
edge of the injector cap 2 clip into the
groove of the spring 1 .
141204

14-12
 14 Engine Assy (CF650-8)

Idle stepping motor, TPS and T-MAP

inspection refer to Electrical System
chapter.

14.3.2.3 Air Intake Pipe

Inspection 1 1
Inspect air intake pipes 1 for cracks or
damage. Replace if they do.

Inspect rubber seal rings 2 for cracks,

hardening or damage. Replace if they do.

2 2
141301
14.3.3 Throttle Valve Assy Assembly

Install T-MAP 1 .
Install screw 2 .

141302

Install TPS 1 .
2
Install screws 2 .
1

141303

14-13
CFMOTO

Install idle stepping motor 1 .

Install screws 2 . 2 2

141401

2 2

Install fuel rail assy 1 .

Install M6 bolts 2 .

1 141402

2 2 2 2

Install air intake pipes assy 1 .

Install M6 inner hex screws 2 .

1
1

141403

Install throttle valve assy 1 .

Tighten clamps 2 .
2 2

141404

14-14
 14 Engine Assy (CF650-8)
14.4 Engine Disassembly

Put the engine on operating bench and fix

it.

Warning: Fix the engine firmly on the

bench, in case it falls down to cause
injury or engine damage.

Warning: Disassemble the engine

when the engine is cool. Otherwise,
wear protective clothes in case of
getting burnt.

14.4.1 Engine Oil Drain

Place a pan under the engine to store the
engine oil from the engine.
Remove M12×22 drain bolt 1 .
2
Remove washer 12 2 .
1
Drain the engine oil.
141501

14.4.2 Starter Motor Removal 1

Remove M6 bolts 1 .
Shake the starter motor 2 to remove it.
If it is too tight, knock the motor gently
with hammer to loose. Do not knock it very
hard. 141502

14.4.3 Magneto Rotor Removal

Remove M6 bolts 1 . 3
Remove cable clip 2 .
1
Remove LH front cover 3 .
2

141503

14-15
CFMOTO

1 1 2
Remove seal gasket .
Remove dowel pins 2 .

Note: Pay attention there are dowel

pins 2 in case of getting lost. Dowel
pins 2 may be on the LH front cover
when removing it.
2
141601

Remove middle gear shaft 1 . 3 4

Remove starter middle gear 2 .

Remove middle gear shaft 3 .
Remove dual gear assy 4 . 1
2

141602

1 2

Remove M12 bolt 1 .

Remove washer 2 .

141603

Use special tool: magneto rotator removing

1
tool 1 to remove the magneto rotor 2 . 2

141604

14-16
 14 Engine Assy (CF650-8)

14.4.4 Ignition Coil and Spark Plug 1 2 2 1

Removal
Remove M6 bolts 1 .
Remove press plate 2 .
Rotate the ignition coil 1 counter
clockwise until it gets loose. 3
Pull out ignition coil 1 .
141701

Use special tool: spark plug sleeve 1 to 2

remove spark plug 2 .

141702

14.4.5 Cylinder Head Cover Removal

1
3
Remove cylinder head cover M6 bolts and
seal rings 1 .
Remove cylinder head cover 2 .
Remove cylinder head cover seal gasket
2
3 .
141703

Note: After cylinder head cover

removal, the seal gasket may remain
on the cover. If the gasket is not
broken, it is not necessary to remove
it.
1

Remove spark plug hole seal ring 1 .

141704

14-17
CFMOTO

1 1
Remove timing inspection hole cap . 2
Remove o-ring 2 . 3
Remove oil filter cover 3 .
Remove o-ring 4 .
4

141801

2
Find a proper sleeve to install on M8 bolt 3
1 . Rotate it clockwise until X/T mark 2 is

aligned with the timing inspection mark 3 1

on RH side cover.

141802

14.4.6 Tensioner Removal

1 2 4
5
Remove M11 spring seat bolt 1 .
Remove washer 2 .
Remove tensioner spring 3 .
Remove M6X14 bolt 4 . 3
Remove tensioner 5 .

4
141803

14.4.7 Camshaft Removal

Remove M6 bolt 1 .
Remove camshaft plate 2 . 1 3
Remove air inlet camshaft seat 3 .
Remove air exhaust camshaft seat 4 . 2

Note: Pay attention to dowel pins 4

1
in case of getting lost when removing
camshaft plate, air inlet&exhaust
camshaft seat. Do not knock parts hard
during removal, in case of damaging 141804
dowel pins and parts.

14-18
 14 Engine Assy (CF650-8)

Remove dowel pins 1 .

Remove camshaft assy 2 .
3 1 2

Note: During camshaft assy 2

removal, hook timing chain 3 in case
it falls down into the engine.

141901

14.4.8 Cylinder Head Removal

Remove M6 inner hex bolts 1 and
washers.
Remove cylinder head M10 bolts 2 and
washers. 3
2
Remove cylinder head 3 . 1

Note: Pay attention to the washers

in case of getting lost or falling into
the engine body when removing bolts. 141902
Cylinder head M10 bolts 2 can be
removed with magnet.

Note: Cylinder head can be removed

by shaking it. Pay attention to dowel
pins in case of getting lost. Hook 2
timing chain 3 in case it falls down
into the engine.
Remove chain guide 1 .
Remove dowel pins 2 . 1 3

Remove cylinder head gasket 3 . 141903

3
2

14.4.9 RH Side Cover Removal

1
Remove M6 bolts 1 .
Remove RH side cover 2 . (Rotate the
clutch rod 3 to the proper position to
remove the RH side cover.)

141904

14-19
CFMOTO

Remove seal gasket 1 . 1

Remove dowel pins 2 .

2 2

142001

14.4.10 Clutch Removal

Remove M6 bolts assy 1 .

142002

Remove clutch springs 1 .

1

142003

Pull the tie-rod 1 to remove clutch press

plate 2 along with tie-rod 1 .
Remove the tie-rod 1 from the press plate
2. 1

142004

14-20
 14 Engine Assy (CF650-8)

1 1 1 1 1 1 1

Remove frication disc assy 1 .

Remove steel plate B 2 . 1
Remove steel plate A 3 .
2

2 2 2 2 2 3
142101

Use special tool: clutch stopping wrench 1

to fix the clutch hub and remove M20 nut
2.
1 2
Remove washer 3 .
Remove central sleeve assy 4 . 4

142102

1 2

Remove washer 1 .
Insert into the holes 3 with needle-nose
pliers and pull out the clutch shaft sleeve 3
2.

142103

4
Remove M6 bolt 1 and washer. (Left-hand
thread)
Pull out oil pump sprocket 2 with needle-
nose pilers. (Oil pump sprocket is still on
the oil pump chain assy.) 1
Remove housing assy 4 , oil pump chain 2
3 and oil pump sprocket together. 3
142104

14-21
CFMOTO

Remove washer 1 .

142201

1 4 . 4 . 11 C ran ks h aft P u lsin g Rot or

Removal

Remove M5 bolt 1 .
Remove trigger assy 2 .

1
1

2 142202

Remove M8 bolt 1 and washer.

Remove crankshaft pulsing rotor 2 . 1

142203

2
3 4
14.4.12 Cylinder Body Removal

Remove M6 inner hex bolts 1 and

washers. 1
Remove M8 bolt 2 .
Loose M10 nut 3 . Loose the cylinder
body 4 by slightly shaking it. Remove M10
nut 3 and washer.
142204

14-22
 14 Engine Assy (CF650-8)

2 1
Lift and pull out cylinder body 1 .

Note: Hook timing chain 2 in case it

falls down into the engine.

142301

Remove dowel pins 1 .

Remove cylinder body gasket 2 .

14.4.13 Piston Removal

2
Rotate the crankshaft to the proper
situation. 142302
Use special tool: piston pin installing tool
4 to remove the circlip 1 from the gap.
Remove the piston pin 2 .
Remove piston 3 .

Note: When removing piston pin, 2

it is not necessary to remove the 1
4
circlip on both sides. One is enough.
The removed circlip can not be used
again. Replace with a new one when
3
installing.
142303
Rotate the crankshaft to proper position to
remove the other piston following the same
procedures.

14.4.14 Tensioner Plate Removal

2
Remove pin shaft 1 .
Remove tensioner plate 2 .
142304

14-23
CFMOTO

14.4.15 Water Pump Removal

Remove M6 bolts 1 .
Remove water pump cover 2 . The seal
gasket 3 may remain on the cover. 3
Remove it along with the water pump 1
cover. 2

142401

Remove dowel pins 1 . 3

Remove M6 bolt 2 . 1
Remove washer 3 .
Remove water pump impeller 4 . 2 4

142402

1
Remove water pump 1 .

142403

14.4.16 Gearshift Assy Removal

Status 1
Remove M6 bolts 1 .
Remove screw 2 . 2
Remove gearshift cover 3 .
1

142404

14-24
 14 Engine Assy (CF650-8)

Remove gearshift cover gasket 1 .

Remove dowel pins 2 .
1

2
142501

Remove screw 1 .
Remove gear sensor 2 .
Remove shift location drum 3 .
Remove roller needle 4 .

1 2 3 4

142502
Status 2
Remove M6 bolts 1 . 1
Remove gear position sensor 2 .
Remove M6 bolts 3 . 2
Remove screw 4 . 4
Remove gearshift cover 5 . 1

5
3

142503

2
Remove gearshift cover gasket 1 .
Remove dowel pins 2 .
1

142504

14-25
CFMOTO

Remove ball contactors 1 .

Remove contactor springs 2 .
1 2
Remove contactor bolt 3 .
Remove gear rotor 4 .
Remove dowel pin 5 .
Remove shift location drum 6 .
Remove roller needle 7 . 1 2 3 4 5 6 7

142601
14.4.17 Oil Pipe IV Removal 1
Remove M6 bolts 1 .
Remove oil pipe IV assy 2 . 3
O-ring 3 remains on oil pipe IV assy 2 .
Remove o-ring 3 .
1 2

142602

14.4.18 Transmission Assy Removal

Remove M6 screw 1 .
Remove M6 screw 2 .
1
Remove oil pump chain guide 3 .

142603

Remove M7 bolts 1 .
Remove M7 bolts 2 . 1

142604

14-26
 14 Engine Assy (CF650-8)

1
2
Pull the main shaft 1 in the arrow direction
(by slightly shaking).
If shaking doesn’t work, slightly knock the
countershaft 2 with rubber hammer in the
arrow direction, then pull out the whole
transmission assy.

142701

14.4.19 Oil Pump Assy Removal

2
Remove M6 bolts 1 .
Remove oil pump cover 2 .
Remove roller needle 3 .
Remove oil pump assy 4 with needle- 1
nose pliers.

4 3
142702

Remove oil pump outer rotor 1 .

1

142703

14.4.20 Oil Filter Removal

Use special tool: oil filter wrench 1 to

remove the oil filter 2 . 2
1

Note: Cover a cloth or rubber

cushion when removing the oil filter, in
case the special tool damages the oil
filter.
142704

14-27
CFMOTO

14.4.21 Oil Pan Assy Removal

Remove M6 bolts 1 .
Remove oil pan 2 .
1
2

142801

Remove seal gasket 1 .

Remove oil suction pan assy 2 .
Remove seal gasket 3 .
Remove oil return pipe rubber sleeve 4 . 4

142802

Remove M6 bolt 1 . 1
Remove oil pipe I press plate 2 .

142803

1 1 1

14.4.22 Engine Case Removal

Remove M8 bolts 1 .
Remove washers 2 .

2 2 2

142804

14-28
 14 Engine Assy (CF650-8)

Remove M7 bolts 1 . 1
1

142901

Remove M9 bolts 1. 1 1
Remove washers 2. 2 2
2

142902

Remove M8 bolts 1 .
Remove M8 bolts 2 . 1 1 2

142903

Remove engine case 1 .

Remove dowel pins 2 .
2
Remove: Pay attention to dowel pins 2
2 during removal in case of getting
lost. 2

142904

14-29
CFMOTO

14.4.23 Timing Chain Removal

1

Remove timing chain 1 .

143001

14.4.24 Crankshaft and Balance Shaft 1

Removal

Remove crankshaft 1 and balance shaft

2 together.
2
Note: Pay attention during
crankshaft and balance shaft removal
in case of parts impact and damage. 143002

14.5 Engine Parts Inspection

3
14.5.1 Cylinder Head Cover Inspection
Inspect cylinder head cover 1 for crack or 1
damage. Replace or repair if any defect
occurs.
Inspect seal gasket 2 for crack, hardening
or damage. Replace if any defect occurs.
Inspect ignition coil 3 for damage. 2
Replace if any defect occurs.
143003

14.5.2 Cylinder Head Inspection

Va l v e C l e a r a n c e I n s p e c t i o n a n d
Adjustment 1
Note: Inspect and adjust when
engine is cool.
2
Adjust first cylinder timing.
Remove cylinder head cover. (Refer to
Engine Disassembly section)
Remove timing inspection hold cap 1 .
Remove oil strainer cover 2 .
143004

14-30
 14 Engine Assy (CF650-8)

Rotate M8 bolt 1 with sleeve and watch

its movement through timing inspection
hole 2 . Stop rotating when mark “1/T” on 2
pulsing rotor is aligned with mark B . This B
is the TDC of first cylinder.
1

Measurement
Use feeler gauge 1 to measure the
143101
clearance of air inlet valve 2 and air
exhaust valve 3 . Record measurement
result. Transfer it to tappet thickness
according to data. If the valve is out of
standard, remove tensioner,
intake&exhaust camshafts and replace the
tappets of proper thickness. Inspect again 1
after installation. 2

Valve Clearance Standard

Exhaust: 0.22 mm~0.28 mm
Intake: 0.08 mm~0.13 mm
3
Installation procedures refer to Installation 143102
section.

Adjust second cylinder timing.

Rotate M8 bolt 1 with sleeve and watch
its movement through timing inspection 2
B
hole 2 . Stop rotating when mark “2/T” on
pulsing rotor is aligned with mark B . This 1
is the TDC of second cylinder.

Measurement
Use feeler gauge 1 to measure the
clearance of air inlet valve 2 and air 143103
exhaust valve 3 . Record measurement
result. Transfer it to tappet thickness
according to data. If the valve is out of
standard, remove tensioner,
intake&exhaust camshafts and replace the
tappets of proper thickness. Inspect again
1
after installation.
2
Valve clearance standard
Exhaust: 0.22 mm~0.28 mm
Intake: 0.08 mm~0.13 mm
Installation procedures refer to Installation
3
section. 143104

14-31
CFMOTO

14.5.3 Camshaft Cover Inspection

Removal/installation procedures refer to
engine disassembly/assembly sections.

Inspect camshaft covers 1 for wear,

1
cracks or damage. Replace camshaft and
cover together if any defect occurs.
Inspect camshaft holding strip 2 for wear,
cracks or damage. Replace if any defect
occurs. 1
Camshaft cover hole diameter
Standard: 24.00 mm~24.021 mm 2
Service limit: 24.05 mm 143201
Note: Replace with new cylinder
head assy if the camshaft cover hole
diameter is beyond service limit.

1 2 3
14.5.4 Camshaft Assy Inspection
Camshaft Disassembly
Remove M6 bolts 1 .
Remove retainer 2 .
Remove timing sprocket 3 .
Remove roller needle 4 .

1 4
143202

Camshaft Neck Diameter Measurement

Measure camshaft neck 1 diameter.

Camshaft neck diameter 1 1 1

Standard: 23.950 mm~23.972 mm
Service limit: 23.920 mm

Note: Replace with new camshafts if

the diameter is beyond service limit.

Clearance between camshaft neck and

camshaft cover 143203
Standard: 0.028 mm~0.071 mm
Service limit: 0.13mm

14-32
 14 Engine Assy (CF650-8)

Camshaft Deformation

Remove camshafts (refer to Camshaft

Removal section).
Replace with new camshafts if the
difference is beyond service limit.
Place camshafts on camshaft fixing tool or
V-block.
Measure camshaft deformation value with
dial gauge as picture shows.
143301

Cam Wear

Remove camshafts (refer to Camshaft

Removal section).
Measure each cam height A with dial
gauge. A
Replace if cam wear is beyond service
limit.

Cam height standard

Exhaust: 35.843 mm~35.957 mm
143302
Intake: 36.543 mm~36.657 mm

Service limit
Exhaust: 35.74 mm
Intake: 36.44 mm

Inspect timing sprocket 1 for teeth break,

damage or wear. Replace if any defect 1
occurs.
Inspect retainer 2 for damage. Replace if
it does.

2
143201
143303

Camshaft Assy Assembly 4 3 2 5

Put roller needle 1 on camshaft 5 .

Install timing sprocket 2 .
Install retainer 3 .
Install M6 bolts 4 .

4 1
143304

14-33
CFMOTO

14.5.5 Cylinder Head Assy Inspection

Cylinder Head Assy Disassembly

Remove tappets 1 .
1

Note: Record every tappet place so

that it can be installed into the original
position.

143401

Put special tool: valve spring compressing

tool 1 in the center 2 of valves as picture
2
shows.

Wa rn i n g: We a r g o g g le s a ll t he 1
way during valve spring removal.
Be caution because the spring may
pop out due to high pressure when
removing it.

143402
Install special tool: valve spring
compressing tool 1 on valve spring upper
seat 3 as picture shows. Tighten it to
compress the spring.
Remove valve clip 2 with tweezers.
Loose valve spring compressing tool 1 . 2
Remove valve spring upper seat 3 . 1

3
Note: The removed valve and related
parts should be marked and put
together in case of getting mixed. 143403

Remove spring 1 .
1
Remove valve stem seal ring assy 2 .
Remove valve spring lower seat 3 .
2

Note: Replace with new seal rings 3

after every removal. The removed seal
rings are sorted into waste.
Note: The removed valve and related
parts should be marked and put
together in case of getting mixed.
143404

14-34
 14 Engine Assy (CF650-8)

2 2 2 2

Compress exhaust valves 1 . Remove

exhaust valves 1 from other side.
Compress intake valves 2 . Remove intake
valves 2 from other side.

Note: The removed valve and related

1 1 1 1
parts should be marked and put
together in case of getting mixed.
143501

Remove M6 bolts 1 .
Remove thermostat cover 2 . 1
Remove o-seal ring 3 .
Remove thermostat 4 .

4 3

143502

14.5.6 Valve Guide Pipe Removal

Removal
Remove valve (refer to Valve Removal
section).
Remove soil seal and spring seat.

A
Heat valve guide pipe nearby area to
120°C~150°C, slightly knock the valve
guide shaft head [A] to remove the valve
guide pipe.

Warning: Do not heat the cylinder

head directly. Otherwise, it will cause
143503
deformation. Soak the cylinder into the
oil and heat the oil, in order to heat the
cylinder head indirectly.
Special tool: valve pipe guide shaft φ4.5

14-35
CFMOTO

14.5.7 Cylinder Head Wear

Cylinder Head Inspection
Put a parallel rule under the different
positions under cylinder head lower
surface 1 . Measure the clearance
between parallel rule and cylinder head
with feeler gauge.
Cylinder head flatness service limit: 0.05
mm
Replace a new cylinder head if beyond
service limit.
If the flatness is less than service limit,
wipe cylinder head lower surface 1 for
service with sandpaper that is fixed on a 1

tablet (first use #200 sandpaper, then 143601

#400).

Valve Clean
Rotate the reamer clockwise until it can
rotate freely in valve guide pipe. Never
rotate counter clockwise, or the reamer
may be dull.
Clean the valve guide pipe.
Tool: Valve guide pipe reamer φ4.5

Valve/Valve Guide Pipe Clearance

Measurement (Swing Method)

Insert a new valve A into guide pipe B . A

Place the dial gauge perpendicular to
valve stem and close to cylinder head B
connecting surface as much as possible.
Swing the valve forward and backward C
to measure the clearance between valve
and valve guide pipe.
Repeat several times to measure. Replace
valve guide pipes if beyond service limit.
Note: The measurement valve is
not the exact clearance, because the C
measuring point is on the valve stem.
Valve/valve guide pipe clearance standard
Exhaust: 0.07 mm~0.14 mm
Intake: 0.02 mm~0.08 mm
Service limit
Exhaust: 0.27 mm
Intake: 0.22 mm
143602

14-36
 14 Engine Assy (CF650-8)

Valve Seat Ring Inspection

Remove valve (refer to Valve Removal B A C
section).
Inspect valve B and the seal surface A of
valve seat ring C .
Measure the outer diameter of valve seat E

ring D .
Service valve seat ring if outer diameter is
too large or small. D
Valve seat ring outer diameter standard
Exhaust: 26.6 mm~26.7 mm
Intake: 32.6 mm~32.7 mm

Measure the valve seat seal surface width

E of no carbon deposition with slide F G

caliper.
F is proper. If it is too wide G , too narrow
H or uneven J , service valve seat ring.

Valve seat ring outer diameter standard H J

Exhaust: 0.9 mm~1.1 mm
Intake: 0.9 mm~1.1 mm
143701

Valve Seat Ring Service

C
Tool: valve seat ring knife A, Holding
shaft B and lever C B

Valve Spring
143702
Valve spring is used to strengthen the
seal effect between valve and valve seat.
Spring elasticity reduce will cause the
engine output power reduce and valve
noise.

Measure spring free length. Replace if less

than service limit.

Valve spring free length standard: 41.6

mm 1

143703

14-37
CFMOTO

Use spring scales 1 to measure the spring

2 elastic force when compressed to
specific length. Replace if beyond
standard. 2
When compressed to 38.4 mm, exhaust
valve closed, the spring force is 103
N~121 N 1
When compressed to 30.5 mm, exhaust
valve open, the spring force is 422 N~466 143801
N
When compressed to 29.8 mm,exhaust
valve open, the spring force is 455 N~503
N

Measure spring lean value. Replace if

beyond service limit.

Spring lean service limit: 2°

1

Thermostat Inspection
143802
Remove thermostat 1 and inspect it at
room temperature.
Replace with a new thermostat if the valve
opens.

To inspect the valve open temperature,

soak the thermostat A into the container
full of water, and gradually heat the water.
The thermostat has to be immersed into
the water, but do not touch container wall A B
or bottom. Place a standard temperature
gauge B into the water at the same level
C with the thermostat. The gauge can not
touch the container neither.

Replace if the value is beyond the

standard. C

Thermostat valve open temperature

Initial open: 70°C~74°C 143803
Full open: 83°C~87°C

14-38
 14 Engine Assy (CF650-8)

Cylinder Head Assy Assembly

2

Install o-seal ring 1 on thermostat cover

2. 4
Install thermostat 3 .
Install M6 bolts 4 .

3 1

143901

Install air exhaust valves 1 according to 2 2 2 2

the records.
Install air intake valves 2 according to the
records.

1 1 1 1
143902

According to records, install valve spring

lower seat 1 . 3

Install valve stem seal ring assy 2 .

Install valve spring 3 . 2

1
Note: Replace with new seal rings
after every removal. The removed seal
rings are sorted into waste.

143903

Put special tool: valve spring compressing

tool 1 in the center 2 of valves as picture
shows. 2

Wa rn i ng : We a r g o g g le s a ll t he 1
way during valve spring removal.
Be caution because the spring may
pop out due to high pressure when
removing it.

143904

14-39
CFMOTO

According to records, install valve spring

upper seat 1 .
Install special tool: valve spring
compressing tool 2 on valve spring upper
seat 1 as picture shows. Tighten it to 3
compress the spring. 2
Install valve clip 3 with tweezers.
1
Loose valve spring compressing tool 2
after the clip is installed.
144001

Install tappets 1 into the original positions

1
according to records.

144002

1
Cylinder head sealing inspection: Inject
cleaning agent into air intake/exhaust
passage 1 . Wait for a while to check
whether there is leaking from valve seat 2
.

144003

14-40
 14 Engine Assy (CF650-8)

14.5.8 Timing Tensioner Inspection 1

Removal procedures refer to Engine

Disassembly section.
Inspect tensioner 1 for damage and
smooth performance. Replace if defects
below occur.
Method:
1. Compress the tensioner arm 2 to the 2
end with hand.
2. Loose the arm, inspect whether the 144101
tensioner arm 2 can return gently and
smoothly. Replace if the return is rough.
Inspect whether chain tensioner arm can
return smoothly or have scratches or not.
Replace if necessary.

14.5.9 Cylinder Body Inspection

B A
Cylinder body removal/installation
procedures refer to Engine Disassembly/
Assembly sections.
Cylinder head has different wear degree in
different directions. Measure at four points
as picture show. Replace cylinder body
if any measuring point is beyond service 144102
limit.
10 mm A
60 mm B
Cylinder body inner diameter
Standard: 83.008 mm~83.026 mm
Service limit: 83.1 mm

Cylinder Body Deformation

Measure the flatness of cylinder sealing
surface with straight edge knife and feeler
gauge at different measuring points.
Replace the cylinder body if any value is
beyond the service limit.

Cylinder body flatness service limit: 0.03

mm

144103
Note: Replace with new piston rings
when replacing cylinder body.

14-41
CFMOTO

14.5.10 Piston Assy Inspection

Removal/Installation procedures refer to

Engine Disassembly/Assembly sections.
Measure piston outer diameter 2 at
different positions which are perpendicular
to piston pin and 10 mm 1 from the
bottom. Replace if the measuring value is 1
less than service limit.
2
Piston diameter
Standard: 82.970 mm~82.988 mm
144201
Service limit: 82.83 mm

According to the above measurement,

figure out the fit clearance between piston
and cylinder body. If the clearance is larger
than 0.10 mm, replace cylinder body and/
or piston.

Piston Ring/Groove Clearance

Piston rings have to be parallel to piston
ring groove. Replace piston and all piston
rings if not parallel.
Use feeler gauge 1 to measure the
clearance between piston ring and groove
1
for several times.
Clearance between first ring and groove
Standard: 0.03 mm~0.06 mm
Service limit: 0.16 mm 144202
Clearance between second ring and groove
Standard: 0.02 mm~0.06 mm
Service limit: 0.16 mm

Piston Ring Groove Width

Measure piston ring groove width with 1
slide caliper at different points. 2

First piston ring groove width 1

Standard: 0.92 mm~0.94 mm
Service limit: 1.02 mm
Second piston ring groove width 2
Standard: 1.01 mm~1.03 mm 144203
Service limit: 1.11 mm

Replace piston if the width of any ring is

beyond service limit.

14-42
 14 Engine Assy (CF650-8)

Piston Ring Thickness

Measure piston ring thickness with dial
gauge at different points.

First piston ring thickness 1

Standard: 0.87 mm~089 mm
Service limit: 0.80 mm

Second piston ring thickness 2

Standard: 0.97 mm~0.99 mm
Service limit: 0.90 mm

Replace piston if the thickness of any ring

is beyond service limit.

Note: If new rings are used on old

piston, inspect the ring groove for wear
condition. If the groove surface is not
parallel, replace piston.

Piston Ring Cut Clearance

Put piston ring 1 into cylinder body and fix
1
it to the end, at which cylinder has
minimum wear.
Measure piston ring cut clearance 2 with
feeler gauge.
Replace all rings if clearance of any ring is
beyond service limit.
2

First piston ring cut clearance

Standard: 0.25 mm~0.40 mm 144301
Service limit: 0.70 mm

Second piston ring cut clearance

Standard: 0.40 mm~0.55 mm
Service limit: 0.80 mm

Piston Pin and Pin Hole

Measure piston pin hole inner diameter
and outer diameter with dial gauge.
Replace piston and piston pin together if
beyond standard.

Piston pin hole inner diameter standard:

19.004 mm~19.010 mm 144302

14-43
CFMOTO
1

Measure piston pin outer diameter 1 at

three points.
Piston pin outer diameter standard: 18.996
mm~19 mm

144401

14.5.11 Camshaft Connecting Rod Assy

Inspection
(Status 1)
Connecting Rod Big Side Clearance
Measurement: Push the big end closely to
the shaft neck surface A . Insert the feeler 1
gauge 1 between surface B and rod to
measure the clearance.
Connecting Rod Bid Side Clearance
Standard:
Standard 0.15 mm~0.30 mm
Service limit 0.50 mm A B
144402
Note: Replace with a new connecting
rod and measure the clearance if
beyond service limit. If the clearance is
still out of standard, replace crankshaft.

Disassembly
Remove connecting rod M9 nut 1 . 2
Remove connecting rod bolts 2 . 4
5
Remove connecting rod cap 3 . 2
Remove connecting rod body 4 . 5 4
Remove the plain bearing 5 from
connecting rod cap 3 and body 4 .
Wa r i n g : P a y a t t e n t i o n d u r i n g 3 2
connecting rod removal, in case it
5
breaks the shaft neck.
1
Note: Mark connecting rod cap and 3
5
body after removal. 144403
Note: If not worn or damaged, plain
bearings 3 are not necessary to
remove.
Note: Connecting rod bolt tighten
method: 29 N·m+90°. Final torque: 65
N·m~90 N·m.

14-44
 14 Engine Assy (CF650-8)
Connecting Rod Parallelism
Remove plain bearings and install 100cm
connecting rod cap.
Insert mandrel 1 into big end hole.
Insert mandrel 2 (100 mm long) into small
2
end hole.
Put connecting rod big end mandrel on 1
3
V-block 3 . Plumb it and measure mandrel
2 height on both sides, the height
difference is the parallelism.
Note: Replace if parallelism is
beyond service limit. 144501
Parallelism service limit: 0.2 mm

Connecting Rod Bend 1 2

Put connecting rod big end mandrel 1 on
V-block 3 .
Measure the mandrel 2 height difference,
which is the bend value.
3
Bend service limit: 0.2 mm
N ot e : R e plac e if bend v alue is
beyond service limit.
144502
Crankshaft Rod Journal/Bearing Shell
Wear 1 1
Measure crankshaft rod journal diameter
1 with micrometer.
Specification:
Standard 37.985 mm~38.00 mm
Service limit 37.97 mm
Note: Replace if diameter is beyond
service limit.
Note: If measured diameter is not
less than service limit but coincide the 144503
marks, re-mark signs.

Connecting rod journal

Journal size Mark
ø37.985~ø37.990 3
ø37.991~ø37.995 2
ø37.996~ø38.000 1
Install on second crankshaft outer circle

14-45
CFMOTO

Measure connecting rod big end hole

diameter 1 . It should coincide the mark.
Otherwise, re-mark.
Connecting rod big end hole diameter mark
1 41.00 mm~41.008 mm
2 41.009 mm~41.016 mm

After connecting rod plain bearing

installation, measure connecting rod big
1
end hole diameter and record the value. 144601
Clearance between connecting rod and
crankshaft journal plain bearing:
0.032 mm~0.042 mm

Note: The weight difference between

two chosen connecting rods should be
≤2g.

Crankshaft Runout Inspection

Measure crankshaft runout value.
Crankshaft runout standard 144602
Standard 0.02mm
Service limit 0.05 mm 1 1 1

Note: Replace with a new crankshaft

if beyond service limit.

Crankshaft Main Journal

Measure crankshaft main journal 1

diameter with micrometer. 1 1 1

Crankshaft main journal diameter 144603

Standard 37.984 mm~38.00 mm
Service limit 37.97 mm

Note: Replace with a new crankshaft

if beyond service limit. Assemble the upper and lower crankcase
according to 14.3.6 Crankcase Assembly
Note: If measured diameter is not
section (without installing other parts).
less than service limit but coincide the
Measure the crankcase hole diameter
marks, re-mark signs.
vertically. It should coincide the mark.
Otherwise, re-mark.
Crankshaft main journal diameter mark
2 37.984 mm~37.992 mm
1 37.993 mm~38.000 mm

14-46
 14 Engine Assy (CF650-8)

Crankcase main shaft hole diameter mark

Yellow 41.000 mm~41.008 mm
Green 41.008 mm~41.016 mm

According to the crankshaft main journal

mark and crankcase main shaft hole, 1
choose main plain bearing 1 . Color mark
2.

Crankcase main shaft hole/main journal/

2
main plain bearing
Crankshaft
Crankcase
main journal M a i n p l a i n
main shaft
d i a m e t e r bearing color
hole mark 144701
mark
Yellow 1 Brown
Yellow 2
Black
Green 1
Green 2 Blue

1 1

14.5.12 Balance Shaft/Plain Bearing

Wear
Measure balance shaft journal 1 diameter
with micrometer.
Balance shaft journal diameter
Standard 27.987 mm~28.000 mm
Service limit 27.96 mm
144702
Note: Replace with a new balance
shaft if beyond service limit.
Note: If measured diameter is not
less than service limit but coincide the
marks, re-mark signs.

Balance shaft journal diameter mark

1 27.987 mm~27.993 mm
2 27.993 mm~28.000 mm

Balance Shaft
Measure balance shaft hole diameter. It
should coincide the mark. Otherwise, re-
mark.
Balance shaft hole diameter mark
Yellow 31.000 mm~31.008 mm
Green 31.008 mm~31.016 mm

14-47
CFMOTO

According to the balance shaft journal

mark and balance shaft hole, choose main
plain bearing 1 . Color mark 2 .
1
Balance shaft hole/balance shaft journal/
balance shaft plain bearing
B a l a n c e Balance shaft
Balance shaft
shaft journal plain bearing 2
hole mark
diameter mark color
Yellow 2 Brown
Yellow 1
Black
Green 2 144801
Green 1 Blue
(Status 2)
Connecting Rod Big Side Clearance
Measurement: Push the big end closely to
the shaft neck surface A . Insert the feeler
gauge 1 between surface B and rod to
1
measure the clearance.
Connecting Rod Bid Side Clearance
Standard:
Standard 0.15 mm~0.30 mm
Service limit 0.55 mm
Note: Replace with a new connecting A B
rod and measure the clearance if 144802
beyond service limit. If the clearance is
still out of standard, replace crankshaft.
Disassembly
Remove connecting rod M9 nut 1 .
Remove connecting rod bolts 2 .
Remove connecting rod cap 3 . 4
Remove connecting rod body 4 . 3
Remove the plain bearing 5 from
connecting rod cap 3 and body 4 . 3
Wa r i n g : P a y a t t e n t i o n d u r i n g 2

connecting rod removal, in case it

breaks the shaft neck. 4
Note: Mark connecting rod cap and 3
body after removal.
1
Note: If not worn or damaged, plain
3
bearings 3 are not necessary to 2 144803
remove.
Note: Connecting rod bolt tighten
method:20N·m+180°±5° for new bolt, Note: Loosen and tighten the
18N·m+180°±5° for old bolt. Connecting connecting rod bolt, the diameter
rod bolts can not be used more than difference at 10° surface should be less
three times. than 0.01mm.

14-48
 14 Engine Assy (CF650-8)
Connecting Rod Parallelism
Remove plain bearings and install 100cm
connecting rod cap.
Insert mandrel 1 into big end hole.
Insert mandrel 2 (100 mm long) into small
end hole. 2
Put connecting rod big end mandrel on 3
1
V-block 3 . Plumb it and measure mandrel
2 height on both sides, the height
difference is the parallelism.
Note: Replace if parallelism is
beyond service limit.
144901
Parallelism service limit: 0.2 mm

1
Connecting Rod Bend 2
Put connecting rod big end mandrel 1 on
V-block 3 .
Measure the mandrel 2 height difference,
which is the bend value. 3
Bend service limit: 0.2 mm
N ot e : R e plac e if bend v alue is
beyond service limit.
144902
Crankshaft Rod Journal/Bearing Shell
1 1
Wear
Measure crankshaft rod journal diameter
1 with micrometer.
Specification:
Standard 37.984 mm~38.00 mm
Service limit 37.97 mm
Note: Replace if diameter is beyond
service limit.
Note: If measured diameter is not 144903
less than service limit but coincide the
marks, re-mark signs.
Crankshaft rod journal diameter mark
3 37.985 mm~37.990 mm
2 37.991 mm~37.995 mm
1 37.996 mm~38.000 mm
Measure connecting rod big end hole
diameter 1 . It should coincide the mark.
Otherwise, re-mark.
Connecting rod big end hole diameter mark
1 41.000 mm~41.005 mm
1
2 41.005 mm~41.010 mm
144904
3 41.010 mm~41.015 mm

14-49
CFMOTO
After connecting rod plain bearing
installation, measure connecting rod big
end hole diameter and record the value.
Clearance between connecting rod and
crankshaft journal plain bearing:
0.032 mm~0.042 mm
Note: The weight difference between
two chosen connecting rods should be
≤2g.

Crankshaft Runout Inspection

Measure crankshaft runout value.
Crankshaft runout standard
Standard 0.02mm
Service limit 0.05 mm

Note: Replace with a new crankshaft

if beyond service limit. 145001

1 1 1
Crankshaft Main Journal
Measure crankshaft main journal 1
diameter with micrometer.
Crankshaft main journal diameter
Standard 37.984 mm~38.00 mm
Service limit 37.97 mm

Note: Replace with a new crankshaft 1 1 1

if beyond service limit.
145002
Note: If measured diameter is not
less than service limit but coincide the
marks, re-mark signs.

Crankshaft main journal diameter mark

2 37.984 mm~37.992 mm
1 37.993 mm~38.000 mm
Measure crankcase main shaft hole
diameter. It should coincide the mark. 1

Otherwise, re-mark.
Crankcase main shaft hole diameter mark
1 41.00 mm~41.008 mm 2
2 41.009 mm~41.016 mm
According to the crankshaft main journal
mark and crankcase main shaft hole,
choose main plain bearing 1 . Color mark 145003
2.

14-50
 14 Engine Assy (CF650-8)
Crankcase main shaft hole/main journal/
main plain bearing
Crankshaft
Crankcase
main journal M a i n p l a i n
main shaft
d i a m e t e r bearing color
hole mark
mark
Yellow 1 Brown
Yellow 2
Black
Green 1
Green 2 Blue

14.5.13 Balance Shaft/Plain Bearing

Wear
Measure balance shaft journal 1 diameter 1 1
with micrometer.
Balance shaft journal diameter
Standard 27.987 mm~28.000 mm
Service limit 27.96 mm
Note: Replace with a new balance
shaft if beyond service limit.
Note: If measured diameter is not
less than service limit but coincide the 145101
marks, re-mark signs.

Balance shaft journal diameter mark

1 27.987 mm~27.993 mm
2 27.994 mm~28.000 mm

Balance Shaft
Measure balance shaft hole diameter. It
should coincide the mark. Otherwise, re-
mark.
Balance shaft hole diameter mark
1 31.000 mm~31.008 mm
2 31.009 mm~31.016 mm
According to the balance shaft journal 1
mark and balance shaft hole, choose main
plain bearing 1 . Color mark 2 .
Balance shaft hole/balance shaft journal/
2
balance shaft plain bearing
B a l a n c e Balance shaft
Balance shaft
shaft journal plain bearing
hole mark
diameter mark color
145102
Yellow 2 Brown
Yellow 1
Black
Green 2
Green 1 Blue

14-51
CFMOTO
5 4 3 1
14.5.14 Overriding Clutch Inspection
Disassembly
Remove starter big gear assy 1 .
Remove M8 inner hex screws 2 .
Remove one-way clutch seat 3 .
Remove one-way clutch assy 4 .
Remove washer 5 .
Note: Never try to knock the AC
generator rotor. Otherwise, magnet will
lose its magnetism. 145201

Inspection
Turn overriding clutch assy gear 1 with
hand. It should rotate counterclockwise
freely, but not clockwise.
1
If overriding clutch assy can not work or
makes noise, disassemble and inspect
overriding clutch parts for damage. 2
Replace if necessary.
145202

Assembly 6 1 2 3 5
Install one-way clutch assy 2 on seat 3 .
Make sure the counter-clockwise direction.
Put the washer 1 under magneto rotor
lower surface. Install one-way clutch assy
2 on rotor 6 . Install M8 inner hex screws
4 (with 243 thread locker).
Tighten torque: 34 N·m
Apply some grease on one-way clutch
4
assy 2 inner side and install starter big
gear 5 . 145203

14.5.15 Magneto Rotor Inspection

Inspect rotor 1 inside for scratch or other
1
damage.
Inspect rotor 1 key groove for skewness
or other damage.
Inspect rotor 1 outer ring teeth for lean or
other damage.
Inspect woodruff key and key groove on
crankshaft for wear or other damage.
Replace the parts above if severely
damaged. 145204

14-52
 14 Engine Assy (CF650-8)

3
14.5.16 Starter Driven Gear, Dual Gear
and Shaft Inspection 2

Inspection
Inspect starter driven gear 1 for wear and
1
damage.
-Measure starter driven gear 1 inner
diameter and outer diameter.
Service limit:
Outer diameter 3 : 51.705 mm~51.718 mm 145301
Inner diameter 2 : 32.025 mm~32.05 mm
Replace starter driven gear 1 if beyond
service limit.
2

Inspect starter middle gear 3 and dual

gear assy 4 for wear and damage. 4
1
Replace if necessary.
Inspect middle gear shaft 1 and 2 for
wear and damage. Replace if necessary.
3

145302

14.5.17 Magneto Stater

Disassembly 3
Remove M6 inner hex bolt 1 . 4
Remove stater assy 2 .
Remove M6 screws 3 .
1
Remove wire-press plate 4 .
2
Remove magneto stater 2 .

145303

Inspection
Inspect stater condition. Replace if broken.

Inspect coil for break, age or other

damage. Replace if necessary.

145304

14-53
CFMOTO

Assembly
5
Install magneto stater 1 on engine LH
4
side cover 2 .
Install M6 inner hex bolt 3 . Install wire-
press plate . 3
Install M6 screw 5 . 1

2
145401

14.5.18 Clutch Assy Inspection

Housing Assy
-If inner damping springs get worn, it will 1
cause waggle between gear and clutch
housing, which makes noise. Replace
primary driven gear assy 1 if the waggle
is severe.
-Replace two gears if worn or damaged.
-Replace two gears if the noise is too loud.
145402

Friction Disc Assy

Inspect friction discs and steel plates for
blocking, overheating (color changed) and
other defects.
Measure friction disc 1 thickness at
different positions.
Replace if any disc gets broken or the 1
thickness is beyond service limit.

Friction disc thickness

Standard 2.95 mm~3.05 mm
Service limit 2.8 mm 145403

Put every friction disc or steel plate on

flatbed. Use feeler gauge 2 to measure
the clearance 1 between flatbed and
friction disc or steel plate. Such clearance
is the friction disc or steel plate 1
deformation value. Replace with new discs 2
or plates if beyond service limit.
Friction disc and steel plate deformation
Standard 0.15 mm or less
Service limit 0.3 mm 145404

14-54
 14 Engine Assy (CF650-8)

Clutch Press Spring

1
Measure clutch press spring 1 free length.
Replace if less than service limit.

Clutch press spring free length

Standard 33.6 mm±0.5 mm
Service limit 32.6 mm

14.5.19 Transmission Case Inspection 145501

Disassembly
Remove main shaft fork shaft 1 .
Remove main shift fork 2 .
1
Remove countershaft fork shaft 3 . 3
Remove countershaft shift fork 3 and 5 . 4
2

145502

Remove M6 inner hex screw 1 .

6 7
Remove gearshift swing arm bushing 2 .
Remove gearshift swing arm assy 3 .
Remove washer 4 . 8
Remove gearshift swing arm spring 5 .
Remove M6 bolt 6 .
Remove gearshift cam 7 .
Remove roller needle 8 .

1 2 3 4 5

145503

2
Remove shift drum hub 1 .
Remove countershaft assy 2 .
Remove main shaft assy 3 .

145504

14-55
CFMOTO
Countershaft Assy

3 4 5 7 9 11

Retainer sharp
corner direction

1 2

13

15 16

8
10

Retainer sharp 12
14
corner direction
145601
1 25×39×2 washer 7 Driven gear (4th gear) 13 Driven gear (1st gear)
2 Driven gear (2nd gear) 8 Driven gear (3rd gear) 14 20.4×28×1.2 washer
3 Driven gear (6th gear) 9 Washer, spline 15 2 0 × 2 6 × 1 3 . 8 n e e d l e
bearing
4 Countershaft 10 30 retainer 16 20 retainer
5 30 washer 11 Driven gear (5th gear)
6 Bearing bushing 12 20.4×25×0.5 washer
Main Shaft Assy

6 7 9 10 11 12 13 14 15 16

1 2 3 4 5
8

Retainer sharp Retainer sharp

corner direction Retainer sharp Retainer sharp corner direction
corner direction corner direction
145602

14-56
 14 Engine Assy (CF650-8)

1 20 retainer 7 Drive gear (6th gear) 13 Washer, spline

2 Needle bearing 8 28×14.7 bearing 14 Drive gear (5th gear)
bushing
3 20.5×30×1.5 washer 9 Washer, spline 15 28×14 bearing bushing
4 Drive gear (2nd gear) 10 28 retainer 16 Main shaft
5 28 retainer 11 Drive gear (3rd and 4th
gear)
6 Washer, spline 12 28 retainer
Note: The removed retainers are
sorted into waste. Replace with new re-
tainers during installation.

Gear Inspection
Inspect every gear to see whether it
becomes blue, rusty or worn. Replace if it
does.
Inspect gear teeth if they become rounded,
misplace or have cracks. Replace if they
do.
Note: Replace gears in pairs. Use
new retainer during installation.

Shift Fork Inspection

1
Inspect shift fork bulge 1 and paw 2 for
scratches, bend or damage. Replace if
yes.

2
145701

Shift Drum
Inspect shift drum groove and surface A for
wear or damage. Replace if necessary.

145702

14-57
CFMOTO

Shift Fork Shaft Inspection

Inspect shift fork shaft 1 and 2 for
deformation, scratches, wear or damage.
Replace if necessary.

145801

According to the picture, slide/rotate shift

fork to check its action. Replace shift fork
or fork shaft if the action isn’t smooth.

145802

Measure shift fork joint thickness with

vernier caliper.
Shift fork thickness: 4.8 mm~5.0 mm

145803

Main Shaft and Countershaft 1

Inspect main shaft 1 and countershaft 2
for bending, wear or damage. Replace if
they do.
2

145804

14-58
 14 Engine Assy (CF650-8)

14.5.20 Gearshift Assy Inspection

Gearshift Rod Inspection 1
Inspect gearshift rod 1 for bending, wear
or damage. Replace if it does.
Inspect gearshift spring 2 for damage or
severe deformation. Replace if it does. 2

145901
Gear sensor 1 inspection refers to
Electrical System chapter.
Inspect shift location drum 2 for damage
or deformation. Replace if it does. 1 2
Inspect gearshift swing arm return spring
3 for damage or deformation. Replace if it
does.

145902

14.5.21 Gearshift Cover Inspection

Inspect gearshift cover 1 for cracks,
damage or severe deformation. Replace if
it does.
Rotate needle bearing 2 to inspect for
block or damage. Replace if it does. 1
Inspect oil seal for damage. Replace if it
does.
2

145903

14.5.22 Water Pump Assy Inspection

Inspect water pump cover 1 for cracks,
damage or severe deformation. Replace if 1 2
it does.
Inspect water pump cover seal ring 2 for
cracks, aging or damage. Replace if
necessary.

145904

14-59
CFMOTO

Water Pump Impeller

Disassembly
Remove water seal moving ring 1 .

146001
Inspection
Inspect water pump impeller 1 for
damage. Replace if it does.

146002

Assembly
Dip some ethyl alcohol with clean cloth to
clean water moving ring. Install the ring
into the mounting hole on water impeller.
1

2
146003

Water Pump Inspection

Inspect 34×2.5 o-seal ring 1 and water 1
pump seal ring 2 for cracks, hardening or
damage. Replace if necessary. 3
Inspect water pump 3 for cracks, damage
2
or severe deformation. Replace if it does.

146004

14-60
 14 Engine Assy (CF650-8)

Water Seal Inspection

1
Watch the water seal to inspect. If any part
breaks, replace the whole water pump
assy. If the seal is good, it is not necessary 2
to remove it.

Removal
Remove oil seal 1 from water pump 2 .

Note: The removed oil seals are

sorted into waste. Use new oil seals 146101
during installation.
2

Use special tool: water seal puncher pin 1

to press out the static ring 2 from water
pump.
1
Note: The removed water seals are
sorted into waste. Use new water seals
during installation.
146102

Assembly
2
Put the water pump on work bench as
picture shows. Apply some surface sealing
glue on 12×32×5.5 oil seal 2 , put the seal
on special tool: water pump oil seal 1
puncher pin. Align the seal with water
pump mounting hole. Knock puncher pin
1 with hammer to install the oil seal 2 .

146103

Apply 5699 sealing glue on water seal

static ring assy 2 . Install it into the water 2

pump mounting hole with special tool:

water seal puncher pin 1 .

146104

14-61
CFMOTO

14.5.23 Crankcase Inspection

Inspect plain bearings on crankcase.

Replace if severely worn.

Inspect upper crankcase 1 for cracks or

damage. Replace in pairs if necessary. 1

146201

Inspect lower crankcase 1 for cracks or

damage. Replace in pairs if necessary.
1

146202

Inspect LH rear cover 1 for cracks or

damage. Replace if necessary.
1

146203

14-62
 14 Engine Assy (CF650-8)

Inspect oil pan 1 for cracks or damage.

Replace if necessary.

146301

Inspect LH side cover 1 for cracks or

damage. Replace in pairs if necessary.

146302

Inspect RH crankcase cover 1 for cracks

or damage. Replace in pairs if necessary. 1

146303

14-63
CFMOTO
14.6 Engine Assembly

14.6.1 Crankshaft and Balance Shaft 1

Installation

Apply MoS2 on crankshaft 1 and balance

shaft 2 journal, then install them.
2

146401

Note: Align teeth marks 1 during

installation.
1

146402

14.6.2 Timing Chain Installation 1

Install timing chain 1 .

146403

14.6.3 Crankcase Installation

Install dowel pins 1 .
2
Apply sealing glue on joint surface evenly
and uninterruptedly.
Combine lower crankcase 2 with upper
crankcase 3 . 1
1

3
1

146404

14-64
 14 Engine Assy (CF650-8)

According to the number sequence, pre-

tighten the bolts 1 ~ 10 with 20 N·m torque
wrench. (Bolts 1 ~ 6 are M9, bolts 7 ~ 10 8 10
are M8.)
According to the number sequence, tighten 7 9
the bolts 1 ~ 10 with 35 N·m torque wrench.
3
(Bolts 1 ~ 6 are M9, bolts 7 ~ 10 are M8.) 1 5
According to the number sequence, tighten
the bolts 1 ~ 6 with 44 N·m torque wrench. 4
6
2
(Bolts 1 ~ 6 are M9, bolts 7 ~ 10 are M8.)
Note: Insert the bolts into holes 146501
before installation. The exposed height
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross
way.
Note: Apply engine oil on thread of
bolts 1 ~ 10 and both sides of washers. 1

Install M8 bolts 1 . Tighten torque: 27.5 N·m. 1

Note: Insert the bolts into holes 1
before installation. The exposed height
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross 146502
way.

Install M7 bolts 1 . Tighten torque: 20 N·m.

Note: Insert the bolts into holes 1
before installation. The exposed height
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross
way.
1

Put washers 1 on M8 bolts 2 and install 146503

the them on crankcase. Tighten torque:
27.5 N·m. 2 2 2

Note: Apply engine oil on thread of

bolts and both sides of washers.
4
Note: When tightening bolts 2 ,
tighten 2~3 times in criss-cross way,
from inside to outside.
1 1 1

3 146504

14-65
CFMOTO

14.6.4 Oil Pan Assy Installation

5

Install oil suction pan seal ring 1 . 2

3
Install oil suction pan assy 2 .
Put two 14x2.5 o-rings on oil pipe I 3 .
Apply some engine oil to the mounting
hose and install the pipe.
4
Install oil return hose damping rubber
sleeve 4 .
Install seal gasket 1 . 1

146601

Install oil pipe I press plate 1 .

Install M6 bolt 2 with 243 thread locker.
Tighten torque: 8 N·m
2

146602

Adjust oil return hose to make it fix into the

mounting groove. Then install oil pan assy
1.
Install M6×25 bolts 2 .
2
Tighten torque: 11~13 N·m 1

146603
14.6.5 Oil Filter Installation

Use special tool: oil filter wrench 1 to

install the oil filter 2 . Tighten torque:
2
16~18 N·m 1

Note: Wrap oil filter with a cloth or

rubber mat, in case the wrench breaks
the filter.

146604

14-66
 14 Engine Assy (CF650-8)

2 1
14.6.6 Oil Pump Installation
Install oil pump outer rotor 1 into the inner
rotor 2 .

146701

Install oil pump 1 .

Install roller pin 2 . 3
Install oil pump cover 3 .
Install M6 bolts 4 .
4

1 2
146702

14.6.7 Transmission Case Installation

Install pins 1 . 1

146703

Install the gearshift cover sub assy 1 to

the proper position in the direction of the
arrow.

146704

14-67
CFMOTO

Install M7×30 bolts 1 with 243 thread

locker.
Tighten torque: 19~21 N·m 1
Install M7×26 bolts 2 with 243 thread
locker. 2
Tighten torque: 20 N·m
Note: Tighten the bolts in criss-cross
way.
146801

Install oil pump chain guide 1 .

Install M6×12 screw 3 with 243 thread
3
locker.
Tighten torque: 10 N·m
1
Install M6×9 screw 2 with 243 thread
locker.
2
Tighten torque: 10 N·m

146802

3
14.6.8 Oil Pipe IV Assy Installation
Apply engine oil on o-seal ring 1 . Install
the ring on oil pipe IV assy 2 . 1
Insert the oil pipe IV assy 2 into the hole
on upper crankcase. After installing 2
3
position confirmed, knock with rubber
hammer to install the pipe.
Install M6 bolts 3 . (Along with a wire clip
1
for each bolt)

146803

14.6.9 Gearshift Assy Installation

Status 1

Install roller needle 1 .

Install shift location drum 2 .
Install gear sensor 3 .
Install screw 4 with 243 thread locker.

4 3 2 1

146804

14-68
 14 Engine Assy (CF650-8)

Install dowel pins 1 .

2
Install seal gasket 2 .
4
Install shift shaft sub assy 3 .
Install washer 4 .

3
1

146901

Install gearshift cover 1 .

Install M6 bolts 2 . Tighten torque: 12 N·m
Install screw 3 .
3

Note: Insert the bolts into holes

2
before installation. The exposed height
should be the same. Adjust the bolt if 1
not. Tighten the bolts in criss-cross
way.
146902

Status 2

Install roller needle 1 .

7 6
Install shift location drum 2 .
Install dowel pins 3 .
Install gear rotor 4
Install contactor bolt 5 .
Install contactor springs 6 .
Install ball contactors 7 .
7 6 5 4 3 2 1
146903

Instatll dowel pins 1 . 2

Install gearshift cover gasket 2 .

146904

14-69
CFMOTO
5

Install gearshift cover 1 . 3

4
Install M6 bolts 2 .
Install screw 3 .
5
Install gear position sensor 4 .
Install M6 bolts 5 .
1
2

147001

14.6.10 Water Pump Installation 3

Install roller needle 1 . 1

4
Apply engine oil on o-ring 2 .
Install seal ring 3 on water pump 4 . Do 5
not drop the seal ring.
Install water pump 4 .
Install roller needle 5 . 2

147002

2
Install water pump impeller 1 .
Put washer 2 on M6 bolt 3 .
Install M6 bolt 3 .
3 1
Note: Measure the clearance
between water pump and impeller
during installation. The clearance
should be 0.2~0.7. 147003

Put seal ring 1 on water pump cover 2 .

Install water pump cover 2 .
Install M6 bolts 3 . 1

3
2

147004

14-70
 14 Engine Assy (CF650-8)

14.6.11 Tensioner Plate Installation

2
Install tensioner plate assy . 1
Install thread pin shaft 2 with 243 thread
locker.
Tighten torque: 20 N·m
1

147101
14.6.12 Piston Installation
Install piston circlip on one side in
advance.
Install piston 1 .
1
Install piston pin 2 .
Install piston circlip 3 on the other side. 2
Adjust the circlip position to make the
angle between circlip cut and piston cut
approximately 30°.
3

Note: Use new piston circlips after

removal. Replace with new ones if 147102
deformed.

Turn crankshaft to adjust the proper

position of the piston. Apply the same
procedures to install the other piston.

Install dowel pins 1 . 1

Install cylinder gasket 2 .
2

147103

14.6.13 Crankshaft Pulsing Rotor

Installation 2
Install trigger assy 1 . 2

Install M5 bolts 2 .

147104

14-71
CFMOTO

Install crankshaft pulsing rotor 1 .

Install M8 bolt 2 with 243 thread locker.
Tighten torque: 40 N·m 2

147201

14.6.14 Cylinder Body Installation

Rotate the crankshaft until first cylinder 1
2
and second cylinder are on the same level.
Apply engine oil inside the cylinder body.
Install cylinder body 1 .

Note: Hook the timing chain 2 in

case it falls into the engine.

Note: There three rings 2 3 4 on

147202
piston. Make sure the top ring 3 cut
align with the mark “0” on piston. Make
180° angle between second ring 2 cut
2
and the mark. Oil ring 4 upper and 1 4
lower rail cuts align with the top ring
and second ring respectively. Make 60°
angle between spacer and rails.
Compress the each ring into the 3
groove before installing into the
cylinder. Install the piston rings one by
one.
Install M10 nut 1 .
147203
Install M8 bolt 2 and washer.
Install M6 bolts 3 and washer.
Install cylinder gasket 4 .

14.6.15 Clutch Assy Installation

Install washer 1 . 1

147204

14-72
 14 Engine Assy (CF650-8)

Put oil pump chain 2 on clutch housing

sprocket 1 , then put the oil pump sprocket
3 on chain 2 .
Adjust oil pump shaft position, Install oil 1
pump sprocket, chain and drive hub assy.
Apply 243 thread locker on M6×20 bolt 4
(left-hand thread). Install the bolt with
6.3×16.3×1.2 washer to fix the oil pump
sprocket. 1
Tighten torque: 12 N·m 3
2
147301
Note: Align the sprocket and gear
during installation.
2 1

Apply engine oil on clutch sleeve 1 . Insert

it (the end with holes faces outside)
between main shaft and clutch housing.
Install washer 2 .

147302

Install central sleeve 1 .

2
Install washer 2 .
Use special tool: clutch stopping wrench 3
to fix the clutch housing.
Install M20 nut 4 with 243 thread locker.
4
Tighten torque: 132 N·m 3

Note: After tightening the nut, rotate 1

the housing. The movement should be
smooth, not blocked.

147303

1 1 1 1 1 1 1
Install friction discs 1 .
Install steel plates A 2 .
Install steel plates B 3 . 1

Note: During installation, align 2

first 6 friction discs opening cut. The
outermost friction disc is dislocated.

3 3 3 3 3 2
147304

14-73
CFMOTO

Install tie-rod 1 .
Install operating pad 2 .

147401

Install springs 1 .

147402

Install M6 bolts assy 1 .

147403

14.6.16 Cylinder Head Installation

Install dowel pins 1 .

Install cylinder head gasket 2 . 1
Install chain guide 3 .

3 2
147404

14-74
 14 Engine Assy (CF650-8)

Install cylinder head 1 .

Install M10 bolts 2 .
Tighten torque: 54 N·m (if the bolts are old 1
2
ones, tighten torque: 49 N·m) 3
Install M6 inner hex bolts 3 and washers.
Note: Hook the timing chain in case
it falls into the engine.
147501

2 3
14.6.17 Camshaft Installation

Install M8 bolt 1 with sleeve. Tighten until

the mark 2 on pulsing rotor aligns the
mark 3 on crankcase.

147502

Install dowel pins 1 .

Install intake camshaft assy 2 . (There is 2
“IN” mark on the intake camshaft.)
Install exhaust camshaft assy 3 . (There is 4 1

“EX” mark on the exhaust camshaft.)

Put the timing chain 4 on timing sprocket. 3

Note: During intake camshaft

installation, the “IN” mark line 2 on
timing sprocket should be parallel with 147503
the cylinder edge 3 . During exhaust
camshaft installation, the “EX” mark 3
line 1 on timing sprocket should be
parallel with the cylinder edge 3 .
Note: The timing chain can not move
during installation, the pulsing rotor
should be at the right position. After 2 1
timing chain installation, check if all
the marks are qualified or not. Reinstall
if not qualified.
147504

14-75
CFMOTO
Install dowel pins 1 .
5
Install intake camshaft seat 2 . 5 5
Install exhaust camshaft seat 3 .
Install camshaft position plate 4 . 2
3
Install M6 bolts 5 .
4
Note: Tighten the bolts 5 for three
times. The tighten torque is 5 N·m, 8 1
N·m and 12 N·m respectively. Tighten 1
the bolts in criss-cross way.
1
Note: The exhaust camshaft cover 147601
has “EX” mark on it while intake
camshaft cover has “IN” mark.
5 4 2
1
14.6.18 Tensioner Installation

Install tensioner 1 . 3
Install M6 bolts 2 (with thread locker).
Install tensioner spring 3 .
Put washer 4 on spring seat bolt 5 .
Install M11 spring seat bolt M11 5 .
2
147602

14.6.19 RH Side Cover Installation

Install dowel pins 1 .
Install seal gasket 2 .

1 1

147603

3
Install RH side cover 2 .(During
1
installation, rotate the clutch tie-rod 3 to
proper position.)
Install M6 bolts 2 . 2

147604

14-76
 14 Engine Assy (CF650-8)

14.6.20 Cylinder Head Cover Installation

Install spark plug seal rings 1 .

147701

Apply 5699 surface sealing glue on

cylinder head 1 .

147702

Put cylinder head seal ring 1 on cylinder 3

1
head cover 2 .
Install cylinder head cover 2 .
Install M6 cylinder head cover bolts and
washers 3 .
2
Tighten torque: 11~13 N·m 147703

1
Use special tool: spark plug sleeve 1 to
install spark plugs 2 . 2
Tighten torque: 15 N·m

147704

14-77
CFMOTO

1 3 2 2 3
Install ignition coils .
Install press plates 2 .
Install M6 bolts 3 .

147801

14.6.21 Magneto Rotor Installation

Apply engine oil on crankshaft and
2 3
magneto rotor inner hole. Install magneto
rotor 1 .
1
Put washer 3 on M12 bolt 2 . Install M12
bolt 2 with 243 thread locker.
Tighten torque: 155 N·m
4

Note: Before tightening the bolt, pull

magneto with hand to make sure it
doesn’t move. Turn the starter big gear 147802
with hand, it can rotate in one direction.

Install middle gear shaft 3 .

3 2
Install dual gear assy 2 .
Install middle gear shaft 1 .
Install starter middle gear 4 . 1
4

147803

2
Install dowel pins 1 . 1

Install seal gasket 2 .

1
147804
14-78
 14 Engine Assy (CF650-8)

Install front LH cover 1 .

Install M6 bolts 2 and M6 bolt 3 . Before
installation, put wire clip 4 on M6 bolt,
then install it. 1

2
Note: Insert the bolts into holes
before installation. The exposed height
4
should be the same. Adjust the bolt if
not. Tighten the bolts in criss-cross 3
way. 147901

1
14.6.22 Starter Motor Installation
Install starter motor 1 . Use rubber
hammer to knock the motor slightly for
installation. 2
Install M6 bolts 2 .
Note: Apply engine oil on starter
motor o-ring before installation. The
o-ring can not be deformed.
147902

14.6.23 Drain Bolt Installation

Install washer 1 .
Install M12 magnetic drain bolt 2 .
Tighten torque: 28~32 N·m

2
1

147903

14-79
CFMOTO

14.7 Lubrication System

14.7.1 Engine Oil Inspection

Warning: Motorcycle operation
with insufficient, deteriorated, or
contaminated engine oil will cause
a c c e l e ra t ed w ea r an d may result
in engine or transmission seizure,
accident, and injury.

Oil Level Inspection

● Check that the engine oil level is 1
between the upper 1 and lower 2 level in 2
the viewer.
Note:
Situate the motorcycle so that it is
perpendicular to the ground. 148001
If the motorcycle has just been used,
Note: If the engine oil type and
wait several minutes for all the oil to
make are unknown, use any brand of
drain down.
the specified oil to top off the level
If the oil has just been changed, start
in preference to running the engine
the engine and run it for several
with the oil level low. Then at your
minutes at idle speed. This fills the oil
earliest convenience, change the oil
filter with oil. Stop the engine, then wait
completely.
several minutes until the oil settles.
Warning: Racing the engine before 14.7.2 Engine Oil Change
the oil reaches every part can cause Make sure the engine is on the horizontal
engine seizure. If the engine oil gets position before changing.
extremely low or if the oil pump or Change the engine oil and oil filter at the
oil passages clog up or otherwise do same time. Change when the engine is
not function properly, the oil pressure warm.
warning light will light. If this light
Note: The engine temperature may
stays on when the engine is running
be very hot when changing. Wait until
above idle speed, stop the engine
the temperature is suitable.
immediately and find the cause.
If the oil level is too high, remove the Note: Engine oil filter removal/
excess oil, using a syringe or some other installation and engine oil drain refer to
suitable device. Engine Disassembly/Assembly section.
If the oil level is too low, add the correct
amount of oil through the oil filter opening.
Use the same type and make of oil that is
already in the engine.

14-80
 14 Engine Assy (CF650-8)
Note: The drain oil can reflect some
conditions of the engine. Inspect
whether there is some metal debris in
the drain oil. The debris reflects the
engine internal problems. Inspect the
engine for trouble shooting.

Remove filler screw plug 1 . Add engine

oil.

148101

14.7.3 Relief Valve

Disassembly
Remove circlip 1 with plier. 1
Remove relief valve spring seat 2 .
2
Remove relief valve spring 3 .
Remove relief valve element 4 . 3
Remove relief valve 5 .
4

Oil Relief Valve Inspection

Inspect to see if the valve 1 slides 148102
smoothly when pushing it in with a wooden
or other soft rod, and see if it comes back
to its seat by spring 2 pressure.
1

Note: Inspect the valve in its

assembled state. Disassembly and 2
assembly may change the valve
performance. Usually, the relief valve
isn’t disassembled.
148103
If any rough spots are found during above
inspection, wash the valve clean with a Note: If cleaning does no solve the
high-flash point solvent and blow out any problem, replace the oil pressure relief
foreign particles that may be in the valve valve as an accessory. The oil pressure
with compressed air. relief valve is precision made with no
Warning: Clean the oil pressure allowance for replacement of individual
relief valve in a well ventilated area, parts.
and take care that there is no spark
or flame anywhere near the working
area. Because of the danger of highly
flammable liquids, do not use gasoline
or low flash point solvent.

14-81
CFMOTO
Assembly
Install relief valve 1 with wrench.
Tighten torque: 15 N·m 5
Install relief valve element 2 .
Install relief valve spring 3 . 4
Remove relief valve spring seat 4 . 3
Clamp circlip 5 with plier. Compress the
valve spring seat to install the circlip 5 . 2

148201

14.7.4 Engine Oil Pump

Disassembly 9 8 7 6
Remove auxiliary oil pump outer rotor 1 .
Remove auxiliary oil pump inner rotor 3 .
Remove roller needle 2 through hole 5 .
Remove main oil pump outer rotor 9 .
Push oil pump shaft 4 towards arrow
direction. Push the main oil pump inner 5 4 3 2 1
rotor 7 towards arrow negative direction
to remove roller needle 8 . 148202
Remove main oil pump inner rotor 7 from
pump shaft 4 .
Remove oil pump shaft 4 from the oil
pump 6 .

Inspection
Inspect oil pump each part for severe wear
and damage. Replace with new oil pump
assy.

Assembly
Install pump shaft 6 on oil pump 4 .
Install main oil pump inner rotor 3 .
Install roller needle 2 .
1 2 3 4
Install main oil pump outer rotor 1 .
Install roller needle 8 through hole 5 .
Install auxiliary oil pump inner rotor 7 .
Install auxiliary oil pump outer rotor 9 .

Note: The auxiliary oil pump rotors

are wider than main oil pump ones. 5 6 7 8 9

148203

14-82
 14 Engine Assy (CF650-8)

14.7.5 Oil Pressure Measurement

Remove engine guard.
Remove main oil passage plug 1 and 3
install the adapter 2 and dashboard 3
into the plug hole.
1
Tool: Oil pressure gauge 10kgf/cm2 2
Oil pressure gauge adapter PT3/8

Start and warm up the engine.

Run the engine at the specified speed, and 148301
read the oil pressure gauge

If the oil pressure is much lower than

the standard, check the oil pump, relief
valve, and/ or crankshaft bearing wear
immediately.

If the reading is much higher than the

standard, check the oil passages for
clogging.

Oil Pressure
Standard: At 4000r/min(rpm), the
temperature is 90°C (194°F) 216~294 kPa
(2.2~3.0 kgf/cm2 ,31~43 psi)

Stop engine.
Remove oil pressure gauge and adapter.

Warning: Take care against burns

form hot engine oil that will drain
through the oil passage when the
gauge adapter is removed.

Apply thread locker on main oil passage

plug. Install and tighten the oil passage
plug. 3 2 1
Tighten torque: 20 N·m

14.7.6 Oil Pressure Warning Switch

Removal
Drain engine oil (refer to Engine
Disassembly section).
Remove protection cover 1 .
Remove screw 2 .
148402
Remove oil pressure warning switch 3 .

14-83
CFMOTO

Inspection
Refer to Electrical System chapter.

Assembly
Apply silicone sealant to the threads of the 1 2 3
oil pressure switch 1 and tighten it.
Tighten torque: 15 N·m
Put the wire on screw 2 and then install
the screw 2 .
Install protection cover 3 on warning
switch 1 .

148401

14-84
 14 Engine Assy (CF650-8)
14.8 Engine Installation
14.8.1 Engine Installation
Put the engine on jack and lift up the
engine. Adjust it to the proper position.

Install engine mounting bracket assy 1 . 2

Install M8 bolts 2 .
Put the M10 bolt 3 through the hole and 1 2
install the nut. Fix the bolt with wrench and
then tighten the nut.

3
138501

Install M8 bolts 1 . 1
Put the M10 bolt 2 through the hole and
install the nut. Fix the bolt with wrench and
then tighten the nut. 1

138502

Put the bolt 1 through the hole and install

the M10 nut. Fix the bolt with wrench and
tighten the nut.
1

148503

Put the M10 bolt 1 and M20 bolt 2

2
through the holes and install the nuts. Fix
the bolts with wrench and tighten the nuts.

148504

14-85
CFMOTO

14.8.2 Output Sprocket Installation

Install output sprocket 1 .
Install washer 2 .
Install M20 pulsing nut 3 with 243 thread
locker.
1
Tighten torque: 125 N·m
3

148601

Install bracket 1 .
Install M6 bolts 2 .
2 1

Note: There are two dowel pins 2 2

under the bracket. Do not lose them
during installation.

148602

Install engine rear LH cover assy 1 .

Install bolts 2 . 1

148603

14.8.3 Gearshift Lever Assy Installation

Install gearshift lever assy 1 .

Install M6 bolt 2 .

1
2

148604

14-86
 14 Engine Assy (CF650-8)

14.8.4 Clutch Cable Installation

Rotate the clutch tie-rod 1 and install the

clutch cable 2 .

2 1

148701

14.8.5 Air Filter Connection

Install throttle valve body 2 properly. 2

Tighten clamp 1 .
1

148702

Tighten clamp 1 .

148703

14.8.6 Inlet/Outlet Pipe Installation 2

Install the outlet pipe 2 on engine.

Tighten clamp 1 .
1

148704

14-87
CFMOTO

Install the inlet pipe 2 on engine.

Tighten clamp 1 .

2
1

148801

Install M6 drain bolt 1 and washer.

148802

14-88
 15 Handlebar Assy
15.1 Handlebar Assy����������������������������������������������������������������������������� 15-1
15.1.1 Handlebar Lever���������������������������������������������������������������������� 15-1
15.1.2 Handlebar Cover��������������������������������������������������������������������� 15-2
15.2 Handlebar Assy Inspection���������������������������������������������������������� 15-2
15.2.1 Throttle Cable Free Play �������������������������������������������������������� 15-2
15.2.2 Clutch Lever Free Play Inspection���������������������������������������� 15-3
15.2.3 Handlebar Interference Inspection ��������������������������������������� 15-3
15.1 Handlebar Assy
15.1.1 Handlebar Lever
Removal
Remove two crossing bolts 1 .
Remove RH handlebar switch assy 2 .

1
2

150101

Remove two M6 bolts 3 .

Remove clutch lever 4 .
4

150102

Remove crossing bolt 5 .

Remove LH handlebar switch assy 6 .
5
6

150103

8
Remove M6 bolt 7 . 9
Remove balance block 8 .
Remove rubber hand grips 9 . 8

150104

15-1
CFMOTO
Installation
Reverse the removal procedures for
installation. 10

Note: Insert the throttle cable 10

into RH grip 11 before installing RH
handlebar switch assy. 11

10
11

150201

12
Note: Align the dowel pin 12 and its
hole 13 during handlebar switch assy
installation.
13

150202

2
15.1.2 Handlebar Cover
3
Removal
Remove four M6 bolts 1 . 1
Remove handlebar cover 2 .
Remove handlebar 3 .

Installation 150203
Reverse the removal procedures for
installation.
Handlebar bolt tighten torque: 20 N•m

15.2 Handlebar Assy Inspection

15.2.1 Throttle Cable Free Play
Inspect throttle lever if it is smooth to grip
or return. 2
3
Inspect throttle cable free play.
Free play standard: 3 mm~6 mm

Throttle Cable Adjustment

Adjustment: Loosen nut 3 , place the
adjusting screw 2 to proper position and
then tighten the nut 3 . 150204

15-2
 15 Handlebar Assy
15.2.2 Clutch Lever Free Play Inspection
Inspect clutch lever if it is smooth to return.
Inspect clutch lever free play 1 . 1
Free play standard: 5 mm~15 mm

150301

Clutch Cable Free Play Adjustment

Minor adjustment: Loosen lock nut 3 and
rotate the adjusting nut 2 for adjustment.
At last, tighten the lock nut 3 . 2

150302

Major adjustment: Loosen lock nut 4 and

rotate the adjusting nut 5 for adjustment.
At last, tighten the lock nut 4 .

150303

15.2.3 Handlebar Interference

Inspection
Turn the handlebar left and right to check
whether cables interfere front wheel.
When the turning angle is the maximum,
check if the handlebar interferes the fuel 150304
tank.

15-3
 16 Triple Clamps

16.1 Special Tool������������������������������������������������������������������������������������ 16-1

16.2 Upper Triple Clamp and Lower Triple Clamp ����������������������������� 16-1
16.2.1 Upper Triple Clamp����������������������������������������������������������������� 16-1
16.2.2 Front Fork Pipe and Lower Triple Clamp Assy�������������������� 16-2

16.1 Special Tool

Nut Locking Tool (to remove&installing lock nut)

A000-050006-922-001

160101

16.2 Upper Triple Clamp and

Lower Triple Clamp

16.2.1 Upper Triple Clamp 2

Removal
Remove two M10 nuts 1 .
Remove handlebar seats 2 .

1
160102

Remove upper triple clamp M27 lock bolt

3.
Remove upper triple clamp 4 . 3

4
Installation
Reverse the removal procedures for 160103
installation.

16-1
CFMOTO
16.2.2 Front Fork Pipe and Lower Triple
Clamp Assy
Removal
Knock and straighten the flanging of 2
retainer 1 . 3
Remove lock nut I 2 with special tool 4 .
4
Remove retainer 1 .
1
Remove lock nut II 3 with special tool 4 .
160201

Remove upper retainer dust cap 5 . 6

Remove front fork pipe and lower triple 5
clamp assy 6 .

160202

Remove bearing cage 7 . 7

8
Remove steel ball assy 8 .

160203

Inspection
1
Inspect upper steel ball assy 1 and lower
steel ball assy 2 for wear or missing.
Replace if does.
2

160204

Inspect bearing cage 3 for cracks or

abnormal wear. Replace if does.

3
Installation
Reverse the removal procedures for
installation.
Upper triple clamp lock nut tighten 160205
torque: 20 N•m
Note: During installation and
replacement, apply enough grease on
bearing top race 3 .

16-2
 16 Triple Clamps

Front Fork Pipe and Lower Triple Clamp Assy

1

2
3

4
5

10

11

12

13

14

160301
Lock bolt, upper
1 5 Retainer 9 Bearing cage 13 Steering column
triple clamp
2 Retainer 6 Lock nut II 10 Steel ball assy 14 Lower triple clamp
Dust cap, upper
3 Upper triple clamp 7 11 Bearing cage
retainer
4 Lock nut I 8 Bearing cage 12 Dust cap, lower retainer

16-3
 17 Ignition System
17.1 Stater Motor����������������������������������������������������������������������������������� 17-1
17.1.1 Brush��������������������������������������������������������������������������������������� 17-1
17.1.2 Commutator���������������������������������������������������������������������������� 17-1
17.1.3 Armature Coil�������������������������������������������������������������������������� 17-2
17.1.4 Oil Seal������������������������������������������������������������������������������������� 17-2
17.2 Starter Relay���������������������������������������������������������������������������������� 17-2
17.3 Engine Starting Notice������������������������������������������������������������������ 17-3

17.1 Stater Motor

1 2 3

Outer side Brush 5

1 5 9 Washer
cover connector 4 6 4
Starter
Brush Inner side
2 6 motor 10
bracket cover
drum
Brush 12
3 7 Washer 11 O-ring
spring
4 O-ring 8 Armature 12 Brush

10 11

7 8 9

170101

17.1.1 Brush
Inspect brush for damage, crack or other
defects.
Replace the brush assy if necessary.

17.1.2 Commutator 170102

Inspect commutator if it changes color,
damages or wears.
If damaged, replace a new one.
If the surface of the commutator changes
color, wipe it with sand paper and then use
a dry cloth to clean the surface. d
If it wears too much, saw part of insulator
(B). The distance between (B) and (A) is d.
d ≥ 1.5 mm B

170103

17-1
CFMOTO

17.1.3 Armature Coil

Use multimeter to check the connection
situation between sections, section and
armature shaft.
If there is no connection between sections
or section and armature are connected,
replace a new armature.
170201

17.1.4 Oil Seal

Inspect the oil seal lip for damage or
leakage.
Replace a new one if it does.

17.2 Starter Relay

Put 12V battery between positive and 170202
negative terminal. Use multimeter to check
if there is continuity between 2 contacts.
If multimeter clicks, there is continuity
between contacts.
If 12V is removed, no continuity remains
between contacts.
If both above 2 items are ok, it indicates
the relay is ok.
Turn multimeter to DIODE.

Note: The voltage loaded between 170203

terminals can not exceed 2 minutes,
otherwise, starter relay may overheat
or burn.
Use multimeter to measure starter relay
coil resistance, if the reading is out of
specification, replace a new relay.
Turn multimeter to 1×10 Ω
Starter relay coil resistance: 3 Ω~5 Ω

170204

17-2
 17 Ignition System
Auxiliary Starter Relay and Fuel Pump
Relay
A
Put 12V battery between auxiliary starter
relay coil positive and negative terminal.
U s e m u l ti meter to ch e ck i f ther e is
continuity between contact A and B.
If multimeter clicks, there is continuity
between contacts.
If 12V is removed, no continuity remains
between contacts.
B
If both above 2 items are ok, it indicates 170301
the relay is ok.
Turn multimeter to 1×100 Ω to measure
1
the coil resistance.
Auxiliary starter relay coil resistance:
90 Ω~100 Ω

Note: On the back side of the

auxiliary starter relay, the side, of
which the direction is the same with
the diode, is the relay coil positive
2
pole. 170302
1 Ground 2 Positive pole

17.3 Engine Starting Notice

Properly route according to starting
schematic diagram.
Before starting, check if all parts are
installed correctly. EFI components
connection refers to EFI section.
Check air intake system.
Check fuel supply system. Ensure there is
no block or leaks.
Test fuel pressure with fuel pressure
gauge.
Pressure in fuel pump outlet:
0.33MPa±0.01MPa
Shift to neutral gear.
Check EFI with PDA for fault. If there is,
eliminate the trouble according to fault 170303
code. Pressure gauge
Close the throttle and turn the engine stop
switch to “RUN”, then push starter switch
for 3~5s to run the engine.
After starting,warm up until idle speed is
stable and check it.
Idle speed: 1450 rpm±145 rpm.

17-3
 18 Clean and Conservation
18.1 Motorcycle Clean��������������������������������������������������������������������������� 18-1
18.2 Inspection and Maintenance in Winter ��������������������������������������� 18-2

18.1 Motorcycle Clean

Note: Clean the motorcycle periodically, to help it keep value and appearance.
Avoid direct sunlight on the motorcycle while cleaning.
Seal air exhaust system to prevent water into the system.
Clean chunks of dirt with gentle water-jet in advance.
Use common motorcycle cleaner to clean serious smudges and wipe it with hairbrush.

Note:
Use the hot water with specialized cleaner for motorcycle and a piece of sponge.
It is not allowed to use the cleaner directly on dry vehicle body. Flush the vehicle
with water in advance.
If the vehicle has been used in snow-melting salt, clean it with cold water.
Otherwise, the hot water will exacerbate erosion.
Dry the car completely after washing the motorcycle with gentle water-jet.
Remove the seal plug for exhaust system.

Warning: The dirty or damp braking system will reduce the braking
performance. Pay attention to keep the brake system clean and dry.
After cleaning, run the vehicle for some distance until the engine reaches certain
temperature.
Push the guard upwards from the handlebar, in order to let the water evaporate.
After the motorcycle cools down, lubricate all sliding parts and bearing parts.
Clean the chain.
Use anti-rusting agent on exposed metal parts (except brake discs and exhaust system).
Use gentle curing agent on all painting parts.

Note: Do not polish the plastic parts which is in delivery. Otherwise, it will
serious effects on the quality.
Use gentle cleaning agent and curing agent on all plastic parts and powder-coated parts.
Lubricate ignition switch lock/steering lock with engine oil.

18-1
CFMOTO
18.2 Inspection and Maintenance in Winter
Note:
If the motorcycle is used in winter, it must be taken into consideration that the
street is covered with snow-melting salt. Therefore, protective measures must be
taken against erosion.
If the vehicle has been used in snow-melting salt, clean it with cold water.
Otherwise, the hot water will exacerbate erosion.
Clean the motorcycle.
Clean brake system.

Note:
If the vehicle has been used in snow-melting salt, clean it with cold water after the
brake calipers and brake pads cool down. Dry all the parts after cleaning. Do not
remove brake parts when cleaning.
Use waxy preservative liquid for engine, swing arms and other exposed or galvanized
parts (except brake pad).

Note:
The preservative liquid is not allowed to get into the brake pads. Otherwise, it will
reduce the braking effect seriously.
Clean the chain.

18-2
 19 Storage
19.1 Parking������������������������������������������������������������������������������������������� 19-1
19.2 Motorcycle Use after Storage������������������������������������������������������� 19-1

19.1 Parking
Note:
If parking for a long time, please execute the following measures.
Before parking the motorcycle, please check its functions and wear condition.
If the bike needs maintenance, service or adjustment, operate it during parking
(when service station has less work), which prevents long wait at the service
station before peak season arrives.
•Add fuel additives for the last refueling before parking the motorcycle.
•Add fuel.
•Clean the motorcycle.
•Replace engine oil, oil filter and clean oil strainer.
•Check coolant and coolant level.
•Check tire pressure.
•Remove battery.
•Charge the battery.
Without direct sunlight condition, battery storage temperature: 0 ～ 35°C
Place the vehicle at a dry place without obvious temperature fluctuation.
Advice to use wheel bracket to lift the motorcycle.
Cover the motorcycle with breathable canvas or cover.
Note:
It is not allowed to use air-proof material to cover the motorcycle. Otherwise, the
moisture can not get out which causes erosion.
The short-time running of the engine will cause severe damage if the motorcycle
has parked. The temperature of the engine is not high enough after short-time
running. The moisture that comes into being during combustion condenses after
the engine cools down, which causes valve body and exhaust pipes erosion.

19.2 Motorcycle Use after Storage

•Remove the motorcycle from front wheel bracket.
•Remove the motorcycle from rear wheel bracket.
•Install battery.
•Inspect and maintain the motorcycle before use every time.
•Drive the motorcycle to test it.

19-1
Appendix A