CF 400NK - 650NK

400NK
CF400- B C F 4 0 0 - B F
650NK
CF650- 7C C F 6 5 0 - 7 F
SERVICE
MANUAL
http://www.cfmoto.com
Edition Date: 20190813
Edition Item: CF400-B,CF650-7C(6KM6-WX-01)SM-20190813
INTRODUCTION INDEX
This manual introduces CF400-B/CF650- General Information 1
7C/CF400-BF/CF650-7F maintenance Maintenance Information 2
information, including disassembly Technical Information 3
procedure checking &adjustment methods, Seat 4
troubleshooting and technical specifications. Body Covering Parts 5
There are some illustrations, drawing to Fuel Tank 6
guide your operation. Lights, Dashboard and Switches 7
The first three chapters mainly introduce Electrical System 8
general operation information, special
Cooling System 9
tool, vehicle structure, basic specification,
Muffler Assy 10
inspection&maintenance methods etc,.
Wheels and Brake System 11
The rest chapters introduce vehicle part
Shock Absorbers and Rear Fork 12
removal, installation, adjustment, service,
Engine Assy (CF400-B/CF400-BF) 13
fault diagnosis and etc,.
CFMOTO has the copyright and final
Engine Assy (CF650-7C/CF650-7F) 14
interpretation of this manual. Do not copy, Handlebar Assy and Triple Clamps 15
translation without CFMOTO permit. Any Cleaning and Conservation 16
transmission or recording is prohibited. Storage 17
This manual has been improved by using Start Diagram AppendixA
many ways to make it accuracy. But we are EFI Diagram AppendixB
no response for any difference and missing. Electrical Diagram AppendixC
CFMOTO reserves right to make
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-B/CF650-7C is
accordance with standard: Q/CFD .
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
August , 2019
Conversion table
A Ampere lb Pound
ABDC After bottom dead m Meter
center
AC Alternating current min Minute
ATDC After top dead center N Newton
BBDC B e f o r e b o t t o m d e a d Pa Pascal
center
BDC Bottom dead center PS Metric horse power
BTDC BTDC Before top dead Psi Pound/Square Inch
center
°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.
CAUTION: This symbol means the special steps for higher efficiency and easier
working.
NOTE: It makes operation process easier or offers clearer information. It has no

symbol.
NOTE:
The vehicle removal procedures are not included electrical parts, police implements
and engine. Electrical parts and engine are shown in the seperate chapters.
All connectors are unplugged by default during removal.
The guide line without serial number in the picture indicates the direction of
removal.
General Information
1.1 Operation Cautions�� 1
1.2 Disassembly and Assembly Cautions�� 3
1.3 VIN and EIN Location�� 7
1.4 Fuel evaporation system diagram�� 8
1.1 Operation Cautions

DANGER: Hazardous compents in WARNING: Don’t touch the engine
exhaust. Do not run the engine in a or muffler with bare hands when the
enclosed or poor ventilated place for a engine has just stopped to avoid hurt.
long time. Wear long-sleeve work clothes.
WARNING: Battery liquid (dilute WARNING: Coolant is poisonous.

sulfuric acid) is highly caustic and may Do not drink or splash to skin, eyes or
cause burns to skin and eyes. Flush clothes. Flush with plenty of soap water
with water if splashed to skin and get if splashed to skin. Flush with water
immediate medical attention. Flush with and consult doctors. If drinking the
water if splashed to clothes to avoid coolant, induce vomiting and consult
burns. Keep battery and liquid away doctors. Keep coolant away from reach
from reach of children. of children.
1-1
General Information
WARNING: Wear proper work clothes, DANGER: Coolant Gasoline is highly
cap and boots. War dust-glass, gloves flammable. No smoking or fire. Also
and mask if necessary. keep against sparks. Vaporized gasoline
is also explosive. Operate in a well-
ventilated place.
DANGER: When charged, Battery may

generate hydrogen which is explosive.
Charge the battery in a well-ventilated WARNING: The asbestos dust on
place. the brake drum is carcinogenic. Do not
clean off the dust with compressed air.
Use cleaning detergent to avoid dust
proliferation.
DANGER: Be careful to get clamped

by the turning parts like wheels and
clutch.
1-2
General Information
1.2 Disassembly and Assembly
Cautions ■Clean the mud, dust before overhauling.
■Use genuine CFMOTO Parts, lubricants
and grease.
■Replace the disassembled washers,O-

rings,piston pin circlip and cotter pin with
new ones.
■Place and store the disassembled parts
■Elastic circlips might get distorted after
separately in order for correct assemble.
disassembled. Do not use the loosed
circlips.
■Clean and blow off the detergent after

disassembling the parts. Apply lubricants
■Measure the data during disassembly for
on the surface of moving parts.
correct assembly.
1-3
General Information
■If not know the length of screws, install ■Pre-tighten the bolts, nuts and screws,
the screws one by one and tighten with then tighten them according to the
same torque. specified torque, from big to small and from
inner side to outer side.
■Check if the disassembled rubber parts

are aged and replace it if necessary. Keep ■Apply or inject recommended lubricant to
the rubber parts away from grease. the specified parts.
■Use special tools wherever necessary. ■If the disassembling of pressed ball
bearing is done by pressing the balls, the
disassembled should not be used again.
1-4
General Information
■Turn the ball bearing with hands to ■Install the one-side dust-proof bearing
make sure the bearing will turn smoothly. in the right direction. When assembling
Replace if the axial or radial play is too the open type or double-side dust-proof
big. If the surface is uneven, clean with bearing,install with manufacturer’s mark
oil and replace. if the cleaning does not outward.
help. When pressing the bearing into
the machine or to the shaft, replace the one-sided dust two-sided dust
bearing if it could not be pressed tight. proof type proof type
open type
■Install the elastic circlip after assembling

to make sure is has been installed into the
slot.
■Keep the bearing block still when blowing
dry the bearing after washing clean. Apply circlip
oil or lubricant before assembling.
chamfer
■Brake fluid and coolant may damage

coating, plastic and rubber parts. Flush
these parts with water if splashed.
After assembling,check if all the tightened
pats are properly tightened and can move
smoothly.
1-5
General Information
■Install oil seal with the side of ■When installing pipes,insert the pipe till
manufacturer’s mark outward. Do not fold the end. Fit the pipe clip, if any, into the
or scratch the oil seal lip. Apply grease to rove. Replace the pipes or hoses that
the oil seal lip before assembling. cannot be tightened.
manufacturer dent
identification grease
clip
joint
■Do not mix mud or dust into engine or the ■Clean the gaskets and washers of the
hydraulic brake system. engine cases before assembling. Remove
the scratches on the contact surfaces by
polishing evenly with an oil stone.
■Do not twist or bend the cables too

distorted or damaged cables may cause
poor operation. ■When assembling the parts of protection
caps, insert the caps to the grooves, if any.
cap
1-6
General Information
1.3 VIN and EIN Location
VIN EIN
010701 010702
1-7
General Information
1.4 Fuel evaporation system diagram
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 main-
tenance 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 working 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 inner pressure of
fuel tank is lower than outside, it is available to replenish air pressure 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.
CF400-B
Fuel vapor hose Ⅵ CF650-7C
Fuel tank assy
Fuel vent
hose
Fuel vapor
Anti-rollover valve hose Ⅰ
Fuel vapor hose Ⅱ

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

Throttle assy 010801
1-8
General Information
CF400-BF
CF650-7F
010901
1-9
Maintenance Information
2.1 Maintenance before Operation�� 1
2.2 Break-in Maintenance Schedule�� 2
2.3 Periodic Maintenance Schedule�� 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.
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
2.2 Break-in Maintenance Schedule
Break-in Maintenance Interval
Item (Service whichever interval comes first)
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
Brake lever - - 1000 Inspect for free 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 for
■ Mobile parts - - 1000
flexibility
■ Bolts and nuts - - 1000 Inspect for fastness
Inspect for damage,
■ Cables and wires - - 1000
bending and routing
2-2
2.3 Periodic Maintenance Schedule
Periodic Maintenance Interval
Engine
Engine oil and oil filter - 6M 5000 Replace
■ Clutch - - 10000
Idle - - 10000 Inspect
- - 10000
■ Coolant
- 24M 30000 Replace
Throttle system - - 10000 Inspect
■ Throttle valve - - 5000 Clean
- - 10000 Inspect
►■ Air filter element
- 24M -
Replace
■ Spark plug - - 10000
■ 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
Brake lever Inspect for free play
- 12M 10000
- 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
Periodic Maintenance Interval
Suspension system
- - 5000
■ Suspension system - - 10000 Inspect
- - 15000
- 12M 10000 Inspect for leaking
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 for
■ Mobile parts
- 48M 30000 flexibility
- 12M 10000
■ Bolts and nuts Inspect for fastness
- 48M 30000
- 12M 5000 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
Technical Information
3.1 General Specifications�� 2
3.2 Engine Specification�� 3
3.3 Maintenance Specifications�� 4
3.3.1 Front Wheel�� 4
3.3.2 Rear Wheel�� 4
3.3.3 Brake System�� 4
3.3.4 Lighting, Dashboard and Switch�� 4
3.4 Service Specification�� 5
3.4.1 Valve Train&Cylinder Head�� 5
3.4.2 Lubrication System�� 6
3.4.3 Cylinder, Piston, Piston Ring and Connecting Rod�� 6
3.4.4 Clutch and Transmission�� 7
3.4.5 Cooling System�� 7
3.4.6 Air Inlet System�� 7
3.4.7 Electrical System�� 7
3.5 Tighten Torque�� 8
3.5.1 Tighten Torque Table for Vehicle�� 8
3.5.2 Tighten Table for Engine�� 9
3.6 Consumption Materials&Assembling Materials�� 12
3.6.1 Vehicle Consumption Materials�� 12
3.6.2 Engine Consumption Materials&Assembling Materials�� 12
3- 1
3.1 General Specifications
Item Specifications
Model 400NK 650NK
Length 2114 mm
Width 830 mm
Height 1100 mm
Wheel base 1415 mm
Engine model 268MQ 283MT
Displacement 400.4 mL 649.3 mL
Fuel grade RQ-95 or above
Gross weight 206 kg
Passengers 2 people (including driver)
Load 150 kg
Front 120/70 ZR17
Tire
Rear 160/60 ZR17
Min. ground clearance 150 mm
Turning circle diameter 2.7 m
Right 32º
Steering Steering angle
Left 32º
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 17 L
Injector Type: F01R00M126
Voltage: DC13.5V
Fuel supplier
Pressure: 0.33 MPa ± 0.01 MPa
Fuel pump
Flow: ≥45 L/h
Current: ≤2.80 A
3- 2
3.2 Engine Specification
Type/Specification
Item
400NK 650NK
Line Engine/duplex cylinder/four strokes/water-
Type
cooled
Bore × Stroke 68.4 mm × 54.5 mm 83 mm × 60 mm
Displacement 400.4 mL 649.3 mL
Compression ratio 11.1 : 1 11.3 : 1
Low idling speed (Idling) 1450 r/min ± 145 r/min
Starting Electric
Ignition type ECU
Spark plug/Electrode
Electrical system NGK CR7E/0.7 mm ~ 0.9 mm
gap
Magneto type Out rotor, flywheel
Combustion chamber Triangular
Combustion
Air filter type Sponge filter
system
Gasoline RQ-95 and above
Valves system Valves type SOHC/chain drive
Lubrication type Pressure and splash
Lubrication Oil pump type Rotor drive
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
system Coolant type -35°C anti-rust and anti-freeze fluid
Clutch Wet and multi-plate clutch
Transmission type 6-gear,constant mesh, step transmission
Reducer gear 6 gears
Mechanical reciprocating
Gearshift methods/orders
1-0-2-3-4-5-6-5-4-3-2-0-1
Primary ratio 2.146 2.095
Drive train Final drive 3.857 3.067
system 1st 2.500 2.353
Secondary ratio
2nd 1.800 1.714

3rd 1.333
4th 1.111
5th 0.966
6th 0.852
L(mm)×W(mm)×H(mm):
Overall size
386 mm × 312.7 mm × 439 mm
Dry weight 31 kg
Output type Chain
When moving forward, counter clockwise(left
Rotation of engine output
view).
3- 3
3.3 Maintenance Specifications
3.3.1 Front Wheel
Item Standard Service limit
Front wheel shaft bending - 0.2 mm
Longitudinal 0.8 mm 2.0 mm
Rim run-out
Front Horizontal 0.8 mm 2.0 mm
wheel Remaining
- 1.6 mm
Tire groove
Tire pressure 250 kPa(2.5 kgf/cm2) -
3.3.2 Rear Wheel

Longitudinal 0.8 mm 2.0 mm
Rim run-out
Rear Horizontal 0.8 mm 2.0 mm
wheel Remaining
- 1.6 mm
Tire groove
Tire pressure 250 kPa(2.5 kgf/cm2) -
3.3.3 Brake System

Front (hand) brake free travel 10 mm ~ 20 mm -
Front brake
Brake disc abrasion 4 mm 3 mm
Rear (foot) brake free travel 10 mm ~ 20 mm -
Rear brake
Brake disc abrasion 4 mm 3 mm
3.3.4 Lighting, Dashboard and Switch

Item Standard
Primary 30A
Fuse
Subsidiary 1×7.5A 1×10A 5×15A
Headlight (Hi/Lo) LED
Position light LED
Light, bulb Tail light LED
Turn light LED
License light LED
3- 4
3.4 Service Specification
3.4.1 Valve Train&Cylinder Head
Service
Standard Remark
Item limit
400NK 650NK
Valve clearance IN 0.08 mm ~ 0.13 mm -
(cold engine) EX 0.22 mm ~ 0.28 mm
Clearance, IN 0.02 mm ~ 0.08 mm -
valve guide
bushing and EX 0.07 mm ~ 0.14 mm -
valve stem
I.D of valve I N &
4.5 mm ~ 4.512 mm -
guide bushing EX
O.D of valve IN 4.475 mm ~ 4.490 mm -
stem EX 4.455 mm ~ 4.470 mm
Free length,
39.5 mm ± 0.68 mm 41.6 mm
valve spring
W h en com pr essed to
When compressed to 35.9 mm,
38.4 mm, elasticity is
elasticity is 95.5N~111.5N.
103N~121N.
Valve spring When compressed to 29.1 mm,
force elasticity is 364.4N~402.4N.
422N~466N.
When compressed to 28.1 mm,
elasticity is 417.6N~461.6N.
455N~503N.
IN 35.743 mm ~ 35.857 mm 36.543 mm ~ 36.657 mm
Camshaft lift
EX 34.743 mm ~ 34.857 mm 35.843 mm ~ 35.957 mm -
Camshaft to
0.028 mm ~ 1.020 mm 0.028 mm ~ 0.071 mm
hole clearance
O.D of camshaft 223.950 mm ~ 23.972 mm -
I.D of camshaft
24 mm ~ 24.052 mm 24 mm ~ 24.021 mm -
mating hole
Camshaft run-
0.02 mm
out
Cylinder head
junction surface 0.05 mm
flatness
3- 5
3.4.2 Lubrication System

Item Standard Service limit Remark
Outer rotor to inner rotor
0.08 mm ~ 0.15 mm -
clearance
Outer rotor to pump body
0.15 mm ~ 0.193 mm -
clearance
Oil pressure 10 kPa ~ 30 kPa at 3000 r/min -
Oil type 10W-40/SJ, JASOMA2 -
Change oil and
1250 mL -
Oil capacity filter
At overhaul 1450 mL -
3.4.3 Cylinder, Piston, Piston Ring and Connecting Rod
Standard Service
Item Remark
400NK 600NK limit
C l e a r a n c e
between piston 0.030 mm ~ 0.045 mm 0.015 mm ~ 0.037 mm
and cylinder
Dia. of piston skirt 68.366 mm ~ 68.384 mm 82.988 mm ~ 82.970 mm -
I.D of cylinder 68.4 mm ~ 68.418 mm 83 mm ~ 83.032 mm -
Cylinder junction
0.03mm -
surface flatness
Piston ring closed 1 Ring 0.15 mm ~ 0.30 mm 0.25 mm ~ 0.40 mm -
gap 2 Ring 0.20 mm ~ 0.40 mm 0.40 mm ~ 0.55 mm -
C l e a r a n c e 1 Ring 0.02 mm ~ 0.06 mm 0.03 mm ~ 0.07 mm
between piston
2 Ring 0.02 mm ~ 0.06 mm 0.02 mm ~ 0.06 mm -
ring and groove
Thickness of 1 Ring 0.97 mm ~ 0.99 mm 0.87 mm ~ 0.89 mm -
piston ring 2 Ring 0.97 mm ~ 0.99 mm 0.97 mm ~ 0.99 mm -
1 Ring 1.01 mm ~ 1.03 mm 0.92 mm ~ 0.94 mm -
Width of piston
2 Ring 1.01 mm ~ 1.03 mm 1.01 mm ~ 1.03 mm -
ring groove
Oil ring 1.5 mm ~ 1.52mm 1.510 mm ~ 1.525 mm
O.D of piston pin 17.996 mm ~ 18 mm 18.996 mm ~ 19 mm -
I.D of connecting
18.01 mm ~ 18.02 mm 19.01 mm ~ 19.02 mm -
rod small end
Connecting rod big
41 mm ~ 41.016 mm -
end side clearance
Connecting rod big
22.85 mm ~ 22.9 mm -
end thickness
Crankshaft run-out 0.02 mm -
3- 6
3.4.4 Clutch and Transmission
Item Standard Service limit Remark
Friction disc 2.95 mm ~ 3.05 mm 2.8 mm
Quantity 7
Steel plate A 1.92 mm ~ 2.02 mm -
Quantity 1
Steel plate B 2.42 mm ~ 2.52 mm
Quantity 5
Driven disc deformation 0.15 mm 0.30 mm
Free length of clutch spring 33.1 mm ~ 34.1 mm 32.6 mm
Quantity 5
Thickness of gearshift fork 5.9~6.0 4.8~5.0
3.4.5 Cooling System
Standard/Specification Service limit Remark
Item
400NK 600NK
Start temp. of thermostat 80 ºC ~ 84 ºC 70 ºC ~ 74 ºC -
Lift range of thermostat -
≥8 mm at 95 ºC ≥8 mm at 85 ºC
valve
Open pressure of -
108kPa
radiator cap
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
Specification Remark
Item
400NK/600NK
Idle air control valve (canister
018B-172000
control valve)
Idle speed 1450 r/min ± 145 r/min
3.4.7 Electrical System
Item Specification Remark
Model NGK CR7E
Spark plug
Gap 0.7 mm ~ 0.9 mm
Spark >8 mm, 1 MPa
Primary 740 MΩ ~ 780 MΩ
Ignition coil resistance
Secondary 10.1 kΩ ~ 11.1 kΩ
Magneto coil resistance Trigger 100 Ω ~ 160 Ω
Magneto Voltage, unloading state (cold engine) >50V(AC) at 5000 r/min
Max power 280 W at 6000 r/min
Stabilized voltage 13.5 V ~ 15.0 V,5000 r/min
Primary peak voltage, ignition coil 12 V
Peak voltage, trigger coil >1.5 V
Starter relay coil resistance 3Ω~5Ω
Starter auxiliary relay coil resistance 90 Ω ~ 100 Ω
3- 7
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)
M12 bolt, nut 54(5.5)
Please use standard torque if without torque value mentioned below table.
CAUTION: 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 bracket bolt 5 5 30(3.1)
Engine bracket 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
Bolt, front brake disc 5 8 30(3.1)
Bolt, front brake caliper 2 10 40(4.1)
Muffler
Nut, muffler front exhaust pipe 2 8 26(2.7)
Bolt, muffler body 1 8 20(2.1)
3- 8
3.5.2 Tighten Torque Table for Engine
Thread dia. Torque
Item Qty. Remark
(mm) N·m
Bolt, crankcase 8 M7 20
Bolt, crankcase 6 M8 27.5
Flange, with engine oil and
MoS2 grease (ratio 10：1)
With engine oil and MoS2
grease (ratio 10：1)
Bolt, breather guard 2 M6 10 With thread locker
Long thread with thread
Hand- locker
Stud, cylinder 1 M10 tighten, Short thread with engine
length limit oil and MoS2 grease (ratio
10：1)
Screw, shaft sleeve press Hand-
1 M6 With thread locker
plate (CF188) tighten
Hand-
Lock nut, cylinder 1 M10×1.25
tighten (49)
Bolt, oil pipe IV (152MI) 2 M6 10 With thread locker
Bolt, breather 4 M6 8 With thread locker
Bolt, lower crankcase
6 M6 10 With thread locker
cover (152MI)
Screw, oil shielding plate 2 M6 8 With thread locker
Bolt, trigger 2 M5 6 With thread locker
Low engine oil warning Hand-
1 R1/8 With silicone sealant
switch tighten (15)
Oil relief valve 1 M12×1.25 15 With thread locker
Hand-
Screw plug, lower crankcase
1 M6 tighten, With thread locker
oil trail
surface
Plug, main oil trail 1 R23/8 20 With thread locker
3/4″
Bolt, oil filter 1 25 With thread locker
(16 thread/in)
Dowel pin, gearshift shaft
spring
Bolt, RH side cover
12 M6 12
(152MI)
Hand-
Hole cap, timing inspection 1 M12×1.5
tighten
Hand-
Filler plug 1 3/4″
tighten
Hand-
Strainer cover (1P72MM) 1 M35×1.5 With engine oil
tighten (25)
Bolt, LH side cover (152MI) 11 M6 12
Bolt, LH side cover
1 M6 12
(1P52MI)
Bolt, engine oil strainer
press plate (152MI)
3- 9
Thread dia. Torque N·m
Item Qty. Remark
(mm) (kgf·m)
Bolt kit, cylinder head
1 M6 10
cover (152MI)
Bolt, clutch cable
bracket (152MI)
New: 25→54 With engine oil and MoS2
Bolt, cylinder head 5 M10
Old: 25→49 grease (ratio 10：1)
New: 25→54 With engine oil and MoS2
Bolt, cylinder head 1 M10×1.25
Old: 225→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)
Hand-tighten
Plug 1/2, cylinder head 3 R21/2 With silicone sealant
(40)
Bolt, cylinder 1 M8 27.5
grease (ratio 10：1)
I n n e r h e x s c r e w,
Hand-tighten
cylinder and cylinder 2 M6
(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
Bolt, magneto rotor
1 M12×1.25 155 With thread locker
assy
Bolt, crankshaft RPM
trigger disc
Bolt, connecting rod 4 M9×1
40→0→29N•m grease (ratio 10：1)
+30°+70°
Final torque: With engine oil and MoS2
Nut, connecting rod 4 M9×1
65N•m~90N•m grease (ratio 10：1)
Bolt, gearshift drum

cam (152MI)
Neutral gear sensor
screw, gearshift cover per 1 M6 Hand-tighten (5) With thread locker
screw
S c r e w, g e a r c a s e Hand-tighten
1 M6 With thread locker
bearing guard 1 (10)
Hand-tighten,
Nozzle, gear case 1 M5 No glue
limit
3- 10
Torque
Thread
Item Qty. N·m Remark
dia.(mm)
(kgf·m)
Screw, countershaft fork shaft
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
(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-
Bolt, oil pump sprocket 1 hand 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- 11
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
Throttle handlebar part
Multi-purpose lithium
Pivot, rear pedal(LH),
base lubrication oil
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 front shock Absorber oil 5#
absorber
3.6.2 Engine Consumption Materials&Assembling Materials

Item Specification Using parts Remark
Rotation and moving
s e c t i o n i n c y l i n d e r,
Oil Capacity:
1 0 W - 4 0 / S J , crankcase and cylinder
Lubricant oil 1250mL(filter change)
JASOMA2 head.
1450mL(at overhaul)
Details refer to lubricant
chart.
Lubricant oil with Piston pin, valve stem,
molybdenum valve oil seal, camshaft
Oil seal, o-ring and rubber
#3 MoS2 lithium
Lubricant grease seal face, bearing with
grease
sealant
-35°C anti-rust
and anti-freeze Cooling system, water seal Capacity depends on
Coolant
fluid with high installation radiator water pipes
boiling point
Crankcase faying face ,
crankcase and cylinder joint
Flange sealant
cylinder head and cylinder
head cover joint
Tread locker Parts of thread
3- 12
Seat
4.1 Seat�� 1
4.1 Seat
Removal
Insert key into seat lock 1 .
Unlock seat lock 1 .
Remove rear seat 2 .
2
040101
Lift front seat corners 3 .

Remove inner hex bolts 4 .
Remove front seat 5 .
4
040102
4-1
Seat
Installation
Insert limit hook 1 into buckle 2 .
040201
Lift front seat corners 3 .

Install inner hex bolts 4 .
040202
Insert limit hook 5 into buckle 6 .

Press lock catch 7 into seat lock 8 .
6
5
7
040203
4-2
Body Covering Parts
5.1 LH&RH Panel�� 2
5.2 LH&RH Middle Panel�� 2
5.3 Fuel Tank Panel�� 2
5.4 Fuel Tank Front Panel�� 3
5.5 LH&RH Rear Deco Plate�� 3
5.6 LH&RH Engine Lower Panel�� 3
5.7 Front Fender�� 3
5.8 Rear Fender�� 4
5.1 LH&RH Panel

Removal
Remove bolt 1 .
Remove fuel tank LH panel 2 .
2
R H p a n e l app l i e s th e sa me rem oval
procedures.
Installation 1
Reverse the removal procedures for
installation.
050101
5.2 LH&RH Middle Panel

Removal bolt 1 .
Remove LH middle panel 2 . 1
RH middle panel applies the same removal
procedures.
Installation
installation.
2
050102
5.3 Fuel Tank Panel

Removal
Remove plastic clasp 1 . 1
Remove bolt 2 .
050103
5-1
Body Covering Parts
Remove two bolts 3 .
Remove fuel tank RH panel 4 .
Panel LH panel applies the same removal 4
procedures.
Installation
installation.
3
050201
5.4 Fuel Tank Front Panel

Removal
2
Remove four plastic clasps 1 . 3
Remove two inner hex bolts 2 .
Remove fuel tank front panel 3 .
Installation
Reverse the removal procedures for 1
installation.
050202
5.5 LH&RH Rear Deco Plate 6 2

3
Removal
Remove bolt 1 .
Remove bolt 2 . 1 4
Remove screw 3 .
Remove plastic clasp 4 .
Remove two bolts and lock seat 5 .
Remove LH rear deco plate 5 .
RH rear deco plate applies the same 5
removal procedures. 4
Installation
050203
installation.
1
5.6 LH&RH Engine Lower Panel
Removal
Remove three bolts 1 .
Remove LH engine lower panel 2 .
RH engine lower panel applies the same
2
removal procedures.
Installation
installation.
050204
5-2
Body Covering Parts
5.7 Front Fender
Removal
Remove three inner hex bolts 1 on each 2
side. 1
Remove front fender 2 . 1
Installation
installation.
050301
Remove three screws 3 .

Separate front fender front part 4 and rear
part 5 .
Installation
installation. 3
4 5
050302
5.8 Rear Fender

Removal
Remove three inner hex bolts 1 .
Remove plastic clasps 2 . 3
Remove rear fender 3 . 1
Installation
installation.
2
050303
5-3
Fuel Tank
6.1 Fuel Tank�� 1
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.
6.1 Fuel Tank

Removal
Lift fuel tank 2 . 2
Pull out adsorption hose and quick joint 5 .
Remove fuel tank 2 .
Danger: Never put fuel tank up side

down, in case of fuel leaking.
1
WARNING: When installing fuel tank,
all hoses, pipes and cables can not be
extruded. 060101
Inspection
Inspect fuel tank if sunk, cracked or other damage. Replace if any defect is found.
Inspect hose if cracked, aged or leaked. Replace if any defect is found.
Installation
Reverse the removal procedures for installation.
NOTE: When installing fuel tank, all hoses, pipes and cables can not be extruded.
6-1
Lights, Dashboard and Switches
7.1 Maintenance Information��07-1
7.1.1 Operation Caution��07-1
7.1.2 Inspection Standard��07-1
7.2 Trouble Shooting��07-2
7.3 Headlight��07-2
7.3.1 Headlight Removal(CF400-B)��07-2
7.3.2 Dashboard (CF400-B)��07-3
7.4 Headlight��07-4
7.4.1 Headlight Removal(CF650-7C)��07-4
7.4.2 Dashboard (CF650-7C)��07-5
7.5 Tail Light/Brake Light��07-5
7.6 Rear License Light��07-5
7.7 Ignition Switch��07-6
7.8 Front Brake Light Switch��07-6
7.9 Rear Brake Switch��07-6
7.10 LH Handlebar Switch��07-7
7.11 RH Handlebar Switch��07-7
7.12 Horn��07-8
7.13 Fuel Level Sensor��07-8
7.14 Battery��07-9
7.15 Vehicle Telematics (CN4)��07-10
7.16 Ground Wire��07-10
7.1 Maintenance Information
7.1.1 Operation Caution
WARNING:
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.
7.1.2 Inspection Standard

Item Standard
Main fuse 30A
Fuse
Auxiliary fuse 1×7.5A 2×10A 4×15A
Headlight (Hi/Lo) LED
Position light LED
Light&Bulb Tail light LED
Turn light LED
License light LED
07-1
7.2 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
7.3 Headlight
7.3.1 Headlight Removal(CF400-B)
Remove screw 2 .
Remove dashboard deco guard 1 . 1
070201
Remove four screws 3 .

Remove headlight upper panel.
070202
Remove inner hex bolts 4 .

Remove headlight assy 5 .
4
Unplug connectors with main cable.
Remove screws 6 .
5
070203
07-2
Remove screws 9 .
Remove screw 8 .
Remove headlight LH&RH panels 7 .
7
070301
Remove screws 10 .
Remove headlight body.
10
070302
7.3.2 Dashboard (CF400-B)

Unplug connectors between dashboard
and main cable.
Remove nuts 2 .
Remove dashboard 1 . 1
070303
07-3
7.4 Headlight
7.4.1 Headlight Removal(CF650-7C)
Remove screws 2 on both sides.

Remove headlight guard panels 1 .
1
2
070401
Remove inner hex screws 3 .

3 3
070402
Remove screws 4 on both sides.

Remove inner hex screws 5 .
Unplug connectors with main cable and
remove headlight assy.
4
NOTE: The headlight is consisted of

LED lights. When the light damages,
replace the whole set. 5
070403
07-4
7.4.2 Dashboard (CF650-7C)
Unplug connectors between dashboard
and main cable.
Remove nuts 1 .
Remove dashboard 2 .
2
070501
7.5 Tail Light/Brake Light

Remove tail guard referring to 05 chapter.
Remove screws 1 .
Remove rear deco cover 2 .
Unplug connectors between tail light and
1 2
main cable.
Remove tail light 3 .
NOTE: The tail light is consisted of 3

LED lights. When the light damages,
replace the whole set.
070502
7.6 Rear License Light 1

Unplug connectors with main cable.
Remove bolts 1 .
Remove rear fender 2 .
070503
Remove crosshead screws 4 .
Remove rear license light 3 .
NOTE: The rear license light is

consisted of LED lights. When the light 3
damages, replace the whole set.
070504
07-5
7.7 Ignition Switch
Inspection
Pull out the connectors between ignition
switch 1 and main cable to check its
performance. 1
Action/Color G BW R B
● ●
● ●
● ●
070601
7.8 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
1
070602
7.9 Rear Brake Switch

Pull out the connectors between rear brake
1
light switch 1 and main cable. Inspect rear
brake switch for its performance.
1) Press rear brake pedal, the rear brake
light is on.
2) Loosen rear brake light is off.
070603
07-6
7.10 LH Handlebar Switch
Unplug the connectors between LH
1
handlebar switch and main cable to check 2
its performance.
Dimmer switch slider 1
Color
Function W L Br W B W Br G
3
● ● ●●
● ● ●●
R 4
Mode switch 2
070701
Color
Function Lg G G Br G
MODE
(ON) ● ● ● ●
5
MODE
(OFF) ● ●
R
Horn switch 3 Turn switch 4

Color
Function B Br Lg Br G
Color
Function O Gr Sb Br G
● ● ●● ● ● ● ●
R ● ● ● ●
R
Override switch 5
Color
Function B Br Br W Br G
● ● ● ● 070702
R
7.11 RH Handlebar Switch

6
Unplug the connectors between RH
handlebar switch and main cable to check
its performance.
Start/Stop switch slider 6 Start/Stop switch slider 6
7
Color
Function Br B B Br Br G Color
Function Br B Y R Br G
● ● ● ● ● ● 8
● ● ● ● R
R
Warning switch 7 070703

Function
Color
O Gr Sb Br G
(ON) ● ● ● ● ●
(OFF) ● ●
R
Illumination switch 8
Color
Function Br W G W B Br G
● ● ●
● ● ● ●
● ● ● ● ●
R
07-7
7.12 Horn
Unplug 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.
070801
7.13 Fuel Level Sensor

Removal
Remove four nuts 1 .
Remove fuel lever sensor 2 .
1 1
CAUTION: Remove fuel level sensor
slowly, in case it deforms.
2
Inspection
Inspect fuel level sensor seal ring 3 070802
for deformation, damage or hardening.
Replace if it does.
Check the electrical resistance of the oil
level sensor at high and low poles.
Resistance:
High: 4~10 Ω
Low: 90~100 Ω
Connect fuel level sensor and main cable.

Turn on ignition switch, the floater of fuel
level sensor swings up and down slowly. 3
See the fuel gauge pointer on dashboard. 070803
If the pointer can not reach F or E, it
means the fuel gauge is not qualified,
replace a new one. 4
If the pointer swings unsteadily, it means
the fuel gauge is not qualified, replace a
new one.
Installation
installation.
CAUTION: Check leakage after fuel
level sensor installation.
070803
07-8
7.14 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.
4. Please wear protective clothing and goggles. Keep the battery away from
sparks and open fire. Only charge the battery in a well-ventilated room.
5. 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.
6. Battery wires are not allowed to be removed while the engine is working.
7. Battery positive/negative wires and electrical control units have to be removed
before welding on the vehicle.
8. It is forbidden to puncture the wire to test the input/output electrical signals.
9. Establish the awareness of environmental protection and effective disposal of
waste generated during maintenance.
CAUTION:
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.
Removal
Remove seat.
Remove battery negative wire lock bolt.
Remove negative wire 1 from the battery. 2 1
Remove battery positive wire lock bolt.
Remove positive wire 2 from the battery.
Remove battery 3 .
CAUTION: Negative wire must be 3

removed first. Otherwise, it will cause
battery short circuit.
070901
Installation
installation.
07-9
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.
7.15 Vehicle Telematics (CN4)

Telematics terminal is located under rear
seat. 1
Remove rear seat.
Remove telematics 1 .
Inspect connectors for performance.
071001
Installation
installation.
7.16 Ground Wire

Ground point is located under rear seat
and telematics.
Inspection
Shut down engine and all electrical parts. 1
Inspect ground wire.
Inspect bolt 1 for looseness.
071002
07-10
Electrical System
8.1 Service Tool�� 8-2
8.2 Charging System�� 8-3
8.2.1 Charging Diagram�� 8-3
8.2.2 Magneto Coil Resistance�� 8-3
8.2.3 MAG Non-loaded Performance�� 8-3
8.2.4 Starter Relay�� 8-4
8.2.5 Regulator�� 8-5
8.3 EFI System�� 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 stepping motor�� 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
8.3.5 Fault Code�� 8-23
8.4 Fault Diagnosis and Treatment�� 8-24
8.5 Trouble Diagnosis In Accordance With Engine Error�� 8-27
8-1
Electrical System
8.1 Service Tool
PDA
Function:
Read erase trouble code of EFI system,
observe data flow and accessories test
etc.
080201
Digital multimeter
诊断仪
Function:
Inspect the parameter of EFI system like
voltage, current and resistant etc.
080201
8-2
Electrical System
8.2 Charging System
8.2.1 Charging Diagram
1
4 5
080301
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)
Resistance between Stator Coil and Core:
∞Ω (Yellow-Ground)
080302
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
080303
8-3
Electrical System
8.2.4 Starter Relay
Put DC12V between positive and negative
terminal. Use multimeter to check
connection between 2 contacts.
If multimeter clicks, there is connection.
If DC12V is removed,no connection
between contacts.
If both above 2 items are proved, it
i n d i c a t e s t h e r e p l a y i s g o o d . Tu r n
multimeter to DIODE.
080401
CAUTION: The voltage loaded
between terminals can not exceed 2
minutes. Otherwise, starter relay may
overheat or burn.
Use multimeter to measure the start relay

coil resistance.
If the resistance is out of standard, replace
with a new one.
Turn multimeter to 1X10Ω
Start auxiliary relay resistance: 3Ω~5Ω
080402
Auxiliary Relay
Put 12V between auxiliary starter relay
positive and negative terminal. Use A
multimeter to check the continuity between
A and B.
Turn multimeter to DIODE.
If multimeter clicks, it indicates there is
connection between A and B.
If 12V is removed, no connection remains
between contacts. B
If both above 2 items are proved, it
indicates the replay is good. 080403
Turn multimeter to 1×100Ω to measure the
relay resistance.
Auxiliary starter relay resistance:
90Ω~100Ω
8-4
Electrical System
8.2.5 Regulator
080401
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
Electrical System
8.3 EFI System
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
8.3.1.1 Sensors 8.3.1.3 Actuators
A sensor is a device that measures a Actuators execute the EFI instruction. Main
physical quantity and converts it into a signal actuators include:
which can be read by an observer or by an Fuel Pump (Provide high-press fuel)
instrument. Sensors in EFI system include: Fuel Injector (Inject the fuel to make it
Air pressure sensor (Air density and spray better)
pressure information) Ignition Coil (Provide high ignition energy
Air temp. sensor (Air density information) to spark plug)
TPS (Load, load range, speed information) Idle Air Control Valve (Provide idle inlet
Trigger (crankshaft information) air)
Water temp. sensor (engine temp.)
Speedometer sensor (Output shaft RPM
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 parameters
a engine needs to keep running by calculating
and analyzing values provided by sensors.
8-6
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
Electrical System
8.3.3 Structure and Performance of EFI
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.
NOTE: Do not load on the cover. Gently
handle it. Do not fall it on ground.
080801
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
3(M2) Ignition 1 19(K2) 35(D3) Neutral switch
signal 1
Oxygen sensor
4(L2) Null 20(J2) 36(C3) Null
signal 2
5(M3) Ignition to ground 21(H2) Null 37(B3) Clutch switch
6(L3) Null 22(G2) Null 38(A3) Roll-over switch
7(M4) Ignition 2 23(F2) Side stand switch 39(K4) Mode switch
Interruptible battery
8(L4) 24(E2) Null 40(J4) RPM output
UBR1
Intake air pressure
9(K1) 25(D2) Brake switch 41(H4) Speed sensor
sensor 1 (DS)
RPM sensor B
10(J1) Sensor to ground 1 26(C2) Starter relay 42(G4)
(DGB)
Intake air temp. sensor Stepping motor phase
11(H1) 27(B2) 43(F4) RPM sensor A (DGA)
(TANS) A
Stepping motor phase
12(G1) TPS (DKG) 28(A2) 44(E4) Null
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) CAN1 I/F 1 Low 31(H2) Null 47(B4) Fuel injector 2
16(C1) CAN1 I/F 1 High 32(G3) Ignition switch KL15 48(A4) Fuel injector 1
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
8-8
Electrical System
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. 2
Pin Function: 3
1
1 Ground
2 5V power
3 Output voltage signal 4
4 TPS 080901
Circuit connecting with ECU.
TPS 080902
CAUTION: Engine idle is completely

controlled by EFI system. Do not adjust
5
idle limit screw 5 manually.
It is not allowed to load on housing or
cover. Gently handle it. Do not drop it
on the ground.
080903
8-9
Electrical System
8.3.3.3 T-MAP
1 2 3 4
This sensor monitor inlet air pressure,
which provides the engine load signal to
ECU.
Pin Function:
1 Intake air pressure signal
2 5V power
3 Intake air temperature signal
4 Ground
081001
T-MAP
081002
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
sensor.
081003
8-10
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
Electrical System
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,
One group is sent to dashboard to monitor
coolant temperature condition.
A and C are one group which provides
water temperature signal to the ECU.
Through ECU, B sends the water 081201
temperature signal to dashboard.
Water temp. sensor

081202
Resistance between B and

Temp. °C
housing (KΩ)
The right table shows the relationship
-20±0.1 13.71~16.94
between temperature and resistance. This
25±0.1 1.825~2.155
signal is sent to ECU.
80±0.1 0.303~0.326
110±0.1 0.1383~0.1451
8-12
Electrical System
8.3.3.5 Oxygen Sensor
This sensor is used in closed-loop
feedback controlled fuel injection to 1 2
improve the air-to-fuel ratio accuracy and
control the emission. It’s located in the 3 4
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
unburnt fuel and make catalytic converter
convert HC, CO and NO X of Nitrogen
efficiently. 081301
Pin Function:
1 Output signal voltage +
2 Heated ground -
3 Output signal voltage -
4 Heated power +
ECU Oxygen sensor 2 Oxygen sensor 1

081302
8-13
Electrical System
8.3.3.6 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
Measure trigger resistance 081402

Set multimeter to 1×100Ω range.
Trigger coil resistance: 100Ω~160Ω(20°C)
Replace a new one when resistance is not
within above value range.
Measure trigger peak voltage
Connect multimeter and peak voltage
adapter as shown as right picture
+Probe: Green (B) wire Magneto
-Probe: Blue (A) wire
Trigger resistance
NOTE: Refer to owner manual when
using peak value voltage adapter.
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
voltage is not within above value range. 081404
8-14
Electrical System
8.3.3.7 Speed Sensor
This sensor provides engine output shaft
speed to ECU. Then ECU can calculate 1 1
the speed according to this signal. It is
a hall switch type device, which outputs
square wave by the change of the 3
magnetic field.
Pin Function:
1 +DC 12V ground
2 Power
3 Output voltage signal (>80% of input 081501
voltage)
3 +12V voltage
ECU
1 2
Hall switch
Ground
Speed sensor
081502
Speed Sensor Inspection

1
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
0V~12V
If the reading doesn’t vary, it indicates
the sensor is defective and needs to be 081503
replaced.
8-15
Electrical System
8.3.3.8 Fuel Pump 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 Ground 1 2
2 Fuel pump relay output port
Performance parameter: 081601
Pressure-regulating valve open pressure:
0.33MPa±0.01MPa
Flow rate: 45L/h
Do not run the fuel pump assy when there

is no fuel inside the fuel tank, in case of
fuel pump damage.
Handle the fuel pump gently. Do not drop it
on hard surfaces.
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 1
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. 2 1
The fuel pump will work for 5 seconds.
When stop working, the oil pressure should
reach the specified value. Otherwise, 2 4
replace with a new fuel pump.
5
After stopping working, the pressure should
maintain 0.2MPa for at least 5 minutes. 3 6
Otherwise, replace fuel pump assy. 081602
Fuel hose pressure release method:
The fuel supply pressure in EFI system ECU pin
1 3 Battery + 5 Stop switch
is high, all fuel hoses are high-pressure 46
resistance. Even the engine does not work, Fuel pump Fuel pump Ignition
2 4 6
the pressure in fuel passage is still high. relay assy switch
So when in the maintenance process, be
careful not to remove the fuel hose causally.
When servicing EFI system, release the
pressure before removing the fuel hose.
Remove the fuel pump relay. Start the
engine and make it idle until the engine
stops automatically.
8-16
Electrical System
8.3.3.9 Fuel Injector
One end of fuel injector mounts into fuel
injector seat, and the other end attaches
1 2
to the injector cap, which connects with a
fuel line. Fuel injector is controlled by ECU
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.
3
Pin function:
+ connects fuel pump relay output 081701
- connects ECU pin 48
Fuel pump Fuel injector
Fuel injector resistance: 12.5Ω±1Ω ( 20°C) 1 2 ECU 3
relay seat
Circuit connecting with ECU. 2
Fuel Injector Installation

Install fuel injector manually. Never knock 48
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 1
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 3
installation to ensure no leaks. 081702
1 ECU 2 F u e l p u m p 3 Fuel injector

relay
8-17
Electrical System
8.3.3.10 Idle stepping motor Idle stepping motor
A B D C
This is used to control the air flow of by-
pass. ECU calculates the engine load and
controls stepping motor through electrical
pulse duration and frequency (commonly
known as duty ratio). It allows different air
flows passed through under different pres-
sure. Therefore, it should be connected
properly. Otherwise, idle speed may be in-
correct.
Pin function: 081801

A connects ECU pin 27 (stepping motor
phase A)
B connects ECU pin 28 (stepping motor
phase B)
D connects ECU pin 18 (stepping motor
phase C)
C connects ECU pin 17 (stepping motor
phase D)
27
17
28
18
ECU
Stepping motor 081802
8-18
Electrical System
8.3.3.11 Ignition coil
Ignition coil transforms the low voltage of 1
primary coil to high voltage of secondary
coil needed to spark the spark plug and
ignite the mixture of air and fuel in cylinder.
Pin function: 2
1 Ground
2 Power +
3 ECU pin 3
081901
Injector
Ignition coil & Ignition coil & ECU

spark plug 2 spark plug 1 081902
Secondary Ignition Voltage Test: Peak voltage measurement

●Connect the engine according to EFI
wiring diagram.
●Connect the peak voltage tester according
to the right diagram.
●Start the engine.
●Secondary ignition voltage should be
more than 15 kV. ECU Battery
Spark plug
081903
Ignition coil parameter chart table:

Value
Item
Min Standard Max Unit
Stated Voltage 14 V
Operating Voltage 6 16.5 V
Resistance Primary 0.74 0.76 0.78 Ω
(20°C~25°C) Secondary 10.1 10.6 11.1 kΩ
Primary Current 7 A
8-19
Electrical System
8.3.3.12 Roll-over Sensor Tilt angle
Roll-over sensor is used for preventing 65°±10° 65°±10°
vehicle from tilting. When vehicle’s tilt
angle is larger than settled tilt angle, an
“OUT” signal will be transferred to ECU.
ECU will stop the engine.
082001
The “UP” faces upward when installing as

picture shows.
082002
1 2
Pin function:
VCC: +DC12V
OUT: ECU pin38
GND: Ground
082003
1 VCC 2 GND 3 OUT
8-20
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

and PDA.
8.3.4.1 Malfunction Indicating Lamp (MIL) Resistant

It indicates different fault codes through 29
the flashes in different frequency.
+12V power
The right picture is the MIL connection LED
circuit. The current in pin 29 to ECU should
be less than 0.5 A.
MIL Flash Principle: ECU

If the ECU detects MIL is in flash code mode,
MIL indicator flashes to show trouble code.
082101
A. MIL in code-flashing mode without
fault in memory:
From ECU formating, MIL is lightened for
4 seconds. After 1 second interval, MIL
indicator flashes every 0.5s. It means
there is no fault. MIL indicator goes off until
engine starts and find RPM.
B. MIL in code-flashing mode with fault
in memory:
From ECU formating, MIL is lightened for 4
seconds. After 1 second interval, MIL light
flashes to display fault code. If all faults
in memory are shown, MIL goes off and
quites flash code mode.
K-line should connect to ground in code-
flashing mode.
C. Read the trouble information by
flashing code:
Turn on ignition switch with K-line to
ground for more than 2.5 seconds. If
the ECU memory has trouble code, MIL
indicator will display the code by flashing.
Take P0203 as an example, its flashing
method is: flashing 10 times-off-flashing
twice-Off-flashing 10 times-Off-flashing
three times.
8-21
Electrical System
8.3.4.2 PDA
PDA has 3 pins, power, ground wire and
data cable K. These pins are connected
with related ECU pins. 1
The right photo refers to operation panel
of PDA. When it comes to detailed keys
function, refer to PDA manual. 2 3
4 5
7
6
082201
1 UP Key 4 EXIT Key 7 Power switch

2 LH Key 5 OK Key
3 RH Key 6 Down Key
Key function:
LH Key: Page up 3 1
UP Key: Scroll Up
RH Key: Page Down
1 2
Down Key: Scroll Down
OK Key: Entrance
EXIT Key: Exit 2 3
PDA Function:
(A) Version Information Display 082202
PDA can display engine,ECU hardware PDA wiring diagram
and soft ware information. 1 +12V power 2 ECU pin 34 3 Ground
(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
Electrical System
8.3.5 Fault Code
No. 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 (Bank 1
5 P0051
Sensor 1)
Second Cylinder Oxygen Sensor Heated Control Circuit High Voltage (Bank 1
6 P0052
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
Electrical System
8.4 Fault Diagnosis and Treatment
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
Electrical System
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
Electrical System
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 Replace chain and

1. Chain stretched out sprocket
Engine abnormal 2. Chain sprocket worn Replace chain and
noise 3. Tensioner failure sprocket
Repair or replace
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
Ignition System:
Replace
1. Flame ignitor malfunction
Replace
2. Spark plug burnt
Adjust
3. Incorrect spark plug clearance
Clean
4. Carbon deposit in spark plug
No spark or weak Replace
6. Battery low voltage
spark Charge or replace
7. Ignition coil malfunction
Replace
8. Trigger coil malfunction
Replace
9. Incorrect trigger clearance
Adjust
10. Other circuit malfunction
Inspect
8-26
Electrical System
8.5 Trouble Diagnosis In Accordance With Engine Error
Before trouble diagnosis by engine problems, initial checking should be done as
follows.
1. Confirm if trouble light is ok.
2. Confirm there’s no trouble code record by PDA checking.
3. Confirm there’s really trouble existing complained by end-users.
Then check the following points:

1. Check fuel hoses if any fuel leakage.
2. Check vacuum pipes if any broken, twist or improper connection.
3. Check intake manifold if any blocked, air leakage or damaged.
4. Check high-tension cable if any damaged, aging or ignition order is correct.
5. Check wiring close to ground if it’s clean and firm.
6. Check connector of all sensors and actuator if any loose or improper connection.
Important note: In case there are some problems as above-mentioned, then
removal work should be done firstly, then go to next diagnosis.
Diagnosis helps:
1. Confirm engine without any trouble record.
2. Confirm there’s really trouble existing.
3. During checking, do not neglect vehicle periodic maintenance, cylinder pressure,
valve timing, fuel supply and so on.
4. Replace ECU to test.
In case trouble disappears, then it’s a problem of ECU. If trouble still exists, then
assemble original ECU and check other points.
Frequent troubles list:

● When starting the engine, engine cannot rotate or rotate slowly.
● When starting engine, starter motor can rotate but cannot start engine.
● Difficult to start warm or hot engine.
● Difficult to start cold engine .
● RPM is ok, but difficult to start engine.
● Starting is ok, but idle speed is unstable at any time.
● Starting is ok, but idle speed is unstable during engine warm-up period.
● Starting is ok, but idle speed is unstable after engine warm-up.
● Starting is ok, idle speed is unstable or engine stop when switch on some lights or
other electric components.
● Starting is ok, but too high idle speed.
● RPM cannot go up or engine stop when acceleration.
● Slow acceleration.
● Insufficient power and bad performance when acceleration.
8-27
Electrical System
(1) Starting Failure/Hard Starting
General failure part: 1. Battery; 2. Starter motor; 3. Wirings harness or ignition switch; 4.
Engine mechanism part.
General diagnosis procedures:
Item Procedures Results Next
Use multi-meter to check battery voltage if YES Next step
1 voltage is between 8-12V or not when engine
NO Replace battery
starts.
Turn on ignition switch, stop switch side stand YES Next step
2 switch and check if voltage of ECU pin 32 is Repair switches or
NO
around 12V. change harness
Keep ignition switch “on”, use multi-meter to YES Next step
3 check if voltage of starting motor anode is over Repair switches or
NO
8V. change harness
Disassemble starting motor and check its Repair or replace
YES
4 working status, especially whether there was starting motor
broken circuit or jammed by bad lubrication. NO Next step
If error only occur in Winter, check if starting Change to proper
YES
5 motor resistance is too big caused by improper lubricant
oil used. NO Next step
Check if mechanical resistance is too big inside Check engine inside
YES
engine. resistance
6
Repeat above
NO
procedures
(2) When starting, engine can rotate but cannot start

General failure part: 1. No fuel; 2. Fuel pump; 3. Trigger; 4. Ignition coil; 5. Mechanical
parts of engine
Connect fuel pressure gauge, turn on ignition YES Next step
1 switch or start engine, check if fuel pressure is Check and repair fuel
around 300kpa. NO
supply system
YES Next step
Connect PDA, check if there's signal of RPM
2 Check and repair RPM
data after starting engine. NO
sensor circuit
Disconnect high-tension cable, connect spark YES Next step
plug and set its electrode 5mm to engine body,
3 Check and repair
then start engine to check if blue and white NO
spark appears. ignition system
Eliminate engine
Test cylinder pressure and check if pressure is YES
4 mechanical failures
enough.
NO Next step
Use PDA to test, turn on ignition switch, YES Use PDA to check
check if power supply of ECU pin 32 and pin
5
33 is normal; check if pin 5 and pin 10 works NO Repair related circuit
normally.
8-28
Electrical System
(3) Difficult to start hot engine
General failure part: 1. Water in fuel tank; 2. Fuel pump; 3. Water temp. sensor; 4.
Ignition coil.
NO
around 300kpa. supply system
2 Check and repair
Disconnect water temp. sensor connector,
YES Change fuel
check whether the engine can be started or not.
3 (Or replace water temp. sensor with a 300Ω
resistance. Check whether the engine can be NO Next step
started or not.)
Check whether the failure happens right after YES Use PDA to check
4
fueling. NO Repair related circuit
Use PDA to test, turn on ignition switch, check YES Use PDA to check
5 if power supply of ECU pin 32 and pin 33 is
normal; check if pin 5 and pin 10 works normally. NO Repair related circuit
(4) Difficult to start cold engine
General failure part: 1. Water in fuel tank; 2. Fuel pump; 3. Engine temp. sensor; 4.
Injector; 5. Ignition coil; 6. Throttle body and by-pass; 7. Mechanical parts of engine
YES Next step
Connect fuel pump gauge ,start engine, check
1 Check and repair fuel
if pressure is around 300kPa. NO
supply system
plug and set its electrode 5mm to engine
2 Check and repair ignition
body, then start engine to check if blue and NO
white spark appears. system
Disconnect water temp. sensor connector, Repair circuit or replace
check whether the engine can be started or YES sensor
3 not. (Or replace water temp. sensor with a
2500Ω resistance. Check whether the engine NO Next step
can be started or not.)
Clean throttle body and
Slightly draw throttle cable and check if engine YES
4 by-pass
could start easily.
NO Next step
Disassemble injector and use special tool to YES Replace injector
5
check if there is leakage or block. NO Next step
Check whether the failure happens right after YES Change fuel
6
filling fuel. NO Next step
Eliminate engine
YES
7 Check if cylinder pressure is insufficient. mechanical failures
NO Next step
8-29
Electrical System
(5) Difficult to start in any conditions
General failure part: 1. Water in fuel tank; 2. Fuel pump; 3. Injector; 4. Ignition coil;
5. Throttle body and by-pass; 6. Air intake pipe; 7. Ignition timing; 8. Spark plug; 9.
Mechanical part of engine
Check and repair air
Check if air filter is blocked or air intake pipe YES
1 intake system
leaks.
NO Next step
YES Next step
Connect fuel pump gauge, start engine, check
2 Check and repair fuel
if pressure is around 330kPa. NO
supply system
3 Check and repair
Check if spark plug is suitable for requirement YES Next step
4
including its type and clearance. NO Adjust or replace
Disconnect water temp. sensor connector, Repair circuit or replace
YES
5 check whether the engine can be started or sensor
not. NO Next step
Clean throttle body and
Slightly draw throttle cable and check if engine YES
6 by-pass
could start easily.
NO Next step
Disassemble injector and use special tool to YES Replace
7
8
Eliminate engine
YES
NO Next step
8-30
Electrical System
(6) Normal starting, but unstable idle speed
General failure part: 1. Water in fuel tank; 2. Injector; 3. Spark plug; 4. Throttle body
and by-pass; 5. Air intake pipe; 6. Air control valve; 7. Ignition timing; 8. Spark plug; 9.
Mechanical part of engine
1 intake system
leaks.
NO Next step
YES Clean or replace
2 Check if air control valve is blocked.
NO Next step
3
Check if there is carbon deposit inside throttle YES Clean
4
body and air control valve. NO Next step
5
6
fueling. NO Next step
Eliminate engine
YES
NO Next step
YES Next step
Check if ignition timing complies with standard
8 Check and repair
regulation. NO
ignition timing
8-31
Electrical System
(7) Normal starting, but unstable idle speed during engine warming
General failure part: 1. Water in fuel tank; 2. Injector; 3. Spark plug; 4. Throttle body and
by-pass; 5. Air intake pipe; 6. Air control valve; 7. Mechanical part of engine
1 intake system
leaks.
NO Next step
2
3
Repair circuit or
Disconnect water temp. sensor connector and YES
4 replace sensor
start engine to check idle speed is stable or not.
NO Next step
5
6
fueling. NO Next step
Eliminate engine
YES
NO Next step
(8) Normal starting, but unstable idle speed after engine warming
General failure part: 1. Water in fuel tank; 2. Injector; 3. Spark plug; 4. Throttle body and
by-pass; 5. Air intake pipe; 6. Air control valve; 7. Mechanical part of engine
1 intake system
leaks.
NO Next step
2
3
Disconnect water temp. sensor connector and Repair circuit or replace
YES
4 start engine to check idle speed is stable or sensor
not. NO Next step
5
6
Eliminate engine
YES
NO Next step
8-32
Electrical System
(9) Normal starting, unstable idle speed or engine stop when it is electronic loaded
(e.g. headlight is on)
General failure part: 1. Air control valve; 2. Injector
Disassemble air control valve and check if YES Clean
1 there is carbon deposit inside throttle body, idle
NO Next step
adjustment and by-pass.
Check if output power increases when lighting, YES Next step
2 by using PDA to test if ignition advance angle, NO Next step
fuel spray and air intake volume is normal. NO Repair air intake system
3 check if there is leakage or blocked or wrong
NO Next step
fuel flow.
(10) Engine starts normally, but idle speed is too high

General failure part: 1. Throttle body and by-pass; 2. Injector seat; 3. Air control valve; 4.
Water temp. sensor; 5. Ignition timing
YES Adjust
1 Check if throttle cable is jammed or too tight.
NO Next step
2 intake system
leaks.
NO Next step
3
Repair wiring or replace
Remove water temp. sensor connector, start YES
4 sensor
engine to check if idle speed is too high.
NO Next step
YES Next step
5 Check and repair
regulation. NO
ignition timing
8-33
Electrical System
(11) RPM cannot increase or engine stop when accelerating
General failure part: 1. Water in fuel tank; 2. TPS; 3. Spark plug; 4. Throttle body and by-
pass; 5. Air intake pipe; 6. Air control valve; 7. Injector; 8. Ignition timing; 9. Exhaust pipe
YES
1 Check if air filter is blocked. intake system
NO Next step
NO
around 250kpa. supply system
3
Remove air control valve and check if there is YES Clean
4 carbon deposit inside throttle body, air control
NO Next step
valve and by-pass.
YES Next step
5 Check if T PS and its circuit is normal. Repair wiring or
NO
replace sensor
6
7
YES Next step
8 Check and repair
regulation. NO
ignition timing
YES Next step
9 Check if exhaust gas exhale smoothly. Repair or replace
NO
exhaust pipe
8-34
Electrical System
(12) Low acceleration
General failure part: 1. Water in fuel tank; 2. TPS; 3. Spark plug; 4. Throttle body and by-
pass; 5. Air intake pipe; 6. Air control valve; 7. Injector; 8. Ignition timing; 9. Exhaust pipe
YES
NO Next step
around 300kpa. NO
supply system
3
NO Next step
valve and by-pass.
YES Next step
5 Check if T PS and its circuit is normal. Repair wiring or replace
NO
sensor
6
7
YES Next step
8 Check and repair
regulation. NO
ignition timing
YES Next step
NO
exhaust pipe
8-35
Electrical System
(13) Difficult to accelerate and bad performance
General failure part: 1. Water in fuel tank; 2. TPS; 3. Spark plug; 4. Ignition coil; 5.
Throttle body and by-pass; 6. Air intake pipe; 7. Air control valve; 8. Injector; 9. Ignition
timing; 10. Exhaust pipe
Check if clutch sliding, low tire pressure, bad YES Repair
1
brake or wrong tire size. NO Next step
YES
NO Next step
around 300kpa. NO
supply system
4 Check and repair
then start engine to check if spark is strong NO
enough. ignition timing
5
including its type and clearance. NO Replace
NO Next step
valve and by-pass.
YES Next step
7 Check if T PS and its circuit is normal. Repair wiring or
NO
replace sensor
8
9
YES Next step
10 Check and repair
regulation. NO
ignition timing
YES Next step
NO
exhaust pipe
8-36
Cooling System
9.1 Cooling System Diagram�� 1
9.2 Cooling System Removal�� 2
9.3 Coolant�� 4
9.4 Seal Inspection�� 4
9.5 Radiator and Water Pipes Inspection and Clean�� 5
9.6 Fan Motor Inspection�� 6
9.1 Cooling System Diagram
1. Fan Motor
3 4 2. Reservoir tank
3. Water pump assy
4. Radiator water outlet
pipe
090101 5. Radiator water inlet
pipe
5 6. Radiator
7. Engine assy
090102
9-1
Cooling System
DANGER:
Coolant is toxic. Don’t drink nor spill on skin, eyes, clothing. If coolant is swallowed,
induce vomit and seek for medical attention. If you get coolant on your skin or in
your eyes, immediately wash it off before medical attention. If you spill coolant on
your clothing, change your clothing.
Rusting and corroding residues in engine and radiator must be treated according to
regulations. The chemical inside can do harm to humans.
CAUTION:
If tap water is added to the cooling system, scale deposit will accumulate inside the
cooling system. When the temperature is below zero, ice will be generated, which
will seriously affect the operation of the cooling system.
Antifreeze is added anti-rust agent and antiseptic. When it is diluted, it will lose
resistance of rust and corrosion. The dilution concentration of antifreeze must be
consistent with the manufacturer's instructions.
The coolant added into the cooling system is green and contains ethylene glycol.
When the ambient temperature is at -35°C, please choose the coolant whose
freezing point is lower than -35°C.
WARNING:
The coolant will be very hot and under pressure when the vehicle is running.
Never open the radiator cap when the engine is still hot. Otherwise, the vapor or hot
coolant will cause injury.
If get scalded, rinse the wound with flowing cold water for more than 10 minutes
until the wound is no longer painful and seek medical advice immediately.
9.2 Cooling System Removal

Place a container under water pump. 2
Remove drain bolt 1 .
Drain coolant.
3
Loosen clamp 2 .
Remove water outlet pipe 3 .
NOTE: After water outlet pipe removal,
there is still some coolant spilling out. 1
090201
Loosen clamp 4 .
Remove water inlet pipe 5 .
4
090202
9- 2
Cooling System
Remove reservoir tank 7 .
6
7
090301
Remove bolt 8 ,
Remove radiator 9 .
Installation
installation.
9
090302
9-3
Cooling System
9.3 Coolant Mixing ratio Freezing point
Coolant in cooling system is a mixture
50% -30°C
of 51.5% distilled water,46% ethylene
glycol antifreeze and 2.5% additive. This 55% -40°C
mixture ratio provides optimized corrosion 60% -55°C
resistance and fine heat production. The (°C)
mixture has good anti-corrosion and 0
endothermic function, and its solidification -10
Freezing point
point is -35°C. If engine works under -35°C, -20
choose coolant of 40% or 50%. -30
CAUTION: -40
Use high quality ethylene glycol base -50
antifreeze mixed with distilled water. -60
Never mix alcohol base anti-freeze or -70
other different brands of antifreeze.
The ratio of mixture should not be more Ratio 0 20 40 60 80 100
than 60% or less than 50%.
Do not use anti-leak additive.
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
Seal Inspection
Connect the pressure gauge with reservoir
joint .
WARNING: Never open the radiator
cap when the engine is still hot.
Otherwise, the vapor or hot coolant will
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- 4
Cooling System
9.5 R a d i a t o r a n d Wa t e r P i p e s
Inspection and Clean
Remove dirt and dust from the radiator with

high-pressure air.
090501
Repair radiator fins with a small screwdriver.
090502
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.
9-5
Cooling System
9.6 Fan Motor Inspection
1
Remove four bolts 1 .
Remove fan motor assy.
090601
Rotate the impeller with hands to inspect

its movement. Replace if the rotation isn’t
4
smooth or the impeller is broken.
Remove nut 2 .
Remove impeller 3 .
3
5
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. 1
Remove three M6 bolts 4 . 090602
Remove motor 5 .
Installation
installation.
9- 6
Muffler
10.1 LH Footrest�� 1
10.2 RH Footrest�� 1
10.3 Muffler�� 2
10.3.1 Removal�� 2
10.3.2 Inspection�� 3
10.3.3 Installation�� 3
10.1 LH Footrest
Removal
Remove LH footrest 2 .
1
Installation
installation. 2
100101
10.2 RH Footrest
Removal
Remove RH footrest 2 .
NOTE: There is rear brake master

cylinder connecting wih brake system 2
1
behind the RH footrest.
Installation
installation.
10-1
Muffler
10.3 Muffler
10.3.1 Removal
Remove two oxygen sensors 1 .
100201
Remove four nuts 2 .
100202
100203
10-2
Muffler
Remove muffler 4 .
100301
10.3.2 Inspection
Inspect graphite ring seal sleeve 1 after 1
removal for crack or rust. Replace if any
defect is found.
100302
Inspect rubber sleeves on bolts 2 for

cracks or other damage. Replace if any
defect is found.
100303
10.3.3 Installation
installation.
10-3
Wheels and Brake System
11.1 Front Wheel�� 1
11.2 Rear Wheel�� 2
11.3 Front Brake Caliper�� 3
11.4 Rear Brake Caliper�� 3
11.5 Rear Brake Master Cylinder�� 3
11.6 Rear View Mirrors�� 4
11.7 Hand Brake Master Cylinder Assy�� 4
11.8 MAB Actuator�� 4
11.9 Wheel Inspection�� 5
11.9.1 Sprocket Seat�� 5
11.9.2 Tire Pressure�� 5
11.9.3 Tire Appearance�� 5
11.9.4 Wheel Bearing�� 6
11.9.5 Rim�� 6
11.10 Brake System Inspection�� 7
11.10.1 Hand Master Cylinder Inspection�� 7
11.10.2 Brake Caliper and Brake disc Inspection�� 9
11.10.3 Rear Master Cylinder Inspection�� 9
11.10.4 Brake Hose Inspection��11
11.11 Free Play�� 12
11.11.1 Front Brake Lever Free Play�� 12
11.11.2 Rear Brake Pedal Free Play�� 12
11.1 Front Wheel
Removal
Remove bolt 1 .
Remove front wheel shaft 2 . 2
110101
Remove front wheel 3 .
110102
11-1
11.2 Rear Wheel
Removal
Remove bolt 1 .
Remove speed sensor 2 .
1
110201
Remove cotter pin 3 .

Remove nut 4 .
Remove rear wheel shaft 5 .
4
CAUTION: The removed cotter pin
can't be reused.
110202
Push rear wheel forward to release the

chain.
Remove rear wheel 6 . 6
NOTE: Do not loss two rear wheel shaft
sleeves 7 .
CAUTION: Lean rear wheel slightly to
7
right during removal, in case of sprocket
seat falling down to cause injury.
Installation
installation.
9 10
Remove two bolts on each side 8 .
Remove RPM sensor 10 . 8
110204
11-2
11.3 Front Brake Caliper
Removal
Remove front brake caliper 2 .
1 2
Installation
installation.
110301
11.4 Rear Brake Caliper

Removal
Remove swing arm RH panel 2 .
3
Remove speed sensor bolt 4 . 1
Remove rear brake caliper 3 . 5
Installation
2
installation. 4
110302
11.5 Rear Brake Master Cylinder

Removal 2
Remove bolt 1 .
Remove rear brake fluid reservoir 2 . 1
CAUTION: Never put brake fluid

reservoir up side down, in case the air
gets into the system, which leads to
brake system failure.
110303

Remove spring 4 .
Remove bolt 5 .
Remove rear brake master cylinder 6 .
3 6
4
5
110304
11-3
11.6 Rear View Mirrors
Removal
Rotate rear view mirrors 1 counter-
clockwise to remove them.
Installation 1
installation.
110401
11.7 Hand Brake Master Cylinder

3
Assy
Removal
Remove press cover 2 .
Remove hand brake master cylinder assy
3. 1
CAUTION: Never put brake fluid 2
reservoir up side down, in case the air
gets into the system, which leads to
brake system failure. 110402
11.8 MAB Actuator 1

Removal
Remove MAB actuator 2 . 2
110403
11-4
11.9 Wheel Inspection
11.9.1 Sprocket Seat
Remove sprocket seat 1 from rear wheel
2.
1
2
110501
Inspect cushion rubber blocks 3 for aging

or cracks. Replace if any defect is found.
Inspect sprocket seat 1 and rear sprocket
for wear or damage. Replace if any defect 3
is found.
110502
11.9.2 Tire Pressure

Remove tire inflation valve cap. 1
Measure the tire pressure with air gauge 1

when it is cool.
Pressure kPa kgf/cm2 psi
Front wheel 250 2.55 36.26
Rear wheel 250 2.55 36.26
Adjust the tire pressure according to the
standard if necessary.
Install tire inflation valve cap.
110503
11.9.3 Tire Appearance 2

Clean the embedded stone 2 or other
inclusions 1 on tires.
Inspect the tire for cracks or damages by
watching it. Replace if any defect is found. 1
If tire expands or has bulges on it, replace
with a new tire.
110504
11-5
Inspect tire for wear condition. The tire may
be punctured or damaged if beyond service
limit. Majority of the tire accidents happen 1
due to exceeding service limit. Pay attention
not to use the tire if the pattern is worn in
case of injury.
When the tire thread wears to the block 1
height, replace a new tire.
110601
11.9.4 Wheel Bearing

Lift the front wheel with jack.
Inspect the front wheel bearing for damage
buy pushing or pulling the wheel A .
Rotate the front wheel B to inspect the for
the smooth movement and noise.
Replace if any defect is found.
A
B
110602
Lift the rear wheel with jack.

Inspect the rear wheel bearing for damage
buy pushing or pulling the wheel A .
Rotate the rear wheel B to inspect the for
the smooth movement and noise.
Replace if any defect is found. A
110603
11.9.5 Rim
Inspect rim if sunk or damaged 1 .
Inspect front wheel or rear wheel completely
if any defect is found. Replace if necessary.
110604
11-6
11.10 Brake System Inspection
WARNING:
Brake fluid can irritate the skin.
Keep the brake fluid out of reach of children.
Do not let brake fluid contact skin, eyes or clothing. Wear protective gears and
goggles during operation.
If swallow brake fluid by accident, seek for medical attention immediately.
If you get brake fluid on skin, rinse contact area with clean water immediately.
If you get brake fluid in your eyes, immediately wash it off and seek for medical
attention.
If you spill brake fluid on your clothing, change your clothing.
11.10.1 Hand Master Cylinder Inspection

Front Brake Fluid Level Inspection
Straighten the vehicle to make the front
brake fluid reservoir parallel the ground. 1
Watch the fluid level through view window
to check if the level is between MAX and
MIN.
Add or reduce the brake fluid until the level
is in between.
110701
Brake Fluid Replacement 1

Remove two screws 1 .
2
Remove reservoir cap 2 .
Remove reservoir gasket 3 . 3
NOTE: Reservoir gasket may be sunk
due to negative pressure caused by
brake fluid reducing. It doesn't affect
normal use but needs to be restored
during installation.
110702
Open air-bleed bolt rubber cap 4 .

Connect a clean hose with air-bleed bolt 5
with other side into a container.
4
110703
11-7
Repeatedly hold and loose A brake lever
A
until it feels hard.
Loose air-bleed bolt 5 a little bit.
Tighten the bolt right after the brake fluid
doesn’t spray out or the lever feels soft.
Add brake fluid.
Repeat the above procedures until the new
brake fluid sprays out.
WARNING: Keep brake fluid level
above MIN, in case air gets into brake
system, which results in brake system
failure and injury. 110801
WARNING: If there is air inside of
brake system, replace brake fluid
repeatedly until there is no air in drained
brake fluid.
Brake Fluid Addition

Add brake fluid until the level is between
MAX and MIN.
110802
1
Install reservoir gasket 3 .
Install reservoir cap 2 . 2
Install two screws 1 .
3
110803
11-8
11.10.2 Brake Caliper and Brake disc
Inspection
Front Brake Caliper
Remove brake caliper.
Inspect each brake pad thickness.
Brake pad thickness service limit: ≥1mm
Replace brake pads before it reaches to
service limit. Replace brake pads in set. ≥ 1mm
Inspect brake pads for deep scratches or
other damages. Replace if any defect is
found.
WARNING: Do not run the vehicle 110901
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.
≥ 3mm
Front Brake Disc
Inspect brake disc thickness.
Brake disc thickness service limit: ≥3mm
Replace brake discs before it reaches to
service limit.
110902
Inspect brake discs for deep scratches or
other damages. Replace if any defect is
found.
11.10.3 Rear Master Cylinder Inspection

Rear Brake Fluid Level Inspection
Straighten the vehicle to make the rear
brake fluid reservoir parallel the ground.
Watch the fluid level to check if the level is
between UPPER and LOWER.
110903
Add or reduce the brake fluid until the level
is in between.
11-9
Brake Fluid Replacement
Remove two bolts 1 . 1
Remove reservoir cap 2 .
Remove reservoir gasket 3 . 2
NOTE: Reservoir gasket may be sunk
due to negative pressure caused by 3
brake fluid reducing. It doesn’t affect
normal use but needs to be restored
111001
Open air-bleed bolt rubber cap 4 .

Connect a clean hose with air-bleed bolt 5
4
with other side into a container.
111002
Repeatedly press and release A brake

pedal until it feels hard.
Loose air-bleed bolt 5 a little bit.
Tighten the bolt right after the brake fluid
doesn’t spray out or the pedal feels soft.
Add brake fluid until the level is between A
UPPER and LOWER.
Repeat the above procedures until the new
brake fluid sprays out.
WARNING: Keep brake fluid level
above MIN, in case air gets into brake 111003
system, which results in brake system
failure and injury.
WARNING: If there is air inside of
brake system, replace brake fluid
repeatedly until there is no air in drained
brake fluid.
11-10
Brake Fluid Addition
Add brake fluid until the level is between
UPPER and LOWER.
111101
1
Install reservoir gasket 3 .
Install reservoir cap 2 . 2
Install two bolts 1 .
3
111102
11.10.4 Brake Hose Inspection

Inspect brake hose, connectors and pipes B A
for damage, cracks or leaking.
With improper maintenance, the high
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
C
B , bulge C or leaking detected.
Tighten all the brake hose connecting bolts
and nuts. 111103
Inspect brake hose route. Reset the hose
route if not proper or correct.
11-11
11.11 Free Play
11.11.1 Front Brake Lever Free Play
Inspect front brake lever free play.
Standard: 3mm~6mm 1
111201
11.11.2 Rear Brake Pedal Free Play

Inspect rear brake lever free play.
Standard: 10mm
111202
11-12
Shock Absorbers and Rear Fork
12.1 Front Shock Absorber�� 1
12.2 Chain�� 1
12.3 Rear Shock Absorber�� 2
12.4 Rear Fork�� 2
12.5 Chain Inspection�� 3
12.6 Front Shock Absorber Inspection�� 6
12.7 Rear Shock Absorber Inspection�� 6
12.1 Front Shock Absorber

1
Remove four inner hex bolts 1 .
Remove handlebar press cover 2 .
Remove handlebar 3 .
2 3
120101
Remove six inner hex bolts 4 .

Remove front shock absorbers 5 .
4 4
120102
12.2 Chain
Removal 2
Remove three inner hex bolts 1 .
Remove rear swing arm RH panel 2 .
120103
12-1
Remove small sprocket guard 4 .
3 4
120201
Remove chain 6 .
120202
12.3 Rear Shock Absorber

Removal
Remove upper mounting bolt 1 . 3
Remove lower mounting bolt 2 .

Remove rear shock absorber 3 .
CAUTION: After rear shock absorber 1
removed, the rear fork is free to fall.
120203
12.4 Rear Fork

Removal 1
Remove nut 1 .
Remove long bolt 2 .
Remove rear fork 3 .
2
3
120204
12-2
12.5 Chain Inspection
Because the chain is installed through the
swing arm, it can only be cut rather then 2
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 picture
shows.
120301
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.
120302
Rotate the pin seat with wrench 3

clockwise to remove the chain pin.
Drive Chain Installation

Install new chain knots on chain to replace
the old ones. 120303
Remove the chain boards of new drive
chain.
Apply grease on chain pin 2 and seal rings 1 2
1.
Engage the chain and rear chain sprocket.
3
Insert chain pins into chain knots.
Install seal rings 1 .
Install chain boards and make the mark 3 1
face outside.
Fix the chain board with hand or plier.
Make sure the seal ring is installed correctly
in case of the chain grease leaking.
120304
12-3
Set the holder 4 and 5 .
120401
Align the holder and chain board.

Rotate the pin seat until it touches the chain
board.
120402
Rotate the pin seat with wrench clockwise

until two pins get into the grooves of holder.
Remove holder 4 .
120403
Set the holder 5 and cutting and riveting

pin 6 as picture shows. 6
120404
12-4
Rotate the pin seat until it touches chain
pin.
120501
Rotate the wrench clockwise until cutting

and riveting pin head touches chain pin to
rivet.
Other chain pins installation follows the
same procedures.
120502
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: 5.45mm~5.55mm
Chain board width
2
Standard: 17.25mm~17.45mm
(0.679in~0.687in)
Cut and re-rivet the chain knots if out of
standard.
120503
Chain Looseness Adjustment

Loosen lock nut 1 .
Adjust adjusting nut 2 according to
requirement.
2
Tighten lock nut 1 .
Chain sag standard: 30mm~40mm
CAUTION: Adjusting nuts must be set
the same distance on both sides.
1
120504
12-5
12.6 F r o n t S h o c k A b s o r b e r
Inspection
Inspect front shock absorber appearance
for damage 2 , cracks 1 or other damage.
3
Clean dust and mud 3 on front shock 2
absorber.
Press down handlebar several times to
check compression/rebound function of 1
front shock absorber.
120601
4
5
Installation
installation.
NOTE: During installation, the upper

surfaces 4 of both shock absorbers 1mm~2mm
should parallel and exceed handlebar
surface 5 1mm~2mm. 120602
3
12.7 R e a r S h o c k A b s o r b e r
Inspection
Inspect rear shock absorber appearance 2
for damage 2 , cracks 1 or other damage.

1
Clean dust and mud 3 on rear shock 120603
absorber.
Press down seat several times to check
compression/rebound function of front
shock absorber.
12-6
Engine Assy (CF400-B)
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
13.1 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
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
13.2 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
CF400-B
Loose clamp 1 .
2
Shake throttle valve body 2 until it looses.
Remove air filter.
1
130802
CF400-BF
Remove AIS valve and air inlet and outlet
pipes；
Remove air filter.
130805-20200909
13.2.3 Clutch Cable Removal

Use tool to rotate clutch rod 2 .
Remove clutch cable 1 .
1 2
130803
13-8
13.2.4 Gearshift Lever Assy Removal

Remove M6 bolt 1 .
Remove gearshift lever assy 2 .
130804
13.2.5 Sprocket Removal

1
Remove M6 bolt . 1
Remove engine LH rear cover 2 .
2
130901
Remove M6 bolt 1 .
Remove bracket 2 .
Note: Pay attention there are two 1 2

dowel pins under the bracket 2 . After
bracket 2 removal, remove dowel pins 1
in case of getting lost.
130902
Knock and straighten the flanging of

retainer 1 .
Remove counter pulse M20 nut 2 .
Remove retainer 1 .
Remove output sprocket 3 .
1
3
130903
13-9
CFMOTO
13.2.6 Engine Assy Removal
Place the jack with soft cushion under the
2
engine to support it.
Remove M10 nut 1 and bolt.
1
Note: Fix the other side with wrench

during removal.
130904
Note: Fix the other side with wrench 1

during removal.
131001
Remove M10 bolt 1 and nut.

Remove M8 bolts 2 .

during removal.
1
2
131002

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
during removal. 3
131003
13-10
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
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
13.4 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
1 2
Remove seal gasket .
2
Remove dowel pins .
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
1
Remove M12 bolt .
Remove washer 2 .
131603
Use special tool: magneto rotator removing

1
tool 1 to remove the magneto rotor 2 . 2
131604
13-16
13.4.4 Ignition Coil and Spark Plug
CF400-BF
Removal 1
Remove bolts 1
Remove spring valve cover 2 ；
Remove spring valve assy 3 . 2
131705-20200909
Remove M6 bolts 1 .
1 2 2 1
Remove press plate 2 .
1
Rotate the ignition coil counter
clockwise until it gets loose.
Pull out ignition coil 1 .
3
131701
1
Use special tool: spark plug sleeve to 1
remove spark plug 2 .
2
131702
13-17
CFMOTO
13.4.5 Cylinder Head Cover Removal
Remove cylinder head cover M6 bolts and 1

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.
1
Remove spark plug hole seal ring .
131704
13-18
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
4
Remove air exhaust camshaft seat .
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
13-19
CFMOTO
Remove dowel pins 1 .

2
Remove camshaft assy . 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

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

1
Remove RH side cover 2 . (Rotate the
clutch rod 3 to the proper position to
remove the RH side cover.)
131904
13-20
1
Remove seal gasket . 1
2
Remove dowel pins .
2 2
132001
13.4.10 Clutch Removal

Remove M6 bolts assy 1 .
132002
1
Remove clutch springs .
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
13-21
CFMOTO
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
13-22
Remove washer 1 .
132201
1 3 . 4 . 11 C ra n 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
13-23
CFMOTO
2 1
Lift and pull out cylinder body 1 .
2
Note: Hook timing chain in case it
falls down into the engine.
132301

Remove cylinder body gasket 2 .
13.4.13 Piston Removal

Rotate the crankshaft to the proper 2
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
13-24
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
13-25
CFMOTO
2
Remove gearshift cover gasket 1 .
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
13-26
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 oil pump assy 4 with needle-
4 3
nose pliers.
132603
Remove oil pump outer rotor 1 .
132604
13-27
CFMOTO
13.4.20 Oil Filter Removal
Use special tool: oil filter wrench 1 to 2

remove the oil filter 2 . 1
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
13-28
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
13-29
CFMOTO
Remove engine case 1 .

1
Remove: Pay attention to dowel pins

2 during removal in case of getting 2
lost. 2
132901
13.4.23 Timing Chain Removal 1
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
13-30
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
hole 2 . Stop rotating when mark "2/T" on
pulsing rotor is aligned with mark B . This
is the TDC of second cylinder. 133004
13-31
CFMOTO
Measurement
result. Transfer it to tappet thickness
1
2
after installation.
Valve clearance standard 3
133101
section.
13.5.3 Camshaft Cover Inspection

1
Removal/installation procedures refer to
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
133102
occurs.
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 .
1 4
133103
13-32
Camshaft Neck Diameter Measurement

1 1 1
Measure camshaft neck 1 diameter.
Camshaft neck diameter

Note: Replace with new camshafts if

the diameter is beyond service limit.
133201
Clearance between camshaft neck and
camshaft cover
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

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
13-33
CFMOTO
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 .
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
13-34
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

1
Remove M6 bolts 1 .
Remove thermostat cover 2 .
Remove o-seal ring 3 .
Remove thermostat 4 .
4 3
133404
13-35
CFMOTO
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

1
service limit.
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
13-36
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

Service limit
Exhaust: 0.27 mm 133601
Intake: 0.22 mm
Valve Seat Ring Inspection

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

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

Intake: 0.5 mm~1.0 mm H J
133602
13-37
CFMOTO
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.
13-38
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. A B
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

2
Install o-seal ring 1 on thermostat cover
2.
Install thermostat 3 . 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
13-39
CFMOTO
According to records, install valve spring 3

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

133901

tool 1 in the center 2 of valves as picture 2
shows.
1
Wa rn i n g: We a r g o g g le s a ll t he
removing it.
133902
According to records, install valve spring

upper seat 1 .
compressing tool 2 on valve spring upper 3
2
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
13-40
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
134001
13.5.8 Timing Tensioner Inspection
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
13-41
CFMOTO
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
134101
Note: Replace with new piston rings
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
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.
clearance between piston ring and groove
for several times.
Clearance between first ring and groove
Clearance between second ring and groove
134103
13-42
Piston Ring Groove Width
Measure piston ring groove width with

slide caliper at different points. 1
2
First piston ring groove width 1
Second piston ring groove width 2

134201
Replace piston if the width of any ring is

Piston Ring Thickness 1

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

Second piston ring thickness 2 134202

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
13-43
CFMOTO
First piston ring cut clearance

Second piston ring cut clearance

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.
134301
Piston pin hole inner diameter standard:
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
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 134303
beyond service limit. If the clearance is
still out of standard, replace crankshaft.
13-44
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. 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
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 alue is
beyond service limit. 1 1
Crankshaft Rod Journal/Bearing Shell

Wear
Measure crankshaft rod journal diameter
1 with micrometer.
Specification:
Note: Replace if diameter is beyond 134404
service limit.
13-45
CFMOTO
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
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
1 1 1


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
13-46
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
2
Crankcase C r a n k s h a f t
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

Note: Replace with a new balance 134602

shaft if beyond service limit.

Balance shaft journal diameter mark

1 27.987 mm~27.993 mm
2 27.994 mm~28.000 mm
13-47
CFMOTO
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 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
13-48
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
13-49
CFMOTO
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
13-50
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

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
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
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
13-51
CFMOTO
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 4 5
3
135101
Remove shift drum hub 1 . 2

Remove countershaft assy 2 .
Remove main shaft assy 3 .
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
13-52
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

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.
13-53
CFMOTO
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
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
13-54
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
2
or damage. Replace if it does.
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
13-55
CFMOTO
13.5.20 Gearshift Cover Inspection

Inspect gearshift cover 1 for cracks,
damage or severe deformation. Replace if
1
it does.
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
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
13-56
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
Inspect water pump 3 for cracks, damage 3
or severe deformation. Replace if it does.
2
135602
1
Water Seal Inspection
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
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
135604
13-57
CFMOTO
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
13-58
Inspect lower crankcase 1 for cracks or

damage. Replace in pairs if necessary.
1
135801
1
Inspect LH rear cover 1 for cracks or
135802
Inspect oil pan 1 for cracks or damage.

1
135803
Inspect LH side cover 1 for cracks or

135804
13-59
CFMOTO
Inspect RH crankcase cover 1 for cracks

or damage. Replace in pairs if necessary.
135901
13-60
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
13-61
CFMOTO
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
2 6
(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

not. Tighten the bolts in criss-cross 136102
way.
Install M7 bolts 1 . Tighten torque: 20 N·m.

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

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
13-62
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.
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
13-63
CFMOTO
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 .

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
13-64
Install M7×30 bolts 1 with 243 thread

locker.
locker. 2
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.
1
locker.
2
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
13-65
CFMOTO

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

1
way.
136502
13.6.10 Water Pump Installation

3

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
13-66
Put seal ring 1 on water pump cover 2 .

Install water pump cover 2 .
Install M6 bolts 3 . 1
3
2
136601

2
Install tensioner plate assy 1 .
Install thread pin shaft 2 with 243 thread
locker.
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
13-67
CFMOTO

Installation
Install trigger assy 1 . 2
2
136701
Install crankshaft pulsing rotor 1 .

2

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 . 1
2
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
13-68
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
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 .
to fix the clutch housing. 4
Install M20 nut 4 with 243 thread locker. 3

Note: After tightening the nut, rotate
the housing. The movement should be
smooth, not blocked.
136804
13-69
CFMOTO
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
1
Install springs .
136903
1
Install M6 bolts assy .
136904
13-70
Install dowel pins 1 . 1

2
Install cylinder head gasket .
Install chain guide 3 .
3 2
137001
Install cylinder head 1 .

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 3
2
Install M8 bolt 1 with sleeve. Tighten until

the mark 2 on pulsing rotor aligns the
mark 3 on crankcase.
137003

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
13-71
CFMOTO
3
Note: During intake camshaft

installation, the “IN” mark line 2 on
timing sprocket should be parallel with
the cylinder edge 3 . During exhaust
2
camshaft installation, the “EX” mark 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 intake camshaft seat 2 .
Install exhaust camshaft seat 3 . 1
Install camshaft position plate 4 . 1
137102
5
Note: Tighten the bolts 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

Install seal gasket 2 .
1 1
137104
13-72
Install RH side cover 2 .(During

installation, rotate the clutch tie-rod 3 to 1
2
proper position.)
137201
13.6.20 Cylinder Head Cover Installation
1
1
Install spark plug seal rings .
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
13-73
CFMOTO
1
Use special tool: spark plug sleeve to
install spark plugs 2 .
137301
1
Install ignition coils . 3 2 2 3
2
Install press plates .
137302
CF400-BF
Install spring valve assy 3 ； 1
Install spring valve cover 2 ；
Install bolts 1 .
2
137305-20200909
13-74
13.6.21 Magneto Rotor Installation
Apply engine oil on crankshaft and
magneto rotor inner hole. Install magneto 2 3
rotor 1 .
Put washer 3 on M12 bolt 2 . Install M12 1
bolt 2 with 243 thread locker.

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 .

Install dual gear assy 2 . 3 2
Install starter middle gear 4 . 1
4
137304
13-75
CFMOTO
2
1
1
Install dowel pins .
2
Install seal gasket .
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

should be the same. Adjust the bolt if 4
way.
3 137402
1
13.6.22 Starter Motor Installation
Install starter motor 1 . Use rubber

hammer to knock the motor slightly for 2
installation.
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 .
2
Install M12 magnetic drain bolt .
2
1
137404
13-76
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.
13-77
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

137602
Inspect to see if the valve 1 slides
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.
13-78
Assembly
Install relief valve 1 with wrench.
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 .
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

5 6 7 8 9
are wider than main oil pump ones.
137703
13-79
CFMOTO
13.7.5 Oil Pressure Measurement

Remove engine guard.
3
Remove main oil passage plug 1 and
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
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 .
13-80
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.
Put the wire on screw 2 and then install
the screw 2 .
Install protection cover 3 on warning
switch 1 .
137901
13-81
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

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
138001
Put the M10 bolt 2 through the hole 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
13-82
13.8.2 Output Sprocket Installation

Install output sprocket 1 .
Install washer 2 .
Install M20 pulsing nut 3 with 243 thread
locker. 3
1
138101
Install bracket 1 .
2 1
Note: There are two dowel pins 2 2

under the bracket. Do not lose them
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
13-83
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
Install AIS valve and air inlet and outlet

pipes. CF400-BF
138205-20200909
13-84
13.8.6 Inlet/Outlet Pipe Installation 2
Install the outlet pipe 2 on engine.

Tighten clamp 1 . 1
138204
Install the inlet pipe 2 on engine.

Tighten clamp 1 .
2
1
138301
Install M6 drain bolt 1 and washer.
138302
13-85
Engine Assy (CF650-7C)
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
�� 14-72
14.6.12 Piston Installation �� 14-72
Installation�� 14-72
�� 14-73
14.6.15 Clutch Assy Installation...
�� 14-73
�� 14-75
14.6.17 Camshaft Installation14-76
14.6.18 Tensioner Installation14-77
14-2
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
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
14.2 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.
Remove air filter.
1
140802
CF650-7F
Remove AIS valve and air inlet and outlet
pipes；
Remove air filter.
140805-20200909
14.2.3 Clutch Cable Removal
Use tool to rotate clutch rod 2 .

Remove clutch cable 1 .
1 2
140803
14-8
14.2.4 Gearshift Lever Assy Removal
Remove M6 bolt 1 .
Remove gearshift lever assy 2 .
140804
14.2.5 Sprocket Removal
Remove engine LH rear cover 2 .

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
14.2.6 Engine Assy Removal 2
Place the jack with soft cushion under the

engine to support it. 1

during removal.
140904
14-9
CFMOTO

during removal.
1
140904

Remove M8 bolts 2 .
2
during removal.
1
2
131002

Remove M8 bolts 2 .
Remove engine front mounting bracket
assy 3 .
Shake the engine and decline the jack
slowly to remove the engine.
2
during removal. 3
131003
14-10
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 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
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
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 .

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
14.4 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 cable clip 2 .
1
Remove LH front cover 3 .
2
141503
14-15
CFMOTO
1 1 2
Remove seal gasket .
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
13.4.4 Ignition Coil and Spark Plug CF650-7F

1
Removal
Remove bolts 1
Remove spring valve cover 2 ； 2
Remove spring valve assy 3 .
3
141705-20200909
Remove M6 bolts 1 .
1 2 2 1
Remove press plate 2 .
Rotate the ignition coil 1 counter
clockwise until it gets loose.
Pull out ignition coil 1 .
3
141701
Use special tool: spark plug sleeve 1 to 1

remove spark plug 2 .
2
141702
14-17
CFMOTO
14.4.5 Cylinder Head Cover Removal
Remove cylinder head cover M6 bolts and

1
seal rings 1 . 3
Remove cylinder head cover 2 .
Remove cylinder head cover seal gasket
3 .
2
Note: After cylinder head cover 141703
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 .
141704
14-18
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.
14-19
CFMOTO

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

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
14-20
Remove seal gasket 1 . 1

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
14-21
CFMOTO
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

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
14-22
Remove washer 1 .
142201
1 4 . 4 . 11 C ra n 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

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
14-23
CFMOTO
2 1
Lift and pull out cylinder body 1 .
Note: Hook timing chain 2 in case it

falls down into the engine.
142301

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
14-24
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 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
14-25
CFMOTO

1
2
142501
Remove screw 1 .
Remove gear sensor 2 .
1 2 3 4
142502
Status 2
Remove gear position sensor 2 .
Remove screw 4 . 4
Remove gearshift cover 5 . 1
5
3
142503
2
1
142504
14-26
Remove ball contactors 1 .

Remove contactor springs 2 .
1 2
Remove contactor bolt 3 .
Remove gear rotor 4 .
Remove dowel pin 5 .
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 .
142604
14-27
CFMOTO
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 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
14-28
14.4.21 Oil Pan Assy Removal
Remove M6 bolts 1 .
Remove oil pan 2 .
1
2
142801

Remove oil suction pan assy 2 .
Remove oil return pipe rubber sleeve 4 . 4
142802
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
14-29
CFMOTO
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 .

2
Remove: Pay attention to dowel pins 2
2 during removal in case of getting
lost. 2
142904
14-30
14.4.23 Timing Chain Removal

1
Remove timing chain 1 .
143001

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
14-31
CFMOTO

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
143101
tappets of proper thickness. Inspect again 1
after installation. 2
Valve Clearance Standard

3
Installation procedures refer to Installation 143102
section.
Adjust second cylinder timing.

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
clearance of air inlet valve 2 and air 143103
1
after installation.
2
Valve clearance standard
3
section. 143104
14-32
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
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 .
1 4
143202
Camshaft Neck Diameter Measurement

Measure camshaft neck 1 diameter.
Camshaft neck diameter 1 1 1

Note: Replace with new camshafts if

the diameter is beyond service limit.
Clearance between camshaft neck and

camshaft cover 143203
Service limit: 0.13mm
14-33
CFMOTO
Camshaft Deformation

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

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 .
4 1
143304
14-34
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

2
shows.
Wa rn i n g : We a r g o g g le s a ll t he 1
removing it.
143402
compress the spring.
Remove valve clip 2 with tweezers.
Loose valve spring compressing tool 1 . 2
Remove valve spring upper seat 3 . 1
3
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

143404
14-35
CFMOTO
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
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
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
14-36
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
Service limit
Exhaust: 0.27 mm
Intake: 0.22 mm
143602
14-37
CFMOTO
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
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

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
14-38
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

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
14-39
CFMOTO
Cylinder Head Assy Assembly

2
Install o-seal ring 1 on thermostat cover

2. 4
Install thermostat 3 .
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

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

Install valve spring 3 . 2
1
143903

shows. 2
Wa rn i n g: We a r g o g g le s a ll t he 1
removing it.
143904
14-40

upper seat 1 .
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
14-41
CFMOTO
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.
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
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.
14-42
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
144201
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.
clearance between piston ring and groove
1
for several times.
Clearance between first ring and groove
Clearance between second ring and groove
Piston Ring Groove Width

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

Second piston ring groove width 2
Standard: 1.01 mm~1.03 mm 144203
Replace piston if the width of any ring is

14-43
CFMOTO
Piston Ring Thickness

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

Standard: 0.87 mm~089 mm
Second piston ring thickness 2

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
2
First piston ring cut clearance

Standard: 0.25 mm~0.40 mm 144301
Second piston ring cut clearance

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
14-44
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)
the shaft neck surface A . Insert the feeler 1
Standard:
Service limit 0.50 mm A B
144402
Note: Replace with a new connecting
rod and measure the clearance if
Disassembly
Remove connecting rod M9 nut 1 . 2
Remove connecting rod bolts 2 . 4
5
Remove connecting rod body 4 . 5 4
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
5
breaks the shaft neck.
1
5
body after removal. 144403
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.
14-45
CFMOTO
Remove plain bearings and install 100cm
connecting rod cap.
2
end hole.
Put connecting rod big end mandrel on 1
3
V-block 3 . Plumb it and measure mandrel
Note: Replace if parallelism is
beyond service limit. 144501
Connecting Rod Bend 1 2

V-block 3 .
which is the bend value.
3
N ot e : R e plac e if bend v a lue is
144502
Wear 1 1
1 with micrometer.
Specification:
Note: Replace if diameter is beyond
service limit.
less than service limit but coincide the 144503
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
14-46

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 standard 144602
Standard 0.02mm
Service limit 0.05 mm 1 1 1

Crankshaft Main Journal

diameter with micrometer. 1 1 1
Crankshaft main journal diameter 144603


if beyond service limit. Assemble the upper and lower crankcase
according to 14.3.6 Crankcase Assembly
section (without installing other parts).
Measure the crankcase hole diameter
vertically. It should coincide the mark.
Otherwise, re-mark.
2 37.984 mm~37.992 mm
1 37.993 mm~38.000 mm
14-47
CFMOTO

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

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

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

Wear
Measure balance shaft journal 1 diameter
with micrometer.
144702
Note: Replace with a new balance

1 27.987 mm~27.993 mm
2 27.993 mm~28.000 mm
Balance Shaft
mark.
Yellow 31.000 mm~31.008 mm
Green 31.008 mm~31.016 mm
14-48
According to the balance shaft journal

plain bearing 1 . Color mark 2 .
1
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)
the shaft neck surface A . Insert the feeler
1
Standard:
Note: Replace with a new connecting A B
rod and measure the clearance if 144802
Disassembly
Remove connecting rod M9 nut 1 .
Remove connecting rod bolts 2 .
Remove connecting rod body 4 . 3
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

breaks the shaft neck. 4
body after removal.
1
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.
14-49
CFMOTO
Remove plain bearings and install 100cm
connecting rod cap.
end hole. 2
Put connecting rod big end mandrel on 3
1
V-block 3 . Plumb it and measure mandrel
Note: Replace if parallelism is
144901
1
Connecting Rod Bend 2
V-block 3 .
which is the bend value. 3
N ot e : R e plac e if bend v a lue is
144902
1 1
Wear
1 with micrometer.
Specification:
Note: Replace if diameter is beyond
service limit.
Note: If measured diameter is not 144903
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
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
14-50
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 standard
Standard 0.02mm

if beyond service limit. 145001
1 1 1
Crankshaft Main Journal
diameter with micrometer.
Crankshaft main journal diameter
Note: Replace with a new crankshaft 1 1 1

145002

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.
1 41.00 mm~41.008 mm 2
2 41.009 mm~41.016 mm
mark and crankcase main shaft hole,
choose main plain bearing 1 . Color mark 145003
2.
14-51
CFMOTO
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

Wear
Measure balance shaft journal 1 diameter 1 1
with micrometer.
Note: Replace with a new balance
less than service limit but coincide the 145101

1 27.987 mm~27.993 mm
2 27.994 mm~28.000 mm
Balance Shaft
mark.
1 31.000 mm~31.008 mm
2 31.009 mm~31.016 mm
According to the balance shaft journal 1
plain bearing 1 . Color mark 2 .
2
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
14-52
5 4 3 1
14.5.14 Overriding Clutch Inspection
Disassembly
Remove starter big gear assy 1 .
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
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).
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
14-53
CFMOTO
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
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

145304
14-54
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

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
14-55
CFMOTO
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
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 .
1 2 3 4 5
145503
2
Remove shift drum hub 1 .
Remove countershaft assy 2 .
Remove main shaft assy 3 .
145504
14-56
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

corner direction Retainer sharp Retainer sharp corner direction
145602
14-57
CFMOTO
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
14-58
Shift Fork Shaft Inspection

Inspect shift fork shaft 1 and 2 for
deformation, scratches, wear or damage.
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
14-59
CFMOTO
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,
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
14-60
Water Pump Impeller

Disassembly
Remove water seal moving ring 1 .
146001
Inspection
Inspect water pump impeller 1 for
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
14-61
CFMOTO
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
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
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
14-62
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

1
146202
Inspect LH rear cover 1 for cracks or

1
146203
14-63
CFMOTO
Inspect oil pan 1 for cracks or damage.

146301
Inspect LH side cover 1 for cracks or

146302
Inspect RH crankcase cover 1 for cracks

or damage. Replace in pairs if necessary. 1
146303
14-64
14.6 Engine Assembly

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

2
Apply sealing glue on joint surface evenly
and uninterruptedly.
Combine lower crankcase 2 with upper
crankcase 3 . 1
1
3
1
146404
14-65
CFMOTO
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.)
way.
bolts 1 ~ 10 and both sides of washers. 1
Install M8 bolts 1 . Tighten torque: 27.5 N·m. 1

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

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

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
14-66
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 .
146601
Install oil pipe I press plate 1 .

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
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
14-67
CFMOTO
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 .
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
14-68

locker.
locker. 2
Note: Tighten the bolts in criss-cross
way.
146801
Install oil pump chain guide 1 .

3
locker.
1
locker.
2
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 gear sensor 3 .
Install screw 4 with 243 thread locker.
4 3 2 1
146804
14-69
CFMOTO

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
should be the same. Adjust the bolt if 1
way.
146902
Status 2

7 6
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
14-70
5
Install gearshift cover 1 . 3

4
Install screw 3 .
5
Install gear position sensor 4 .
1
2
147001
14.6.10 Water Pump Installation 3

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 .
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 .
3
2
147004
14-71
CFMOTO

2
Install tensioner plate assy . 1
Install thread pin shaft 2 with 243 thread
locker.
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.

2
147103

Installation 2
Install trigger assy 1 . 2
147104
14-72
Install crankshaft pulsing rotor 1 .

147201

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.
14.6.15 Clutch Assy Installation
Install washer 1 . 1
147204
14-73
CFMOTO
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
2
147301
Note: Align the sprocket and gear
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 .
to fix the clutch housing.
Install M20 nut 4 with 243 thread locker.
4
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
14-74
Install tie-rod 1 .
Install operating pad 2 .
147401
Install springs 1 .
147402
Install M6 bolts assy 1 .
147403

Install cylinder head gasket 2 . 1
Install chain guide 3 .
3 2
147404
14-75
CFMOTO
Install cylinder head 1 .

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 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
14-76
5
Install intake camshaft seat 2 . 5 5
Install exhaust camshaft seat 3 .
Install camshaft position plate 4 . 2
3
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

1 1
147603
3
Install RH side cover 2 .(During
1
installation, rotate the clutch tie-rod 3 to
proper position.)
147604
14-77
CFMOTO
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
1
Use special tool: spark plug sleeve 1 to
install spark plugs 2 . 2
147704
14-78
1 3 2 2 3
Install ignition coils .
Install press plates 2 .
147801
CF650-7F
1
Install spring valve assy 3 ；
Install spring valve cover 2 ；
Install bolts 1 . 2
147805-20200909
14.6.21 Magneto Rotor Installation

Apply engine oil on crankshaft and
magneto rotor inner hole. Install magneto
2 3
rotor 1 .
Put washer 3 on M12 bolt 2 . Install M12 1
bolt 2 with 243 thread locker.
4
Note: Before tightening the bolt, pull
magneto with hand to make sure it
doesn’t move. Turn the starter big gear
with hand, it can rotate in one direction. 147802

Install dual gear assy 2 . 3 2
Install starter middle gear 4 .
1
4
147803
14-79
CFMOTO
2
1
147804
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
before installation. The exposed height 2
way.
3
147901
14.6.22 Starter Motor Installation

Install starter motor 1 . Use rubber 1
hammer to knock the motor slightly for
installation.
Note: Apply engine oil on starter 2
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 .
2
1
147903
14-80
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 te d 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.
14-81
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.
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.
14-82
Assembly
Install relief valve 1 with wrench.
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 .
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
14-83
CFMOTO
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
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 .
14-84
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.
Put the wire on screw 2 and then install
the screw 2 .
Install protection cover 3 on warning
switch 1 .
148401
14-85
CFMOTO
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

Put the M10 bolt 3 through the hole and 1 2
then tighten the nut.
3
138501
Put the M10 bolt 2 through the hole 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
14-86
14.8.2 Output Sprocket Installation

Install output sprocket 1 .
Install washer 2 .
Install M20 pulsing nut 3 with 243 thread
locker.
1
3
148601
Install bracket 1 .
2 1
Note: There are two dowel pins 2 2

under the bracket. Do not lose them
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
14-87
CFMOTO
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
CF650-7F
Install AIS valve and air inlet and outlet
pipes.
148705-20200909
14-88
14.8.6 Inlet/Outlet Pipe Installation
2
Install the outlet pipe 2 on engine.

Tighten clamp 1 .
1
148704
Install the inlet pipe 2 on engine.

Tighten clamp 1 .
2
1
148801
Install M6 drain bolt 1 and washer.
148802
14-89
Handlebar and Triple Clamps
15.1 Special Tools�� 1
15.2 RH Handlebar Switch�� 1
15.3 LH Clutch Lever�� 1
15.4 LH Handlebar Switch�� 2
15.5 Handlebar �� 2
15.6 Installation�� 2
15.7 Handlebar Inspection�� 3
15.7.1 Throttle Cable Free Play �� 3
15.7.2 Clutch Lever Free Play Inspection�� 3
15.8 Handlebar Interference Inspection�� 4
15.9 Triple Clamps and Front Fork�� 4
15.1 Special Tools

Lock Nut Tool (to install/remove lock nut)
A000-050006-922-001
150101
15.2 RH Handlebar Switch

1
Remove RH handlebar switch 2 .
2
150102
15.3 LH Clutch Lever

3
Remove press cover 2 .
Remove LH clutch lever 3 .
1
150103
15-1
15.4 LH Handlebar Switch
Remove LH handlebar switch 2 .
2
1
150201
15.5 Handlebar
Remove balance blocks 2.
Remove rubber sleeves 3. 1
150202
15.6 Installation
installation.
Insert throttle cable 1 on RH grip 2 when

installing RH handlebar switch.
2
1
2
150203
Align dowel pin 3 with its hole 4 during

LH&RH handlebar switch installation.
3 4
150204
15-2
15.7 Handlebar Inspection
15.7.1 Throttle Cable Free Play
Inspect throttle lever if it is smooth to grip or
return.
Inspect throttle cable free play. 3
2
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 .
150301
15.7.2 Clutch Lever Free Play Inspection

Inspect clutch lever if it is smooth to return.
Inspect clutch lever free play 1 .
Free play standard: 5 mm~15 mm
150302
Clutch Cable Free Play Adjustment

Minor adjustment: Loosen lock nut 3 and
2
rotate the adjusting nut 2 for adjustment. At
last, tighten the lock nut 3 .
150303
Major adjustment: Loosen lock nut 4 and

rotate the adjusting nut 5 for adjustment. At
last, tighten the lock nut 4 .
4
150304
15-3
15.8 H a n d l e b a r I n t e r f e r e n c e
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
tank.
150401
15.9 Triple Clamps and Front Fork

Removal
Remove rubber plug 1 .
150402
Remove screw plug and washer 2 .

Remove upper triple clamp 3 .
150403
Knock and straighten the flanging of retainer

4.
Remove lock nut I 5 with special tool 7 .
Remove retainer 4 . 7
Remove lock nut II 6 with special tool 7 . 5

6
4
150404
15-4
Remove retainer dust-proof cap 8 .
Remove front fork lower triple clamp assy
9.
9
8
150501
Remove bearing cage 10 .

Remove steel ball assy 11 .
10 11
150502
Installation
installation.
Upper triple clamp lock nut torque: 20N•m
NOTE: During installation and
replacement, apply enough grease on
bearing top race.
Inspection
Inspect steel ball assy 1 for wear or
missing. Replace if any defect is found.
Inspect bearing cage for cracks or abnormal
wear. Replace if any defect is found.
150503
15-5
Clean and Conservation
16.1 Motorcycle Clean�� 1
16.2 Inspection and Maintenance in Winter �� 2
16.1 Motorcycle Clean

CAUTION: 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.
CAUTION:
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.
CAUTION: 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.
16- 1
Clean and Conservation
16.2 Inspection and Maintenance in Winter
CAUTION:
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. Other-
wise, the hot water will exacerbate erosion.
Clean the motorcycle.
Clean brake system.
CAUTION:
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).
CAUTION:
The preservative liquid is not allowed to get into the brake pads. Otherwise, it will
reduce the braking effect seriously.
Clean the chain.
16- 2
Storage
17.1 Parking�� 1
17.2 Motorcycle Use after Storage�� 1
17.1 Parking
CAUTION:
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.
CAUTION:
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.
17.2 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.
17-1
Appendix A
Appendix B
PIN-NO. SIGNAL FUNCTION
1 (M1) A_S_LSH2 LAMBDA SENSOR HEATING

2 (L1) A_S_LSH1 LAMBDA SENSOR HEATING
3 (M2) A-P-ZUE1 IGNITION COIL1
4 (L2) A-S-SAL SECOND AIR SOLENOID
5 (M3) M-M-ZUE IGNITION GROUND
6 (L3) A-S-CPV CANISTER PURGE VALVE
7 (M4) A-P-ZUE2 IGNITION COIL2
8 (L4) U-U-UBR SWITCHED BATTERY VOLTAGE
9 (K1) E-A-DS INTAKE AIR PRESSURE SENSOR
A_S_LSH2
E_A_LSVK2
A_S_LSH1
M_R_SEN1
B_D_CANL
10 (J1)
21 E_S_DIAG2
E_A_LSVK1
B_D_CANH
M-R-SEN1 SENSOR GROUND 1
36 E_S_DIAG1
E_A_DKG
E_A_TMOT
A_P_ZUE2
A_P_ZUE1
E_S_KL15
10 M_R_SEN1
11 E_A_TANS
A.S.LAMP
A_S_SAL
A_S_CPV
A_T_EV2
A_T_EV1
U_U_UBD
A_U_5V1
M_M_ZUE
E_F_DGA
E_F_DGB
11 (H1)
U.U.UBR
A.T.SMA
A.T.SMC
E-A-TANS INTAKE AIR TEMPERATURE SENSOR
A.T.SMD
A.T.SMB
12 (G1) E-A-DKG THROTTLE POSITION SENSOR
13 (F1) E-A-TMOT ENGINE COOLANT TEMP.SENSOR
14 (E1) A-S-HR MAIN RELAY
15 (D1) B-D-CANL CAN1 L
12
30
16
33
15
32
44
13
47
48
27
28
42
17
43
18
8
19
4
3
6
5
16 (C1) B-D-CANH CAN1 H
2
17 (B1) A-T-SMD STEPPER MOTOR PHASE D
18 (A1) A-T-SMC STEPPER MOTOR PHASE C
19 (K2) E-A-LSVK1 LAMBDA SENSOR UPSTREAM 1
20 (J2) E-A-LSVK2 LAMBDA SENSOR UPSTREAM 2
21 (H2) E-A-DIAG2 IGNITION DIAGNOSIS FOR COIL2
R 68K
R 68K
22 (G2)
23 (F2) E-S-RES1 SIDE SHORE SWITCH
24 (E2) 21 36
25 (D2)
115
116
A_S_OT1
44
26 (C2) CRANK RELAY
27 (B2) A-T-SMA STEPPER MOTOR PHASE A 30 85 86 87
28 (A2) A-T-SMB STEPPER MOTOR PHASE B
29 (K3) A-S-MIL MIL FUNCTION INDICATOR LIGHT
30 (J3) A-U-5V1 REGULATED SENSOR SUPPLY 1
10/1
31 (H3)
10/2
30/1
98
99
93
92
30/2
90
91
13
47
10/3
48
32 (G3) E-S-KL15 IGNITION SWITCH
42
43
4
3
11
12
27
28
17
18
9
33 (F3) U-U-UBD CONTINOUS SUPPLY VOLTAGE 2 1+ 2 1+ A B 2 1+ 2 1+
34 (E3) B-D-DIAK DIAGNOSIS K-LINE -
1 2
-
+ + -
10/5
3 4 1 2 2 3 1 - - -
10/4
A D C B
104
104
E_S_NGEAR
20
35 (D3) NULL GEAR SWITCH
19
1
2
36 (C3) E-A-DIAG1 IGNITION DIAGNOSIS FOR COIL1 HEAD LIGHT
37 (B3) E_S_RES2 CLUTCH SWITCH 4 3 21 4 3 21
RELAY
15
16
38 (A3) E_S_RES3 DUMP SWITCH P
3 3
E_S_RES6 HLR
39 (K4) SPORTS-MODE SWITCH GND TO GND TO VDD
40 (J4) A-P-DMTN ENGINE SPEED OUTPUT(TD/TN) THROTTLE ENGINE ENGINE Zyl.1
FUSE 5A
FUSE 5A
t INTAKE Zyl.1
41 (H4) E_F_VFZ VEHICLE SPEED SIGNAL SECOND AIR CANISTER ENGINE COOLANT POSITION t
INJECTOR 1 INJECTOR 2
PRESSURE STEPPER MOTOR
E-F-DGB ENGINE SPEED SENSOR B SOLENOID PURGE TEMP. SENSOR SENSOR IGNITION COIL2 IGNITION COIL1 (CYL.1) (CYL.2)
42 (G4) SENSOR
43 (F4) E-F-DGA ENGINE SPEED SENSOR A TEV-6 VALVE TMOT DS-S3-TF DKG ZS-K1X1 ZS-K1X1 EV14 EV14 STEPPER
44 (E4) A-S-LAMP HEAD LIGHT RELAY TEV CAN INTERFACE
CDI CAN
45 (D4) A-S-FAN1 FAN RELAY
LSF LSF
46 (C4) A-S-EKP FUEL PUMP RELAY
FUSE
47 (B4) A-T-EV2 INJECTIOR 2(CYL.2)
48 (A4) A-T-EV1 INJECTIOR 1(CYL.1)
105
104
115
98
99
93
116
90
91
92
8
32
33
kl.87(HR)
5
UB kl.15
UB kl.30 SSW
GROUND P
E_S_NGEAR
E_S_RES1
E_S_RES2
E_S_RES3
E_S_RES6
A_S_OT1
E_S_KL15
E_F_VFZ
A_P_DMTN
B_D_DIAK
A_S_EKP
U_U_UBD
M_M_ZUE
A_S_MIL
U.U.UBR
A.S.HR
A.S.FAN1
23
37
33
32
14
41
46
26
38
39
29
35
40
34
8
45
5
120
119
S5 S1 S2 S3 S6
45
112
114
113
100
101
14
26
30 85 86 87
96
94
46
95
30 85 86 87 30 85 86 87
95
30 85 86 87
1 2 3 4
40
FAN 1
23
37
29
39
35
38
41
RELAY
FUSE
ENGINE M
MAIN
34
SPEED FAN1
RELAY CRANK RELAY
FUSE
OUTPUT FUEL PUMP RELAY
FUSE
MIL FUNCTION SW5 SW1 SW2 SW3 VFZ SW6 HR
FUSE 30A
(TD/TN) EKP-RELAY CRANK-RELAY
DIAK INDICATOR LAMP ELECTRIC FUEL PUMP
119
MIL EKP
101
112
113
114
120
96
32
33
kl.87(HR)
5
UB kl.15
100
94
UB kl.30 SSW
GROUND P
Appendix C

CF 400NK - 650NK

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400NK

How to get Long Service Life:

How to use this manual:

NOTE: It makes operation process easier or offers clearer information. It has no

1.1 Operation Cautions

WARNING: Battery liquid (dilute WARNING: Coolant is poisonous.

DANGER: When charged, Battery may

DANGER: Be careful to get clamped

■Replace the disassembled washers,O-

■Clean and blow off the detergent after

■Check if the disassembled rubber parts

■Install the elastic circlip after assembling

■Brake fluid and coolant may damage

■Do not twist or bend the cables too

Fuel vapor hose Ⅱ

Fuel vapor hose Ⅲ

Fuel vapor hose Ⅱ

2.1 Maintenance before Operation

2nd 1.800 1.714

3.3.2 Rear Wheel

3.3.3 Brake System

3.3.4 Lighting, Dashboard and Switch

3.4.2 Lubrication System

3.4.3 Cylinder, Piston, Piston Ring and Connecting Rod

Bolt, gearshift drum

3.6.2 Engine Consumption Materials&Assembling Materials

Lift front seat corners 3 .

Lift front seat corners 3 .

Insert limit hook 5 into buckle 6 .

5.1 LH&RH Panel

5.2 LH&RH Middle Panel

5.3 Fuel Tank Panel

5.4 Fuel Tank Front Panel

5.5 LH&RH Rear Deco Plate 6 2

Remove three screws 3 .

5.8 Rear Fender

Remove rear fender 3 . 1

6.1 Fuel Tank

Danger: Never put fuel tank up side

7.1.2 Inspection Standard

Remove four screws 3 .

Remove inner hex bolts 4 .

7.3.2 Dashboard (CF400-B)

7.4.1 Headlight Removal(CF650-7C)

Remove screws 2 on both sides.

Remove inner hex screws 3 .

Remove screws 4 on both sides.

NOTE: The headlight is consisted of

7.5 Tail Light/Brake Light

NOTE: The tail light is consisted of 3

7.6 Rear License Light 1

NOTE: The rear license light is

7.8 Front Brake Light Switch

7.9 Rear Brake Switch

Horn switch 3 Turn switch 4

7.11 RH Handlebar Switch

Warning switch 7 070703

7.13 Fuel Level Sensor

Connect fuel level sensor and main cable.

CAUTION: Negative wire must be 3