CFMOTO

SERVICE
MANUAL

CFORCE 1000
CF1000AU
CF1000ATR
CFMOTO

Edition No.:20180817
Edition item: CF1000AU(9AY0-WX-01-1)SM-20180817

Website:www.cfmoto.com

1
 CFMOTO
FOREWORD Maintenance Information 1
This manual introduces CF1000AU, Body Covering Parts 2
CF1000ATR maintenance information, Inspection and Adjustment 3
removal & installation procedures, checking Alongside Engine 4
& adjustment methods, troubleshooting and Engine 5
technical specifications. Vehicle Chassis 6
Signal and Lighting System 7
Chapter 1 mainly introduces general Starter Wiring Diagram Appendix A
operation information, service tools, vehicle EFI Wiring Diagram Appendix B
structure and basic specifications.
Electric Wiring Diagram Appendix C
Chapter 2 mainly introduces assemble and
disassemble procedures of body covering
parts.

Chapter 3 mainly introduces checking &

adjustment methods and how to do vehicle
maintenance.

Chapter 4 mainly introduces how to remove

the parts at alongside of the engine.

Chapter 5 mainly introduces how to remove,

check and maintain the engine parts.

Chapter 6 mainly introduces the information

of the vehicle chassis.

Chapter 7 mainly introduces how to check

and maintain the lighting system and signal
system.

Appendix: electrical schematic diagram

CFMOTO reserves right to make

improvements and modifications to the
products without prior notice. Overhaul and
maintenance should be done according to
the actual condition of vehicle.

Zhejiang CFMOTO Power Co., LTD.

All rights reserved
Aug. 2018

2
CFMOTO

Unit Conversion Table

Item Unit conversion

1kgf/cm²=98.0665kPa;
Pressure 1psi= 6.895kPa = 0.06895bar
1mmHg= 133.322Pa=0.133322kPa
1kgf·m=9.80665N·m
Torque 1N·m=8.85(lbf·in)
1N·m=0.7375621(lbf·ft)
1mL=1cm³=1cc
Volume
1L=1000cm³
Force 1kgf=9.80665N
Length 1in=25.4mm

Danger/Warning/Caution
Please read below explanations carefully. It explains the meaning of “DANGER/
WARNING/CAUTION”:

Danger: The Danger alert and icon indicates a potential hazard that may cause serious
injuries or death.
Warning: The Warning alert and icon indicates a potential hazard that may cause light or
medium injury.
Caution: The Caution alert and icon indicates a potential hazard that requires you to pay
attention.
NOTE or NOTICE: A note or notice alerts to important information or instructions.

Please pay attention: Danger, Warning and Caution cannot include all the risks during use
or maintenance of the vehicle. Therefore, besides the notice on the vehicle, the person
who maintains the vehicle must have basic mechanical and safety knowledge, or ask a
senior mechanic for help.

3
 01 Maintenance Information
1 Maintenance Information
1.1 Precautions . ..................................................................  ..... ...............1-1
1.2 Location of VIN/EIN..................................... ...................... .................1-3
1.3 Main Specification ....................................................... ............ ...........1-4
1.4 Specification   .......................................................................... ............1-6
1.5 Tighten Torque   ...................................................................... .............1-8
1.6 Lubricant and Sealant ....  ....................................................................1-10
1.7 Cable,Cooling System and Brake System   .........................................1-11
1.7.1 Wiring Diagram...............................................................................1-11
1.7.2 Brake System Diagram ..................................................................1-14
1.7.2.1 Brake System (Left-hand park) ...............................................1-14
1.7.2.2 Brake System (EU 167 Left-hand park) ..................................1-15
1.7.2.3 Brake System (Right-hand park) ............................................1-16
1.7.3 Cooling System Diagram .................................... ...........................1-17
1.1 Precautions

Safety Cautions
1. Wear suitable work clothes, cap, boots. Wear glasses, dust-proof mask, and gloves if
necessary.
2. Exhausted gas is posionous. Do not run the engine in a closed or bad ventilated area
for a long time.
3. Engine and muffler temperatures are still high when the engine is just stopped. Avoid
getting burned. Do not touch the engine before it has completely cooled down.
4. Battery electrolyte (dilute sulfuric acid) is highly caustic and can result in burns. If you
spill electrolyte on skin, flush with water and seek for medical attention immediately. If you
spill electrolyte on clothes, flush with water to avoid burns. Keep battery and electrolyte out
of reach of children.
5. Coolant is poisonous. Do not drink or spill it on skin, eyes or clothes. If you spill coolant
on skin, wash with soap and water. If you spill coolant on eyes, flush with water and seek
prompt mediacal attention. If coolant is swallowed, induce vomiting and ask a doctor for
medical care. Keep coolant out of reach of children and away from pets.
6. Gasoline is highly flammable. Keep gasoline away from sparks. Vaporized gasoline is
also explosive. Fuel and operate vehicle in a well-ventilated area.
7. Be careful not to get pinched by the turning parts, like wheels, axles, and clutch.
8. When more than two persons are working on the vehicle, remind each other of
operational safety.
Cautions for Removal and Installation
1. Use genuine CFMOTO parts, lubricants and service products.
2. Store the removed components separately in order for correct installation.
3. Clean mud, dust before servicing.
4. Replace removed washers, O-rings, piston pin retainers, cotter pins with new ones.
5. Elastic retainers might get distorted after disassembly. Do not use loosened retainers.
6. Clean and blow off the detergent after removal. Apply lubricants on the surface of
moving parts.
7. If you do not know the length of screws, install the screws one by one and make sure
they are screwed with the same depth.
8. Pre-tighten the bolts, nuts and screws, then torque them to specified specification.The
basic sequence is: from big to small, from inside to outside and criss-cross.

01-1
CFMOTO
9.Replace aged rubber parts when assembling. Do not splash gasoline, grease onto the
surface, as this could cause damage.
10. Apply or inject recommended lubricant into the specified lubrication points.
11. Use the correct special tools for removal and installation.
12. When a ball bearing is removed by pressing steel balls, it can not be reused.
·Replace bearings if the axial or radial free play is too big.
·If the running surface feels uneven, clean with oil and check. Replace it if the cleaning
does not work.
·When pressing the bearing into the machine or onto the shaft, if the bearing can not
be securely seated, replace it.
13. Install one-side dust-proof bearings in the right direction. When assembling open type
or double-side dust-proof bearings, install with the manufacturer’s mark outward.
14. Install the elastic circlips properly. Turn the circlip after assembling to make sure it has
been installed into the slot.
15. After assembling, check that all the tightened parts are properly tightened and can
move smoothly.
16. Brake fluid and coolant may damage painting, plastic and rubber parts. Flush with
water if splashed on these parts.
17. Install oil seals with the side of manufacturer’s mark outward.
·Do not fold or scratch the oil seal lip.
·Apply grease to the oil seal lip before assembling.
18. When installing pipes, insert the pipe until it bottoms in the end of the joint. Fit the pipe
clip, if any, into the groove. Replace the pipes or hoses that cannot be tightened.
19. Do not allow mud or dust into the engine and/or the hydraulic brake system.
20. Clean the gaskets and washers off the engine casing before assembling. Remove the
scratches on the joint faces by polishing evenly with a polish stone.
21. Do not twist or bend the cables too much. Distorted or damaged cables may cause
poor operation or even damaged components.
22. When assembling the parts with protection caps, insert the caps to the grooves.

01-2
 01 Maintenance Information
Engine Break-in
There are many movable components inside the engine, such as the piston, piston rings,
cylinder, crankshaft, gears, ect. During initial use period, proper run-in for every critical
component is necessary. Break-in can help engine components match to each other and
adjust to working conditions. Careful treatment of a new engine will result in more efficient
performance and a longer service life.

Recommended break-in period: First 600km

Operation guide:
0~300km: Do not operate continously at more than 50% throttle position. Cool down the
engine for 5~10 minutes after every one hour of operation. Avoid sudden acceleration.Vary
the throttle position slowly and smoothly.
300km~600km: Avoid long-time running at more than 75% throttle position. Do not open
throttle completely during this period.

NOTE:
1.Maintain and repair with regular procedures during break-in period.
2.After break-in, check and maintain the engine before normal use.

1.2 Location of VIN/EIN

Model:CF1000AU;CF1000ATR
1.Vehicle identification number(VIN): LCELV1Z5; LCELVYZ8~
2.Name plate (Vehicle identification number label)
3.Engine identification number(EIN): 2V91Y

 1

 2

 3

010301

010302

01-3
CFMOTO
1.3 Main Specification

Item Specification
Model CF1000AU CF1000ATR
Size length×width×height 2310 mm×1250 mm×1420 mm
Wheelbase 1480mm
Engine model 2V91Y
Displacement 962.6mL
Fuel type Minimum 89 or higher octane unleaded gasoline
Dry weight 447kg 490kg
Passengers 2(Include driver)
Max load allowed 210 kg
Front wheel 27×9.00-12 51K;27×9.00R14 60L;
Specification
Rear wheel 27×11.00-12 57K;27×11.00R14 66L;
Min. ground clearance 285mm
Min. turning radius 7800mm
Starting Electric
V-twin cylinder, 4-stroke, liquid-cooled, 8 valves,
Type
SOHC
Valves Timing chain drive
Bore×Stroke 91mm×74mm
Compression ratio 10.6:1
Engine
Lubrication Compressed splashing
Oil pump Rotor
Oil filter Paper filter
Engine oil type SAE15W-40/SG rated or higher
Cooling system Liquid-cooled/close-loop cooling
Coolant type -30°C anti-corrosion and anti-freezing

01-4
 01 Maintenance Information
Item Specification
Air filter Foam, paper filter
Type 0JY0-173000-10000/0JY0-173000-20000
Throttle body
Valve diameter 54mm
Tank capacity 30L
Clutch type Dry and auto centrifugal
Transmission type CVT+ Gearshift
Gear shift High, low, reverse and parking
Gear order Manual/H-L-N-R-P
(CVT)ratio 0.7~2.88
“H”gear “L”gear “R”gear
Final 1.333
Transmission Gear shift ratio Secondary 1.952
Single 1.143 2.529 2.231
Total 2.975 6.585 5.807
Front 33 / 9 = 3.667
Ratio of drive axle
Rear 33 / 9 = 3.667
Output type Front/Rear shaft drive
Rotation of engine
clockwise (rear view) when tranmission in forward
output
inner 32.5°
Steering Turn angle
outer 24.2°
Front Hydraulic Disc
Brakes
Rear Hydraulic Disc
Front:Double A-arm and independent
Suspension Type
Rear:Daggle arm
Frame Steel tube

01-5
CFMOTO
1.4 Specification
● Lubrication
Item Standard Service
limit
Oil capacity Replace oil with filter 2500mL
Total dry 2600mL
Gear oil capacity Total capacity 600mL
Recommend engine oil SAE15W-40 oil for 4-stroke engine.
20W-50 Select alternative according to the
15W-40，15W-50
following specifications.:
API level:SG or higher;
10W-40，10W-50
SAE rating: Choose from the left chart
10W-30 for cold climate operation
5W-40

Recommend gear oil 75W/90/GL5

Oil pump rotor Clearance between inner and outer rotor 0.06mm~0.14 mm 0.25mm
Clearance between outer rotor and bore 0.09mm~0.15mm 0.25mm
Rotor end clearance 0.023mm~0.109mm 0.20mm
Oil pressure When engine RPM is 1300r/min and oil
temperature is 90°C, oil pressure should
be 100kPa~400kPa, usually is 200kPa.
When engine RPM is 6000r/min and oil
temperature is 90°C, oil pressure should
be 350kPa~700kPa, usually is 580kPa.
●Intake system(See 05-Engine)
●Cooling system
Item Standard Remark
Total About 4000mL
Coolant capacity Reservoir 200mL~380mL
Density 50%
Opening pressure 108 kPa (1.1kgf/cm2)
Open temp. 65°C±2°C
Thermostat Full open temp. 85°C
Full open clearance >5mm when 85°C,
Resistant of B Resistant of A,C
Relations between Coolant temp(°C)
terminal(Ω) terminal(kΩ)
water temp. and
-20 ---- 28.582±0.004
resistance
25 ----- 2.795±0.0025
of water temp
50 216.0~264.0 0.98±0.00227
sensor
80 74.6~90.6 0.334±0.00204
110 32~36 0.133±0.00252
Working temp . of Off-on About 88°C
Thermo switch On-off About 82°C
Coolant type 30 °Canti-freezing, anti-corrosive and high boiling point

01-6
 01 Maintenance Information
●Wheel (Front and Rear)
Item Standard Service limit
Axial 0.8mm 2.0mm
Wheel Jump
Radial 0.8mm 2.0mm
Groove deepness - 3.0mm
Tire
Pressure 45kPa(0.45kgf/cm2) -
●Brake
Item Standard Service limit
Front brake Brake disc thickness 5.0mm 4.0mm
Brake pedal freeplay 95 mm ~105 mm -
Rear brake
Brake disc thickness 5.0mm 4.0mm

●Battery/ Charger/ Ignition coil

Item Standard
Type Magneto 3-phase A/C generator
Output 3-phase A/C output
Resistance of coil(20°C) 0.1Ω~0.3Ω
A/C Resistance of pick-up coil 300Ω~500Ω
magneto Voltage without load (cold engine) >50V(AC),5000r/min
Output power 350W,5000r/min; 460W,5000r/min
Stable voltage 13.5V~15.0V
Peak voltage of pick-up ≥3V,200 r/min
Regulator type 3-phase supply power circuit
Capacity 12Vdc/30Ah
Fully recharged 14.4V
Voltage between terminals
Battery Not-fully recharged <11.8V
Standard 2.7A/5h~10h
Recharging current/time
Quick 12A/1h
●Ignition equipment

Item Standard
Ignition controller ECU
Type Resistance control
Model DCPR8E (NGK)
Sparkplug
Spark clearance 0.8mm~0.9mm
Spark specification >8mm,100 kPa
Ignition timing BTDC8º 1300r/min
Primary 0.70Ω
Ignition coil resistance
Secondary 6.9kΩ
Ignition primary >14V
Peak voltage
Pulse starter ≥27kV
Start relay coil resistance 3Ω~5Ω
Start auxiliary coil resistance 70Ω~90Ω

01-7
CFMOTO
●Light/Dashboard/Switch
Item Standard
Main 30A
Fuse
Secondary 40A×1(EPS) 15A×3 10A×2
Headlight 12V ,12W/14W LED
Brake light/Tail light 12V, 4.8W 12LED
Front turning light 12V, 1.2W 7LED
Light and bulb
Rear turning light LED
Indicators LED
Rear license light 12V, W5W (BULB)

●Valve mechanism and cylinder head(See 05-Engine)

●Cylinder+Piston+Piston ring+Crank Connecting-rod(See 05-Engine)
●Clutch and transmission (See 05-Engine)

1.5 Tighten torque

NOTE:
Cover the screw with anti-rust grease before installation.
●Special torque list refers to frame chapters

01-8
 01 Maintenance Information
Tightening Torque List
Fasteners not included in below table should also be torqued to specification.
NOTE: Threads and contact area should be coated with engine oil.
No. Item Type Qty Torque(N•m)
1 Front left mounting bolt, engine GB5789 M10×1.25×130 1 40~50
2 Front right mounting bolt, engine GB5789 M10×1.25×100 1 40~50
3 Bolt, engine front left mounting plate GB5789 M8×20 2 35~45
4 Bolt, engine front right mounting plate GB5789 M8×20 2 35~45
5 Front mounting bracket, engine GB5789 M10×1.25×20 2 40~50
6 Front mounting shaft, engine 7030-000401 1 60~70
7 Bolt, front suspension swing arm GB5789 M10×1.25×70 8 45~55
8 Lock nut, front & rear shock absorber GB6187 M10×1.25 8 45~55
9 I-type hex nut 9010-100002 4 45~55
10 Lock nut, swing arm 9AWA-060108 2 210~220
11 Mounting nut, rim 901A-07.00.02 16 70~80
12 Hex flange nut 5HY0-110001 4 220~250
13 Mounting nut, front axle GB6187 M10×1.25 3 50~60
14 Mounting nut, rear axle GB6187 M10×1.25 3 60~70
15 Screw, rear drive shaft GB/T70.1 M10×1.25×25 4 40~50
16 Nut, steering lever ball pin 9010-100002 4 40~50
17 Bolt, handlebar cover GB5789 M8×60 4 30~40
18 Bolt, front brake caliper GB5789 M10×1.25×20 4 40~50
19 Bolt, front brake disc 9010-080003 16 30~35
20 Bolt, rear brake caliper GB5789 M10×1.25×20 4 40~50
21 Banjo bolt 7020-081004 8 35~45
22 Mounting bolt, master cylinder GB5789 M8×25 2 25-35
23 Mounting bolt, muffler body GB5789 M10×1.25×70 1 40~50
24 Mounting bolt, muffler body GB5789 M8×65 1 30~40
25 Nut, exhaust pipe joint 8010-020001 2 25~35
26 Bolt, front steering knuckle GB5789 M10×1.25×40 2 40~50
27 Mounting bolt, towing bracket GB5789 M10×1.25×140 2 40~50
28 Mounting bolt, winch motor GB5789 M8×20 4 35~45
29 Mounting bolt, cable pulley GB5789 M10×1.25×20 2 40~50
30 Mounting bolt, fuel pump GB/T5789 M5×14 6 5~8
31 Oxygen sensor 018B-176000 1 40~60
32 Mounting nut, rim 9010-070002-A000 16 70~80
33 Universal joint bolt, EPS steering shaft 9CR6-102003 1 35~45
34 Lock bolt, EPS steering arm 9CR6-102003 1 35~45

01-9
CFMOTO
●Special torque for engine(See 05-Engine)
●Follow the specifications below to tighten up normal parts
Type Torque N•m Type Torque N•m
5mm bolt, nut 5 5mm screw 4
6mm bolt, nut 10 6mm screw 9
8mm bolt, nut 20~30 6mmSH flange bolt 10
10mm bolt, nut 30~40 6mm flange bolt and nut 12
12mm bolt, nut 40~50 8mm flange bolt and nut 20~30
10mm flange bolt and nut 30~40
Engine working tool(See 05-Engine)
Engine special tool(See 05-Engine)
1.6 Grease and sealant
Covering position Pre-cautions Grease
Steering bearing
Throttle cable connecting point
Throttle pedal moving point
Brake pedal moving point
Multifunction lithium grease
Rocker arm moving point
Steering column inner face
Seat lock moving point
Shifting mechanism moving point

Cable, bearing and other moving parts lubrication.

Parts Item Grease
Steering shaft ball sleeve
Rear wheel hub
Shock absorber knuckle bearing
Throttle lever axle and cable connecting Lithium grease for auto GB/
Lubrication
point T5671
Brake lever axle
Parking cable connecting point
Rear brake pedal moving point
Engine running materials and mounting materials(See 05-Engine)
Engine running materials include lubricating oil (Engine oil), grease and coolant. Mounting
materials include sealing glue and thread locker.

01-10
 01 Maintenance Information
1.7 Cable, Brake System and Cooling System
1.7.1 Wiring Identification
16 15
driving direction
 1

 2

 3

 4  5  6  7  8  9 10 11 12 13 14

011101

1 RH headlight connector 7 Connector,brake switch 13 Starter relay

2 EPS fuse 8 LH handlebar A,B 14 LH headlight connector
3 Fuse box 9 Dashboard connector A,B,C 15 USB output socket
Daytime running light control
4 EPS connector 10 16 Power output connector
unit connector A,B
5 Connector,front axle motor 11 RH handlebar connector
Connector,ignition swich
6 12 Fan motor connector A,B
lock

 8

 1  2  3  4  5  6 011103
 7

 9

011102
011104
1 2/4 WD Relay 4 Fan Motor Relay 7 Battery
2 4/4WD-Lock Relay 5 DRL Relay 8 Diagnose Connector
3 Fuel Pump Relay 6 Main Relay 9 ECU
Note: Remove the body covering parts before inspection. Removal procedures refer to
Chapter 2.

01-11
CFMOTO
 2
 4

 1

 5

 3 011201
1 Rectifier 4 Coolant Temperature sensor
2 Ignition Coil 5 CPS
3 Starter Motor
Note: Remove the body covering parts before inspection. Removal procedures refer to
Chapter 2.

 1

 3

 2

011202

1 Idle Stepping Motor 2 TPS 3 Injector

Note:Remove the seat assembly before inspection of those part. Removal procedures
refer to Chapter 2.

01-12
 01 Maintenance Information
1 Speed Sensor Connector
 1
2 Gear Sensor Connector(EU 167)
3 Seat Pressure Sensor Connector
4 Fuel Pump Connector  2
 3
Note:Remove the right panel before
working on the parts mentioned above.
Removal procedures refer to Chapter 2.

 4

011301

Driving direction

 4

 3

 2
 1
011302
1 Connector, Right Turn 3 License Light Connector
2 Connector, Left Turn 4 Tailer Power Connector

Note: Remove the body covering parts before inspection. Removal procedures refer to
Chapter 2.

01-13
CFMOTO
1.7.2 Brake System Parts Diagram
1.7.2.1 Brake System (Left-hand park)

 1
22

21  2

 4  3
20

 6
19  5

18

10  9
11
12  8  7

17 16 13
14

15 011401

No. Name Qty No. Name Qty

1 Parking brake lever 1 12 Front Brake Hose, LH 1
2 Fluid Reservoir Assy 1 13 Front Brake Caliper, LH 1
3 Fluid Reservoir Hose 2 1 14 Front Brake Pad 2
4 Fluid Reservoir Hose 1 1 15 Hydraulic Induction Switch 1
5 Master Cylinder Assy 1 16 Front Brake Caliper, RH 1
6 Rear Brake Fluid Hose 1 17 Front Brake Pad Assy 2
7 Rear Brake Pad 2 18 Front Brake Hose, RH 1
8 Rear Brake Caliper, LH 1 19 Footrest Assy 1
9 Rear Brake Caliper, RH 4 20 Hydraulic Distribution Valve 1
10 Rear Brake Pad 2 21 Hand Brake Fluid Hose 1
11 Front Brake Fluid Hose 1 22 Hand Brake Pump Assy 1

01-14
 01 Maintenance Information
1.7.2.2 Brake System (EU 167 Left-hand park)

 1
22

21  2

 4  3
20

 6
19  5

18

10  9
11
12  8  7

17 16 13
14

15

011501

No. Name Qty No. Name Qty

1 Parking brake lever 1 12 Front Brake Hose, LH 1
2 Fluid Reservoir Assy 1 13 Front Brake Caliper, LH 1
3 Fluid Reservoir Hose 2 1 14 Front Brake Pad 2
4 Fluid Reservoir Hose 1 1 15 Hydraulic Induction Switch 1
5 Master Cylinder Assy 1 16 Front Brake Caliper, RH 1
6 Rear Brake Fluid Hose 1 17 Front Brake Pad Assy 2
7 Rear Brake Pad 2 18 Front Brake Hose, RH 1
8 Rear Brake Caliper, LH 1 19 Footrest Assy 1
9 Rear Brake Caliper, RH 4 20 Hydraulic Distribution Valve 1
10 Rear Brake Pad 2 21 Hand Brake Fluid Hose 1
11 Front Brake Fluid Hose 1 22 Hand Brake Pump Assy 1

01-15
CFMOTO
1.7.2.3 Brake System (Right-hand park)

 3

 1

 2

011601

No. Name Qty

1 Parking Lever Assy 1
2 Parking Brake Cable 1
3 Rear View Mirror Seat Assy 1
Remark: Others please refer to chart 011401(Exclude 21 and 22)

 4
 3
 1
 2 011602

1 Front Brake Fluid Hose 3 Master Cylinder Assy

2 Shifting Locking Cable 4 Rear Brake Fluid Hose

Note: Remove the body covering parts before inspection. Removal procedures refer to
Chapter 2.

01-16
 01 Maintenance Information
1.7.3 Cooling System Parts Diagram

 8
 1

 2

 7  3

 6

 5

 4

011701
1 Radiator Assy 4 Coolant Inlet Hose 7 Exhaust Pipe I, Idle
2 Coolant Filler/Connecting Pipe 5 Flow Hose, Reservoir 8 Coolant Reservoir Assy
3 Coolant Outlet Hose 6 Hose, Coolant Reservoir

Note: Remove the body covering parts before inspection. Removal procedures refer to
Chapter 2.

01-17
 02 Body Covering Parts
2.1 Maintenance Information ........ 2-2 2.5.2 Front Licence Plate...........2-13
2.2 Tighten Torque.........................2-2 2.5.3 Front Bumper Block.......  ..2-13
2.3 Seat Assy, Air Filter Cover Assy, 2.5.4 Front Bumper....................2-14
Shifting Cover, Gearshift Deco Cover, 2.5.5 Front Deco Cover, LH/RH.2-14
Seat heat Insulator, Rear Seat 2.5.6 Headlight Cover, LH/RH. ..2-15
Bracket 2.5.7 Front Deco Plate.............  .2-15
2.3.1 Rear Seat ..........................2-3 2.5.8 Front Ventilate Cover........2-15
2.3.2 Front Seat........... ............ . 2-3 2.5.9 Headlight Plate..................2-16
2.3.3 Air Filter Cover Assy.......... 2-3 2.6 Front Fender LH/RH, Front Upper
2.3.4 Air Filter Left Cover...........  2-4 Inner fender LH/RH, Front Fender,
2.3.5 Air Filter Right Cover.......... 2-4 Engine Left Deco Cover, Rear Fender
2.3.6 Air Filter Upper Cover....... .2-4 LH/RH, Footrest LH/RH, Rear Licence
2.3.7 Gearshift Deco Cover ................. Plate, Rear Cargo Box Cover, Rear
Plate, Rear Cargo Box and Bracket,
...................................................... 2-5
Tailight Cover LH/RH, Rear Fender
2.3.7.1 Gearshift Deco Cover ( Normal
2.6.1 Front Fender LH/RH........2-17
status ) .......................... 2-5
2.6.2 Front Upper Inner Fender LH/
2.3.7.2 Gearshift Deco Cover (Russian
RH.................................... 2-17
status ) .........................  2-5
2.6.3 Front Fender............... ..... 2-18
2.3.8 Side Cover, LH.................. 2-5
2.6.4 Engine Left Deco Cover.... 2-19
2.3.9 Side Cover, RH................. .2-6
2.6.5 Rear Fender LH/RH .........2-19
2.3.10 Seat Heat Insulator..........2-6
2.6.6 Footrest LH/RH.... ............2-20
2.3.11 Rear Seat Bracket........... 2-6
2.6.7 Rear Licence Plate ...........2-20
2.4 Front/Rear Rack Cover, Front/
2.6.8 Tool Box Cover .................2-20
Rear Rack, Handlebar Cover, Hand
2.6.9 Rear Cargo Bracket..........2-21
Guard, Dashboard Cover
2.6.10 Rear Plate.......................2-21
2.4.1 Front Rack Cover...............2-7
2.6.11 Tool Box Locker Bracket.2-21
2.4.2 Front Rack.........................2-7
2.6.12 Tailight Cover LH/RH......2-22
2.4.3 Rear Rack Cover................2-8
2.6.13 Rear Fender ...................2-23
2.4.4 Rear Rack................. ........2-8
2.7 Front/ Mid/ Rear Lower Panel,
2.4.5 Handlebar Cover ...............2-9
Front Suspension Panel LH/RH, Rear
2.4.6 Hand Guard.......................2-9
Suspension Panel LH/ RH, Reservoir
2.4.7 Dashboard Cover............ 2-10
Bracket, Pipe Plug
2.4.8 Dashboard Cover, RH .....2-11
2.7.1 Front Lower Plate..............2-24
2.4.9 Dashboard Cover, LH ......2-11
2.7.2 Mid Lower Plate................2-24
2.4.10 Dashboard Lower Cover2-12
2.7.3 Rear Lower Plate .............2-24
2.4.11 Dashcover .....................2-12
2.7.4 Front Suspension Cover LH/
2.4.12 Dashboard Front Cover..2-12
RH ....................................2-25
2.5 Front Lower Panel, Front Licence
2.7.5 Rear Suspension Cover LH
Plate, Front Bumper Block, Front
RH  .............. .....................2-25
Bumper, Front Deco Cover, Headlight
2.7.6 Reservoir Bracket ............2-25
Cover, Front Deco Plate, Front
2.7.7 Pipe Plug..........................2-25
Ventilate Cover, Headlight Cover
2.8 Seat Belt(EU 167)..................2-26
2.5.1 Front Lower Panel.............2-13

02-1
CFMOTO

2.1 Maintenance Information

Pre-cautions
This chapter mainly introduces the body covering parts removal and installation
procedures. Also the rack, seat, backrest removal and installation instructions.
Follow the drawings to arrange the cables, pipes and wirings to the correct position.

2.2 Tighten Torque:

M8 bolt 20 (2.0) Torque N·m(kgf·m)
M6 bolt 10 (1.0) Torque N·m(kgf·m)
M5 bolt 5 (0.5) Torque N·m(kgf·m)
Screw 4 (0.4) Torque N·m(kgf·m)

02-2
 02 Body Covering Parts
2.3 Seat Assy, Air Filter Cover Assy,  1
Shifting Cover, Side Cover, Seat heat
Insulator, Rear Seat Bracket

2.3.1 Rear Seat

Removal  2
Lift the hook (1).
Lift up the rear part and pull out seat (2).
Installation
Reverse the removal procedures for
installation. Make sure the seat is totally
locked after it is assembled.

020301

 2  1
2.3.2 Front Seat
Removal
Remove the rear seat (See 2.3.1).
Lift the front seat hook (1).
Lift the rear part of front seat and pull seat
out
Installation
Reverse the removal procedures for
installation. Make sure the seat is totally
locked after it is assembled.

020302

2.3.3 Air Filter Cover Assy

Removal
Remove the front seat (See 2.3.2).
Loosen three rubber sleeves at each
 3
side(1).
Lift up the rear part to loosen the rubber
sleeve (2).  4
Loosen two rubber sleeves (3) and two  5
plastic clips (4).
Remove air filter cover (5).  2
Installation
Reverse the removal procedures for
 1
installation.

020303

02-3
CFMOTO
2.3.4 Air Filter Cover, LH  3  2
Removal
Remove the air filter cover (See 2.3.3).
Remove three self-tapping scews (1).
Remove plastic clip (2).
Remove the air filter left cover (3).
Installation
Reverse the removal procedures for
installation.  1

020401

2.3.5 Air Filter Cover, RH

 2
Removal
Remove air filter cover (See 2.3.3).
Remove three self-tapping scews (1).
Remove plastic clip (2).
Remove air filter right cover (3).
Installation
Reverse the removal procedures for  1
installation.

2.3.6 Air Filter Upper Cover

Removal  3 020402
Remove air filter cover (See 2.3.3).
Remove six self-tapping screws (1).
Remove two plastic clips (2).
Remove air filter upper cover (3).
Installation
Reverse the removal procedures for
installation.

 3  1  2

020403

02-4
 02 Body Covering Parts

2.3.7 Gearshift Deco Cover

2.3.7.1 Gearshift Deco Cover (Normal
status )
 4
Removal
Remove air filter cover sassy(See 2.3.3).  1
Loosen rubber sleeve (1).
Loosen locking point (2).  2
Loosen a plastic clip to the rear (3).
Remove the gear shifting deco cover (4).
Installation  3
Reverse the removal procedures for 020501
installation.

2.3.7.2 Gearshift Deco Cover (Russian

status )  3  4
Removal
Remove air filter cover sassy(See 2.3.3).  2
Loosen rubber sleeve (1).
Loosen locking point (2).
Loosen a plastic clip to the rear (3).
Remove the gear shifting deco cover (4).
Installation  1
Reverse the removal procedures for 020504
installation.

Lock Cover
Removal
Loose the clip (1) by pulling outside.
Remove the lock cover (2).
Installation
 2
Reverse the removal procedures for
installation.  1

020502

 2  3  2
2.3.8 Left Side Cover
Removal
Remove shifting deo cover (See 2.3.7).
Loosen six rubber sleeves (1).
Loosen two plastic clips (2).
Remove left side cover (3).
Installation
Reverse the removal procedures for
installation.
 1
 1 020503

02-5
CFMOTO
2.3.9 Side Cover, RH  1
Removal  1
Remove the air filter cover (See 2.3.3).
Loosen four rubber sleeves (1).
Loosen three plastic clips (2).
Remove right side cover (3).
Installation
Reverse the removal procedures for
installation.

 3

 2 020601

2.3.10 Seat Heat Insulator

Removal
Remove left side cover (See 2.3.8).
Remove right side cover (See 2.3.9).  1
Remove two screws (1).
Remove diagnose connector (2).  2  6
Remove two screws (3).
Remove the fluid reservoir (4).  3
Remove four M6 bolts (5).
 5
Remove seat heat insulator (6).
Installation  4
Reverse the removal procedures for 020602
installation.

2.3.11 Rear Seat Bracket

Removal
Remove the front seat (See 2.3.2).  1
Remove five M6 bolts (1).  2
Remove rear seat bracket (2).
Installation
Reverse the removal procedures for
installation.

 1
020603

02-6
 02 Body Covering Parts
2.4 Front/Rear Rack Cover, Front/
Rear Rack, Handlebar Cover, Hand
Guard, Dashboard Cover
 1
2.4.1 Front Rack Cover
Center cover
Removal
Pull the rubber band (1) up.  2
Lift up the center cover.
Remove the center cover (2).
Installation
Reverse the removal procedures for
installation.

020701
Right Cover
Removal
Remove four M6 bolts (1).
Lift up to remove the cover (2).
Installation
Reverse the removal procedures for
installation.
 1

Left Cover
Removal/Installation
See right cover instructions.

 2 020702

2.4.2 Front Rack

Removal
Remove front rack cover (See 2.4.1).
Remove four M8 bolt (1).
Remove two M6 bolts (2) from fender (One
piece on each side- See picture 020801).
Remove front rack (3).
Installation
Reverse the removal procedures for
installation.  1

 3 020703

02-7
CFMOTO

 2

2.4.3 Rear Rack Cover

Removal
Remove nine M6 bolts (1). 020801
Lift up to remove rear rack cover (2).
Installation
Reverse the removal procedures for
installation.  2

 1  1

2.4.4 Rear Rack

Removal
Remove the bracket cover (See 2.4.3).  1 020802
Remove four M8 bolts (1).
Remove two M6 bolts (2) from fender (One
piece on each side - See 020901).
Remove rear rack (3).
Installation
Reverse the removal procedures for
installation.

 1

 3 020803

02-8
 02 Body Covering Parts

2.4.5 Handlebar Cover  2 020901

Removal
Pull it up
 2
Loose two plastic clips (1).
Remove the handle bar cover (2).
Installation
Reverse the removal procedures for
installation.

2.4.6 Hand Guard, LH/RH

Hand Guard, RH  1 020902
Removal
Remove one M6 bolts (1).
Remove one M8 bolts (2).
Remove right hand guard.  1  4  2
Installation
Reverse the removal procedures for
installation.

Hand Guard, LH
Removal/installation
See right guard instructions.  8

 3 020903

02-9
CFMOTO
Hand Guard, RH
Removal
Remove two M5 bolts (3) (See picture
020903).
Remove right hand guard (4) (See pic
020903).
Remove right hand guard rod (5).
Installation  7
Reverse the removal procedures for
installation.

Hand Guard, LH
Removal / installation
See right guard instructions.

Handlebar Deco Cover, RH  5  6 021001

Removal
Remove two screws (6) (See pic 021001).
Loose five plastic clip (7) (See pic 021001).
Remove the deco cover (8)(See pic
020903).
Installation
Reverse the removal procedures for
installation.

Handlebar Deco Cover, LH

Removal/ installation
See right cover instructions.

2.4.7 Dashboard Cover Assy

Removal
Remove air filter cover (See 2.3.3).
Loose two rubber sleeves 1
Loose two plastic clips 2
Disconnect dashboard connector (3) (See  2
picture 021101).
Remove the dashboard.
Installation
Reverse the removal procedures for
installation.  1
021002

02-10
 02 Body Covering Parts

2.4.8 Dashboard Cover, RH

Removal
Remove the dashboard cover (See 2.4.7).
Disconnect the ignition switch  3 021101
Remove two screws (1) from dashboard
cover.
 2
Remove the ignition switch (2).
Loose three plastic clips (3).
Remove right dashboard cover (4).
Installation
Reverse the removal procedures for
installation.  1

2.4.9 Dashboard Cover, LH

Removal
Remove the dashboard cover (See 2.4.7).  3
Remove two screws (1) from dashboard  4
cover.
Loose three plastic clips (2). 021102
Remove left dashboard cover (3).
Installation
Reverse the removal procedures for  3
installation.

 1

 2 021103

02-11
CFMOTO
2.4.10 Dashboard Lower Cover
Removal
Remove dashboard right cover (See 2.4.8).
Remove dashboard left cover (See 2.4.9).
Remove eight screws (1) (See picture
021201,021202)
Loose two M6 nuts (2) on the back (See pic
021202).
Remove dashboard lower cover (3).
 1
Installation
Reverse the removal procedures for
installation.

 3 021201

2.4.11 Dashboard Cover

Removal
Remove dashboard lower cover (See
2.4.10).
Remove five screws (4) (See picture
021203).
Loose four plastic clips (5) (See picture  2
021203).
Remove the dashboard cover (6) (See
picture 021203).
Installation  1
Reverse the removal procedures for
installation.

021202

 7
2.4.12 Front Dashboard Cover
Removal
Remove dashboard lower cover (See
2.4.10).
Remove five screws (4).
Loose four plastic clips (5).  5  5
Remove front dashboard cover (7).
Installation
Reverse the removal procedures for
installation.
 4

 6 021203
02-12
 02 Body Covering Parts
2.5 Front Lower Panel, Front License
Plate, Front Bumper Block, Front
Bumper, Front Deco Cover, Headlight
Cover, Front Deco Plate, Front
Ventilate Cover, Headlight Cover
2.5.1 Front Lower Panel
Removal
Remove four M6 bolt (1).  1
Remove front lower panel (2).
Installation
Reverse the removal procedures for
installation.

 2 021301
2.5.2 Front Licence Plate
Removal
Remove four M6 bolt (1).  2
Remove front licence plate (2).
Installation
Reverse the removal procedures for
installation.

 1
2.5.3 Front Bumper Block, RH
Remove front license plate (See 2.5.2).
Remove one M6 bolt (1).
Remove front right bumper block.
Installation
Reverse the removal procedures for 021302
installation.
Front Bumper Block, LH
Removal/ installation  1
See right bumper block instructions.

021303

02-13
CFMOTO
2.5.4 Bumper Assy  2
Removal
Remove front licence plate (See 2.5.1).
Remove two M8 bolt (1).
Remove the bumper (2).
Installation
Reverse the removal procedures for
installation.

Front Bumper Cover, LH(EU)

Removal
Remove one M6 bolt (1).  1 021401
Remove front bumper left cover (2).
Remove the reflector (3).
Installation
Reverse the removal procedures for
installation.  1
Front Bumper Cover, RH
Removal
See left bumper cover instructions.  2

Front Bumper Cover, LH(US)

Removal  3 021402
Remove one M6 bolt (1).
Remove front bumper left cover (2).
Remove the reflector (3).  3
Installation
Reverse the removal procedures for
installation.

Front Bumper Cover, RH

Removal  1
See left bumper cover instructions.
 2
2.5.5 Front Deco Cover, RH 021403
Removal
Remove front license deco plate (See 2.5.2).
Remove three screws (1).  2  4
Remove one screw (2).
Loosen two plastic clip (3).
Remove front deco right cover (4).  3
Installation
Reverse the removal procedures for
installation.

Front Deco Cover, RH

Removal
See left deco cover instructions.
 1 021404

02-14
 02 Body Covering Parts
2.5.6 Headlight Cover, RH  4
Removal
Remove front right deco cover (See 2.5.5).  2
Remove four screws (1).
Remove two screws (2).
Remove M6 bolt (3).
Remove headlight right cover (4).
Installation
Reverse the removal procedures for  1
installation.

Headlight Cover, LH
Removal/installation
See right headlight cover instructions.
 3
021501
2.5.7 Front Deco Plate
Removal  1
Loosen four rubber sleeve (1).
Loosen two plastic clip (2).
Loosen plastic clip (3).
Remove the deco plate (4).
Installation  2
Reverse the removal procedures for  4
installation.

2.5.8 Front Vent Cover, LH

Removal  3 021502
Loosen three rubber sleeve (1).
Loosen one plastic clip (2).  2
Remove front left vent cover (3).
Installation
Reverse the removal procedures for
installation.

Front Vent Cover, RH

Removal/installation
See left vent cover instructions.
 3

 1 021503

02-15
CFMOTO
2.5.9 Headlight Cover  1
Removal
Remove front deco plate (See 2.5.5).
Remove headlight guard (See 2.5.6).
Remove front deco plate(See 2.5.7).  2  6
Remove front vent cover (See 2.5.8).
Loose two rubber sleeve (1).
Remove the relay box (2).
Remove four screws (3) (Two on each side
- See picture 021602).  5
Remove two screws (4) (one on each side).
Remove four screws (5) (See picture  6 021601
021601).
Remove four M6 bolts (6) (See picture  4
021601).
Disconnect two headlight connectors (7)
(One for each side - See picture 021603).
Remove headlight panel (8).
Remove eight screw (9) (Four on each side  3
- See picture 021604).
Remove headlight (See picture 021604).
Installation
Reverse the removal procedures for
installation.
 8 021602

 7

021603

 9

10 021604

02-16
 02 Body Covering Parts
2.6 Front Flare Fender LH/RH, Front
Upper Inner fender LH/RH, Front
Fender, Engine Left Deco Cover,
Rear Flare Fender LH/RH, Footrest
LH/RH, Rear License Plate, Rear
Cargo Box Cover, Rear Plate, Rear
Cargo Box and Bracket, Tailight
Cover LH/RH, Rear Fender

2.6.1 Front Flare Fender, RH

Removal
Loosen six screws (1).
Remove front right fender (2).  2
Installation
Reverse the removal procedures for
installation.

Front Flare Fender, LH  1

Removal
See right fender instructions.

2.6.2 Front Inner Fender, RH 021701

Removal
Remove right headlight cover (See 2.5.6)
Remove six screws 1
Remove front right inner fender 2
Installation
Reverse the removal procedures for
installation.  2
Front Inner Fender, LH
Removal/installation
See right fender instructions.
 1

021702

02-17
CFMOTO
2.6.3 Front Fender  1
Removal
R e m o v e s i d e c o v e r, L H / R H ( S e e
2.3.8,2.3.9).
Remove front rack (See 2.4.2).
Remove the dashboard cover (See 2.4.7).
Remove the headlight panel (See 2.5.9).
Remove front widen fender, LH/RH(See
2.6.1).
Remove front inner fender, LH/RH(See
2.6.2).
Remove four M6 bolts (1) (Two on each  3 021801
side - See picture 021801,021802)
Remove one M6 bolt (2) (See picture  2
021802).
Remove two M6 bolts (3) (See picture
021803).
Loosen four plastic locking points (4) (two
on each side).
Loosen the screw to remove the power
output (5) (See picture 021804).
Loosen the screw to remove the USB
connector (6) (See picture 021804).
 1
Remove the relay box (7) (See picture
021803). 021802
Remove the front fender (8) (See picture
021803).
 7
Installation
Reverse the removal procedures for
installation.

 6

021803
 5  4

021804

02-18
 02 Body Covering Parts
2.6.4 Engine Side Cover, LH
Removal
Loosen three rubber sleeves (1).
Loosen two plastic clips (2).
Remove the engine side cover (3).
Installation  1
Reverse the removal procedures for  2
installation.

 3 021901

Side Cover Bracket

Removal
Remove three M6 bolt (1).  2
Remove side cover bracket (2).
Installation
Reverse the removal procedures for
 1
installation.

021902

2.6.5 Rear Flare Fender, RH

Removal
Remove five screws (1).
Remove rear right widen fender (2).
Installation  2
Reverse the removal procedures for
installation.

Rear Flare Fender, LH

Removal  1
See right fender instructions.

021903

02-19
CFMOTO
2.6.6 Footrest, RH
Removal  4
Remove front fender (See 2.6.3).
Remove side cover, LH/RH (See  1
2.3.8,2.3.9).
Remove rear fender (See 2.6.13).
Remove five M6 bolts (1).
Remove four M6 bolts (2).
Remove anti-sliding claws (3).
Remove right footrest (4).  1
Installation
Reverse the removal procedures for
installation.

Footrest, LH  2  3 022001
Removal/installation
It is same with right footrest.

2.6.7 Rear License Plate

 3
Removal
Remove two M6 bolts (1).
Remove rear licence plate (2).
Remove one screw (3).
Disconnect rear license light.
 4
Remove rear license light (4).
Installation
Reverse the removal procedures for
installation.

 1

 2 022002
2.6.8 Tool Box Cover
Removal
Open the tool box cover (1).
Remove the cottor pin (2).
Remove the axle (3).
Remove the tool box cover (1).
Installation
Reverse the removal procedures for
installation.

 2  3  1 022003

02-20
 02 Body Covering Parts
2.6.9 Tool Box Locker  3  1
Removal
Open the tool box cover (1).
Loosen two plastic clips, two on each side
Remove the tool box locker (3).
Installation
Reverse the removal procedures for
installation.

 2

022101

2.6.10 Rear Plate

Removal
Remove rear seat (See 2.3.1).  3  1
Remove rear cargo bracket (See 2.4.4).
Open tool box cover (1).
Remove six screws (2).
Remove two screws (3).
Remove rear plate (4).
Installation
Reverse the removal procedures for  2
installation.
 4

022102

2.6.11 Tool Box Locker Bracket  2

Removal
Remove rear plate(See 2.6.10).
Remove four screws (1).
Remove tool box locker bracket (2).
Installation
Reverse the removal procedures for
installation.

 1
022103

02-21
CFMOTO
2.6.12 Taillight Cover, RH  1  4
Removal
Open the rear case cover (1).
Loosen three screws (2).
Loosen one M6 bolt (3).
Loosen two plastic clips (4) at the bottom.  2
Disconnect taillight connector (5) (See
picture 022203). 10  6
Remove right taillight cover (6).
Installation
Reverse the removal procedures for
installation.

Reflector
Removal  3  7  8  9 022201
Loose two M6 bolts (7).
Remove rear reflector bracket (8).  5
Loose two M6 nuts (9).
Remove rear reflector (10).
Installation
Reverse the removal procedures for
installation.

Right Taillight
Removal
Remove four screw (11) (See picture
022203).
Remove taillight (12) (See picture 022203).
Installation
Reverse the removal procedures for
installation. 022202
Taillight Cover, LH
Removal
See right taillight cover instructions.

11

12 022203

02-22
 02 Body Covering Parts
2.6.13 Rear Fender
Removal
Remove side cover, LH/RH (See 2.3.8,  1
2.3.9).
Remove flare fender, LH/RH (See 2.6.5).
Remove tool box cover locker bracket (See
2.6.11).
Remove taillight plate, LH/RH (See 2.6.12).
Remove two M6 bolt (1).
Remove four M6 bolt (2). (2 on each side -
See picture 022302).
Loose four plastic clips (3) (2 on each side -
See picture 022302)
Remove the tank cover (4) (See picture  5 022301
022303)
Remove rear fender (5).
Installation
Reverse the removal procedures for
installation.

 2

 3 022302

 4

022303

02-23
CFMOTO
2.7 Front/ Mid/ Rear Lower Panel,
Front Suspension Panel LH/RH, Rear  2
Suspension Panel LH/ RH, Reservoir
Bracket, Pipe Plug

2.7.1 Front Lower Plate

Removal
Remove five M6 bolts (1).
Remove front lower panel (2).
Installation
Reverse the removal procedures for
installation.

 1 022401

2.7.2 Middle Lower Plate  2

Removal
Remove five M6 bolts (1).
Remove middle lower plate (2).
Installation
Reverse the removal procedures for
installation.

 1 022402

 2
2.7.3 Rear Lower Plate
Removal
Remove four M6 bolts (1).
Remove rear lower plate (2).
Installation
Reverse the removal procedures for
installation.

 1 022403

02-24
 02 Body Covering Parts
2.7.4 Front Suspension Cover, RH
Removal
 1
Remove two M6 bolts (1).
Remove front right suspension cover (2).
Installation
Reverse the removal procedures for
installation.

Front Suspension Cover, LH

Removal/ installation
See right suspension cover instructions.

 2

022501

2.7.5 Rear Suspension Cover, LH

Removal
Remove one M6 bolt (1).
Remove rear left suspension cover (2).  1
Installation
Reverse the removal procedures for
installation.

Rear Suspension Cover, RH

Removal/ installation
See left suspension cover instructions.

 2

022502

2.7.6 Pipe Plug

Removal
Remove rear lower plate (See 2.7.3)
Remove pipe plug (1).
Installation
Reverse the removal procedures for
installation.
 1

022503

02-25
CFMOTO
2.8 Seat Belt(EU 167)
Removal
Remove two bolts 1 ; 1
Remove seat belt assy 2 .
Installation
Reverse the removal procedures for
installation.
2

022601

02-26
 03 Periodic Inspection and Adjustment
3 Periodic Inspection and Adjustment
Maintenance Information   ...........3-1 3.6 Shifting Mechanism ............3-11
3.1 Maintenance Period ..............3-2 3.7 Fuel System .........................3-11
3.2 Maintenance Method  ............3-3 3.8 Throttle Inspection  ..............3-12
3 . 3 S te e r i n g C o l u m n & B r a k e 3.9 Cooling System....................3-13
System ........................................ 3-5 3.10 Light System ......................3-15
3.4 Wheel  .....................................3-8 3.11 Selective Shock Absorber
3.5 Suspension System ............3-10 View ........................................... 3-16
3.12 Shock Absorber Selection ......
.................................................... 3-18

Maintenance Information
Precautions
DANGER
·Exhaust contains carbon monoxide and other poisonous components. Do not run the
engine in a enclosed area for long time.
·The muffler and engine temperature is still high when the engine is just stopped. It may
cause burns when touched to skin. Wear long sleeves and gloves if you have to perform
maintenance when the engine is just stopped.
·Gasoline is highly flammable. No smoking or fire in the work place. Pay attention to open
flames and electric sparks. Gasoline vapors have a risk of explosion. Maintenance must be
done in a well ventilated area.
·Do not let the moving parts pinch hands or clothes.

NOTE
Place vehicle on flat stable ground for maintenance.

03-1
CFMOTO
3.1 Maintenance Period

Vehicle maintenance is a periodic work. Maintaining the vehicle in the specific periods can
keep the engine in good performance, reliable running.

Note: This chart is designed for normal operation. For severe operating conditions,
maintenance should be performed more frequently.

A:Adjust
C:Clean Every Every Every 100h Every 200h
10h or
I:Inspect 25h or 50h or or 3000km or 6000km Remark
300km
L:Lubricate 750km 1500km or a year or 2 year
R:Replace
Engine
Oil and oil filter R R
Gear oil R I R
Oil strainer I,C I,C
Valve adjustment I,A I,A
Engine sealing I I
Engine suspension I I
Air filter element C R
Coolant I I R
Radiator and cooling
I I
system
Spark plug I R
Fuel system
Throttle valve I I,L
CVT
Belt I R
Drive and driven pulley I,C
CVT air inlet pipe and air
I I,C
outlet pipe

03-2
 03 Periodic Inspection and Adjustment
3.2 Maintenance Method
Working Item Period
Half
One Service standard
Part Inspection Item Normal a
year
year
Handle bar Handle smoothly ○
Steering Damage ○
Steering
column Steering system condition ○
system
Ball pin movement ○
Brake Clearance ○ ○
handle Brake effect ○ ○
Connecting
rod and Loose or damaged ○ ○
hoses
Brake Level should be higher
Brake fluid level ○ ○
than LOWER line
Brake
When the front and
system and
rear disc thickness
disc Brake disc wear ○ ○
is less than 4mm,
replace the disc.
Front:45kPa(0.45kgf/
cm²)(6.5PSI)
Tire pressure ○ ○ Rear:45kPa(0.45kgf/
cm²)
(6.5PSI)
Tire cracks or damaged ○ ○
Riding The groove depth
Wheel Tire groove depth and
System ○ ○ should be deeper than
wear
3mm.
Wheel nut and axle
○ ○
looseness
Front wheel bearing
○ ○
movement
Rear wheel bearing
○ ○
movement
Connecting shock and
Pivot arm ○ ○
other damage
Shock
Shock
absorber Oil leaking and damage ○ ○
absorber
Running ○
Front axle Drive and lubrication ○ ○
Rear axle Drive and lubrication ○ ○
Drive
Loosen the filling bolt,
system
Gear box Oil leaking and level ○ ○ the oil level should
reach to the hole.

03-3
CFMOTO
Item Period
Half
Standard
Part Inspection Item Daily a Yearly
year
Output Connector loose ○ ○
Drive
shaft(Drive
system Spline movement ○
shaft)
Spark clearance:
Ignition Sparkplug ○
0.8mm~0.9mm
system
Ignition ○
Electrical
Connectors
equipment Battery ○
condition
Connecting loose
Wiring ○
and damage
Fuel leaking ○
Fuel system Throttle lever clearance:
Throttle lever ○
3mm~5mm
Water level ○ ○
Cooling system
Leaking ○

Item Period
Half
Standard
Part Inspection Item Daily a Yearly
year
Lighting system Function ○ ○
Warning and 4WD locker Function ○
Dashboard Function ○
Loose or damage ○
Muffler
Muffler function ○
Frame Loose or damaged ○
Other Frame ○
Components abnormal on
Make sure it is normal ○
running

03-4
 03 Periodic Inspection and Adjustment
3.3 Steering Column and Brake
System
Stop the vehicle on a flat ground. Move the
handlebar and move up and down to see
handlebar's movement.

If no movement found, inspect and maintain

as necessary.

If the steering column has movement,

tighten the fasteners or disassemble the
steering column for maintenance.

Stop the vehicle on flat ground and turn the

handlebar slowly to check for interference.
If any portion of the steering jammed,
inspect the main cable or other cables for
interference. If the steering rod end position
has not been inspected, make sure it has
no interference and the steering bearing is
OK.

CAUTION: Make sure the steering

system is moving smoothly. Failure of the
030501
steering system will cause an accident.

Front Brake

Clearance of the front brake handle

Check the clearance of the front brake

handle. Pre-operate the brake handle,
check brake effect and handle action. The
lever should be firm and never contact the
handlebar.

030502

03-5
CFMOTO
Front Brake Fluid Level
Inspect the fluid level. When the brake Upper line
fluid level is lower than (1) (LOWER) line,
inspect the master cylinder, brake hose and
other for leakage.(See picture 030601)
Loosen two screws (2) to remove the fluid
cap. (See picture 030602)
Add DOT 3 or DOT 4 brake fluid until the
level reachess the upper line.
NOTE
· Do not add fluid to a low reservoir without
checking for brake pad wear first.
· Do not allow dust or water into the brake
fluid.
·Use only DOT 3 or DOT 4 brake fluid to
avoid chemical reaction.  1 030601
·Don't spill brake fluid on plastic or rubber
parts, as it could damage them.
·Turn handlebar to left or right as necessary
to keep the master cylinder level before the
reservoir cap is removed.

 2

Front Brake Disc&Brake Pads

Brake Pad Wear
030602
Inspect brake pads from the marked place.
Replace brake pads if they are worn to
service limit groove.
Braking Pad service limit: 1.5mm
 3
CAUTION:
Pads should be replaced as an assembly.

Brake Disc Inspection & Replacement

Inspect brake disc (3) for excessive wear
or damage. Replace brake disc when its
thickness is less than 4mm.

Braking Disc service limit: 4.0mm

Brake Fluid Replacement

Replace brake fluid every year.
030603

03-6
 03 Periodic Inspection and Adjustment
Rear Brake Fluid Level
Inspect brake fluid level.
When brake fluid level is below the
"LOWER" mark, inspect master cylinder,
brake lines and connections for leaks.
Unscrew reservoir cap (1) to remove it.  1
Add DOT 4 brake fluid only. Never exceed
the mark "UPPER".
NOTE
· Do not add fluid to a low reservoir without
checking for brake pad wear first.
· Do not allow dust or water into the brake
fluid.
·Use only DOT 3 or DOT 4 brake fluid to
avoid chemical reaction. 030701
·Don’t spill brake fluid on plastic or rubber
parts, as it could damage them. LOWER LINE

Brake Fluid Replacement

Replace brake fluid every year.

Rear Brake Disc & Rear Brake Pads

Brake Pad Wear
Inspect rear brake pads from the marked
place.
Replace rear brake pads if they are worn to
service limit groove.
Braking Pad service limit: 1.5mm

CAUTION:
 2
Pads should be replaced as an assembly.

Brake Disc Inspection & Replacement

Inspect brake disc (2) for excessive wear 030702
or damage. Replace brake disc when its Rear brake disc
thickness is less than 4 mm.

Braking Disc service limit: 4.0mm

Brake Fluid Replacement

Replace brake fluid every year.

03-7
CFMOTO
3.4 Front Wheel
Position the vehicle on a level ground.
Elevate the appropriate side of the vehicle
by placing a stands or other suitable tool
under the footrest frame. Shake the wheel
to check for free play or looseness. If any
freeplay or looseness is found, inspect
A-arms, axle, rim bolts and nuts and tighten
them if necessary.
If free play or looseness still remains,
inspect bearings, A-arm bushings, ball
joints, pins and replace if necessary.

030801
Wag from side to side

Front Wheel Toe-in

Position the vehicle on a level ground to
measure the front wheel toe-in.
Front: A. Rear: B
Toe-in: B-A= 4mm~10mm

030802

If the measurement is out of specification,

adjust the tie rod (1) and tighten locking
nuts (2).

CAUTION:
Drive the vehicle slowly after the adjustment
is completed. Ensure that the handlebar is
positioned properly.
 1

 2 030803

03-8
 03 Periodic Inspection and Adjustment
Tire Pressure
Use tire pressure gauge to measure tire
pressure.

CAUTION:
Test tire pressure when the tire is cold.
Maintain proper tire pressure. Improper
inflation may affect ATV maneuverability,
comfort, or uneven wear to tires. tire gauge

030901

Tire and tire pressure

Front wheel Rear wheel
Tire 45kPa(0.45kgf/cm²)(6.5PSI) 45kPa(0.45kgf/cm²)(6.5PSI)
Tire size 27×9.00-12 51K 27×11.00-12 57K
Tire size 27×9.00R14 60L 27×11.00R14 66L

Tire groove
Replace tires when tire tread depth is worn
to 3mm or less. OVER 3mm

CAUTION:
When tread depth is worn to 3mm or less, 030902
replace tires immediately. Avoid sliding
when driving.

03-9
CFMOTO
Wheel Nut and Axle
Inspect the front wheel axle, rear wheel axle
nut (1) and pin for looseness.
If any looseness inspected Tighted up to the
specific torque.

Torque:
Front axle nut: 220N·m~250N·m
 1
(22kgf·m~25kgf·m)
Rear axle nut: 220N·m~250N·m
(22kgf·m~25kgf·m)

031001

3.5 Suspension System

Set the vehicle on a flat ground. Press on the vehicle body several times at the position
sshowed below. If there is noise or movement, inspect the shock absorber and check oil
leaking. Check that all the locking parts are not damaged or loose.

031002

03-10
 03 Periodic Inspection and Adjustment
3.6 Shifting Mechanism
Shifting mechanism (See picture 031101)
Shift the vehicle to inspect if the shifting
mechanism can work smoothly and the gear
 3
is meshed.
If shifting is not smooth, lubricate the pivots.
If necessary, adjust shifting rod (2) length.  1
Loosen the nut (3) to adjust it.
 2

Remove three M8 bolts (4)

Remove shifting mechanism (5). (See 031102
picture 031102)  4

 5

031102

3.7 Fuel System

Inspect Fuel System Condition
Remove seat (See 2-3);
Check fuel lines for aging, damage;
Replace fuel line if aging, damage is found.
Inspect fuel tank breather hose and the
hose of fuel evaporation control system
(if appliable) for damages and bending.  3
Replace the hoses if any damage is found.
(See picture 031103 and 031104)
031103

The fuel tank is at the back of the vehicle.

 1  2 031104

03-11
CFMOTO
3.8 Throttle Inspection

Inspect throttle lever (1) for free play. (See

picture 031201)

Free play: 3mm~5mm(See picture 031202)

 1
031201

Adjust throttle lever if free play is out of

specification.

Slide sleeve (2) out of place.

loosen throttle cable locking nut (3).
Turn adjuster to change the throttle lever 031202
free play.
Reinstall locking nut (3) and throttle cable
sleeve (2). Free play 3mm~5mm
If the adjuster fails to change throttle lever  2  3
free play to specified value, replace throttle
cable.

Speed Limiter
Speed limiter is designed to adjust throttle 031203
lever travel, so as to limit the max speed.
Inspect the max length of limiter screw
threads.
Max limiter screw threads:a=12mm a=12mm
Adjustment
Loosen the locking nut (1).
Use a cross screw driver to turn the limiter
screw (2) clockwise or counter-clockwise to
adjust throttle lever travel.

CAUTION:For beginners, keep the

adjuster screw turned clockwise to the max.
For experienced riders, turn the adjuster
screw counter-clockwise to change the
throttle lever travel according to speed
requirements.
12mm is the screw limit length.
 1  2

031204

03-12
 03 Periodic Inspection and Adjustment
3.9 Cooling System
CAUTION: UPPER
For safety when checking the coolant
level in the reservoir tank, never open the
pressure cap when the engine is hot (more
than 100 C). Escaping steam and fluid can
cause severe burns. Engine must be cool
before removing pressure cap.
-Coolant is toxic. Don't drink or spill on skin,
eyes or clothing.
-If you spill coolant on your skin or clothing,
immediately wash it off with soap.
-If you get coolant in your eyes, immediately
wash it off and seek medical attention.
-If you swallow coolant, immediately spit it
out and gargle then seek medical attention.
-Coolant must be kept out of reach of
children and pets. 031301
LOWER Coolant
Coolant Level
Coolant can decrease due to evaporation,
etc. Inspect coolant level periodically.

CAUTION:
Coolant is anti-rust and anti-freezing. Using
tap water can corrode the engine, and may
crack the engine when it's freezing. Always
use specified coolant.
Position the vehicle on level ground before
cooling system inspection.
Allow the engine to cool before inspecting
the cooling system.

Inspection
Shut off the engine and allow it to cool.
Inspect the coolant level, ensure that the
level is between "LOWER"and "UPPER"
line.

03-13
CFMOTO
If the coolant level is below the mark
Reservior
"LOWER" (1), remove the reservoir tank
cap and add coolant to the mark "UPPER"
(2). (See picture 031401)
Recommended Coolant: Any commercially
available coolant that is safe for aluminum.
Standard Mixture Ratio: 50% Coolant - 50%
Water (The freezing temperature varies
according to the mixture ratio. Adjust the
mixture ratio according to freeze protection
required in your area.)
When coolant level is reduced significantly,
inspect the cooling system for leaks. If no
coolant remains in the reservoir tank, there
may be air in the cooling system. Purge the
cooling system of air during the refill.

Coolant Leakage  2
Inspect radiator hoses, water pump and
connections for leaks.
If any leaks are found, repair the cooling
system. Inspect radiator hoses for aging,  1
damages and cracks.
Hoses ages over time due to special
working conditions and may crack. Bend a
hose to inspect for cracks. If any damage
or cracks are found, replace it with a new
hose. 031401

Check coolant hose clamps and tighten the

loose ones.  3

Inspect radiator fins (3) for damages or

mud. Correct any fin bending. Use water
and compressed air to clean off mud or
debris.

The radiator should be replaced when

20% of fins (3) are damaged. (See picture
031402)

031402

03-14
 03 Periodic Inspection and Adjustment
Coolant Gauge Inspection
The indicator (1) should indicate 0-1 bar when the engine is cold. Start the engine to
check coolant gauge for response. If the indicator doesn't move when the engine is warm,
determine the cause and repair. (See picture 031501)

OPC

 1
031501

3.10 Lighting
Headlight Beam Adjustment
Remove headlight protector.
In order to adjust headlight beam, turn the
screws (1) to adjust the headlight beam
vertically and horizontally. (See picture
031502)

 1
031502

03-15
CFMOTO
3.11 Selective Shock Absorber View

Damping Force Knob for Compression Damping Force Knob for Compression

Spring adjust
nut Spring adjust
nut

Damping
Damping
Force Knob
Force Knob
for Restoring
for Restoring

031601

03-16
 03 Periodic Inspection and Adjustment
Front Shock Absorber Adjustment
According to load deviation, adjust  1
damping force knob for compression (1)
and damping force knob for restoration (2).
The resistance increases when adjusting
in the direction of "Slow". The resistance
decreases when adjusting in the direction of
"Fast".

 2
031701

Rear Shock Absorber Adjustment

According to load deviation, adjust  1
damping force knob for compression (1)
and damping force knob for restoration (2).
The resistance increases when adjusting
in the direction of "Slow". The resistance
decreases when adjusting in the direction of
"Fast".

 2

031702

03-17
CFMOTO
3.12 Shock Absorber Selection
Front/Rear Shock Absorber Shape Selection

Adjusting
retainer

Adjusting
retainer

031801
Front shock absorber Rear shock absorber

03-18
 03 Periodic Inspection and Adjustment
Front shock absorber spring preload
adjustment
Use shock absorber adjusting tool. Adjusting
the preload position (1) depends on the
vehicle load. Turn it clockwise to increase
the spring preload. (See picture 031701)

 1

031901

Rear shock absorber spring preload

adjustment
Use shock absorber adjusting tool. Adjusting
the retainer position (1) depends on the
vehicle load. Turn it clockwise to increase
the spring preload. (See picture 031702)

 1

031902

03-19
 04 Alongside Engine
4 Alongside Engine
Maintenance Information...............4-1 4.3 Exhaust System.......................4-5
4.1 Fuel System.............................4-2 4.4 Cooling System........................4-6
4.2 Intake System..........................4-3 4.5 Engine Removal and Installation
.................................................4-7
Maintenance Information
Precautions
·Make sure the vehicle engine is off for more than 1 hour to avoid protential injuries.
·Do not damage the frame, engine body, bolts, or cables. Be careful when working.
·Wrap the frame in appropriate areas where might it be scratched to avoid damage during
engine removal and installation.
·Use special containers to collect drained coolant, engine oil and fuel when removing the
engine.
·Replace the coolant and oil as standard procedure after assembling the engine.

It is not necessary to remove the engine when servicing the following parts:
-Oil pump
-Throttle valve and air filter
-Cylinder head cover, cylinder head, cylinder body, camshaft
-CVT cover and system
-Left side cover, magneto and water pump
-Pistons, piston rings, piston pins.

·It is necessary to remove engine when servicing the following parts:

-Crankshaft
-Transmission

Tightening Torque:

Name Type Torque(N•m)

Front left mounting bolt, engine GB5789 M10×1.25×130 40~50
Front right mounting bolt, engine GB5789 M10×1.25×100 40~50
Front mounting bracket, engine GB5789 M10×1.25×20 40~50

04-1
CFMOTO
4.1 Fuel System
Canister Removal (US)
Remove body covering parts. (Refer to
Chapter 2 Body Covering Parts)  1
Remove the clamp A10(1)
Remove fuel vapor hose II (2).

 2

040201

Remove the clamp A10 (1).  1

Remove fuel vapor hose I (2).

 2
040202

Remove nuts (1).

Remove canister (2).
Reverse the removal procedures for
installation.

Inspection  1
Check canister for damage. Replace if  2 040203
necessary.
Check fuel vapor hose for age or damage.
Replace if necessary.

04-2
 04 Alongside Engine

 1

040301
4.1 Fuel System
Removal
Remove body covering parts (See 02 body
covering parts).
Remove four M6 bolt (1).
Remove fuel pump connector (2).
Disconnect fuel pump quick joint (3).
Remove the tank (4).
Remove quick joint (5).
Remove the whole fuel pipe assembly (6).  2  3  4

040302

 5

 6 040303

04-3
CFMOTO
CAUTION
Gasoline is highly flammable. Smoke and fire is forbidden in the work place. Also be highly
careful with electric spark.
Gasoline vapor has a risk of explosion. Please work in a well ventilated area.
Installation
Reverse the removal procedures for installation.
All the connectors should in right position. Quick joints will make a click sound when
connected.
Make sure all the pipes and hoses are installed properly.

4.2 Intake System

(See 5.7 engine intake system)
Removal
Remove body covering parts. (See 02 body
covering parts)  2

Use screwdriver (2) to remove clamp (1).

 4
Remove intake pipe assembly (3).

 3

 1

040401

1 Screw clamp 3 Intake pipe assembly

2 Screwdriver 4 Air filter strainer

04-4
 04 Alongside Engine
Remove three M6 bolt (4)

 4

040501

Remove clamp (5)

Remove exhaust pipe (6).  8
Remove clamp (7).
Remove air filter (8).
 7
NOTE
The air filter foam element should be
washed and the main air filter replaced if it
is dirty. Never attempt to clean or re-use a
 5
dirty air filter. (For maintenance frequency  6
refer to 3.1)

Installation
Reverse the removal procedures for
installation.
040502

04-5
CFMOTO
4.3 Exhaust System
Removal
Remove the rear seat (1).
Remove the front seat (2).
Remove right side cover (3) (See 02 body
covering part).

 1  2  3 040601
Remove four M6 bolt (1).
Turn up the seat insulator (2) to the left.

 1

 2
040602

 1
Remove four M6 bolt (1).
Remove two screws (2).
Remove rear outside heat insulator (3).
Remove front insulator (4).
 4
Warning
Temperature of exhaust system is very high  3
when the engine is running. Do not conduct  2 040603
maintenance until the exhaust system cools
down.

 1
Remove two M8 bolts (1).
040604

 2

Remove one M8 bolt (2).

Pull the muffler (3) to the back to remove it
(keep the sleeve and washer stored).
 3 040605

04-6
 04 Alongside Engine
Remove oxygen sensor (1).
Remove two M8 muffler connector nut (2).
Remove two M8 bolt.
Remove two-into-one exhaust pipe
(Keep the exhaust washer on cylinder head stored).

 3

 1

 2

040701

 2
Oxygen sensor (1).
Remove two M8 muffler connector nut (2).
Remove front cylinder exhaust pipe (3)
(Keep the exhaust washer on cylinder head
stored).

Installation
Reverse the removal procedures for  3
installation.

NOTE  1
Spring pressure should be suitable. Test the
muffler after assembled. Leaking or noise
should not be heard. 040702

4.4 Cooling system

See engine 5.8 cooling system

04-7
CFMOTO
4.5 Engine Removal and Installation
Remove body covering part (See 02 body
covering part).
Remove fuel system (See 4.1).
Remove intake system (See 4.2).
Remove exhaust system (See 4.3).  1
Remove cooling system (See 4.4).
Disconnect electrical connector.
Remove throttle cable.
Remove throttle valve (1).
Remove engine left side cover (See 2.6.4).
040801

Remove shifting mechanism (See 3.6).

Remove bolt (4)
Disconnect the shifting rocker arm (5) from
the engine.

 5
 4

040802

Remove related cables and connectors(See

1.7.1)

04-8
 04 Alongside Engine
Remove inlet pipe filer cover (1).

 1

040904

Remove screw clamp (1).

Disconnect inlet connector (2) from the
engine.
 1

 2

Loose the screw clamp (3). 040901

Disconnect outlet connector (4) from the
engine.

Remove front drive shaft.

 3
Remove rear drive shaft.
Remove one M10×1.25×100 bolt (1).
Remove one M10×1.25×130 bolt (9).
Remove two M10×1.25 nuts (7).
Remove four M8 bolts (2).  4
Remove three M8 nuts (3).
Remove two M10×1.25×20 bolts (5).
Remove two M10×1.25 nuts (7).
Remove front engine mounting shaft (11). 040902
Remove one M12×1.25 nut (10).
Remove engine front left mounting plate (8).
Remove engine front right mounting plate
(4).
Remove engine front mounting bracket (6).
Remove the engine.
Installation
Reverse the removal procedures for
installation.
040903

04-9
 5.1 Engine Maintenance Information
05 Contents
5.1 Maintenance Information………………………………...........…….....5-2
5.2 Intake Pipe, Cylinder Head and Cylinder Body ……….............….…5-20
5.3 Case, Crankshaft and Gear Transmission ……................................5-67
5.4 CVT………...……………………………………………………..………5-110
5.5 Engine Lubrication System …….……………………………....………5-128
5.6 Engine Starting System………………………………………....………5-145
5.7 Intake System…………………………………………………....………5-157
5.8 Cooling System……………………………………………….....………5-163
5.9 Electrical System……………………………………………..….………5-188
5.10 Troubleshooting …………………………………………..……………5-219

05-1
CFMOTO
5.1 Maintenance Information
Unit Form ...............................................................................................5-3
5.1.1 Pre-cautions ..................................................................................5-4
5.1.2 Fuel, Engine Oil, Gear Oil and Engine Coolant.............................5-5
5.1.3 Engine Break-in.............................................................................5-5
5.1.4 EIN Location................................................................................. 5-6
5.1.5 Engine Specification......................................................................5-7
5.1.6 Service Limits  ................................................................................5-8
5.1.7 Engine Tightening Torque Form ....................................................5-13
5.1.8 Engine Service Tool ......................................................................5-15
5.1.9 Engine Service Materials...............................................................5-18
5.1.10 Engine Service Schedule ............................................................5-19

05-2
 5.1 Engine Maintenance Information
Unit Form

Item Unit calculation

2
1kgf/cm =98.0665kPa
Pressure 1psi=6.895kPa=0.06895bar
1mmHg=133.322Pa=0.133322kPa
1kgf·m=9.80665N·m
Torque 1N·m= 8.85(lbf·in)
1N·m= 0.7375621(lbf·ft)
1mL=1cm3=1cc
Volume
1L=1000cm3
Force 1kgf=9.80665N
1in=25.4mm

Danger/Caution/Note
Please read below instruction carefully.

DANGER: The Danger alert and icon indicates a potential hazard that may result in
death or serious injury.

WARNING :The Warning alert and icon indicates a potential hazard that may result in
injury.

NOTE: The Note alert and icon indicates a potential hazard that may result in self-hurt
or hurt others.

Please pay attention: Danger, Warning and Caution cannot include all the risks during
use or maintenance of the engine. Therefore, besides the notice on vehicles, the person
who maintains the vehicle must have basic mechanical safety knowledge, or ask a
senior mechanic for help.

05-3
CFMOTO
5.1.1 Precautions

WARNING: Working on the engine in the right way is important for technicians safety
and engine reliability.

·Make sure the exhaust gas can be vented out if starting the engine indoor.
·Use extreme caution when working with poisonous or high-flammable material. And
make sure the working place is well ventilated.
·Do not use gasoline as washing liquid.
·To avoid heat burns, do not touch the uncooled engine oil, radiator and exhaust system.
·If fuel, lubrication, cooling and exhaust system has been maintained. Inspect for leaking
and level.
·To protect the environment, dispose of wasted oil or coolant properly.

WARNING :
·Use CFMOTO authorized parts or recommended products.
·If the removed parts need to be reused, please put them in order to avoid mixing up.
·Make sure the part for assembly is clean. Pre-lubricate it if needed.
·Use special oil, glue and sealant for engine assembly.
·When tightening bolts, screws or nuts, tighten larger ones first, and then tighten up from
inside to outside.
·Use a torque wrench to tighten bolts to special torque. If the screws have grease or oil,
it must be cleaned up.
·When a part is removed, it should be inspected and cleaned up before measuring.
·Inspect the part tightening and running after installation.
·Do not use used oil-seals, O-rings, gaskets, self-lock nuts, locking gasket, cottor pins
and retainers. Replace with new ones.

05-4
 5.1 Engine Maintenance Information
5.1.2 Fuel, Engine Oil, Gear Oil and
Coolant
Fuel: Use RQ-92# gasoline or higher
20W-50
Oil: SAE15W-40, SG or higher level in API.
15W-40，15W-50
If SAE15W-40 engine oil is not available,
follow the chart on the right to choose 10W-40，10W-50
one oil according to the enviornment 10W-30
temperature.
5W-40
Gear oil: 75W/90 GL-5

Engine coolant: Coolant has anti-freeze

liquid properties. The frozen temp is lower
than enviorment temperature (Typically -5
degrees C or lower).

Recommend: -30ºC, high level anti-freeze,

rust and high boil point coolant that is safe
for aluminum.

DANGER: Coolant is poisonous.

WARNING: Do not mix the coolant with different brands.

5.1.3 Engine Break-in

There are many movable components inside the engine, such as piston, piston ring,
cylinder, crankshaft, gears and ect. During initial use period, proper run-in for every
critical component is necessary. Break-in can help engine components match each other
and adjust working condition. Careful treatment of a new engine will ensure the engine
has more efficient performance and a longer service life.

Recommended break-in period: First 600km

Operation guide:
0~300km: Do not operate continously at more than 50% throttle position. Cool down
the engine for every 5~10 minutes after every one hour operation. Avoid sudden
acceleration.Vary the throttle position slowly and smoothly.
300km~600km: Avoid long-time running at more than 75% throttle position. Do not open
throttle completely during this period.

NOTE:
1.Maintain and repair with regular procedures during break-in period.
2.After break-in, check and maintain the engine before normal use.

NOTE: Follow the maintenance chart in break-in period. And troubleshoot the engine
in time. After break-in, get a full 600km break-in maintenance before normal operation.

05-5
CFMOTO
5.1.4 EIN Location

Engine left side 050601

EIN Location

Engine right side 050602

05-6
 5.1 Engine Maintenance Information
5.1.5 Engine Specification
NO. Item Specification
1 Style V-twin, water cooled, 4-stroke,8 valves, SOHC
2 Bore×Stroke 91mm×74mm
3 Displacement 962.6mL
4 Compress ratio 10.6:1
5 Idle speed 1300r/min±130r/min
6 Starting method Electrical start
Ignition style/angle ECU/BTDC8° 1300r/min
Electrical Sparkplug/spark
7 DCPR8E(NGK)/0.8mm~0.9mm
system clearance
Magneto AC 3-phase.350W/5000r/min; 460W/5000r/min
Throttle body 0JY0-173000-10000/0JY0-173000-20000
Burning
8 Air filter Foam, paper filter element
system
Gasoline RQ-92 or higher
9 Valve system Style SOHC/chain drive
Lubrication style Compress + splashing
Oil pump Rotor
Lubrication
10 Filter style All flow paper filter
system
Engine oil SAE15W-40/SG or higher API level
Gear oil 75W/90 GL-5
Cooling Cooling style Close circulating coolant flowing
11
system Coolant -30°C Anti-freeze and corrosion liquid
Transmission way CVT+ vehicle stop transmission
Gears 2 drive gears,1 reverse,1 parking
Gear order Manual/L-H-N-R-P
CVT ratio range 2.88~0.70
Transmission Final :1.333(20/15,Bevel gear)
12
system Secondary :1.952(41/21)
Speed Gears
Step speed ratio
L gear:2.529(43/17);H gear:1.143(32/28) ;
R gear: 2.231(29/13)
Total ratio : L:6.585;H:2.975 ';R:5.807
Length(mm)×Width(mm)×Heigth (mm):679mm
13 Size
×619mm×519mm
14 Mass 76kg
15 Output style Front and rear shaft output
16 Engine running direction Clockwise

05-7
CFMOTO
5.1.6 Service Data
Lubrication system
Item Standard Service limit
Replace oil with filter 2500mL( Crankcase )
Oil Capacity
Total dry 2600mL( Crankcase )
Gear oil Total capacity 600mL (Gearcase )

SAE15W-40, SG or
20W-50
higher level in API. If
15W-40，15W-50 SAE15W-40 engine
10W-40，10W-50
oil is not available,
Recommended follow the chart on
engine oil 10W-30 the left to choose
5W-40 one oil according
to environment
temperature.

Recommended
75W/90/GL5
gear oil
Oil pump rotor Inner and oute rotor clearance 0.06mm~0.14 mm 0.25mm
Out rotor and case body clearance 0.09mm~0.15mm 0.25mm
Oil pump rotor side clearance 0.023mm~0.109mm 0.20mm
Engine speed 1300r/min , oil temp 90ºC:
100kPa~400kPa, usually 200kPa
Oil pressure
Engine speed 6000r/min , oil temp 90ºC:
500kPa~700kPa, usually 580kPa

Cooling system
Item Standard Limit
Valve open temp 65ºC ± 2ºC
Thermostat Full open temp 85ºC
Open clearance 85ºC,≥ 5mm
Radiator cap open pressure 108kPa (1 .1kgf/cm 2 )
Resistan ce B to
Temp.(ºC) the resistance of A and C
case (Ω)
resistance precision
Thermo sensor value(Ω) (±%)
resistance and -20 —— 28582 4
temp relations 25 —— 2795 2.5
50 216~264 980 2.27
80 74.6~90.6 334 2.04
110 32~36 133.1 2.52
Thermo switch Off — On About 88 ºC
working temp On — Off About 82 ºC
Coolant style -30ºC anti-corrosion and rust coolant

05-8
 5.1 Engine Maintenance Information
Induction system
Item Standard
Throttle body 0JY0-173000-10000/0JY0-173000-20000
Intake pressure and thermo sensor 0JY0-175000
Injector 0JYA-171000
Idle speed 1300r/min±130r/min

Electrical system
Item Standard Remark
Type DCPR8E(NGK)
Spark plug
Clearance 0.8mm~0.9mm
Spark size >8mm,101kPa
First level 0.7Ω~0.75Ω
Ignition coil resistance
Secondary level 6.0kΩ~7.0kΩ
Coil resistance (20°C) 0.2Ω~0.3Ω
Ignition coil resistance 250Ω~300Ω
350W,5000r/min;
AC magneto Magneto output power
460W,5000r/min
Stable voltage 13.5V~15.0V,5000r/min
Ignition coil peak voltage ≥1.5V,200r/min
Ignition coil secondary peak voltage ≥27kV
Start relay coil voltage 3Ω~5Ω
auxiliary relay coil resistance 70Ω~90Ω

05-9
CFMOTO
Valve mechanism and cylinder head

Item Standard - mm Limit Remark

Intake 33 ——
Valve diameter
Exhaust 29 ——
Valve thickness Intake and exhaust 1 0.5
Valve clearance(Cold Intake 0.06~0.14 ——
engine) Exhaust 0.11~0.19 ——
Valve conducting pipe
Intake and exhaust 5.000~5.012 5.045
diameter
Intake 4.965~4.980 4.93
Valve rod outer diameter
Exhaust 4.955~4.970 4.93
Valve conducting pipe Intake 0.020~0.047 ——
and rod clearance Exhaust 0.030~0.057 ——
Valve rod roundness(run
Intake and exhaust 0.01 0.05
out)
Valve rod end run out Intake and exhaust 0.02 0.05
Intake 90.1 ——
Valve length
Exhaust 88.7 ——
Valve bevel side run out Intake and exhaust 0.03 0.05
Intake 1.2±0.1 1.7
Valve sealing line width
Exhaust 1.3±0.1 1.8
Valve spring free length Intake and exhaust 40 38.2
Compress to
33mm:200.5N~235.5N
Valve spring force Intake and exhaust ——
Compress to
23mm:531N~587N
Intake 32.931~33.051 32.831
Cylinder 1 cam height
Exhaust 32.945~33.065 32.845
Intake 33.019~33.139 32.919
Cylinder 2 cam height
Exhaust 32.853~32.973 32.753
Φ35 34.959~34.975 34.95
Camshaft neck
Φ22 21.959~21.980 21.95
Cam shaft bearing Φ35 35.007~35.025 35.04
diameter Φ22 22.012~22.025 22.04
Camshaft bearing fitness Φ35 0.032~0.066 0.09
clearance Φ22 0.032~0.066 0.09
Camshaft axial clearance 0.12~0.28 ——
Camshaft runout 0.10
Rocker arm inner hold
Intake and exhaust 12.000~12.018 12.03
diameter
Rocker arm shaft
Intake and exhaust 11.973~11.984 11.96
diameter
Rocker arm shaft fit
Intake and exhaust 0.016~0.045 0.07
clearance
Rocker arm shaft axial
Intake and exhaust 0.06~0.34 ——
clearance
Cylinder head flatness 0.03 0.05

05-10
 5.1 Engine Maintenance Information
Cylinder, Piston, Piston Ring, Crankshaft and Connecting Rod
Item Standard - mm Limit Remark
Cylinder compress pressure 1000kPa ——
Cylinder body roundness
0.038 0.090
(3 diameter run out)
Cylinder roundness (Diameter
0.015 0.020
run out)
Cylinder hole diameter 90.99~91.01 ——
Above
Piston diameter 90.94~90.96 90.85 8mm from piston
bottom
Cylinder clearance 0.04~0.06 0.10
Cylinder upside and bottom
0.03 0.05
flatness
1st:0.25~0.40 1.35
Piston ring open clearance 2nd:0.30~0.45 1.35
Oil:0.2~0.7 1.5
1st:1.17~1.19 ——
Piston ring thickness 2nd:1.47~1.49 ——
Oil:2.37~2.47 ——
1st:1.21~1.23 ——
Piston ring groove depth 2nd:1.51~1.53 ——
Oil:2.50~2.52 ——
1st:0.02~0.06 0.15
Piston ring/groove thickness 2nd:0.02~0.06 0.15
Oil:0.03~0.15 0.25
Piston pin hole inner diameter 22.004~22.010 ——
Connecting rod small end
22.01~22.02 22.06
inner diameter
Piston pin diameter 21.995~22.000 21.980
Piston pin hole/Piston pin
0.004~0.015 0.08
clearance
Connecting rod small end
0.010~0.025 0.08
hole/Piston pin clearance
Connecting rod big end axial
0.3~0.56 0.8
clearance
Connecting rod joint diameter 43.930~43.950 43.915
Connecting rod big end
43.970~44.000 44.03
bearing diameter
Connecting rod big end radial
0.028~0.049 0.09
clearance
Crankshaft main joint diameter 41.960~41.970 41.935
Crankcase main bearing hole
41.980~42.020 42.10
diameter
Crankshaft main joint radial
0.02~0.05 0.09
clearance
Crankshaft axial clearance 0.15~0.54 0.64

05-11
CFMOTO
CVT
Item Standard - mm Limit Remark
Drive belt width 33.7(Fiber level) 32.2
Driven pulley sliding sleeve
38.10~38.14 38.30
diameter
Shifting fork and groove
0.20~0.40 0.50
clearance
Shifting fork moving
5.80~5.90 5.70
thickness
H/L sliding fork groove
6.10~6.20 6.30
width
Output main gear sliding
6.10~6.20 6.30
groove width
Shifting groove width 8.02~8.12
Shifting fork pin diameter 7.90~7.95 7.83
Shifting gear hole diameter 29.000~29.021 29.025
Reverse dual gear hole
29.007~29.028 29.032
diameter
Φ30:28.980~29.993 29.970
Shifting main shaft diameter
Φ17:16.983~16.994 16.978
Φ24:23.980~23.993 23.974
Driven shaft diameter
Φ17:16.983~16.994 16.978
Drive bevel gear shaft
Φ17:16.983~16.994 16.978
diameter
Reverse dual gear shaft
Φ25:24.980~24.993 24.974
diameter

05-12
 5.1 Engine Maintenance Information
5.1.7 Engine Tighten Torque
Torque
Item Qty Type (mm) Remark
(N·m)
Bolt M14×1.5 4 M14×1.5 40
Oil drain bolt M14×1.5 1 M14×1.5 25
Screw plug 1 ZM14 20 Cover with thread locker
Drain bolt M12×1.5 1 M12×1.5 20
Flange bolt M8×12.5 (Left
1 M8×12.5 20
crankcase)
Screw cap 1 R21/8 20 Cover with thread locker
Screw R21/8 (Oil line in right
1 R21/8 20 Cover with thread locker
crankcase)
Screw M4×10 (Crankshaft washer
2 M4×1 3 Cover with thread locker
locking nut)
Bolt (Left cover) 2 M5×10 6 Cover with thread locker
Bolt M12×1.25×35 (Magneto rotor) 1 M12×1.25 60
Valve clearance adjusting nut 8 M6 12
Timing chain bolt 2 M8 30 Cover with thread locker
Tensioner bolt plug 2 M16×1.5 4.5
Cylinder locking screw 8 M10 20,60
Pushing nut M8 (Exhaust side) 4 M8 13
Spark Plug 2 M12×1.25 20
Stud M8×42(Exhausting side) 4 M8×42 25 Cover with thread locker
Screw plug M12×1.5 (Front
1 M12×1.5 20
cylinder head)
Screw ST4.8×13 (Thermostat
2 ST4.8×13 5
cover)
Tensioner locking pin 2 M6×16 10 Cover with thread locker
Intake pipe bolt M8×25 4 M8×25 20
Connecting rod bolt 4 M9×1 10,20,60
Drive pulley nut 1 M22×1.5 180 Counter clockwise
Drive pulley bolt (CVT) 1 M12×1.5 60 Counter clockwise
Main drive shaft nut (CVT driven
1 M20×1.5 150
pulley)
Bevel gear locking nut 1 M22×27×1.5 145
Bolt M8×28 (Drive bevel bearing
4 M8×28 32
seat)
Screw M8×25 (Drive bevel bearing
4 M8×25 15
pressing )
Front output shaft bearing retainer 1 M55×1.5 80 Cover with thread locker
Bearing locking nut M65×1.5 1 M65×1.5 110 Cover with thread locker
Bolt M8×28 (Driven bevel bearing
4 M8×28 25
seaat)
Screw T25 (Shifting drum) 1 M5×8 6
Shifting locking spring seat 1 M12×1 20

05-13
CFMOTO
Type Torque
Item Qty Remark
(mm) (N·m)
Bolt M5×16 (Oil pump) 3 M5×16 7 With thread locker
Screw M8×20 (Overriding clutch) 6 M8×20 30 With thread locker
Bolt M6×30 (Magneto stator) 3 M6×30 16 With thread locker
Bolt M6×35 (High power magneto With thread locker
3 M6×35 16
stator)
Cylinder head cover bolt assy 8 M6 7
Bolt M6×45 (Front cylinder thermostat
2 M6×45 6
cover)
Bolt M6×25 (Tensioner and rear
6 M6×25 6
thermostat cover)
Coolant temperature sensor 1 M12×1.5 16
Oil pressure switch 1 M10×1 12
Oil cooler mounting bolt 4 M6×18 10
Oil cooling seat mounting bolt 2 M10×20 25
With thread locker.
Front output bearing retainer 1 M55×1.5 80
Counter-clockwise
M5 4.5~5.5
Other bolts M6 8~12
M8 25

05-14
 5.1 Engine Maintenance Information
5.1.8 Engine Service Tools
Measuring tool

No. Tool name Specification Usage Remark

1 Vernier caliper 0~150mm Measure the length and thickness
Measure rocker arm shaft, valve rod,
2 Micrometer 0~25mm
camshaft’s diameter.
3 Micrometer 25mm~50mm Measure the max-range of cam
4 Micrometer 75mm~100mm Measure the piston size
Cylinder inner dial
5 Measure the cylinder diameter runout
gauge
Measure rocker arm inner diameter,
6 Inner dial caliper 10mm~34mm cylinder pin hole, connecting rod
small hole.
7 Dial gauge 1/100 Measure the running out
8 Flatness gauge Measure the flatness
Measure the flatness and adjust the
9 Clearance gauge
valve clearance.
Plastic clearance
10 Measure fitness clearance
gauge
11 Force gauge Measure the spring force
12 RPM gauge Measure the engine speed
Cylinder pressure
13 gauge and Measure cylinder pressure
connector
Oil pressure
14 Measure oil pressure
gauge
Air pressure
15 Measure radiator cap open pressure
gauge
16 Ohm meter Measure the resistance and voltage
17 Ampere meter Measure the current
18 Thermo gauge Measure the temperature
19 Timing flasher Test the ignition timing
20 Torque wrench Measure the tighten torque
Usual and auxiliary tool
21 Alcohol lighter Heating up
Magneto gauge
22 Install dial gauge
stand
23 Flat plate Supplement the measuring
24 V-block Measure the running out data
25 Caliper Install valve locking block
26 Retainer caliper Install and remove the caliper
27 Caliper Install and remove the retainer
Impact screw
28 Remove the screw
driver
29 Screwdriver(-)
30 Screwdriver(+)

05-15
CFMOTO
Engine Service Special Tools
P/N Tool name Usage
0JWA-000000-871-001 Oil pipe connector measure the oil pressure
Bearing 60/28 removing
0800-014001-922-003 Remove bearing 60/28
tool
0800-014001-921-002 Bearing pressing tool Press bearing
0800-041000-922-001 Crankshaft locking screw Lock the crankshaft
0800-031000-922-001 Magneto removing tool Remove magneto rotor
0800-031000-922-003 Rotor locker Lock the crankshaft
Separate the driven pulley for belt
0800-052000-922-003 Driven pulley separator
assembly
0800-052000-922-002 Driven pulley separator Disassemble the drive pulley
CVT driven pulley locking
0800-052000-922-001 Lock the pulley
wrench
901-18.01.00-922-001 Testing cap Measure the cooling system pressure
0JWA-081000-922-001 Water seal removing tool Remove the water seal
0JWA-081000-922-002 Water seal assembly tool Install the water seal
Water pump bearing
0800-014001-922-001 Remove the bearing
3200A removing tool
0800-014001-921-003 Bearing pressor Install bearing
0800-022800-922-001 Sparkplug sleeve Remove/install the sparkplug
0800-024001-922-001 Camshaft locking tool Lock the camshaft
0800-000000-871-002 Pressure gauge seat Measure the cylinder pressure
0800-040003-922-001 Piston ring pressor Press the piston ring
0800-040005-922-001 Piston pin retainer caliper Install the retainer
0800-011201-923-001 Breather oil seal pressor Install the oil seal 15×26×6
Breather gear shaft
0800-011201-921-003 The block for gear shaft installation
installing tool
Breather gear shaft
0800-011201-921-001 Press the gear shaft
pressor
0JWA-012000-921-004 Bearing 6205 pressor Install the bearing 6205

05-16
 5.1 Engine Maintenance Information
P/N Name Use to
Front output shaft oil seal For oil seal 35×61×9
0800-060000-923-001
pressor installation
Front output shaft bearing Assemble and removal the
0JWA-012000-922-005
retainer wrench bearing retainer
0800-062301-923-001 Front output shaft pressor Install front output shaft
Driven bevel gear nut
0800-062206-922-001 Install/remove the locking nut
sleeve
0800-062204-923-001 Bevel gear oil seal pressor Install bevel oil seal 34×50×7
Bevel gear clearance Measure the bevel gear
0JWA-062000-922-001
measuring tool clearance
Left case bearing removing
0800-011000-922-001 Remove bearing
tool
0800-012000-922-001 Bearing 5206 removing tool Remove bearing 5206
CF188-014001-921-001 Bearing 60/28 installing tool Install bearing 60/28
0JY0-050000-922-001 Drive pulley locking tool Lock the drive pulley
172MM-080005-923-001 Oil seal pressor Install the oil seal 10×20×5
CF188-022006-922-001 Valve spring pressor Remove the valve spring
Front output bearing
CF188-060008-922-001 Install/remove bearing retainer
retainer wrench
CF188-062201-921-003 Bearing 6207C3 pressor Install the bearing
CF188-062103-921-002 Bearing 6305 pressor Install the bearing
152MI-060002-921-002 Bearing 6203 installing rod Install the bearing
CF188-012100-921-004 Bearing 3206A installing rod Install the bearing
CF188-011100-921-004 Bearing 6303 pressor Install the bearing
1P39MB-012001-921-002 Bearing 6203 pressor Install the bearing
0JY0-050000-922-002 Removing tool, drive pulley Remove drive pulley

05-17
CFMOTO
5.1.9 Engine Service Materials
Engine service materials include engine oil, gear oil, grease, coolant, flat sealing glue,
cylinder locking glue and so on.
Name Specification Use position Remark

Cylinder inner moving

parts. Crankcase, CVT
SAE15W-40
case inner moving parts. Capacity
API level: SG or higher
Oil Cylinder head moving 2500mL(With filter)
(See chapter 5.1.2 for
parts. 2600mL(Totally dry)
more details)
Check lubrication system
for more details

Gear oil 75W/90 GL-5 Gear case Capacity:600mL

Piston pin, Valve rod,
Lubrication oil
Valve oil seal, Camshaft
Oil seal lip, O-ring and
3# MoS2 lithium other sealing material
Grease
grease surface and sealed
bearing.
-30°C high level anti-
corrosion, anti-freeze, Cooling system, water Capacity depends on
Coolant
high boiled point seal installation cooling system
coolant
Magneto stator wire
rubber sleeve and
Flat surface left crankcase cover.
sealant Crankcase and cylinder
body. Water seal and
water pump and washer.
Thread locker Screws See chapter 5.1.7
Cylinder Oil seal and crankcase
locking glue surface

05-18
 5.1 Engine Maintenance Information
5.1.10 Engine Maintenance Schedule

NOTE: This schedule is designed for normal use. Under severe use, maintenance the
engine and vehicle more frenquently.

A:Adjust
C:Clean Every Every Every 100h Every 200h
10h or
I:Inspect 25h or 50h or or 3000km or 6000km Remark
300km
L:Lubricate 750km 1500km or a year or 2 year
R:Replace
Engine
Oil and oil filter R R
Gear oil R I R
Oil strainer I,C I,C
Valve adjustment I,A I,A
Engine sealing I I
Engine suspension I I
Air filter element C R
Coolant I I R
Radiator and cooling
I I
system
Spark plug I R
Fuel system
Throttle valve I I,L
CVT
Belt I R
Drive and driven pulley I,C
CVT air inlet pipe and air
I I,C
outlet pipe

05-19
CFMOTO
5.2 Intake Pipe, Cylinder Head and Cylinder Body
5.2.1 Service Tool and Material ..............................................................5-21
5.2.2 General Information.......................................................................5-26
5.2.3 Maintenance and Inspection..........................................................5-27
5.2.4 Intake Pipe ....................................................................................5-31
5.2.5 Cylinder Head Cover......................................................................5-32
5.2.6 Timing Chain Tensione...................................................................5-33
5.2.7 Cam Timing Sprocket.....................................................................5-35
5.2.8 Rocker Arm....................................................................................5-38
5.2.9 Cylinder Head ...............................................................................5-41
5.2.10 Camshaft .....................................................................................5-43
5.2.11 Valve Spring.................................................................................5-52
5.2.12 Valve............................................................................................5-54
5.2.13 Cylinder Body ..............................................................................5-57
5.2.14 Piston...........................................................................................5-59
5.2.15 Piston Ring ..................................................................................5-65

05-20
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
5.2.1 Service Tool and Material
Service Tools
Name P/N Page
Spark plug socket 0800-022800-922-001 5-28
Camshaft locking tool 0800-024001-922-001 5-29/35/37
Pressure gauge seat 0800-000000-871-002 5-30
Crankshaft locking screw 0800-041000-922-001 5-47
Valve spring compressor CF188-022006-922-001 5-52/53
Piston ring compressor 0800-040003-922-001 5-58/59
Piston pin circlip 0800-040005-922-001 5-63
Service materials
Name P/N Page
Engine oil 5-22/23/24/25/34/40/56/58/63
243 thread locker 5-22/23/24

05-21
CFMOTO
Intake Pipe

 1
 2
12  3
11

 4
10

 6

 9
 8  7

 5
052201

1 0.5N·m (5 lbf·in) 5 20N·m (5 lbf·ft) 9 Oil

2 6N·m (53 lbf·in) 6 0.5N·m (5 lbf·in) 10 Oil
3 243 thread locker 7 243 thread locker 11 243 thread locker
4 Oil 8 6N·m (53 lbf·in) 12 6N·m (53 lbf·in)

05-22
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Cylinder head(Ι)

 2

 4
20
19
 1  5
 3
 6
18 15

 7
16  8
17
14

12
13
11 10
 9
052301

1 Oil 9 Oil 17 10N·m(89 lbf·in)

2 12N·m(106 lbf·in) 10 20N·m(15 lbf·ft) 18 30N·m(22 lbf·ft)
3 60N·m(44 lbf·ft) 11 243 thread locker 19 7N·m(62 lbf·in)
4 Oil 12 Oil 20 243 thread locker
5 20N·m(15 lbf·ft) 13 12N·m(106 lbf·in) 21
6 5N·m(44 lbf·in) 14 Oil 22
7 6N·m(53 lbf·in) 15 Oil 23
8 20N·m(15 lbf·ft) 16 10N·m(89 lbf·in) 24

05-23
CFMOTO

14

13
11

12
15
16

17

10 18

 1  3
 2
19
 9

 8
 4

 7

 6

 5

052401

1 10N·m(89 lbf·in) 9 Oil 17 10N·m(89 lbf·in)

2 30N·m(22 lbf·ft) 10 20N·m(15 lbf·ft) 18 20N·m(15 lbf·ft)
3 243 thread locker 11 12N·m(106 lbf·in) 19 243 thread locker
4 Oil 12 Oil
5 Oil 13 12N·m(106 lbf·in)
6 6N·m(53 lbf·in) 14 7N·m(62 lbf·in)
7 5N·m(44 lbf·in) 15 Oil
8 16N·m(141 lbf·in) 16 60N·m(44 lbf·ft)

05-24
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Cylinder Body and Piston

 4
 1
 3
 1

 5

 3
 4

 5

 2
052501

1 Oil 2 Oil 3 10N·m (89 lbf·in) 4 5N·m (44 lbf·in) 5 Oil

05-25
CFMOTO
5.2.2 General
General rules should be followed below:

In cylinder head/cylinder body exploded

view, same part uses the same numbers;
different parts or only one part, use
different part numbers.

The service difference between cylinder 1

and cylinder 2 has special instructions in
this manual.

When the engine shows trouble, the

cylinders should be diagnosed separately.
The vehicle must be stopped on a flat
ground.
 1
Note: For better understanding, most of
the drawings show the engine in a removed
 2
state. If there is no need to remove the
engine, make sure the work below is done:

1.Disconnect the negative cable of the

battery before working on engine. Then
disconnect the positive cable.
2.Many parts may not need to be removed
when working on only one part. CFMOTO 052601
recommends to remove only that part for 1 Cylinder #1 2 Cylinder #2
inspection if possible.
3.During assembly, follow the exploded
views for the torque and service materials.
4.Clean the screw threads before covering
with thread locker.

Warning: Use torque wrench to tighten

up screws. Locking parts (Locking washer,
Locking nut, Cotter pin) must be replaced.

If removing many same parts (i.e. Valves).

Please mark the position (i.e. PTO/MAG,
#1 cylinder/#2 cylinder), and separate
them. If parts are damaged, it will be easier
to find out the reason from related parts.

05-26
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
5.2.3 Maintenance and Inspection
Maintenance
Valve Clearance Adjustment

Note: Inspect and adjust of the valve

clearance must be performed on a cold
engine.

R e m o v e t h e c y l i n d e r h e a d c o v e r.
Turn the crankshaft until the cylinder is at
TDC. See camshaft timing in this chapter.
Use clearance gauge to test the valve
clearance.
Valve clearance
0.06 mm~0.14 mm
Intake
(0.0024 in ~ 0.0055 in)
0.11 mm~0.19 mm
Exhaust
(0.0043 in ~ 0.0075 in)
If the clearance is out of limit, follow the  1
steps below to adjust:

Note: Follow the medium data to adjust  2

clearance and make sure the data is right.

Tighten up the locking nut after getting the  3

right clearance.
Repeat the work on every valve.
Check the valve clearance again before
installing the cylinder head cover.

Inspection
Leakdown test 052701
Confirm the items below before cylinder Adjusting Clearance Locking
leaking test : 1 2 3
screw gauge nut
—Tight up the clamp
—Radiator and hose

Note: For accurate inspection, the

leaking test should be performed under
normal engine working temperature.

Warning: Avoid get heat burns during

working procedures.

Warning: Disconnect the battery.

Disconnect the negative line first.

05-27
CFMOTO
Remove the radiator cap

Warning: Wear suitable protecting

equipment when removing the radiator cap
to avoid heat burns.

Remove parts to access the cylinder head.

Remove ignition line.  1
Clean the place around the spark plug, use
spark-plug socket (0800-022800-922-001)
 2
Remove spark plug from cylinder head.

052801
1 Ignition line 2 Spark plug

 1

Remove the cylinder head cover.

 2
Turn the crankshaft to TDC (see camshaft
in this chapter).
Turn the crankshaft using a dial gauge to
make sure the piston is at TDC.
052802
Note: If there is no gauge, use a similar
tool instead of a dial gauge. Cylinder head cover Cylinder
1 2
mounting bolt head cover

 1

052803
1 Dial gauge

05-28
 5.2 Intake Pipe, Cylinder Head and Cylinder Body

Warning: Do not scratch or damage the  3

piston or cylinder head surface.

Note: The sign on timing sprocket must

align with the surface of the cylinder head.
(See picture 052901)

Use camshaft locking tool (0800-024001-

922-001) to lock the camshaft at TDC.  1

 2
052901
1 Sign on sprocket
2 Cylinder head surface
Camshaft locking tool
3
(P/N:0800-024001-922-001)

052902
Camshaft locking tool
1
(P/N:0800-024001-922-001)

05-29
CFMOTO
Leakdown Test
Connect to suitable air power, set the  1
pressure gauge to zero.

Note: All the air pressure gauge has

detailed instructions and pressure range.

Set the pressure gauge seat on cleaned

spark plug hole (0800-000000-871-002).  2
Inject compressed air into the cylinder.
Follow the pressure gauge and record the
leaking percentage.
Leaking
Engine performance
percentage
0%~15% Very good
16%~25% Good - wear is evident
26%~40% Bad - Diagnose and repair
≥41% Repair
Diagnose 053001
Leaking reason: 1 Pressure gauge 2 Air hose
— Intake valve leaking causes air
leaking noise from intake.
— Exhaust valve leaking cause air
leaking noise from exhaust.
— Cylinder head gasket leaking causes
the radiator coolant to bubble.
— Damage/bolt loose causes the
air or oil to come out from
crankcase(See crankcase).
— Damage/bolt loose causes
air or coolant to come out from cylinder
head(See intake pipe, cylinder head
and cylinder body).
— Cylinder body wearing too much/ or
piston ring broken cause the air flow
noise in crankcase(See intake pipe,
cylinder head or cylinder body).

Note: Please check the related chapter

of the engine for trouble diagnosing.

Assembly
Reverse the removal procedures for
installation. Make sure the specified torque
is used and use right materials. Check
exploded views if needed.

05-30
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
5.2.4 Intake Pipe
Intake pipe removal
Unplug the fuel pump power connector.
Run the engine until it dies to release the  1
fuel pipe pressure.

Warning: Fuel pipe may be under

pressure. Use absorbable cloth to cover
the pipe connector. Disconnect the pipe,
release the pressure slowly, and absorb  3
the fuel flow.  2

Remove the seat, two side plates, medium 053101

plate and fender. (See body covering
parts)
Remove air filter cover. Air filter Intake pipe Throttle
Remove air filter element. 1 2 3
room connector body
Loose the air filter mounting screw.
Loose the clamp between throttle body
and intake manifold.
Remove the intake manifold.
Remove injector fuel pipe.  1
Disconnect 2 injector connectors.
Disconnect air pressure temp sensor
connector.
Loosen intake pipe bolts
f r o m c y l i n d e r h e a d .
Remove the intake pipe from vehicle.  2

053102
1 Fuel pipe 2 Injector connector

Note: Remove the injector from intake

pipe as necessary.

Intake pipe inspection

 1
Inspect the intake pipe to see if it is
cracked, flange is damaged or other
problems. Replace the part if necessary.
Intake pipe assembly
Reverse the removal procedures for
installation.
Tighten the mounting bolts to 20N·m 053103
(15 ft-lb). Connect the fuel pump power
Connector( Intake pressure and temp
connector. 1
sensor)

05-31
CFMOTO
5.2.5 Cylinder Head Cover  1
Removal
Loosen the cylinder head cover mounting
bolts.

 2

053201
Cylinderhead cover Cylinderhead
1 2
mounting bolt cover

Remove cylinder head cover and sealing

gasket.
Cylinder head cover inspection
Inspect the cylinder head cover for cracks
or hardness. Replace if necessary.
Cylinder head assembly
Reverse the removal procedures for
installation. Tighten the mounting bolts the  2  1
torque value in criss-cross procedure.

053202

Cylinder head
1 Cylinder head cover 2
sealing gasket

05-32
 5.2 Intake Pipe, Cylinder Head and Cylinder Body

5.2.6 Timing Chain Tensioner

Note: Make sure the front cylinder

is at TDC position before removal and 1
installation. See Camshaft section. 2

Tensioner Removal

Warning: The spring of the timing chain

tensioner is loaded. Do not operate it
when the engine is working, because the
exhaust system is very hot. Operate it until
exhaust system cools down. 053301

P l u g s c r e w, c h a i n
1 2 O-seal ring
tensioner

Remove chain tensioner plug screw.

Remove O-seal ring.

Remove chain tensioner mounting bolts.

Remove chain tensioner body and seal 1
gasket.

Tensioner Inspection
Inspect tensioner for damage or normal
4
performance. Replace new one if it does.
●Inspection methods for performance
stability 3
1. Turn the tensioner adjusting screw
2
clockwise with screw driver, then press the
push-pull arm to the end with hands. 059701
2. Remove the screw driver and then loose
the push-pull arm slowly to see whether it
can return smoothly. Replace if it returns
roughly. Inspect chain tensioner push- 1 B o l t s , c h a i n 3 Push-pull arm
pull arm for smooth performance and/or tensioner
scratches. 2 Chain tensioner 4 Seal gasket
body

05-33
CFMOTO
Tensioner Installation

Reverse the removal performances for

installation. However, pay attention to the
following items.

Note: Before installing chain tensioner,

make sure the camshaft timing sprocket
can rotate forwards and backwards.

Apply some engine oil on push-pull arm

before installing tensioner.

Note: Insert the straight screwdriver into

the groove on the end of the tensioner. 053401
Then rotate it clockwise to lock the
tensioner spring. Rotate the timing sprocket
1
forwards and backwards
Warning: Wrong installation of timing
chain may damage the engine.

Install timing chain tensioner and new seal

gasket.
Install chain tensioner bolts and tighten
them to the specific torque.

Note: Do not forget to install the o-seal

ring on chain tensioner plug screw.

Tighten the tensioner plug screw to 5N·m

(44 lbf·in).

05-34
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
5.2.7 Camshaft Timing Sprocket
Removal the timing sprocket
Remove the cylinder head cover. Turn
the crankshaft to front cylinder TDC.
R e f e r t o c a m s h a f t i n t h i s c h a p t e r.
Loosen the timing chain tensioner. Remove
the camshaft timing sprocket bolt. To avoid
the timing chain moving when removing
sprocket, please use special tool(0800-
024001-922-001) to lock the camshaft.
Remove the sprocket.

Note: Use a hook or wire to hold the

timing chain.
053501
Camshaft locking tool
1
(P/N:0800-024001-922-001)

Inspect the timing sprocket

Inspect the camshaft timing sprocket to
inspect wear or damage. If tooth wear or
damage is significant, replace the chain
and sprocket together. See crankshaft
in crankcase chapter to inspect the  1
crankshaft sprocket.

 2

 3

053502
Camshaft locking tool
1
(P/N:0800-024001-922-001)
2 Camshaft timing chain bolt
3 Camshaft timing sprocket

05-35
CFMOTO
Installation the timing sprocket
Reverse the removal procedures for
installation.
Clean the assembly surfaces and camshaft
screw before installation.

 1
 2

053601
1 Camshaft assemble surface 2 Screw

Make sure the timing sprocket and

crankshaft is at TDC before assembly.
 1
Warning: When assembling the cam
timing sprocket and chain, make sure the
camshaft is at TDC.

The marks of the camshaft timing sprocket  3

must be parallel with the cylinder head.  2
Remove crankshaft locking bolt and
camshaft locking tool after installation of
the timing sprocket and camshaft.

NOTE: Adjust the timing chain tensioner 053602

during assembly of the timing sprocket. Camshaft timing Cylinderhead
(See timing chain tensioner). Re-verify the 1 2
alignment bottom surface
marks of the timing sprocket to see the 3 Camshaft timing sprocket
alignment is still true.

05-36
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Install all the removed parts.

 1

 2

 3

053701
1.Camshaft locking tool
1
(P/N:0800-024001-922-001)
2 Camshaft timing sprocket bolt
3 Camshaft timing sprocket

05-37
CFMOTO
5.2.8 Rocker Arm
Remove the rocker arm
Remove the cylinder head cover.
Remove chain tensioner and camshaft
timing sprocket.
Remove the bolt (3) and camshaft locking  3
plate (2).
 2

 1

053801
Camshaft
1 Cylinderhead 2 3 Bolt
locking plate

Remove the rocker arm shaft.

Remove the rocker arm assembly (Intake  1
and exhaust), including adjusting screw
and nut.  2

 3

 5  4

053802
Rocker
1 Nut 3 Exhaust arm 5
shaft
Adjusting
2 4 Intake arm
screw

05-38
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Remove the thrust washers.
 2  1  2
Wa r n i n g : D o n o t m i s s t h e t h r u s t
washers (2) or drop them into timing chain
room.
 3

 4

053901

1 Rocker arm 3 Rocker shaft

Thrust This side to the spark
2 4
Washer plug

Inspection the rocker arm

Inspect the rocker arms for cracks or
scratches. If damaged, replace the parts.
 1
Inspect the rocker arm to see it is wearing
 3
smoothly or not. Check for damage or too
large runout. Replace parts as necessary.
Measure the rocker arm hole inner
diameter. If out of standard, replace the
rocker arm.
Rocker arm inner diameter
12.000 mm~12.018 mm  2
New
(0.4724 in~0.4731 in) 053902
Service
12.030 mm (0.4736 in)
limit Rocker Rocker arm inner
1 2 3 Roller
Inspect the adjusting nut to see if it can arm hole diameter
turn freely, has cracks or too large jump. If
damaged, replace the parts.

 1
053903
1 Adjusting screw freely turning

05-39
CFMOTO
Rocker arm shaft inspection
Inspect rocker arm shafts for scratches.
Replace shafts as necessary.
Measure rocker arm shaft diameter.
Rocker arm diameter
New 11.973mm~11.984mm
(0.4714in~0.4718in)
Service 11.960mm
limit (0.4709in)  1
If reached the service limit, parts must be
replaced. 054001
1 Diameter measuring position

Install the rocker arms

Note: Use the same way to install the

intake and exhaust rocker arm.

Pre-lubricate the rocker arm shaft. Insert

the bevel side first. Then follow the steps
below to complete the installation:
Insert the rocker arm shaft to the hole on
the rocker arm.
Install the washer and make sure the arm
is right (Intake or Exhaust).
Then push the shaft until it reaches the
end.
 1
Install another washer then push the shaft  3  2
to the end.
054002
Timing chain Washer
See timing chain in CRANKCASE chapter. Washer Rocker
(Timing
1 (Spark plug 2 3 arm
chain
side) shaft
side)

05-40
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
5.2.9 Cylinder head  1
Remove the cylinder head
The 2 cylinder heads remove in the same
manner.
Drain out the coolant (See cooling system).

Note: Use compressed air to blow

out the coolant left before removing the  2
cylinder head. If the coolant flows into the
engine, it will cause engine oil dilution.

Remove the both side panels and inner

fenders.(See body covering parts).
Disconnect the ignition.
Disconnect the temp sensor connector on
054101
the cylinder head.
Disconnect the radiator inner hose. 1 Cylinder head bolt M10 2 Bolt M6
Remove the chain tensioner.
Remove exhaust pipe spring and clamp.
Remove exhaust nuts.
Remove the air filter housing.
Remove the throttle valve.
Remove the intake manifold.
Remove the cylinder head cover and
gasket. (See cylinder head cover)
Remove camshaft timing sprocket.
Follow the special order to remove the  1
cylinder head mounting bolt M6 and M10.
Pull out the cylinder head.  2
Remove the timing chain guide.  4
Remove the gasket (4) and discard it.

 3
054102

1 Cylinder head 3 Chain guide

2 Timing chain 4 Cylinder head gasket

05-41
CFMOTO
Cylinder head inspection
Inspect timing chain guide for wear,
cracks or other damages. Replace if
damaged. Check for cracks between
valve seats. If any, replace cylinder head.
Check mating surface between cylinder
and cylinder head for contamination. If
any, clean both surfaces. Clean oil supply
through the cylinder head of contamination.

 3  2  1
054201
Oil Supply to Camshaft Journal Spark
1
Plug Side
Oil Port to lubricate Camshaft Lobes
2
Intake/Exhaust
Oil Supply to Camshaft Bearing
Cylinder head installation 3
Journal Timing Chain Side
Note: The cylinder heads are not
identical in design. Do not invert the
cylinder heads during assembly.

Reverse the removal procedures for

installation.  1

Ensure dowel pins are in place. Install a

NEW cylinder head gasket.

Warning: Chain guide (1) has to be fixed  2

between cylinder and cylinder head.

054202
Chain Guide (fixed between cylinder
1
and cylinder head)
Chain Tensioner Guide (mounted in
2
Crankcase)

05-42
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
First, torque cylinder head screws M10  1
in a criss-cross sequence to 20N.m (15
ft-lb.), then tighten to 60N.m (44 ft-lb).
Install cylinder head screws M6.
Check chain guide for movement.

 2

054301
054301

Cylinder Head Cylinder Head

1 2
Screws M10 Screws M6
5.2.10 Camshaft

Note: The engine is equipped with two

different camshafts.

 4  1

 3  2

054302

Camshaft of 3.Cylinder 1 cam

1 3
Cylinder 2 sign 2V91YI
Cylinder 2 cam Camshaft of
2 4
sign 2V91Y II Cylinder 1

05-43
CFMOTO
Camshaft Timing

 1
Note: If a piston (cylinder 1 or 2) is set
to TDC, the camshaft timing gear of the
opposite cylinder should appear in the
following position. (See picture 054401)

 2

054401

Marks on Timing Gear Cylinder

1 2
of Opposite Cylinder Head Base

Camshaft Timing Cylinder 2

Turn crankshaft until piston is at TDC
ignition as follows:
Remove spark plug of both cylinders.
Remove valve cover of both cylinders.
Remove magneto end cover (3). (See
picture 054402)  3

 1

 2

054402

1 Gasket 2 Screws 3 Cover

05-44
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Remove the crankshaft position sensor (2).
(See picture 054501)  1

 2

054501

Crankshaft Position
1 Screw 2
Sensor (CPS)

Use an 18mm socket to turn crankshaft

until piston 2 (rear) is at TDC. (See picture
054502)

 1

054502

1 18mm Socket

05-45
CFMOTO
When the rear piston is at TDC, “2“ mark
on magneto flywheel and the magneto
cover mark (center of bore) are aligned.

 1

 3

 2
054601

1 Mark “2” on MAG Flywheel

2 CPS Location
3 Notch on MAG Cover

At TDC, the printed marks on the camshaft  1

timing gear should be parallel to the
cylinder head.

 2

054602
Marks on Camshaft Cylinder Head
1 2
Timing Gear Base

05-46
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
To lock crankshaft at TDC, remove from
crankcase plug screw with sealing ring.

 3
 1

 2
054701

Crankcase PTO Plug Sealing

1 2 3
Side Screw Ring

Lock crankshaft with the crankshaft locking

bolt (0800-041000-922-001).

Note: Make sure the locking bolt

engages in the groove of the crankshaft.

 1

054702
Crankshaft Locking Bolt
1
(P/N:0800-041000-922-001)

05-47
CFMOTO
Camshaft Timing Cylinder 1
Turn cylinder 2 to TDC, see Camshaft
Timing, Cylinder 2.
 2
Note: Do not lock crankshaft.  1

Use a 18mm socket, turn crankshaft

280 counter-clockwise, until “1” mark on
magneto flywheel and the magneto cover
mark (center of bore) are aligned.

054801

18mm Turn Crankshaft 280

1 2
Socket Counterclockwise

 2  1

 3 054802
054802

1 Mark “1” on MAG Flywheel

2 CPS Location
3 Notch on MAG Cover

05-48
 5.2 Intake Pipe, Cylinder Head and Cylinder Body

Note: At TDC, the printed marks on the

camshaft timing gear should be parallel to  1
cylinder head.

Warning: Crankshaft can not be locked

at cylinder 1 TDC.

 2

054901
Marks on Camshaft Cylinder Head
1 2
Timing Gear Base

Camshaft Removal
The removal procedures are the same for
both camshafts. Each camshaft is different
in design.
Thus, it is important not to mix up any parts
of the camshaft assembly with that of ths
other cylinder. Keep parts as a group.  3
Remove valve cover (see VALVE COVER).  2
Remove chain tensioner (see CHAIN
TENSIONER).
Remove camshaft timing gear (see
CAMSHAFT TIMING GEAR). Remove  1
camshaft retaining plate.

054902

Camshaft
Cylinder
1 2 Retaining 3 Screw
Head
Plate

05-49
CFMOTO
Remove rocker arms (see ROCKER
ARM).
Remove camshaft.

Note: For removal, rotate camshaft so  3

 1
that intake/ exhaust lobe shows to upper
side of cylinder head.
 2
Camshaft Inspection
Check each lobe and bearing journal of
camshaft for scoring, scuffing, cracks or
other signs of wear. Measure camshaft 055001
journal diameter and lobe height using a
Area for Camshaft
micrometer.
1 Crankshaft 2 Retaining 3 Camshaft
Cylinder 1 Camshaft Lobes Plate
Cam Lobe - Exhaust
32.945 mm~33.065 mm
New
(1.2970 in~1.3018 in)  4
Service  3  2  1
32.845 mm (1.2931 in)
limit
Cam Lobe - Intake
32.931 mm~33.051 mm
New
(1.2965 in~1.3012 in)
Service
32.831 mm (1.2926 in)
limit

Cylinder 2 Camshaft
Cam Lobe - Exhaust 055002
32.853 mm~32.973 mm
New
(1.2934 in~1.2981 in)
1 Camshaft Journal (Spark Plug Side)
Service
32.753 mm (1.2895 in) 2 Camshaft Lobe (Intake Valves)
limit
Cam Lobe - Intake 3 Camshaft Lobe (Exhaust Valves)
33.019 mm~33.139 mm
New 4 Camshaft Journal (Timing Chain Side)
(1.300 in~1.3047 in)
Service
32.919 mm(1.2960 in)
limit

Camshaft Journal (Timing chain)

34.959 mm~34.975 mm
New
(1.3763 in~1.3770 in)
Service
34.950 mm(1.3760 in)
limit
Camshaft Journal (Spark plug)
21.959 mm~21.980 mm
New
(0.8645 in~0.8654 in)
Service
21.950 mm(0.8642 in)
limit

05-50
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Measure matching clearance between two
ends of camshaft and cylinder head
Camshaft bearing hole diameter
(Timing chain side)
35.007 mm~35.025 mm
New
(1.3782 in~1.3789 in)
Service
35.040 mm(1.3795 in)
limit
 1
Camshaft bearing hole diameter
(Spark plug side)
22.012 mm~22.025 mm
New
(0.8666 in~0.8671 in)
Service  2
22.040 mm(0.8677 in)
limit
055101

1 Camshaft Bearing (Timing Chain Side)

2 Camshaft Bearing (Spark Plug Side)

Camshaft Installation
For installation, reverse the removal
procedures. Pay attention to the following  1
details.
 2
Wa r n i n g : T h e c a m s h a f t s a r e n o t
identical in design. Do not invert the  3
camshafts during assembly. Any mix-
up of the components will lead to engine
damage.
055102
Place the camshaft retaining plate in the
slot of the camshaft. Camshaft
Slot Direction
For other parts, refer to proper installation Retaining
1 2 Retaining 3 of
procedures. Plate
Shaft Movement
Position

05-51
CFMOTO
5.2.11 Valve Spring
Valve Spring Removal
Remove rocker arm(see ROCKER ARM
above). Remove cylinder head(see  1
CYLINDER HEAD above). Use valve
spring compressor clamp(0180-022 006-
922- 001) to compress valve spring.

Warning: Always wear safety glasses

when assembling valve springs. Be careful
when unlocking valves. Components could
fly away because of the strong spring 055201
preload. Valve Spring Compressor Clamp
1
(P/N: CF188-022006-922-001)

 1

055202
1 Valve Spring Compressor Cup

 1

055203

Align Valve Spring Compressor Clamp

1
with the Center of Valve

05-52
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Remove valve cotters.

Withdraw valve spring compressor, valve

spring retainer and valve spring.
 1
 3
 2

055301
Valve Spring Compressor Clamp
1
(P/N: CF188-022006-922-001)
2 Valve Spring Compressor Cup
3 Valve Cotter
Valve Spring Inspection
Check valve spring for visible
damages, If any, replace valve spring.
Check valve spring for free length and
straightness. (see picture 055302)
Valve sprint free length
New 40 mm (1.575 in)
Service
38.2 mm (1.504 in)
limit
Replace valves springs if not within
specifications.
 1
Valve Spring Installation 055302
For installation, reverse the removal
procedure. Pay attention to the following 1 Valve Spring Length
details. Colored area of the valve spring
must be placed on top. (see picture
055303)
 1
To ease installation of cotters, apply oil
or grease on them so that they remain in
place while releasing the spring.

Note: Valve cotter must be properly  2

engaged in valve stem grooves.

After spring is installed, ensure it is 055303

properly locked by tapping on valve stem
end with a soft hammer so that valve Position of the Valve
1 Valve Cotter 2
opens and closes a few times. Spring

Warning: An improper locked valve

spring will cause engine damage.

05-53
CFMOTO
5.2.12 Valve
Valve Removal
R e m o v e v a l v e s p r i n g ( s e e VA LV E
SPRING). Push valve stem, then pull
valves (intake and exhaust) out of valve
guide.

 1
 2

055401
Intake Valve Exhaust Valve
1 2
33mm 29mm

Remove valve stem seal with seal pliers  1

and discard it.

055402

1 Pliers

 1

 2
055403

1 Pliers 2 Valve Stem Seal

05-54
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Valve Inspection
Valve Stem Seal
Always install new seals whenever valves
are removed.
Valve  1
Inspect valve surface, check for abnormal
stem wear and bending. If out of
specification, replace with a new one.
Valve stem roundness (Diameter runout)
(Intake and exhaust)
New 0.01 mm (0.0004 in)
Service
0.05 mm (0.0020 in) 055501
limit
Valve Stem and Valve Guide Clearance 1 Valve Stem Diameter
Measure valve stem and valve guide in
three places with a micrometer and a small
bore gauge

Note: Clean valve guide to remove

carbon deposit before measuring.
Change valve if valve stem is out of  1
specification or has other damages such  3
as wear or friction surface.

Valve stem diameter  2

Exhaust
4.955 mm~4.970 mm 055502
New 055502
(0.1951 in~0.1957 in)
Service Valve Face
4.930 mm (0.1941 in) Exhaust Valve
limit Valve (Contact
1 2 Contaminated 3
Intake Seat Surface to
Area
4.965 mm~4.980 mm Valve Seat)
New
(0.1955 in~0.1960 in)
Service
4.930 mm (0.1941 in)
limit
Replace valve guide if valve guide is out of
specification or has other damages, such
as wear or friction surface.
Valve guide diameter (Intake and exhaust)
5.000 mm~5.012 mm
New
(0.1969 in~0.1973 in)
Service
5.045 mm (0.1986 in)
limit

05-55
CFMOTO
Valve Bevel and Valve Seat
Check valve face and seat for burning
or pitting Replace valve or cylinder
head if there are signs of damage.
Ensure seating of valves properly. Apply
some lapping compound to valve face and
 2  1
work valve on its seat with a lapping tool
(see Valve Installation Procedure below).
Measure valve face contact width.

Note: The location of contact area

should be in center of valve seat.

Measure valve seat width with a caliper.

Valve seat width
055601
Exhaust
1.20 mm~1.40 mm Va l v e S e a t Valve Contact
New 1 2
(0.047 in~0.055 in) Contact Width Surface Width
Service limit 1.80 mm (0.071 in)
Intake
1.10 mm~1.30 mm
New
(0.043 in~0.051 in)
Service limit 1.70 mm (0.067 in)
If valve seat contact width is too wide or
has dark spots, replace the cylinder head.

Valve Installation
For installation, reverse the removal
procedure. Pay attention to the
 2
following details. Install a NEW valve
stem seal. Make sure spring seat  1
is installed before installing seal.
Apply engine oil on valve stem and install
it. 055602
Warning: Be careful when valve stem is Valve Spring Sealing Lips of Valve
1 2
passed through sealing lips of valve stem Lower Seat Stem Seal
seal.

To ease installation of cotters, apply oil

or grease on them so that they remain
in place while releasing the spring.
After spring is installed, ensure it is
properly locked by tapping on valve stem
end with a soft hammer so that valve
opens and closes a few times.

Warning: An improper locked valve

spring will cause engine damage.

05-56
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
5.2.13 Cylinder
Cylinder Removal
Remove chain tensioner (see CHAIN  4
TENSIONER).
Remove the camshaft timing gear (see
CAMSHAFT TIMING GEAR).  3
Remove cylinder head (see CYLINDER
HEAD).
Pull cylinder.  1
Discard cylinder base gaskets.  2

055701

Camshaft Timing Cylinder Base

1 3
Chain Gasket
2 Piston Assembly 4 Cylinder

Cylinder Inspection A
Check cylinder for cracks, scoring and
wear ridges on the top and bottom of the 1
cylinder. If any, replace cylinder. B
2
Cylinder Taper C
Measure cylinder bore. If it is out of
specification, replace cylinder and
piston rings. Measure cylinder bore at 3
3 recommended positions. (See picture
055702)
Cylinder taper (Run out) 055702
New 0.038 mm (0.0015 in)
Service 1 First Measuring of Diameter
0.090 mm (0.0035 in)
Limit 2 Second Measuring of Diameter
Difference between measurements should
3 Third Measuring of Diameter
not exceed the service limit.
A 6mm(0.2362 in)
B 43mm(1.6929in)
C 116mm(4.5669in)

05-57
CFMOTO
Cylinder out of Round
Measure cylinder diameter in piston axis
direction from top of cylinder. Take another
measurement from the angle of 90° and
compare with the first one. (See picture
055801)  B

Note: Take the same measuring points

 A
described in Cylinder Taper.

Cylinder out of round (Diameter run out)

New 0.015 mm(0.0006 in) 055801
Service Perpendicular to Parallel to
0.020 mm(0.0008 in) A B
limit Crankshaft Axis Crankshaft Axis

Cylinder Installation
Reverse removal procedure for installation.
Pay attention to the following details. (See
picture 055901)

Warning: Always replace cylinder base

gasket before installing cylinder.
 1
First mount cylinder 2.Then remove
crankshaft locking bolt(P/N 529 035 617).
Turn crankshaft to piston 1TDC, then mount
055802
cylinder 1. Cylinder cannot be pushed fully
over the piston unless the piston is located Piston Ring Compressor Tool
1
at TDC. Apply engine oil in the bottom area (P/N:0800-040003-922-001)
of the cylinder bore and also on the brand
of the piston ring compressor tool (0800-
040003-922-001).

Note: Pull timing chain through the

chain pit then put the cylinder in place.

Warning: Chain guide must be fixed

between cylinder and cylinder head.

Note: After both cylinders are installed,

turn crankshaft until piston of cylinder 2 is
at TDC ignition and lock crankshaft. Refer
to CAMSHAFT.

05-58
 5.2 Intake Pipe, Cylinder Head and Cylinder Body

 1

 3
 2

055901
Piston Ring
Compressor
1 Cylinder 2 Piston 3
Tool (P/N:0800-
040003-922-001)
5.2.14 Piston
Piston Removal
Remove cylinder head (see CYLINDER
HEAD) Remove cylinder (see CYLINDER).
Place a rag under piston in the area of
the timing chain compartment to avoid
dropping circlips inside the crankcase.
 1
Warning: Piston circlips are spring pre-
loaded.

Remove one piston circlip and discard it. 055902

Note: Removal of both piston circlips is 1 Piston Circlip

not necessary when removing piston pin.

Push piston pin out of piston pin bore  2

(connecting rod small end hole).
Detach piston from connecting rod.

 1

055903
1 Piston Pin 2 Piston

05-59
CFMOTO
Piston Inspection
Inspect piston for scoring, cracking or
other damages. Replace piston and piston
rings if necessary.  1
Measure piston at 8mm (0.315 in)
perpendicularly (90°) to piston pin with a
micrometer.
The measuring dimension should be as
described in the following tables. If not,
replace piston.  A
Piston side
90.940 mm~90.960 mm 056001
New
(3.5803 in~3.5811 in) Measuring
8 mm
Service 1 Perpendicularly (90°) A
90.85 mm (3.577 in) (0.315 in)
limit to Piston Pin

05-60
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Piston/Cylinder Clearance
Adjust and lock micrometer to the piston
dimension.
With the micrometer set to the dimension,
adjust a cylinder bore gauge to the
micrometer dimension and set the indicator  1
to 0 (zero).
056101
Position the dial bore gauge 20mm (0.787
in) above cylinder base, measuring 1 Micrometer Set to the Piston Dimension
perpendicularly (90°) to piston pin axis.
Read the measurement on the cylinder  2
bore gauge. The result is the exact piston/
cylinder wall clearance.
Piston/cylinder body clearance
0.040 mm~0.060 mm
New
(0.0016 in~0.0024 in)
Service
0.100 mm (0.0040 in)  1
limit
056102

Note: Make sure used piston is not Use Micrometer to

1 2 Dial Gauge
worn. Adjust the Dial gauge

If clearance exceeds specified tolerance,

replace piston with a new one and
measure piston/cylinder clearance again.

Note: Make sure the cylinder bore

gauge indicator is set exactly at the same
position as with the micrometer, otherwise
 1
the reading will be false.

056103
1 Indicator Set to 0 (zero)

05-61
CFMOTO
Connecting Rod/Piston Pin Clearance
Use synthetic abrasive woven to clean
piston pin from deposits. Inspect piston pin
for scoring, cracking or other damages.
Measure piston pin. See the following
illustration for the proper measurement
positions.
Piston pin diameter
21.995 mm~22.000 mm
New
(0.8659 in~0.8661 in)  1 056201
Service
21.980 mm (0.7866 in)
limit 1 Piston Pin Diameter
Replace piston pin if diameter is out of
specification.

Measure inside diameter of connecting rod

small end hole.
Connecting rod small end inner diameter
22.010 mm~22.020 mm
New
(0.8665 in~0.8669 in)
Service  1
22.060 mm (0.8685 in)
limit
Replace connecting rod if diameter is out
of specifications. (Refer to crankcase)  2  2
Compare measurement to obtain the
connecting rod/piston pin clearance.
Connecting rod/piston pin clearance
056202
Service
0.080 mm (0.0035 in)
limit 1 Bore Gauge 2 Connecting Rod

05-62
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Piston Installation
R e v e r s e the remova l p roce d ur e for  1
installation.
Pay attention to the following details.  4
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting
rod.

Note: Make sure the mounting direction

of the piston is correct.
 2
 3
For each cylinder, install piston with the
arrow on piston dome pointing toward the
transmission of the engine. (See picture
056301)
Front cylinder: Arrow on top of piston must 056301
show to intake side.
1 Piston of Front Cylinder
Rear cylinder: Arrow on top of piston must
show to exhaust side. Mark on Piston Must Show to Intake
2
Side of Front Cylinder
3 Piston of Rear Cylinder
Mark on Piston Must Show to
4
Exhaust Side of Rear Cylinder
Use circlip installer (0800-040005-922-001)
to assemble the NEW piston circlip as per
 1
following procedure.

Warning: Replace removed piston

circlip(s) with new ones every time. Place
a rag on cylinder base to avoid dropping
the circlip inside the engine.

056302
Circlip Installer
1
(P/N:0800-040005-922-001)

05-63
CFMOTO
Place circlip inside sleeve. (See picture
056401)

 1
 2

 3

056401

Assembly Jig
Piston Pin
1 from Piston 2 3 Sleeve
Circlip
Clip Installer
Push taper side of assembly jig until circlip
reaches middle of sleeve. Align sleeve with
piston pin axis and push assembly jig until  1  2
the circlip engages into the piston. (See
picture 056501)

 3

 4
056402

Hold Piston while Pushing Circlip in

1
Place
2 Sleeve
3 Assembly Jig
4 Direction to Push Circlip

05-64
 5.2 Intake Pipe, Cylinder Head and Cylinder Body
Note: Take care that the hook of the
piston circlip is positioned properly.

5.2.15 Piston Rings

Remove the piston.(see PISTON)
Ring Inspection
Ring/Piston Groove Clearance
Use a feeler gauge to measure each ring/
piston groove clearance. If the clearance
is too large, the piston and piston rings
should be replaced.
Piston ring/groove clearance  1
Piston ring ( 1 )
0.020 mm~0.060 mm
New 056501
(0.0008 in~0.0024 in)
Service limit 0.150 mm(0.0059 in)
1 Correct Position of the Piston Circlip
Piston ring( 2 )
0.020 mm~0.060 mm
New
(0.0008 in~0.0024 in)
Service limit 0.150 mm(0.0059 in)  2
Oil ring  1
0.030 mm~0.150 mm
New
(0.0012 in~0.0059 in)
Service limit 0.250 mm(0.0098 in)

Place the ring in the cylinder in the area

of 8-16mm(5/16-5/8in) from top of cylinder
when measuring the ring end gap.
Piston ring gap clearance 056502
Piston ring ( 1 )
1 Feeler Gauge 2 Piston
0.15 mm~0.30 mm
New
(0.006 in~0.012 in)
Service limit 1.50mm(0.059 in)
Piston ring ( 2 )
0.15 mm~0.30 mm
New
(0.006 in~0.012 in)
Service limit 1.50 mm(0.059 in)
Oil ring
0.20 mm~0.70 mm
New
(0.008 in~0.028 in)
Service limit 1.50 mm(0.059 in)
Note: In order to position the ring in the
cylinder correctly, use piston as a pusher.

Use feeler gauge to measure the open

clearance. If out of specification, replace
the rings and measure the cylinder bore.

05-65
CFMOTO
Ring Installation
Reverse the removal procedure for
installation. But pay attention to items
below.  1

 2
Note: First install spring and then rings
of oil scraper ring.  3

Install oil ring first, then piston ring (2) with

the mark “TOP” facing up, then piston ring
(1) with the mark “ATG” facing up.
056601
Warning: Ensure that top and second
Piston Piston
rings are not interchanged. 1 2 3 Oil Ring
Ring (1) Ring (2)
Note: Use a ring expander to prevent
breakage during installation. The oil ring  A
must be installed by hand.
 A  A
Check that rings rotate smoothly after
installation. Space the piston ring end gaps
apart greater than or equal to 120°, and
do not align the gaps with the piston pin
bore or the thrust side axis. (See picture
056602)  1

 2

056602
Don’t Align Ring Gap with Piston
1
Thrust Side Axis
Don’t Align Ring Gap with Piston Pin
2
Bore Axis
A 120° spacing

05-66
 5.3 Crankcase, Crankshaft and Gears
5.3 Crankcase, Crankshaft and Gears
5.3.1 Service Tool, Material and View.....................................................5-68
5.3.2 General..........................................................................................5-72
5.3.3 Drive Gear......................................................................................5-72
5.3.4 Timing Chain..................................................................................5-73
5.3.5 Timing Chain Tensioning Plate......................................................5-74
5.3.6 Crankcase.....................................................................................5-74
5.3.7 Crankshaft.....................................................................................5-78
5.3.8 Front Output Shaft.........................................................................5-85
5.3.9 Driven Bevel Gear..........................................................................5-87
5.3.10 Drive Bevel Gear..........................................................................5-89
5.3.11 Bevel Gear Washer Adjusting Washer..........................................5-91
5.3.12 Gearing System...........................................................................5-93

05-67
CFMOTO
5.3.1 Service Tool, Material and View

Service tool
Name P/N Page
Breather oil seal pressor 0800-011201-923-001 5-73
Breather gear shaft mounting tool 0800-011201-921-003 5-73
Bearing gear shaft pressor 0800-011201-921-001 5-73
Front shaft retainer wrench 0JWA-012000-922-005 5-76/77
Bearing 6205 removing tool 0JWA-012000-922-006 5-76
Front shaft oil seal 25×40×8 pressor 0JWA-012000-921-003 5-77
Bearing 6205 pressor 0JWA-012000-921-004 5-77
Crankshaft locking screw 0800-041000-922-001 5-80
Front shaft retainer wrench CF188-060008-922-001 5-86
Front output bearing seal pressor 0800-060000-923-001 5-86
Front output shaft pressor 0800-062301-923-001 5-86
Driven bevel gear nut sleeve 0800-062206-922-001 5-88
Oil seal pressor (Driven bevel gear) 0800-062204-923-001 5-88
Bearing 6305 pressor CF188-062103-921-002 5-88/90
Bearing 6207C3 pressor CF188-062201-921-003 5-88
Gear clearance measuring tool 0JWA-062000-922-001 5-91
Left crankcase bearing remover 0800-011000-922-001 5-96
Bearing 5206 removing tool 0800-012000-922-001 5-96
Oil seal SD15×25×5 pressor CF188-065002-923-001 5-103
Breather connector pressor 0JWA-065100-921-001 5-103
Bearing 6203 pressing rod 152MI-060002-921-002 5-105
Bearing 3206A pressing rod CF188-012100-921-004 5-105
Bearing 6303 pressor CF188-011100-921-004 5-105
Bearing 6203 pressor 1P39MB-012001-921-002 5-105
Service material
Name P/N Page
243 Thread locker 5-69/70/71/81/86/88
648 Cylinder locking glue 5-70/71/86/88
5-69/70/71/73/77/84/8
Oil
8/90/104/108

05-68
 5.3 Crankcase, Crankshaft and Gears

 9

10

 1

12

11

 2

 3

 8

 5
4

 7

 6 056901

1 Oil 5 Oil 9 10N·m(89 lbf·in)

2 Oil 6 See Assemble Steps 10 243 Thread Locker
3 243 Thread Locker 7 Oil 11 Oil
4 10N·m(89 lbf·in) 8 Oil 12 Refer to 05-84 for torque

05-69
CFMOTO

Enclosure

12 13 14
15
11

16

 8

10  9

 3
 7
 2
 1

 5  4
 6
057001

1 10N·m(89 lbf·in) 7 Oil 13 Oil

243 Thread Locker 3N·m
2 Oil 8 14 648 Cylinder Locking Glue
(27 lbf·in)
3 25N·m(18 lbf·ft) 9 Oil 15 243 Thread Locker 80N·m(59 lbf·ft)
4 Oil 10 10N·m(89 lbf·in) 16 Oil
5 10N·m(89 lbf·in) 11 25N·m(18 lbf·ft)
6 20N·m(15 lbf·ft) 12 10N·m(89 lbf·in)

05-70
 5.3 Crankcase, Crankshaft and Gears

Gear transmission
1

 2
 3

16  4

 5

15
 6

14

 7

13  8

 9

10

11
12 057101

1 55N·m(41 lbf·ft) 7 10N·m(89 lbf·in) 13 Oil

2 Oil 8 Oil 14 15N·m(11 lbf·ft)
3 648 Cylinder Locking Glue 9 Oil 15 145N·m(107 lbf·ft)
243 Thread Locker 243 Thread Locker
4 25N·m(18 lbf·ft) 10 16
80N·m(59 lbf·ft) 110N·m(81 lbf·ft)
5 Oil 11 648 Cylinder Locking Glue
6 32N·m(24 lbf·ft) 12 55N·m(41 lbf·ft)

05-71
CFMOTO
5.3.2 General
During assembly/installation,use the torque
value and serivce products as shown in
the exploded view(s).
Clean the screw before applying the thread
locker.

Warning: Torque Wrench Tightening

specifications must strictly be adhered to.
Locking devices(e.g.: lock ing tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc) must be replaced with new ones
where specified.

Note: Before disassembly, drain engin

oil and engine coolant.

5.3.3 Drive Gear  1

The drive gears are located on the MAG
side behind the magneto cover.
Removal
Remove:  2
-Magneto cover(refer to Mageneto Cover
Assy)
-Retainer ring No.10
-Magneto, driven gear  3
-Oil pump intermediate gear
-Breather intermediate gear
-Oil pump gear
-water pump gear  4
-Breather gear
057201
Inspection
Inspect oil pump inter gear/breather inter Oil Pump
1 Breather Gear 3
gear/oil pump gear for wear or other Intermediate Gear
damage, replace a new one if damaged. Breather
2 4 Oil Pump Gear
Breather Gear Intermediate Gear
The engine is equipped with a breather
gear in order to prevent engine oil coming
out though the breathing system into the
air box.
Inspect gear for wear or damage .
Check ball bearing for excessive play and
smooth operation .Replace breather gear
assembly if necessay
Installation
The installation is essentially the reverse
of the remove procedure, but pay attention
to the follow details:

05-72
 5.3 Crankcase, Crankshaft and Gears
1. Replace the oil seal of the breather
gear. 2. Adequately oil the ball bearing of
the breather gear. 3. All drive gears on the
same plane. 4.Replace the retainer ring
No.10
Service Tools: Breather Oil Seal Installer
0800-011201-923-001
Installation Jig,Breather Gear Shaft 0800-
011201-921-003
Press Tool,Breather Gear Shaft 0800-
011201-921-001
5.3.4 Timing Chain
The engine is equipped with two chains.  1
One is located on the magneto side. The
other is loacted on the CVT side.
Removal (MAG side)
 2
Remove: -Valve cover chaintensioner,
camshaft timing gear(refer to Intake
 3
Manifold, Cylinder Head and Cylnder) 057301
-Magneto, driven gear, oil pum
intermediate gear, breather intermediate Chain Timing Timing Chain
1 2 3
gear. -Timing chain guide and lower timing Tensioner Chain Guide
chain guide. Carefully pull the timing chain
sideward and down from the crankcase.
Note: Mark the operation direction of  1
the timing chain before removal.
Removal(CVT side)
Remove:-valve cover chain tensioner
and camshaft timing gear(refer to Intake
Manifold, Cylinder Head and Cylnder)
-CVT cover CVT drive gear CVT driven
gear. Belt
Note :Mark operation direction of the
belt
-CVT case-Timing chain guide and lower 057302
timing chain guide. Carefully pull the 1 Timing Chain
timing chain sideward and down from the
crankcase.
Note:Mark the operation direction of the
timing chain before removal.
Timing chain inspection
1.The two timing chain inspection way are
the same.2.Inspect the timing chain
clearance on sprocket.3.Inspect the timing
chain wearing4.If the chain wearing too
much or damaged. Replace the chain and
sprockets together.
Timing chain installation
Two timing chains installing in the same
way.

05-73
CFMOTO
The installation is essentially the reverse
of the remove procedure, but pay attention
to the follow details:
Note: Ensure performing proper valve
timing lock crankshaft(see Crankshaft )and
camshaft at TDC ignition(refer to Intake
Manifold, Cylinder Head and Cylinder
section). Install timing chain with camshaft
timing gear then, adjust chain tension
(refer to Intake Manifold, Cylinder Head
and Cylinder section).Loosen crankshaft,
turn 440 degree on clockwise direction
(from CVT side) and camshaft at TDC
ignition. Install timing chain with camshaft
timing gear then, adjust chain tension to
perform proper valve timing(refer to Intake
Manifold, Cylinder Head and Cylinder
 2
section).
Warning: Improper valve timing will  1
damage engine components. 057401
5.3.5 Timing Chain Tensioner
Removal 1 Chain Tensioner 2 Screw
Refer to TIMING CHAIN above.
Inspection
Check timing chain tensioner for wear,
cracks or other damage, replace if
necessary.
Installation
The installaiton is the reverse of the
 2
removal procedure.
5.3.6 Crankcase
Note: Before disassembly, drain engin
oil and engine coolant.  1
Crankcase Disassembly
Note: Before splitting the crankcase, 057402
measure crankshaft axial play(refer to
Crankshaft). 1 Start Motor 2 Bolt
Remove: -Front drive shaft, ring gear(refer
to Front Drive Shaft, Ring Gear)
-CVT cover, CVT, belt, CVT air guide and
clutch(refer to CVT and Clutch)
-Start motor
-Left crankcase cover(refer to Left
Crankcase Cover)
-Drive gears(refer to Drive Gears)
Note: Oil pump removal from crankcase
is not necessary, but recommended to see
the condition of oil pump.

05-74
 5.3 Crankcase, Crankshaft and Gears
-Electric starter drive gear(refer to Starting
System)  1
 1  2
-Oil filter(refer to Lubrication System)
-Cylinder head and cylinder (refer to Intake
Manifold, Cylinder Head and Cylinder)
-Timing chain, tensioner and guide(refer to  6
Timing Chain,Tensioner and Guide)
Remove all bolts of crankcase(see pic  2
057501 and 057502).  5
 4
 3

 1
057501
11 Bolts 1 Bolts 3 Bolts
1 3 5
M6×45 M6×55 M6×75
4 Bolts 1 Bolts 1 Bolts
2 4 6
M8×60 M8×106 M8×73

 2
 7

 5  8
057502
7 3 Bolts M6×105 8 2 Bolts M8×50
Carefully split crankcase halves with a soft
hammer.

Note: During disassembly, do not

damage the sealing surface of the  1
crankcase halves.

Pull crankshaft out of crankcase. Do not

damaged the bearing.

057503
1 Soft Hammer

05-75
CFMOTO
Remove front output shaft bearing retainer,
the bearing and oil seal. Bearing retainer
and bearing need special tools.
Special tool:  2  1
Bearing retainer wrench  3
0JWA-012000-922-005
Bearing 6205 removing tool
0JWA-012000-922-006

Note: If the oil seal and bearing are not

damaged, do not remove them off. 057601
Bearing Antifriction
1 2 3 Oil Seal
Retainer Bearing
Crankcase Cleaning
 4
Warning: Use safety goggles to avoid
 3
eye injuries.

Use cleaning tool to clean the crankcase.

Use compressed air to dry the crankcase.  2
Use compressed air to clean up the
lubrication line.
Crankcase Inspection
Check crankcase halves for cracks or  1
other damage. Replace if necessary.
Check plain bearing for scoring or other
damages. 057602

Note: Measure plain bearing inside Crankshaft Locking Slide

1 3
diameter and compare to magneto and Plate Bearing
CVT side journal diameter of crankshaft 2 Bearing Inner Diameter 4 Oil Hole
(refer to Crankshaft). Replace if the
measurements are out of specification.

Bearing inner diameter(CVT/

MAG)
Service 42.100mm(1.6575in)
limit

05-76
 5.3 Crankcase, Crankshaft and Gears
The installation of front output shaft oil
seal, bearing and retainer installation is the
reverse of removal procedure. Use special
 2  1
tool to install the oil seal, bearing and  3
retainer.

Note: Oil specification sign should face

to bearing.

Tool:
Oil seal 25*40*8 pressor 057701
0JWA-012000-921-003 Bearing Antifriction
Bearing 6205 pressor 1 2 3 Oil seal
Retainer Bearing
0JWA-012000-921-004
Retainer install/remove wrench
0JWA-012000-922-005
Crankcase Installation  3
Reverse the removal procedure for
13  2 15
installation. But pay attention to the detail  8  1
below:
Clean the oil line. Make sure it isn't 11
18
jammed. 12
Clean all the metal parts.  4
 6
Clean all the closed surface up.  7
 5
Crankcase washer must be replaced.
Cover the engine oil on bearing when
assembling the crankshaft.
 9 16 19 14 17 10 057702
Warning: Assemble the crankshaft in the
right way(See Crankshaft).

Tight up the locking bolt following the 20

orders on pic 057702, 057703.

24
22
26
23 21
25 057703

05-77
CFMOTO
5.3.7 Crankshaft  1

 2

Crankshaft Locking Procedure 057801

1 Crankshaft 2 Crankcase RH
Note: When crankshaft is locked, rear
cylinder(Cylinder No.2 ) is at TDC ignition.
Crankshaft cannot locked at TDC of front
cylinder(Cylinder No. 1)

Remove:
-Spark plug cable and spark plugs of both  3
cylinders
-Valve covers of both cylinders
-Plug cover and gasket of plug cover

 1
 2
057802
1 Screws 2 Gasket 3 Plug Cover

05-78
 5.3 Crankcase, Crankshaft and Gears
-CPS
 1

 2

057901
1 Bolt 2 CPS

-Bolt and sealing washer

 3
 2

 1

057902
Crankcase LH, Sealing
1 2 Bolt 3
Front Side Washer

Use 18mm sleeve to turn the crankshaft to

the TDC of cylinder 2.

 1

057903
1 18mm Sleeve

05-79
CFMOTO
When piston of rear cylinder is at TDC,
Marks on magneto flywheel and magneto
cover are aligned.
 1

 3

 2

058001

Mark“2” on Notch on
CPS
1 Magneto 2 3 Magneto
Location
Flywheel Cover

Use screwdriver to check if V-type groove

of crankshaft balancer is aligned with the  1
hole.

058002
1 Screwdriver

Lock crankshaft with crankshaft locking

bolt(P/N: 0800-041000-922-001).

 1

058003
Crankshaft Locking Screw
1
(P/N:0800-041000-922-001)

05-80
 5.3 Crankcase, Crankshaft and Gears
Crankshaft Removal
Refer to Crankcase.
Crankshaft Inspection

Note: Check each bearing journal of

crankshaft for scoring, scuffing, cracks or
other signs of wear.

Note: Replace the crankshaft if the

gears are worn or otherwise damaged.
 1
Warning: Components with less than the
service limit always have to be replaced. 058101
Otherwise servere damage may be caused 1 Timing Sprokcet (Gear) of Crankshaft
to the engine.

Crankshaft Axial Play  3

Note: Axial play of crankshaft needs  1

to be measured before splitting the
crankcase.
Use dial gauge to measure crankshaft
axial play at MAG side.

 2  1
Crankshaft axial play
0.150mm~0.540mm
New
(0.006in~0.021in)
Service 058102
0.64mm(0.025in)
limit
Connecting
If the clearance is out of standard. The 1 2 Crankshaft 3 Gauge
Rod
clearnace plate and crankshaft needs
replaced.(The clearance plate locking
screw must be covered with 243 thread
locker. Tighten torque: 3N·m)
Connecting Rod Big End Axial Play
Using a feeler gauge, measure the distance
between butting face of connecting rods
and crankshaft counterweight. Replace the
crankshaft if out of standard
Connecting Rod Big End Axial Play
0.300mm~0.560mm
New
(0.012in~0.022in)
Service limit 0.8mm(0.031in)

05-81
CFMOTO
Connecting Rod/Piston Pin Clearance
Refer to Intake Manifold, Cylinder Head
and Cylinder.  1
Connecting Rod Big End Radial Play
 3
Note: Make sure the same marking of
connecting rod to assemble together, do
not mix it and exchange between cylinder
 2
1 and cylinder 2.
Remove connecting rod from crankshaft. 058201

Warning: If remove the connecting rod Connecting Plain Connecting

1 2 3
bolt, replace the bearing when assemble Rod Bearing Rod Screws
back.

Measure the diameter of crankpin and

compare to inside diameter of connecting  1
rod big end.
Assemble the bearing back like original.
Assemble the connecting rod and follow
the tighten torque on page 5-84 then
 2
measure the big end inner diameter.
058202
Connecting
1 Crankshaft 2
Joint Diameter

Connecting joint diameter

43.930mm~43.950mm
New  A
(1.7295in~1.7303 in)
Service limit 43.915mm(1.7290 in)
Connecting rod big end inner diameter
Service limit 44.03mm(1.7335 in) 058203
Connecting rod big end axial clearance A Connecting Rod Big End Innerdiameter
Service limit 0.09mm(0.0035 in)

05-82
 5.3 Crankcase, Crankshaft and Gears
Crankshaft Joint Clearance
Main Joint Clearance
 2  3  4
Measure the main joint diameter and
compare with
the bearing inner diameter(see Crankcase
chapter).
Crankshaft main joint clearance(CVT/
MAG side)
 1
41.960mm~41.970mm 058301
New
(1.652in~1.6524 in) CVT side main
Service limit 41.935 mm(1.651 in) 1 Crankshaf 3
joint diameter
Crankshaft main jo int a xial cleara CVT case joint MAG side main
2 4
nce(CVT/MAG sid e) diameter joint diameter
Service limit 0.09mm (0.0035in)

CVT Case Joint Clearance

Measure the CVT joint diameter on CVT
case. Com-pare with the CVT case inner
bearing diameter(see CVT Case chapter).

CVT joint diameter on crankshaft

31.960mm~31.970mm
New
(1.2583in~1.2587 in)
Service limit 31.940 mm(1.2575 in)
CVT case axial clearance to crankshaft
Service limit 0.10mm(0.0039in)

05-83
CFMOTO
 1
Note: Follow the table below to
assemble crankshaft, connecting rod and
connecting rod plain bearing.

Inside
Bearing of  3
diameter of
Crank pin connecting
connecting
rod
rod big end
Ι Black  2 058401
A
‫װ‬ Blue Nose of Plain Bearing in Line with
Ι Red 1
B Connecting Rod Groove
‫װ‬ Black 2 Split Surface of the Connecting Rod
Cranksahft assembly procedure is the Half Plain Bearing of Connecting Rod
reverse of disassembly procedure. 3
Big End
However, the following details should be
noted:
When inside diameter of connecting rod
big end is less than service limit, replace  3
with a new connecting rod bearing.
After installing bearing into big end of  1
connecting rod, use compressed air to
clean connecting rod split surface.

Note: Oil inner surface of connecting rod

plain bearing and crankshaft pin surface
before installation.

There is an oil passage plug at CFMOTO

logo side of cylinder 1 and cylinder 2  2 058402
connecting rod.
S c r e w o f c on n e cti ng ro d sho u ld be Mark A
Plug of Oil
tightened by following methods. 0JYO or B on
1 2 3 Passage
Logo Connecting
Shaft

-Firstly torque to 10N·m(7.5 lbf·ft). DO

NOT apply threadlocker.
-Then torque to 20N·m(15 lbf·ft).
-Finally torque to 60N·m(35.25 lbf·ft).
 1

058403
1 Torque Wrench

05-84
 5.3 Crankcase, Crankshaft and Gears

Warinng: Improper installation will cause  1

screw looseness and engine damage.  3

Note: Bearing of connecting rod big end

and piston pin rotation cannot be changed

Crankshaft Installation
The procedure of crankshaft installation  2
is the reverse of removal, but following
detailes should be cared. Do not mix
connecting rod of cylinder No.1 and No.2 058501

Warinng: Do not damage plain bearing 1 Crankcase RH

of crankcase when installing crankshaft 2 Connecting Rod of Cylinder No.2
(together with connecting rod).
3 Connecting Rod of Cylinder No.1
Note: Before installation of camshaft
and valve rocker arm, do not forget to
install locking bolt to make sure crankshaft
on top dead position.

5.3.8 Engine Front Output Shaft

Removal the Engine Front Output Shaft
Remove the bolt, washer, front collar,O-
ring, oil seal and bearing retainer(Counter
clockwise).
Remove front output shaft
 7
 6
 5
 4
 3
 2
 1
058502
Front
1 Bolt 4 Oil Seal 7 Output
Shaft
2 Washer 5 O-ring
Bearing
3 Front Collar 6 Retainer
(Clockwise)

05-85
CFMOTO
Inspection the Engine Front Output Shaft
Inspect the bearing to see if it can work
smoothly or have other wearing. Replace
the part if necessary.  1
Installation the Engine Front Output Shaft
Reverse the removal procedure for
installation.But pay attention to details
below:
When installing front output shaft, cover  2
the 648 cyl-inder locking glue on bearing
 3
surface(See pic on right). Do not cover on 058601
spline.
Cover 243 thread locker on bearing Cover 648
retainer(Counterclockwise). Use special Front Output Cylinder
1 2 3 Bearing
tool to tight up in special torque. Shaft Locker
Tighten torque 80N·m Position
Replace the oil-seal with grease on the lip.
Tool:
Bearing 6205 pressor
CF188-062301-921-001
Bearing retainer wrench
CF188-060008-922-001
Oil seal pressor
0800-060000-923-001
Front output shaft pressor
0800-062301-923-001

05-86
 5.3 Crankcase, Crankshaft and Gears
5.3.9 Driven Bevel Gear
Removal the Driven bevel gear
Remove rear output sleeve mounting bolt.
Remove the washer and sleeve  6
Remove driven bevel gear mounting bolt.
Remove the speed sensor, gear and gear
adjusting washer.
Remove O-ring and oil seal.  3
 2
 1

 9  8  7  6  5  4 058701

Rear Output
Sleeve Speed
1 4 Oil Seal 7
Mounting Sensor
Bolt
Driven
2 Washer 5 O-ring 8 Bevel
Gear
Driven
Bevel
Rear Output Adjusting
3 6 Gear 9
Sleeve Washer
Bearing
Use suitable protection for bevel gear end. Bolt
Hold the bevel gear bearing seat and press
the gear out.

 1

 2

 3
058702
Driven
Bevel Gear
1 Sleeve 2 3 Bevel
Bearing Seat
Gear

05-87
CFMOTO
Use bench vice to fix bearing carrier, then
remove bearing and use special wrench
(0800-062206-922-001) to remove thrust
nut, finally remove bearing.
Gear Inspection
Inspect gear for any surface damage,
wear. Replcae the drive and driven gears
together if necessary.  1
Inspect bearing for operation condition.
Replace the part if any trouble inspected.
Otherwise, no need to remove.
Gear Installation  2
Installation procedure is the reverse of
removal procedure. Pay attention to the
details:
Use oil seal 058801
installer(0800-062204-923-001) to install Driven Bevel Gear Limiting But Socket
NEW oil seal and O-ring. 1
(P/N:0800-062206-922-001)
When replacing the right crankcase, ring 2 Driven Bevel Gear Bearing Seat
gear or bearing seat,the adjustment shiim
should be adjusted again(see Bevel Gear
Clearance Adjustment)
 3  1

Cover the 648 cylinder locking glue

between gear and bearing surface when
assembly(see right pic). Do not cover
on spline. O-ring should be cover with
engine oil. Oil seal lip must be covered
with grease. Bearing locking nut should be
covered with 243 thread locker. And tight  2
up in specific torque with special tool.
Tighten torque: 110N·m 058802
Tool:
Bearing 6305 pressor CF188-062103- Cover 648
Bevel Gear
921-002 Bearing 6207C3 pressor CF188- Bevel Cylinder
1 Bearing 2 3
062201-921-003 Gear Locking Glue
Seat
Position

05-88
 5.3 Crankcase, Crankshaft and Gears
5.3.10 Drive Bevel Gear
Removal  2
Separate left and right crankcase(see
Crankcase)
Remove drive bevel gear bearing seat bolt.
Remove drive bevel gear
Remove drive bevel gear shaft retainer and
output driven gear.
 1
058901
1 Bolt 2 Drive Bevel Gear

 1
Remove the retainer on the drive bevel
gear shaft and remove output driven bevel
gear.

 2

058902
1 Output driven bevel gear 2 Retainer

put the drive bevel gear on the drive bevel

gear on the drive bevel gear stopping tool
(0JYA-062100-922-003)  2
 1
Loosen drive bevel gear nut with bevel gear
lock nut sleeve B(0JYA-062100-922-002)
Then remove the drive bevel gear and
adjusting washers.  3

058903

1 Drive bevel gear seat

Bevel gear lock nut sleeve B
2
(P/N:0JYA-062100-922-002)
Drive bevel gear stopping tool
3
(P/N:0JYA-062100-922-003)

05-89
CFMOTO
Drive bevel gear inspection 11
Inspect drive bevel gear and output driven
gear teeth for rusting, scratches, wear.
Replace if necessary. 10
Inspect if bearing turns freely and smoothly
Replace if necessary.  9
When replacing any of crankcase, drive
pinion gear and drive pinion gear carrier,  8
the adjustment shim should be readjusted.
Refer to the content further.  7
 1
Drive bevel gear installation  6
Reverse the removal procedure for  5
installation.Oil bearing and tighten nut to  4
sepecified torque.
Tightening Torque:145N·m  3  2
Tool:
059001
Bearing 6305 pressor CF188-062103-921-
002 Adjusting
1 Retainer 5 Bolt 9
Nut
Drive
Output
2 6 Bearing 10 Bevel
Driven Gear
Gear
Drive
Drive Bevel Bearing
3 7 11 Bevel
Gear Plate
Gear Nut
Drive Bevel
4 Bearing 8 Screw
Seat

05-90
 5.3 Crankcase, Crankshaft and Gears

5.3.11 Shim Adjustment Procedure

When crankcase and/or drive pinion gear
and/or ring gear and/or bearing carrier are
replaced, the shim must be adjusted.

Warning: Both gear backlash and tooth

contact should be in specification.  3

Bevel Gear Clearance  2

Install the drive and driven bevel gear on
the crankcase. Set the gasket and close
the case . Then lock the case with several  1
059101
bolts. Use a screw driver to go through the
sealing cap mounting hole and insert into Crankcase Screw Sealing Cap
1 2 3
drive bevel bearing seat hole. Lock the LH Driver Mounting Hole
driven bevel gear.
Install bevel gear clearance measuring tool
(0JWA-062000-922-001) and dial gauge.
Turn the drive and driven bevel gear to
 3
measure the clearance.

Note: Test 4 points in vertical direction.

If side clearance is not in standard, please

adjust the thickness of adjusting shim and
test the clearance again and again until  1
the clearance is up to standard. Bevel gear
clearance: 0.1mm~0.2mm  2 059102
Adjusting method
Measure Adjusting shim 1 46mm (1.81in)
clearance thickness Gear Clearance Measuring Tool (P/N:
2
<0.1mm Get thicker 0JWA-062000-922-001)
0.1mm~0.2mm OK 3 Dial Gauge
>0.2mm Get thinner

05-91
CFMOTO
Tooth Contact  1
After backlash adjustment is carried out,
the tooth contact must be checked. Pay
attention to the following procedures:
Remove ring gear from crankcase.
Clean and degrease drive pinion gear and
ring gear teeth.
Apply a coating of machinist’s layout dye
or paste to several teeth of the driven gear; 059201
Install ring gear.
Rotate the ring gear several turns in both
directions. Remove drive pinion gear and  2
ring gear, then inspect the the coated teeth
of the drive pinion gear.The tooth contact
pattern should be as shown below;
Contact at tooth
Pattern 1 Incorrect
top
Contact at tooth
Pattern 2 Correct
middle
Contact at tooth
Pattern 3 Incorrect 059202
root
If gear tooth contact is found to be correct
(pattern 2), continue the next step.
If gear tooth contact is found to be  3
incorrect (pattern 1 and 3), the shim
thickness between the drive pinion gear
and ring gear must be changed and the
tooth contact re-checked until correct.

Note: Clean the dye coated on the gear

teeth after the tooth contact adjustment is
finished. 059203

Adjustment Steps
Tooth contact Shim adjustment
Tooth contact Reduce shim
pattern 1 thickness
Tooth contact Increase shim
pattern 3 thickness

Warning: Make sure to check the

backlash after the tooth contact has been
adjusted, since it may have changed.
Adjust the tooth contact and backlash until
they are both within specification. If the
correct tooth contact cannot be maintained
when adjusting the backlash, replace the
drive gear and ring gear.

05-92
 5.3 Crankcase, Crankshaft and Gears
5.3.12 Gearing System
Gearing Sector Gears Removal
Remove shift lever cover screws.
Remove shift lever cover and gasket.

 1

 2

 3

059301
Shift Lever Shift Lever
1 2 3 Screws
Gasket Cover

Remove driven shift sector gear assembly.

Remove drive shift sector gear assembly.

 3
 1

 2

059302
Driven Shift
Drive Shift
Sector
1 2 Screw 3 Sector Gear
Gear
Assembly
Assembly

05-93
CFMOTO
Mainshaft, Secondary Shaft, Shifting
Drum, Fork/Fork shaft Removal
Remove gearing locking sprint seat.
Take out spring and steel ball.

 6  5  4  3  2  1
059401
Steel
1 3 Washer 5 Washer
Ball
Spring Shifting Shifting
2 4 6
Locking Bolt Spring Seat
Split crankcase(see Crankcase).
Remove gearshift driven shaft washer,
driven low range gear.
 1

 2

Remove drive bevel gear.

 3

059402
Driven Drive Bevel
1 Washer 2 3
Low Gear Gear

05-94
 5.3 Crankcase, Crankshaft and Gears
Set the gear to low gear to remove the
main shaft.

 1

059501
1 Main Shaft

Remove gearshift driven shaft assy, shift

drum, shift forks, parking lock lever;  1

 2
 4

 3

059502

1 Shift Drum 3 Parking Lock Lever

2 Shift Fork 4 Driven Shaft Assy

05-95
CFMOTO
Reverse Intermediate Gear Removal  4  5
 3
Note: If reverse intermediate gear and  1
needle bearing turn freely and smoothly,
and clearance of them is normal, no need
to remove them.

Use retainer plier to remove the retainer.  2

And remove the washer, reverse
intermediate gear, needle bear-ing and
washer in orders.
059601
Reverse Intermediate
1 Retainer 3
Gear
2 Washer 4 Needle Bearing
5 Intermediate Gear Shaft

Bearing Removal in Crankcase

If necessary, heat crankcase up to 100ºC
(212 F) for easier bearing removal.

Warning: Clean oil outside and inside

crankcase before heating.

Warning: Always support crankcase

properly when bearing is removed.  1
Crankcase damages may occur if this
procedure is not performed correctly.
 2
To remove ball bearing in crankcase, use a
blind hole bearing puller
059602
Tool:
Crankcase bearing removing tool 0800- Crankcase LH bearing removing tool
1
011000-922-001 (P/N: 0800-011000-922-001)
Bearing 5206 removing tool 0800-012000- 2 Ball Bearing 6303
922-001

05-96
 5.3 Crankcase, Crankshaft and Gears
Inspection
Always verify for the following when
inspecting components in crankcase:
-gear teeth damage
-worn or scoured bearing surface
-excessively worn, scoured or bent shift
fork  2
-excessively worn, scoured or bent shift
fork shaft
-rounded engagament dogs and slots
-excessively worn, scoured parking lock  1
lever
-worn shift fork engagement pins
-worn shift track on shift drum 059701
-worn or scoured shift fork claw
-worn splines on shafts and gears 1 Bearing 2 Inner Rotor Ring
-excessively worn and scoured parking
cam  1
Bearing
Check if bearing turns freely and smoothly.
If any binding or abnormal noise has been
found, replace it with a new one.
Shift Fork/Shaft
Check both shift forks for excessice wear.
Check shift fork claw for bending.
Measure shift fork claw thickness.
Shifting fork (Left, right fork )
5.8mm~5.9mm
New
(0.228in~0.232in)
Service
5.7mm(0.224in)
limit

059702
1 Shifting Fork Thickness

05-97
CFMOTO
Measure shift fork pins.
Shifting fork diameter (Left and right fork)
5.8mm~5.9mm
New  1
(0.228in~0.232in)
Service
5.7mm(0.224in)
limit

059801
1 Frok Pin Diameter
Fit shift fork onto the shift fork shaft, then
move the shaft as illustrated. Check if shift
fork slides smoothly. Replace if necessary.

059802

Place shift fork shaft on a level surface and

roll it. If any bending has been found,
replace it with a new one.

Warning: Do not try to correct the bend

shift fork pin.

059803
Schematic Diagram

05-98
 5.3 Crankcase, Crankshaft and Gears
Inspect shift fork springs for damages.
Replace if necessary.
 2

 1
059901
1 Thin Fork Spring (Free Length 114mm)
2 Rough Fork Sprint (Free length 82mm)

Shift Drum
Inspect shift drum tracks for excessive
wear and other damages.
Inspect parking lock cam on shift drum
for excessive wear and other damages.  3
Replace if necessary. Inspect limit washer
for damages.  1
Replace if necessary.

 2
059902
Limit Parking
1 2 3 Shifting Drum
Washer Cam

05-99
CFMOTO
Parking Lever
Inspect the lever for cracks or other
damage.  1

0510001
1 Parking Lever
Shifting Main Shaft
Check gearshift main shaft for damages.
Check gear teeth of gearshift main shaft
for pittings, scuffing and excessive wear.  2  1 0510002
Replace if necessary.
Measure main shaft neck diameter of two 1 CVT Side Diameter (Less than 35mm)
ends as shown. If the meassurements are 2 MAG Side Diameter
less than the service limit, replace it.
Shifting main shaft diameter
Service limit
MAG side 16.978mm(0.6684in)
CVT side 29.97mm(1.18in)

05-100
 5.3 Crankcase, Crankshaft and Gears
Gearshift Driven Shaft Assy
Disassemble gearshift driven shaft assy as
shown.  1
Check teeth of each gear for fittings,  2
scuffing and excessive wear. Check needle  3
bearing and circlip for wear and damages.  6  3
Replace if necessary.  4
 5
 6
 3  6
 6
12  7
 8
11
10  9
0510101
Shifting
Driven
Washer
1 5 Slide
9 Output
17.5×32×1
Sleeve
Shaft
Driven
Driven Low Retainer
2 6 10 Reverse
Gear 29
Gear
Driven
Needle Retainer
3 7 High 11
Bearing 29
Gear
Washer Driven Parking
Gear 4 8 12
24.5×33.5×1 Shaft Gear

Note: Gears must be replaced in pair.

Always replace circlip after removal.

-driven shaft output gear for reverse gear

shifting  1
-gearshift sliding sleeve for high and
low gear shifting. Measure the width for
engegement of shift fork. If the width is out
of specification, replace the gear.
The width for engegement of shift fork on
the gear should be the same with the one
on the sliding sleeve.
Shifting groove width
6.1mm~6.2mm
New
(0.240in~0.244in)
Service limit 6.3mm(0.248in)

0510102
1 Groove Width

05-101
CFMOTO
Inspect reverse driven gear, high range
gear, low range gear for damages.
Measure the gear inner diameter, if it’s out
of specification, replace the gear.  A
The inner diameter of reverse driven gear,
high range gear, low range gear are the
same.
Gear inner diameter
29mm~29.021mm
New
(1.1417in~1.1426in)
Service limit 29.025mm(1.1427in)
0510201
A .Gear Inner Diameter
Driven Shaft
Check driven shaft for damages.
Check driven shaft for pittings, scouring
and excessive wear. Replace if necessary.
Measure driven shaft neck diameter, if it’s  A  B  B  B  A
out of specification, replace it.
Driven s haft
Service limit
A 16.978mm(0.6684in)
B 23.974mm(0.9439in)

0510202

Reverse Intermediate Gear

Check reverse intermediate gear for
damages. Measure the inner diameter. If
it’s out of specifiacation, replace it.
Reverse inter gear inner diameter  A
29.007mm~29.028mm
New
(1.1420in~1.1428in)  1
Service limit 29.032mm(1.1430in)

0510203
Reverse Intermediate Gear Inner
1 A
Gear Inner Diameter Diameter

05-102
 5.3 Crankcase, Crankshaft and Gears
Reverse Intermediate Gear Shaft
Check reverse intermediate gear for
damages. Measure reverse intermediate  1
gear shaft neck diameter. If it’s out of
specification, replace it.
Reverse intermediate gear shaft
diameter  2  A
24.980mm~24.993mm
New
(0.9835in~0.984in)
Service
24.974mm(0.9832in) 0510301
limit

Reverse
Note:When press to install reverse Reverse
Intermediate
intermediate gear shaft ,align oil groove 2 1 Intermediate A
Gear Shaft Neck
and case groove. Gear Shaft
Diameter
Note:Check reverse intermediate gear
2 Oil groove
and needle bearing for free play. If the
clearance is okay, it is not necessary to
disassemble.

 3

Shifting Sectors
Inspect the shifting room cover to see if it  2
gets cracks or other damage. Inspect the
breather connector to see if it gets loosen
and oil seal damage. Replace the part if  1
necessary. 0510302
Tool: Shifting
Breather Oil Seal
Oil seal SD15×25×5 pressor 1 Room 2 3
Connector SD15×25×5
CF188-065002-923-001 Cover
Breather connector pressor
0JWA-065100-921-001

05-103
CFMOTO
Check drive shift sector gear and driven
shift sector for cracks, deformation,wear  1
and other damages. Replace if necessary.

 2
0510401
Drive Shift Sector Driven Shift
1 2
Gear Sector Gear

Assembly
Reverse the removal procedure for
installation. Pay attention to the item
below:
Always use a new circlip. Pay attention to
the direction when installing a new circlip.
Perform the installation as illustrated.
Lightly oil gears and shafts before
assembly.

 1 0510402
Warning: Once circlip is removed, it has
been damaged. Therefore, never use it for 1 Round corner side
a second time.

When installing a new circlip, do not open  7

the circlip too much.
After circlip installation is finished, make
 6
sure the circlip is in place.
 5
When installing shift fork shaft, ensure shift
forks and shift fork springs are in correct
locations as illustrated.
 4
 3

 2

 1
0510403
Shift Fork Shift Fork Spring
1 4 7
Shaft Spring(thin) Seat
2 Circlip 12 5 Right Shift Fork
Left Shift Shift Fork
3 6
Fork Spring(thick)

05-104
 5.3 Crankcase, Crankshaft and Gears
Installation
Crankcase installation procedure is the
reverse the removal procedure. However,
pay attention to the following details:  5
Do not use a hammer to install ball bearing
unless its structure is special. Only use a
press tool to install a bearing.
If necessary, heat crankcase up to 100ºC
before install the bearing.
 2  3  2  1
Warning: Clean oil, inside and outside,  4
from crankcase before heating.

Put a new ball bearing in an icebox or

0510501
equivalent facility to chill for 10 minutes
before installation.
Use sevice tool to install the ball bearings
in left crankcase and right crankcase. 1 Retainer 3 Reverse Intermediate Gear
2 Washer 4 Needle Bearing
Note: Always support crankcase 5 Boss on Reverse Intermediate Gear
properly when installing ball bearings.

Perform the correct procedure when

installing a new oil seal(refer to Oil Seal
Installation above).
Tool:
Bearing 6203 push rod
152MI-060002-921-002 Bearing 3206A
push rod
CF188-012100-921-004
Bearing 6303 pressor
CF188-011100-921-004
Bearing 6203 pressor
1P39MB-012001-921-002

Other Parts in Crankcase

Reverse the removal propcedure for
installation to in-stall the reverse
intermediate gear.

Note: The boss of the intermediate

gear should be face inside by following the
drawing on the right.

05-105
CFMOTO

Note: Press bearing No.2 before

installing reverse intermediate gear.
 1

 2

 3

0510601
1 Reverse Intermediate Gear
2 Bearing 3 Left Crankcase

Place parking lever in place in crankcase.

Engage shift fork assy with gearshift driven
shaft assy, then fit them in place in left
crankcase.

Note: Do not install the washer

17.5×32×1 and driven low gear.

 1
 3

 2

0510602
Driven Parking Shift Fork
1 2 3
Shaft Assy Lever Assy

05-106
 5.3 Crankcase, Crankshaft and Gears
Install the drive bevel gear and tight up 4
mounting bolts.

Note: When assembling the drive bevel

gear, the small hole(3) position should
follow the drawing on the right.

 3

 1

 2
0510701
1 Bolt 2 Drive bevel gear 3 Small hole

Turn the parking rocker arm into parking

position and align the shifting drum to
shifting fork pin. Then install the shifting  1
drum on left crankcase.

 2

0510702
1 Shift Drum 2 Axial Track

05-107
CFMOTO
Use an appropriate tool to shift to low
range, then install gearshift main shaft.
Install the low range gear and washer  3
17.5×32×1.  1
Use an appropriate tool to shift to neutral
range.  2
Turn main shaft, check if gears rotate
freely and smoothly.

NOTE: When installing rotational parts,

equally apply oil to shaft necks.

0510801

Main Driven Low Washer

1 2 3
Shaft Gear 17.5×32×1

Install a new crankcase gasket.  1

Note: Always use a new crankcase after

splitting crankcase.

Place the right crankcase on the left

crankcase. Install screws and torque to
specifications.

Warning: Do not turn shift drum before

shift lever installation is completed.
0510802
1 Crankcase Gasket

05-108
 5.3 Crankcase, Crankshaft and Gears
Install shifting drive and driven sector
gears.
Tight up the mounting bolt in standard for
shifting drive and driven sectors.
 3
 3
Note: When installing driven shift lever
assy and drive shift lever assy, the marks
on their teeth should be aligned as shown  1
on the right drawings.

 2

 4
 3
0510901
1 Bolt 3 Mark
Shift Driven Shift Drive
2 4
Sector Gear Sector Gear
Install the shifting room gasket and cover.
Install the shifting room mounting screws
and tight up in special torque in criss cross
way.
Install other related part back.

 1

 2

 3

0510902
Shift
Shift Lever
1 2 Lever 3 Screws
Cover Gasket
Cover

05-109
CFMOTO
5.4 CVT Drive
5.4.1 Service Tools, Material and View .................................................5-111
5.4.2 General  ........................................................................................5-113
5.4.3 CVT Cover ...................................................................................5-114
5.4.4 Drive Pulley, Driven Pulley and Belt  ............................................5-115
5.4.5 CVT Case ....................................................................................5-125

05-110
 5.4 CVT drive

5.4.1 Service Tools, Material and View

Service Tools
Name P/N Page
Drive pulley locking wrench 0JY0-051000-922-001 5-115/124
Drive pulley removing tool 0JY0-050000-922-002 5-116
CVT driven pulley locking wrench 0800-052000-922-001 5-116/124
Driven pulley disassemble tool 0800-052000-922-002 5-120
Driven pulley seperator 0800-052000-922-003 5-124
Oil seal 32×55×10 pressor 0JY0-013103-921-001 5-126

Service Material
Name P/N Page
Oil 5-112/127
648 locking glue 5-112

05-111
CFMOTO
CVT(Exploded View)

T2

Cylinder locking
glue
Oil
Counter
clockwise
T3

Counter
clockwise
T1 T4

T5

0511201

T1 10N•m(89 lbf•in)
T2 7N•m(62 lbf•in)
T3 60N•m(44 lbf•ft)
T4 180N•m(132.8 lbf•ft)
T5 150N•m(110.6lbf•ft)

05-112
 5.4 CVT drive

5.4.2 General

Note: For a better understanding, the following illustrations are shown with engine
out of vehicle. To perform some instructions, it is not necessary to remove the engine.
During assembly/installation, use the torque values and service products as in the
exploded views. Clean threads before applying a threadlocker.

Warning
Torque wrench tightening specifications must strictly be adhered to. Locking devices
(e.g.: locking tabs, lock nuts,cotter pin,etc.) must be replaced with new ones.

Warning
Never touch CVT while the engine is running. Never drive the vehicle when CVT cover
is removed.

Warning
Any drive pulley repairs must be performed by an authorized CFMOTO dealer.
Subcomponent installation and assembly tolerances require strict adherence to the
procedures detailed.

Warning: Never use any type of impact wrench for drive pulley removal and
installation.

05-113
CFMOTO
5.4.3 CVT Cover

 3

 1
 2 0511401
Tighten CVT CVT
1 2 3
Bolt Cover Case

CVT Cover Removal

Remove CVT cover mounting bolts.
Remove CVT cover.
Remove CVT cover gasket.

 1
 3
 2
0511401
CVT CVT Cover
1 2 Bolts 3
Cover Gasket

05-114
 5.4 CVT drive
CVT Cover Assy Inspection  5  1
Inspect the CVT assy to see if it has  7
cracks. Replace the cover if damaged.
If CVT cover seal has aging or other
damage, replace the seal.
Check the heat insulation screws for being
loose. Replace the CVT case cover if any
are found.  3
Check the heat insulation for wear.
Replace the CVT case cover and heat  4
 2  6
insulation if damaged. 0511501

Insulating
1 CVT Case Cover 5
sponge (2)
CVT Cover Installation
Sealing Ring, CVT Rear Heat
2 6
Case Cover Insulation
Reverse the removal procedures for CVT
cover installation. Front Heat
3 Screw (QTY:9) 7
Insulation
Insulating sponge
4
Note: Locking bolts should be tightened (1)
in criss-cross procedure.

 2

 1
5.4.4 Drive Pulley, Driven Pulley,
Drive Belt

Removal

Remove CVT cover assy. (See CVT  3

Cover) 0511502

R e m o v e d r i v e p u l l e y. ( B o l t 3 i s 1 Socket (18mm)
counterclockwise thread - See picture Drive Pulley Locking Wrench
2
0511502) (P/N: 0JY0-050000-922-001)
Drive Pulley Mounting Bolt
3
Tool: (Counterclockwise)
Drive pulley locking tool 0JY0-050000-922-
001

05-115
CFMOTO

Remove main drive shaft nut 3. (See

picture 0511601)
 2
Tool:
CVT driven pulley locking wrench
0800-052000-922-001
 3

 1

0511601

1 Socket (36mm)
CVT Driven Pulley Locking Wrench
2
(P/N: 0800-052000-922-001)
3 Main Drive Shaft Nut

Use CVT drive pulley removing tool (0JY0-

050000-922-002) to push the drive pulley
out.

Remove drive and driven pulley together

with drive belt.

Remove the drive belt.

 1 0511602
Note:
If the drive belt has no revolving arrow. Drive Pulley Removing Tool
1
Please mark it before removal to avoid (P/N: 0JY0-050000-922-002)
wrong assembly.

05-116
 5.4 CVT drive

8
21
9

10
20
11

12 19

18

17
16

14
13

15
0511701

1 Lock nut, drive pulley 8 Washer 15 Adjusting washer

2 Thrust collar 9 Spring seat 16 Spring, driven pulley
3 Nylon slider 10 Drive pulley bearing 17 Driven sliding pulley
4 Clutch shoe 11 CVT belt 18 Nylon washer
5 Drive sliding pulley 12 Drive fixed pulley 19 Taper key
6 Spring, drive pulley 13 Circlip 20 Driven fixed pulley
7 Nylon bush 14 Cam plate 21 Nut, main drive shaft

05-117
CFMOTO

Drive Pulley
Drive Pulley Disassembly
Before disassembly, mark the drive
clutch for balance alignment. (See picture
0511901)

Loosen and remove the shaft nut, remove

the washer, and seperate the drive pulley.
(See picture 0511701)

Remove the Thrust collar and clutch shoe.

 2  3
Remove the Nylon slider from the Thrust
collar.  1 0511801

Drive Pulley Inspection Nylon

1 Clutch Shoe 2 3 Thrust collar
slider
Clutch Shoe Inspection

Check clutch shoes for wear and other

damage. Replace all the clutch shoes if
trouble is suspected.

Note: Clutch shoes must be replaced as

a set. Do not replace individual shoes.

Slider Inspection
Check slider wear and other damages.
Replace if necesary. (Recommend: replace
all 3 sliders at the same time)

Adjusting Washer Thickness Inspection 0511802

Use vernier calipers to measuere the Adjusting Washer Thickness Measuring

adjusting washer thickness. If the value
is less than 1.75mm , replace the washer
and adjust the thickness again.
 1
Adjusting washer (new) thickness:
1.90mm~2.00mm

Drive Pulley Moving and Stable Plate  2

Inspection. 0511803
Inspect the drive surface. If it has wearing
or damage, Replace the parts. Drive Surface on Drive Surface on
1 2
Stable Pulley Moving Pulley

05-118
 5.4 CVT drive

Drive Pulley Assembly

Reverse the removal procedures for

installation. The washer must be locked  1
in the position on the shaft and tightened
to the specific torque (Counterclockwise).
Tighten torque: 180N·m.

Warning
The washer must be locked on the shaft
 2
or the drive pulley will be damaged. Make
sure the balance aligning marks are in one
straight line. 0511901

1 Nut 2 Balance Aligning Mark

 2
Driven Pulley Disassembly

Note:
Before disassembly, mark the spring
installation holes and cam feet to sliders
positions.
 1

0511902

1 Cam and Slider Marks

2 Spring Installation Holes Marks

05-119
CFMOTO

Place driven pulley on the special tool base

and assemble the rest of the tool over the
driven pulley. (See picture 0512001)
 1
Special tool: Driven pulley disassemble
tool (0800-052000-922-002)
 2

0512001

Driven Pulley Disassemble Tool

1
(P/N: 0800-052000-922-002)
2 Driven Pulley

Turn special tool handle to compress the

cam and spring. Use a circlip remover to  2
remove the circlip.  1

Note: Use the special tool to remove the

spring retainer to avoid spring seat fly up,
causing injuries.
 3
 4
0512002
Driven Pulley Disassemble Tool
1
(P/N: 0800-052000-922-002)
Retainer Driven
2 3 Retainer 4
Caliper Pulley

05-120
 5.4 CVT drive

Slowly loosen tool handle to release the

spring tension and remove the special tool.
Remove the spring seat.
Remove the guide key.
Remove the spring and sliding sheave of
the driven pulley.

0512101

 3
 1
 2

 4
0512102

1 Spring Seat 2 Guide key 3 Spring

4 Sliding Sheave of Driven Pulley

Driven Pulley Inspection

Driven Pulley Fixed Sheave Inspection  1

Check driven pulley faces for any abnormal

conditions, such as heavy wear or visible
damage. Replace if necessary.

Note: Clean fixed sheave of driven

pulley before inspection.

Note: Driven pulley assembly is

precisely matched. If only the fixed sheave
or sliding sheave is replaced, vibration 0512103
may increase. It’s recommended to replace
both when replacement is required. 1 Drive Face of Fixed Sheave

05-121
CFMOTO

Driven Pulley Sliding Sheave Inspection

Inspect the drive face of sliding sheave

for heavy wear and damage. Replace if
necesary.

 1
0512201

1 Drive Face of Sliding Sheave

Inspect the sliders on driven pulley for wear  2  2

and other damage. If the worn thickness
is over the measurement illustrated in the
figure 0512203, replace all 3 sliders at the
same time.

 2
 1

Note: Clean the sliding sheave before 0512202

inspection.
1 Slider 2 Sliding Sleeve

The slider wear limit ‘A’ is 1.5mm.

 A

0512203

05-122
 5.4 CVT drive

Spring Cam Seat Inspection  2

 2
Check spring cam sliding face for wear
and other damages. replace if necessary.

 1

 2
0512301
1 Cam 2 Sliding Face

Driven Pulley Spring Inspection

 A
Check the spring free length. If it is shorter
than the limit length, replace it.

Spring free limit length: A = 219mm.

Driven Pulley Assembly

0512302
Reverse the disassembly procedures for
driven pulley assembly. A Spring free length
Note: Special tool is required during
driven pulley assembly.

Drive Belt

Inspect the belt for oil, dirt, cracks or other

damage. Use vernier caliper to measure
the belt width.
 1
If any damage is found or the belt width is
out of service limit, replace the belt.
Drive belt service limit: 32.2mm
Tool: Vernier caliper
 2
Note: If oil, dirt or grease have covered
the belt, the belt must be thoroughly 0512303
cleaned before reinstalling.

1 Drive Belt 2 Drive Belt Inner Line

05-123
CFMOTO

Drive/Driven Pulley and Belt Installation.  2  5  4  1

Use special tool(0800-052000-922-003) to

seperate the driven pulley discs.
Set the belt on drive pulley and driven
pulley.

Note:
The belt and pulley should not assembled  3 0512401
with oil or dirt still on the surfaces. Drive
Driven
belt arrow direction should be as same as Drive Driven Pulley
1 2 3 Pulley Slide
removal. Pulley Stable Disc
Disc
Drive Driven Pulley Seperator
4 5
Belt (P/N: 0800-052000-922-003)

Install the CVT pulleys and belt together.

Use special tools and tighten the bolt and
nut to the specified torque.

Note: Drive pulley mounting bolt is

counterclockwise.

Drive pulley bolt torque: 60N·m.

Main drive shaft nut torque: 150N·m.
 2
Tool:  1 0512402 
CVT driven pulley locking wrench
0800-052000-922-001
Drive Pulley Main Drive Shaft
CVT drive pulley wrench 1 2
Mounting Bolt Nut
0JY0-050000-922-001

05-124
 5.4 CVT drive

5.4.5 CVT Case Assy  2

 1  2
CVT Case Removal

Note: Drain out the engine oil before

removal.  3
 2
Remove the CVT cover. (See CVT Cover)  1
 1
Remove the drive/driven pulley and drive  4
belt. (See Drive Pulley, Driven Pulley, Drive
Belt) Remove CVT case bolt to remove the 0512501
CVT case assy.
Bolt Bolt
Bolt M6×50
Note: Before removing CVT case, 1 M6×22 (6 2 3 M6×55
(9 pcs)
clean up the dirt on the crankshaft. When pcs) (2 pcs)
removing the case body, do not damage CVT case
4
the sealing surface and bearing. body

Take out the locking pins (3-optional) and

CVT gasket (1), CVT case gasket (2).  2
 1

 3
0512502

CVT CVT Locking

1 2 3
Gasket Gasket Pin

05-125
CFMOTO

CVT Case Cleaning

Warning  2
Use eye protection to avoid eyes getting
hurt.

Use cleaning tools to clean CVT case.

Use compressed air to dry CVT case.
 3
CVT Case Assy Inspection
 1
Inspect the CVT case for cracks or other
damage, replace if damage is found. 0512601
Inspect the oil seal, replace if damaged or
appears worn. CVT Slide
1 2 3 Oil Seal
Case Bearing
Tool:
Oil seal 32×55×10 pressor
0JY0-013103-921-001

Inspect the plain bearing for scratches or

other damage. Replace if necessary.

 1

 3
 2
Note: Measure the inner diameter of the
plain bearing and the CVT shaft diameter
(See Crankshaft). If out of service limit, 0512602
replace the parts.

Slide bearing inner diameter

32.100mm Lubricating Slide Inner
Service limit 1 2 3
(1.2638in) Hole Bearing Diameter

05-126
 5.4 CVT drive
CVT Case Installation

Reverse the removal procedures for

installation.

Note:
1. Lay the CVT case gasket flat on the
crankcase. Use a new gasket.
2. CVT case gasket (2) is not symmetrical,
please align the hole in position. (See
picture 0512502)
3. Pre-lubricate the plain bearing with
engine oil and install the case. Use care
not to scratch the bearing surface.
4.Tighten the bolts to specification in criss-
cross procedure.

05-127
CFMOTO

5.5 Engine Lubrication System

5.5.1 Service Tool, Material and View...................................................5-129
5.5.2 General .......................................................................................5-132
5.5.3 Engine Oil Inspection...................................................................5-132
5.5.4 Engine Oil Replacement..............................................................5-133
5.5.5 Gear Oil Inspection......................................................................5-134
5.5.6 Gear Oil Replacement.................................................................5-134
5.5.7 Engine Oil Pressure Inspection ...................................................5-136
5.5.8 Oil Filter Element .........................................................................5-137
5.5.9 Oil Pressure Limitor......................................................................5-138
5.5.10 Oil Pump....................................................................................5-139
5.5.11 Oil Strainer ................................................................................5-142
5.5.12 Oil Cooler...................................................................................5-142

05-128
 5.5 Engine lubrication system

5.5.1 Maintenance Tools, Material and View

Service tool
Name P/N Page
Pipe connector 0JWA-000000-871-001 5-136

Service tool
Name P/N Page
Engine oil 5-130/138
243 thread locker 5-130
5699 sealing glue 5-130
Washing liquid 5-142

05-129
CFMOTO

Exploded View

Oil

T1
New

Oil

Oil

243
thread locker T2
T4

T3
T3

T1

New

T1 T3

5699 Sealing Glue

T1 20N·m(15 lbf·ft)
T2 12N·m(107 lbf·in)
T3 10N·m(89 lbf·in)
T4 6N·m(53 lbf·in)
0513001

05-130
 5.5 Engine lubrication system

Lubrication line

 1
 1
 2
11

10

 9

 8

 3  7
12

 6

 5
 4

0513101

1 Camshaft Bearing 5 Oil Strainer 9 Oil Cooler Inlet Pipe

2 Oil Pressure Switch 6 Oil Pump 10 Oil Cooler Outlet Pipe
3 Oil Filter Element 7 Main Bearing 11 Oil Cooler
4 Limit Valve 8 Connecting Rod Bearing 12 CVT Case Bearing

05-131
CFMOTO

5.5.2 General
Lubrication is employed to reduce the
wear of some components, such as
piston, crankshaft, camshaft, etc, which
moves relative against other parts. Proper
lubrication is the basis for engine normal
operation.
The engine crankcase and gear box use
different oil for lubrication. Lubricating oil
has cleaning, anti-rust, sealing, cooling
and other functions besides lubrication.

Warning
Torque wrench must be used when
tightening. Locking devices(e.g.: locking
tabs, elastic stop nuts,cotter pin, etc.) must
be replaced with new ones.

5.5.3 Engine Oil Level Check

Ensure vehicle is on a level surface;
Start the engine and allow it to idle for a
few minutes, then shut it off. Wait for a few
minutes to allow oil flow down to crankcase
then check oil level;
Unscrew dipstick and wipe the oil residue
off, then put dipstick in the hole. Don’t
screw in dipstick to read oil level, just make
dipstick threads contact the hole surface;
Remove dipstick and read oil level;
Engine oil level must be between “upper”
and “lower” marks;
If oil level is below “lower”, refill the oil and
check the level again and again until it is  1
OK.
Install the oil dipstick back.  2

Note: 0513201
Strictly follow the procedure above,
otherwise wrong oil level may be indicated; Oil dipstick line:
Vehicle must be placed on a level surface; 1 Upper 2 Lower
Don’t screw in dipstick to read oil level.

05-132
 5.5 Engine lubrication system

5.5.4 Engine Oil Replacement

Ensure vehicle is on a level surface before
working. Replace engine oil and filter
element at the same time when engine is
warm.

Note: The engine oil can be very hot.

Wait until engine oil is warm.

Place a drain pan under the engine oil

drain plug area;
Clean the drain plug area;
Unscrew oil dipstick, drain plug and
discard the gasket ring;
Wait sevearal minute. Allow oil to drain
completely from crankcase;

Note:  2
Oil condition gives information about
the engine condition. Check the drained
engine oil for engine shavings and residue.  1
Presence of debris indicates a failure
0513301
inside the engine. Check engine to correct
the proplem. 1 Drain Plug 2 Washer

Clean the drain plug. If the sealing washer

damaged, replace the washer and tighten
the plug up.

Drain plug tightening torque: 20N·m

Replace oil filter element refer to Oil Filter

further in this section;

Refill engine with recommended engine

oil through dipstick hole;

Oil capacity(With filter): 2.5L

After filling, check engine oil level with
dipstick(refer to Engine Oil Level Check
above).

Install dipstick. Run the engine to ensure

oil filter and drain plug areas are not
leaking;

05-133
CFMOTO

5.5.5 Gear Box Oil Inspection

Ensure the vehicle is on flat surface.
Start the engine and run the engine for
several minutes. Stop the engine and wait
for several minutes to make sure the gear
oil totally flew back to bottom. Unscrew
dipstick and wipe the oil residue off, then
put dipstick in the hole. Don’t screw in
dipstick to read oil level, just make dipstick
threads contact the hole surface;
Remove dipstick and read oil level;  1
Engine oil level must be between “upper”  2
and “lower” marks;
If oil level is below “lower”, refill and
0513401
inspect again and again until it is OK.
Tighten the oil dip stick back.
Oil level:
1 Upper 2 Lower
Note:
Strictly follow the procedure above,
otherwise wrong oil level may be indicated;
Vehicle must be placed on a level surface;
Don’t screw in dipstick to read oil level

5.5.6 Gear Oil Replacement

Ensure the vehicle is on flat surface before

 3
start working

Note: The gear case can be very hot.

Wait until gear oil is cooled down.
 2
 1

Place a drain pan under the gear box oil

drain bolt.
Clean the drain bolt area. 0513402
Remove the oil dipstick
Remove the drain bolt and the drain bolt
sealing gasket to drain the gear oil.
Sealing
1 Drain Bolt 2 3 Oil dipstick
Note: When draining the gear oil, Gasket
remove oil dipstick first to release the
pressure, in case of oil spilling out.

05-134
 5.5 Engine lubrication system

Note:
Oil condition gives information about the
gear box condition. Check the drained
gear oil for gear shavings and residue.
Presence of debris indicates a failure
inside the gear case. Check engine to
correct the proplem.

Clean the drain plug up.

If the sealing washer damaged, replace
a new one first then tighten up the drain
plug.
Drain plug tighten torque: 20N·m

Refill the gear case with 75W/90 GL-5

gear oil through dipstick hole
Capacity: 0.6L

Inspect the gear oil after filled(See related

chapter)

Start the engine to make sure the drain

plug without leaking.

05-135
CFMOTO
Oil Pressure Switch
Oil pressure switch service voltage:
0.6bar±0.1bar(0.6kPa±0.1kPa)
It sends the oil pressure signal to
dashboard. When the engine starts, it
comes into working.
Inspection
Start the engine and do idle running, if the
oil pressure warning indicator goes off on
dashboard, it is normal. If the indicator is
still on, then make trouble-shooting.
- Inspect oil pressure switch harness for
normal performance.
- Inspect the oil pressure to see if it is
within the pressure value in the table
above.

If the result of the inspections are okay,

then replace the oil pressure switch.

5.5.7 Engine Oil Pressure

The engine oil pressure test should be

done with a warm engine 90 celcius(194 F
) and the recommended engine oil.
Remove engine oil pressure switch.

Install engine oil pressure gauge 0513601

(0JWA-000000-871-001) and adapter
hose. Oil Pressure Gauge

The engine oil pressure should be within

the following values:

Oil pressure 1300r/min 6000r/min

Min 100kPa 500kPa
Normal 200kPa 580kPa
Max 400kPa 700kPa

If the engine oil is out of specifications,

check the points described in Trouble
Shooting section. Remove engine oil
pressure gauge and adapter hose after
tested.
Reinstall the engine oil pressure switch.
0513602
Note: To remove adapter hose from
engine oil pressure gauge, use the service Adapter Hose
tool. (P/N:0JWA-000000-871-001)

05-136
 5.5 Engine lubrication system

5.5.8 Oil Filter Element

Removal

Remove oil filter cover screws;

Remove oil filter cover;
Remove o-ring;
Remove oil filter element.

 1  2  3  4
0513701

Inspection
1 Screw 2 Oil Filter Cover
Check and clean the engine oil filter 3 O-ring 4 Oil Filter Element
inlet and outlet area for dirt and other
contaminations.

 1

 2

0513702

Oil outlet port of

Oil inlet port of
filter lead to each
1 filte lead to oil 2
parts that need
pump
lubrication

05-137
CFMOTO

Oil Filter Element Installation  1

Install a new o-ring on oil filter cover;

Apply engine oil on o-ring and the end of
filter;
Install the element into oil filter bore;
Install the oil filter cover on the engine.
Torque screws to 10N·m.  2
0513801
5.5.9 Oil Pressure Limit Valve
1 Apply a Light Coating of Oil here
Oil pressure limit valve is on engint right 2 Apply a Light Coating of Oil here
crankcase(On CVT side).
The valve works when the oil pressure
exceeds 450kPa(65PSI).
Status 1
Removal
Status 1
Remove limit valve screw and O-ring;
Remove the ring and screw.
Status 2  3
Remove relief valve screw plug and O-ring.  4
Remove washer, spring and steel ball.
 5
Inspection
 1
Inspect the steel ball, O-ring, pressure limit  2
bolt (with the washer) got damaged or not. 0513802
Replace the part if trouble inspected. Limit Valve
1 Steel Ball 2 3 O-ring
Sprint
Inspect the pressure limit valve spring
Pressure
free length. If out of standard, replace the 4 5 Mark A
Limit Bolt
spring.
Spring free length Status 2
New 24.1mm
Service limit 23mm
Installation
Reverse the removal procedure for
installation.Install the oil pressure limit  5  4  2  1
 3
valve. Set the O-ring on screw (with the
washer) of the limit valve,then spring and
set the steel ball in the installing hole.
Finally tight the valve up.

Note:
The bolt has mark A. 1 S c r e w, r e l i e f 2 O - s e a l 3 Washer
It is not necessary to do this if the pressure valve ring
is normal 4 S p r i n g , r e l i e f 5 Steel ball
valve

05-138
 5.5 Engine lubrication system
Note: Relief valve screw plug has
mark “A” when at status 1.When the
oil pressure is within thespecification,
it is not necessary to do this work.
Note:When relief valve has both
statuses, do the maintenance
according to the different status. The
washers varies in number in status 2.
Normally the number is 0~2.

5.5.10 Oil Pump

Oil pump is located on the engine MAG

side(under magneto cover).  1

0513901
1 Oil Pump

Removal
 4
Remove magneto cover and related  2
 3
parts(see Magneto Cover Removal);  1
Remove magneto rotor(see Rotor
Removal);
Remove circlip, oil pump gear, needle pin,
thrust washer in turn;

0513902

1 Circlip 3 Needle Pin

2 Oil Pump Gear 4 Thrust Washer

 1
 2

Remove oil pump cover screws and oil

pump cover;
Remove pump shaft with inner rotor and
outer rotor.

0513903
1 Screws 2 Oil Pump Cover

05-139
CFMOTO

Inspection

Inspect oil pump for marks or other

damages. Check for scratches in
crankcase between outer rotor and oil
pump bore. If so,replace damaged parts;

 1  2  3  4
 5
0514001
Outer
1 Oil Pump Bore 2 Needle Pin 3
Rotor
4 Oil Pump Shaft 5 Inner Rotor

Check inner rotor for corrosion pin holes

or other damages. If so, replace oil pump
shaft assembly.

Inspect the inner rotor pitting wearing. If  1

wearing too much, replace the inner rotor.
0514002

1 Pittings on the Teeth

 1

Use a feeler gauge to measure the  2

clearance of inner and outer rotors plus
the clearance between outer rotor and oil
pump bore as shown.

If clearance between inner rotor and outer

rotor exceeds the tolerance, replace the  A
inner and outer rotor.
Make sure to check oil pump cover. If
damaged, replace the oil pump cover.  A

0514003

1 Outer Rotor 2 Inner Rotor

A Service Limit: 0.25mm

05-140
 5.5 Engine lubrication system

If clearance between outer rotor and its

bore in crankcase exceeds the tolerance,
replace outer rotor assembly and/or
crankcase.

Use a depth gauge to measure the axial

clearance of the oil pump as shown.
Difference between measurements should
not exceed 0.1mm(0.008in). If so, replace
the inner and outer rotor.

Use a depth gauge to measure the axial 0514101

depth of the part that extends to oil pump
bore as shown. Measurement A

Use a depth gauge to measure the axial

depth of the part that extends to oil pump
bore as shown.

Reault: A-B≤0.2mm

Note: When the axial clearance of the

oil pump shaft assembly increases, the oil
pressure decreases.
0514102

Measurement B
Installation
Reverse the removal procedure for
installation.

Note: No marks on inner and outer rotor.

 1
When installating outer rotor, no secified
direction for outer rotor. After installation,
check for smooth operation of the oil pump
assembly.

Final Test

After engine is completely reassembled,

start engine and make sure oil pressure
is within specifications(refer to Engine Oil 0514103
Pressure above.) 1 Outer Rotor

05-141
CFMOTO

5.5.11 Engine Oil Strainer  2

The engine oil strainer is located on the  3

bottom of left crankcase half.

Removal
 1
Remove the bolt and covering nut. Use
screwdriver to remove the strainer cover  4
and washer. Use caliper to remove the 0514201
strainer.

1 Oil Strainer Side Cover 3 Nut

2 Bolt 4 Screwdriver

Strainer Cleaning and Inspection

Use washing liquid to clean the strainer

and dry out with compressed air.  5
 2
Note: Always wear eye protector.
Chemicals can cause a rash break out and
 1
injure your eyes.
 4

Inspect the strainer to see if it gets cracks  3

or other damage. Replace if necessary.

Strainer Installation 0514202

Clean up the case and strainer side cover. Strainer Strainer
1 Strainer 2 3
Replace the gasket with a new one. Gasket Side Cover
Then reverse the removal procedure to 4 Bolt 5 Nut
installation to install the strainer.

5.5.12 Oil Cooler

 2  1
 3
0514203

Oil Cooler Oil Cooler Oil

1 2 3
Inlet Pipe Outlet Pipe Cooler

05-142
 5.5 Engine lubrication system
Removal

Drain out the engine coolant.

 7
Loose the 2 clamps on oil cooler water
inlet/outlet pipe. Then remove the water  4
pipes on oil cooler.  8

Remove 2 bolts on oil cooler inlet pipe.

Then remove 1 bolt on oil cooler out let  3
pipe.  1
 2  6  5 0514301
Note: Inspect the damage of bolt
gasket. Bolt
1 Clamp D25 4 Bolt 7
M10×20
Loose 2 oil cooler mounting bolt M10×20 Oil Cooler Oil Cooler water
remove the oil cooler. 2 Water Inlet 5 Oil Inlet 8 pipe
Pipe Pipe bracket
Oil Cooler Oil Cooler
3 Water Outlet 6 Oil Outlet
Note: Drain out the engine oil left in the Pipe I Pipe
cooler before removing the oil cooler water
pipe.

 4  3
 2

Oil Cooler Inspection

Remove 4 bolts M6×18 to remove the oil

cooler from the bracket. Take out the O-ring
17×2.5 to see if damaged or becoming
harder. Remove the parts if necessary.
 2  1
0514302

1 Oil Cooler Bracket 3 Oil Cooler

2 O-ring 17×2.5 4 Bolt M6×18

05-143
CFMOTO
Oil Cooler Inlet/Outlet Pipe Inspection.
 5

Inspect the oil cooler inlet/outlet pipe for

damage or leaking. If trouble inspected,
replace the parts.

 2  3  4
Oil Cooler Cleaning
 1
Clean the oil cooler and bracket. Use
0514401
compressed air to dry the water way and
oil way. Oil cooler
1 3 Exhaust pipe
inlet pipe
Oil cooler Oil cooler outlet
2 4
outlet pipe I pipe II
Oil Cooler and Accessories Installation 5 Flange bolt M6×6 and sealing ring

Reverse the removal procedures for

installation.

Note: Follow the marks on the right

picture to assemble the water pipe. The
marks on the water pipe must be aligned  1
with the boss on the pipe.

Bolt tighten torque: 40N·m  2

Bolt M10 ×20 tighten torque: 25N·m
Bolt M6 ×18 tighten torque: 10N·m
Flange bolt M6 ×6 tighten torque: 5N·m
Outlet pipe connector tighten torque: 0514402
15N·m
Oil cooler outlet Outlet pipe and
1 2
pipe II sealing ring

0514403
0514403

05-144
 5.6 Engine Start System
5.6 Engine Start System
5.6.1 Service Tool, Material and View................................................... 5-146
5.6.2 General ...................................................................................... 5-148
5.6.3 MAG-side Crankcase Cover........................................................5-148
5.6.4 Magneto Stator.............................................................................5-150
5.6.5 Magneto Rotor.............................................................................5-151
5.6.6 Overriding Clutch.........................................................................5-154
5.6.7 Driven Gear .................................................................................5-155
5.6.8 Start Gear Assy............................................................................5-156

05-145
CFMOTO

5.6.1 Service Tool, Material and View

Service tool
Name P/N Page
Bearing 60/28 removing tool 0800-014001-922-003 5-148
Bearing 60/28 pressor CF188-014001-921-001 5-148
Mag-side crankcase cover pressing
0800-014001-921-002 5-148
tool
Crankshaft locking screw 0800-041000-922-001 5-151
Magneto rotor removing tool 0800-031000-922-001 5-151
Rotor locking tool 0800-031000-922-003 5-153

Material
Name P/N Page
Oil 5-147/149/152/155/156
Coolant 5-149
243 thread locker 5-147/155
5699 sealing glue 5-147/149

05-146
 5.6 Engine Start System

View

T3

Oil

T1 5699 sealing glue

243 thread locker

T4

T5
Oil
T2

243 thread locker

Oil T3

T1 60N·m (44 lbf·ft)

T2 30N·m (22 lbf·ft)
T3 10N·m (89 lbf·in)
T4 6N·m (53 lbf·in)
T5 16N·m (12 lbf·ft)
0514701

05-147
CFMOTO
5.6.2 General

Always perform electrical tests before

removing or installing components.
During assembly/installation, use the
torque values and service products as
shown in the exploded view. Clean threads
before applying thread locker.

Warning
Torque wrench tightening specification
must be strictly adhered to. Locking
devices(e.g.: locking tabs, elastic lock
nuts, cotter pins, etc.) must be installed or
replaced with new ones where specified.  3  1
If the efficiency of a locking device is
impaired, it must be renewed.
 2
5.6.3 MAG-side Crankcase Cover  2
 2  2
 2
Removal
 2
Drain engine oil and coolant. (Refer to  2
Lubrication System and Cooling System)  5

Remove the CPS;  4

Remove Mag-side crankcase cover bolts. 0514801
Remove Mag-side crankcase cover. Left
1 Crankcase 2 Locking Bolt 3 CPS
Inspection and Cleaning Cover
4 Flow Hose 5 Wire Clamp
Inspect the Mag-side crankcase cover
for cracks or other damage. Replace it if
necessary.

Inspect the bearing 60/28 to see if it works

well or not. Replace it if necessary.

Tool: Mag-side crankcase bearing 60/28

removing tool (0800-014001-922-003)
Bearing 60/28 presser (CF188-014001-
921-001) Mag-side crankcase cover
bearing pressing tool (0800-014001-921-
002)

05-148
 5.6 Engine Start System
Note:
Clean all metal components with a metal
cleaner safe for aluminum. Use suitable
tools to remove gasket.

 1
Warning:
We a r s a f e t y g l a s s e s a n d w o r k i n a
well ventilated area when working with
chemical products. Also wear suitable non-
absorbent gloves to protect your hands.

0514901
Installation
For installation, reverse the removal 1 Cover 5699 Sealing Glue
procedures.

Pay attention to details below:

Note:
Replace with a new magneto cover gasket.
Apply sealing compound on stator cable
grommet as shown in picture 0514901.
Apply oil on bearing.

 3
 1 11  7
Tighten screws on magneto cover in  9 15
sequence. See illustration 0514902.  5
Torque the screws to N·m. 13
 2
 8
Refill engine with recommended oil and 17 14
 6
coolant. 10 16
 4 12

Note: 0514902
Do not use sharp objects to touch the Tighten order
water pump gear when installing the
crankcase cover.

05-149
CFMOTO
5.6.4 Magneto Stator

Removal  1
Remove Mag-side crankcase cover.
 3
Remove screws securing holding strip.

Remove stator retaining screws and the  4

stator.
 2

0515001
1 Stator 3 Holding Strip
Stator Retaining Holding Strip
2 4
Screws Screws

Inspection

Check stator condition, replace it if

damaged.

Check if stator wires are brittle, hard, or

otherwise damaged.  1

0515002
1 Stator
Stator Installation
 1

For installation, reverse the removal

procedure.

Warning
 2
The cables must be into its own position
when installing magneto (Cable groove).

Note:
There is only one position for the stator
(notch in the magneto housing cover).
0515003
1 Cable Pressor Screw Hole
2 Magneto Stator Direction

05-150
 5.6 Engine Start System
5.6.5 Magneto Rotor

Removal  1  2

Remove Mag-side crankcase cover.

Remove the O-ring and gasket on
crankshaft.

 3
Note: Use crankshaft locking screw
(0800-041000-922-001) to lock the
crankshaft (See Intake Pipe, Cylinder 0515101
Head and Cylinder Body).
Tighten Magneto
1 Bolt 2 3
Sleeve Rotor

 2
 1

Use special tool to remove the rotor.

Tool: Magneto removing tool (0800-

031000-922-001)
0515102
Note:
Apply grease to magneto puller end prior 1 Grease Covering Position
to install rotor puller in order to protect Magneto Removing Tool
2
crankshaft. (P/N:0800-031000-922-001)

 1

Fully thread magneto removing tool body

onto the rotor.

Screw in bolt of magneto removing tool (2)

to release the rotor from the crankshaft.

Note:  2
If the rotor will not release, tapping the 0515103
puller bolt with a hammer may assist in
releasing the rotor from the crankshaft. 1 Magneto Rotor
Magneto Removing Tool
2
(P/N:0800-031000-922-001)

05-151
CFMOTO
Inspection

Check inner side of rotor for scratches or

other damage.
Check key-way of rotor for wear or other
damage.
Check if trigger wheel teeth (1) are
damaged.

Check woodruff key and key-way on the

crankshaft for wear or other damage.

Replace parts if necessary.

 1

0515201
1 Rotor with Trigger Wheel

Installation  3

For installation, reverse the removal

procedure.
Pay attention to the following details:
Clean crankshaft taper and rotor with
cleaner.
Verify woodruff key is installed in the key-
 1  4
way.
Oil sprag clutch (1) in sprag clutch housing  2
0515202
(2) and install sprag clutch gear (3). Slide
rotor onto crankshaft. The woodruff key 1 Sprag Clutch 3 Sprag Clutch Gear
and the key-way must be aligned. Sprag Clutch Apply Engine Oil
2 4
Housing here

05-152
 5.6 Engine Start System

Slide spacer bushing onto crankshaft and

torque the bolt to specified value.  4
Tighten torque 60N·m.
 1  5
Warning: The magneto bolt torque must
follow the special torque or it may cause  2
the magneto rotor cannot be removed.

 3  6

0515301

Double Dual Locking

1 3 5
Gear Gear Sleeve
Breather Driven
2 4 6 Bolt
Big End Gear

Tool:
Rotor locking tool 0800-031000-922-003

Turn driven gear clockwise to make sure

the double gear turns freely.

 1
Note: Breather shaft end with chamfer
should face outward.

0515302

Rotor Locking Tool

1
(0800-031000-922-003)

05-153
CFMOTO
5.6.6 Overriding Clutch
 2
 4
 3
Removal  1
Remove Mag-side cover (refer to Magneto
Cover);  1

Remove rotor (refer to Rotor);

Remove the driven gear.

0515401
Remove the clutch housing bolts (1) and
housing (4). 1 Bolt 3 Sprag Clutch
2 Rotor 4 Clutch Housing
Note: If sprag clutch has no breakdown,
there is no need to remove it.

Inspection

Perform a functional test of the sprag

clutch. To do so, rotate driven gear in
sprag clutch.
 1
Inspect sprag clutch and sprag clutch
housing for wear or other damages.

Note:
Sprag clutch must lock in counterclockwise
direction.
Sprag clutch, housing and gear must be
replaced at the same time if damaged. 0515402
Function Test
1 Locking Direction

05-154
 5.6 Engine Start System
Installation
 3

For installation, reverse the removal

procedure.

Pay attention to the following details:

Apply thread locker on threads of sprag
clutch housing screws.
 1  4
Install clutch housing onto the rotor, then
 2
install and torque clutch housing screws to 0515501
30N·m.
Overriding
1 3 Driven Gear
Apply engine oil on sprag clutch and inside Clutch
sprag clutch gear hole (4). Clutch
2 4 Engine Oil Position
Housing

5.6.7 Driven Gear  1

Driven Gear Removal

Remove rotor(refer to ROTOR );

Pull driven gear away from the rotor.

 2
0515502

1 Rotor 2 Driven Gear

05-155
CFMOTO
Inspection

Inspect gear, especially teeth (1) and  3

sprag clutch collar (2), for wear and other
damage.

Check needle bearing condition.

Replace drive gear if necessary.

Installation  2
 1
0515601
Reverse the removal procedure for
installation.
INSPECT
1 Teeth 2 Collar 3 Needle Bearing
Note:
Apply engine oil on needle bearing and
collar of drive gear.

5.6.8 Start Gear Assy

The starter gears are located on the engine

MAG side behind the magneto cover.

Removal  4
 3
Remove Mag-side crankcase cover (See
Magneto).  2

Remove gear shafts (4), dual gear (1) and

double gear (3).

Inspection  1

Inspect gears and shafts for wear or

damage. Replace if necessary. 0515602

Installation
1 Dual Gear 2 Starter Gear
Reverse the removal procedure for 3 Double Gear 4 Gear Shaft
installation.

Note: The gear shaft big end must face

outward and all the gears must be pre-
lubricated by oil.

05-156
 5.7 Intake System
5.7 Intake System
5.7.1 Service Material and Exploded View  .........................................5-158
5.7.2 General.......................................................................................5-160
5.7.3 Air Filter.......................................................................................5-160
5.7.4 Air Filter Housing.........................................................................5-161

05-157
CFMOTO

5.7.1 Service Material and Exploded View

Material
Name P/N Page
Air filter washer 5-160

05-158
 5.7 Intake System

Air filter (exploded view)

10N·m(89 lbf·in)

2.5N·m
(22 lbf·in)

2.5N·m(22 lbf·in)

6N·m(53 lbf·in)

2.5N·m(22 lbf·in)

0515901

05-159
CFMOTO
5.7.2 General

During assembly/installation, use the

torque values and service materials as in
the exploded views.

Warning:
To r q u e w r e n c h m u s t b e u s e d w h e n
tightening.
Locking devices (e.g.:Locking tabs, elastic
lock nuts, cotter pin, etc.) must be replaced
with new ones.
Do not cut down or modify any parts of the
air intake system. The engine management
system has been adjusted accurately for  1
the components. Otherwise, the engine will
be low on power or even damaged.

5.7.3 Air Filter

 2
Removal 0516001

Remove the seat pad and housing cover 1 Locking Clamps 2 Air Filter Cover
(See Body Covering parts).
Loosen the locking clamps (1) to remove
the air filter cover (2).
Loosen the clamp to remove the air filter
element.
 1
 2
Note: If vehicle is used in dusty areas,
inspect more frequently than specified in
the maintenance chart.
If liquid/deposits are found, wash, squeeze
and dry the foam pre-filter. Replace the
main filter element if damaged.

Warning: Do not start engine if liquid or  3

deposits are found. If there is oil in the air 0516002
filter housing, check engine oil level. Oil
level may be too high.
1 Clamp 2 Air Filter 3 Air Filter Cover
Pour air filter cleaning solution or an
equivalent into a bucket. Put the foam pre-
filter in to soak. Do not wash the main filter
element.
While the pre-filter soaks, clean inside of
the air filter housing.

05-160
 5.7 Intake System
Rinse foam pre-filter with warm water and
let it dry completely.
If the main filter appears dirty or it is
clogged with debris, replace the main filter.
Do not blow compressed air on the main  4  2
filter element to clean it.

Air Filter Installation

Properly reinstall removed parts in the

reverse order of their removal.
 3

 1

5.7.4 Air Filter Housing 0516101

1 Clamp 3 Intake Pipe

Removal
2 Screwdriver 4 Air Strainer

Remove body covering parts (See Body

Covering)
Use screw driver to loosen the clamp.

Loose the clamp (1) and circlip (2) then

unplug the air hose (3).

 1
 2

 3
0516102
1 Clamp 2 Circlip 3 Air Hose

05-161
CFMOTO
Remove 3 air filter housing mounting bolts.

Pull out air filter housing.

 1

0516201

1 Mounting Bolt

Installation

Reverse the removal procedure for  1

installation.

0516202

Warning: 1 Mounting Bolt

Check the throttle valve operation several
times to make sure it is normal.

 1

0516203
1 Mounting Bolt

05-162
 5.8 Cooling System
5.8 Cooling System
5.8.1 Service Tool, Material and Exploded View ..................................5-164
5.8.2 General........................................................................................5-167
5.8.3 Inspection  ................................................................................... 5-167
5.8.4 Maintenance................................................................................5-168
5.8.5 Thermostat...................................................................................5-170
5.8.6 Radiator ......................................................................................5-171
5.8.7 Water Pump   ............................................................................... 5-178

05-163
CFMOTO

5.8.1 Service Tool, Material and

Exploded View

Service tool
Name P/N Page
Testing cap 901-18.01.00-922-001 5-167
Water seal removing tool 0JWA-081000-922-001 5-181
Bearing 3200A removing tool 0800-014001-922-001 5-181
Oil seal pressor 172MM-080005-923-001 5-183
Bearing pressor 0800-014001-921-003 5-184
Water seal assemble tool 0JWA-081000-922-002 5-184/185/186/187

Material
Name P/N Page
Coolant 5-168
Oil 5-166/183
648 locking glue 5-166/183
5699 Sealing glue 5-166/184/185/187

05-164
 5.8 Cooling System
Radiator (exploded view)

7 N·m
(62 lbf·in)

7 N·m
(62 lbf·in)
7 N·m
(62 lbf·in)

7 N·m
(62 lbf·in)

0516501

05-165
CFMOTO

Waterpump (exploded view)

Oil

648 cylinder locking glue

Oil
5699 Sealing glue

10N·m(89 lbf·in)

0516601

05-166
 5.8 Cooling System
5.8.2 General

Warning
Never start the engine without coolant.
Some engine parts such as the rotary seal
on the water pump shaft can be damaged.

During installation, use the torque values

and service products as indicated in the
exploded views.

Warning
Torque wrench tightening specifications
muststrictly be adhered to. Locking
devices(e.g.: locking tabs, plastic lock
nuts, self-locking fasteners, etc.) must be
installed or replaced with new ones where 0516701
specified. If the efficiency of a locking
device is impaired, it must be replaced.
Testing Cap
(P/N:901-18.01.00-922-001)

5.8.3 Inspection

Cooling System Sealing Test

Warning
To avoid potential injuries, don’t remove
the radiator cap or loosen the cooling drain
plug if the engine is hot.

Remove battery cover to access and

remove radiator cap.
Install the test cap (P/N 901-18.01.00-922-
001) on the filler neck.
Use a pressure/vaccum pump to
pressurize system to 103kpa (15PSI).

 1
0516702
Testing Cap
1
(P/N: 901-18.01.00-922-001)

05-167
CFMOTO
Check all hoses, radiator and cylinder(s)/
base for coolant leaks or air bubbles.

Inspection
Check general condition of hoses and
clamps tightness.
Check the leak indicator hose for oil or  1
coolant.

Note: A small amount of coolant from

the water seal in the hose is considered
normal. A leak inidcator hose continously
dripping is leaking. The water seal must 0516801
be replaced. Leaking coolant indicates a
defective rotary seal. Leaking oil indicates Leak Indicator
1
a defective inner oil seal. If either seal is Hose
leaking, both seals must be replaced at
the same time. Refer to Water Pump Shaft
and Seals in this section.

5.8.4 Maintenance

Coolant Replacement

Warning
To avoid potential injuries, don’t remove
the radiator cap or loosen the cooling drain
plug if the engine is hot.

Use premixed coolant or a blend of 50%

antifreeze with 50% water.
To avoid antifreeze deterioration, always
use the same brand. Never mix different
brands unless cooling system is completely
flushed and refilled.

Warning: To prevent rust formation or

freezing condition, always fill the system
with premixed coolant or with 50%
antifreeze and 50% water. Don’t use tap
water, 100% antifreeze or 100% water in
the system.Tap water contains minerals
and impurities which build up in the
system. During cold weather, 100% water
causes the system to freeze while 100%
antifreeze thickens and does not have
the same efficiency. Always use ethylene
glycol antifreeze containing corrosion
inhibitors specifically recommended for
aluminum engines.

05-168
 5.8 Cooling System
Draining the System

Warning
Never drain or refill cooling system when
engine is hot.

Remove the radiator cap.

Place a suitable container underneath the

water pump housing drain plug

Unscrew cooling drain plug located at the

water pump housing.

When the cooling system is drained  1

completely, remove cooling drain plug
completely and install a new washer.
Screw the cooling drain plug and torque it 0516901
to 10N·m (89 Ibf.in)
1 Coolant Drain Plug

Refilling the System

Remove related parts.

 1
Unscrew bleeding screws on top of
thermostat housing

Note: Both two cylinders must be bled  1

0516902

1 Bleeding Screws

05-169
CFMOTO
With vehicle on a flat surface, refill radiator
with coolant. When coolant comes out of
the thermostat housing hole, install the
bleeding screw and washer. Torque to
5N.m (44 Ibf.in).  1  2

Fill up the radiator and install radiator cap.

Fill the reservoir tank and keep the coolant
level even at “LOWER” mark, then install
reservoir tank cap. Run the engine until
thermostat opens, then shut off the engine.
Recheck the coolant level in reservoir
0517001
tank after the engine is completely cooled
down. Refill coolant if necessary. 1 Washer 2 Bleeding Screw
Maintain coolant level between “LOWER”
and “UPPER”.

Note: Each year or every 100 hours or

when vehicle reaches 3000km (1865mi),
check coolant concentration (freezing
point) with a proper tester.

5.8.5 Thermostat

The thermostat is a single way valve.

Note: Thermostat is located on the

top of cylinder head, on intake side(front
cylinder).  2
 1
Thermostat Removal

Dain the coolant from the system.

Remove thermostat housing screws and

pull thermostat housing.

0517002

1 Thermostat Cover 2 Screws

05-170
 5.8 Cooling System
Remove the thermostat with O-ring from
the seat.

Thermostat Inspection

To check thermostat, put it in water and  1

heat water. Thermostat should begin to
open when water temperature reaches
approximately 65°C (149°F).
Check if the seal ring is brittle, hard or
damaged. If trouble is suspected, replace
the thermostat.
0517101

Thermostat Installation
1 Thermostat with Seal Ring
During the installation, reverse the removal
procedure. Pay attention to the following
details.
Install the thermostat cover then torque
screws to 6N·m (53 lbf·in).
Check coolant level in radiator and
reservoir tank and top-off as necessary.

Warning:
Don’t forget to bleed the cooling system.
Refer to Coolant Replacement.

 1
5.8.6 Radiator

Radiator Cap

Using a pressure cap tester, check the

efficiency of radiator cap. If the pressure is
low, install a new 110kPa (16PSI) cap (do
not exceed this pressure).
0517102

1 Radiator Cap

05-171
CFMOTO

Radiator Clean and Inspection

 1
Inspect the cooling fins for jammed or  2
damaged areas.
Use compressed air or low pressure water
to clean mud or other kinds of debris.

0517201

1 Compressed Air 2 Radiator

Inspect the cooling fins. If any are bent or

folded and blocking airflow, carefully use a  2
screw driver to restore them.

Warning:  1
Use extreme caution to not damage the
radiator cooling tubes.
0517202

1 Screwdriver 2 Radiator

05-172
 5.8 Cooling System

 2

 3
 1
0517301
Radiator Radiator
1 B clamp 2 3
inlet pipe outlet pipe
Radiator Removal

Drain the coolant.

Remove body covering parts. (See chapter

2)

Use special plier to remove B clamp (1).

Remove radiator inlet pipe (2) and outlet

pipe (3).  4

Remove A clamp (4) with plier

Remove radiator overflow pipe (5).

 5
Use T wrench to remove 2 M6 bolts (6).  6

Remove radiator (7).

 7

0517302

4 A clamp 6 M6 Bolts
5 Radiator leaking pipe 7 Radiator

05-173
CFMOTO
Radiator Installation

Reverse the removal procedure for

installation.
Pay attention to the following details.  1
Set the rubber washer at the bottom
between radiator and bracket.
Fill the coolant.(See related chapter).
Inspect the radiator and engine hoses for  2
leaking.

Reservoir

As the coolant temperature increases  3

(Until 100°C~110°C [212°C~230°C])
coolant expands, and the system pressure
increases. If the pressure reaches 110 kPa
(16PSI), the cap valve will open and let the
coolant flow back to the reservoir. 0517401
Make sure the reservior pipe is not
1 Reservior hose 2 A clamp 3 M6 bolt
restricted.

Reservoir removal

Remove body covering parts.

Remove reservoir hose.
Remove 2 M6 bolt.
Remove the reservoir.

Reservoir installation

Reverse the removal procedure for

installaition.

Radiator cooling fan

Cooling fan running

Fan controlled by thermoswitch function.

When the coolant reaches approximately

88°C, the thermoswitck closes and the
cooling fan should start working. When
the coolant temperature falls back to
approximately 82°C, the thermoswitch
opens and the fan stops.

05-174
 5.8 Cooling System
Cooling fan testing
Follow the flow chart below to analyze the fan cooling system.

Y
Fan working? Finish
N
See fuse(30A) Y
burnt? Replace the fuse

N
Short cut the relay Inspect relay 1

Y
Fan working? Replace the relay
N
Connect to 12V power Inspect the fan

N
Fan working? Replace the fan
Y
Inspect thermoswitch

N
Thermoswitch Replace the
worked? thermoswitch
Y
Inspect wire and
connector
N Repair or replace the
OK?
parts.
Y

0517501
Removal

Remove radiator shroud.

Remove the bolts.
Remove the radiator fan.

Installation

Reverse the removal procedure for installation.

05-175
CFMOTO
Radiator fan relay

Installation

Note: The the relay can be installed

180° for normal installing and working.
Make sure the pins are aligned with the
holes in the relay box.
 1
0517601

1 Radiator fan relay

Relay function test

The easiest way to test a relay circuit is

remove the relay and use a jumper on the
connector. If the fan works, replace the
relay. (See picture 0517602)

 1

0517602
1 Jumper the connector

Relay working test

Remove the relay

Set the multi-meter to Ω to test the relay.
Test the pin locations as shown in picture
0517603.

Pin Resistance
30 87 Open (OL)

0517603
Pin testing position

05-176
 5.8 Cooling System
Test the relay again with battery connected
as shown in picture 0517701.

Pin Resistance
0.5Ωmax.
30 87
(Continuous)

If one test failed, replace the relay.

0517701
Connect the battery and test the relay
again.

Thermoswitch testing

Drain the coolant.

Remove the thermoswitch. Fan Motor Ammeter

Follow the right picture to see the thermo Battery

switch ON & OFF temperature. Put the
thermo switch into a pan with water and
a thermometer. Heat the water slowly
to above 88°C and then let it cool. Pay
attention to the temperature when the
thermoswitch turns on and off.  2
 1
Thermoswitch working temp:
OFF-ON: Approximately 88°C
ON-OFF: Approximately 82°C

WARNING Oil
Do not drop or tap on the thermoswitch
with tools. The thermoswitch will be
damaged. For accurate temperature  3
readings, do not let thermoswitch or
thermometer touch the pan.
0517702
Install the thermoswitch with new O-ring
and tighten the thermoswitch to specific 1 Thermoswitch 2 Thermometer
torque. 3 O-ring
Thermoswitch tighten torque:17N·m
Inspect the coolant level after installing a
new thermoswitch. Refill as necessary.

05-177
CFMOTO
5.8.7 Waterpump
 3
Water pump cover

Wa t e r p u m p c o v e r i s o n M A G - s i d e
crankcase cover.  3
Removal

WARNING
To avoid potential burns, don't remove the
radiator cap or loosen the cooling drain
plug if the engine is hot.
 2
 4  5
 1 0517801
Drain the cooling system.
Remove radiator outlet hose and oil cooler
inlet hose from the water pump housing. Coolant draining Sealing
1 2 3 Bolt
Remove screws retaining water pump bolt gasket
housing. Water pump Leaking
4 5
Pull water pump housing to remove it. cover hose

Inspection

Check gasket. If it is brittle, hard, or

damaged, replace as necessary.

Installation
 1
Reverse the removal procedure for
installation.

WARNING: To prevent leaking, take

care that the gasket is fully installed in the
groove when you reinstall the water pump 0517802
housing.
1 Gasket

Tighten screws of water pump housing in a

criss-cross sequence.

05-178
 5.8 Cooling System
Water pump cover outlet pipe O-ring
(If not leaking, this step is not necessary.)

Follow the drawing to remove waterpump

cover outlet connector (1) and O-ring  2
15.8x2.4 (2).  1

Inspect the O-ring 15.8x2.4 (2) to see if it

is damaged. Replace if necessary.

Reverse the removal procedure for O-ring  3

installation 15.8x2.4 (2) and water pump
0517901
cover outlet connector (1) and tighten to
specification.
Waterpump
O-ring
1 outlet 2 3 Waterpump
15.8x2.4
connector

Water pump impeller, water seal, oil seal,

bearing and gear

Removal  1

Drain the cooling system.

Drain the engine oil. (See lubrication
system)
Remove water pump cover.
Remove left crankcase cover. (See left
crankcase cover)  2
Remove water pump idler gear and gear
shaft. 0517902

Water pump idler

1 Gear shaft 2
gear

05-179
CFMOTO
Remove the water pump gear by hand.

Press inward on the water pump impeller.  4

Remove the needle and gasket on water
pump shaft.
 3

 2
 1
0518001

1 Water pump gear 3 Water pump shaft

2 Needle 4 Gasket

Lock the water pump shaft. Use a socket

 2
to remove the bolt. And in order to remove
the water pump impeller and washer.

WARNING: Take care not to damage

the impeller during removal. Bolt 1 is
counter-clockwise thread.

 3
 1
0518002

1 Bolt (Counterclockwise)
2 Waterpump impeller
3 Washer

05-180
 5.8 Cooling System
Use the water seal removing tool as shown
in picture 0518101. Turn the bolt clockwise
to pull out the water seal.
 2

Note: The inner claws of the removing

tool must be grasp the wall tightly, and
outer claws must be hold the moving ring.

 1

0518101
1 Water seal
Removing tool
2
(P/N:0JWA-081000-922-001)

Use water pump shaft bearing 3200A

removal tool (0800-014001-922-001) to
pull the bearing out. Replace the bearing if
removing.

 1  2
0518102

1 Bearing 3200A
Bearing 3200A Removing tool
2
(P/N:0800-014001-922-001)

05-181
CFMOTO

Remove the oil seal.

WARNING:
Be careful not to damage the rotary seal
surface.

 2
 1

0518201
1 Oil seal 2 Mounting surface

Inspection

Check impeller for cracks or other

damage. Replace the impeller if damaged.
Inspect water pump intermediate gear
and water pump gear for cracks, wear and
other damage (especially on the interface
mechanism to the needle pin). Replace if
necessary.  2  1
Turn the bearing inner ring by hand. The
bearing should turn smoothly.If it is stuck,
has noise or other defects, replace it.
0518201

1 Bearing 2 Inner ring

05-182
 5.8 Cooling System
Installation

For installation, reverse the removal

procedure. However, pay attention to the
following;

NOTE: For installation,use the torque

values in the exploded view. Apply engine
oil on intermeadiate shaft, water pump
shaft and oil seal inner surface. Don't use
oil in the press fit area of the oil seal or
rotary water seal. 0518301

WARNING: Always replace rotary seals Oil seal pressor

and stationary seals (oil seal) at the same (P/N:172MM-080005-923-001)
time.

Use oil seal pressor (172MM-080005-923-

001) to install the oil seal.

Apply oil on oil seal lip. Apply a light coat

of sealant on the oil seal and Mag-side
crankcase cover fitting surfaces.  2

NOTE: When installing the oil seal on

the pressor, make sure the sealing lip
points away from the tool.
 1
Use the oil seal pressor to drive the oil seal
into position.

0518302

1 Oil seal
Oil seal pressor
2
(P/N:172MM-080005-923-001)

05-183
CFMOTO
Place suitable support blocks under the
crankcase cover.
Set the bearing on pressor (0800-014001-
 3
921-003) and drive the bearing into the
crankcase cover.

NOTE: The left crankcase cover may be

damaged if no appropriate support blocks  2
are placed under it.
 1

0518401

1 Bearing
2 Left crankcase cover
Bearing pressor
3
(P/N:0800-014001-921-003)

Waterseal Installation: Mag-side crankcase

cover removed

 1
Put the water seal pressor on a flat surface
‘A’ side up, then insert the water seal  4
spring side down. Apply sealant to the
water pump shaft location #4. (See picture
0518402). Press the water pump shaft into  2
the water seal until it bottoms in the tool.
Do not use a hammer to install the shaft.

 3

0518402

1 Water pump shaft

2 Water seal
Water seal pressor
3
(P/N:0JWA-081000-922-002)
4 Sealing glue position

05-184
 5.8 Cooling System
Use the water seal pressor ‘B’ side to
press the assembly into the Mag-side
crankcase cover in the direction as shown
in picture 0518501.

 3
NOTE: Use care not to damage water
seal assemble tool ‘A’ side.

 2
 4
 1
0518501

1 Left crankcase cover

2 Water pump shaft and water seal
Water seal pressor
3
(P/N:0JWA-081000-922-002)
4 Support plate(With hole)

Apply a light coat of sealant on the surface

of the pump shaft end and water seal, then
place the water seal washer on the water
pump shaft.
Install the impeller and LH thread bolt.
Place the washer on the bearing side of  1
the water pump shaft.
Press on the water pump impeller by hand
until the cross shaft hole shows above the
bearing and washer surface. Install the  7
cross shaft and align it so both sides are  6
the same length.
Align the groove of the water pump
gearand cross shaft, then push the water
pump gear onto the shaft.  2  3  4  5 0518502
Torque the impeller bolt to specification.
Left Water
NOTE: Cover the flat sealing on water Cross
1 crankcase 4 seal 6
seal gasket. Tighten the impeller bolt in Shaft
cover washer
counter-clockwise direction.
Water
3 Impeller 5 Washer 7
WARNING: Ensure the water pump pump gear
gear is in position or the coolant may not 2 Bolt (Counterclockwise)
not circlate, causing cylinder gasket failure.

05-185
CFMOTO
Install the gear shaft into left crankcase
cover. Make sure the large end is out. Put
the water pump idle gear on the gear shaft.
For remaining parts installation,reverse the
removal procedures.  1
Fill the coolant and engine oil. (Refer to
maintenance chapter)

 2

0518601

1 Breather shaft 2 Idle gear

Wa t e r S e a l I n s t a l l a t i o n : M a g - s i d e
crankcase cover installed

Apply sealant to the water pump shaft  3

location #3.
Use a soft hammer and water seal pressor
‘A’ side to drive the water seal onto the
water pump shaft until the shaft bottoms
on the tool.This sets the seal sleeve into
position on the water pump shaft. (See
picture 0518602)  1
Warning: Be careful not to damage the  2
‘B’ side.
0518602

1 Water seal
Water seal pressor
2
(P/N:0JWA-081000-922-002)
3 Sealant covering position

05-186
 5.8 Cooling System
Use a soft hammer and ‘B’ side of the
water seal pressor to drive the water seal
casing into the Mag-side crankcase cover.
(See picture 0518701)

Warning: Be careful not to damage the

‘A’ side.

 1
 2
0518701

1 Water seal
Water seal pressor
2
(P/N:0JWA-081000-922-002)

Install the water seal washer, impeller, and

LH thread bolt. Torque the LH thread bolt
to specification.

NOTE: Cover the flat sealing on water

seal gasket. Tighten the impeller bolt in
counter-clockwise direction.

.
 1

 3
 2 0518702

1 Water seal washer

2 Water pump impeller
3 Bolt (Counterclockwise)

05-187
5.9

CFMOTO
5.9 Electrical System
5.9.1 Charging System����������������������������������������������������������������������� 189
5.9.1.1 Charging Wire Diagram������������������������������������������������������ 189
5.9.1.2 Magneto Coil Resistance���������������������������������������������������� 189
5.9.1.3 Magneto with Non-loaded�������������������������������������������������� 189
5.9.1.4 Voltage Regulator���������������������������������������������������������������� 190
5.9.2 Electrical Starting System�������������������������������������������������������� 191
5.9.2.1 Starter Motor������������������������������������������������������������������������ 191
5.9.2.2 Brush������������������������������������������������������������������������������������ 191
5.9.2.3 Commutator������������������������������������������������������������������������� 192
5.9.2.4 Armature������������������������������������������������������������������������������ 192
5.9.2.5 Oil Seal��������������������������������������������������������������������������������� 192
5.9.2.6 Starter Relay������������������������������������������������������������������������ 193
5.9.2.7 Auxiliary Starter Relay and Fuel Pump Relay������������������� 194
5.9.2.8 Engine Starting Notice�������������������������������������������������������� 194
5.9.3 EFI����������������������������������������������������������������������������������������������� 195
5.9.3.1 EFI Structure������������������������������������������������������������������������ 195
5.9.3.2 EFI system��������������������������������������������������������������������������� 195
5.9.3.3 EFI System Maintenance Notice���������������������������������������� 196
5.9.3.4 Service Tools����������������������������������������������������������������������� 197
5.9.4 EFI Components and Function������������������������������������������������� 199
5.9.4.1 ECU��������������������������������������������������������������������������������������� 199
5.9.4.2 Throttle Body����������������������������������������������������������������������� 200
5.9.4.3 Intake Temperature and Pressure Sensor������������������������ 201
5.9.4.5 Oxygen Sensor�������������������������������������������������������������������� 204
5.9.4.6 Mileage Sensor (Speed Sensor)���������������������������������������� 205
5.9.4.7 Gear Sensor������������������������������������������������������������������������� 206
5.9.4.8 Fuel Pump���������������������������������������������������������������������������� 207
5.9.4.9 Fuel Injector������������������������������������������������������������������������� 208
5.9.4.10 Idle Stepping Motor����������������������������������������������������������� 209
5.9.4.11 Ignition Coil������������������������������������������������������������������������ 210
5.9.5 EFI Self-Diagnosis��������������������������������������������������������������������� 212
5.9.5.1 MIL���������������������������������������������������������������������������������������� 212
5.9.5.2 PDA��������������������������������������������������������������������������������������� 213
5.9.5.3 PDA Function����������������������������������������������������������������������� 213

05-188
 5.9 Electrical System
5.9.1 Charging System

5.9.1.1 Charging Wire Diagram

5 6

3
1

0518901
1 Magneto 3 Voltage regulator 5 Battery
2 Regulator 4 Fuse 6 Load

5.9.1.2 Magneto Coil Resistance

● Measure 3-phase magneto stator coil
resistance.
● If resistance is out of specification,
replace with a new stator coil.
● Check for the insulation between stator
coil and stator core.

Turn multimeter to 1×10Ω

Magneto Coil Resistance: 0518902
0.5Ω~1.5Ω (Yellow-Yellow) Measure resistance
Resistance between Stator Coil and Core:
∞Ω (Yellow- Ground)

5.9.1.3 Magneto with Non-loaded

● Start the engine and run it at 5000r/min.
Use multimeter to measure the voltage
between 3 output lines.
● If the reading is below the specification,
replace with a new magneto.
Turn Multimeter to V(AC)
Voltage between output lines when MAG 0518903
Non-loaded: Measure voltage
>50V(AC) at 5000r/min

05-189
CFMOTO

5.9.1.4 Voltage Regulator

3
0519001

●Measure the resistance between ●After engine running and battery full
terminals by a multimeter. If any reading charged,if the voltage between positive
is out of specification, replace with a new and negative terminal is greater than 15V
regulator. or is lower than 12V, replace with a new
Turn Multimeter to DIODE regulator.

Note: When probes of multimeter don’t connect, replace battery if the voltage is
lower than 1.4V.

(+)
1 2 3 (-) (+)
1 ∞ ∞ 100~800 ∞
2 ∞ ∞ 100~800 ∞
(-)
3 ∞ ∞ 100~800 ∞
(-) ∞ ∞ ∞ ∞
(+) 100~800 100~800 100~800 100~800

05-190
 5.9 Electrical System

5.9.2 Electrical Starting System

5.9.2.1 Starter Motor

1
3

2
5

12

8
11

10
0519101
1 Outer side cover 5 Brush connector 9 Washer
2 Brush bracket 6 Motor sleeve 10 Inner side cover
3 Brush spring 7 Washer 11 O-ring
4 O-ring 8 Armature 12 Brush

5.9.2.2 Brush
●Check brush for damages, cracks or
other faults.
●If any damages were found, replace a
new brush assembly.
0519102

05-191
CFMOTO

5.9.2.3 Commutator
●Check for color change, damage and
wear.
●If any damages, replace with a new
commutator.
●If the color changes, polish the
commutator surface with sand paper and
wipe it up with a clean dry cloth.
●If there is too much wear, cut a part of
0519201
insulator B and keep the distance between
A and B as d.
d≥1.5mm

5.9.2.4 Armature
Use a multimeter to check the armature
coil continuity and continuity between
coil and the shaft. If armature coil has no
continuity or there is continuity between
the coil and the shaft, replace the armature
with a new one.
0519202

5.9.2.5 Oil Seal

Check for damages or leaks.
If there are damages or leaks, replace with
a new starter motor.

0519203

05-192
 5.9 Electrical System

5.9.2.6 Starter Relay

●Load 12V between positive and negative
terminal. Use multimeter to check if there
is continuity between 2 contacts.
●If multimeter clicks, there is continuity
between contacts.
●If 12V is removed, no continuity remains
between contacts.
●If both the above two items are in good
condition, it indicates the replay is well.
Turn multimeter to DIODE.

Note: Loading voltage between

terminals can not exceed 2 minutes,
otherwise, starter relay may overheat or
0519301
burn.

●Use multimeter to measure starter relay

coil resistance, if the reading is out of
specification, replace a new relay.
●Turn multimeter to 1×10Ω

Starter Relay Coil Resistance: 3Ω~5Ω

0519302

05-193
CFMOTO

5.9.2.7 Auxiliary Starter Relay and Fuel

Pump Relay A
●Load 12V between auxiliary starter
relay positive and negative terminal. Use
multimeter to check the continuity between
A and B.
(Turn multimeter to DIODE)
●If multimeter clicks,it indicates there is
continuity between A and B. B
●If 12V is removed, no continuity remains
0519401
between contacts.
●If both the above two items are in good
condition, it indicates the replay is well.
●Turn multimeter to 1×100Ω, measure
auxiliary starter relay resistance.
Auxiliary starter relay resistance:
70Ω~90Ω

5.9.2.8 Engine Starting Notice

●Properly route according to starting
schematic diagram.
●Before starting, check if all parts are
fitted correct. Regarding EFI components
connection, refer to EFI section.
●Check air intake system.
●Check fuel supply system. Ensure there
is no block or leaks.
●Test fuel pressure with fuel pressure
gauge.
Pressure in fuel pump outlet:
0.33MPa±0.01MPa
●Place the transmission in Neutral.
●Check EFI with PDA for fault. If there
is, eliminate the trouble according to
DTC(Diagnostic Trouble Code).
●Turn on the engine ignition switch, then
press starter switch for about 3~5 seconds.
●After starting, warm up until idle speed is
0519402
stable and check it.
Idle Speed:1300r/min±130r/min

Note: If the idle speed is not stable or

too high, turn the ignition off for a few
seconds. Then start the engine again.

05-194
 5.9 Electrical System
5.9.3 EFI
5.9.3.1 EFI Structure
Air filtyer
Throttle valve
Idle stepping motor
T-MAP
Air
Water temp. sensor
Oxygen sensor
Ignition coil

ECU
CPS

Fuel pump

0519501
5.9.3.2 EFI system
EFI system is composed of three subsystems.
(1)Sensors: (2)ECU:
A sensor is a device that measures a Electronic Control Unit,the brain of EFI
physical quantity and converts it into a system,which determines the amount of
signal which can be read by an observer or fuel injection, ignition timing and other
by an instrument. Sensors in EFI system parameters a engine needs to keep
include: running by calculating and analyzing
●Intake pressure sensor values provided by sensors.
●Intake temperature sensor (3)Actuator:
●TPS Execute the EFI instruction. Main actuators
●CPS include:
●Water temperature sensor ●Fuel pump
●Gear sensor ●Injector
●Mileage ●Ignition coil
●Oxygen sensor ●Idle control valve
●4WD-lock switch
●Overriding switch

05-195
CFMOTO

5.9.3.3 EFI System Maintenance Notice

●Always use genuine CFMOTO parts for ●If possible, don't do the spark test. If
maintenance. Otherwise, it can not assure spark test is done unavoidably, try to
a normal performance to EFI system. complete the test as soon as possible.
●During the maintenance procedure, never Besides, don't open the throttle. Otherwise,
try to disassemble the EFI components. a large quantity of unburnt fuel would enter
●In the course of maintenance, EFI parts muffler,causing the catalytic converter
must be handled carefully. damage.
●Ignition switch must be shut off before ●Idle speed is controlled by ECU, so it's
connecting or disconnecting connectors. unadjustable. The throttle limiter screw
Otherwise, it may cause the EFI parts has been adjusted by manufacturer before
damage. sale. Therefore, it's not recommended to
●When removing fuel pump from fuel tank, adjust it by the user.
do not energize the fuel pump. Otherwise, ●Don't reverse the battery cable
a spark can cause a fire. connections. This may damage electrical
●Fuel pump is not allowed to operate components.
in a dry environment or under water. ●Never remove the battery cables When
Otherwise, its service life would be the engine is running.
shortened. Besides, reverse connections ●Always remove cables and electrical
between positive and negative terminal of control units which are connected with
fuel pump is prohibited. battery terminals.
●The fuel pressure in EFI fuel supply ●Never test the component input and
system is very high (about 330kPa), output electric signal by piercing the cable
accordingly, all fuel lines are high pressure plastic jacket.
resisting. Even if the engine is not running, ●Respect the environment and dispose of
the fuel pressure is still high. Therefore, the waste left during maintenance.
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.

05-196
 5.9 Electrical System

5.9.3.4 Service Tools

PDA

Function:
Read/clear EFI system trouble codes,
observe data stream.

0519701
Digital Multimeter PDA

Function:
Measure voltage, current and resistance
and other parameters in EFI system.

0519702
Multimeter

Vaccum Gauge

Function:
Check the manifold for air pressure.

0519703
Vaccum gauge

05-197
CFMOTO

Timing Light

Function:
This light is used to check engine ignition
timing. 0519801
Timing Light

Compression Tester

Function:
This tester is used to check cylinder
compression.

0519802
Compression Tester

Fuel Pressure Gauge

Function:
T h i s g a u g e i s u se d to te st th e fuel
pressure, so as to check fuel pump and
fuel pressure regulator working conditions.

0519803
Fuel Pressure Gauge

05-198
 5.9 Electrical System
5.9.4 EFI Components and Function ECU
5.9.4.1 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.
0519901
ECU pin position

0519902
No. Function No. Function No. Function
1(Q1) / 23(O2) Auxiliary relay 45(F3) Oxygen sensor 1
Engine RPM sensor B
2(P1) Oxygen sensor heat 1 24(N2) / 46(E3)
side
Engine RPM sensor A
3(Q2) Ignition coil 1 25(M2) Intake temp. sensor 47(D3)
side
4(P2) Oxygen sensor heat 2 26(L2) TPS 48(C3) Power ground
Injector 2 (Second
5(Q3) Ignition coil ground 27(K2) Clutch switch 49(B3)
cylinder)
Injector 1 (First
6(P3) / 28(J2) / 50(A3)
cylinder)
Non continuous power
7(Q4) Ignition coil 2 29(H2) Oxygen sensor 2 51(O4)
supply
Non continuous power
8(P4) 30(G2) / 52(N4) /
supply
9(O1) Engine RPM output 31(F2) / 53(M4) /
10(N1) / 32(E2) Main relay 54(L4) Sensor ground 3
11(M1) Over-roll switch 33(D2) / 55(K4) /
12(L1) / 34(C2) / 56(J4) /
Stepping motor phase
13(K1) Mode switch 35(B2) 57(H4) /
C
Stepping motor phase
14(J1) Neutral switch 36(A2) 58(G4) /
D
Canister magnetic Intake pressure
15(H1) K-line 37(O3) 59(F4)
valve sensor
Continuous power
16(G1) 38(N3) / 60(E4) Fuel pump relay
supply
17(F1) Ignition switch 39(M3) Sensor ground 1 61(D4) /
18(E1) 5V power 2 40(L3) Sensor ground 2 62(C4) Fan relay
19(D1) 5V power 1 41(K3) Water temp. sensor 63(B4) /
20(C1) MIL 42(J3) Side stand switch 64(A4) /
Stepping motor phase
21(B1) 43(H3) Signal ground
B
Stepping motor phase
22(A1) 44(G3) /
A

05-199
CFMOTO
Limit Data:
Data Unit
Item
Min Standard Max
Battery volt Running 9.0 14.0±0.1 16.0 V
Limit 6.0~9.0 16.0~18.0 V
Maximum voltage Part of functions is available,
26.0V 5 min
and time fault diagnosis can be done
Working temp. -40 70 °C
Storage temp. -40 90 °C

● It's not allowed to apply a heavy load on ECU housing, or it may deform and
damage ECU.
● Always handle ECU gently. Never drop it, especially on a hard surface.

status 1
1
5.9.4.2 Throttle Body
Connected between air filter and engine.
When throttle lever is applied, the valve 2
butterfly in throttle body would spin at a
certain angle. TPS can monitor the position
of valve butterfly and send the signal to A
ECU. B
C 0520001

Pin function 1 Stepping motor

A. To 5V power 2 TPS
B. Ground
C. Output voltage signal status 2
1

A
B
C
0520002

05-200
 5.9 Electrical System

The right picture shows ECU route.

TPS 0520101

5.9.4.3 Intake Temperature and Pressure

Sensor
4 3 2 1
The pressure sensor measures the intake
manifold pressure and give the signal to
ECU.
The temperature sensor is an NTC thermo
resistance. The resistance becomes
lower when the air temperature becomes
higher. But it isn't a linear relationship. The
temperature sensor assembled together 0520102
with pressure sensor.
Pin function:
1. Ground
2. Intake temp. sensor
3. To 5V power
4. Intake pressure signal

Connection between sensors and ECU.

ECU

T-MAP
0520103

05-201
CFMOTO
The following figure refers to output volatge-pressure relation.
Testing pressure range: (10~115)kPa

5
4.65
Output Voltage Uout in V

0.4
0
0 10 115
Absolute Pressure Pabs in KPA 0520201

The following chart explains resistance-temperature relation.

60000

50000

40000

30000

20000

10000

-10000
Temp.(°C) Resistance(OHM) 0520202

05-202
 5.9 Electrical System
5.9.4.4 Water Temperature Senser
This sensor is a negative temperature
2
coefficient(NTC) thermistance, whose
1 3
resistance increases with the temperature
of coolant decreases. It outputs 2 set of
coefficients, one is for ECU to monitor the
temperature of coolant, the other is for
meter display.

1 and 3 consists of one group, which

provides signal for ECU.

Water temperature sensor 0520301

Connection between sensors and ECU.

Water temperature sensor

0520302

The right from is the property list between Resistance(kΩ)

temperature and resistance of 1 and 3. Temperature(˚C)
(1&3)
The signal is to ECU. -20±0.1 13.71~16.94
25±0.1 1.825~2.155
80±0.1 0.303~0.326
110±0.1 0.1383~0.1451

05-203
CFMOTO
5.9.4.5 Oxygen Sensor
It's located in the exhaust stream to
measure the amount of oxygen in exhaust
and send the signal to ECU, which can
revise the fuel injector output, so as to
reduce the amounts of both unburnt
fuel and oxides of nitrogen entering the
atmosphere.
D
Pin function: C
A. To heating power positive B
B. To heating power negative pole A
C. Output signal negative
D. Output signal positive
0520401

Connection between sensors and ECU.

Oxygen Oxygen
snesor 2 snesor 1
0520402

05-204
 5.9 Electrical System

5.9.4.6 Mileage Sensor (Speed Sensor)

This sensor is used to detect the rotating 1 2 3
speed of the engine output shaft and
provide the signal for ECU to determine
the vehicle speed. It belongs to Hall effect
sensor, that varies its output voltage in
response to a magnetic field.

Pin function:
1. Ground
2. Output voltage signal Mileage sensor 0520501
3. Power+DC12V

Connection between sensors and ECU.

+12V Power

Ground

Hall switch

Mileage sensor
0520502

2
Mileage sensor test 3

●Ground pin 1and connect pin 3 with +12V

power.
●Fix a gear 2.5mm away from a speed
sensor as the right figure illustrates.
●Turn multimeter to DCV range.
●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,that indicates Gear
the sensor is defective and needs to be
replaced.
0520503

05-205
CFMOTO

5.9.4.7 Gear Sensor Gear sensor

This sensor is used to provide the gear
position signal for meter display.
H L
N
Pin function: R P

L(Low Gear)
H(High Gear)
N(Neutral)
R(Reverse Gear)
P(Park Gear)

0520601

●When each pin at a certain gear position,

there is continuity between this pin and
engine. Otherwise, there is no continuity.

Reverse pre-caution:
●The reverse signal will give to the ECU
and dashboard at the same time. The ECU
will limit the vehicle speed depends on this
signal.

05-206
 5.9 Electrical System
5.9.4.8 Fuel Pump Fuel pump
This fuel pump assembly includes fuel
pump, plastic support, preliminary filter,
fine filter and pressure regulator. It supplies
fuel for engine under a certain pressure
and flow.
Pin function:
1. Ground
2. To fuel pump relay output
Parameters:
Pressure regulator opening pressure:
0.33MPa±0.02MPa
Flow speed: more than 35L/h
●This fuel pump is located in fuel tank.
●Don't operate the fuel pump in dry
condition in order to prevent damage.
●Always handle the fuel pump gently.
Never drop the fuel pump, especially on a
hard surface.
●Battery supplies power for fuel pump
assembly via fuel pump relay, which
connects the fuel pump circuit only with the
engine started. 0520701
Fuel pressure test:
●Connect the fuel pressure gauge with fuel
outlet and tighten the joint with a clamp to
prevent fuel leaks.
●Route according to the right circuit.
●Turn both ignition switch engine stop
switch on.
●At this moment, fuel pump will operate
for 5 seconds. After the fuel pump stops
running, fuel pressure should be in
specification. Otherwise, replace it.
●After the engine stops running,0.25MPa
fuel pressure should be kept for more than
5 minutes. Otherwise, replace the fuel
pump.
Pressure relief in fuel system:
In an EFI model, the pressure in fuel
system is very high, so all the line is
high pressure resistant. Even though the
engine is not started, the pressure in fuel
system remains high. Therefore, it's not
recommended to remove fuel lines before
pressure relief.
Follow the procedure below to perform
pressure relief:
Remove fuel pump relay. Start the
engine and allow it to idle until the
engine stops automatically.

05-207
CFMOTO
5.9.4.9 Fuel Injector
One end of fuel injector mounts into fuel
injector seat, and the other end attaches to
the injector cap, which connects with a fuel
line. Fuel injector is controlled by ECU to 1 2
inject fuel at stated time into the engine.
This injector nozzle is a 4-hole style. Don't
turn injector after the joint between injector
and injector cap is installed.

Pin function:
1. Connect ECU’s A3 terminal for first
cylinder injector Injector
0520801
1. Connect ECU’s B3 terminal for first
cylinder injector
2. Connect with main relay output terminal

Main relay output terminal

Connection between injectors and ECU.

Fuel injector installation:

●Install fuel injector manually. Never knock
fuel injector with a hammer.
●When removing and installing fuel
injector, the o-rings on both ends must be
replaced.
●Perform pressure relief before fuel
Injector 1 Injector 2
injector removal if necessary.
0520802
●Test the fuel injector sealing after
installation to ensure no leaks.

05-208
 5.9 Electrical System

status 1
1

5.9.4.10 Idle Stepping Motor

Idle stepping motor controls the air flow
speed. The motor is controlled by ECU
depending on engine load by electric pulse
time and frequency. The air flow speed
is different when vehicle runs in different
situation. So the ECU adjusts this to suit 0520901
the situation and let the engine work of
high efficiency.

status 2
1

0520902

Pin function:

1. Pin 1 to ECU's A1

2. Pin 2 to ECU's A2

3. Pin 3 to ECU's B1

4. Pin 4 to ECU's B2

Connection between stepping motor and

ECU.

Idle stepping motor

0520903
0520902

05-209
CFMOTO

5.9.4.11 Ignition Coil

Ignition coil transforms the low voltage of
primary coil to high voltage of secondary
coil needed to spark the spark plug and 1

ignite the mixture of air and fuel in cylinder.

2

Pin function: 3
1. Ignition coil 1 of first cylinder to ECU's
Q3 (Ground)
1. Ignition coil 2 of second cylinder to
ECU's Q3 (Ground) 0521001
2. Ignition coil 1 of first cylinder to ECU's
F1 (Power "+")
2. Ignition coil 2 of second cylinder to
ECU's F1 (Power "+")
3. Ignition coil 1 of first cylinder to ECU's
Q2 (Control signal)
3. Ignition coil 2 of second cylinder to
ECU's Q4 (Control signal)

Connection between ignition coils and

ECU.

Ignition coil 1 & Ignition coil 2 &

spark plug spark plug 0521002

05-210
 5.9 Electrical System
Secondary ignition voltage test

Peak voltage meter

●Connect the engine according to EFI

wiring diagram.
●Connect the peak voltage tester according
to the right diagram.
●Start the engine.
Battery
●Secondary ignition voltage should be Spark plug
more than 27 kV.

0521101

Ignition Coil Parameters

Value Unit
Item
Min Standard Max
Stated Voltage 14 V
Operating Voltage 6 16.5 V
Resistance Primary 0.7 Ω
(20°C~25°C) Secondary 6.9 kΩ

05-211
CFMOTO

5.9.5 EFI Self-Diagnosis

ECU constantly monitors sensors, actuators, circuits, MIL, battery voltage etc., even
itself. It also tests sensors output signal, actuator drive signal and inner signal (such as
closed-loop control, coolant temp., signal, idle speed control, battery voltage control etc.
for reliability). If any malfunction or suspectable signal found, ECU would record the fault
information in RAM.
Fault information comes in form of fault codes, which are then displayed on PDA, in
sequence of which fault comes first.
PDA or MIL can be used to locate the part in trouble immediately after fault happens.
The EFI system can do self-diagnosis by MIL indicator and PDA.

5.9.5.1 MIL
MIL is a light-emitting diode and located
on instrument panel. It indicates different
fault codes through the flashes in different
frequency.
MIL Circuit: The current to ECU's C1 pin
should be less than 0.1A. 2

MIL flash principles:

1
3
a:In flashing mode and no trouble in
memory
ECU
If the ECU shows MIL on flashing mode.
The MIL indicator will flash to show the
fault codes in memory. MIL keeps on 0521201
since the ECU formats. If MIL keeps on. It
means no trouble. The indicator will be off
1 +12V Power 2 Resistance 3 LED
after the engine start.
b:In MIL mode and the got trouble code
(Including engine start and not start)
MIL turns on for 5 seconds and turns off.
Then MIL flashes to indicate a fault code:
The interval between fault codes is 3.5s,
between digits is 1.2s, and a flash lasts
for 0.4s as well as the interval between 2
flashes. MIL flashes 10 times to indicate 0.
For 1-9, how much it counts depends on
how many times MIL flashes.

05-212
 5.9 Electrical System
5.9.5.2 PDA
PDA uses OBD standard line. Just connect
the cable to diagnose connector.

Picture shows the PDA key functions.

Please read the PDA owners manual for
more details. 2 3
Note: Remove the K-line before
diagnosing. 4 5

6
Key function:
LH Key: Page up
UP Key: Scroll Up 7
RH Key: Page Down 0521301
Down Key: Scroll Down
OK Key: Entrance
EXIT Key: Exit
1 UP Key 4 EXIT Key 7 Power
2 LH Key 5 OK Key
3 RH Key 6 Down Key

5.9.5.3 PDA Function

(A) Version Infomation Display
PDA can display engine, ECU hardware and soft ware information.
(B) Fault Display
PDA monitors IAP sensor,IAT sensor, coolant temperature sensor, TPS, O2S, O2S
heater circuit, air-to-fuel ratio revision, fuel injector, fuel pump relay, CPS, speed signal,
idle speed, idle air control valve, system voltage, ECU, FI indicator and displays the fault
code.
(C) Engine Data stream Display
PDA can display battery voltage, RPM, desired idle speed, vehicle speed, coolant
temperature, coolant temperature sensor signal voltage, inlet air temperature, IAT sensor
signal voltage, inlet air pressure, inlet air flow, IACV target position, TPS signal voltage,
throttle body position, throttle body relative position, canister duty, charging time, FI
pulse width, park advance angle, O2S voltage, engine relative load, cansiter 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.

05-213
CFMOTO
5.10 Trouble shooting
5.10.1 Engine ..................................................................................... 5-220
5.10.2 Trouble code diagnosing...........................................................5-225
5.10.3 Trouble analyzing......................................................................5-231

05-214
 5.10 Troubleshooting

5.10.1 Engine
Trouble Reason Solution

1.Inspect electric system Inspect or replace

● Fuel pump inactive Inspect or charge
● Battery low Inspect or replace
● EFI connection bad
2.Inspect the sparkplug Inspect or replace
● Ignition coil bad Inspect or replace
●Ignition bad or aging Inspect or replace
●RPM sensor problem Inspect or replace
●Magneto problem Adjust or replace
● Spark plug gap clearance Clean or replace
● Spark plug dirty Dry or replace
● Spark plug wet
3. Inspect fuel system
● Fuel pump leaking Repair or replace
Engine cannot ● Fuel pipe leaking Inspect tightness
start ● Fuel not enough Inspect fuel tank
● Injector jammed or failed Replace
4.Inspect cylinder pressure
● Cylinder wearing Replace
● Piston ring wearing Replace
● Head Gasket leaking Replace
● Valve wear Replace
●Valve sealing not suitable Repair or replace
● Spark plug loose Tighten to specification
● Start RPM low Inspect starter system
● Valve timing wrong Repair
● Valve clearance not suitable Adjust
5. Idle control valve problem Clean or replace
6. Not in neutral To Neutral/Apply brake
7. MIL flashing/Trouble code Diagnose EFI

1.Idle valve not adjusting See engine control

2.TPS not in 0 See engine control
3.Air filter dirty Replace
4.Cylinder pressure too low Repair
5.Inspect the sparkplug Inspect the reason
Engine hard to
●Spark plug aging Replace
start
●Spark plug mounting bad Replace
●Spark plug damaged Replace
●Spark plug dirty Replace
6.Fuel not enough or pressure too low Inspect the reason
7.EFI bad connection Replace the parts

05-215
CFMOTO
Trouble Reason Solution
1.Coolant level too low Refill
2.Cooling system has bubble Drain the air and refill
3.Water temp sensor problem Replace
4.Thermostat cannot open Replace
5.See leaking hole to see leaking Replace the water seal
6.Inspect the water hose and clamp
●Water pipe cracked or aging Replace
Engine ●Clamp loose Tight
overheat 7.Water pump impeller broken Replace
8.Water pump gasket leaking Tight or replace
9.Cylinder head or body gasket leaking Replace
10. Water pump drain bolt leaking Tight or replace the
gasket
11. Water pump gear wearing Replace
12. Water pump shaft jammed Replace the parts

1.Inspect the oil level to see case or oil seal

leaking.
●Case broken Replace
●Case bolt loose Tighten
●Sealing ring/O-ring/Sealing gasket damaged Replace
Oil pressure low or no pressure

●Piston ring broken(Blue smoke) Replace

●Piston ring broken(Pressure low) Replace
●Oil seal damaged or aging Replace
2.Filter plugged Replace the seals
3.Inspect the oil drain bolt Replace the filter, oil
●Case bottom bolt loose
●Crankcase drain bolt loose or without Tighten
Lubrication

washer Tight or with washer

4.Oil leaking Replace the oil seal
5.Oil strainer jammed Clean, Replace the
strainer
6.Inspect the oil pump
●Oil pump rotor wearing Replace
●Oil leaking or air income jam the pump Replace
●Oil pump gear broken Replace
●Wrong oil Use recommend oil
1. Leaking indicate the oil and water mixed up and Replace the oil and
Oil becoming

leaking water seals

white

2. Cylinder head or body gasket damaged Replace

3. Cylinder head bolt loose Tighten or replace the oil
and damaged parts

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 5.10 Troubleshooting

Trouble Reason Solution

1.CVT Belt narrow / burned Replace
2.Inspect drive pulley
●Weight roller wear Replace all shoe
●Drive pulley rolling track wear Replace
3.Drive/driven pulley moving unsmooth Clean or replace
Abnormal 4.Driven pulley spring press to much Replace
accelerate 5.Driven pulley wear Replace
6.Drive/Driven pulley damaged Replace

7.Intake/Exhaust valve clearance Adjust

8.Cylinder pressure low Repair
9.Spark plug bad ignition Replace

1.Inspect“Abnormal accelerate”item 1~3

Top speed 2.CVT got oil or water / dirt Clean and replace
low 3.Main pulley jammed Clean or replace
4.Driven pulley spring damaged Replace
CVT 1.Inspect drive pulley
●Inspect“Abnormal accelerate”item 1~2
Gearing not
2.Inspect driven pulley
smooth
●Driven pulley spring damaged Replace
●Driven pulley shoe or surface damaged Replace
1.Inspect CVT cooling pipe
●CVT room plugged Clean
●Drive pulley impeller jammed Clean
Belt burned 2.Inspect groove surfaces
●Pulley groove has oil / dirt Clean and replace belt
●CVT room got water income

1.Belt Wearing Replace

2.Wrong belt Replace
3.Wearing in some places Replace
Belt trouble 4.Belt cracked Clean CVT‚Relace
5.Pulley groove oil / dirt Clean
6.Pulley got damaged by rubble Replace
7.Belt is aging Replace

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CFMOTO

Trouble Reason Solution

1.Valve clearance not suit Adjust or replace
2.Tensioner broken Replace
3.Chain guide wear Replace
Cylinder
4.Chain becoms longer or wearing Replace
head noise
5.Chain sprocket bolt loose Tighten
6.Valve rocker arm or camshaft wear Adjust or replace
7.Wrong valve timing Adjust or repair
1.Main bearing damaged Replace
Camshaft 2.Connecting bearing damaged Replace
noise 3.Magneto rotor loose Tight or replace
4.Crankcase bearing wearing Replace
1.Oil leaking Replace, tighten and
Case noise refill
2.Gear teeth damaged Repair
1.Drive pulley slide sleeve wear Replace drive pulley
2.Inspect slide pulley
3.Weight roller wear Replace rollers
Engine
CVT idle 4.Drive pulley roller track wear Replace
noise
noise 5.Drive slide pulley track wearing Replace
6.Nylon sleeve wearing Replace all
7.Moveable side got jammed Clean or replace
8.Drive pulley nut loose Tighten
1.Inspect“Idle noise”1~3
CVT 2.Drive pulley dirty Clean or drain
accelerate 3.Drive/driven pulley nut loose Tight
noise 4.Driven pulley slide sleeve wearing Replace
5.Belt or pulley got damaged Clean and replace
1.Main pulley nut loose
CVT drive Tight
2.Slide pulley sleeve clearance is not Replace
pulley
proper
shake
3.Weight roller wear Replace all
4.Washer not in position Replace
CVT driven
Driven pulley sleeve clearance is not
pulley Replace
proper
movement

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 5.10 Troubleshooting

EFI Trouble Codes

No. Pcode Decription(UAES)

1 P0030 O2 Sensor 1 Heater Contr. Circ. Open
2 P0031 O2 Sensor 1 Heater Contr. Circ. Low
3 P0032 O2 Sensor 1 Heater Contr. Circ. High
4 P0050 O2 Sensor 2 Heater Contr. Circ. Open
5 P0051 O2 Sensor 2 Heater Contr. Circ. Low
6 P0052 O2 Sensor 2 Heater Contr. Circ. High
7 P0107 Manifold Abs.Pressure or Bar.Pressure Low Input
8 P0108 Manifold Abs.Pressure or Bar.Pressure High Input
9 P0112 Intake Air Temp.Circ. Low Input
10 P0113 Intake Air Temp.Circ. High Input
11 P0117 Engine Coolant Temp.Circ. Low Input
12 P0118 Engine Coolant Temp.Circ. High Input
13 P0122 Throttle Pos.Sensor Circ. Low Input
14 P0123 Throttle Pos.Sensor Circ. High Input
15 P0130 O2 Sensor Circ.,Bank1-Sensor1 Malfunction
16 P0131 O2 Sensor Circ.,Bank1-Sensor1 low Voltage
17 P0132 O2 Sensor Circ.,Bank1-Sensor1 High Voltage
18 P0134 O2 Sensor Circ.,Bank1-Sensor1 No Activity Detected
19 P0150 O2 Sensor Circ.,Bank1-Sensor2 Malfunction
20 P0151 O2 Sensor Circ.,Bank1-Sensor2 low Voltage
21 P0152 O2 Sensor Circ.,Bank1-Sensor2 High Voltage
22 P0154 O2 Sensor Circ.,Bank1-Sensor2 No Activity Detected
23 P0201 Cylinder 1- Injector Circuit
24 P0261 Cylinder 1- Injector Circuit Low
25 P0262 Cylinder 1- Injector Circuit High
26 P0202 Cylinder 2- Injector Circuit
27 P0264 Cylinder 2- Injector Circuit Low
28 P0265 Cylinder 2- Injector Circuit High
29 P0322 Ign./Distributor Eng.Speed Inp.Circ. No Signal
30 P0480 cooling fan control Circuit Open
31 P0508 Idle Air Control Circuit Low
32 P0509 Idle Air Control Circuit Low High
33 P0511 Idle Air Control Circuit Open
34 P0560 System Voltage Malfunction
35 P0562 System Voltage Low Voltage
36 P0563 System Voltage High Voltage
37 P0627 Fuel Pump “A” Control Circuit /Open
38 P0629 Fuel Pump “A” Control Circuit High
39 P0650 Malfunction Indicator Lamp Control Circ.
40 P0691 cooling fan control Circuit Low
41 P0692 cooling fan control Circuit High
42 P1116 Engine Coolant Temp High

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5.10.2 Trouble code diagnosing

Instruction:
1. Make sure the trouble is stable first, or it will cause wrong diagnosing.
2.The A/V/O meter to use is a digital style meter. Do not use a pin-point meter to
diagnose the EFI system.
3. If a trouble code shows a voltage low, this may indicate the wire may be short to
ground or open. If the trouble code shows a voltage high, it may indicate the wire is short
to power. If the trouble code shows the wire has no signal, it may indicate the wire may
open or have different troubles.
Help:
1.If a trouble code cannot clear, it means the trouble remains. If it happens
occasionally, pay attention to connection problems.
2. Do not ignore the vehicle maintenance. Make sure that all EFI harness
connections are clean and in good condition.
3. If a trouble cannot be erased, replace the original ECU and test with a known
good ECU. If the trouble code can be erased, it indicates the trouble is in the ECU.
Replace the original ECU and test again.
The following pages provide the trouble code's meaning, possible reason for the
code, and a testing solution. They can be used as examples for diagnostics.

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 5.10 Troubleshooting

Trouble code P0032/P0052:Cylinder 1/Cylinder 2 heating coil high voltage

Possible Reason Testing Solution

Trouble may coming from: Check:
1. ECU to oxygen sensor pin2 1. Measure ECU connecting pin to pin
disconnected 2 of oxygen sensor resistance.
2. Oxygen sensor pin 1 to main relay 2. Measure oxygen sensor pin 1 to
disconnected main relay resistance.
3. Oxygen sensor pin 1 to pin2 3. Measure oxygen sensor pin 1 to 2
disconnected. pin resistance (8.5Ω).

Trouble code P0031/P0051‚Cylinder 1/Cylinder 2 heating coil low voltage

Possible Reason Testing Solution
Trouble may coming from: Check:
1. ECU pin line short to the ground 1. Measure ECU pin to ground
2. ECU pin line short to pin 1 of oxygen resistance
sensor. 2. Measure ECU voltage
3. ECU short to other line. 3. Measure ECU pin to pin D1
resistance (8.5Ω).

Trouble code P0131/P0151:Cylinder 1/Cylinder 2 Oxygen sensor voltage low

Oxygen sensor diagnose instructions: The system will judge the signal by measuring pin
A and pin B output voltage.
The oxygen sensor may be damaged by condensated liquid, especially in cold start
period
Possible Reason Testing Solution
Trouble may coming from: Check:
1. ECU pin line short to the ground 1. Measure ECU pin to ground
2. ECU pin line short to pin 1 of oxygen resistance
sensor. 2. Measure ECU voltage
3. ECU short to other line. 3. Measure ECU pin to pin 1 resistance
4. Oxygen sensor damaged. (8.5Ω).

Trouble code P0132/P0152:Cylinder 1/Cylinder 2 oxygen sensor high voltage

Possible Reason Testing Solution
Trouble may be coming from: Check:
1. The ECU line to pin 3 and pin 4 1. Replace the oxygen sensor
disconnected 2. Replace the ECU
2. Oxy gen s ens or pin 3 and pin 4 3. Line test
disconnected

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CFMOTO

Trouble code P0107:Intake pressure sensor low voltage or open

Possible Reason Testing Solution
Trouble may coming from: Inspect :
1. ECU test the signal line may short to the 1. ECU pin resistance to the ground
ground

Trouble code P0108:Intake pressure sensor high voltage

Possible Reason Testing Solution

Trouble may be coming from: Inspect:
1. ECU test the signal line short to power 1. ECU pin voltage

Trouble code P0112: Intake temp. sensor low voltage

Possible Reason Testing Solution
Trouble may be coming from: Inspect:
1. ECU pin signal line short to the ground 1. Measure ECU pin line resistance to the
ground

Trouble code P0113:Intake temp. sensor high voltage or open

Possible Reason Testing Solution
Trouble may be coming from: Inspect:
1. ECU pin signal line short to power. 1. Measure ECU signal line voltege

Trouble code P0117:Thermo sensor low voltage

Possible Reason Testing Solution
Trouble may be coming from: Inspect:
1. ECU pin signal line short to the ground. 1. Measure ECU line resistance to the
ground.

Trouble code P0118:Thermo sensor high voltage or open

Possible Reason Testing Solution

Trouble may be coming from: Inspect:
1. ECU pin signal line short to the power 1. Measure the ECU pin voltage

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 5.10 Troubleshooting

Trouble code P0122:TPS low voltage or open

Possible Reason Testing Solution
The trouble may be coming from: Inspect:
1. ECU pin line short to the ground 1. Measure the ECU pin line resistance to
the ground.

Trouble code P0123:TPS voltage high

Possible Reason Testing Solution

The trouble may be coming from: Inspect:
1. ECU Pin line short to other line. 1. Measure the voltage from sensor to ECU
pin.

Trouble code P0201/ P0202: Cylinder 1/2 injector coil trouble

Possible Reason Testing Solution

The trouble may be coming from: Inspect:
1. Injector coil disconnected 1. Measure the injector resistance.
2. Injector is not well connected to 2. Inspect the connecting cable to
ECU. check it well connected.
3. Injector is not connected to the relay. 3. Measure the resistance to ECU
4. The running line to ECU short to the 4. Measure the voltage to ECU.
ground.
5. The line to ECU is short to other line.

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CFMOTO
Trouble code P0627: Fuel pump relay coil open.
Trouble code P0629: Fuel pump relay coil short to power.
Possible Reason Testing Solution
Trouble may be coming from: Inspect:
1. Fuel pump relay to ECU is open 1. Measure the fuel pump relay coil
to fuel pump/short to the ground/Short to resistance or voltage to ECU.
power. 2. Measure resistance between fuel
2. Fuel pump relay is open to main pump relay and main relay.
relay. 3. Measure the resistance between 2
3. Fuel pump relay coil open pins of relay

Trouble code P0562:Battery voltage low

Trouble code P0563:Battery voltage high
Possible Reason Testing Solution
Trouble may be coming from: Inspect:
1. Magneto damaged or battery energy 1. Test the magneto ability(Measure the
fl ow. voltage after start)
2. Magneto stator coil open 2. Measure rectifi er output voltage.
3. Rectifi er damaged.

Trouble code P0650: MIL wiring trouble

Possible Reason Testing Solution
Trouble may be coming from Inspect the item below
1. MIL indicator to ECU wire open to 1. Measure the resistance or voltage
indicator/Short to ground/short to power. between MIL indicator and ECU.
2. MIL indicator open to main relay
3. MIL indicator burnt

Trouble code P0322: No RPM sensor signal

Reason:After the engine start. The ECU will test the signal from CPS and other parts.
Judge from the signal reasonability.
Possible Reason Testing Solution
Trouble may be coming from Inspect:
1. Wire connection short or open 1. Inspect cable connectors connection.
interval. 2. Inspect magneto fl ywheel bosses
2. C r a n k s h a f t s i g n a l d i s c w r o n g 3. Measure the resistance between
position. CPS and ECU.
3. RPM sensor wrong position. 4. Measure CPS resistance
4. CPS open to ECU 5. Measure CPS peak voltage
5. CPS short to ECU
6. CPS coil open

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 5.10 Troubleshooting

5.10.3 Trouble analyzing

Before trouble diagnosis by engine problems, initial checking should be done as follows.
1. Confirm if trouble light is valid;
2. Confirm there’s no trouble code record by PDA checking.
3. Confirm trouble existing complained by end-user. Then check the following points.
(1)Check fuel hoses for any fuel leakage;
(2)Check vacuum pipes for any broken, twisted or improper connection;
(3)Check intake manifold for blockage, air leakage or damaged;
(4)Check high-tension cable for any damaged, aging;or ignition order is correct.
(5) Check wiring grounds are clean and firm;
(6) Check connector of all sensors and actuators for any loose or improper connection.
Important note: In case there’re some problems as mentioned, repair work should be
done first, then go to next diagnosis.
Diagnosis tips:
1. Confirm engine has no previous trouble record;
2. Confirm there’s really trouble existing;
3. During checking, do not neglect vehicle periodic maintenance, cylinder pressure,
valve, fuel supply, etc.
4. Replace ECU to test.
In case trouble disappears, then it is a problem of the ECU. If trouble still exists, then
original ECU and check other points.
Common troubles list:
● When starting 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 stops when switching on lights or other
electrical components.
● Starting is ok, but too high idle speed.
● RPM cannot go up or engine stop when accelerating.
● Slow acceleration.
● Insufficient power and bad performance when accelerating.

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CFMOTO
1) Starting Failure/Hard Starting
Possible defective parts: 1. Battery; 2. Starter motor; 3. Wirings harness or ignition
switch; 4. Engine mechanism part.
General diagnostic procedures

Item Procedures Results Next

Use multi-meter to check battery voltage if voltage YES Next Step
1
is between 8V~12V or not when engine starts NO Replace battery
YES Next Step
Keep ignition switch “on”, use multi-meter to check
2 Repair switches or
if voltage at the starting motor is over 8V. NO
change harness
Disassemble starting motor and check its working Repair or replace
YES
3 status, especially whether there was broken circuit starting motor
or jammed by bad components. NO Next Step
Change to proper
If error only occurs in winter, check if starting motor YES
4 lubricant
resistance is too big caused by improper oil used
NO Next Step
Check resistance
YES
Check if mechanical resistance is too big inside inside engine
5
engine Repeat above
NO
procedures

(2) When starting, engine can rotate but cannot start

Possible defective parts:1.No fuel;2.Fuel pump;3.Pick up;4.Ignition coil;5.Mechanical
parts of engine
General diagnostic procedures:

Item Procedures Results Next

Connect fuel pressure gauge, and turn on ignition YES Next Step
1 switch or start engine, check if fuel pressure is Repair fuel supply
approximately 300kPa NO
system
YES Next Step
Connect PDA, check if there’s signal of RPM data
2 Check and repair
after starting engine NO
RPM sensor circuit
Disconnect high-tension cable, connect spark YES Next Step
3 tester and set its electrode to 5mm, then start Check and repair
NO
engine to check if blue and white spark appears ignition system

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 5.10 Troubleshooting

Eliminate engine
YES
4 Check if cylinder pressure is sufficient Mechanical failures
NO Next step
Use PDA to test, turn on ignition switch, check if power YES Use PDA to check
5 supply of ECU pin 1 and pin 21 is normal; check if pin 2 Repair related
NO
and pin 17 works normally circuit

(3) Difficult to start hot engine

General failure part (1)Water in fuel tank(2)fuel pump(3)water temp. sensor(4)Ignition
coil.
General diagnostic procedures:

Item Procedures Results Next

Connect fuel pump gauge, start engine, check YES Next step
1 ifpressure is approximately 300kPa Repair fuel supply
NO
system
Disconnect high-tension cable, connect spark YES Next step
2 tester and set its electrode to 5mm, then start Repair ignition
NO
engine to check if blue and white spark appears system
Disconnect water temp.sensor connector and Repair wiring or
YES
start engine to check if engine can start.(or use replace sensor
3
one 300ohm resistance to replace water temp.
NO Next step
sensor)
Check whether the failure happens right after YES Change fuel
4
filling fuel NO Next step
Connect PDA and switch on ignition to check YES Use PDA to check
ECU-G1,F1,P4, and O4 pin if it is powered
5 Repair related
normally; Check ECU-Q2,H3 and C3 pin if it is NO
circuit
connected to ground normally.

(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)Throttlebody and by-pass(7)Mechanical parts of engine
General diagnostic procedures:

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CFMOTO
Item Procedures Results Next
Connect fuel pressure gauge, and turn on ignition YES Next step
1 switch or start engine. Check if fuel pressure is Repair fuel supply
approximately 300kPa. NO
system
YES Next step
Disconnect high-tension cable, connect spark tester
Repair ignition
2 and set its electrode to 5mm, then start engine to
NO System
check if blue and white spark appears
Repair circuit or
Disconnect water temp.sensor connector and start YES
replace sensor
3 engine to check if engine can start.(or use one
2500ohm resistance to replace water temp.sensor) NO Next step

Clean throttle body

Slightly draw throttle cable and check if engine can YES
4 and by-pass
start easily
NO Next step
Replace
Disassemble injector and use special tool to check YES
5 injector
if there is leakage or block
NO Next step
Check whether the failure happens right after filling YES Change fuel
6
fuel NO Next step
Eliminate engine
YES
7 Check if cylinder pressure is sufficient mechanic failures
NO Next step
Connect PDA and switch on ignition to check ECU- YES Check with PDA
G1,F1,P4, and O4 pin if it is powered normally;
8
Check ECU-Q2,H3 and C3 pin if it is connected to NO Check circuit
ground normally.

(5) Difficult to start in any conditions.

General failure part 1.Water in fuel tank 2.Fuel pump 3.Water temp. sensor 4.Injector
5.Ignition coil 6.Throttle body and by-pass 7.Air intake pipe 8.Ignition timing 9.Spark plug
10.Mechanical part of engine.General diagnostic procedures:

Item Procedures Results Next

Repair air intake
YES
1 Check if air filter is blocked or air intake pipeleaks system
NO Next step

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 5.10 Troubleshooting

Item Procedures Results Next

Connect fuel pressure gauge, and turn on ignition YES Next step
2 switch or start engine. Check if fuel pressure is Repair fuel
approximately 300kPa. NO
Supply system
Disconnect high-tension cable, connect spark tester YES Next step
3 and set its electrode to 5mm, then start engine to Repair ignition
NO
check if blue and white spark appears System
Check if spark plug is in good condition (including YES Next step
4
its type and clearance) NO Adjust or replace
Repair circuit or
Disconnect water temp. sensor connector and YES
5 replace sensor
start engine to check if engine can start.
NO Next step
Clean throttle body
Slightly draw throttle cable and check if engine can YES
6 and bypass
start easily
NO Next step
Disassemble injector and use special tool to check YES Replace injector
7
if there is leakage or blocked. NO Next step
Check whether the failure happens right after filling YES Change fuel
8
fuel NO Next step
Eliminate
YES mechanical
9 Check if cylinder pressure is sufficient
failures
NO Next step
YES Next step
10 Check if ignition timing
NO Adjust ignition timing
Connect PDA and switch on ignition to check ECU- YES Use PDA to check
G1,F1,P4, and O4 pin if it is powered normally;
11 Repair related
Check ECU-Q2,H3 and C3 pin if it is connected to NO
circuit
ground normally.

(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
General diagnostic procedures:

Item Procedures Results Next

Repair air intake
YES
1 Check if air filter is blocked or air intake pipe leaks system
NO Next step

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CFMOTO
YES Clean or replace
2 Check if air control valve is blocked
NO Next step
Check if spark plug is in good condition (including its type YES Next step
3
and clearance) NO Adjust or replace
Check if there are carbon deposits inside throttle bodyand YES Clean
4 air control valve
NO Next step
Disassemble injector and use special tool to checkif there YES Replace
5
is leakage or blocked or wrong fuel flow NO Next step
Check whether the failure happens right after fillingfuel YES Change fuel
6
NO Next step
Eliminate mechanical
YES
7 Check if cylinder pressure is sufficient failures
NO Next step
YES Next step
8 Check if ignition timing
NO Repair ignition timing
Connect PDA and switch on ignition to check ECU- YES Use PDA to check
G1,F1,P4, and O4 pin if it is powered normally; Check Repair related
9
ECU-Q2,H3 and C3 pin if it is connected to ground NO circuit
normally.

(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

General diagnostic procedures:

Item Procedures Results Next

Repair air intake
YES
1 Check if air filter is blocked or air intake pipe leaks system
NO Next step
Check if spark plug is in good condition (including YES Next step
2
its type and clearance) NO Adjust or replace
Check if there are carbon deposits inside throttle YES Clean
3
body and air control valve NO Next step
Repair circuit or
Disconnect water temp. sensor connector and start YES
4 replace sensor
engine to check idle speed is stable
NO Next step
Disassemble injector and use special tool to check YES Replace
5
if there is leakage or blocked or wrong fuel flow NO Next step

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 5.10 Troubleshooting
Check whether the failure happens right after YES Change fuel
6
fillingfuel NO Next step
Eliminate
YES mechanical
7 Check if cylinder pressure is sufficient
failures
NO Next step
Connect PDA and switch on ignition to check ECU- YES Use PDA to check
G1,F1,P4, and O4 pin if it is powered normally;
8 Repair related
Check ECU-Q2,H3 and C3 pin if it is connected to NO
circuit
ground normally.

(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

General diagnostic procedures:

Item Procedures Results Next
Repair air intake
YES
1 Check if air filter is blocked or air intake pipe leaks system
NO Next step
Check if spark plug is in good condition (including YES Next step
2
its type and clearance) NO Adjust or replace
Check if there are carbon deposit inside throttle YES Clean
3
bodyand air control valve NO Next step
Repair circuit or
Disconnect water temp. sensor connector and start YES
4 replace sensor
engine to check idle speed is stable or not
NO Next step
YES Replace
Disassemble injector and use special tool to checkif
5
there is leakage or blocked or wrong fuel flow NO Next step

Check whether the failure happens right after YES Change fuel
6
fillingfuel NO Next step
Eliminate
YES
7 Check if cylinder pressure is sufficient mechanicalfailures
NO Next step
Connect PDA and switch on ignition to check ECU- YES Use PDA to check
G1,F1,P4, and O4 pin if it is powered normally;
8 Repair related
Check ECU-Q2,H3 and C3 pin if it is connected to NO
circuit
ground normally.
Turn off the ignition switch for 3 seconds then start YES
9
again NO Check the wire again

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CFMOTO
(9) Engine starts normally, but idle speed is unstable or engine stops when working
partially
General failure part: 1. Air control valve 2. Injector
General diagnostic procedures:
Item Procedures Results Next
Disassemble air control valve and check if there is Clean related
YES
1 carbon deposit inside throttle body, idle adjustment parts
and by-pass NO Next step
Check if output power increases when lighting, by YES To step 4
2 using PDA to test if ignition advance angle, fuel
NO Next step
spray and air intake volume is normal
Repair air intake
NO
System
Disassemble injector and use special tool to check
3 "Replace
if there is leakage or blocked or wrong fuel flow YES
injector"
NO Next step
Connect PDA and switch on ignition to check ECU- "Use PDA to
YES
G1,F1,P4, and O4 pin if it is powered normally; check"
4
Check ECU-Q2,H3 and C3 pin if it is connected to Repair related
NO
ground normally. circuit

(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 temperature sensor 5. Ignition timing
General diagnostic procedures:

Item Procedures Results Next

YES Adjust
1 Check if throttle cable is jammed or too tight
NO Next step
Check if there’s leakage between air intake pipand Repair air intake
YES
2 injector seat system
NO Next step
Clean related
Remove air control valve and check if there is YES
Parts
3 carbon deposit inside throttle body, air controlvalve
and by-pass NO Next step
Repair wiring or
Remove water temp. sensor connector, start engine YES
4 replace sensor
to check if idle speed is too high
NO Next step
YES Next step
Check if ignition timing
5 Repair ignition
NO
Timing
Turn off the ignition switch for 3 seconds then restart
6
the vehicle NO Check the wire

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 5.10 Troubleshooting

Connect PDA and switch on ignition to check ECU- YES Use PDA to check
G1,F1,P4, and O4 pin if it is powered normally; Check
7
ECU-Q2,H3 and C3 pin if it is connected to ground NO Repair related
normally. circuit

(11) RPM cannot increase or engine stops 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
General diagnostic procedures:

Item Procedures Results Next

Repair air
YES
1 Check that air filter is blocked intake system
NO Next step
Connect fuel pressure gauge, and turn on ignition YES Next step
2 switch or start engine. Check if fuel pressure is Repair fuel
NO
approximately 300kPa. supply system
YES Next step
Check if spark plug is in good condition (including
3 Adjust or
its type and clearance) NO
replace
Remove air control valve and check if there is Clean related
YES
4 carbon deposit inside throttle body, air controlvalve parts
and by-pass NO Next step
YES Next step
5 Check that TPS and its circuit is normal Repair circuit
NO
or replace TPS
Disassemble injector and use special tool to check YES Replace
6
if there is leakage or blocked NO Next step
Check whether the failure happens right after filling YES Change fuel
7
fuel NO Next step
YES Next step
8 Check if ignition timing Adjust ignition
NO
timing
YES Next step
Repair or
9 Check if exhaust gas exhales smoothly
NO replace
exhaust pipe
Connect PDA and switch on ignition to check ECU- Use PDA to
YES
G1,F1,P4, and O4 pin if it is powered normally; check
10
Check ECU-Q2,H3 and C3 pin if it is connected to Repair related
NO
ground normally. circuit

05-233
CFMOTO
(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

General diagnostic procedures:

Item Procedures Results Next
Repair air intake
YES
1 Check that air filter is blocked system
NO Next step
Connect fuel pressure gauge, and turn on ignition YES Next step
2 switch or start engine. Check if fuel pressure is Repair fuel supply
NO
approximately 300kPa. system
Check if spark plug is in good condition (including YES Next step
3
its type and clearance) NO Adjust or replace
Remove air control valve and check if there is YES Clean related parts
4 carbon deposit inside throttle body, air controlvalve
NO Next step
and by-pass
YES Next step
5 Check that TPS and its circuit is normal Repair circuit or
NO
replace TPS
Disassemble injector and use special tool to check YES Replace
6
ifthere is leakage or blocked NO Next step
Check whether the failure happens right after YES Change fuel
7
fillingfuel NO Next step
YES Next step
8 Check if ignition timing Adjust ignition
NO
timing
YES Next step
9 Check if exhaust gas exhales smoothly Repair or replace
NO
Exhaust pipe
Connect PDA and switch on ignition to check ECU- YES Use PDA to check
G1,F1,P4, and O4 pin if it is powered normally;
10 Repair related
Check ECU-Q2,H3 and C3 pin if it is connected to NO
circuit
ground normally.

(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

05-234
 5.10 Troubleshooting
General diagnostic procedures:

Item Procedures Results Next

Check clutch performance, low tire pressure, bad YES Repair
1
brake or wrong tire size NO Next step
Repair air intake
YES
2 Check that air filter is blocked system
NO Next step
Connect fuel pressure gauge, and turn on ignition YES Next step
3 switch or start engine. Check if fuel pressure is Repair fuel supply
NO
approximately 300kPa. system
Disconnect high-tension cable, connect spark YES Next step
4 tester and set its electrode to 5mm,then start Repair ignition
NO
engine to check if spark is strongenough system
YES Next step
Check if spark plug is in good condition (including
5 Adjust or
its type and clearance) NO
replace
Clean related
Remove air control valve and check if there YES
Part
6 iscarbon deposit inside throttle body, air
controlvalve and by-pass NO Next step
YES Next step
7 Check that TPS and its circuit is normal Repair circuit or
NO
Replace sensor
Disassemble injector and use special tool to YES Replace
8
check if there is leakage or blocked NO Next step
C h e ck w he th e r th e fa i l u r e happens r ight YES Change fuel
9
afterfilling fuel NO Next step
YES Next step
10 Check if ignition timing Repair ignition
NO
Timing
YES Next step
11 Check if exhaust gas exhales smoothly
NO Repair or replace
Connect PDA and switch on ignition to check YES Use PDA to check
ECU-G1,F1,P4, and O4 pin if it is powered
12 Repair related
normally; Check ECU-Q2,H3 and C3 pin if it is NO
circuit
connected to ground normally.

05-235
 06 Vehicle chassis
6 Vehicle chassis
Maintenance information........................................................................6-2
6.1 Troubleshooting................................................................................6-3
6.2 Wheels..............................................................................................6-3
6.3 Braking system.................................................................................6-4
6.4 Suspension system.......................................................................... 6-6
6.5 Steering system................................................................................6-10
6.6 Front and rear gear case..................................................................6-17
6.6.1 Front and rear gear case maintenance information.....................6-17
6.6.2 Front and rear gear case removal and installation.......................6-19
6.6.3 Front and rear gear case oil replacement.....................................6-20
6.6.4 Front gear case service................................................................6-21
6.6.4.1 Front gear case disassembly..................................................6-21
6.6.4.2 Front gear case inspection.....................................................6-22
6.6.4.3 Front gear case assembly and adjustment............................6-23
6.6.5 Rear gear case service (No-spin differential)...............................6-26
6.6.5.1 Rear gear case disassembly.. ...............................................6-26
6.6.5.2 Rear gear case inspection.....................................................6-27
6.6.5.3 Rear gear case assembly and adjustment.............................6-28
6.6.6 Rear gear case service (No differential).......................................6-30
6.6.6.1 Rear gear case disassembly.. ...............................................6-30
6.6.6.2 Rear gear case inspection.....................................................6-31
6.6.6.3 Rear gear case assembly and adjustment.............................6-32
6.6.7 Rear gear case service (Automatic lock differential)....................6-34
6.6.7.1 Rear gear case disassembly..................................................6-34
6.6.7.2 Rear gear case inspection.....................................................6-35
6.6.7.3 Rear gear case assembly and adjustment.............................6-36
6.7 Drive shaft.........................................................................................6-38
6.7.1 CV shaft and drive shaft information............................................6-38
6.7.2 CV shaft and drive shaft removal and installation.........................6-39
6.7.3 Front and rear CV shaft disassembly...........................................6-41
6.7.4 Front and rear CV shaft inspection..............................................6-42
6.7.5 Front drive shaft disassembly and inspection..............................6-43
6.7.6 Rear drive shaft disassembly and inspection...............................6-44

06-1
CFMOTO
Maintenance information
Precautions
NOTE:
·The vehicle must be lifted and supported on the frame before working on wheels and
suspension.
·Do not use excessive force on the wheel to avoid wheel damage.
·Use special rim protector to avoid damage the rim when removing it.
Maintenance specifications
Service
Item Standard
limit
Rim Axial run-out 0.8mm 2mm
Radial run-out 0.8mm 2mm
Tread Depth -- 3mm
Tire Front Pressure
45kPa(0.45kgf/cm2) (6.5PSI)
Rear Pressure
Front brake Brake lever clearance 8mm~12mm

Tighten torque*
Name Size Tighten torque (N·m)
Steering rod nut M10×1.25 30~40
Steering shaft locking nut M14×1.5 100~120
Brake disc bolt 901-08.00.03 25~35
Brake caliper bolt M8×16 15~25
Axle nut M24×2 220~250
M10×1.25×50
Shock absorber nut 40~50
M10×1.25×70
Wheel nut 9010-070002 70~80
Suspension arm bolt M10×1.25×70 40~50
*Refer to Chapter 1 for a comprehensive list of torque values when a torque value is not
specifically listed.

Tools
Item Size
Open-end wrench S8~S10, S14~S17, S18
Criss-cross Screw driver
Standard Screw driver
Caliper
O-ring caliper
Hammer

06-2
 06 Vehicle chassis
6.1 Trouble shooting Wheel cannot turn freely
.. Faulty wheel bearing.
Heavy steering: .. Wheel installed improperly.
.. Upper thread is over-tightened. .. Brake drag.
.. Steering bearing is damaged or worn. Suspension too soft
.. Inner & outer bearing races are damaged .. Weakened shock absorber/mis-adjusted.
or not well tightened. .. Tire pressure is too low.
.. Steering stem is distorted. Suspension too hard
.. Low tire pressure. .. Shock absorber is damaged/mis-
.. Tire worn. adjusted.
Excessive handlebar free play: .. Tire pressure is too high.
.. Steering bearing is damaged or not well Noise from front shock absorber
tightened. .. Faulty shock absorber.
.. LH and RH shock absorber settings are .. Loosened parts of shock absorber.
not matched. Poor brake performance
.. Defective tires. .. Faulty brake adjustment.
.. Deformed frame. .. Worn brake disc.
.. Worn tires. .. Brake pads worn.
.. Defective wheel bearing.
Severe front wheel run-out:
.. Wheel rim distorted.
.. Faulty wheel bearing.
.. Faulty tires.
.. Improper balance of wheels.
.. Improper tightening of axle nut on shaft.

6.2 Wheels (See picture 060301)  1

Removal:  2
Lift and support the vehicle at the frame.
Make sure there is no force on the wheel.
Remove 4 wheel nuts 1.
Remove the wheel.
Remove decorating cover 2 if required.

060301
Rim Inspection:
Check wheel for damage, deformation,
nicks.
Slowly turn wheel in a tire balancer, and
use a dial gauge to measure the rim run-
out.
Service limit: 2.0mm (Axial)
2.0mm (Radial)
If any abnormal condition has been found,
replace it.

Installation:
Assemble wheel and nuts on the hub.
Wheel nuts tightening torque:
70N·m~80N·m  1  2  3  4  5 060401

06-3
CFMOTO
Wheel Hub and Brake Disc
Removal
Remove wheel and brake caliper (See
picture 060401).
Remove the retainer pin 2 and wheel hub
nut 3.
Remove the brake disc and hub assembly.
Remove the 4 brake disc bolts 6 (if
required).
Remove front wheel hub 4 from the brake
disc 5 (if required).
Inspection
Thickness of brake disc: If less than 4mm,
replace it. 060402
Installation
Reverse the removal procedure for
installation.
NOTE:
Tightening torque of axle nut:
110N·m~130N·m
Tightening torque of brake disc bolts 6:
25N·m~35N·m (apply thread locker).
Rear wheel procedures are the same as  2
the front wheel.  1

6.3 Brake system

Front Brake Caliper
Removal: (See picture 060403)
060403
Remove front wheel.
Remove the two bolts 2.
Remove caliper 1.
Inspection:
Check for any cracks of brake calipers and
leaks from tightening areas. Replace if
necessary.  3
Installation:
Tightening torque of brake caliper bolt:
40N·m~50N·m (Apply thread locker)
 4  4
060404
Brake Pad Removal (See picture 060403)
Remove brake caliper.
Remove main sliding shaft of brake pads 3
with wrench.
Remove brake pads 4.
Measure thickness of brake pad friction
surface 4. If it is less than 1.5mm, then
replace both pads at the same time.
Installation:
Reverse the removal procedure for
installation.

06-4
 06 Vehicle chassis
Front brake master cylinder
Removal: (See picture 060501)  1  2
Remove right hand guard.
Remove bolts 2.
Separate front brake master cylinder 1
from the handlebar. It's not necessary to
remove it if replacement is not required.
Installation:
Reverse the removal procedure for
installation.
NOTE: Do not hang the master cylinder
by the brake line, keep the master cylinder
upright (not inclined) while installing it to
avoid air entering brake line. Keep the  2 060501
brake line routed properly (refer to Chapter
1) and ensure it is not kinked.
After installation, bleed the brake system
anytime it has been repaired and check
brake performance.

Foot brake master cylinder

Removal: (See picture 060502)
Remove brake pedal (See 2.6.6).
 5
Remove the retainer pin and pin shaft 3.
Remove 2 bolts 4.
Remove the master cylinder 5.
Remove 2 bolts 6.  4  4  3
Remove oil cup 7 (See 060503). 060502
Installation:
Reverse the removal procedure for
installation.  7
NOTE:
1. In order to avoid air entering the master
cylinder, keep it level at all times.

2. Keep the brake line routed properly and  6

ensure it is not, and cannot, be kinked.

3. After installation, bleed the brake system

anytime it has been repaired and check
brake performance. 060503

06-5
CFMOTO
PCV
Removal: (See picture 060601)
Remove bolt 1 to remove PCV 2.  2
Installation:
Reverse the removal procedure.
NOTE: Refer to 1.7.2 to arrange the
brake pipe routing. If front and rear braking  1
system are not working together, check for
leaking or jammed lines.

Rear brake caliper

Removal: (See picture 060602)
Remove bolts 1 and remove caliper 2. 060601
Installation:
Reverse the removal procedure for
installation.
NOTE: Inspect the brake switch and
brake light function to make sure it is
working.
 2
 1
6.4 Suspension system
Front suspension system
Removal: (See pictures 060603, 060604) 060602
Set the vehicle on flat ground. Use lifting
jack to lift up the vehicle and support on
the frame.
Remove front wheel.
Remove front protector of suspension.
Remove brake caliper.
Remove wheel hub and brake disc  2  1
assembly.
Remove shock absorber bolt and nut 1.
Remove shock absorber 2.
Remove cotter pin and locking nut 6 of
steering tie rod.
Remove cotter pin and nut 5 assembled
060603
on steering knuckle.
Remove locking bolt 7 assembled on
steering knuckle.
Remove steering knuckle from CV shaft.
Remove A-arm mounting bolt and nuts 3.  4
Remove upper A-arm 4 and lower A-arm 8.  3
 5
Installation:
Reverse the removal procedures for  6
installation.

NOTE: Front suspension system RH

is same as the LH method.  7  8 060604

06-6
 06 Vehicle chassis
Rear suspension system
Removal: (See picture 060701, 060702)  1
Set the vehicle on flat ground. Use lifting
jack to lift up the vehicle and support on
the frame.
Remove the rear wheel.
Remove the rear brake caliper.
Remove the cotter pin and locking nut 3 on  1
CV shaft.
Remove rear wheel hub and brake disc
assembly.
Remove rear torsion bar ball pin nut 2.  3  2  4
060701
Remove rear shock absorber mounting
bolt and nut 1. Remove shock.
Remove rear suspension arm bolt and nut
4.
Remove rear suspension arm from CV
shaft.
Installation:
Reverse the removal procedure for
installation.
NOTE: Front suspension system RH
is same as the LH method.

060702
1 Rear suspension arm 7 Suspension arm shaft bolt 13 Bolt
2 Suspension arm bearing 8 Suspension arm inner sleeve 14 Suspension guard
3 Oil seal 9 Rear shock absorber 15 Wheel bearing
4 Dust boot 10 Bolt 16 Retainer
5 Sleeve 11 Nut 17 Rear brake disc guard
6 Locking nut 12 Bolt 18 Bolt

06-7
CFMOTO

060801

1 Front shock absorber 8 Brake disc guard 15 Upper suspension A-arm

2 Nut 9 Bolt 16 Bolt
3 Suspension guard 10 Hub bearing 17 Groove nut
4 Retainer 11 Steering knuckle 18 Cotter pin
5 Upper ball joint 12 Lower ball joint 19 Bolt
6 Lower suspension A-arm 13 Rubber bushing 20 Bolt
7 Retainer 14 Bushing cover

NOTE: Left and right suspension arms have the same method of removal and
installation.

Front upper A-arm

Inspection:
Remove front upper A-arm 3 (See picture
060801, 060802)
Remove the retainer 2 (if required).
Remove upper ball joint 1 (if required).
Inspect the ball joint 1 to make sure it
works smoothly. Push and pull on the
joint to check for clearance. If there is
clearance, replace the part.
Inspect the dust proof boot for wear or
cracking. Replace the ball joint if boot
damage or cracking is found.
Remove the bushings 5.
Check bushings for damage or aging.
060802
Replace as necessary.
Installation:
Reverse procedures of disassembly. Use
special tool to press ball joint into A-arm.

06-8
 06 Vehicle chassis
Front lower A-arm
Remove front Lower A-arm 2 (See picture  4
 5  5  4
060901).
Remove the retainer 3 (if required).  4
Remove lower ball pin 1 (if required).  4
Inspect the ball joint 1 to make sure it
works smoothly. Push and pull on the ball  3
joint to check for clearance. If there is
clearance, replace the part.
Inspect the dust proof boot for wear or  2
cracking. Replace the ball joint if boot  1
damage or cracking is found.
060901
Inspect for damage or wear. Replace if
necessary.
Remove bushings 5.
Check bushings for damage or aging.
Replace as necessary.
Installation:
Reverse procedures of disassembly. Use
special tool to press ball joint into A-arm.
NOTE: Upper and lower A-arms should
not have after installation, otherwise
replace bushings 5,7.

Steering knuckle
Remove steering knuckle 3.
Check hub bearing for damage, noise,
moves freely, or too large clearance.
Replace if necessary. 060902
Remove retainer 1.
Use special tool to press hub bearing 2.
Reverse procedures of disassembly. Use
special tool to press bearing into knuckle.

Rear suspension arm

Remove rear suspension arm 1 (See
picture 060903) 060903
Remove retainer 6.
Remove wheel bearing 5, oil seal 3,
suspension arm bearings 2. CV Shafts - See 6.7.2
Inspect the wheel bearing 5 and rear NOTE: Method and procedure of
suspension arm bearings 2 for damage, removal, inspection and installation
noise, working freely. Replace the parts as between front and rear drive shafts (LH &
necessary. RH) are similar.
Installation:
Reverse the removal procedure for Installation:
installation. Use special tool to press Install as reverse procedures of
bearing 5, suspension arm bearings 2, oil disassembly.
seals 3, into the suspension arm.

06-9
CFMOTO
6.5 STEERING SYSTEM
Handlebar cover
Removal (See picture 061001)
Pull up to remove the handle bar cover 1.
Installation
Reverse the removal procedure for
installation.

Winch control switch  1

Removal (See picture 061002) 061001
Remove the bolt 1.
Remove winch controlling switch 2.
Installation
Reverse the removal procedure for
installation.

Right handlebar switch

Removal (See picture 061003)
Remove screw 1.
Remove right handlebar switch 2.  1  2
061002
Installation
Reverse the removal procedure for
installation.

Left handlebar switch

Removal (See picture 061004)
Remove screw 3.
Remove left handle bar switch 4.  2  1 061003
Installation
Reverse the removal procedure for
installation.

 4
Loose the connector
Removal (See picture 061005)
Disconnect the connector of left handle bar
switch 5.  3  3 061004
Disconnect the connector of right handle
bar switch 6.
Installation
Reverse the removal procedure for
installation.
 5
 6

061005

06-10
 06 Vehicle chassis
Rear view mirror
Removal (See picture 061001)
Remove M6 bolts 2.  1
Remove rear view mirror 1 (LH shown).

Installation:
Reverse the removal procedure for  2
installation.
Handlebar pipe
Removal (See picture 061002)
Remove handlebar cover. 061101
Remove left and right handlebar switch.
Remove the winch switch.
Remove rear parking break switch.  1
Remove the hydraulic breaking pump
from the handle bar.
Remove left and right hand protector (See
2.4.2).  3
Remove 4 M8 bolts 1.
Remove the handlebar aluminum cover 2.  2
Remove the handle bar pipe 3.
Installation
Reverse the removal procedure for 061102
installation.
Attention
Handlebar clamp bolt: M8x55
Tightening torque:
30N·m~40N·m (3.0kgf·m~4.0kgf·m)  2
 1

Throttle cable
Removal (See picture 061003)
Remove 3 screws 1. 061103
Remove the top cover of right handlebar
switch 2.
Remove throttle cable connector 3 (See
picture 061004).
Remove throttle connector 4.
Remove throttle cable 5.
Installation
Reverse the removal procedure for
installation. Adjust throttle freeplay
accordingly.

 5  4  3 061104

06-11
CFMOTO

061201

No. Name No. Name

1 Bolt M8×55 14 Steering bearing seat
2 Handle bar clamp 15 Ball bearing
3 Steering bushing assembly 16 Sleeve
4 Bolt M8×75 17 Bolt M8×25
5 Locking plate 18 Steering seat locking plate
6 bracket 19 Nut M8
7 Sleeve 20 Bolt M8×35
8 Steering shaft inner bearing seat 21 Washer 8
9 Steering shaft bushing 22 Steering arm
10 O-ring 32×1.8 23 Nut M12×1.25 26
11 Steering shaft outer bearing seat 24 Cotter pin 2.5×20
12 Steering shaft 25 Nut M10×1.25
13 Bolt M8×22 26 Washer 10
27 Steering tie rod assembly
Non-EPS steering shaft
Removal (See picture 061201)
Remove plastics.
Remove 4-wheel hand brake lever.
Remove hand brake master cylinder.
Remove handle bar pipe (Including electric
connectors).

06-12
 06 Vehicle chassis
Remove the front wheels.
Remove nut of steering tie-rod and 12
steering column 25. To remove the tie
rod 27. Remove the bolt 20 . Remove the
steering rocker arm 22.
 5
Use screw driver and hammer to flat the
piece 5.
Remove 2 bolt 4.Remove steering shaft
12.
Installation
 4
Reverse the removal procedure for
installation. 061301
NOTE: Refer to Chapter 1 to route and connect the cables and lines. After assembly,
make sure the steering moves freely through the full range of motion. When assembling
the steering arm, set it in the middle position and then install the steering shaft. Make
sure the steering angle is the same as installed before tightening fasteners.
EPS Steering system (See picture 061302)

061302
1 Bolt M8×55 11 EPS steering shaft 21 Nut M10×1.25
2 Handle bar cover 12 BoltM8×35 22 Washer 10
3 Steering shaft sleeve 13 Washer 8 23 Steering rocker arm
4 Bolt M8×75 14 EPS driver 24 Washer 12
5 Locking piece 15 Bolt M6×30 25 Nut M12×1.25
6 Fardage 16 Sleeve 26 Cotter pin 2.0×16
7 Steering shaft outer sleeve 17 Bolt M8×25 27 Steering rod
Steering seat mounting
8 O-ring 32×1.8 18 28 EPS controller
bracket
9 Steering shaft inner ball sleeve 19 Bolt M10×20
10 Sleeve 20 Cotter pin 2.0×16

06-13
CFMOTO
Removal
Remove body covering parts.
Remove 4-wheel hand brake lever.
Remove hand brake master cylinder.
Remove handle bar pipe (Including electric connectors).
Use screw driver and hammer to make the locking plate 5 flat.
Remove 2 bolt 9.
Remove the bolt 13.
Lift up the EPS steering shaft 24 to remove the shaft.
Installation
Reverse the removal procedure for installation.
NOTE: Refer to Chapter 1 to route and connect the cables and lines. After assembly,
make sure the steering moves freely through the full range of motion. When assembling
the steering arm, set it in the middle position and then install the steering shaft. Make
sure the steering angle is the same as installed before tightening fasteners.

EPS motor
Removal
Remove EPS steering shaft (See picture
061302).
Remove the connector 1 (See picture
061401).
Remove the front wheel.
Remove steering rod locking nut 21.
Remove the steering rod 27.
Remove the bolt 13 and nut 25.
Remove steering rocker arm 23.
Remove 4 bolt 19 (See picture 061302). 061401
Remove the steering shaft bracket 23 (See
picture 061303).
Remove bolt 16.
Remove EPS motor 14 (See picture
061302).
Installation
Reverse the removal procedure for
installation.

NOTE:
Refer to Chapter 1 to route and connect the cables and lines. After assembly, make
sure the steering moves freely through the full range of motion. When assembling the
steering arm, set it in the middle position and then install the steering shaft. Make sure
the steering angle is the same as installed before tightening fasteners.

06-14
 06 Vehicle chassis
EPS controller
Removal:
Remove body covering parts. Disconnect the connectors. Remove 3 M6 bolt 25, 26.
Remove EPS controller 27.
Installation:
Reverse the removal procedure for installation.
EPS steering system diagnostic
The EPS indicator light turns on when the vehicle is equipped with EPS. Under normal
conditions, EPS the indicator light remains on after turning the power switch on, but the
EPS will not work. The EPS indicator light turns off after the engine is started and the
EPS begins to work.
NOTE: Internal components in the EPS system cannot be serviced. If a faulty
component is suspected, replacement of the component is required.

EPS system fault code table

The EPS indicator light on the dashboard flashes when a fault occurs. At that time, do
not turn off the power, but instead observe the frequency of flashing and record the order
it displays. Refer to the table to find the code. Every fault code consists of two digits. A
long flash time that lasts two seconds indicates a multiple of ten digit (The first number)
and short flash time that lasts a second indicates a single digit (The second number).
The indicator light is off for three seconds between flash codes. Any time the power is
turned off, the fault code memory is erased and the fault condition must repeat.

Code Waveform Diagnosis Solution

21 Main sensor is disconnected
Main sensor output abnormal
22
(Voltage high or low)
Secondary sensor is Inspect wire harness, wire
23
disconnected connectors, and connector pins
Secondary sensor output
24
abnormal (Voltage high or low)
Discrepancy of the main and
25
secondary torque values
Replace EPS
Main torque sensor phase
26 controller
compensation is over limit
Inspect wire harness, wire
32 Motor running wrong
connectors, and connector pins
EPS controller current out of
33 service limit (Voltage high or Replace the EPS controller
low)
34 Motor one side no power Replace the EPS controller

35 Zero point run-out over limit Replace the EPS controller

Inspect wire harness, wire
36 Motor open
connectors, and connector pins

06-15
CFMOTO
EPS Trouble analyze and solution

No. Fault Probable Cause Solution

1 - Connectors of wire
1 - Check whether wire connectors are
has bad contact
fully inserted
Steering without 2 - The fuse is blown
1 2 - Replace the fuse (30A)
power assistance 3 - Relay damage
3 - Replace the relay
4 - The controller‚ motor
4 - Replace component(s)
or sensor is damaged

1 - The median output

Power assist 1 - Non-adjustable. Replace
voltage has deviation
2 uneven to left and components
2 - Controller‚ motor or
right 2 - Replace components
sensor is damaged

1 - Motor polarity is
System is on; the 1 - Exchange the position of red wire
reversed
3 steering swings to and black wire at the motor terminal
2 - Controller or sensor
both sides 2 - Replace components
is damaged

1 - Battery has power

loss 1 - Charge battery / check electrical
Steering becomes 2 - M o t o r d a m a g e system
4
heavy (power reduction) 2 - Replace components
3 - Air pressure of the 3 - Inflate tires
front tires is insufficient.

1 - Motor damage
2 - System parts worn,
1 - Replace components
clearances are too large
2 - Replace components
5 System has noise 3 - S t e e r i n g s h a f t
3 - Check all fasteners and tighten to
assembly or mechanical
specification
steering assembly is
loose.

06-16
 06 Vehicle chassis
6.6 Front and Rear gear case
6.6.1 Gear case maintenance information
Maintenance schedule

Lubricating schedule
Service schedule
Item Type Capacity
First time After
Front axle 0.23L
SAE80W-90 GL-5
350km 5000km
Rear axle 0.40L

Tighten torque
Torque
Code Item Qty Specification Remark
(N·m)
1 Axle case locking bolt 5 M8×25 25
2 Axle motor locking screw 3 M6×18 8
3 Front axle locking pin 1 M8×10 13 With thread locker
4 Front axle bolt 1 M10×1.25×20 50 With thread locker
5 Front differential bolt 8 M8×1×22 40 With thread locker
6 Front axle oil filling bolt 1 M14×1.25 ×12 25
7 Front axle oil draining bolt 1 M14×1.25 ×12 25
8 Front axle input bearing bolt 4 M8×25 25
9 Rear axle input bolt 1 M10×1.25×20 50 With thread locker
10 Rear axle input bearing bolt 4 M8×28 25
11 Rear axle case locking bolt 6 M8×28 25
12 Rear axle case locking bolt 2 M10×1.25×25 40
13 Rear differential bolt 8 M10×1.25×70 60 With thread locker
14 Rear axle bevel gear bolt 8 M10×1.25×18 60 With thread locker
15 Rear differential bolt 8 M10×1.25×22 60 With thread locker
16 Rear axle oil filling bolt 1 M14×1.25×12 25
17 Rear axle oil draining bolt 1 M14×1.25×12 25

06-17
CFMOTO
Gear case inspection and maintenance
Troubleshooting diagnostic
Trouble Probable Cause
A. Bearing damaged
1. Vehicle is unstable when accelerating, B. Gear clearance too large or too small
decelerating or during normal running. C. Gear wear
D. Gear teeth loose
2. Front or rear axle noise. E. Driveshaft damaged
F. Lubricant loss - level too low
3. Engine power cannot transmit to wheels. G. Case has small pieces inside - gears
are damaged
NOTE: Probable Cause A, B, and C require careful analysis. Isolate the trouble to
make sure the engine and drive lines are OK before disassembling a gear case to
inspect.
Inspect and analyze:
1.Pay attention for any strange noise.
a. If the vehicle accelerates and decelerates with noise (but not keep on) and the noise
has no relation to the engine or drive line, it may be wheel bearings.
b. If the vehicle has noise when accelerating and decelerating, it may be a gear or gear
clearance problem.
NOTE: Front and rear gear clearance that is out of specification may cause gear
wearing, gear noise, or broken gear teeth.
c. If the vehicle has noise at low speed (It may not be detected at high speed), it may
be broken gear teeth.
Warning: If vehicle has trouble during use, stop the vehicle to check and diagnose the
trouble. Operating it may cause an accident.
2.Inspect the lubrication oil
Check to see the oil condition is normal or not. Check for metal in the oil.
3.Inspect for lubricating oil leaking
a. The gear case has no oil residue outside before inspecting.
b. Inspect for oil residue on the floor.
c. Inspect for oil splash residue onto other components.
Determine if seal leaking or case leaking. Replace the damaged parts as necessary.

06-18
 06 Vehicle chassis
6.6.2 Front and Rear gear case removal and installation
Removal:
Use lifting jack to lift up the vehicle and support on the frame.
Remove the front and rear wheels, suspension arms, CV shafts and other related parts.
Remove 2 mounting bracket bolts 1(See 061901).
Remove the mounting bolts 4 and nuts 6 (See 061901).
Remove front gear case mounting bracket 2 (See 061901).
Remove front gear case mounting sleeve 5 (See 061901).
Remove front gear case 3 (See 061901).

061901
Remove 2 mounting bracket bolts 1 (See 061902).
Remove rear gear case mounting bolts 3 and nuts 5 (See 061902).
Remove rear gear case mounting bracket 2 (See 061902).
Remove rear gear case 4 (See 061902).

061902

Installation: Reverse the removal procedures for installation

Front gear case mounting nut (M10×1.25) Torque: 50N·m~60N·m
Rear gear case mounting nut (M10×1.25) Torque: 60N·m~70N·m

06-19
CFMOTO
6.6.3 Front/Rear gear case oil replacement
Make sure the vehicle is on flat ground
before working.

NOTE: The front and rear gear case

temperature may be very high. Make
sure it is cooled down before working.

Set a suitable container under the front/

rear gear case.
Clean the drain bolt area.
Remove the drain bolt 2 and sealing
washer 1 (See 062001, 062002).
Wait few minutes to make sure the oil is
completely drained out.
Clean the oil drain bolt area. 062001
Install the drain bolt and sealing washer.
Tighten to the specified torque; 1 Sealing washer 2 Front axle drain bolt
Tighten torque: 25N·m 3 Sealing washer 4 Front axle fill bolt

Remove the oil fill bolt 4 and sealing

washer 2 (See 062001, 062002).
Fill the lubricating oil:
Oil capacity: Front 0.23L / Rear 0.40L
Install the fill bolt and sealing washer.
Tighten to the specified torque;
Tighten torque: 25N·m

NOTE: If a sealing washer is damaged,

replace with a new one. Do not install
without a sealing washer or leaking will
occur.

062002

1 Sealing washer 2 Rear axle drain bolt

3 Sealing washer 4 Rear axle fill bolt

06-20
 06 Vehicle chassis
6.6.4 Front gear case service
6.6.4.1 Front gear case disassembly

062101
No. Name Qty No. Name Qty
1 Bolt M10 × 1.25 × 20 1 19 Retainer 55 1
2 Washer 10 × 27 × 4 1 20 Bearing 6006 1
3 Engine drive sleeve 1 21 Screw M8 × 10 1
4 O-ring 25 × 2 1 22 Pin 1
5 Oil seal 35 ×50×7 1 23 Oil drain bolt M14 × 1.25 × 12 1
6 Bevel bearing 33005 1 24 Washer 14 2
7 Bolt M8 × 28 9 25 Gear case 1
8 Bearing seat 1 26 Bolt M14 × 1.25 × 12 1
9 O-ring 55 × 2.5 1 27 Oil seal 24 × 38 × 8 2
10 Adjusting shim 1~3 28 Fork 1
11 Adjusting shim 32 × 25.4 2 29 Rack 1
12 Front Gear Case Complete - 30 O-ring 67.5 × 2 1
13 Bevel bearing 32006 1 31 Front axle motor 1
14 Drive bevel gear 1 32 Bolt M6 × 18 3
15 Differential 1 33 Adjusting shim 54.5×43 1~2
16 Adjusting shim 79.5×68 1~2 34 O-ring 130 × 2 1
17 Spline 1 35 Gear case cover 1
18 Spline sleeve 1

06-21
CFMOTO
6.6.4.2 Front gear case disassembly and inspection

●Inspect the gear case and cover for cracks or damage and the condition of bearing
seats. Replace as necessary.

●Check gear case bearing free-play, rotation, bearing cages, steel balls, and needle
condition. Replace as necessary (special tools required).

●Check teeth of gear case drive input gear and ring gear for wear or damage. Replace
as necessary.

●Inspect the gear surfaces of the differential and differential bracket. Replace the parts if
abnormal wearing is present.

●Inspect the 4WD motor and check the function. Replace the part if necessary. Use the
wire harness on the vehicle to inspect the 4WD motor function.

●Check that the oil seal lips and O-ring shape are normal. Replace as necessary.

●Check the cylindrical surfaces that contact the oil seal lips for wear or grooves. Replace
as necessary.

●Check gear case inside and outside shaft splines for wear. Replace as necessary

●Inspect the sliding rack for wear or damage. If any problem is suspected, replace the
parts.

●Check other parts for wear or damage and replace as necessary.

06-22
 06 Vehicle chassis
6.6.4.3 Front gear case assembly and
adjustment
●Front axle drive bevel gear assembly
a. Use suitable adjusting washer on11,
make sure 14 roates smoothly and
clearance less than 0.05mm.
Part 1 tighten torque 50N·m

NOTE: Oil seal, bearing, and spline

062301
must be covered with engine oil.

Part 1 must be covered with thread locker

Adjusting shim 11 thickness

2.10 2.20 2.30 2.40 2.42
2.44 2.46 2.48 2.50 2.60
2.70 2.80 2.90 3.00

●Differential assy assembly

NOTE: Cover bearings, differential

gears with oil before assembly.

Use suitable 38 adjusting shims to make

sure the gears in differential can rotate
smoothly. Part 36 differential driven gear
shaft axial clearance is 0.1mm~0.4mm.
Part 37 CV shaft gear axle axial clearance
is 0.1mm~0.4mm.
Cover thread locker on part 39.

Adjusting washer 0.1 0.2 0.3 0.4

thickness (mm) 0.5 1.0

062301
Part 39 tighten torque 40N·m

06-23
CFMOTO
●Front gear case assembly and adjustment

Tighten torque
Part 7 25N·m
Part 21 13N·m
Part 32 8N·m
Oil fill bolt 25N·m
Oil drain bolt 25N·m

a. Adjust the bevel gears side clearance by

choosing the suitable adjusting shim 10,
16, and 33 thickness. Make sure the bevel
gear side clearance is 0.10mm~0.25mm

Adjusting shim 0.1, 0.2, 0.3,

clearance 0.4, 0.5, 1.0

Installing clearance shim

0.2 0.3
thickness
b. Refer to drawing 062401 to check gear
side clearance. Assemble the auxiliary
measuring tool, and torque the pressing
bolts accordingly. Set the dial gauge.
Torque bolt M14×1.25×60. Make sure the
gauge testing point is 20mm to the center.
Turn the measuring tool to read the data.

062401

Dial gauge standard: 0.10~0.25mm

062402

06-24
 06 Vehicle chassis

c. The rack fork and spine should be

pushed to the direction shown (See
062501). It may be necessary to rotate the
input shaft to obtain full engagement.

062501

d. Use the vehicle 4WD motor wire

harness to set the motor to 4WD-LOCK
position.

e. Make sure that step ‘c’ and ‘d’ are

completed, then use 5mm rods to guide
the motor into the correct position as
shown (See Image 062502).

062502

06-25
CFMOTO
6.6.5 Rear gear case service
6.6.5.1 Rear gear case disassembly (No-spin differential)

063201
No. Name Qty No. Name Qty
1 Bolt M10 × 1.25 × 20 1 20 No-spin differential assy 1
2 Washer 10 × 27 × 4 1 21 Gear case cover 1
3 Rear axle input flange 1 22 Bolt M10 × 1.25 × 25 2
4 O-ring 25 × 2 1 23 O-ring 151 × 3 1
5 Oil seal 35 × 50 × 7 3 24 Bolt M10 × 1.25 × 70 8
6 Bevel bearing 33005 1
7 Bolt M8 × 25 10
8 B e a r i ng s e at 1
9 Adjusting shim 1~3
10 O-ring 55 × 2.5 1
11 Adjusting washer 32×25.4 2
12 Bevel bearing 32006 1
13 Rear axle bevel bearing 1
14 Oil drain bolt M14 × 1.25 × 12 1
15 Washer 14 2
16 Oil inner bolt M14 × 1.25 ×12 1
17 Gear case 1
18 Bevel gear 32910 2
19 Adjusting washer 61×50.5 4~6

06-26
 06 Vehicle chassis

6.6.5.2 Rear axle inspection after disassembly

●Check for damage or cracks on the rear gear case and the condition of bearing seats.
Replace as necessary.

●Check rear gear case bearing free-play, rotation, bearing cage, steel balls, needles
condition. Replace as necessary (special tools required).

●Check teeth of gear case drive input gear and ring gear for wear or damage. Replace
as necessary.

●Check that the oil seal lips and O-ring shape are normal. Replace as necessary.

●Check the cylindrical surfaces that contact the oil seal lips for wear or grooves. Replace
as necessary.

●Check gear case inside and outside shaft splines for wear. Replace as necessary.

●Inspect the differential and differential lock surface. Replace the part if any trouble is
suspected.

●Check other parts for wear or damage and replace as necessary.

06-27
CFMOTO
6.6.5.3 Rear gear case assembly and
adjustment
●Rear axel drive bevel gear assembly
a. Choose suitable adjusting shim 11 to
make sure 13 rotates smoothly and axial
clearance is less than 0.05mm.
Part 1 tighten torque 50N·m

NOTE: Oil seal, bearing, spline should

be covered with oil during assembly.

Adjusting washer 11 thickness

2.10 2.20 2.30 2.40 2.42 062801
2.44 2.46 2.48 2.50 2.60
2.70 2.80 2.90 3.00

●Differential lock

Part 24 tighten torque 60N·m

Part 24 cover with thread locker
NOTE: Pre-lubricate before assembly.

062802

06-28
 06 Vehicle chassis

●Rear gear case adjustment

Follow the drawing to assemble (See
063201).
Tighten torque
Part 7 25N·m
Part 22 40N·m
Oil filler bolt 25N·m
Oil drain bolt 25N·m

a. Adjust shim 9 and 19 thickness. Make

sure:
1. Rear axle bevel gear 13 side clearance
0.10mm~0.20mm
2. Bevel bearing 18 axial clearance should
be less than 0.06mm.
3. All rotating parts must be working
smoothly.

Adjusting washer 19 thickness

0.1, 0.3, 0.5, 0.9, 0.92
0.94, 0.96, 0.98, 1.00

Adjusting washer 9 thickness

0.2, 0.3

b. Refer to 062902 to check gear side

clearance. Set the dial gauge. Torque the
bolt M14×1.25×60. Make sure the gauge
testing point is 37mm to the center. Turn 062901
the measuring tool to read the data.

Standard data�0.17mm~0.34mm

062902

06-29
CFMOTO
6.6.6 Rear gear case service
6.6.6.1 Rear gear case disassembly (Non-differential)

063001

No. Name Qty No. Name Qty

1 Rear axle 1 20 61×50.5 Adjusting washer 4
2 M10×1.25×20 Bolt 1 21 Mount seat 1
3 10×27.5×4 Washer 1 22 Screw 2
4 Coupler 1 23 Oil guard 1
5 25×2 O-seal ring 1 24 Cover, rear axle case 1
6 35×50×7 Oil seal 3 25 Joint, breather hose 1
7 Bearing 1 26 M10×1.25X25 Bolt 2
8 M8×28 Bolt 10 27 151×3 O-seal ring 1
9 Bearing seat 1 28 M10×1.25×18 Bolt 8
10 Adjusting washer 1
11 55×2.5 O-seal ring 1
12 32×25.4 Adjusting washer 2
13 Bearing 1
14 Bevel gear, rear axle 1
15 M14×1.25×12 Magnetic drain bolt 1
16 Washer 2
17 M14×1.25×12 Bolt 1
18 Rear axle case 1
19 Bearing 2

06-30
 06 Vehicle chassis

6.6.6.2 Rear gear case inspection after disassembly

●Check for damage or cracks on the rear gear case and the condition of bearing seats.
Replace as necessary.

●Check rear gear case bearing free-play, rotation, bearing cage, steel balls, needles
condition. Replace as necessary (special tools required).

●Check teeth of gear case drive input gear and ring gear for wear or damage. Replace
as necessary.

●Check that the oil seal lips and O-ring shape are normal. Replace as necessary.

●Check the cylindrical surfaces that contact the oil seal lips for wear or grooves. Replace
as necessary.

●Check gear case inside and outside shaft splines for wear. Replace as necessary.

●Inspect the differential and differential lock surface. Replace the part if any trouble is
suspected.

●Check other parts for wear or damage and replace as necessary.

06-31
CFMOTO
6.6.6.3 Rear axle assemble and adjustment

●Rear axel drive bevel gear assembly

a. Choose suitable adjusting shim 11 to
make sure 13 rotates smoothly and axial
clearance is less than 0.05mm.

Part 1 tighten torque 50N·m

NOTE: Oil seal, bearing, spline should

be covered with oil. Apply thread locker
with part 1.

Adjusting washer 11 thickness

2.10 2.20 2.30 2.40 2.42 063201
2.44 2.46 2.48 2.50 2.60
2.70 2.80 2.90 3.00

●Driven bevel gear assembly

Part 24 tighten torque 60N·m

Part 24 covered with thread locker
NOTE: Pre-lubricated before assembly

063202

06-32
 06 Vehicle chassis

●Rear axle assemble and adjustment

Follow the structure on right drawing to
assemble
Tighten torque
Part 7 25N·m
Part 22 40N·m
Oil filler bolt 25N·m
Oil drain bolt 25N·m

a. Adjust the adjusting shim 9 and 19

thickness, make sure:
1. Rear axle bevel gear 13 side clearance
0.10mm~0.20mm.
2. Bevel bearing 18 axial clearance should
be less than 0.06mm.
3. All rotated parts must be working
smoothly.

Adjusting washer 19 thickness

0.1 0.3 0.5 0.9 0.92
0.94 0.96 0.98 1.00 063301

Adjusting washer 9 thickness

0.2 0.3

b. Follow the drawing on the right to check

gear side clearance. Set the dial gauge.
Torque bolt M14×1.25×60. Make sure the
gauge testing point is 37mm to the center.
Turn the measuring tool to read the data.

Standard data� 0.17mm~0.34mm

063302

06-33
CFMOTO
6.6.7 Rear gear case service
6.6.7.1 Rear gear case disassembly (Automatic lock differential)

063401
No. Name Qty No. Name Qty
1 Bolt M10 × 1.25 × 20 1 20 Automatic lock differential assy 1
2 Washer 10 × 27 × 4 1 21 Rear axle cover 1
3 Rear axle input flange 1 22 Bolt M10 × 1.25 × 25 2
4 O-ring 25 × 2 1 23 O-ring 151 × 3 1
5 Oil seal 35 × 50 × 7 3 24 Bolt M10 × 1.25 × 18 8
6 Bevel bearing 33005 1 25 Inner friction disk 3
7 Bolt M8 × 25 10 26 Outer friction disk 4
8 B e a r i ng s e at 1 27 Mat 1
9 Adjusting shim 1~3 28 Inner friction disk 1
10 O-ring 55 × 2.5 1 29 Polished section, outer friction disk 1
11 Adjusting washer 32×25.4 2
12 Bevel bearing 32006 1
13 Rear axle bevel bearing 1
14 Oil drain bolt M14 × 1.25 × 12 1
15 Washer 14 2
16 Oil inner boltM14 × 1.25 ×12 1
17 Rear axle case 1
18 Bevel gear 32910 2
19 Adjusting washer 61×50.5 4~6

06-34
 06 Vehicle chassis

6.6.7.2 Rear gear case inspection after disassembly

●Check for damage or cracks on the rear gear case and the condition of bearing seats.
Replace as necessary.

●Check rear gear case bearing free-play, rotation, bearing cage, steel balls, needles
condition. Replace as necessary (special tools required).

●Check teeth of gear case drive input gear and ring gear for wear or damage. Replace
as necessary.

●Check that the oil seal lips and O-ring shape are normal. Replace as necessary.

●Check the cylindrical surfaces that contact the oil seal lips for wear or grooves. Replace
as necessary.

●Check gear case inside and outside shaft splines for wear. Replace as necessary.

●Inspect the differential and differential lock surface. Replace the part if any trouble is
suspected.

●Check other parts for wear or damage and replace as necessary.

06-35
CFMOTO
6.6.7.3 Rear axle assemble and adjustment

●Rear axel drive bevel gear assembly

a. Choose suitable adjusting shim 11 to
make sure 13 rotates smoothly and axial
clearance is less than 0.05mm.

Part 1 tighten torque 50N·m

NOTE: Oil seal, bearing, spline should

be covered with oil. Apply thread locker to
part 1.

Adjusting washer 11 thickness 063601

2.10 2.20 2.30 2.40 2.42
2.44 2.46 2.48 2.50 2.60
2.70 2.80 2.90 3.00

●Differential assembly

Part 24 tighten torque 60N·m

Part 24 covered with thread locker
NOTE: Pre-lubricate before assembly

063602

06-36
 06 Vehicle chassis

●Rear axle assemble and adjustment

Refer to 063701 to assemble.

Tighten torque
Part 7 25N·m
Part 22 40N·m
Oil filler bolt 25N·m
Oil drain bolt 25N·m

a. Adjust the adjusting shim 9 and 19

thickness. Make sure:
1.Rear axle bevel gear 13 side clearance
0.10mm~0.20mm.
2.Bevel bearing 18 axial clearance should
be less than 0.06mm.
3.All rotated parts must be working
smoothly.

Adjusting washer 19 thickness

0.1 0.3 0.5 0.9 0.92
0.94 0.96 0.98 1.00

Adjusting washer 9 thickness

0.2 0.3
063701

b. Refer to 063702 to check gear side

clearance. Set the dial gauge. Torque the
bolt M14×1.25×60. Make sure the gauge
testing point is 37mm to the center. Turn
the measuring tool to read the data.

Standard data�0.17mm~0.34mm

063702

06-37
CFMOTO
6.7 Drive shaft
6.7.1 Maintenance information of CV shaft and driveshafts
Inspection and repair
If the troubles below come out, it means the CV shaft or drive shafts are damaged.

Trouble Probable Cause

1,The vehicle running unstable during A. CV shaft pulled out from axle.
acceleration and deceleration. B. CV shaft rod broken or ball joint
2.CV shaft and drive shaft noise. damaged.
3,CV shaft leaking grease C. CV shaft, drive shaft boot cracks.
4,Engine power cannot transmit to front or D. Front drive shaft joint damaged.
rear wheel. E. Rear drive shaft broken or splines
damaged.
F. Locking bolts loose.

NOTE: Probable Causes requires careful analysis. Isolate the trouble to make sure
the engine and gear cases are not the cause. Remove the part if necessary.
Inspect and analyze:
1.Pay attention for any strange noise.
a. If the vehicle accelerates and decelerates with noise, the noise may not be related
to engine and gear cases.
b. Possible CV shaft joint damage.
c. Possible vehicle bearing damage.
2.Inspect the CV shaft boots and drive shaft boots. Replace if damaged.
3.If a CV shaft will not install, inspect for damage to the splines. A failure will cause the
power transmission to cut.
Warning: If vehicle has trouble during use, stop the vehicle to check and diagnose the
trouble. Operating it may cause an accident.

06-38
 06 Vehicle chassis
6.7.2 CV shaft and drive shafts removal and installation
CV shaft removal
Lift and support the front and rear of the vehicle at the frame. Make sure there is no
force on the wheels.
Remove the wheels and suspension arms.
Pull the parts 1, 3, 4, 6 from the axles. Do not pull too hard to avoid damage. If several
times cannot pull out, please turn small angle then pull out.

063901
Front drive shaft removal
Lift and support the front of the vehicle at the frame. Make sure there is no force on the
wheels.
Remove the wheels and suspension arms. (See chapter 6.2 ~6.4)
Use special tool or pilers to remove 2 locking rings (2, 4 below) to remove the front drive
shaft covers, (See 063902) then the drive shaft can be removed.
NOTE: Apply grease (15g-18g) on the splines during assembly.

063902

06-39
CFMOTO
Rear drive shaft removal�
Lift and support the rear of the vehicle at the frame. Make sure there is no force on the
wheels.
Remove the wheels and suspension arms (See chapter 6.2 ~6.4).
Use special tool or plier to remove the locking ring (Part 1). Remove 4 bolt connect to
the drive shaft (Part 3). Rear drive shaft (Part 2) can be removed.
NOTE: Apply grease (15g~18g) on the splines during assembly.

064001

Reverse the removal procedure for installation

Rear driveshaft mounting bolt (M10×1.25×25) Torque: 40N•m~50N•m

06-40
 06 Vehicle chassis
6.7.3 Front and rear CV shaft disassemble view

064101

064102

06-41
CFMOTO
6.7.4 Front and rear CV shaft inspection

●The two joints of the CV shaft should rotate freely. If jammed, not smoothly running or
noise in normal angle, replace the parts.

●Inspect the rotating clearance between the joint and splines. If the clearance is more
than 1.5 degrees, replace the part.

●Inspect the rubber boots. Replace if damaged or leaking.

●Inspect the spline and strainer. Replace if worn or damaged.

●Inspect the joint bracket, sleeve, balls, ball tracks and splines. Replace if any trouble is
suspected.

●Inspect other part of CV shafts. Replace the parts if trouble is suspected.

NOTE: Shaft cage universal joint uses MoS2 lithium grease.

Front shaft: Fill 28g ± 5g grease in fixed end cage universal joint, 32g ± 5g grease in
fixed end seal enclosure, 65g±10g grease in axial movement cage universal joint.
Rear shaft: Fill 45g ± 5g grease in fixed end cage universal joint, 50g ± 5g grease in
fixed end seal enclosure, 120g±10g grease in axial movement cage universal joint.

06-42
 06 Vehicle chassis
6.7.5 Front drive shaft disassemble and inspection

064301

●The two joints of the drive shaft should move freely. If jammed, not smoothly running or
noise in normal angle, replace the parts.

●Inspect the dust boots (2 and 6) on drive shaft. Replace the parts if damaged.

●Check that the inside of the boots have sufficient grease, or the splines may be
damaged or worn.

●Inspect the splines on both ends, Replace the parts if worn or damaged.

●Inspect the inner and outer spline rotating clearance. If the clearance is more than 1.5
degrees, replace the parts.

NOTE: Inject 15g~18g grease into both ends during assembly.

06-43
CFMOTO
6.7.6 Rear drive shaft disassemble and inspection

064401

●The two joints of the drive shaft should move freely. If jammed, not smoothly running or
noise in normal angle, replace the parts.

●Inspect the dust boots (2 and 6) on drive shaft. Replace the parts if damaged.

●Check that the inside of the boots have sufficient grease, or the splines may be
damaged or worn.

●Inspect the splines on both ends. Replace the parts if worn or damaged.

●Inspect the inner and outer spline rotating clearance. If the clearance is more than 1.5
degrees, replace the parts.

NOTE: Inject 15g~18g grease into both ends during assembly.

06-44
 07 Signal and lighting system
07 Signal and lighting system 7.5 Handlebar switch..................7-4
Maintenance information............7-1 7.6 Brake light switch..................7-6
7.1 Trouble diagnose..................7-2 7.7 Horn..................................... 7-7
7.2 Light and indicator................7-2 7.8 Fuel pump ............................7-7
7.3 Bulb replacement..................7-2
7.4 Ignition switch.......................7-4
Maintenance Precautions

NOTE:
·Pay attention to the following when replacing a headlight bulb:
*Do not replace the bulb when it is turned on. Keep ignition switch in the OFF position,
and replace after the bulb is cooled down totally.
*Replace the bulb with hands in clean gloves to avoid oil rsidue on the glass surface.
*Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any
oil residue on the glass surface. Replacing with bare hand or stained glove will leave oil
residue on the glass face which may form hot spot and cause early failure of the bulb
·If the inspection has to be done with battery, make sure the battery is fully charged.
·Inspection of switch continuity can be done at the connectors without removing switches
from the vehicle.
·After the inspecting and maintenance of each part, cables and wires should be routed
properly (Refer to Chapter 1.7.1)
·Refer to Chapter 2 for removal and installation of taillight and rear turning lights.

Maintenance Specifications

Item Standard
Main 30A
Fuse
Secondary 40A×1(EPS) 15A×3 10A×2
Headlight 12V ,12W/14W LED
Braking light 12V, 4.8W 12LED
Rear steering light 12V, 1.2W 7LED
Light and bulb
Dashboard indicator LED
Indicators LED
Rear license light 12V, W5W (BULB)

07-1
CFMOTO
7.1 Troubleshooting
Head Light Cannot Turn On
Inspection
..Blown fuse
..Open circuit of main cable
..Burnt bulb
..Defective switch
..Relay damaged or not connected
7.2 Indicator light
Inspection
Set ignition switch ON. Put the headlight
on to see the headlight on or not.
ON: Normal
No Light:  1  2
·Main cable broken or short
·Blown fuse
·Switch damaged.

7.3 Bulb Replacement

Headlight Bulb(EU)
Removal  3
Remove headlight plate (See chapter 2)  4  5
Remove the headlight (See chapter 2)
Installation 070201
Reverse the removal procedure for
installation. Low beam Front steering
1 2 3 DRL
light light
Front turn signal light Front position High beam
Removal 4 5
light light
Remove headlight plate (See chapter 2)
Remove the headlight (See chapter 2)
Installation
Reverse the removal procedure for  1
installation.

Headlight Bulb(US)
Removal
Remove headlight plate (See chapter 2)
Remove the headlight (See chapter 2)
Installation  2
Reverse the removal procedure for  3  4
installation.
070202
NOTE:
The headlight, turn signal light and 1 Low beam light 2 DRL
other lights are an LED assembly. Items 3 Front position light 4 High beam light
cannot be replaced seperately. If failed
or damaged, the whole headlight assy
must be replaced.

07-2
 07 Signal and lighting system
Tail light replacement
Removal(See pic 070302)
Remove the 3 screws as show in the photo
and remove the taillight from the fender.

Remove
Reverse the removal procedure for
installation

Tail light replacement is the same for LH

and RH.
 1  1
070301

NOTE:
1.Be careful when replacing the taillight.
Hold the light when removing the screws
to avoid the light falling down suddenly.
2.As The tail light is an LED assembly.
Bulbs cannot be replaced. Please replace
the whole assembly if tail light is failed or
damaged.

 1  2  3
070302
EU
1 Rear braking light
2 Rear position light
3 Rear steering light

 1  2
070302
US
1 Rear braking light 2 Rear position light

07-3
CFMOTO
7.4 Ignition switch
Removal
Remove the dashboard cover (See chapter
2)
Remove ignition switch connector  1
Turn counter-clockwise to remove screw 2
Remove ignition switch 1  2
Installation
Reverse the removal procedure for
installation

Follow the chart to check the connection.If

●-● connected is OK.
070401

 2

 1
 2 070402

7.5 Handle bar switch

Handle bar switch(EU)
Removal (See picture 070402,070403)
 1
Remove body covering parts (See chapter  3
2)
Remove left handle bar switch connector 1
and right handle bar switch 2;
Follow the chart to check the connections.  2  4
If ●-● connected is normal.

070403
Handle bar switch(US)
Removal (See picture 070402,070403)
Remove body covering parts (See chapter
2)  1
Remove left handle bar switch connector 1  3
and right handle bar switch 2;
Follow the chart to check the connections.
If ●-● connected is normal.

070404

07-4
 07 Signal and lighting system

Light switch (No.1)

Black/ Brown/ White/

Brown Blue White
Brown White Blue
● ● ● ● ●
● ● ● ● ●
OFF
● ● ●

Emergency switch (No.2)

Sky
Orange Grey
blue
Press
● ● ●
down
Press up

Engine stop switch (No.3) Engine start switch (No.4)

Black/ Black/ Yellow/
Yellow Yellow
White Brown Red
● ●
● ● ●

Power switch (No.5)

Grey/  5
Green
Black

● ●

070501

07-5
CFMOTO
Steering signal switch (No.1)
Sky
Orange Grey
blue
← ● ●
●
→ ● ●
 1

Horn switch (No.2)  2

Light Black/ 070601

green Brown

● ●

2WD, 4WD, 4WD-LOCK switch

Blue/ Blue/ Brown/ Brown/ Grey/ Light green/

Grey Green
Black Green Red Green White Brown
2WD ● ● ●
4WD ● ● ● ●
LOCK ● ● ● ● ● ●

If any trouble inspected, replace the handle

bar switch.
Installation
Reverse the removal procedure for
installation.
7.6 Brake light switch  1
Inspection
Unplug the brake light switch connector.
Check the connector connection.
Inspecting method: Pull the brake lever to  2
the handle bar. The brake switch should
be closed. Release the brake lever. The
switch should open. This is normal.
070603
If any trouble is suspected, replace the
brake light switch. 1 2WD, 4WD, 4WD-diff lock
Installation 2 Brake light switch
Reverse the removal procedure for
installation.

07-6
 07 Signal and lighting system
7.7 Horn
Removal
Remove the vent-plate.
Remove horn connector 1.
Remove horn mounting bolt 2.
Remove the horn.
Inspection  2
Connect 12V battery
Let the horn up 3 times
Replace the horn if operation is not normal.  1
Installation
Reverse the removal procedure for
installation.
 3

070701

7.8 Fuel pump

Removal
Remove the fuel pipe connector 1.
Remove fuel sensor connector.
Remove fuel pump cover 2.
Remove the fuel pump from fuel tank 3
 1
(Fuel sensor 4 cannot be disassembled).
Installation
Reverse the removal procedure for
installation.  2

Inspection
Use hand to rotate the fuel sensor arm.
Make sure the dashboards shows the  3
same position as the sensor.
If the position isn't same, please check for
the wire disconnected or short.
If no trouble, please inspect the fuel sensor
and fuel gauge.
Replace the pump assembly if fuel sensor
is damaged.  4

070702

07-7
CFMOTO
Inspecting:
Connect the fuel sensor to AVO meter (See
picture 070801)
Use hand to rotate the sensor arm to see
the resistance.

Connector:
Top:
Red-Black: 4Ω~10Ω(20˚C)
Bottom:
Red-Black: 90Ω~100Ω(20˚C)
Replace the fuel pump if any trouble is 070801
suspected.

Fuel sensor connector diagram

4 3 2 1
070802

1 Fuel level sensor“+” 3 Fuel pump“+”

2 Fuel level sensor“-” 4 Fuel pump“-”

07-8
Appendix A
Appendix B
Appendix C