Z Force 1000 Service Manual 2018-19 PDF

CFMOTO
CF1000US-2
SERVICE MANUAL
WWW.CFMOTO.COM
Edition No. ：20170331
Edition item：CF1000US-2 v1.pdf
WWW.CFMOTO.COM
All rights reserved

Zhejiang CFMOTO Power Co., LTD
MAR 2017
INDEX
1 General infor m ation
2 Body and m uffler
3 Inspection and adjustm ent
4 Cooling system
5 Engine contents
6 Engine,transm ission and shifting m achenism
7 Electrical system
8 Light,Dashboard,Sw itch
9 Front w heels, B reaking ,Suspenion and Steering
10 Rear w heel,Breaking,Suspension
11 Frot and rear Axle
12 Vehicle C hassis
FOREWORD
This manual introduces CF1000US-2 maintenance information,

removal & installation procedure, checking & adjustment methods,
troubleshooting and technical specifications in detail. There are illus-
trations to guide your operations.
Read this manual carefully. Follow the instructions to do mainte-
nance can extend parts service life, improved engine performance and
vehicle reliability.
CFMOTO reserves right to make

improve-ments and modifications to
the products without priornotice.
Overhaul and maintenance should All rights reserved
be done according to actual condi- Zhejiang CFMOTO Power Co., LTD.
tion of vehicle. MAR. 2017
Conversion Table
Item Conversion
1kgf/cm2=98.0665 kPa；1kPa=1000Pa
Pressure
1mmHg=133.322 Pa=0.133322kPa
Torque 1kgf·m=9.80665N·m
Volume 1mL=1cm3=1cc
3
1L=1000cm
Force 1kgf=9.80665 N
Length 1in=25.4mm
Dangerous/Warning/Note
Please read below explanation carefully,it explained the meaning of “DANGER/

WARNING/NOTE”, pls pay attention during mentain the engine.
Danger:This is the safety alert symbol. It is used to alert you to
potential personal injury hazards.
Warning:A WARNING indicates a hazardous situation. It could result in death or
serious injury if not avoided.
Note：A NOTE indicates special precautions that must be taken to
avoid damage to the vehicle or other property.
But, pls notice, the “Danger / Warning / Note” can’t cover all potential risks
during use or maintain the engine. So,beside these notice on vehicles, the
person who maintains the vehicle must have the basic mechanical safety
knowledge.If you don’t have, pls ask for help from senior mechanist.
1 GENERAL INFORMATION
Maintenance information………….............. 1-1 Tightening torque table........................ 1-12

Location of VIN /EIN…………………........... 1-3 Lubricants and service products.......... 1-19
General specifications……………….......... 1-4 MIL/ EPS system................................. 1-20
Maintenance specifications………............. 1-6 1
MAINTENANCE INFORMATION
Operation cautions
1. Engine exhaust fumes are poisonous and can result in loss of consciousness or death. Do not run
the engine in an enclosed or poorly ventilated area.
2. Do not touch the engine or muffler with bare hands after the engine has been just stopped to avoid
burns. Wear long-sleeve work clothes and gloves for operation.
3. Battery electrolyte (dilute sulfuric acid) is highly caustic and can result in burns from contact with
skin and eyes. If you spill electrolyte on skin, flush with water and seek for medical attention imme-
diately. If you spill electrolyte on clothes, flush with water to avoid burns. Keep battery and electro-
lyte out of reach of children.
4. Coolant is poisonous. Do not drink or spill it on skin, eyes or clothes. If you spill coolant on skin, im-
mediately wash with soap and water. If you spill coolant on eyes, flush with water and seek prompt
medical attention. If you swallow coolant, induce vomit and see the doctor. Keep coolant out of
reach of children.
5. Wear proper work clothes, cap and boots. If necessary, wear dust-glass, gloves and mask.
6. Gasoline is highly flammabl . No smoking or fire. Also keep gasoline away from sparks. Vaporized
gasoline is also explosive. Operate in a well-ventilated area.
7. When the battery is being charged, it produces explosive gases. Charge the battery in a well-venti-
lated area.
8. Be careful not to get pinched by the turning parts like wheels and clutch.
9. When more than two people are operating, keep reminding each other for safety purpose.
Cautions for removal and installation

1. Use genuine CFMOTO parts, lubricants and service products.
2. Clean mud, dust before servicing.
3. Store the removed components separately in order for correct installation.
4. Replace the removed washers, o-rings, piston pin retainers, cotter pins with new ones.
5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers.
6. Clean and blow off the detergent after removal. Apply lubricants on the surface of moving parts.
Measure the data during removal for correct installation.
7. If you do not know the length of screws, install the screws one by one and make sure they are
screwed in with the same depth.
8. Check if the removed rubber parts are aged and replace if necessary. Keep the rubber parts away
from grease.
9. Pre-tighten the bolts, nuts and screws, then torque to specification. The basic sequence is from big
to small, from inner side to outer side and criss-cross.
10. Replace aged rubber parts when assembling. Do not splash gasoline, grease onto the surface,as
this could cause damage.
11. Apply or inject recommended lubricant to the specified lubrication points
12. Use special tools when necessary.
13. When ball bearing is removed by pressing steel balls, it can not be reused.
14. Finger turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly.
• Replace if the axial or radial play is too big.
• If the surface is uneven, clean with oil and replace, 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.
01-1
15. Install the one-side dust-proof bearing in the right direction. When assembling the open type or
double-side dust-proof bearing, install with manufacturer’s mark outward.
16. Keep the bearing block still when blowing dry the bearing after washing clean. Apply oil or lubricant
before installation.
17. Install the elastic circlip properly. Turn the circlip after assembling to make sure is has been in-
stalled into the slot.
18. After assembling, check if all the tightened parts are properly tightened and can move smoothly.
19. Brake fluid and coolant may damage painting, plastic and rubber parts. Flush with water if splashed
on these parts.
20. Install oil seal 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.
21. When installing pipes, insert the pipe till the end of joint. Fit the pipe clip, if any, into the groove. Re-
place the pipes or hoses that cannot be tightened.
22. Do not mix mud or dust into engine and/or the hydraulic brake system.
23. Clean the gaskets and washers of the engine casing before assembling. Remove the scratches on
the joint faces by polishing evenly with an oilstone.
24. Do not twist or bend the cables too much. Distorted or damaged cables may cause poor operation
and damage.
25. When assembling the parts of protection caps, insert the caps to the grooves, if any.
Engine break-in
The engine has many moving parts such as piston, piston ring, cylinder body and gears. For this reason.
Engine break-in work in first mileages is amust. Engine breaking in can let the moving parts fit for eachother
and adjust the working clearance. And finally build up a good smooth surface can hold a large working load.
Engine broken-in has highly performance and reliability.
Recommend break-in for 600km，The standard like below:：
0~300km：
Avoid≥1/2 throttle, running continously change vehicle speed as often as possible. Do not let the throttle
in one position for too long. Stop engine engine for 5 to 10min for every 30km working. Press the throttle
slowly to avoid suddenly acceleration.
300~600km：
Avoid≥3/4 throttle running for too long time. Vehicle can use freely but without full throttle.
Note: Follow the maintenance chart in break-in period. And shoot the engine
trouble in time.After break-in, get a fully 600km break-inmaintenance, then
normal driving.
01-2
LOCATION OF VIN/EIN
Model Number CF1000US-2
1. Vehicle identi ication number(VIN): LCELV1Z4 ~
2. Engine identi ication number(EIN): 2V91Y ~
1
1. Vehicle identification number(VIN) 010301
2.Engine identification number(EIN) 010302
01-3
General specifications
Item Specifications
Model type CF1000US-2
Overall length 2870mm
Overall width 1510mm
Overall height 1845mm
Wheelbase 2040mm
Engine type 2V91Y
Displacement 962.6mL
Fuel type and Octane No. RQ-92 or higher unleaded gasoline
Dry weight 590kg ± 15Kg
Passengers 2 persons (including driver)
Total vehicle load allowed 315kg
Front 27× 9.00R14 60L; 27× 9.00-14 61L

Tire
Rear 27× 11.00R14 66L; 27× 11.00-14 70L
Min. ground clearance 310mm

Min. turning radius 9500mm
Starting Electric start
Type V-twin cylinder,4-stroke,liquid-cooled,8 valves
Valves SOHC /Timing chain drive
Bore×Stroke 91mm×74mm
Compression ratio 10.6:1
Engine Lubrication dry sump, replaceable oil fi ter
Oil pump Rotor drive
Oil fil er Paper type, replaceable
Engine oil type SAE15-W-40/SG or higher
Cooling system Liquid-cooled/close-loop cooling
Coolant type -30 oC anti-corrosion and anti-freezing
01-4
Item Sp e c i fi c a t i on s
Air filter typ e P aper filter elem e nt
Ai r i n ta k e Type 0JY0-173000
d e vices Throttle body Diam eter of throttle body 54 mm 1
F u e l ta n k c a p a c i t y 27 L
C lutc h typ e Dry clutch system
Tr ansm i s s ion type C V T+ Gearshift
G ears h ift H i g h , L o w a n d R e ve r s e
G ears h ift
Ma n u a l o p e r a t i o n /L - H - N - R- P
m ethods / orders
C V T r atior a nge 2.88~0.70
“H” gear “ L” g e a r “R” gear
Final r a tio 1 . 333
S econdary ratio 1 . 952
Gea rs hift
ratio Single gear ratio 1.143 2.529 2.231
Total r a tio 2.975 6.585 5.807
Driv e trai n
Front 33 / 9 = 3.667
Ratio of drive gear Rear 33 / 9 = 3.667
O ut puttype Front/Rear shaft drive
R ota tion of engine output When forward, clockwise (rear view)
Le ft 34º
Steering Turnangle R ight 28º
Front H y d r a u l i c Di s c
Brakes R ear H y d r a u l i c Di s c
S u spension D o u b l e A -a r m a n d i n d e p e n d e n t
Fra m e type Steel tube a nd plate
01-5
Lubrication System
Item Standards Service Limit
Transmission gear oil SAE75W-90/GL5 Total dry:600mL -
Oil Change 2400mL(without oil fil er replacement) -

Engine OiL
Capacity Oil Change 2500mL(with oil filter replacement) -
Total dry: 2600mL -
Oil Inside the Oil Radiator Add 500mL after the first start, add -
and Hoses 450mL after the maintenance.
Recommended engine oil15W-405W-50
20W-50
15W-40, 15W-50 • Recommended engine oil: SAE-15-W-40

Multigrade 10W-40, 10W-50 • API classifications: SG or highe
10W-30
• Viscosity rating: according to the left chart
5W-50
Co -30 -20 -10 0 10 20 30 40

Temp.
Fo -22 -4 14 32 50 68 86 104
Clearance Between
0.06mm~0.14mm
Inner and Outer Rotor 0.25mm
Clearance Between Outer
0.09mm~0.15mm 0.25mm
Rotor and Bore
Oil Pump Rotor
Rotor End Clearance 0.023mm~0.109mm 0.20mm
1300 RPM: 70kPa~300 kPa(90 ℃) ,
Normal:180kPa
Oil Pressure
6000 RPM: 350kPa~700kPa(90℃) ,
Normal:420kPa
Air Intake System

Item Standards and Specifications
Throttle Body Part NO. 0JY0-173000
T-MAP Sensor Part No. 0JY0-175000
Fuel Injector Part No. 0JYA-171000
Idle speed 1300r / min±130r / min
01-6
Cooling System
Service
Item Sta nd a rd s
l im i t
F u l l c apacity 3 000 mL
1
Capac ity o f r e s e rv o i r
C o o l a nt c apacity 230 mL~68 0 mL
tank
Standard d ens i ty 50 %
O pening p ressure 1 0 8 k Pa (1 . 1 k g f /c m 2 )
O pening
65oC±2 oC
temperature
Fully o pening 85oC
Thermostat
Travel when
When 850C,> 5mm
fully opening
W ater temperature
/ Resistant of A,C
terminal(kΩ)
( oC)
Relations b e t we e n wa t e rt -20 / 10.31±0.5

e m p a n d r e s i s ta nt o f
wa te rtemp . sens or 25 / 0.73±0.4
50 / 0.25±0.2
80 / 0.08±0.01
110 / 0.0325±0.002
Coolant typ e -300C anti -freezing , anti -corrosive and high boiling point
01-7
Front Wheel
Item Sta nd a rd v a lu e S e r v i c e l im i t
Lo ng it ud e 1.0 m m 2.0mm
R im run out
Tr a n s v e rs e 1.0 m m 2.0mm
F r o n t wh e e l
Re m a i n i n g
3.0 m m
gro o v e
F r o n t ti re 2
P r e ssur e 70k P a (0 .70k g f/ cm )
Rear Wheel
Lo ng it ud e 1.0 m m 2 . 0 mm
Rim run out Tr a n s v e rs e 1.0 m m 2.0 m m
R e a r wh e e l Re m a i n i n g
3.0 m m
R e a r t i re gro o v e
2
P r e ssur e 100 k P a (1.00k g f /cm )
Brake System
Th i c k n e s s o f b r a k e d i s c 5 mm 4mm
Front brake
Free play of brake pedal 10 mm~15m m

R e a r b ra k e
Th i c k n e s s o f b r a k e d i s c 5 mm 4mm
01-8
Item Sta n d a rd s
Typ e Magneto 3 - p h a s e AC g e n e r a t o r
Outpu t 3 - p h a s e AC o u t p u t 1
R e s is ta n c e o f c o il (20 oC) 0.2Ω ~ 0.3Ω
R e s is ta n c e o f p ick - u p co il 250Ω~300Ω
AC F l yw h e e l
Vo lta g e wit h o u t lo a d ( c o l d e n g in e ) > 100V (AC), 5 0 0 0 RPM
M a x . o u t p ut p o wer 460W,5000 r/min (EPS)
Output voltag e 13.5V~1 5 . 0 V, 5 0 0 0 RPM
Peak voltage of pick -up coil ≥1.5V,200 RPM
3 - p h a s e supply power of t h yr is t o r
R e g u la t o r t yp e
t r ig g e r c ir c u it
C a pa c it y 1 2 V 30 Ah
Vo lta g e F u ll y r e c h a r g e d >13. 0V
betwee n
Ba t t e r y N o t - f u ll y r e c h a r g e d < 11. 8 V
t e rm in a ls
R e c h a r g in g Sta n d a r d 2.7A/5 ~10H
c u r r e n t / t im e Q u ick 12A/ 1h
Item Sta n d a rd s
I g n it io n t yp e EC U
Type Resistant-type
Sta n d a r d DCPR8E (NGK)
Spa r k p lu g
G a p o f s park p lu g 0.8mm~ 0 . 9 mm
C h a r a c t e r is t ic > 8m m u n d e r 1 Kpa
0
I g n it io n t im e BT D C 9 1 3 0 0 r / m in
R e s i s ta n c e o f Pr im ar y 0.70Ω~0.75Ω
ig n it i o n c o il Se c o n d l y 6.0kΩ~7.0 kΩ
Pr im ar y > 1 5 0V
Pe a k vo lta g e
Pu ls e vo lta g e 2V
R e s is ta n c e o f s ta r t er r elay c oil 3Ω ~5Ω
R e s is ta n c e o f a ux ilia r y r e lay c oil 90Ω~100Ω
Item Sta n d a rd s
M a in 3 0A
F u se
Au x ilia r y 10A ×2 1 5 A×3 5A×1
H e a d lig h t (Hi / Lo ) H7/H1 12V —5 5W /55W×2
F r o nt p o s it ion lig ht LED
Br a k e lig h t /Ta il lig h t LED
L ig ht & Bulb Turn s ig n a l lig ht LED
D a s h b o a r d in d ic a t o r li g h t LCD
Wat er t em p er a t u r e , f u e l le ve l, 2 /4 d r ive in d ic a t o r lig h t LCD
MIL LED
01-9
Item Standard value Service limit Remarks
Intake valve Φ33 ‑—
Valve diameter
Exhaust valve Φ29 ‑—
Thickness of valve neck Intake/Exhaust 1 0.5
Intake 0.06~0.14 ‑—
Valve clearance(cold engine)
Exhaust 0.11~0.19 ‑—
Inner dia. Of valve guide Intake/Exhaust 5.000~5.012 5.045
Intake valve 4.965~4.980
Valve stem O.D.
Exhaust valve 4.955~4.970
Gap between valve guide and Intake 0.020~0.047
stem Exhaust 0.030~0.057
Intake 90.1
Valve length
Exhaust 88.7
Intake valve 1.2 ± 0.1 1.7
Width of valve seat seal
Exhaust valve 1.3± 0.1 1.8
Valve spring free length Intake/Exhaust 40 38.2
33: 200N~235N
Elasticity of valve spring
Intake/Exhaust 23: 530N~587N
Axial clearance of camshaft 0.12~0.28
Camshaft run-out 0.10
Bore diameter of rocker arm Intake/Exhaust 12.000~12.018 12.03
Flatness of cylinder head bottom
0.03 0.05
surface
01-10
Cylinder, Piston, Piston Ring & Crankshaft

Item Standards Service limit Remarks
Cylinder compression 1000kPa

1
Piston/Cylinder clearance 0.03~0.05 0.10
Flatness of cylinder top and bottom
0.03 0.05
surface
1st ring 0.25~0.40 1.5
Gap of piston ring 2nd ring 0.35~0.45 1.5
Oil ring 0.2~0.7 1.5
1st ring 1.17~1.19
Height of piston ring 2nd ring 1.47~1.49
Oil ring 2.37~2.47
1st ring 1.21~1.23
Height of piston groove 2nd ring 1.51~1.53
Oil ring 2.50~2.52
1st ring 0.02~0.06 0.15
Ring/Piston groove clearance
2nd ring 0.02~0.06 0.15
Oil ring 0.03~0.15 0.25
Piston bore 22.004~22.010
Inner diameter of small end of
22.01~22.02 22.06
connecting rod
Diameter of piston pin 21.995~22.000 21.980
Gap of piston/piston pin 0.004~0.015 0.08
Gap of piston pin/small end hole of
0.010~0.025 0.08
connecting rod
Side gap of bi g end of con necting
0.3~0.56 0.8
rod
Gap of connecting rod bearing 0.022~0.049 0.09
Gap of main bearing 0.02~0.05 0.09
Gap of crankshaft axial direction 0.05~0.35 0.6
01-11
Clutch + CVT + Gearbox
Item Standard value Service limit Remarks
Inner dia. of clutch friction disc 140.00~140.15 140.5
Clutch engagement RPM 1800r/min~2400r/min
Belt width 34.5 (Cord layer) 33.5

Free length of driven pulley spring 238.5
Hole dia. of driven pulley collar 38.10~38.14 38.30
Groove width of gearshift 6.10~6.20 6.30
Output gear width of driven shaft 6.10~6.20 6.30
Thickness of left and right gearshift fork 5.80~5.90 5.70
Clearance between gearshift fork and
0.20~0.40 0.50
engagement groove
Groove width of gearshift drum 8.05~8.10
Dia. of gearshift pawl pin 7.90~7.95 7.83
Tightening Torque
Items To r q u e (N.m) Items To r q u e (N.m)
5 m m Bo l t , N u t 5 ( 0 .5 ) 5 m m Sc re w 4 ( 0. 4. )
6 m m Bo l t , N u t 10 (1 . 0) 6 m m Sc re w 9 ( 0. 9. )
8 m m Bo l t , N u t 20 (2 . 0) 6mmSH Flanged bolt 10 (1 . 0)
1 0 m m B o l t , Nu t 34 (3 . 5) 6 m m F l a n g e d b o l t, n u t 12 (1 . 2)
1 2 m m B o l t , Nu t 54 (5 . 5) 8 m m F l a n g e d b o l t, n u t 20 (2 . 0)
10mm Flanged bolt, nut 39 (4 . 0)
01-12
Fasteners not included in below table should also be torqued to specification. Note: Threads and contact area
should be applied by engine oil.
Ref. No. Items Part number Qty Torque

1
1 Front mount bolt, engine GB5789 M12×1.25×190 1 50~60
2 Mount bolt, rear and left side of engine GB5789 M10×1.25×100 1 40~50
3 Mount bolt, rear and right side of engine GB5789 M10×1.25×130 1 40~50
4 Front A-arm shaft 9060-050103 6 40~50
5 Rear A-arm bolt GB5789 M10×1.25×90 4 40~50
6 Upper bolt, rear knuckle GB5789 M8×20 6 35~45
7 Lower bolt, rear knuckle
8 Lower shaft, rear knuckle 9060-060704 2 40~50
9 GB5789 M10×1.25×55 4 40~50

Bolt, front shock absorber
GB5789 M10×1.25×55 2
10 40~50
Bolt, rear shock absorber GB5789 M10×1.25×60 2
11 Bolt, bracket of rear wheel axle GB6187 M12×1.25 1 50~60
12 Mount nut, rim 901-07.00.02A 16 70~80
13 Nut, rim shaft 5HY0-110001 4 220~250
14 Bolt, rear brake caliper GB5789 M10×1.25×45 4 40~50
15 Bolt, front brake disc GB5789 M10x1.25x20 8 40~50
16 Bolt, front brake caliper GB5789 M10×1.25×35 4 40~50
17 Nut, steering linkage GB9457 M10×1.25 4 15~25
18 Upper bolt, mufflr body GB5789 M8×40 2 30~40
19 Lower bolt, muffler body GB5789 M8×60 2 30~40
20 Nut, rear axle GB6187 M10×1.25 4 60~70
21 Nut, front axle GB6187 M10×1.25 1 50~60
22 Bolt, front axle GB5789 M10×1.25×25 1 50~60
23 Bolt, front axle GB5789 M10×1.25×30 1 50~60
24 Bolt, bracket of front axle GB5789 M8×14 4 30~40
25 Bolt, front drive shaft 9010-290001 8 35~45
26 Bolt, rear drive shaft GB/T70.1 M10×1.25×25 8 40~50
27 Output coupler bolt GB 5789 M10×30 2 70~80
29 / / / /
30 Tie rod nut GB 9457 M10×1.25 4 40~50
31 Fuel pump screw GB 70 M5×16 5 5
01-13
Item Qty Dia. Of thread(mm) Torque (N.m) Remarks
Bolt M14X1.5 2 M14×1.5 25
Plug screw, oil passage of left crankcase 1 ZM14 20 Apply glues
Oil drain boltM12×1.5 1 M12×1.5 20
Flange bolt M8×12.5 (left crankcase) 1 M8×12.5 20
Screw R21/8 (oil passage) 2 R21/8 20 Apply glues
Nut M6(right crankcase) 4 M6 10
Stud AM6×35-8.8 (right crankcase) 4 AM6×35 10 Threadlocker
Screw M6×12（CVT cover） 1 M6×12 8
Bolt of wiring clamper(left crankcase cover) 2 M5×10 6 Threadlocker
Screw of oil seal plate(left crankcase cover) 3 M6×8 8
Bolt M12×1.25(Magneto rotor) 1 M12×1.25 105 Threadlocker
Adjust nut, valve clearance 8 M6 12
Bolt, timing sprocket 2 M8 30 Threadlocker
Plunger, tensioner 2 M16×1.5 0.1
Plug screw, tensioner 2 M18×1 4.5
Bolt, cylinder 8 M10 20,60
Thrust nut M8（exhaust pipe） 4 M8 13
Spark plug 2 M12×1.25 20
Stud M8x42（exhaust pipe） 4 M8×42 25 Threadlocker
Plug screw M12×1.5（head of cylinder 1） 1 M12×1.5 20
Tapping screw ST5.5×13(thermostat cap) 1 ST4.8×13 5
Screw, tensioner plate 2 M6×15.5 10 Threadlocker
Bolt M8, intake manifold 4 M8 20
Bolt, connecting rod 4 M9×1 10,20,50
Nut M18x1.5(left)（right crankcase） 1 M18×1.5 70 Left thread
01-14
To be continued
Torque
Item Qty Thread Dia. (mm) Remarks
(N.m)
Nut, drive shaft（CVT drive pulley） 1 M20×1.5 115 Threadlocker

1
Nut,main shaft（CVT driven pulley） 1 M20×1.5 115 Threadlocker
Lock nut, bevel gear 1 M22×1 145
Bolt M8x28(bearing seat, drive bevel gear) 4 M8×28 32
Screw M8x5（bearing holder, drive bevel gear） 4 M8×5 15
Stopper nut,M65X1.5(driven bevel gear) 1 M65×1.5 110 Threadlocker
Nut M8X28(bearing housing, driven bevel gear) 4 M8×28 25
Screw T25(shift fork drum) 1 M5×8 6
Spring seat, Limit 1 M12×1 20
Screw M5×16（oil pump） 3 M5×16 7 Threadlocker
Screw M8X20（overriding clutch） 6 M8×20 30 Threadlocker
Bolt M6×30（Magneto stator） 3 M6×30 10 Threadlocker
Bolt, valve cap 8 M6 7
Bolt M6×45(thermostat cap, cylinder 1) 2 M6×45 6
Bolt M6×25 (Tensioner, thermostat cap ofcylinder 2） 6 M6×25 6
Water temperature sensor 1 M12×1.5 16
Switch of oil pressure 1 M10×1 12 Threadlocker
Threadlocker,
Retainer, bearing (left) 1 M55×1.5 80
left thread
M5 4.5~5.5
Other bolts M6 8~12
M8 25
01-15
Engine Service Tools
Item Tool name Specifications Purposes
1 Vernier caliper 0-150mm Measure length and thickness
2 Micrometer 0-25mm Measure outer diameter of rocker arm shaft, valve stem, camshaft
3 Dial gauge 25-50mm Measure Max. travel of camshaft
4 Dial gauge 75-100mm Measure size of piston skirt
Inner di a. of
5 Measure cylinder size & pressure
cylinder meter
Inside caliper Measure inner diameter of rocker and piston pin hole, connecting
6 10-34mm rod hole
micrometer
7 Dial indicator 1/100 Measure jump
8 Knife straight edge Measure fla ness
9 Feeler gauge Measure fla ness and adjust valve clearance
10 Oil guage Measure fuel level of carburetor
11 Plastigauge Measure fi clearance
12 Spring balance Measure elasticity of spring
13 RPM meter Measure RPM

Compression
14 Measure cylinder compression
tester and adapter
15 Oil pressure meter Measure oil pressure
16 Air pressure meter Measure opening pressure of radiator cover

17 Ohmmeter Measure resistance and voltage
18 Amperometer Measure current of switch
19 Thermometer Measure coolant temp.
20 Timing light Measure ignition timing
21 Torque wrench One set Measure tightening torque
22 Alcohol light Warm up or increase temp.
Magnetic meter
23 Mounting dial indicator
seat
24 Plate Auxiliary measurement
25 V-shaped bluff Auxiliary measurement for jump
26 Nipper Mounting valve lock-clip
27 Double clip reed Disassembly and assembly of double clip
28 Pinching tools Disassembly and assembly of retainer
29 Impact driver Disassembly of crosshead bolt
30 Screw driver
31 Plus driver
01-16
Service Tools
Part number Tool name Purposes
0800-000000-871-001 Joint, oil hose Measure oil pressure
0800-014001-922-003
Remover, bearing 60/28 of left
crankcase
Remove bearing 60/28 1
0800-014001-921-002 Press tool, bearing of left crankcase Press bearing
0800-041000-922-001 Screw, locking crankshaft Lock crankshaft
0800-031000-922-001 Remover, magneto rotor Remove magneto rotor
0800-013201-922-001 Remover, bearing 6003 of CVT case Remove bearing 6003
Support CVT case cover when pressing

0800-013201-921-001 Damper, CVT case cover
bearing
Split driven fixing and moving sheave to

0800-052000-922-003 Split tool, drive & driven pulley
install belt
0800-051204-923-001 Installation tool, drive pulley oil seal Install drive pulley oil seal 35×42×4
0800-052000-922-002 Remover, driven pulley
0800-052000-922-001 Wrench, CVT driven pulley Fix nut of driven pulley when installation
0800-013101-922-001 Remover, bearing 6208 of CVT case Remove bearing

0800-013101-921-001 Damper, CVT case Support CVT case when pressing bearing
Install oil seal of CVT clutch
0800-013104-923-001 Installation tool, clutch housing oilseal
housing34×55×9
9010-180100-922-001 Radiator test cap Measure cooling system pressure
0800-014001-922-002 Puller, oil seal Remove oil seal
0800-014001-922-001 Puller, bearing Remove bearing
0800-014001-921-003 Press tool, bearing Press bearing
0800-022800-922-001 Sleeve, spark plug Disassemble/install spark plug
0800-024001-922-001 Locking tool, camshaft Lock up and fix camshaft
0800-000000-871-002 Joint, cylinder pressure meter Measure cylinder pressure
0800-022102-922-001 Remover, valve guide Remove valve guide
0800-022102-922-002 Installer, valve guide Install valve guide
0800-040003-922-001 Compressor, piston ring Compress piston ring when installation
0800-040005-922-001 Installer, circlip Install circlip of piston pin
0800-011201-923-001 Oil seal installer, breather Install oil seal of breather
0800-011201-921-003 Installation jig, breather gear shaft Support breather gear shaft
0800-011201-921-001 Press tool, breather gear shaft Press breather gear shaft
Support tool, left crankcase plain Support left crankcase when removing
0800-011101-922-001
bearing removing plain bearing
Support tool, right crankcase plain Support right crankcase when removing
0800-012101-922-001
bearing removing plain bearing
0800-011102-922-001 Remove/install tool, roller bearing Remove/install bearing
0800-060000-923-001 Press tool, front output shaft oil seal Install oil seal35×61×9 of front output shaft
01-17
0800-062301-923-001 Installer, front output shaft Install front output shaft
0800-062206-922-001 Nut sleeve, driven bevel gear bearing Install/remove nut of driven bevel gear
Install oil s eal of dr iven bev el gear

0800-062204-923-001 Press tool, oil seal of driven bevel gear
34×50×7
Measure backlash between drive
0800-062000-922-001 Backlash measurement tool
bevel gear and driven bevel gear
Remove shaf t of r everse

0800-060002-922-001 Remover, shaft of reverse immediate gear
immediate gear
0800-011000-922-001 Remover, left crankcase bearing Remove bearing of left crankcase
0800-012000-922-001 Remover, right crankcase bearing 5206 Remove bearing 5206
0800-012101-921-001 Damper, right crankcase Support right crankcase
0800-011101-921-001 Damper, left crankcase Support left crankcase
0800-060000-922-001 Press tool, reverse immediate gear shaft Press reverse immediate gear shaft
0180-014001-921-001 Press tool, left crankcase cover bearing 60/28 Press bearing 60/28
0180-013201-921-001 Press tool, CVT case cover bearing 6003 Press bearing 6003
0180-013207-923-001 Press tool, oil seal of CVT case cover Press oil seal
0180-051000-922-001 Holding Wrench, CVT drive pulley Stop rotation of drive pulley
0180-013101-921-002 Press tool, CVT case bearing 6207 Press bearing
0180-053100-921-002 Press tool, clutch housing Press clutch housing
Support clutch housing when pressing

0180-053100-921-001 Damper, clutch housing
clutch
0180-054000-922-001 Holding wrench, clutch Stop clutch rotation

Install oil seal 10×20×5 of water
0110-080005-923-001 Press tool, oil seal of water pump
pump
0010-081004-921-001 Press tool, water seal Press water seal
0180-022006-922-001 Valve spring compressor clamp Compress, remove valve spring
Install/Remove front output shaft
0180-060008-922-001 Wrench, circlip of front output shaft bearing
bearing circlip
Press tool, driven bevel gear shaft
0180-062201-921-003 Press bearing
bearing（6207C3）
Press tool, drive bevel gear shaft
0180-062103-921-002 Press bearing
bearing（6305）
0010-060002-921-002 Installer, bearing 6203 Press bearing
0180-012100-921-004 Installer, bearing 3206A Press bearing
0180-011100-921-004 Press tool, gearshift shaft bearing 6303 Press bearing
0040-012001-921-002 Press tool, bearing 6203 Press bearing
01-18
Lubricants and Service Products

Item Type Lubrication points Remarks
SAE15W-40
Cylinder, Crankcase, Cylinde
Engine oil API : SG or higher
(Alternative please see page 1-6)
head, see page（10-3） 1
Molybdenum Piston pin, valve stem, valve
disulfide grease oil seal, camshaft
Oil seal, O-ring and other

rubber seals. Sealed
Grease No. 3 MoS2 grease
bearing, CVT bearing and
bushing
-30℃ Anti-freezing, anti- Coolant capacity
Coolant corrosive, high-boiling Engine cooling system depends on
coolant radiator pipes
Crankcase splitting
surfaces, contact surface
between crankcase and
Silicone sealant Loctite5699
cylinder, contact surface
between cylinder head and
valve cover
Threadlocker KB243 Some threads
Retaining compound KB648 Oil seal
01-19
MIL 1
MIL is located at position No. 1.
When the light flashes, it will indicate there·s
Something wrong in vehicle.
PDA can be used for diagnosis.
012001
EPS fault
EPS is located at position No. 1.
EPS is matching device.some of the vehicles is not installde. Failure by two flsah mode fcombination.
respectiveiy by the trouble light as long bright times and short bright times said.The trouble light bright 2s
long.short light 1s. put out a second.trouble light extinguished interval between fauit code for
3seconds.
EPS fault code meaning and processing method：
Code Diagnosis of content Processing method
21 The main sensors disconnect
The main sensor outtput（High voltage low

22 eves)
23 Vice sensor disconnect Check the sensor wire harness

Vice sensor output abnormalities（High voltage
24 low eves)
The main secondary moment difference is too
25 large
The main deviation transfinite torque sensor
26 phase compensation
33 The controller current overrun Replace the ECU
34 Motor unilateral no power
35 Current sensor zero offset is too large
Check the electrical contact situation.or replace

32 Abnormal motor power
the ECU
36 The motor wire break Check the motor line
01-20
2 BODY AND MUFFLER
Maintenance Information…………………....... 2-1 Seat, Shift Lever, Shiftgear Cover.................... 2-8

Air filter&Battery Cover, LH&RH Bumper Pan
Hood, Front LH& RH Panel, Front Fender...... 2-2 2-9
el.....................................................................
Front LH&RH Fascia, Front LH&RH Fender Rear Lower&Upper Panel, LH&RH Cargo Box
Flare, Front LH&RH Bumper Protector.......... 2-3 Fascia, Rear Fender........................................ 2-10
Front Lower&Center panel, Dashboard...........

2-4
Service Cover, LH&RH Connection Panel....... 2-11
2
Front Upper Panel, Rear LH&RH Fender Pan Rear Cargo Box, Center Console Cover,
2-11
el..................................................................... 2-5 Electric Cover..................................................
Front Glove Compartment, Front Roll Cage, Document Box, Fuel Tank Panel, Battery Box,
2-12
Front Fender.................................................... 2-6 Brake Pedal.....................................................
Rear L&R fascia, LH&RH Panel, Front Grille.. 2-7 Fooboard......................................................... 2-13
Front Console Panel........................................ 2-15
Operation Cautions
WARNING:
Gasoline is highly flammable, therefore smoke and re are strictly forbidden in the work place.
Special attention should also be paid to sparks. Gasoline may also be explosive when it is va-
porized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold
● This chapter is on the removal and installation of rack, visible parts, exhaust pipe, muffler and fuel
tank.
● Hoses, cables and wires should be routed properly.
02-1
Hood 1 1
Removal
Push the release lever No. 1.
Remove the hood No. 2.
LH Panel, Front Fender

Removal 020201
Remove the plastic rivet no. 3. 1. Release lever 2. Hood
3 3
Remove the front LH wheel fender 4. 4

3
Installation
Reverse the removal procedure for installation.
3.Plastic rivet 020202

4. LH panel, front fender
RH Panel, Front Fender

Refer to LH Panel, Front Fender Removal& In-
stallation.
020203
02-2
2 BODY AND MUFFLER
Front Fascia, LH
Removal 1
Remove the LH panel, front fender. 1 1
Remove the plastic rivet No. 1.
Remove the front fascia, LH. 1 1
Installation
Reverse the removal procedure for installation. 1 2
2 1
1
Front Fascia, RH
Refer to FRONT FASCIA, LH Removal& Instal-
1. Plastic rivet 2. Front, fascia, LH 020301
lation.
3
3
3 3
3
Front, LH Fender Flare
Removal 3
Remove the LH panel, front fender. 4
Remove the front, fascia, LH.
Remove the plastic rivet No. 3. 5
Remove the bolt No. 5. 020302
Remove the front, LH fender flare 3. Plastic rivet 4. Front, LH fender flar
5. Bolt
Installation
6 6
Front, RH Fender Flare 6 6

Refer to FRONT, LH FENDER FLARE Remov-
al& Installation.
8
7
Front Protector, LH, RH
Removal 6. Bolt M6 ˣ 22 020303
Remove the bolt M6 ˣ 22 no.6. 7. Front protector, LH
Remove the front protector, LH no.7. 8. Front protector, RH
Remove the front protector, RH no. 8.
Installation
02-3
Lower Panel, Front
Removal
Remove the plastic rivet.
Remove the bolt M6X14. 2
Remove the lower panel, front no.3.
Installation 1
1
Reverse the removal procedure for installation. 1
2 1
3 2
Center Panel, Front

1. Bolt M6X14 2. Plastic rivet 020401
Removal
Remove the front protector, LH&RH.
Remove the lower panel, front. 4 4
Remove the center panel, front.
Installation
5
3. Lower panel, front 4. Bolt M6X14

020402
Hood/ Dashboard
Removal
Remove the bolt no. 6.
Remove the hood/ dashboard.
6
Installation
7 6
5. Center panel, front 6. Bolt 020403

7. Hood/ dashboard
02-4
2 BODY AND MUFFLER
Upper Panel, Front

Removal 1 1
Remove the hood.
Remove the LH&RH panel, front fender. 1 1
Remove the LH&RH front protector.
Remove the LH&RH front fascia. 1 1
Remove the LH&RH front fender flare.
Remove the bolt M6X14. 2
Remove the plastic rivet 1. 2
Loose the headlight connector.
Remove the upper panel, front.
1.Plastic rivet 2. Upper panel, front 020501
Installation
3. Bolt M6X14 020502 020503
LH Panel, Rear Fender

4 4
Remove the plastic rivet 4.
Remove the LH panel, rear fender.
Installation 4
RH Panel, Rear Fender

Refer to LH Panel, Rear Fender Removal 4.Plastic rivet 020504
& Installation.
4
5
4
4
4
5. LH panel, rear fender 020505
02-5
Front Glove Compartment
Removal
Remove the hood
Remove the self-tapping screw 1. 1 1
Remove the bolt 3. 1 1
Remove the front glove compartment. 1 2 1
Installation
3
2
1. Shift Lever 2. Lock Nut
Front Roll Cage 1

Removal
Remove the hex cap bolt. 1. Self-tapping screw 2. Front glove compartment
Remove the front roll cage. 3. Bolt 020601
Installation
5
Front Panel Fender 4
Removal 4
Remove the hood
Remove LH&RH front fender panel 3. Air Filter Cover 4. Fuel Tank Cap Strap
Remove LH&RH front plastic rivet
Remove LH&RH front fender flare 4
Remove the front glove compartment
Remove the front roll cage
Remove bolt 7. 4
Remove Speaker Cover screw 8.
Loose the electric parts and connectors on the
front panel fender. 4
Installation
Reverse the removal procedure for installation. 4. Hex cap bolt 5. Front roll cage 020602
7 7
8 8
6. Front panel fender 7. Bolt 020603

8. Speaker Cover screw
02-6
2 BODY AND MUFFLER
Rear Fascia, LH
1 1
Removal 1
Remove the LH panel, rear fender
Remove the flastic rivet 1 1
Remove the rear fascia, LH 2. 1
1
Installation 1 1
Rear Fascia, RH
1
1
2
2 1
Refer to Rear Fascia, LH
Removal& Installation.
1. Plastic rivet 2. Rear Fascia, LH 020701

Left Panel
Removal 3
3
Remove the LH panel, front fender 4 3 3 3 3
Remove the front fascia, LH 4
Remove the rear fascia, LH
Remove the flastic rivet 3
Remov ethe bolt 4.
Remove the left panel 5. 5
Installation
Reverse the removal procedure for installation. 3. Plastic rivet 4. Bolt 5. Left panel 020702
Right Panel
Refer to Left Panel Removal& Installation.
4
4
4
020703
6 6
7
7
6
6
6. Plastic rivet 7. Front grille 020704
02-7
The Driver Seat
Removal 1
Pull the seat release handle 1.
Pull the driver seat over to the front to remove it.
The Passenger Seat
Refer to The Driver Seat Removal.
Shift Lever 1. Seat release handle 2. Seat 020801

Removal
Loose the shift gear lever lock nut No.4.
3
Rotate the shift lever No.3 out.
4
Shift Gear Cover
Removal
Pull the shift gear cover 5.
3. Shift lever 4. Shift gear lever 020802
5. Shift gear cover 020803
02-8
2 BODY AND MUFFLER
Air Filter Cover

Removal
RemovetheboltM6X14.
Remove the airfilter cover. 1
Installation
Reverse theremoval procedureforinstallation. 2

1
1 2
1. Bolt M6X14 2. Air filter cove 020901
3
Battery Cover
Removal
RemovetheboltM6X14.
Removethebatterycover.
Installation 4
Reversetheremovalprocedureforinstallation.
3
Rear LH&RH Protector
Removal
Removethebolt.
RemovetherearLHprotector.
3. Bolt M6X14 4. Battery Cover 020902
RemovetherearRHprotector.
Installation
5
5
LEFT SIDE PANEL
Removal
Remove the left side door
Remove the front , LH fender flare 6
Remove the rear , LH fender flare 7
Remove the bolt No.1.
Remove the bolt No.4(The dotted line means it

can be seen only after removing the front LH
fender flare 5. Bolt 6. RH Protector 020903
Remove the self-tapping screw No.5(The dotted 7. LH Protector
line means it can be seen only after removing the
rear LH fender flare
Remove the plastic rivet No. 2.
Remove the front fender flare No. 3
Installation
02-9
Lower Panel, Rear
Removal
Remove the rear RH protector
Remove the bolt M6 ᵡ 14. 1
Remove the Lower panel, rear 2. 1
2
Installation
RH Cargo Box Fascia
Remove bolt 3.
Remove the RH cargo box fascia. Installation 021001
1. Bolt M6 ᵡ 14 2. Lower panel, rear
LH Cargo Box Fascia
Refer to LH Cargo Box Fascia Removal
& Installation. 4
3
3 3
Upper Panel, Rear
Removal
3
Remove the LH&RH panel, rear fender.
Remove the LH&RH rear fascia.
Remove the LH&RH rear protector.
Remove the LH&RH cargo box fascia.
Remove the plastic rivet 1.
Remove the reflector bolt 3. Bolt 4. RH cargo box fascia 021002
Loose the taillight&rear brake light connectors.
Remove the upper panel, rear. 5
5 5
Installation
5
5
Rear console cover
Removal
Remove the front grille. 6
Remove the seat.
7
Remove the self-tapping screw 9. 7
Remove the bolt 10. 5. Plastic rivet 6 Rear upper panel 7. Reflecto 021003
Remove the rear console cover 8.
Installation
9
10
10
10
11 11 11 11
8. Rear console 9. Self-tapping screw 021004

10. Bolt 11. Plastic rivet
02-10
2 BODY AND MUFFLER
Service Cover
Removal
Remove the bolt M6 ᵡ 14.
Remove the service cover.
Installation 1
LH connection panel
Removal 2
Remove the Rear fascia, LH. 1. Service Cover 2. Bolt M6 ᵡ 14 021101
Remove the seat.
Remove the center console.
Remove the plastic rivet 3. 3
Remove the bolt 5.
Remove the bolt M6 ᵡ 14. 3
Remove the LH connection panel.
3
Installation
RH connection panel
Refer to Refer to LH connection panel
Removal&Installation.
5
4
3. Plastic rivet 4. LH connection panel 021102

5. Bolt
6. Bolt M6 ᵡ 14 021103
02-11
Rear Cargo Box
Removal
Remove the LH&RH panel, rear fender. 1 1
1
Remove the LH&RH Rear fascia.
Remove the front grille.
Remove the seat.
1
Remove the rear LH&RH protector.
Remove the LH&RH cargo box fascia. 1
Remove the rear panel.
Remove the rear upper panel 1
Remove the LH&RH connection panel.
Remove the service cover. 2
Remove the bolt M6 ᵡ 14.
Remove the rear cargo box. 1. Bolt M6 ᵡ 14 2. Cargo box 021201
Installation
Center Console Cover 3

Removal 1
Remove the gear shift cover.
Remove the shift lever.
Remove the seat. 5
3 5 5 021202
Remove the rear console panel.
Remove the LH&RH connection panel. 3. Bolt 4. Center console cover 5. Self-tapping screw
Remove the bolt 3.
Remove the self-tapping bolt 5.
Remove the center console cover 4.
3
Installation
Electric Cover 5
5 5
Removal
Remove the seat. 5
Remove the bolt 6.
Remove the electric cover 7. 021203
Installation
6
6
6. Bolt 7. Electric cover 021204
02-12
2 BODY AND MUFFLER
Document Box
Removal 1
Remove the hood.
Remove the front glove compartment.
Remove the front fender.
Remove the bolt 1. 1 1
Remove the document box. 1
Installation 2
2
Fuel Tank Cover
Removal 1. Bolt 2. Document Box 021301
Remove the Rear fascia, LH.
Remove the grille.
Remove the rear console panel.
Remove the LH connection panel. 3
4
Remove the center console cover.
Remove the bolt 3. 3
Remove the fuel tank cover
Installation
3
BATTERY BOX
Removal 3. Bolt 4. Fuel tank cover 021302
Remove the RH panel, rear fender.
Remove the Rear fascia, RH.
Remove the seat. 5
Remove the rear console panel. 6
5
Remove the RH connection panel.
5
Remove the bolt No.5. 5
Remove the battery box. 5
Installation
Reverse the removal procedure for installation. 5. Bolt 6. Battery Box 021303
8
Brake Pedal 7
Removal 8
Remove the bolt 8.
Remove the throttle cable.
Remove the brake pedal bolt.
Remove the brake pedal.
Installation
7. Brake pedal 8. Bolt 021304
02-13
Footboard
Removal
Remove the LH&RH panel, front fender.
Remove the LH&RH front fascia.
Remove the LH&RH panel, rear fender.
Remove the LH&RH Rear fascia. 1
Remove the LH&RH panel. 1 1 1 1 1 1
Remove the front grille. 1
Remove the seat.
3 2
Remove the gear shift cover.
Remove the shift lever.
Remove the LH&RH connection panel. 1. Bolt 2. Bolt 3. Footboard 021401
Remove the fuel tank cover.
Remove the battery box.
Remove the bolt 1.
Remove the bolt 2.
Remove the bolt 4. 1

Remove the footboard. 1 1
Installation
021402
4. Bolt 021403
02-14
2 BODY AND MUFFLER
Front Console Panel

1
Removal
Remove the LH&RH panel, front fender. 1 1
Remove the hood.
Remove the LH&RH front fascia.
Remove the LH&RH front fender flare.
Remove the dashboard.
Remove the front fender.
Remove the LH&RH panel.
Remove the brake pedal. 2
Remove the document box. 2
Remove the footboard.
Remove the bolt 1. 1. Bolt 2. Front Console Panel 021501
Remove the front console panel.

Installation 1
021502
021503
Side door
Removal
Remove the Jump ring. no.1
Remove the Pin. no.2 3 2
Press down the key.
Remove the side door. no.3
Installation
1
021504
1. Jump ring 2. Pin 3.Side door
02-15
3 INSPECTION AND ADJUSTMENT
Maintenance Information……..............................3-1 Suspension System………….……..................3- 9

Maintenance Interval…………………..................3-2 Shift Linkage, Fuel System….....................….3-10
Maintenance Procedure……………....................3-3 Throttle Lever……………………..............……3-11
Steering Column, Brake System…......................3-5 Cooling System………………………..........….3-12
Wheel……………………………………................3-7 Lighting System………………………...............3-14
Operation Cautions WARNING:
3
● Engine exhaust contains poisonous carbon dioxide and can cause loss of consciousness resulting in
severe injury or death. Never run an engine in an enclosed area.
● Don’t perform the maintenance immediately after the engine stops, as the exhaust system and en-
gine become very hot. Serious burns could result from the contact with the exhaust system or en-
gine. Wear long-sleeved uniform and gloves to operate when necessary.
● Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work plac
● Special attention should also be paid to sparks. Gasoline may also be explosive when it is vaporized,
so operation should be done in a well-ventilated place.
● Don’t get pinched by the drive system and other rotational parts.
ATTENTION:
Always position the vehicle on level ground.
03-1
Maintenance Intervals
Careful periodic maintenance will assure your vehicle good performance, reliability, economy and du-
rability.
Inspection, adjustment, lubrication and other details are explained in below periodic maintenance
chart.
ATTENTION Maintenance intervals in the following chart are based upon average riding conditions.
Vehicles subjected to severe use must be inspected and serviced more frequently.
10 hours or 300 km
A : Adjust
Every 20 hours or 750 km
Every 50 hours or 1500 km
C : Clean
Every 100 hours or
3000 km or 1 year
I : Inspect Every 200 hours or
6000 km or 2 years
L : Lubricate
Remark
R : Replace
Engine
Engine Oil and Filter R R
Valve Clearance I, A I, A
Condition of Engine Seals I I
Engine Mounting Fasten-
I I
ers
Air Filter C R
Coolant I I I R
Radiator Cap, Cooling
System I I
Pressure Test
Spark Plug I R
Fuel System
Throttle Body I I, L
CVT
CVT Belt I R
Primary Pulley, Driven pul-
I, C
ley
Clutch I
CVT blast pipe/discharge pipe I I, C
03-2
Maintenance information
Inspection Item Maintenance Interval

Every Criteria
Task Item Daily 6 Yearly
Months
Handlebar Agility ○
Damage ○
Steering
System Steering Installing condition ○
System Free play of ball joint
○
pin
3
Free play ○ ○
Brake Lever
Braking performance ○ ○
Brake
Looseness&damage ○ ○
lines&fitting
Brake Brake fluid should be
System FR&RR brake fluid
○ ○ between “LOWER”
level
and “UPPER”
Hydraulic
brake&Brake If front brake disc
disc Brake disc&pads thickness is less than
○ ○
wear&damage 4 mm , replace the
disc.
Front tire: 70
kPa(0.70kgf/c2) 10PSI
Tire pressure ○ ○
Rear tire: 100
kPa(1.00kgf/c2)14PSI
Crack&damage ○ ○
Tread Tread depth should be
depth&abnormal ○ ○ more than 3.0 mm.
Drivetrain Wheel wear
Looseness of wheel
○ ○
nuts&axle
FR wheel bearing
○ ○
free play
RR wheel bearing
○ ○
free play
A-arm Free play&damage ○ ○
Suspension
Shock Leaks or damages ○ ○
System
function ○
03-3
F Diff Leaks&lubrication ○ ○
Transmission
R Diff Leaks&lubrication ○ ○
System
Transmission Leaks&oil level ○ ○
Looseness of
Transmission ○ ○
Propshaft connection
System
Free play of splines ○
Spark plug clearance
Spark plug condition ○
Ignition 0.8mm~0.9 mm
Timing ○
Electrical
System Connections of
Battery ○
terminals
Electric Looseness&damages
○
Routing of connections
Fuel leakage ○
Fuel System Throttle lever free
Throttle condition ○
play: 3mm~5 mm
Coolant level ○ ○
Cooling
Leaks ○
Lights&Turn Signal Indicators Function ○ ○
Alarming&locking Components Function ○
Meters Function ○
Looseness&damages ○
Exhaust Pipe&Muffle
Muffler functio ○
Looseness&damages ○
Frame
Lubrication ○
Others Abnormal conditions ○
03-4
STEERING COLUMN
Position the vehicle on level ground. Grip the
steering wheel and shake the steering wheel and
shake the steering wheel in the direction as illus-
trated in the right figure to check for free pla .
If there is a free play, determine the source of it.
If the free play comes from steering column,

tighten the steering column locking nut or remove
steering column for further inspection and repair.
Position the vehicle on level ground. Turn the

steering wheel clockwise or counterclockwise to 030501
check for agility.
If the steering is binding at some points, inspect
3
the wiring, cables or tie-rod ends for interference.
If no interference, check the steering bearing for
damages.
WARNING
Inspect the agility of steering wheel before

every ride. Steering failure may result in se-
vere injury or death.
BRAKE SYSTEM
Front Brake Lever Free Play
Check the free play of front brake lever and the
performance of front brake.
1
1. Brakepedal 030502
03-5
MASTER CYLINDER
<Brake Fluid Level>
Check brake fluid level
If the brake fluid level is below the mark“lower”, 1
check master cylinder, brake lines and connec-
2
tions for leaks.
Open the reservoir cap.
DOT 4 brake fluid only. Never ex-ceed the mark
no. 1.
● When adding brake fluid, always avoid dirt or

water.
● Always use specified brake fluid
● Don’t spill brake fluid on plastic or rubber parts,
030601
as it would damage them. 1. Upper limit 2.Lower limit
● Check the brake fluid level in the brake fluid
reservoir when the vehicle is on a level surface.
BRAKE DISC&BRAKE PADS

<Brake Pad Wear>
Inspect brake pads from the marked place.
Replace brake pads if they are worn to service
limit groove.
CAUTION:
Always replace the brake pads in a pair.
Brake Disc Inspection&Replacement

Inspect brake disc for excessive wear or damage.
Replace brake disc when its thickness is less
than 4.0 mm
Front brake disc service limit thickness:4.0 mm 3
Brake Fluid Replacement 3. Brake Disc 030602

<Brake Fluid Replacement>
Replace brake fluid every yea .
03-6
WHEEL
Position the vehicle on level ground. Elevate the
appropriate side of the vehicle by placing a suit-
able stand or other tool under the footrest frame.
Push and pull the wheel to check for free play or
looseness. If any free play or looseness is found,
inspect A-arms, axle, rim bolts and nuts and tight-
en them if necessary.
If free play or looseness still remains, inspect
bearing, A-arm bushings and ball joint pin and re-
place if needed.
030701
3
Front Wheel Toe-in
Position the vehicle on level ground to measure
the front wheel toe-in.
Toe in: B-A=4 mm~10 mm
If the measurement is out of specification, adjust

the LH&RH tie rod .
● Hold the tie rod with a spanner.
● Loosen the lock nut No. 2 with another spanner.
● Adjust the tie rod.
● Tighten the lock nut.
Lock nut tightening torque: 40 N·m~50 N·m
030702
WARNING
Drive the vehicle slowly after the adjust-
ment is completed. Ensure that steering
wheel works properly.
1 2
1
2
1. Tie Rod 2. Lock Nut

030703
03-7
TIRE PRESSURE
Use tire pressure gauge to measure tire pressure.
WARNING:
Measure tire pressure when the tire is
cold. Maintain proper tire pressure. Im-
proper inflation may affect UTV maneu-
verability, comfort, or uneven wear to dif- 1
ferent tires.
030801
1. Tire Pressure
Speci ied Tire Pressure/Tire
Front Rear
Pressure 70 kPa (10PSI) 100kPa(14PSI)
Size See chapter 1 See chapter 1
Over
3 mm
TIRE TREAD DEPTH

Replace the tire when tread depth is worn to 1/8”
(3 mm) or less.
030802
WARNING:
When the tread depth is worn to 3 mm or less,
replace the tire immediately.
03-8
AXLE NUTS AND AXLE

Check wheel nut No. 1 and axle nuts No. 2 for
looseness.
If axle nuts are loose, torque them to specifie
values.
Torque Speci ication:

Wheel Nut: 220N· m~250 N· m
( 13. 2 kgf· m~13.3 kgf· m) Axle
Nut: 70N· m~80 N· m
( 7.2 kgf·m~8.3 kgf·m)
3
030901
1. Axle Nut 2. Wheel Nut
Wheel Bearing Free Play

Elevate the appropriate side of vehicle by plac-
ing a suitable stand under the footrest frame. Pull
and push the wheel to check for free play.
If there is a free play, inspect the wheel bearing.
030902
SUSPENSION
Position the vehicle on level ground, push and
release the vehicle as illustrated. If the vehicle
is unstable or abnormal sound is found, check
shocks for leaks, damages or looseness of fas-
teners.
030903
03-9
Shock Absorber Adjustment
1
Rotate the adjuster cam No. 2 clockwise with
a special tool to decrease the spring tension or
counter-clockwise to increase the spring tension.
3
1. Recovery damping adjuster 031001

2. Spring preload adjuster
3. Compression damping adjuster
SHIFT LINKAGE
Shift to check shift for smoothness. If not, attempt
to adjust the length of shift rod by turning the lock-
ing nuts no. 3. Loosen the lock nut
4
No. 4. Adjust the length of the gearshift linkage
lever. 5
4. Gearshift 031002
FUEL SYSTEM
Fuel System Condition.
Remove seat.
Check fuel lines for aging, damage.
Replace fuel line if aging or damage is found.
Inspect fuel tank breather hose and the hose of
Evaporation Emission Control System(if appli-
able) for damages, bending. Replace the hoses if
any damage is found.
6. Fuel tank
031003
03-10
Throttle Pedal Inspection

Inspect that if the throttle pedal can return to rest
position freely when released.
Inspect throttle cable for free play.
Free Play:3mm ~5 mm
Adjust throttle cable if free play is out of specific -
tion
1
3
031101
1. Throttle Pedal Nut
Adjust Throttle Cable

Remove the service cover.
Loosen the lock nut No. 2. Turn adjuster to
change the throttle cable free play.
Reinstall locking nut no. 2 and install the sercice
cover.
If adjuster fails to change throttle lever free play
to specified value, replace throttle cable
2. Throttle body nut 031102
03-11
COOLING SYSTEM WARNING:
● For safety, check the coolant level in the reser-

voir tank, not radiator. Never open the pressure
cap when the engine is hot(more than 100 OC).
Escaping steam can cause severe burns. The 1
engine must be cool before removing pressure
cap.
● Coolant is toxic. Don’t drink nor spill on skin,
eyes, clothing.
If you spill coolant on your skin or clothing, imme-

2
diately wash it off with soap.
If you get coolant in your eyes, immediately wash 1. Upper limit 2. Lower limit 031201
it off before medical attention.
If coolant is swallowed, induce vomit and seek for

medical.
● Coolant must be kept out of reach of children.
Coolant Level
Coolant would decrease due to evaporation, etc.
Inspect coolant level periodically.
WARNING:
● Coolant is anti-rust and anti-freezing. Using tap
water will rust the engine, and may crack the 3
4
engine when it’s freezing. Always use specifie
coolant.
● Position the vehicle on level ground before
cooling system inspection.
● Start the engine and warm it up before inspect-
ing the cooling system.
Start the engine and warm it up.

Shut off the engine.
Inspect the coolant level, ensure that the level is

between “LOWER” and “UPPER”. 3. Reservoir Tank Cover 031202
4. Radiator Cover
03-12
When the coolant level is below the mark No. 1-

”LOWER”, remove the reservoir tank cap and add
coolant to the mark No. 2-”UPPER”.
Recommended Coolant: CFMOTO cool-

ant. 1
Standard Mixture Ratio: 50%(The freezing
temperature varies according to the mix-
ture ratio. Adjust the mixture ratio accord-
ing to freeze protection required in your
area.)
2
When coolant is reduced significantly, inspect the
cooling system for leaks. If no coolant remains in
1. Upper Limit 2. Lower Limit 031301
the reservoir tank No. 3, there may be air in the
cooling system. Purge the cooling system of air.
3
Coolant Leakage
Inspect radiator hoses, water pump, and connec-
tions for leaks.
If any leaks are found, repair the cooling system.
(→Chapter 4)
Inspect radiator hoses for aging, damages and

cracks. Hoses ages over time due to special
working conditions and may crack. Bend a hose
to inspect for cracks. If any damages or cracks
are found, replace it with a new hose.
Inspect coolant hose clamps and tighten the

loose ones.
Inspect radiator fins for damages or mud

Correct the fin bending. Use tap water or com-
Coolant Radiator 031302
pressed air to clean off the mud.
The radiator should be replaced when 20% fins

are damaged.
See : Coolant Radiator
03-13
Coolant Gauge Inspection
The indicator should point at 0 when the engine
is not working. Start the engine to check coolant
gauge for response. If the indicator doesn’t work,
determine the cause and take a repair. 1
LIGHTING
Headlight Beam Adjustment 1. Indicator 031401
Turn the screw to adjust the headlight beam.
2. Headlight Beam 031402
03-14
Muffler Spark Arresto

Remove 3 bolts no. 1.
Remove the spark arrestor no. 2.
NOTE: Clean the Carbon Deposits Regularly. 1
2
3
1. Bolt 2. Spark Arrestor 031501
03-15
4 Cooling system
4 Cooling system
4.1 Service tool and Accessories……………………………………………4-2
4.2 General information………………………………………………………4-5
4.3 Inspect………………………………………………………………………4-5
4.4 Maintenance……………………………………………………………… 4-6
4.5 Thermostat…………………………………………………………………4-8
4.6 Radiator…………………………………………………………………… 4-9
4.7 Pump………………………………………………………………………4-16
4-1
4.1 Service tool and Accessories
Service tool
Name P/N Page
Testing radiator cap 901-18.01.00-922-001 4-5

Water seal removing tool 0JWA-081000-922-001 4-19
Bearing 3200A removing tool 0800-014001-922-001 4-19
Oil seal pressor 172MM-080005-923-001 4-21
Bearing pressor 0800-014001-921-003 4-22
Water seal assembly tool 0JWA-081000-922-002 4-22/23/24/25
Accessories
Name P/N Page
Coolant 4-6
Oil 4-4/21
648 cylinder locking glue 4-4/21
5699 flat sealant 4-4/22/23/25
4-2
4 Cooling system
Radiator
7 N ·m
(62 lbf·in)
7 N ·m
(62 lbf·in)
7 N ·m
(62 lbf·in)
7 N ·m
(62 lbf·in)
7 N ·m
(62 lbf·in)
040301
4-3
Water pump
Oil
Oil
Oil
648 Cylinder
locking glue
Oil
5699 flat sur-

face locking
glue
10 N·m(89 lbf·in)
040401
4-4
4 Cooling system
4.2 General
WARNING
Do not start the engine without coolant. Or the
engine parts maybe damaged by high heat.
Please follow the exploded view to assemble the parts

and tight up in specific torque.
4
WARNING
Use torque wrench to tight up the parts.
Locking parts(Exp: Locking piece,Locking nut,
Cottor pin.)Must be replaced into new one. If
locking parts becoming weak, must be replaced.
040501
Testing cap
（P/N：901-18.01.00-922-001）
4.3 Inspection
Cooling system sealing test.
WARNING
To avoid protential hurt. Do not remove the ra-
diator cap or drain bolt when the engine is hot.
Remove parts(See body covering parts) and radiator

cap.
Use testing cap on radiator coolant entery(901-18.01.
00-922-001 ).
Use vaccum pump to set the pressure to 103kpa(15
PSI).
1
040502
1.Testing cap
（P/N：901-18.01.00-922-001）
4-5
Inspect the pipes, radiator , cylinder, cylinder head
and flat connections to see leaking or bubbles.
1
Inspection
Check the pipes and clip tightness.
Inspect leaking pipe to see coolant or oil leaking.
Note: The water seal have a little leaking is OK.

Only the pipe is totally full with continously dripping.
This is really leaking , The water seal must be
replaced.Because it is damaged. Oil leaking shows
the oil seal damaged. If one of the seal got leaking.
The two seals must be replaced at the same time.
040601
1.Leaking hose
4.4 Maintenance
Coolant replacement
WARNING
To avoid protential injuries. Do not remove the
radiator cap or drain bolt when the engine is
hot.
Use CFMOTO special coolant or 50% anti-freeser and

50% water mixture. To avoid the coolant getting bad.
Please use same brand and model coolant . Do not use
mixed coolant unless the coolant is totally washed.
WARNING
To avoid rusteese comes out or frozen. Please
use CFMOTO special coolant or 50% anti-
freezer and 50% water mixture. Do not use
hard water, pure anti-freezer or pure water. Or
the cooling system may become bad. For
aluminum alloy engine. Recommand to use
glycol coolant with anti-rusteese.
4-6
4 Cooling system
Drain out system
WARNING
Do not drain out or inject the cooling system
when the engine is still hot.
Open the radiator cap.
Loose the drain out bolt without removed.

1
When the cooling system totally drained out. Remove

4
the drain bolt and replace the washer.Install the drain
bolt and tight it to 10N.m(89 lbf.in).
040701
1.Coolant drain bolt
Coolant injecting
Remove the body covering part(See related chapter)
Remove the drain screw on the thermostat cap. 1
Note: Both cylinders needs to drain air out.
1
040702
1.Drain out screw
4-7
Set the vehicle on flat surface and let the engine cooled.
After the air comes out from the thermostat cap fully.
Install the screw with washer and tight it into 5N.m(44
lbf.in).
2
Fill the radiator full and install the cap.

Fill the reservior to reach the upper line and install the
cap. Start the engine until the thermostat is open.
Then stop the engine. After the engine is cool down 1
inspect the level of radiator and reservior, refill if
necessary. The level should between LOWER and
UPPER line.
Note:Test the coolant density with special tool 040801

every year or 100h or 3000KM. 1.Sealing washer
2.Drain screw
4.5 Thermostat
Thermostat is a singal-way valve.
Note:Thermostat is on 2 cylinder head intake

side top.
1 2
Thermostat removal
Jam the two hose with clamps and remove the bolts 2
to disassembe the thermostat cap.
040802
1.Thermostat cap
2.Bolt
4-8
4 Cooling system
Pull out the thermostat out from mounting seat.
Thermostat inspection
Put the thermostat in water and heat it up for inspection. 1

When the water temp is 65℃(149°Ｆ)Thermostat
open.
Inspect the thermostat to see damaged getting hard
or cracked. If so replace the thermostat.
4
Thermostat assembly 040901
1.Thermostat seal
Reverse the removal procedure to assemble. But
please note these steps.
Install the thermostat cap and tight up to 6N·m(53
lbf·in).
Inspect the level in radiator and reservior and refill if
necessary.
WARNING :Do not forget to drain out the

cooling system. See coolant replacement.
4.6 Radiator
Radiator cap 1
Use radiator cap to test the effective pressure. If the
pressure too low, replace the new cap at 110 kPa
(16PSI)(Do not higher then this pressure).
040902
1.Pressure cap
4-9
Radiator cleaning and inspection
Inspet the radiator fin to see jammed or damaged.
1 2
Use compressed air or low-pressure water to clean up
the insets mud or other jamming trash.
041001
1.Compressed air gun
2.Radiator
Inspect the cooling fin. Repair it by using a screw driver

if got damaged.
041002
1.Small screw driver
2.Radiator
4-10
4 Cooling system
5 2
4 3
1 1 4
041101
1.A clamp 2.Rediator assy inlet pipe 3.Radiator outlet pipe 4.Coolant inner connecting pipe
5.Radiator flow pipe
Radiator removal
Drain out the cooling system
Remove body covering part (See chapter 2 body
covering part).
6
Use screw driver or other suitable tool to remove 2
A-clamp [1].
Remove the radiator inlet pipe [2] radiator outlet pipe
[3].
Remove radiator flow pipe [5].
Remove 2 M8 bolt 6.
Remove the radiaror 7. 7
041102
6.M8 bolt
7.Radiator
4-11
Radiator assemble
Reverse the removal procedure for installation .

But pay at tention to the items below.
Put the rubber washer between radiator bottom and
bracket.
Fill the coolant. Refers to coolant replacement in this
chapter.
Inspet the radiator and hose to see leaking.
3
Reservior
With the temperature higher（until 100℃～110℃

（212°Ｆ～230°Ｆ））Coolant expend the sys-
tem pressure getting higher. If the pressure limit reach
1 2
to 110 kPa（16PSI). The radiator cap release valve
will be goes up to allow the coolant get into the drain
041201
hose to reservior. 1.M8 bolt
Make sure the reservior hose is not jammed. 2.Reservior hose
3.Radiator drain hose
Reservior removal
Remove the body covering part(See body covering 2

part on chapter 2).
Remove reservior pipe.
Remove 2 M6 bolt.
Remove the reservior.
1
Reservior assembly
1.M6 bolt
2.Reservior
Radiator fan
Radiator fan running

The fan is controlled by the data of thermoswitch.
When coolant reached 88℃. The fan should be start
working. When the coolant fall below 82℃ the fan
should be stop working.
4-12
4 Cooling system
Radiator fan testing
Follow the logic drawing below to analyze the fan

trouble.
041301
Radiator fan removal
Remove radiator protector.
Remove the bolt.
Remove the radiator fan.
Radiator fan assembly

4-13
1
Radiator fan relay
Relay assembly
Note: The relay can turn 180 degrees. Make sure

in-stallation and working normally. And the pin is
alig-ned to the groove of fuse box.
041401
1.Radiator fan relay
Relay test
The easiest way to test relay is remove the relay

line and short cut the connector. If radiator fan
works, the relay needs replaced. Short connecting
way like the photo on the right.
041402
1.Short cut line
Relay connecting test
Remove the relay.

Put the AVO meter at OHM position to test the relay.
Pin position on the right.
Pin Resistance
30 87 Opened（OL）
041403
Pin testing positiono
4-14
4 Cooling system
Connect the relay to the battery and test the relay

again like right picture.
Pin Resistance
0.5Ωmax.
30 87
（Connected）
Replace the relay if relay test failed.
041501
Connect the battery and test the relay
again
4-15
4.7 Waterpump
Waterpump cover 5
3
Waterpump cover is on left crankcase cover.
Waterpump cover removal

3
WARNING
To avoid protential hurt. Do not remove the ra-
diator cap or drain bolt when the engine is hot.
Drain out the cooling system. 4 2

Remove the drain pipe from waterpump cover.
Waterpump cover mounting bolt.
1
Remove the waterpump cover
041601
1.Coolant drain bolt
2.Sealing Washer
3.Bolt
4.Waterpump cover
5.Drain out hose
Waterpump cover inspection

Inspect the waterpump cover sealing washer to see
got hard, cracked or damaged. Replace if necessary.
Waterpump cover assembly
NOTE: To avoid leaking.Make sure the sealing

1
washer is in groove when assemble the
waterpump cover.
Tight up the waterpump mounting bolt in criss cross

way.
041602
1.Sealing washer
4-16
4 Cooling system
Water pump outlet pipe assy and O-ring 13x2
removal, inspection and assembly(Needn’t do this
without leaking)
Follow the right picture to remove the bolt(No.2).Re-
move the water pump outlet connector(No.1)And O-
ring 13x2 (No.3).
Inspect the O-ring 13x2(No.3) To see if it got damaged.

Replace if needs.
Reverse the removal procedure to install the O-ring

13x2 (No.3)And waterpump cover assy(No.1).Tight up
the bolt(No.2).
4 4
1 2 3
041701
1.Pump cover outlet pipe
2.Pump cover outlet pipe mounting bolt
3.O-ring 13x2
4.Waterpump cover
Waterpump peller assy, water seal, oil seal, bear-

ing and gear removal.
1
Drain out the cooling system.
Drain out the engine oil(To see engine lubrication
system).
Remove the waterpump cover.
Remove left crankcase cover(See left crankcase assy
removal).
Remove the waterpump idle gear and breathing shaft.
2
041702
1.Breathing shaft
2.Waterpump idle gear
4-17
Use hands to remove waterpump gear.
Press down the waterpump peller in axial direction to

remove the needle and washer on water pump shaft.
4
2 1
041801
1.Waterpump gear
2.Needle
3.Waterpump shaft
4.Washer
Hold the waterpump shaft. Remove the bolt with sleeve.

Then remove the peller and washer in orders. 2
WARNING : Be careful when removal. Do not

damage the leave on peller. Bolt 1 is counter
clockwise screw.
1 3
041802
1.Bolt（Counter clockwise screw）
2.Waterpump peller
3.Washer seal washer
4-18
4 Cooling system
Use water seal removing tool like drawing on the right.

And turn the bolt clockwise to get the water sealant 2
out.
Note: Water seal removing tool’s inside 2 claws

must be grap the water seal tightly. Out side claws
grap the moving ring on sealant.The left crankcase
cover must be on left crankcase. Then remove the
water seal to remove the water seal. 4
1
041901
1.Water seal assy
2.Water seal removing tool
(P/N：0JWA-081000-922-001)
Use water pump bearing 3200A removing tool(0800-

014001-922-001)To remove 3200A from crankcase
cover(Replace the bearing if inspected needs).
1
2
041902
Exp
1.Bearing 3200A
2.Water pump bearing 3200A removing tool
（P/N：0800-014001-922-001）
4-19
Remove the oil seal
WARNING : Be careful removing the oil seal.

Do not damage the surface between the
water seal and crankcase cover.
2
1
042001
1.Oil
2.Surface
Inspection
Inspect the waterpump peller to see cracks or other
damages.Replace if needs.
Inspect the waterpump idle gear and waterpump gear
to see cracks, damage or other broken point.(Needles
on water pump gear must be pay extra attention)£¬Re-
place if needs.
2 1
Use hand to turning the inner circle of the bearing.

Bearing working should be smooth and quiet. If bear-
ing working got jammed noise or other damage must
042002
be replaced. 1.Bearing
2.Inner circle
4-20
4 Cooling system
Reverse the removal procedure for installation. But

must be attention below.
Note: Follow the exploded view to tight up the

part in specific torque. Water pump idle gear shaft,
waterpump shaft out surface and oil seal should be
covered with oil. Water seal and oil seal surface with
left crankcase cover should not be covered with oil.
NOTE: When replace the water seal. The oil

seal(behind the waterseal) must be replace at
4
the same time. 042101
Oil seal pressor
（P/N：172MM-080005-923-001）
Use oil seal pressor(172MM-080005-923-001)To as-

semble the oil seal.
Cover the engine oil on oil seal lip.

Cover the 648 cylinder locking glue on oil seal surface 2
with cylinderhead cover.
Oil seal covered on oil seal pressor. Make sure the lip
to the pressor out side. Then use pressor to press the
seal into the position..
042102
1.Oil seal
2.Oil seal pressor
（P/N：172MM-080005-923-001）
4-21
Put suitable heel block under the left crankcase cover.
Put the bearing on pressor(0800-014001-921-003)and
use hammer to knock the bearing into the position.
3
Note: Without heel block when assemble the bear-
ing will cause the left crankcase damaged.
2 1
042201
1.Bearing
2.Left crankcase cover
3.Bearing pressor
（P/N：0800-014001-921-003）
Water seal assy assemble(With left crank-

case cover removed):
Put the water seal pressor on flat surface(Like picture 1
shown A side up) Put the water seal assy on it like the
picture shows.
Cover 5699 sealant glue on water seal surface to 4
pumpshaft. Follow the direction to press the water
pump shaft into the water seal.
2
042202
1.Water pump shaft
2.Water seal
3.Water seal pressor
（P/N:0JWA-081000-922-002）
4.Cover 5699 sealant glue position
4-22
4 Cooling system
Put the assembled waterpump shaft and water seal
assy together and press them into the left crankcase
cover with water seal pressor.
3
Note: Water seal pressor A mark. 2

4
1
4
042301
2.Water pump shaft and water seal assy.
（P/N:0JWA-081000-922-002）
4.Flat（With hole）
Put the washer on waterpump shaft.And put the

washer on waterpump shaft. Use hands to press the
waterpump shaft untill the needle mounting hole shows
1
up. Install the needle and let the needle out showing
length same. And align the needle on groove. Then
7
push the water pump gear on the shaft.Then assemble 6
the water seal washer, peller. Tight up the bolt. And
cover the 5699 sealant glue and tight up the bolt.
Note:Cover 5699 sealant on water seal washer

when assembly and turn counterclockwise to
tight up.
2 3 4 5
NOTE: Pay attention to water pump gear
should with click when totally assembled. Water 042302
pump gear must be assembled totally or the 1.Left crankcase cover 5.Washer
coolant cannot be circled or even break the 6.Needle
2.Bolt（Counterclockwise）
cylin-der head gasket.
3.Peller 7.Water pump gear
4.Water seal washer
4-23
Install the breather shaft on left crankase. Make sure
the long chamfer side is out side. Install the waterpump
idle shaft on breather shaft.
Reverse the removal procedure for installation other 1

removed parts.
Follow the specification to fill the coolant and engine
oil.
042401
1.Breathing shaft
2.Waterpupm idle gear
Water seal assembly:(Without left crank-

case cover removed)
Cover 5699 sealing glue on water pump shaft adapt-

3
ing surface to water seal. Use water seal pressor to
press the water seal to left crankcase cover. Let the
waterpump shaft and seal are in position.
NOTE: Be careful with the water seal A mark

position.
2 1
042402
1.Water seal assy
2.Water seal assembly tool
（P/N:0JWA-081000-922-002）
3.Cover 5699 sealing glue position.
4-24
4 Cooling system
Use another side of water seal pressor to press the

water seal into the left crankcase cover to make sure
the water seal is on position of left crankcase cover.
NOTE: Be careful with A mark on water seal

pressor.
1
2
4
042501
1.Water seal
（P/N:0JWA-081000-922-002）
Install the water seal washer and peller .Then tight up

the bolt.(10N.m)
Note: Cover 5699 sealing glue when assembly

and tight up in counterclockwise direction.
3 1
2
042502
1.Water seal washer
2.Water pump peller
3.Bolt（Counterclockwise）
4-25
Engine
5 Engine contents
5.1 Maintenance information………………………………………5-2

5.2 Intake manifold, cylinder head and cylinder body……… 5-20
5.3 Case crankshaft and gear…………………………………… 5-67
5.4 CVT system………………………………………………………5-110
5.5 Engine lubrication system ……………………………………5-128
5.6 Engine start system ……………………………………………5-143
5.7 Intake system ……………………………………………………5-155
5
5-1
5.1 Maintenance information
Unit form…………………………………………………………………………5-3
5.1.1 Pre-cautions………………………………………………………………5-4
5.1.2 Fuel,oil,gear oil and coolant……………………………………………5-5
5.1.3 Engine break-in …………………………………………………………5-5
5.1.4 Engine No. position………………………………………………………5-6
5.1.5 Engine tech-standard……………………………………………………5-7
5.1.6 Service limits………………………………………………………………5-8
5.1.7 Engine tighten torque form ……………………………………………5-13
5.1.8 Service tools………………………………………………………………5-15
5.1.9 Engine service equipment………………………………………………5-18
5.1.10 Engine service period…………………………………………………5-19
5-2
U nit fo rm
It em U nit
2
1kgf/cm =98.0665kPa 1kPa=1000Pa
P ressu re 1 psi =6.895kPa=0.06895bar
1mmHg=133.322Pa=0.133322kPa
1kgf·m=9.80665N ·m
To rq ue 1N·m=8.85 lbf·in
1N·m=0.7375621 lbf·ft
1mL=1cm 3=1cc
Vo lu m e
3
1L=1000cm
F orce 1kgf=9.80665N 5
Danger/Warning/Note
Please read the instructions below carefully. It shows the meaning of Danger/
Warning/Note it should be paid more attention when doing engine maintenance.
Danger: It has risk cause serious injure or death Warning: It has risk cause serious
injure
Note : It has risk cause hurt.
But, pay attention. The Danger/Warning/Note cannot include all the risk in engine
maintenance. So the technicians should be with basic safty knowladge except the
danger instructions. If you cannot make sure you can finish all the maintenance
works. Please ask technicians with more experience.
5-3
5.1.1 Pre-cautions
Warning：M aintenance in truly way is a must for technicians safety and engine
reliability.
·W h en two or more pe op le wor ks. Warn up to e ach othe r for safety.
· The exh au st g as m ust be o utle t w he n start the en gine ind oo rs n ee d.
· If use po iso no us or flammab le mate ria l. Ple ase fo llo w the instru ction s give n fr om su pp lie rs an d m ake
sure th e w ork ing p la ce we ll-ve ntila ted .
· Do n ot use ga soline as cle an ing liq uid .
· Do n ot tou ch un coo le d o il, rad ia tor a nd exh au st syste m pa rts. Or it can cau se h ea t wo un d ed .
· If fue l, lub rica tion , co o lin g an d e xha ust system g ot m ain te na nce . T he l eve l an d le aki ng m ust be
insp ecte d.
· To kee p th e en viro n me nt. D o no t h a nd le o ptio na lly the use d o il, coo la nt an d wa ste d p arts.
Warning：
·If yo u ne ed r ep la ce th e pa rts whe n ma inte na nce . Ple ase u se pu re CFM OTO ap prove d pa rts o r
pa rts re comm en d.
· If th e re mo ved p arts n ee ds r eu sed . Ple ase p ut the m in ord er to avo id m ixed up .
· Fo llo w th e se rvice m a nu al to m ake su re u se sp ecia l too l.
· Ma ke su re th e pa rts fo r a ssem ble is cl ea ne d. Pre-lu bri cate if n ee ds.
· Use spe cial o il, gl ue a nd sea la nt.
· W he n tigh ten ing bo lts, scr ews o r nu ts. Tigh ten b ig on e first the n tig hten up fr om i nsid e to
o utside .
· Use to rq ue wren ch to tig ht the bo lt w ith spe cia l to rq ue . If the scr ews h as grea se o r oil. It m ust
be cle an u p.
· W he n pa rt rem ove d. It sh ou ld b e in sp ected an d cle a n up be fore me asu rin g.
· Insp ect the p art tig hte n a nd run ning a fte r in stalla tio n.
·Do n ot use u sed o il- sea l, O-r ing , g aske t, sel f- loc k n ut, lo ckin g ga sket, co tto r pin a n d reta ine rs.
Repla ce th em in to n ew o ne .
5-4
5.1.2 Fuel, oil, gear-oil and coolant.
Fuel: Use octane value 93# or higher level unleaded

gasoline.
Oil: The crankcase room use SAE15W-40 oil for 4 Density level
stroke moto in SG or higher level. If no SAE15W-40
oil. Please choose the oil depends on outer temp.
Gear oil: Gear case use SAE75W-90 GL5 oil.
Engine coolant: As the anti freeze coolant has
anti rust and corrosions ability. So the coolant has
anti-freeze liquid and freezing point shoild be lower Temp
then outer temp.(As usual for 5 degree.)
5
Recommend -30℃: High level anti-freeze, rust and high

boil point coolant.
Danger: Coolant is poisonous. It is not drinkable and storage safty.
WARNING : Do not mix the coolant with different brands.
5.1.3 Engine break-in

The engine has many moving parts such as piston, piston ring, cylinder body and gears. For this reason.
Engine break-in work in first mileages is amust. Engine breaking in can let the moving parts fit for eachother
and adjust the working clearance. And finally build up a good smooth surface can hold a large working load.
Engine broken-in has highly performance and reliability.
Recommend break-in for 600km，The standard like below:：
0~300km：
Avoid≥1/2 throttle, running continously change vehicle speed as often as possible. Do not let the throttle
in one position for too long. Stop engine engine for 5 to 10min for every 30km working. Press the throttle
slowly to avoid suddenly acceleration.
300~600km：
Avoid≥3/4 throttle running for too long time. Vehicle can use freely but without full throttle.
Note: Follow the maintenance chart in break-in period. And shoot the engine
trouble in time.After break-in, get a fully 600km break-inmaintenance, then
normal driving.
5-5
5.1.4 Engine No. position.
050601
Engine left side
Engine No. Position
Engine right side 050602
5-6
5.1.5 Engine tech stantard
No. Item Specification

1 Style V-twin, Water cool,4 stroke,8 valves、
SOHC
2 Bore×Stroke 91mm×74mm
3 Displacement 962．6mL
4 Pressing ratio 10.6:1
5 Idle 1300r/min±130r/min
6 Starting way Electric start
Ignition/Timing ECU sparking/BTDC10° 1500r/min
Electric
Spark DCPR8E（NGK）/0.8mm～0.9mm 5
7 plug/Clearance
system
Magneto 3-phase AC，350W/5000r/min；
460W/5000r/min
Throttle valve 0JY0-173000
8 Conbustion Air filter Sponge, paper element
Gasoline RQ-92 or higher
9 Admission Style SOHC/Chain drive
Style Press+ splash
Oil pump Rotor
10 Lubrication Filter Fully flow paper element
Crankcase oil SAE15W－40/SG or higher
Gear oil SAE75W-90/GL5
Cooling Style Close circle cooling
11
system Model -30℃ anti-rust coolant
Transmit CVT+ gear transmission.
Rear position 2 drive gears，1 reverse，1 parking
Shifting way/Order Manual/L－H－N－R－P
CVT ratio 2.88～0.70
Driving
12 Final 1.333（20/15，bevel gear）
system
Second 1.952(41/21)
Gear
L:2.529(43/17)；H：1.143(32/28) ；
ratio Gearing
R: 2.231(29/13)
Total L:6.585；H：2.975 ；R:5.807
5-7
5.1.6 Service data
Lubrication system
Ite m St a n d a r d S e rv ic e
li m it
O il w i th o u t fi lt e r 24 0 0m L
Engine oil 25 0 0m L
O il w i th f il te r
capacity
T o ta l d ry 26 0 0m L
Gear oil T o ta l d ry 60 0 m L
Engine oil:SAE15W-40 oil for 4-

stroke engine. If ne ed s replaced.
SAE level Fo llow th e specificat ion below ：
AP I level： SG o r h igh er
level；
SAE standard：Depends on form
on left side
Temp
R e c o m m e n d g e a r o il S A E 7 5 W -9 0 /G L 5
In n e r a n d ou te r r o to r
0.06mm～ 0.14mm 0 .2 5 m m
O il c le ara n c e
pu m p Outer rotor and case
0.09mm～ 0.15mm 0 .2 5 m m
r o to r clearance
Oil pump side clearance 0 . 0 2 3 m m ～ 0 .1 0 9 m m 0. 2m m
Engine RPM 1300r/min ， Oil temp
90℃ ：100kPa ～400kPa，
Norm al: 200kPa； Engine RPM
Oil pressure
6000r/m in ， O il temp 90℃：350kPa
～700kPa ， Normal:580kPa。
Cooling system
It e m Standard Limit
Valve open
6 5 ℃ ±2 ℃
temp
Thermostat
Full open 8 5℃
Open total
85 ℃，=5mm
clearance
Radiator cap open pr
108 kPa (1.1kgf/cm 2 )
essure
Water B side to ou t A、 C side
Water temp（℃） cover（ Ω ） resistance （ kΩ ）
temp and -25 — — 38.583 ±0.004
0 — — 9.399 ±0.0025
sensor 25 — — 2.795±0.002527
resistance 45 265～323 ——
relation 80 74.6 ～ 90.6 0.334 ±0.00204
115 25.7～ 31.7 0.135 ±0.00252
-30 ℃ high t level anti-freeze, rust and
Coolant
corrosion style.
5-8
T
Intake system
Item Standard
Throttle valve 0JY0-173000
Intake pressure and temp sensor 0JY0-175000
Injector 0JYA-171000
Idle 1300 r/min±130r/min
Electric system
Item Standard Remark 5

Spark Model DCPR8E（NGK ）
plug Clearance 0.8mm～0.9mm
Spark ＞8mm，1 atm
Ignition First 0.7Ω～0.75Ω
coil Secondary 6.0 kΩ～7.0 kΩ
resistance
Charging coil resistance（20℃） 0.2Ω～0.3Ω
Magneto peak coil resistance 250Ω～300Ω
Magneto empty voltage（Engine ＞100V（AC），5000r/min
AC cold）
magneto Magneto power 350W，5000r/min
460W，5000r/min
Stable Voltage 13.5V～15.0V，5000r/min
Peak voltage ≥1.5V，200r/min
Ignition coil output voltage ≥27kV
Start relay coil resistance 3Ω～5Ω
Start auxiliary relay resistance 90Ω～100Ω
5-9
Valve controlling
Item Standard (mm) Limit (mm) Remark
Intak e 33 ——
Valve disc diameter
Exhaust 29 ——
Intake/Exhau
Valve disc thickness 1 0.5
st
Intak e 0.06～0.14 ——
Valve clearance(Cold)
Exhaust 0.11～0.19 ——
Valve conductor diameter Intake/Exhaust 5.000～5.012 5.045
Intak e 4.965～4.980 4.93
Valve rod diameter
Exhaust 4.955～4.970 4.93
Valve rod and conductor Intak e 0.020～0.047 ——
clearance Exhaust 0.030～0.057 ——
Valve rod roundness Intake/Exhaust 0.01 0.05
Valve rod side jump Intake/Exhaust 0.02 0.05
Intak e 90.1 ——
Valve length
Exhaust 88.7 ——
Valve disc runout Intake/Exhaust 0.03 0.05
Intak e 1.2±0.1 1.7
Valve sealant width
Exhaust 1.3±0.1 1.8
Valve spring free length Intake/Exhaust 40 38.2
At 33mm： 200.5N～
235.5N
Valve spr ing force Intake/Exhaust ——
To 23mm：
531N～587N
Intak e 32.931～33.051 32.831
Cylinder 1 cam height
Exhaust 32.945～33.065 32.845
Intak e 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
Camshaft bearing φ35 35.007～35.025 35.04
diameter φ22 22.012～22.025 22.04
Camshaft bearing φ35 0.032～0.066 0.09
clearance φ22 0.032～0.066 0.09
Camshaft axial clearance 0.12～0.28 ——
Camshaft run out 0.10
Intake/Ex hau
Rocker arm hole diameter 12.000～12.018 12.03
st
Rocker arm shaft Intake/Ex hau
11.973～11.984 11.96
diameter st
Rocker arm shaft Intake/Ex hau
0.016～0.045 0.07
clearance st
Rocker arm axial Intake/Ex hau
0.06～0.34 ——
clearance st
Cylinder head bottom
0.03 0.05
flatness
5-10
Cylinder+piston+piston ring+crankshaft and connecting rod
Item Stand ard (mm) Lim it (mm) Re mark
Cylinder pre ssu re 1 000kPa ——
Cylinder inner diameter
0 .038 0.090
bevel
Cylinder round ness 0 .015 0.020
Cylinder hole diameter 90.9 9～9 1.01 ——
M ea sure at
Piston dia me ter 90.9 4～9 0.96 90.85 8 mm from
bottom
Cylinder clea ra nce 0.0 4～0 .06 0.10
Cylinder flatness 0.03 0.05
st
1 0.15～ 0.30 1.35
Piston ring close
2 nd 0.15～ 0.30 1.35
clea ran ce
Oil 0.2～ 0.7 1.5 5
1 st 1.17～ 1.19 ——
Piston ring thickn ess 2 nd 1.47～ 1.49 ——
Oil 2.37～ 2.47 ——
st
1 1.21～ 1.23 ——
Piston ring g roo ve height 2 nd 1.51～ 1.53 ——
Oil 2.50～ 2.52 ——
1 st 0.02～ 0.06 0.15
Piston ring groove nd
2 0.02～ 0.06 0.15
clea ran ce
Oil 0.03～ 0.15 0.25
Piston pin hole diameter 22.00 4～ 22.010 ——
Connecting ro d diam eter 22.0 1～2 2.02 22.06
Piston pin diam eter 21.99 5～ 22.000 2 1.980
Piston pin clearance (to
0.00 4～0 .015 0.08
piston)
Piston pin clearance (to
0.01 0～0 .025 0.08
connecting rod)
Co nnecting rod side
0.3～ 0.56 0.8
clea ran ce
Connecting ro d n eck 43.94 6～ 43.960 43.93
Conn ectin g rod bearin g
43.97 0～ 44.000 44.03
hole
Conn ectin g rod bearin g
0.02 8～0 .049 0.09
clea ran ce
M ain ne ck 41.96 0～ 41.970 4 1.935
Case main bearing hole 41.98 0～ 42.020 42.10
M ain bearin g clearance 0.0 2～0 .05 0.09
Cran kshaft axial
0.26～ 0 .54 0.64
clea ran ce
5-11
Clutch+ Transmission (mm)
Item Standard (mm) Limit (mm) Remark
Drive belt width 33.7(Inner level) 32.2
Driven disc sleeve diameter 38.10～38.14 38.30
Gearing fork-groove
0.20～0.40 0.50
clearance
Gearing fork thickness 5.80～5.90 5.70
H,L gear groove width 6.10～6.20 6.30
Out let main gear groove

6.10～6.20 6.30
width
Shifting drum groove width 8.02～8.12
Shifting fork pin diameter 7.90～7.95 7.83
Gear hole diameter 29.000～29.021 29.025
Reverse idle gear 29.007～29.028 29.032
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
Main bevel gear shaft

φ17 16.983～16.994 16.978
diameter
Reverse idle shaft clearance φ25 24.980～24.993 24.974
5-12
5.1.7 Engine tighten torque form

Q
Sc rew s ize Torque
Item t Rem ark
（ mm ）（N· m ）
y
Bolt M 14 ×1.5 4 M1 4×1.5 40
O il dra in b olt M 14 ×1.5 1 M1 4×1.5 25
Scre w blo ck 1 ZM 14 20 W ith thread locker
O il dra in b olt M 12 ×1.5 1 M1 2×1.5 20
Bolt M 8×12.5(Le ft ca se) 1 M8 ×1 2.5 20
R educ e block er 1 R 2 1/8 20 W ith thread locker
Scre w R 2 1/8 (Rig ht ca se o il lin e) 1 R 2 1/8 20 W ith thread locker
Scre w M4 ×10 2 M4 ×1 3 W ith thread locker 5

N ut M 6(Right case ) 4 M6 10
Scre w AM 6×30-8.8(R ight case) 4 AM 6×30 10 W ith thread locker
C able loc ker bolt(Left ca se cover) 2 M5 ×1 0 6 W ith thread locker
Bolt M 12 ×1.25×35 (Mag neto rotor) 1 M1 2×1.25 60
Va lve cleara nce nut 8 M6 12
Tim ing g ear b olt 2 M8 30 W ith thread locker
Tensioner locker 2 M1 6×1.5 4 .5
C ylin der bolt 8 M1 0 2 0、6 0
N ut M 8(Exhau st） 4 M8 13
Spark plug 2 M1 2×1.25 20
Scre w M8 ×42（ Exhaust） 4 M8 ×4 2 25 W ith thread locker
Scre w M1 2×1.5 （Front cylind erh ead） 1 M1 2×1.5 20

Scre w ST4.8×13 (Th erm ostat c over) 2 ST4.8×13 5
Tensioner pin 2 M6 ×1 6 10 W ith thread locker
Intake bolt M8×2 5 4 M8 ×2 5 20

C onnecting rod bo lt 4 M9 ×1 1 0 、 2 0、 6 0
D rive n pulley n ut 1 M2 0×1.5 1 30 Cou nterclock wise
D rive pulley bo lt（C VT） 1 M1 2×1.5 60 Cou nterclock wise

D rive shaft nut（ CV T） 1 M2 0×1.5 115
Bevel gea r loc king nut 1 M2 7 × 1.5 1 45

Bolt M 8×28 4 M8 ×2 8 32
Scre w M8 ×25 4 M8 ×2 5 15
Bearing retaine r 1 M5 5×1.5 80 W ith thread locker
Bearing lockin g nu t M6 5×1.5 1 M6 5×1.5 110 W ith thread locker
Bolt M 8×28(Driv en b evel gear) 4 M8 ×2 8 25
Scre w T25 (Shift drum ) 1 M5 ×8 6

Shiftin g spring s eat. 1 M1 2×1 20
5-13
Size Torque
Item Qty Remark
（mm）（N·m）
With thread
Bolt M5×16（Oil pump） 3 M5×16 7
locker
With thread
Screw M8×20（Overriding clutch） 6 M8×20 30
locker
With thread
Bolt M6×30（Magneto stator） 3 M6×30 16
locker
With thread
Bolt M6×35（Large magneto） 3 M6×35 16
locker
Cylinderhead cover bolt 8 M6 7
Bolt M6×45(Cylinder 1 thermostat cover) 2 M6×45 6
Bolt M6×25（Cylinder 2 thermostat cover） 2 M6×25 6
Bolt M6×25（Tensioner） 4 M6×25 10
Water temp sensor 1 M12×1.5 16

Oil pressure switch 1 M10×1 12
Oil cooler mounting bolt 4 M6×18 10
Oil cooler seat mounting bolt 2 M10×20 25
With thread
Front output shaft retainer 1 M55×1.5 80 locker and
counterclockwise
M5 4.5～5.5
Others M6 8～12
M8 25
5-14
5.1.8 Engine service tool
Measuring tool
No Tool Size U sed to Remark
1 Verni er calipers （0～150）m m M easuri ng length or thickness

M easure val ve rocker arm, Valve
2 M icrometer （0～25）m m
rod, camshaft diameter
3 M icrometer （25～50）m m M easure cam hight

4 M icrometer （75～100）mm M easure piston ski rt diameter
Cylinder inner M e a s u r e t h e cylinder inner
5
diam eter m eter diameter
M easure rocker ar m inner
6 Inner diameter caliper （10～34）m m diam eter. Piston pin hol e, 5
c onnecting rod hole diameter
7 Dial gauge 1/100 R un out measure

8 Flatness gauge Flatness measuring
M easure fl atness and valv e

9 Cl earance gauge
clearance
10 C learance piece M easure clearance
11 Force gauge M easure spr ing for ce

12 RP M meter M easure engi ne RPM
C ylinder pressure M easure cylinder pressure

13
gauge
14 Oil pressur e M easure oil pressure
M easure r adiator cap open

15 A ir pressure gauge
pressure
16 Ohm meter M easure resistance
17 Am pere m eter M easure cur rent
18 T hermometer M easure liqui d tem p
19 Timing light M easure ignition tim ing

20 Torque wrench Total M easure tighten torque
Usual tools
21 Alcohol heater H eating
22 Magnet seat For dial m eter l o c k i n g
23 Flat piece For auxiliar y m easur e
24 V block For run-out measuring
25 Caliper For valve locker i n s t a l l a t i o n
26 Retai ner cal iper R etainer r em oval and installation
For retainer removal and
27 Caliper
installation
28 Knocking screw For screw removal
5-15
Engine service special tool
Tool number Tool name Use for
Measure the oil
0JWA-000000-871-001 Pipe connector
pressure
0800-014001-922-003 Roll bearing 6028 removing tool Remove bearing 60/28
Left crankcase bearing pressing Install bearing
0800-014001-921-002
tool
0800-041000-922-001 Crankshaft locking screw Lock the crankshaft
0800-031000-922-001 Magneto rotor removing tool Remove magneto rotor
CVT bearing 6003 removing Remove bearing 6003
0800-013201-922-001
tool
To make the bearing
0800-013201-921-001 CVT cover bearing pad
setting flat.
Separate the driven
0800-052000-922-003 Driven pulley separator pulley for belt
installation.
Oil seal installation
0800-051204-923-001 Drive pulley oil seal
35×42×4
0800-052000-922-002 Driven pulley removing tool
0800-052000-922-001 CVT pulley locker Lock the driven pulley
CVT bearing 6208 removing Remove bearing
0800-013101-922-001
tool
0800-013101-921-001 CVT bearing 6208 pressor Make the bearing flat
Clutch cover oil seal installing Remove CVT cover oil
0800-013104-923-001
tool seal 34×55×9
Test the cooling system
901-18.01.00-922-001 Test cap
pressure
0JWA-081000-922-001 Water seal removing tool Remove the water seal
0JWA-081000-922-002 Water seal assembly tool Install water seal
0800-014001-921-003 Bearing pressor Install bearing
Remove and install the
0800-022800-922-001 Sparkplug driver
spark plug
0800-024001-922-001 Camshaft locking tool Lock the camshaft
Cylinder pressure
0800-000000-871-002 Air pressure gauge connector
connector
Remove valve
0800-022102-922-001 Valve conductor removing tool
conductor
Install the valve
0800-022102-922-002 Valve conductor installing tool
conductor
Press the ring for
0800-040003-922-001 Piston ring pressor
piston assemble
Install the piston pin
0800-040005-922-001 Piston pin strainer caliper
strainer
For breather oil seal
0800-011201-923-001 Breather oil seal installer
15×26×6
0800-011201-921-003 Breather gear shaft tool Make the shaft flat.
5-16
Tool number Name Use to

0800-062301-923-001 Front output shaft installer Install the front output shaft
0800-062206-922-001 Driven bevel gear nut sleeve Install and remove the nut
0800-062204-923-001 Driven bevel gear oil seal pressor Install the oil seal 34×50×7
Bevel gear clearance measuring Measure the clearance
0JWA-062000-922-001
tool between the bevel gear
0800-060002-922-001 Reverse gear shaft pressor Remove the reverse gear
Left crankcase bearing removing
0800-011000-922-001 Remove the bearing
tool
0800-012000-922-001 Bear 5206 removing tool Removing bearing 5206
0800-012101-921-001 Heel block Make right crankcase flat
0800-011101-921-001 Heel block Make left crankcase flat
0800-060000-922-001 Reverse gear shaft presser Press the reverse gear shaft 5
CF188-014001-921-001 Bearing 60/28 presser Install bearing 60/28
CF188-013201-921-001 CVT bearing 6003 presser Install bearing 6003
CF188-013207-923-001 CVT oil presser Install bearing
CF188-051000-922-001 CVT drive pulley locker Lock the drive pulley
CF188-013101-921-002 CVT bearing 6208 presser Install bearing
CF188-053100-921-002 Clutch cover presser Install the clutch cover
CF188-053100-921-001 Heel block for clutch Make the clutch flat
CF188-054000-922-001 Clutch locking wrench Lock the clutch
172MM-080005-923-001 Oil seal presser Install the oil seal 10×20×5
152MI-081004-921-001 Water seal cover Install the water seal
Remove and install the
CF188-022006-922-001 Valve spring compressor
spring
Install and remove the front
CF188-060008-922-001 Strainer wrench
bearing strainer
CF188-062201-921-003 Bearing 6207C3 presser Install bearing
CF188-062103-921-002 Bearing 6305 presser Install
152MI-060002-921-002 Bearing 6203 presser Install
CF188-012100-921-004 Bearing 3206A presser Install
CF188-011100-921-004 Bearing 6303 presser Install
1P39MB-012001-921-002 Bearing 6203 presser Install
Install/remove drive
0JYA-062100-922-002 Belvel gear locking sleeve B
bevel gear locking nut
Install/remove drive
0JYA-062100-922-003 Drive bevel gear locking tool
bevel gear locking nut
Drive bevel geal
0JYA-062100-921001 Install the bearing.
bearing(63/82)pressor
5-17
5.1.9 Engine service material
Engine running material including lubricating oil, grease and coolant.
Assemble material including flat sealant, thread locker ,glue and etc.
Name Type Position Remark
Inner cylinder revolving and
sliding part
Inner Crankcase revolving Capacity
4 stroke moto
Oil and sliding part. Inner 3300m L（Oil only）
SAE15W-40
cyliyder head revolving and 3400 m L（With filter）
SG or higher level
sliding part. See lubricating 3500 m L（Total dry）
view.
Gear
SAE75W-90/GL5 Gear case 600mL
oil
Oil with Piston pin, Valve rod, Valve
Mo oil seal,Camshaft.
Oil lip 、 O- ring and other
rubber sealant surface,
Grease 3# MoS2 grease
Bearing with seal, CVT shaft
and sleeve.
-30℃ anti-freeze
Coolant Cooling system or water Capacity depends on
anti-rust and high
seal system design
boil temp coolant
Flat Some flat surface needs

sealant sealing.
Thread
Some screws See 5.1.7
locker
Cylindri Oil seal and case sealing

cal glue point
5-18
5.1.10 Engine maintenance period

En gine mainten ance is a perio dic wo rk. It is a m ust to maintain th e en gin e period ic
to keep the eng in e goo d wo rkin g in b etter p erform ance an d reliable. Here is t he fo rm for
2V 9 1 Y e ng i ne s er v ic e.
N ote ： The fo rm is on ly i n n or m a l s itu ati on w o rk. It ne e ds m o re freq ue ntly

to ma in ta in the e ng ine i f in ba d e nv ir on m e nt.
A ： A dju st 1 0 h or 30 0 km
C： C le a n 2 5 h or 75 0 km
I： In sp ect io n E ve ry 5 0 h or 15 0 0km
L： L u brica te E ve ry 1 0 0h o r 3 00 0km or 1
R： R e pla ce ye a r
E ve ry 2 0 0h or 60 0 0km
or 5
2 Re m a rk
ye a r
E ng ine
O il an d o il f ilte r R R
G e ar oil R I R
O il stra in e r I， C I， C
Va lve a dju stm e nt I， A I， A
E ng ine se a la n t I I
E ng ine su sp en sion I I
O il filt er elem en t C R
Co o la n t I I R
Ra d ia to r ca p , co oling I I
syst e m p ressu re
Sp ark p lu g I R
Fu el syste m
Th rot tle valve I I， L
CV T
B elt I R
Drive a nd d rive n p u lley I， C
CV T coo lin g p ip e I I， C
5-19
5.2 Intake pipe, cylinder head and cylinder body
5.2.1 Service tool, material and attachment…………………………………………5-21
5.2.2 General………………………………………………………………………………5-26
5.2.3 Maintenance and inspection……………………………………………………5-27
5.2.4 Intake manifold……………………………………………………………………5-31
5.2.5 Cylinderhead cover………………………………………………………………5-32
5.2.6 Timing chain tensioner …………………………………………………………5-33
5.2.7 Camshafting 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
5-20
5.2 Intake manifold, cylinderhead and cylinder body
5.2.1 Service tool, material and attachment

Service tool
Name P/N Page
Spark plug 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 pressor Piston CF188-022006-922-00 5-52/53
ring pressor 1 5-58/59
Piston pin retainer caliper 0800-040003-922-001 5-63
0800-040005-922-001 5
Material
Name P/N Page
Oil 5-22/23/24/25/34 /
40/56/58/63
243 thread locker 5-22/23/24
5699 flat sealant 5-58
5-21
Intake manifold
243 T2
thread
locker
243
thread
Oil
T2 locker
T3
T2
243
thread
locker
Oil
T1
Oil T3
T1 20 N·m(15 lbf·ft）
T1 T2 6 N·m(53 lbf·in)
T 3 0. 5 N ·m （5 lb f ·i n ）
052201
5-22
Cylinderhead 1
243
T4
thread
T6 locker 5
Oil
Oil T3
T1
T2 T8
T5
T7
T5 243
Oil thread
Oil
lockT3
er
Oil
T4
243
T3
thread Oil
locker
T1 60N·m (44 lbf·ft) T6 7N·m (62 lbf·in)

T4 12N·m (106 lbf·in)
T5 10N·m (89 lbf·in)
052301
5-23
Cylinderhead 2
T6
T4
T4
T1
T5
T2
Oil
Oil
T5 243
thread
T3 T3 locker
243
T8 thread
locker
T9 T7
243
thread
locker
Oil

T4 12N·m (106 lbf·in) T9 5N·m (44 lbf·in)
052401
5-24
Cylinder body and piston
Oil
T2 Oil
T1 5
Oil
T1
T2
Oil
Oil

052501
5-25
5.2.2 General
In exploded view, the 2 cylinder heads and cylinder bodies
use t he sam e par t num ber. Bet ween t wo
cylinderheads/cylinderbodies. Different parts or spe-
cial part use different numbers. The instructions be-
low followed this rule.
The different between cylinder 1 and cylinder 2 has
special note.
When diagnose engine troubles different cylinders 2
should be seperated. 1
Vehicle must be on a flat surface
Note: For better understand. Most pictures shows

the engine removed. If it doesn’t need to remove
the engine.The working below is a must.
Before doing engine repairing. Make sure the negative

line on the engine disconnect first. Then disconnect
the positive line.
When repairing signal part. Many parts needn’t
removal. Just remove the part needs for inspection.
When assemble or installation.Follow the exploded
view to make sure the tighten torque is in standard. 052601
1.Cylinder 1
Clean the screw befroe covering the thread locker
2.Cylinder 2
WARNING
Use torque wrench is a must when tighten.
Locking equipment(Exp: Locking piece,Plas-
tic locking nut,cottor pin)Must be replaced.
When removing many same parts(Exp: Valve).Please

mark the position(Power output/Magneto,Cy1/Cy2).
And keep it in order. If any damaged part inspected. It
would be easier to find out the reason. Also the old
part has been totally broken-in when the engine on
running. It will be easier to fit the other parts when
assemble back.
5-26
5.2.3 Maintenance and inspection
Maintenance
Valve clearance adjustment
Note: The valve inspection and adjustment should
be on cold-engine.
Remove the cylinderhead cover

Turn the crankshaft to front cylinder TDC to in spect
the valve clearance.See camshaft in this chapter.
Use clearance gauge to measure the clearance
V a lv e c le a ra n c e
0.06mm ～ 0.14mm
Intake
（ 0.0024in～ 0.0055in） 5
0.11mm ～ 0.19mm
E xhaust
（ 0.0043in～ 0.0075in）
2
1
If the valve clearance is out of limit. Follow the steps
below to adjust the clearance.
Note: Use midium standard to makesure the ad-

justing is right
Turn the adjusting screw on right position. Then tight

up the locking nut.
Follow the steps mentioned to adjust every valve.
Inspect the valve clearance again before install the
cylinderhead cover.
Inspection
Leaking inspection
Before cylinder leaking inspection. Check the items
3
below: 052701
—Tighten clamp. 1. Adjusting screw
—Radiator and water hose. 2. Locking screw
3. Clearance gauge
Note: For accurate inspection.Leaking inspection
must be inspect on cold engine.
WARNING
Be careful got hurt by engine’s high heat.
Prepare
Disconnect the battery.
WARNING
Always disconnect the negative pole first.
Remove the radiator cap.
5-27
WARNING
Wearing protecting equipment to avoid potential 1
Injuries by high heat.
Remove related covering parts.

Remove ignition line
Clean up the spark plug aside and use the
sleeve(0800-022800-922-001) to remove the spark
plug from cylinderhead. 2
052801
1.Igntion line
2.Spark plug
Remove the cylinderhead cover by loosing 4 bolts .

1
2
052802
1.Cylinder head cover bolt
2.Cylinder head cover
Turn the crankshaft to TDC.(Refers to camshaft in
this chapter.)
Turn the crankshaft. Use dial gauge to let the piston
at TDC.
1
Note: If no dial meter. Use screw driver or
similar tool instead.
052803
1.Dial meter
5-28
WARNING
Do not scrach or damage the piston/
cylinder surface. 3
Note: The timing sign must be at same

level as cylinderhead flat surface.
Use camshaft locking tool(0800-024001-922-001) 2

to lock the camshaft.
5
1
052901
1.Timing chain sprocket
2.Cylinder head surface
3.Camshaft locking tool
(P/
N:0800-024001-922-001)
Camshaft locking tool 052902

(P/N:0800-024001-922-001)
5-29
Leaking inspection
Find suitable compressed air
Set the pressure gauge at 0.
Note: All the pressure gauge has its own manual

and range.
Install pressure gauge seat(0800-000000-871-002) on

1
spark plug hole.
Inject compressed air to conbustion room.
Record and calculate the leaking percentage(Depends
on pressure data tested).
Leaking
percentage Engine 2
0％～ 1 5 ％ Ve ry g ood
1 6 ％～ 25％ Go od
053001
2 6 ％～ 40％ Bad
Ve ry b ad. Nee ds
≥ 41％ rep air the eng ine 1.Pressure gauge
2.Air pipe
Diagnose
Reason ：
—Intake leaking cause the air getting out from valve/
throttle.
—Exhaust leaking cause the air getting out from ex-
haust valve.
—Cylinder head leaking cause the radiator got bubble.
—Gasket damaged or bolt loose cause the air or oil
comes out from crankcase.
—Gasket damaged or bolt loose cause the air/cool-
ant blew out from cylinder body or cylinder head.(See
intake pipe, cylinder head and body)
—Cylinder body wearing or piston ring broken cause
the air leaking to crankcase(See intake pipe, cylinder
head and cylinderbody)
Note:For the items mentioned. Refers to related

chapter about diagnose and maintenance.
Assemble
Reverse the removal procedure to assemble. Make
sure the torque is right and use the approved parts
and lubricant.See exploded view on other chapter if
needs.
5-30
5.2.4 Intake manifold
Removal
Disconnect the fuel pump connector. Use the enginne
continously running to let the pue pump pressure low.
3
NOTE
There is compressed oil in fuel pipe.Use
mag-netic cloth to cover the connectors and
discon-nect the pipe to release pressure and
clean up the fuel.
Remove the cover of cargo box. Refer to body cover- 2 1
ing parts.
Loose the connector between throttle body and air
1.Intake manifold
053101 5
filter
2.Throttle body
Loose the clamp between throttle body and intake
3.Air filter pipe
manifold.
Remove throttle body.
Remove throttle body connecting pipe. 2
Remove quick joint on fuel injector.
Disconnect 2 fuel injector connectors.

Disconnect intake pressure and temp sensor
connector.
1 1
Remove intake pipe bolt from cylinder head.
Remove intake pipe from vehicle.
053102
Note: Remove fuel injector from intake pipe first. 1.Injector connector
2.Fuel pipe
Intake pipe inspection

Intake pipe has no cracks.Make sure the flange is not
damaged. Replace if necessary.
Intake pipe assemble

1
Reverse the removal procedure to assemble. But pay
attention. Tight up the intake manifold bolt to 20N·
m in once（15 lbf·ft）
.And connect the oil pump
connector
053103
1.Connector(Intake pressure and temp sensor)
5-31
5.2.5 Cylinder head cover 1
Removal
Remove the cylinder cover bolt.
2
053201
1.Cylinderhead cover bolt
2.Cylinderhead cover
Remove the cylinder head cover and gasket.
Cylinderhead cover inspection 2

Inspect cylinder cover gasket to see cracks, hardness
or broken. Replace if inspected out.
Installation
Reverse the removal procedure to installation. And tight
1
up the bolt in criss-cross way.
053202
1.Cylinder head cover
2.Cylinder head cover gasket
5-32
5.2.6 Timing chain tensioner

Note: Make sure the front cylinder is in TDC be-
2 1
fore start working.See camshaft in this chapter.
Tensioner removal
WARNING
Timing chain tensioner is spring loaded. Do
not do the work when engine just stopped to
avoid heat burnt.make sure the engine is
totally cool down.
Loose tensioner screw.

Remove the tensioner screw. 5
Remove the O-ring. 053301
1.Chain tensioner screw
2.O-ring
3.Spring
Loose chain tensioner bolt to remove the tensioner

and gasket.
2 1
Tensioner inspection
Inspect the tensioner to see the damage and working
ability. If any trouble inspected. Replace the part.
● Working reliablity inspection.
1.Use screw driver turn the tensioner clockwise the
adjusting screw and use hand to push the pressing
4 3
arm to the limit.
2.Move away the screw driver ald loose the pressing 053302
1.Chain tensioner bolt
arm. Make sure the arm can be back smoothly. Or
2.Chain tensioner body
replace the part. 3.Pushing arm
Inspect the chain tensioner arm to see it can smoothly 4.Paper gasket
work or not. Or to inspect the cracks. Replace the
part if necessary.
Replace the paper gasket together with the parts.
5-33
Tensioner assembly
Reverse the removal procedure to installation.But pay
attention to below.
Note: Make sure the timing sprocket can turn

smoothly before assemble the tensioner.
Pre-lubricate the tensioner screw befroe asseble.
Note: Use screw driver turn the screw clockwise

to lock the spring.
Warning 053401
Adjusting timing chain in wrong way may Turn the timing sprocket.
damage the engine.
Assemble the timing chain tensioner and new paper

gasket.
Assemble the timing chain tensioner bolt and tight up
in torque standard.
Note: Do not forget to install the O-ring on

tensioner screw.
Tight the tensioner screw to 5N·m(44 lbf·in).
5-34
5.2.7 Camshaft timing sprocket
Removal
Remove the cylinder head gasket.
Turn the crankshaft to front cylinder TDC.Refers to
camshaft in this chapter.
Loose timing chain tensioner.
Remove the camshaft timing sprocket bolt.
To avoid the timing chain getting longer when remov-
ing sprocket. Please use special tool(0800-024001-
922-001)To lock the camshaft.
Remove the sprocket.
5
Note: Use a hook to hold the timing chain
053501
Note: Remove the tensioner first before Camshaft locking tool
the timing chain (P/N:0800-024001-922-001)
Inspection
Inspect the camshaft timing sprocket to see wearing
or damaged.
1
If the teeth wearing or damaged replace the chain and
sprocket together. 2
See crankshaft in crankcase chapter to see the crank-
shaft sprocket.
3
053502
(P/N:0800-024001-922-001)
2.Camshaft timing chain bolt
3.Camshaft timing sprocket
5-35
Installation
Reverse the removal procedure to instllaion. But pay

attention the items below.
1
Clean the assemble surface and camshaft screw be-
fore installation.
053601
1.Camshaft assemble surface.
2.Screw.
Make sure the timing sprocket and crankshaft must

be at TDC before assemble.
Warning
When assemble the cam timing sprocket and
chain, make sure the camshaft is at TDC.
The sign of camshaft timing sprocket must be paralle

with cylinder head(Like picture on the right.)
Remove crankshaft locking bolt and camshaft locking

2
tool after installed the timing sprocket and camshaft.
3 1
Note:Adjust the timing chain tensioner before
assemble the timing sprocket.(See timing chain
053602
tensioner).And check the sign of timing sprocket to 1.Camshaft timing chain sign.
see the paralllelism. 2.Cylinderhead bottom surface
3.Camshaft timing sprocket.
5-36
Install all the removed parts back.
5
3
053701
(P/N:0800-024001-922-001)
2.Camshaft timing sprocket bolt
3.Camshaft timing sprocket.
5-37
5.2.8 Rocker arm
Removal
Remove the cylinder head cover.
2
Remove chain tensioner and camshaft timing
sprocket.
Remove the bolt and camshaft locking plate.
3
1
053801
1.Cylinderhead
2.Bolt
3.Camshaft locking plate
Remove the rocker arm shaft.

Remove the rocker arm assy(Intake and exhaust)In- 4 3
cluding adjusting screw and nut.
5
2
1
053802
1.Rocker arm
2.Intake arm
3.Exhaust arm
4.Adjusting screw
5.Nut
5-38
Remove the washer.
1 2 1
Warning
Do not missing the washer or drop it into
timing chain room. 3
4
053901
1.Washer 5
2.Exhaust arm
Inspection 3.Cylinder head. Spark plug side.
4.Big side to the spark plug.
Inspect the rocker arms to see cracks or scraches. If
so, replace the parts.
Inspect the rocker arm to see it can running smoothly 2 1
or not. And check the damage or to large run out.
Replace te part if need.
Measure the rockarm hole inner diameter.If out of
standard. Replace the rocker arm.
A
R o c k e r a rm in n e r d ia m e te r
12.000mm～12.018mm
New
(0.4724in～0.4731in)
12.030mm 053902
Service limit
(0.4736in) 1.Exhaust arm
2.Rollor
Inspect the adjusting screw to see it can running A.Rocker arm hole inner diameter.
smooth or not. And check the cracks or too large run
out.
053903
1.Adjusting screw working smoothly
5-39
Rocker arm shaft
Inspect every rocker arm shaft to see scraches. Re-
place the shaft if inspected out.
Measure rocker arm shaft diameter.
Rocker arm diameter

11.973mm～11.984mm
New
(0.4714in～0.4718in)
11.960mm
Service limit
(0.4709in)
A
Every piece reached the service limit must replace
the part. 054001
A.Diameter measureing position
Installation
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 finish 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 reach
the end.
1 2 3
Install another washer then push the shaft to the end.
054002
Timing chain 1.Rocker arm shaft
2.Washer(Timing chain side)
See timing chain on CRANKCASE chapter.
3.Washer(Spark plug side)
5-40
5.2.9 Cylinderhead
Removal
The 2 cylinderheads remove in the same orders.
2
Drain out the coolant(See cooling system).
Note: Use compressed air to blow up the coolant

left before removing the cylinder head. If the cool-
ant left flow into the engine. It may cause the enging 1 1
oil polluted.
Disconnect the ignition line.

5
Disconnect the temp sensor connector on rear cylin- 2
der head.
Remove the both side panels and inner fenders.(See
054101
body covering parts). 1.Cylinder head bolt M10
Remove exhaust pip spring and clamp. 2.Bolt M6
Remove exhaust nuts.
Unplug the radiator inner hose.
Remove the air filter
Remove the throttle valve
Remove the intake manifold(See chapter before).
1
Rem ov e t he chai n t ensi oner(See ch ap ter
mentioned).
Remove the cylinder head cover and gasket(See cyl- 2
inder head cover chapter). 4
Remove camshaft timing sprocket.
Follow the special order to remove the cylinder head-
body mounting bolt M6 and M10.
3
Pull out the cylinderhead
Remove the timing chain conductor.
Remove the gasket and waste it.
054102
1.Cylinder head
2.Timing chain
3.Chain conducting plate
4.Cylinder head gasket
5-41
Cylinder head inspection
Inspect the timing chain conducting plate to see wear-
ing ,cracks or other damages.Replace if inspected out.
Inspect the cylinder head valve seat to see cracks.If
so, replace the valves.
Inspect the cylinder head and body connecting sur-
face to see the dirt. If dirt inspected out, clean up.
Clean the lubrication line of cylinder head.
2 1
3
054201
1.Cam lubricating hole
2.Camshaft joint lubricating hole(timing chain side)
3.Camshaft joint lubricating hole(sparkplug side)
Cylinderhead assembly
WARNING: The front and rear cylinderhead is

dif-ferent design.Do not mix them up.
Reverse the removal procedure to installation. But pay

attention to the items below.
Make sure the locking pin position.
1
Warning
2
Chain conducting plate must be locked between
cylinder head and body.
054202
1. Chai n conduct i ng pl at e(Locked between
cylinderhead and body)
2.Chain tensioning plate(Mount on crankcase)
5-42
Replace the cylinderhead gasket into new one.

Tight up the cylinderhead mounting bolt in criss cross
way to 20N.m(15 lbf.ft)first. Then tight to 60N·m(44
lbf·ft).
Tight the bolt M6.
Inspect the chain conducting plate to see it can move
or not.
2 1 1
054301
1.c y l i n d e r h e a d b o l t M10
2.b o l t M6
5.2.10 Camshaft
NOTE: The camshafts are in different shapes. 1 2
4
3
054302
1.Cylinder 1 camshaft
2.Cylinder 2 camshaft
3.Cylinder 1 camshaft sign I
4.Cylinder 2 camshaft sign II
5-43
Camshaft timing
Note: If cylinder or piston(1 or 2) at TDC. The other

one must be at the bosition like picture on the right
side(Mark paralle to the ground).
2
1
054401
1.Another cylinder timing sign.

Camshaft timing sproket 2.

Follow the steps below to turn the cylinder 2 at TDC.
Remove 2 spark plug 8
Remove the 2 cylinderhead covers
6
Remove the fan cover.
4
Remove the fan peller and plate 2
7
5
3
1
054402
1.Bolt
2.Sleeve
3.Fan cover
4.Bolt
5.Short sleeve
6.Fan peller
7.O-ring
8.Plate
5-44
Remove the CPS.
054501
5
1.CPS
2.Bolt
Use 18mm sleeve to turn the crankshaft until the cyl-

inder 2 at TDC.
054502
1.18mm sleeve
5-45
When rear cylinder is at TDC the 2 mark on magneto
flywheel would be aligned to the mark of left crank-
case cover(The center of the hole). 11
33
22
054601
1.Magneto flywheel mark 2.
2.Left crankcase cover groove.
3.CPS mounting hole.
At TDC. Camshaft timing sprocket sign should be

paralle with cylinder head surface.
2
1
054602
1.Camshaft timing sprocket mark.
5-46
Follow the steps below to lock the crankshaft to keep

the cylinder 2 at TDC.
Remove the bolt and washer from the crankcase.
2
1
3
054701
1.Bolt
5
2.Washer
3.Left crankcase front side.
Use crankshaft locking screw(0800-041000-922-001)

to lock the crankshaft.
Note: Make sure the screw is lock the crankshaft. 1
054702
1.Camshaft locking screw
(P/N:0800-041000-922-001)
5-47
Cylinder 2 camshaft timing
Turn the crankshaft to TDC of the cylinder 1.See 2
cyl-inder 2 timing. 1
Note: Do not lock the crankshaft.
Use 18mm sleeve turn the crankshaft clockwise 280

degree. Until yousee the mark on the flywheel aligned
to the mark on the crankcase cover.
054801
1.18mm sleeve
2.Turn crankshaft clockwise 280°
1
3
054802
1.Magneto flywheel mark
2.Crank case cover groove
3.CPS mounting hole
5-48
NOTE: When at TDC. The camshaft

timing sprocket mark must be paralle to
the cylinder head surface.
Warning
The crankshaft cannot be locked when cylin-
der 1 is at TDC.
2
1
5
054901
1.Camshaft timing sprocket mark

2.Cylinder head surface.
Camshaft removal
Remove 2 cylinders in the same way.
As the camshafts for 2 cylinders are different. So do
not mix the camshafts and other related parts. Put
parts for each cylinder together. 3 2
Remove the cylinderhead cover( See cylinderhead
cover)
Remove the timing chain tensioner( See timing chain
tensioner)
Remove timing chain sprocket( See related chapter
1
mentioned).
Remove camshaft locking plate. 054902
1.Cylinderhead
2.Bolt
3.Camshaft locking plate
5-49
Remove the rocker arm(See rocker arm chapter).
Remove the camshaft. 2 1
Note: Turn the camshaft when removing it. Let
the intake and exhaust cam goes up from the cyl-
inder head.
3
Camshaft inspection
055001
Check each lobe and bearing journal of camshaft for 1.Cam avoid area
scoring, scuffing,cracks or other signs of wear. 2.Camshaft
Measure camshaft journal diameter and lobee 3.Camshaft locking plate
height using a micrometer.
C amshaft for cylinder 1

Cam（ Exhaust） C B
32.945 mm～33.065 mm A D
New
(1.2970 in～1.3018 in)
Service limit 32.845 mm(1.2931 in)
C am（ Intake）
32.931 mm～33.051 mm
New
(1.2965 in～1.3012 in)
C amshaft for cylinder 2

C am（ Exhaust）
32.853 mm～32.973 mm 055002
New
(1.2934 in～1.2981 in) A.Camshaft Lobe(Exhaust Valves)
Service limit 32.753 mm(1.2895 in) B.Camshaft Lobe(Intake Valves)
C am（ Intake） C.Camshaft Journal(Timing Chain Side)
33.019 mm～33.139 mm D.Camshaft Journal(Spark Plug Side)
New
(1.300 in～ 1.3047 in)
Camshaft journal（Timing chain）

34.959 mm～34.975 mm
New
(1.3763 in～1.3770 in)
Camshaft journal（Spark plug）
21.959 mm～21.980 mm
New
(0.8645 in～0.8654 in)
5-50
Measure matching clearance between two ends of

camshaft and cylinder head.
C a m s h a ft b e a rin g d ia m e te r （ T im in g
c h a in ）
3 5 .0 0 7 m m ～ 3 5 .0 2 5 m m
New
(1 .3 7 8 2 i n～ 1 .3 7 8 9 in )
S e rvic e li m i t 3 5 .0 4 0 m m (1 .3 7 9 5 i n)
C a m s h a ft b e a r in g d ia m e te r（ S p a rk
p lu g ）
B
2 2 .0 1 2 m m ～ 2 2 .0 2 5 m m
New
(0 .8 6 6 6 i n～ 0 .8 6 7 1 in )
S e rvic e li m i t 2 2 .0 4 0 m m (0 .8 6 7 7 i n)
Replace the part if out of service limit

A
5
055101
A.Camshaft Bearing(Timing Chain Side)
B.Camshaft Bearing(Spark Plug Side)
Camshaft assemble
Reverse the removal procedure for installation. But pay
attention to items below. 1
Warning
The camshafts are not identical in design. Do
not invert the camshafts during assembly. Any
3
mix-up of the components will lead to engine
damage.
Place the camshaft retaining plate in the slot of the

camshaft. 2
For other parts, refer to proper installation procedure 055102
1.Camshaft Retaining Plate
2.Slot Retaining Shaft
3.Camshaft Retaining Plate Direction of Movement
5-51
5.2.11 VALVE SPRING
Valve Spring Removal

Remove rocker arm(see ROCKER ARM above).
Remove cylinder head(see CYLINDER HEAD
above).
Use valve spring compressor clamp(0180-022 006-
922- 001)to compress valve spring.
Warning
Always wear safty glasses when removing valve
springs. Be careful when unlocking valves. Com-
ponents could fly away because of the strong 055201
spring preload. Valve Spring Compressor Tool
(P/N: CF188-022006-922-001)
055202
Valve Spring Compressor Cap
055203
Align valve spring compressor clamp with the center
of Valve
5-52
Remove valve cotters.
Withdraw valve spring compressor, valve spring
retainer and valve spring.
2
3
1
055301
1.Valve Spring Compressor Clamp 5
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.
V a lv e s p r in g le n g th
New 4 0 m m (1 .5 7 5 in )
S e rv ic e lim it 3 8 .2 m m (1 .5 0 4 in )
Replace valves springs if not within specifications
Valve Spring Installation

A
For installation, reverse the removal procedure. Pay
055302
attention to the following details.
A.Valve Spring Length
Colored area of the valve spring must be placed on
top.
To ease installation of cotters, apply oil or grease on
them so that they remain in place while releasing
2
the spring.
NOTE: Valve cotter must be properly engaged

in valve stem grooves.
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.
1
055303
WARNING: An improper locked valve
1.Position of the Valve Spring
spring will cause engine damage. 2.Valve Cotter
5-53
5.2.12 VALVE
Valve Removal
Remove valve spring, see VALVE SPRING above.
Push valve stem, then pull valves(intake and
exhaust) out of valve guide.
1 2
055401
1.Intake Valve 33mm
2.Exhaust Valve 29mm
Remove valve stem seal with Snap-on pliers and

discard it.
055402
Plier
2
055403
1.Plier
2.Valve Stem Seal
5-54
Valve Inspection
Valve Stem Seal

Always install new seals whenever valves are
removed.
Valve
Inspect valve surface, check for abnormal stem wear A
and bending. If out of specification, replace by a new
one.
V a lve ro d ro u n d n ess(D ia m eter ru n

o u t)
（ In take a n d ex h au st)
Ne w 0.01 m m(0.00 04 in)
S ervice lim it 0.05 m m(0.00 20 in)
055501
5
Valve Stem and Valve Guide Clearance A.Valve Stem Diameter
Measure valve stem and valve guide in three places

using 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 specification or
has other damages such as wear or friction surface.
Valve stem diameter

Exhaust 3 2
New 4.955 mm～4.970 mm
(0.1951 in～0.1957 in)
Service 4.930 mm(0.1941 in)
Intake
New
4.965 mm～4.980 mm 1
(0.1955 in～0.1960 in)
Service 4.930 mm(0.1941 in)
Replace valve guide if valve guide is out of

specification or has other damages, such as wear or
055502
friction surface.
1.Valve Seat
Valve guide inside diameter 2.Exhaust Valve Contaminated Area
（ Intake and exhaust） 3.Valve Face(Contact Surface to Valve Seat)
5.000 mm～5.012 mm
New
(0.1969 in～0.1973 in)
Service limit 5 .045 mm(0.1986 in)
5-55
Valve Bevel and Seat
Check valve face and seat for burning or pittings and
replace valve or cylinder head if there are signs of
damage.
Ensure to seat valves properly. Apply some lapping
compound to valve face and work valve on its seat
with a lapping tool(see Valve Guide Procedure
below).
B
Measure valve face contact width.
A
NOTE: The location of contact area should be
in center of valve seat.
Measure valve seat width using a caliper.
Valve seat sealant width

Exhaust
1.20 mm～1.40 mm
New
(0.047 in～0.055 in)
Service limit 1.80 mm(0.071 in) 055601
Intake A.Valve Contact Surface Width
1.10 mm～1.30 mm B.Valve Seat Contact Width
New
(0.043 in～0.051 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 following details. 2
Install a NEW valve stem seal. Make sure thrust
washer is installed before installing seal.
Apply engine oil on valve stem and install it.
WARNING: Be careful when valve stem is

passed through sealing lips of valve stem seal.
1
To ease installation of cotters, apply oil or grease on
them so that they remain in place while releasing
the spring. 055602
After spring is installed, ensure it is properly locked 1.Valve Spring Lower Seat
by tapping on valve stem end with a soft hammer so 2.Sealing Lips of Valve Stem Seal
that valve opens and closes a few times.
WARNING: An improper locked valve

spring will cause engine damage.
5-56
5.2.13 CYLINDER
Cylinder Removal 1
Remvoe chain tensioner(see CHAIN TENSIONER).
Remove the camshaft timing gear(see CAMSHAFT 3
TIMING GEAR).
Remove cylinder head(see CYLINDER HEAD).
Pull cylinder. 2
Discard cylinder base gasckets.
4
055701
1.Cylinder 5
2.Piston Assembly
3.Cylinder Base Gasket
4.Camshaft Timing Chain
Cylinder Inspection
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder.If so, replace 3
cylinder. C
Cylinder Taper 1
Measure cylinder bore and if it is out of A
specifications, replace cylinder and piston rings. B
Measure cylinder bore at 3 recommended positions.
2
See the following illustration.
Cylinder taper inner diameter
New 0.038 mm(0.0015 in)
1.First Measuring of Diameter
Distance between measurements should not exceed 2.Second Measuring of Diameter
the service limit mentioned above. 3.Third Measuring of Diameter
A.7mm(0.276 in)from Cylinder Bottom
B.68mm(2.68 in)
C.32mm(1.260 in)
5-57
Cylinder Out of Round
Measure cylinder diameter in piston axis direction

from top of cylinder. Take another measurement 90
from first one and compare.
NOTE: Take the same measuring points like

described in Cylinder Taper above. B
A
C ylinder ro undn ess
N ew 0.015 mm(0.0006 in)
055801
A.Perpendicular to Crankshaft Axis
B.Parallel to Crankshaft Axis
Cylinder Installation(See pic 055901)
Reverse removal procedure for installation. Pay

NOTE: Always replace cylinder base gasket

before installing cylinder.
First mount cylinder 2.Then remove crankshaft

locking bolt(P/N 529 035 617). Turn engine to piston
1 at TDC, mount cylinder 1.Cylinder can not be
pushed fully over the piston unless the piston is
located at TDC.
Apply engine oil in the bottom area of the cylinder
bore and also on the brand of the piston ring
compressor tool(0800-040003-922-001). 055802
Piston Ring Compressor Tool
(P/N: 0800-040003-922-001)
NOTE: Put timing chain through the chain pit then
put the cylinder in place.
NOTE: Chain guide has to 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.
5-58
3
2
5
055901
1.Piston Ring Compressor Tool
2.Piston
3.Cylinder
5.2.14 PISTON
Piston Removal
Remove cylinder head(see CYLINDER HEAD
above)
Remove cylinder(see CYLINDER above).
Place a rag under piston and in the area of timing
chain compartment.
WARNING
Piston circlips are spring loaded.
1
Remove one piston circlip and discard it.
055902
1.Piston Circlip
NOTE: Removal of both piston circlips is not
necessary to remove piston pin.
1
Push piston pin out of piston.
Detach piston from connecting rod.
055903
1.Piston
2.Piston Pin
5-59
Piston inspection
Inspect piston for scoring, cracking or other
1
damages.
Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 8mm(0.315
in)perpendicularly(90 )to piston pin.
The measuring dimension should be as described in
the following tables. If not, replace piston.
Piston size
A
90.940 mm～90.960 mm
New
(3.5803 in～3.5811 in)
1.Measuring perpendicularly (90¡ã) to pston pin
A.8 mm(0.315 in)
5-60
Piston/Cylinder Clearance
Set the micrometer into the piston size.

Use micrometer size setted to adjust the cylinder dial
gauge. The set the dial gauge at 0.
Using a micrometer, measure piston at 20 mm(0.

787 in)perpendicularly(90 degree )to piston pin.
1
The measuring dimension should be as described in
the following tables. If not, replace piston.
056101
1.Set the micrometer at piston size.
Piston/Cylinder body clearance

0.040 mm～0.060 mm
New
(0.0016 in～0.0024 in)
2 5
Note: Make sure the piston is not worn
If clearance exceeds specified tolerance, replace

piston by a new one and measure piston/cylinder 1
clearance again.
NOTE: Make sure the cylinder bore gauge
indicator is set exactly at the same position as with 056102
the micrometer, otherwise the reading will be false. 1.Use the micrometer to set the cylinder bore gauge
2.Dial Bore Gauge
056103
1.Indiacator set to 0 (zero)
5-61
Connecting rod/Piston pin clearance
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measuring piston pin. See the following illustration
for the proper measurement positions.
Piston pin diameter
21.995 mm～22.000 mm
New
(0.8659 mm～0.8661 in)
A
Replace piston pin if diameter is out of
056201
specifications.
A.Piston Pin Diameter
Measure inside diameter of connecting rod small

end bushing.
C o n n e c tin g r o d s m a ll e n d in n e r
d ia m e te r
2 2 .0 1 0 m m ～ 2 2 .0 2 0 m m
N ew
(0 .8 6 6 5 i n ～ 0 .8 6 6 9 i n)
S e r v ic e lim it 2 2 .0 6 0 m m (0 .8 6 8 5 in ) 1
Replace connecting rod if diameter of connecting 2
rod small end is out of specifications. Refer to
BOTTOM END for removal procedure.
Compare measurement to obtain the connecting
rod/piston clearance
C o n n e c tin g r o d /P is to n p in c le a r a n c e
S e rvi c e lim it 0 .0 8 0 m m (0 .0 0 3 5 in )
056202
1.Bore Gauge
2.Connecting Rod
5-62
Piston Installation
Reverse the removal procedure for installation. Pay
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
3 4
WARNING: Make sure the mounting direction
of the piston is correct.
For each cylinder, install piston with the punched 1

arrow on piston dome pointing toward the rear side
of the engine.
Front Cylinder: Mark on top of piston must show to 2

intake side.
Rear cylinder: Mark on top of piston must show to
5
exhaust side.
056301
1.Piston of Cylinder 1
2.Mark on piston must show to exhaust side of
cylinder 1
3.Piston of Cylinder 2
4.Mark on piston must show to exhaust side of
cylinder 2
Use the piston appropriate circlip installer (0800-

040005-922-001)to assemble the NEW piston circlip
as per following procedure:
WARNING: Always replace disassembled

piston circlip(s) by new ones. Place a rag on
cylinder base to avoid dropping the circlip
inside the engine.
056302
Circlip Installer
(P/N: 0800-040005-922-001)
5-63
Place circlip in sleeve as per following illustration.
3
1
2
056401
1.Piston Pin Circlip
2.Sleeve
3.Assembly Jig from Piston Clip Installer
Push taper side of assembly jig until circlip reaches

middle of sleeve.
Align sleeve with piston pin axis and push push
assembly jig until engages in piston. 2 3
1
056402
1.Hold piston while pushing circlip in place
2.Sleeve
3.Assembly Jig
4.Direction to push circlip
5-64
NOTE: Take care that the hook of the piston circlip

is positioned properly.
5.2.15 PISTON RINGS

Ring Removal
Remove the piston(see PISTON above).
Ring Inspection
Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the
piston and piston rings should be replaced..
Piston ring/groove clearance
Piston ring（ 1） 5
0.020 mm～ 0.060 mm
New
(0.0008 in～ 0.0024 in) 056501
Piston ring（ 2）
0.020 mm～ 0.060 mm
New
(0.0008 in～ 0.0024 in)
Oil ring 2
0.030 mm～ 0.150 mm
New
(0.0012 in～ 0.0059 in) 1
P isto n rin g o pe n clea ran ce

P isto n ring （ 1 ）
0.15 m m ～ 0.30 m m
New
(0.010 in～ 0.016 in)
S ervice lim it 1.50 m m (0.059 in)
P isto n ring （ 2 ）
0.15 m m ～ 0.30 m m
New 056502
(0.012 in～ 0.018 in)
S ervice lim it 1.50 m m (0.059 in) 1.Feeler Gauge
Oil rin g 2.Piston
0.20 m m ～ 0.70 m m
New
(0.008 in～ 0.028 in)
S ervice lim it 1.50 m m (0.059 in)
To measure the ring end gap, place the ring in the

cylinder in the area of 8~16mm(5/16~5/8in) from top
of cylinder.
NOTE: In order to correctly position the ring in the

cylinder, use piston as a pusher.
Use clearance gauge to measure the pistion ring clear-

ance if clearance out of limit. Replace the ring.
5-65
Ring Installation
Reverse the removal procedure for installation. But
pay attention the items below.
1
NOTE: First install spring and then rings of oil
scraper ring. 2
Install oil scraper ring first, then piston ring(2) with
the word “N and TOP” facing up, then piston ring(1)
3
with the word “N and TOP” facing up.
WARNING: Ensure that top and second

rings are not interchanged. 056601
1.Upper Compression Ring
2.Lower Compression Ring
3.Oil Scraper Ring
NOTE: Use a ring expander to prevent
breakage during installation.The oil ring must
be installed by hand.
Check that rings rotate smoothly after installation.

Space the piston ring end gaps 120°,apart and do A
not align the gaps with the piston pin bore or the A A
thrust side exis.
056602
1.Don’t align ring gap with piston thrust side axis
2.Don’t align ring gap with piston pin bore axis
A.120°
5-66
5.3 Crankcase,crankshaft and gearing system

5.3.1 Service tool, material and views…………………………………………………5-68
5.3.2 General………………………………………………………………………………5-72
5.3.3 Driving gear…………………………………………………………………………5-72
5.3.4 Timing chain ………………………………………………………………………5-73
5.3.5 Timing chain tension 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
5.3.10 Drive bevel gear…………………………………………………………………5-89
5.3.11 Bevel gear washer adjustment…………………………………………………5-91
5.3.12 Gearing system……………………………………………………………………5-93
5-67
5.3.1 Service tool, material and views
Service tool
Name P/N Page
Breather Oil Seal Installer 0800-011201-923-001 5-73

Installation Jig,Breather Gear Shaft 0800-011201-921-003 5-73
Press Tool,Breather Gear Shaft 0800-011201-921-001 5-73
Front output shaft bearing retainer plier 0JWA-012000-922-005 5-76/77
Bearing 6205 removing tool 0JWA-012000-922-006 5-76
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 output shaft retainer wrench CF188-060008-922-001 5-86
Front output shaft oil seal pressor 0800-060000-923-001 5-86
Front output shaft pressor 0800-062301-923-001 5-86
Driven bevel gear shaft bearing nut sleeve 0800-062206-922-001 5-88
Driven bevel gear shaft oil seal pressor 0800-062204-923-001 5-88
Bearing 6305 pressor CF188-062103-921-002 5-88
Bearing 6207C3 CF188-062201-921-003 5-88
Sleeve B, bevel gear lock nut 0JYA-062100-921-002 5-89
Holder, drive bevel gear 0JYA-062100-921-003 5-89
Bevel gear clearance measuring tool 0JWA-062000-922-001 5-91
Left case bearing removing tool 0800-011000-922-001 5-97
Right case bearing 5206 removing tool 0800-012000-922-001 5-97
Oil seal SD15 × 25 × 5 pressor CF188-065002-923-001 5-97
Breather connector pressor 0JWA-065100-921-001 5-103
Bearing 6203 pressing rod 152MI-060002-921-002 5-105
Right case 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
Engine oil 5-69/70/71/73/77/84
/88/90/104/108
5-68
Exploded view
10 N.m(89 lbf.in)
243 thread locker
5
Oil
See assemble
details
Oil
Oil
2 4 3
Oil Thread
locker
Oil
10 N.m(89 lbf.in)
Oil
See assemble
details
056901
5-69
Case(Exploded view)
25 N.m
(18 lbf.ft)
10 N.m (89 lbf.in)

Oil
648 cylinder
243 thread locker
locking glue
80 N·m(59 lbf·ft)
Oil 10 N.m
(89 lbf.in)
25 N.m
Oil
(18 lbf.ft)
10 N.m
(89 lbf.in)
Oil
Oil
243 thread locker
3 N.m Oil
(27 lbf.in)
20 N.m
(15 lbf.ft)
10 N.m
(89 lbf.in)
057001
5-70
Gearing system (Exploded view)

55 N ·m
(41 lbf·ft)
648 cylinder lock-
ing glue 25 N ·m
(18 lbf·ft)
110 N·m
(81 lbf·ft)
243 thread
locker 5
Oil
32 N ·m
(24 lbf·ft)
15 N ·m
1 4 0 N ·m
(11 lbf·ft)
(103 lbf·ft)
Oil
Oil
Oil
10 N ·m
(89 lbf·in)
243 thread locker
80 N·m(59 lbf·ft)
648 Cylinder locking glue

55 N·m
(41 lbf·ft)
057101
5-71
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 covering the thread locker.
WARNING
Torque Wrench Tightening specifications must
strictly be adhered to .Locking devices (e.g.:
locking 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 GEARS
The drive gears are located on the MAG side behind
the magneto cover.
Removal
Remove ：
-Magneto cover(refer to Magneto Cover Removal,
Chapter 11 ) 4
-Retainer ring no.10
-Magneto,driven gear
-Oil pump intermediate gear 3
-Breather intermediate gear
-Oil pump gear (refer to LUBRICATION SYSTEM)
-Water pump gear
-Breather gear
2
1
Inspection
Oil Pump Intermediate Gear/Breather Intermediate
057201
Gear/Oil Pump Gear 1.Oil Pump Gear
Inspect gears for wear or damage,replace if 2.Oil Pump Intermediate Gear
damaged. 3.Breather Intermediate Gear
Breather 4.Breather Gear
The engine is equipped with a breather gear which
prevents 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 essentially the reverse of the
removal procedure ,but pay attention to the follow
details:
5-72
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 .one is
located on the magneto side .the second is loacted
on the CVT side. 5
Removal(MAG side)
Remove ：
-Valve cover chain tensioner,camshaft timing gear(refer
to INTAKE MANIFOLD,CYLINDER HEAD AND
CYLINDER)
-Magneto,driven gear,oil pump intermediate gear,
breather intermediate gear.
-Timing chain guide and lower timing chain guide. 3
Carefully pull the timing chain sideward and down
from the crankcase.
NOTE:Mark the operation direction of the timing
chain before removal. 2
Removal(CVT side) 1
Remove:
-Valve cover chain tensioner and camshaft timing 057301
gear (refer to INTAKE MANIFOLD,CYLINDER
1.Timing Chain Guide
HEAD AND CYLINDER)
2.Timing Chain
-CVT cover CVT drive gear CVT driven gear and Belt
3.Chain Tensioner
Note Mark operation direction of the belt .
-CVT case Clutch
-Timing chain guide and lower timing chain guide.
Carefully pull the timing chain sideward and down
from the crankcase. 1
Note:Mark the operation direction of the timing
chain before removal.
Timing Chain inspection
Inspect 2 same timing chain
Inspect the radial clearance between timing chain and
sprocket.
Inspect the chain piece to see wearing
If the chain wearing too much or even damaged. Re-
place all the timing chains and sprockets.
Timing chain installation 057302

1.Timing Chain
Two chains installing in the same way.
5-73
The installation essentially the reverse of the remove
procedure ,but pay attention to the follow details:
Note:Ensure to perform 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 timingrefer to intake
manifold , cylinder head and cylinder section).
WARNING
Improper valve timing will damage engine
components.
5.3.5 TIMING CHAIN TENSIONER

Removal
Refer to TIMING CHAIN above.
Inspection
Check timing chain tensioner for wear ,cracks or
other damage ,replace if necessary.
1 2
Installation
057401
The installaiton is the reverse of the removal 1.Chain Tensioner
procedure 2.Screw
5.3.6 CRANKCASE
NOTE: Before disassembly ,drain engin oil and
engine coolant.
Crankcase Disassembly
NOTE: Before splitting the crankcase,measure
crankshaft axial play (refer to CRANKSHAFT).
Remove:
-Front output shaft, Bevel gear(Refer to front output
shaft, driven bevel gear)
-CVT cover,CVT,belt,CVT air guide and clutch(refer
to CVT AND CLUTCH)
-Left crankcase cover and start motor(Refer to start
system)
-Drive gears(refer to DRIVE GEARS)
NOTE:Oil pump removal from crankcase is not
necessary ,but recommended to see condition of oil
pump.
5-74
-Electric starter drive gear(refer to STARTING

2 1
SYSTEM)
-Oil filter(refer to LUBRICATION SYSTEM)
1
-Cylinder head and cylingder( refer to INTAKE
MANIFOLD,CYLINDER HEAD AND CYLINDER)
-Timing chain,tensioner and guide.(refer to TIMING
8
CHAIN,TENSIONER AND GUIDE).
Remove all bolts of crankcase 3 2
(see 057501，057502) 5
6 5
1 057501
2 7
3 4
057502
1.11 bolts M6 × 45 2.4 bolts M8 × 60
3.3 bolts M6 × 75 4.2 bolts M8 × 50
5.1 bolt M8 × 106 6.1 bolt M6 × 55
7.3 bolt M6 × 105 8.1 bolt M8 × 73
Carefully split crankcase halves by using a soft

hammer 1
NOTE: During disassembly ,do not damage the
sealing surface of the crankcase halves.
Pull crankshaft out of crankcase. Be careful not to
damaged the crankshaft bearing.
057503
1.Soft hammer
5-75
Remove the bearing retainer of the front output shaft,
bearing and oil seal, Bearing retainer. The bearing
removing must be use the special tool.
Special tool:
3 2
Front output shaft bearing retainer wrench
0JWA-012000-922-005
1
Bearing 6205 removing tool
0JWA-012000-922-006
Note: If the oil seal and bearing not damaged. It

is unecessary to remove it. 057601
1.Bearing retainer
Note:the output shaft intermediate bearing 2.Bearing
ring thread 3.Oil seal
Crankcase cleaning
Warning
Use eye-proctetor to avoid hurt the eye.
Use cleaning tool clean the crankcase.
2 1
Dry the crankcase by using compressed air.
Clean the lubrication line.
A
Crankcase inspection
Inspect the left or right crankcase got cracks or
other damaged. Replace if needs. 3
Inspect the slide bearing to see scrached or other
damage.
Note: Measure the inner diameter of slide bear-
ing and compare the magneto side and CVT side
(See crankshaft) If difference too much. Needs 057602
1.Oil hole
replaced.
2.Slide bearing
3.Push washer
Slide bearing inner diameter（CVT/MAG）
A.Bearing inner diameter
Service limit 42.100mm(1.6575in)
5-76
Installation
Reverse the removal procedure for installation. Use
special tool to install the oil seal bearing and
1 2
retainer.
3
Note: When installing the oil-seal. The oil seal
size mark must to the bearing.
Tool:
Oil seal 25 × 40 × 8 pressor
0JWA-012000-921-003
Bearing 6205 pressure
057701
0JWA-012000-921-004
1.Oil seal
Front output shaft bearing retainer plier
2.Bearing
5
0JWA-012000-922-005
3.Retainer
Crankcase Assembly
Reverse the removal procedure to assemble. But pay
3
attention the items below:
Clean the oil line. Make sure it is not jammed. 13 15
8 2
Clean all the metal parts. 1
The locking surface of left and right crankcase must 18 11
be cleaned up. 12
Gasket must be replaced. 6 4
7
Pre-lubricate the bearing when assemble the
5
crankshaft.
Warning 19 14 10
9 16 17
Install the crankshaft in the right way(See
057702
crankshaft)
20
Follow the order in pic 057702 and 057703 to tight up
the locking bolts.
24
22
26
23 21
25
057703
5-77
2
5.3.7 CRANKSHAFT
1
057801
Crankshaft Locking Procedure

8
Note: When crankshaft locked at Cylinder 2TDC.
6
The crankshaft cannot be locked at cylinder 1 TDC. 4
2
-Remove:
7
-Ignition lines and spark plugs.
-2 cylinderhead covers. 5
-Fan cover 3
-Fan peller and plate.
1
057802
1.Bolt
2.Long Sleeve
3.Fan cover
4.Bolt
5.Short Sleeve
6.Fan peller
7.O-ring
8.Plate
5-78
-CPS
057901
1.CPS
5
2.Bolt
-Bolt and sealing ring

1 2
057902
1.Bolt
2.Sealing ring
3.Left crankcase. Front side.
Use 18mm sleeve, turn the crankshaft to cyl-

inder 2 TDC.
057903
1.18mm Sleeve
5-79
When cylinder 2 is at TDC. The mark "2" on the
fly-wheel must be aligned to the timing groove on
left crankcase cover.
1
3
058001
1. Mark “2” on magneto flywheel
2.Notch on magneto cover
3.CPS Location
Use screwdriver to check if V-type groove of

crankshaft balancer is aligned with the hole.
058002
1.Screwdriver
Lock crankshaft with crankshaft locking bolt

(0800-041000-922-001)
058003
1.Crankshaft locking screw
(P/N:0800-041000-922-001)
5-80
Crankshaft Removal
Refer to CRANKCASE
Crankshaft Inspection
NOTE:Check each bearing journal of crankshaft
for scoring,scuffing,cracks and other signs of wear.
NOTE:Replace the crankshaft if the gears are
worn or otherwise damaged.
WARNING: Components with less than the

service limit always have to be replaced.
Otherwise servere damage may be caused to 1
the engine.
058101
1.Timing sprokcet (gear) of crankshaft 5
Crankshaft Axial Play
NOTE: Axial play of crankshaft needs to be
measured before splitting the crankcase.
Use dial gauge to measure crankshaft axial play at
MAG side.
Crankshaft axial clearance
0.260mm～0.540mm
New
（0.010in～0.020in）
Service limit 0.64mm(0.025in )
If the clearance is out of the form mentioned. Replace
the crankshaft washer or crankshaft.(Crankshaft axial
washer screw needs thread locker covered and tighten
torque: 3N.m) 3
2
Connecting Rod Big End Axial Play
Using a feeler gauge,measure the distance between
butting face of connecting rods and crankshaft
counterweight.
Connecting rod axial clearance 2

0.300mm～0.560mm
1
New
（0.012in～0.022in）
Service limit 0.8mm(0.031in ) 058102
1.Crankshaft
2.Connecting Rod
3.Gauge
5-81
Connecting Rod/Piston Pin Clearance
Refer to INTAKE MANIFOLD,CYLINDER HEAD 3
AND CYLINDER.
Connecting Rod Big End Radial Play
Note: Make sure the same marking of connecting 1
rod to assemble together, do not mix it and
exchange between cylinder 1 and cylinder 2. 2
Remove connecting rod from crankshaft.
058201
Warning: Replace the connecting rod bearing 1.Connecting Rod Screws
together if the connecting rod bolt 1 removed. 2.Plain Bearing
3.Connecting Rod
A
Measure the diameter of crankpin and compare to
inside diameter of connecting rod big end.
Reverse the removing procedure to assemble the con-

necting rod bearing
Assemble the bolt and follow the discribtion on page
5-84. Then measure the connecting rod big end inner
diameter. 058202
1.Crankshaft
Connecting rod big end diameter A.Diameter of Crankpin
43.946mm～43.960mm
New
(1.7302in～1.7307 in)
Service limit 43.93mm(1.7295 in)
Connecting rod big end inner diameter
A
Connecting rod bearing/big end clearance
058203
A. Inside Diameter of Connecting Rod Bid End
5-82
Crankshaft Radial Play,MAG/PTO Side
Crankshaft main joint clearance

Measure crankshaft on MAG/PTO side and
compare to inside diameter of MAG/PTO plain
bearing(see CRANKCASE).
Crankshaft diameter
B
C
41.960mm～41.970mm
New
(1.652in～1.6524 in)
5
Crankshaft radial clearance 1
Service limit 0.09mm (0.0035in)
058301
1.Crankshaft
A.CVT side main joint diameter
CVT neck diameter B.MAG side main joint diameter
C.CVT neck diameter
Measure the CVT neck diameter of crankshaft and
conpare the inner diameter(Refer to CVT case)
CVT case neck diameter

31.955mm～31.970mm
New
(1.2581in～1.2587 in)
CVT case/crankshaft neck clearance

Service limit 0.09mm (0.0035in)
5-83
NOTE: Follow the table below to assemble
crankshaft,connecting rod and connecting rod plain 3
bearing.
C o n n e c ti n g
C o n n e c ti n g
ro d inn e r B e a ri n g
jo i n t
d i a m e te r
Ⅰ B la c k
A
Ⅱ B lu e
Ⅰ Red
Ⅱ
B
B la c k 1
Cranksahft assembly procedure is the reverse of
disassembly procedure.However,the following 2
details should be noted.
When inside diameter of connecting rod big end is
less than service limit, replace and use new 1.Half Plain Bearing of Connecting Rod Big End
connecting rod bearing. 2.Split Surface of the Connecting Rod
After installing bearing into big end of connecting 3.Nose of Plain Bearing in Line with Connecting Rod
rod,use compressed air to clean connecting rod Groove
split surface.
NOTE: Oil inner surface of connecting rod plain
bearing and crankshaft pin surface before
2
installation 1
Both sides of the connecting rod with 0JY0 sign must
be to outer side of the crankshaft.
3
058402
1.0JY0 sign
2.Oil plug
3.Connecting rod sign A or B
Screw of connecting rod should be tightened by

following methods.
-Firstly torque to 10N·m(7.5 lbf·ft)，
Without threadlocker
-Then torque to 20N·m(15 lbf·ft)。
-Finally torque to 60N·m(35.25 lbf·ft)。
1
058403
1.Torque wrench
5-84
WARNING: Improper installation will cause

2 1
screw looseness and engine damage.
ATTENTION: Bearing of connecting rod big end

and piston pin rotation cannot be changed.
Crankshaft Installation
The procedure of crankshaft installation is the
reverse of removal. But pay attention to items below:
Do not mix connecting rod of cylinder No. 1 and No.
2
ATTENTION:Do not damage plain bearing of
crankcase when installing crankshaft (together
with connecting rod). 3 5
058501
ATTENTION:Before installation of camshaft 1.Crankcase
2.Connecting rod of cylinder No.1
and valve rocker arm, do not forget to install
3.Connecting rod of cylinder No.2
locking bolt to make sure crankshaft on top
dead position.(Refer to crankshaft locking)
5.3.8 Front Output Shaft

Front Output Shaft Removal
Remove bolt,gasket,terminal pad,oil seal,O seal ring
and retainer ring.
Remove front output shaft
058502
1.Bolt
2.Washer
3.Terminal pad
4. 4.Oil
5.O-ring
6.Retainer
7.Front output shaft
8.Bearing
5-85
Inspection
Inspect if bearing turns freely and smoothly,or has 1
abnormal wear.Replace if necessary.
2
Installation
Reverse the removal procedure for installation.Pay
attention to the following details. 1
When assemble the output shaft. Cover the cylinder
glue between bearing 2 and shaft 3(See right side) Do
not covered on spline.
3
Use service tool to tighten bearing retainer (left 058601
1.Front output shaft
thread) by applying threadlocker.
2.Bearing
Tighten torque：80 N·m
3.Thread locker position
Replace the oil seal.Apply grease on oil seal lip.
Service Tool ：
Bearing 6205 presser
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
5-86
5.3.9 Driven bevel gear

Removal
Remove rear output sleeve mounting bolt.Remove the 5
washer and rear sleeve. 4
Remove the gear bearing seat mounting bolt to re- 9
move the speed sensor, bevel gear and adjusting
washer.
8
7
Remove the O-ring and oil seal
6
3
2 5
1
058701
1.Rear output sleeve mountingbolt
2.Washer
3.Rear output sleeve
4.Oil seal
5.O-ring
6.Bevel gear bearing seat mounting bolt
7.Speed sensor
8.Bevel gear
9.Adjusting washer
Use suitable equipment to protect the bevel gear

end. Hold the bevel gear bearing seat and press
1
the gear out.
2 3
058702
1.Cover
2.Bevel gear bearing seat
3.Bevel gear
5-87
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.
Inspection
Inspect gear for any surface damage,wear. Replcae 1
if necessary( in pairs).
Inspect bearing for operation condition. Replace if 2
any problems comes out. Or do not remove the
bearing
Installation
Installation procedure is the reverse of removal
procedure.Pay attention to the details
Use oil seal installer (0800-062204-923-001) to

install NEW oil seal and O-ring.
058801
1.Special Tool
When replacement of right crankcase,ring gear or
(P/N:0800-062206-922-001)
bearing seat, adjusting washer should be chekced
2.Bearing Carrier of Ring Gear
and adjusted. See related chapter.
Cover the cylinder locking glue on 3 position on the

right picture. Do not cover the glue on spline. The O-
ring must be pre-lubricated. Oil seal must be grease
covered and bearing locking nut must covered by 3 2
thread locker. Then use special tool to tight up at torque
in standard.
Tighten torque:110N·m
Torque: 1
Bearing 6305 pressor CF188-062103-921-002
Bearing 6207C3 pressor CF188-062201-921-003
058802
1.Bevel gear
2.Bevel gear bearing seat
3.Cylinder locking glue cover position
5-88
5.3.10 Drive bevel gear
Drive bevel gear removal 1
Open the crankcases(See crankcases chapter)
Loose up 4 bolts [1]
Remove the drive bevel gear
2
058901
1.Bolt
2.Drive bevel gear
5
Remove the retainer on drive bevel gear shaft to re-
move the out put driven gear [1]. 1
1.Out put dirve bevel gear 058902

2.Retainer
2
1
Place drive bevel gear on the holder

(0JYA-062100-922-003)
3
Use sleeve B(0JYA-062100-922002) to

loosen bevel gear nut, and remove drive bevel
gear and adjusting washer in order. 058903
1. Seat, drive bevel gear
2. Sleeve B, bevel gear lock nut
(P/N:0JYA-062100-922-002)
3. Holder, drive bevel gear
(P/N:0JYA-062100-922-003)
5-89
Drive bevel gear inspection
Inspect the drive and driven bevel gear to see any 9
corrosion, damaged or wearing, if trouble inspected,
replace the parts
8
Inspect the bearing running. If trouble inspected, re-
place the parts. 10 6
Left crankcase, drive bevel gear or gear bearing seat 5
replaced. The adjusting washer needs adjust again
see bevel gear washer adjustment.
8
Drive bevel gear installation 7
the bearing should be covered with engine oil. And
5 2
tight up the bevel gear locking nut in standard.
Tighten torque: 145N·m 4
Tool: 3
Drive bevel gear bearing (6305) pressing tool CF188-
062103-921-002 1
059001
1.Retainer
2.Output driven bevel gear
3.Bevel gear locking nut
4.Drive bevel gear seat
5.Bolt
6.Bearing
7.Bearing pressing plate
8.Screw
9.Adjusting washer
10.Drive bevel gear
5-90
5.3.11 Bevel gear washer adjustment

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 1
be in specification.
Gear clearance
Install drive pinion gear and ring gear, then install
crankcase gasket;
2 5
Close crankcase with several bolts and install some
screws;
To lock drive pinion gear,using a clean screwdriver,
reach the hole of drive pinion gear seat through 3
speed sensor hole,then pry output driven gear out of
place in its axial direction; 059101
1.Screw driver
2.Sealing plug hole
3.Crankcase
Install gear backlash measurement tools and dial

gauge;
Rotate ring gear shaft from engagement to
2
engagement to measure gear backlash.
NOTE:Measure the gear backlash at 4 positions.
Rotate the shaft 90 each time.
If gear backlash is out of specification,make the

adjustment
by adjusting the thickness of ring shim.
Gear Backlash:0.1-0.2mm(0.004-0.008in)
Adjusting way
A
Clearance measured Adjusting method 1
＜0.1mm Add thicker 059102
0.1mm～0.2mm Suitable 1.Gear clearance measuring tool
(P/N: 0JWA-062000-922-001)
＞0.2mm Getting thin
2.Dial gauge
A.46mm(1.81 in)
5-91
Tooth Contact
After backlash adjustment is carried out,the tooth
contact must be checked.Pay attention to the 1
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;
Install ring gear;
Rotate the ring gear several turns in both directions;
Remove drive pinion gear and ring gear,then inspect
the the coated teeth of the drive pinion gear.The
tooth contact pattern should be as shown below;
059201
Pattern ① Contact at tooth top Incorrect 2

Pattern ②Contact at tooth middle Correct
Pattern ③ Contact at tooth root Incorrect
If gear tooth contact is found to be correct(pattern

2), continue the next step.
If gear tooth contact is found to be incorrect(pattern
1 and pattern 3),the shim thickness between the
drive pinion gear and ring gear must be changed and
the tooth contact re-checked until correct. 059202
NOTE:Clean the dye coated on the gear teeth after
the tooth contact adjustment is finished.
3
Adjustment Steps
Tooth Contact Adjustment

Pattern① Reduce washer thickness
Pattern③ Increase washer thickness
WARNING:Make sure to check the backlash

after the tooth contact has been
059203
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.
5-92
5.3.12 Shift Lever Assy Removal

Shifting sector gear removal
Remove shift lever cover screws;
Remove shift lever cover and gasket;
5
5
4
1 2 3
059301
1.Breathing pipe
2.Clamp
3.Bolt
4.Gear room cover
5.Gasket.
Remove driven shift lever assembly;

Remove drive shift lever assembly.
1
059302
1.Bolt
2.Gear driven sector gear
3.Gear dirve sector gear
5-93
Main Shaft,Driven Shaft Assembly,Shift
Drum,Shift Fork/Shaft Removal
Remove gearshift limit spring seat;

Remove limit spring and steel ball;
4 5 6
1 2 3
059401
1.Steel ball
2.Spring
3.Washer
4.Gear locking bolt
5.Washer
6.Gear locking sprint seat
Split crankcase(see CRANKCASE);

Remove gearshift driven shaft washer,driven lo range
gear; 1
Remove drive bevel gear
059402
1.Washer
2.Driven low gear assy
3.Drive bevel gear
5-94
Remove gearshift main shaft by shifting to low gear

range;
1
059501
1.Shifting main shaft
Remove gearshift driven shaft assy,shift drum,shift

forks,parking lock lever; 4
1 2
3
059502
1.Shift Drum
2.Shift Fork
3.Parking Lock Lever
4.Driven Shaft Assy
5-95
Reverse Intermediate Gear Removal
NOTE: If reverse intermediate gear and needle
bearing turn freely and smoothly,and clearance of 4 3
them is normal,no need to remove them.
Use retainer plier to remove the retainer and remove
the washer, intermetiate gear, needle bearing and
washer in order.
5 2 1
059601
1.Retainer
2.Washer
3.Reverse intermediate gear
4.Needle gear
5.Intermediate gear shaft
Bearing Removal in Crankcase

If necessary,heat crankcase up to 100 (212 ) before
bearing removal.
WARNING
Clean oil,outside and inside,from crankcase
1
before heating.
WARNING:Always support crankcase properly
when bearing is removed.Crankcase damages
may occur if this procedure is not performed
correctly.
To remove ball bearing in crankcase,use a blind hole
bearing puller. 2
Tool£ŗ
059602
Crankcase bearing removing tool 0800-011000-922-
1.Crankcase bearing removing tool
001
(P/N:0800-011000-922-001)
Bearing 5206 removing tool 0800-012000-922-001
2.Ball bearing 6303
5-96
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
-excessively worn ,scoured,or bent shift fork shaft 2
-rounded engagament dogs and slots
-excessively worn ,scoured parking lock lever
-worn shift fork engagement pins
1
-worn shift track on shift drum
-worn or scoured shift fork claw
5
-worn splines on shafts and gears
-excessively worn and scoured parking cam 059701
1.Bearing
Bearing
2.Inner ring
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
A
Check both shift forks for excessice wear.Check
shift fork claw for bending.
Measure shift fork claw thickness
Shift fork thickness（ LH,RH fork）

5.8mm～5.9mm
New
(0.228in～0.232in)
Service limit 5.7mm(0.224in) 059702
A.Shift fork thickness
5-97
Measure the fork pin diameter (LH, RH fork).
Shift fork pin diameter(Both)

A
7.9mm～7.95mm
New
(0.311in～0.313in)
059801
A.Shift fork 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
View
5-98
Inspect shift fork springs for damages.Replace if

necessary. 1 2
059901
1.Thin fork spring( Free length 114mm)
5
2.Thick fork spring( Free length 82mm)
Shift Drum
Inspect shift drum tracks for excessive wear and
1
other damages.
3
Inspect parking lock cam on shift drumfor excessive
wear and other damages.Replace if necessary.
Inspect limit washer for damages. Replace if
necessary.
2
059902
1.Shift drum
2.Parking cam
3.Limit washer
5-99
Parking Lock Lever
Check parking lock lever for cracks or other 1
damages.
0510001
Gearshift Main Shaft

Check gearshift main shaft for damages. 35mm
Check gear teeth of gearshift main shaft for pittings,
B
A
scuffing and excessive wear.Replace if necessary.

Measure main shaft neck diameter of two ends as
shown.If the meassurements are less than the
service limit,replace.
Gearshift Main Shaft Neck Diameter

Service Limit
0510002
MAG side 16.978mm(0.6684in) A.MAG side diameter
CVT side 29.97mm(1.178in) B.CVT side diameter(Smaller than 35mm)
5-100
Gearshift Driven Shaft Assy 5

Disassemble gearshift driven shaft assy as shown. 6
Check teeth of each gear for fittings,scuffing and 3 1
excessive wear.Check needle bearing and circlip for
6
wear and damages.Replace if necessary 2
3
10 3
11 4
7
8
9
6 5
12
0510101
1.Washer 17.5×32×1 7.Driven Hi Range Gear
2.Driven Lo Range Gear 8.Driven Shaft
3.Needle Bearing 9.Driven Output Gear
4.Washer 24.5×33.5×1 10.Reverse Driven Gear
5.Gearshift Sliding Bushing 11.Circlip 29
6.Circlip 29 12.Parking Lock Gear
Gears
NOTE:Gears must be replaced in a pair.Always
replace circlip after removal.
A
-driven shaft output gear for reverse gear shifting
-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.
Fork groove w idth 0510102
6.1mm～ 6.2mm
New
(0.240in～ 0.244in) A.Fork groove width
5-101
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 is the same.
Gear hole inner diameter

29mm～29.021mm
New
(1.1417in～1.1425in)
0510201
A.Gear hole inner diameter
Driven shaft
Check driven shaft for damages.
Check driven shaft for pittings,scouring and
excessive wear.Replace if necessary.
B
B
A
A
Measure driven shaft neck diameter,f it’s out of
specification,replace it.
D riven shaft
S ervice limit
A 16.978mm(0.6684in)
B 23.974mm(0.9439in) 0510202
View
Reverse Intermediate Gear
Check reverse intermediate gear for damages.
Measure the inner diameter.If it’s out of
specifiacation,replace it.
A
1
R e v e rs e In te rm e d ia te G e a r In n e r
D ia m e te r
2 9 .0 0 7 m m ～ 2 9 .0 2 8 m m
Ne w
(1 .1 4 2 0 in～ 1 .1 4 2 8 in)
S e rvice lim it 2 9 .0 3 2 m m (1 .1 4 3 0 in)
0510203
1.Reverse Intermediate Gear
A.Inner diameter
5-102
Reverse Intermediate Gear Shaft 1

Check reverse intermediate gear for damages.
Measure reverse intermediate gear shaft neck
diameter If it’s out of specification,replace it.
R e v e rs e In te rm e d ia te G e a r N e c k
D ia m e te r
A
2 4 .9 8 0 m m ～ 2 4 .9 9 3 m m
New
(0 .9 8 3 4 in～ 0 .9 8 4 in)
S e rvic e lim it 2 4 .9 7 4 m m (0 .9 8 3 2 in)
0510301
1.Reverse Intermediate Gear Shaft 5
A.Reverse Intermediate Gear Shaft Neck Diameter
3
Gearing sector assy
Inspect the shifting room cover to see scraches, cracks
or other damage. Inspect the breather to see if it get-
ting loose. And oil seal damage. Replace the part if
trouble inspected.
Tool:
Oil seal SD15 × 25 × 5 pressor
CF188-065002-923-001
Breather connector pressor
0JWA-065100-921-001
2 1
0510302
1.Gear room cover
2.Breather connector
3.Oil seal SD15 × 25 × 5
5-103
Check drive shift sector and driven shift sector for 2
cracks, deformation,wear and other damages.
Replace if necessary.
1
0510401
1.Drive Shift Lever
Assembly 2.Driven Shift Lever
Assembly procedure is the reverse of disassembly
procedure.Pay attention to the following details:
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.
WARNING:
Round edge
Once circlip is removed,it has been damaged.
facing the
Therefore,never use it for a second time.When
gear
installing a new circlip,do not open the circlip
too much. 0510402
After circlip installation is finished,make sure the View

circlip is in place.
When installing shift fork shaft,ensure shift forks and 7
shift fork springs are in correct locations as
illustrated. 6
5
4
3
2
1
0510403
1.Shift Fork Shaft 2.Circlip 12;
3.Left Shift Fork 4 Shift Fork Spring(thin)
5.Right Shift Fork 6.Shift Fork Spring(thick)
7 .Spring Seat
5-104
Installation
Crankcase installation procedure is the reverse to
removal installation procedure.However,pay attention
to the following details:
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 100 celcius (212
F) before removing ball bearing.
WARNING
Clean oil,inside and outside,from crankcase
before heating.
Put a new ball bearing in an icebox or equivalent 5
facility to chill for 10 minutes before installation.
Using sevice tool,install the ball bearings in left
crankcase and right crankcase.
WARNING:Always support crankcase properly

when installing ball bearings.
Perform the correct procedure when installing
a new oil seal
Tool:
Bearing 6203 pressing rod
152MI-060002-921-002
Bearing 3206A pressing rod
CF188-012100-921-004
3 1
Bearing 6303 pressor 1 2
CF188-011100-921-004
Bearing 6203 pressor
1P39MB-012001-921-002
4
Other Parts in Crankcase
5
Fit needle bearing onto reverse intermediate gear 0510501
shaft, 1.Washer
2.Needle bearing
NOTE Reverse intermediate gear collar faces
reverse intermediate gear shaft small end.
4.Retainer
5.Boss of the gear
5-105
NOTE:Press bearing no.2 before installing reverse
intermediate gear
2 1
3
0510601
2.Bearing
3.Left crankcase
Place parking lock lever in place in crankcase. 1

Engage shift fork assy with gearshift driven shaft
assy, then fit them in place in left crankcase.
2
NOTE:Do not install washer 17.5×32×1 and
reverse range gear into gearshift driven shaft assy.
3
0510602
1.Shift Fork Assy
2.Driven Shaft Assy
5-106
Install drive bevel gear assy then tighten the 4

retaining screws.
1
1
Note:The hole position should be like pic on the
right when install the drive bevel gear.
3 2
0510701 5
1.Bolt
2.Drive bevel gear
3.Bearing seat hole
Place parking lock lever in parking position,then 1

align shift drum tracks with shift forks and fit it in left
crankcase.Shift parking lock lever to parking
position, then align shift drum axial track with shift
fork pin and fit it in the left crankcase.
2
0510702
1.Shift Drum
2.Axial Track
5-107
Using an appropriate tool,shift to low range,then 1
install gearshift main shaft.
Install washer and low range gear. 3
Using an appropriate tool,shift to neutral range.
Turn main shaft,check if gears rotate freely and
smoothly.
NOTE:When installing rotational parts, pre-
lubricate the shaft necks with oil..
0510801
1.Washer 17.5 × 32 × 1
2.Lo Range Gear
3.Main Shaft
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
installa tion is completed.
0510802
1.Crankcase Gasket
5-108
Install driven shift sector assy and drive shift sector

assy.;
Torque driven shift sector screw to specified value;
1 1
NOTE:When installing driven shift lever assy and 2

drive shift lever assy,the marks on their teeth should
be aligned
4 1 3
5
0510901
1.Marks
2.Screw
3.Driven Shift Lever Assy
4.Drive Shift Lever Assy
Install shifting room cover gasket and shifting room

cover.
Install shifting room cover mounting bolt and tight up
the bolt in criss cross way.
Install other removed parts. 5
4
1 2 3
0510902
1.Breathing pipe
2.Clamp
3.Bolt
4.Shifting room cover
5.Shifting room cover gasket.
5-109
5.4 CVT system
5.4.1 Service tool, material and attach…………………………………………5-111
5.4.2 General……………………………………………………………………… 5-113
5.4.3 CVT cover……………………………………………………………………5-114
5.4.4 Drive pulley, Driven pulley,Belt…………………………………………5-115
5.4.5 CVT case assy………………………………………………………………5-125
5-110
5.4 CVT system
5.4.1 Service tool, material and attach
Service tool
Name P/N Page
Drive pulley removing tool 0JY0-050000-922-002 5-116

Driven pulley removing tool 0800-052000-922-002 5-120
Driven pulley seperating tool 0800-052000-922-003 5-124
CVT driven pulley locking wrench 0800-052000-922-001 5-116/124
CVT drive pulley wrench 0JY0-051000-922-001 5-115/124
5
Oil seal 32 × 55 × 10 pressor 0JY0-013103-921-001 5-126
Material
Name P/N Page
Engine oil 5-112/127
Cylinder locking glue 5-112
5-111
CVT
Cylinder lock-
ing glue
Oil
T1
T2
T1
T1
Counter
Counter
clockwise
clockwise
T4
T3
T5
T1 10N·m(89 lbf·in)
T3 60N·m(44 lbf·ft)
0511201
5-112
5.4 CVT system
5.4.2 General
NOTE: For a better understanding, the following

illustrations are taken with engine out of vehicle.To
perform the following instructions,it is unecessary
to remove engine.
During assembly/installation,use the torque values
and service products as in the exploded views.
Clean threads before applying a threadlocker.Refer
to LUBRICANTS AND SERVICE PRODUCTS at
the beginning of this manual for complete procedure.
5
WARNING
Torque wrench tightening specifications must
strictly be adhered to.Locking devices(e.g.:
locking tabs, elastic stop nuts,cotter pin,etc.)
must be replaced with new ones.
WARNING
Never touch CVT while engine is running.
Never drive 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 procedures detailed.
Note: Never use any type of impact wrench

at drive pulley removal and installation.
Note: The drive pulley on engine must be

turned by hand to make sure the pulleies
pre-tightened.
5-113
5.4.3 CVT cover
2
3 1
0511401
1.Screw
2.CVT Cover
3.CVT Case
CVT Cover Removal
Remove CVT cover screws;

Remove CVT cover comp.; 1
Remove gasket.
2
3
0511402
1.CVT Cover
2.Screw
3.Gasket
5-114
5.4 CVT system
CVT Cover Inspection

1
Inspect the CVT cover to see cracks or other damage.
If trouble inspected, replace the CVT cover.
Inspect CVT cover gaskets to see aging ot other
damage. If trouble inspected. Replace the gasket.
CVT Cover Installation

Reverse the removal procedure for CVT Cover
installation. 2
NOTE: Tighten bolts in criss-cross sequence; 5
0511501
1.CVT cover
2.CVT cover gasket
5.4.4 Drive pulley, Driven pulley,Belt

2
Removal
1
Remove CVT cover and gasket(Refer to CVT
Cover);
Remove drive pulley bolt(Counterclockwise)；
Tool:
Drive pulley locking wrench 0JY0--050000-922-001
3
0511502
1.Socket(18mm)
2.Drive pulley locking wrench
(P/N: 0JY0-050000-922-001)
3.Drive pulley bolt(Counterclockwise)
5-115
2
Remove main drive shaft nut.
To o l ：
CVT driven pulley locking nut 3
0800-052000-922-001
0511601
1.Socket(36mm)
2.CVT driven pulley locking nut
(P/N: 0800-052000-922-001)
3.Main driveshaft nut
Use drive pulley removing tool(0JY0-050000-922-002)

Remove the drive pulley.
Remove the drive and driven pulley, drive belt together.
Take out the belt.

1
NOTE: 0511602
If no printed arrow mark has been left on 1.Drive pulley removing tool
drive belt, remark the belt during removal to (P/N: 0JY0-050000-922-002)
avoid incorrect installation.
5-116
5.4 CVT system
1.Nut
1 2.Washer
3.Limit plate
2 4.Slider
3 5.Clutch shoe
4 6.Drive moving pulley
7.Drive pulley sprint
8.Adjusting washer
5 9.Drive belt
10.Drive moving pulley
11.Driven moving pulley
16 12.Retainer
6
13.Spring seat
5
14.Driven pulley sprint
15.Key
16.Driven stable pulley
7
15
9
10
11
14
13
12
0511701
5-117
DRIVE PULLEY
Drive Pulley Disassembly
Loose the nut up and remove the washer to seperate
the drive moving and stable pulley(See pic 0512001)
Remove locking plate and clutch shoe
Remove the slider from the locking plate.
Inspection
Clutch shoe inspection

Check clutch shoe for wear and other damages.
1 2 3
Replace all the clutch shoe if trouble inspected.
0511801
Note: Clutch shoes must be replace all of them. 1.Clutch shoe
2.Slider
Slider inspection 3.Locking plate
Check slider wear and other damages. Replace if
necesary.(Recommend: replace all 3 sliders in the
same time)
Adjusting washer thickness inspection
Use vernier calipers to measuere the adjusting washer

thickness. If out of service limit. Replace the washer
and adjust the thickness again
Adjusting washer thickness: 3.8mm～4mm,One

piece:1.90mm～2.00mm, 2 pcs usually.
0511802
Adjusting washer thickness measuring
Drive pulley moving and stable plate

inspection. 1
Inspect the drive surface trouble. If got wearing or
damaged. Replace the parts.
2
0511803
1.Drive surface on stable pulley
2.Drive surface on moving pulley
5-118
5.4 CVT system
Drive pulley assemble

Reverse the removal procedure for installation. The
washer must be locked in the position of the plate and 1
tight up in specific torque(Counterclockwise).
Tighten torque:130N·m
WARNING
The washer must be totally locked on the shaft. Or
the drive pulley will be damaged. Make sure the bal- 2
ance mark in one straight line. 3
5
0511901
1.Washer
2.Nut
3.Balance aligning mark
DRIVEN PULLEY
Disassembly
NOTE: 2
Before disassembly, mark on the spring
installation holes and cam feet to sliders
positions.
0511902
1.Cam and slider marks
2.Spring Installation Holes Marks
5-119
As the illustration shows, place driven pulley on the
special tool base.
Special tool: Driven pulley disassemble tool(0800-

052000-922-002) 1
0512001
1.Driven pulley disassemble tool

(P/N: 0800-052000-922-002)
2.Driven pulley
NOTE:Turn special tool handle to compress the cam

and spring.Using a circlip remover(a plier),remove
circlip.
2
3
4
0512002
1.Driven pulley disassemble tool

(P/N: 0800-052000-922-002)
2.Retainer caliper
3.Retainer
4.Driven pulley
5-120
5.4 CVT system
Slowly loosen tool handle to release the spring
tnesion and remove the special tool;
Remove cam;
Remove guide pin;
Remove spring and sliding sheave of driven pulley.
0512101
3 2 1
5
4
0512102
1.Cam
2.Guide Pin
3.Spring
4.Sliding Sheave of Driven Pulley
Driven Pulley Inspection 1

Driven Pulley Fixed Sheave Inspection
Check driven pulley faces for any abnormal

conditions, such as heavy wear or visible damage.
NOTE: Clean fixed sheave of driven pulley before

inspection.
NOTE:Driven pulley assembly is precisely

matched. If only fixed sheave or sliding sheave is
0512103
1.Drive Face of Fixed Sheave
replaced,the vibration may increase.It’s
recommended to replace both when necessary.
5-121
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 3 sliders on driven pulleyfor wear and

other damages.If the worn thickness is over the
1 1
measurement illustrated in the following figure,
replace all 3 sliders at the same time.
2 1
NOTE:Clean the sliding sheave before
inspection.
0512202
1.Slider
2.Sliding Sleeve
On the right picture A should be thicker than 1.5mm.
0512203
5-122
5.4 CVT system
Cam Inspection
2
Check spring cam sliding face for wear and other 2
damages. replace if necessary.
0512301
1.Cam
2.Sliding Face
5
Driven Pulley Spring Inspection
A
Check spring free length. If it is shorter than limit
length, replace it
Spring free limit length A: 219mm.
Driven Pulley Assembly 0512302

A.Spring free length
Reverse the disassembly procedure for driven pulley
assembly.
NOTE: Special tool is also required in driven pulley

assembly.
Drive belt
Inspect the belt to see oil dirt, cracks or other damage.
and use vernier caliper to see the belt width. 1
If any damage inspected tor the width out of service

limit, replace the belt.
Drive belt service limit: 32.2mm 2

Tool: Vernier caliper
0512303
Note: If oil dirt and grease govered on the belt. 1.Drive belt
The dirt and grease must be totally cleaned up. 2.Drive belt inner line
5-123
Drive/driven pulley and belt installation. 2 5 1
4
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 assemble with oil dirt.
Drive belt direction should be as same as removal.
3
0512401
1.Drive pulley
2.Driven pulley stable disc
3.Driven pulley slide disc
4.Drive belt
5.Driven pulley seperator
(P/N: 0800-052000-922-003)
Install the whole CVT together. Use special tool and

tight the bolts and nuts in special torque.
No te: Dri ve p u ll ey mo u n ti n g b o l t i s
counterclockwise. 1
Drive pulley bolt torque: 60N·m
Main drive shaft nut torque: 115N·m
Tool:
CVT driven pulley locking wrench
0800-052000-922-001
CVT drive pulley wrench
0JY0-050000-922-001
2
0512402
1.Drive pulley mounting bolt
2.Main drive shaft nut
5-124
5.4 CVT system
5.4.5 CVT case assy 2 2

1
CVT case removal
Note: Drain out the engine oil before removal.
3
Remove the CVT cover(See CVT cover)
Remove the drive/driven pulley and drive belt.(See
related chapter)
Remove CVT case mounting bolt and nut to remove
5 1 2 4
the CVT case assy.
0512501 5
1.Nut
Note: Before removing CVT case.Clean up the 2.Bolt M6 × 50( 9 pcs)
dirt on the crankshaft. When removing the case 3.Bolt M6 × 55( 2 pcs)
body. Do not damage the sealing surface and 4.Bolt M6 × 22( 2 pcs)
bearing. 5.CVT case
2 1
Take out the locking pin( or not)and CVT gasket(1),
CVT case gasket(2).
3
0512502
1.CVT gasket(1)
2.CVT gasket(2)
3.Locking pin
5-125
CVT CASE CLEANING
WARNING
Use eye proctetor to avoid eyes getting
hurt.
Use cleaning tool to clean CVT case.

2
Use compressed air to dry up CVT case.
CVT CASE ASSY INSPECTION

Inspect the CVT case to see cracks or other damage,
replace if necessary.
Inspect the oil seal, replace if damaged.
Tool: 3
Oil seal 32 × 55 × 10 pressor
0JY0-013103-921-001
1
0512601
1.CVT case
2.Slide bearing
3.Oil seal
Inspect the slide bearing to see scraches or other
damage. Replace if necessary.
1
Note: Measure the inner diameter of the slide
bearing and fit the CVT joint inner diameter.(See
crankshaft)If out of service limit, replace the parts.
A
2
Slide bearing innerdiameter
0512602
Service limit 32.100mm(1.2638in) 1.Lubricating hole
2.Slide bearing
A.Inner diameter
5-126
5.5 Engine lubrication system
CVT CASE INSTALLATION
Note:
1.Put the CVT case gasket flat enough, and use
new gasket.
2.CVT case gasket(2) is not symmetry, please
align the hole position.
3.Pre-lubricate the slide bearing by engine oil.
4.Tight the bolt and nut in criss-cross way.
5-127
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
5-128
5.5.1 Service tool, Material and view
Service tool
Name P/N Page
Pipe connector 0JWA-000000-871-001 5-134
Material
Name P/N Page
Engine oil 5-130/136
243 thread locker 5-130
5699 sealing glue 5-130
Washing liquid 5-140
5-129
Engine lubrication system
New Oil
T3
Oil Oil
T2
243
T4
thread T3
locker
T3
T1
New
New
T3
T1
5 69 9 Fl at s ur -
20N·m(15 lbf·ft)
T1 f a c e se a l i n g
T2 12N·m(107 lbf·in) glue
T3 1 0 N · m ( 8 9 l b f · i n )
T4 6 N · m ( 5 3 l b f · i n )
0513001
5-130
Engine oil distribution
1 1
2 12
10
9
8
5
3
7
6 11
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.CVT case bearing
4.Limit valve 8.Connecting rod bearing 12.Oil cooler
5-131
5.5.2 GENERAL
Gear box:
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
1
Torque wrench must be used when tightening.
Locking devices(e.g.: locking tabs, elastic stop
nuts,cotter pin,etc.)must be replaced with new
2
ones.
0513201
Oil dipstick line: 1.Upper 2.Lower
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 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 Crankcase:
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 OK. 1
Install the oil dipstick back.
2
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. 0513202
Oil dipstick line: 1.Upper 2.Lower
5-132
5.5.4 Engine Oil Replacement
Crankcase:
Ensure vehicle is on a level surface before working.
Replace engine oil and filter element at the same
time when engine is warm.
WARNING
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;
2
Unscrew oil dipstick,drain plug and discard the
5
gasket ring; 1
Wait sevearal minute. Allow oil to drain completely
from crankcase;
NOTE: 0513301
Oil condition gives information about the engine 1.Drain plug
condition.See TROUBLESHOOTING section. 2.Washer
Check the drained engine oil for engine shavings
and residue.Presence of debris indicates a failure
inside the engine.Check engine to correct the
proplem.
Clean the drain plug. If the sealing washer damaged.

Replace the washer and tight 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;
5-133
5.5.5 Gear Box Oil Inspection
Ensure the vehicle on flat surface.Start the engine

and run the engine for several minute.Stop theengine
and wait for several minute to makesure thegear oil
totally flew back to bottomUnscrewdipstickand wipe
the oil residue off,thenput dipstickin thehole.Don’t
screw in dipstick to read oil
level, just make dipstick threads contact thehole
surface;
Remove dipstick and read oil level; 1
Engine oil level must be between “upper” and “lower”
marks;
If oil level is below “lower”,refill. and inspect again 2
and again. Until OK.
Tight the oil dip stick back. 0513401
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 on flat surface before start working
WARNING
The engine oil can be very hot.Wait until
engine oil is warm.
Place a drain pan under the engine oil drain plug 1 2

area;
Clean the drain plug area;
Unscrew the drain plug.
Unscrew the dipstick
Wait for several minutes to make sure the oil is
0513402
totally drained out. 1.Drain plug
2.Sealing gasket
5-134
NOTE:
Oil condition gives information about the gear box
condition.See TROUBLESHOOTING section.
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 tight up the drain plug.
Drain plug tighten torque: 20N·m
5
Refill the gear case with 75W/90/GL5 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 no

leaking.
5-135
5.5.5 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

(0JWA-000000-871-001)and adapter hose.
The engine oil pressure should be within the

following values:
0513601
Oil pressure gauge
Oil pressure 1300r/min 6000r/min

Min 100kPa 350kPa
Normal 200kPa 580kPa
Max 400kPa 700kPa
If the engine oil is out of specifications,check the

points described in THROUBLESHOOTING section.
Remove engine oil pressure gauge and adapter
hose after tested
Reinstall the engine oil pressure switch.
0513602
Adapter Hose
(P/N:0JWA-000000-871-001)
NOTE:To remove adapter hose from engine oil
pressure gauge,use the service tool.
5-136
5.5.6 OIL FILTER ELEMENT
Removal
Remove oil filter cover screws;

Remove oil filter cover;
Remove o-ring;
Remove oil filter element.
1 2 3 4
5
0513701
1.Screw
2.Oil Filter Cover
3.O-ring
4.Oil Filter Element
Oil Filter Element Inspection
Check and clean the engine oil filter inlet and outlet
area for dirt and other contaminations.
1
2
0513702
1.Inlet bore from the oil pump to the oil pump
2.Outlet to the engine oil providing system
5-137
Oil Filter Element Installation
Install a NEW o-ring on oil filter cover;
Apply engine oil on o-ring and the end of filter; 1
Install the element into oil filter bore;
Install the oil filter cover on the engine.
Torque screws to 10N.m(89Ibf.in).
5.5.7 OIL PRESSURE LIMIT VALVE

Oil pressure limit valve is on engint right crankcase
2
(On CVT side).
0513801
1.Apply a light coating of oil here
2.Apply a light coating of oil here
The valve works when the oil pressure exceeds
450kPa(65PSI).
Removal
Remove limit valve screw and O-ring
Remove the ring and screw.

3 4
Inspection
Inspect the steel ball, O-ring, pressure limit bolt got 5

damaged or not, Replace the part if trouble
inspected.
Inspect the pressure limit valve spring free length. If

1 2
out of standard. Replace the spring.
0513802
S pring free length 1.Steel ball 4.Pressure limit valve
2.Limit valve sprint 5.Mark A
New 24.1mm
3.O-ring
S ervice limit 23mm
Installation
Note:
The bolt has mark A.
It is no need to do this if the pressure is normal
5-138
5.5.8 OIL PUMP
Oil pump is located on the engine MAG side(under

magneto cover).
0513901
1.Oil pump
5
Removal
Remove magneto cover and related parts(see

4 2
Magneto Cover Removal); 3 1
Remove magneto rotor(see Rotor Removal);
Remove circlip,oil pump gear,needle pin,thrust

washer in turn;
0513902
1.Circlip 2.Oil Pump Gear
3.Needle Pin 4.Thrust Washer
Remove oil pump cover screws and oil pump cover;

Remove pump shaft with inner rotor and outer rotor. 1
2
0513903
1.Screws 2.Oil Pump Cover
5-139
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
1.Oil Pump Bore 2.Outer Rotor
3.Oil Pump Shaft 4.Needle Pin
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 wearing too

much. Replace the inner rotor.
1
0514002
1.Pittings on the teeth
1
Using a feeler gauge,measure the clearance of inner 2
and outer rotors plus the clearance between outer
rotor and oil pump bore as shown.
If clearance between inner rotor and outer rotor A

exceeds the tolerance,replace the inner and outer
rotor. A
Ensure to also check oil pump cover,if damaged,
replace the oil pump cover.
0514003
1.Inner Rotor 2.Outer Rotor
A.Service Limit:0.25mm
5-140
If clearance between outer rotor and its bore in
crankcase exceeds the tolerance,replace outer rotor
assembly and/or crankcase.
Using a depth gauge,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.
0514101
5
Measurement A
Using a depth gauge,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
NOTE:No marks on inner and outer rotor.When

installating outer rotor,no secified direction for outer 1
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 0514103
(refer to Engine Oil Pressure above.)
1.Outer rotor
5-141
5.5.9 ENGINE OIL STRAINER 2
The engine oil strainer is located on the bottom of 3
left crankcase half.
Removal
1
Remove the bolt and covering nut. Use screwdriver
to remove the strainer cover and washer use caliper 4
to remove the strainer. 0514201
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 5
with compressed air.
WARNING
Always wear eye protector.Chemicals can
cause a rash break out and injure your eyes.
Strainer installation 4
Clean up the case and strainer side cover. Replace 3
the gasket into new one. Then reverse the removal 2
procedure to installation to install the strainer.
1
0514202
1.Strainer 4.Bolt
2.Strainer gasket 5.Plug
3.Strainer side cover
5.5.10 Oil Cooler
3 2
1
0514203
1.Oil cooler inlet pipe
2.Oil cooler outlet pipe
3.Oil cooler
5-142
Removal
Drain out the engine coolant. 4

Loose the 2 clamps on oil cooler water inlet/outlet
pipe. Then remove the water pipes on oil cooler. 7
Remove 2 bolts on oil cooler inlet pipe. Then remove
3
1 bolt on oil cooler out let pipe.
1
Note: Inspect the damage of bolt gasket. 6
2 5
Loose 2 oil cooler mounting bolt M10×20 remove
the oil cooler. 5
0514301
1.Clamp D25
Note: Drain out the engine oil left in the cooler 2.Oil cooler water inlet pipe
before removing the oil cooler water pipe. 3.Oil cooler water outlet pipe
4.Bolt
5.Oil cooler oil inlet pipe
6.Oil cooler oil outlet pipe
7.Bolt M10 × 20
Oil Cooler Inspection

4 3 2
Remove 4 bolts M6×18 to remove the oil cooler
from the bracket. Take out the O-ring 17×2.5 to
see if got damage or becoming harder. Remove the
parts if needs.
2 1
0514302
1.Oil cooler bracket
2.O-ring 17×2.5
3.Oil cooler
4.Bolt M6 × 18
5-143
Oil cooler inlet/outlet pipe inspection.
Inspect the oil cooler inlet/outlet pipe got damage or

leaking. If troule inspected. Replace the parts.
Oil cooler cleaning
Clean the oil cooler and bracket. Use compressed

air to dry the water way and oil way.
Oil cooler and accessories installation

MARK
Note: Follow the marks on the right pic to assemble
the water pipe. The marks on the water pipe must
be aligned with the boss on the pipe.
Bolt tighten torque: 40N·m

Bolt 10 × 20 tighten torque: 25N·m
Bolt 6 × 18 tighten torque: 10N·m
0514401
5-144
5.6 Engine start system

5.6.1 Service tool, material and view………………………………………………5-146
5.6.2 General …………………………………………………………………………5-148
5.6.3 Left 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
5-145
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
Left crankcase cover pressing tool 0800-014001-921-002 5-148
Crankshaft locking screw 0800-041000-922-001 5-151/153
Magneto rotor removing tool 0800-031000-922-001 5-151
Driver fixed spanner 0JY0-051000-922-001 5-153
Material
Name P/N Page
Oil 5-147/149/152
/155/156
Coolant 5-149
243 threak loker 5-/147/155
5699 sealing glue 5-147/149
5-146
View
T3
T1
Oil
5699 Sealing
glue
5
243 thread
locker
T4
T5
Oil
T2
243
thread Oil
locker
Oil
T5 16N·m(12 lbf·ft) T3
0514701
5-147
5.6.2 General
Always perform the electric tests before removing or

installing whatever component.
During assembly/installation,use the torque values
and service products as in the exploded view. Clean
threads before applying threadlocker.
WARNING
Torque wrench tightening specification must
strictly be adhered to.Locking devices.(e. g .:
locking tabs ,elastic stop nuts,cotter pins , etc.)
must be installed or replaced with new ones
where specified.If the efficiency of a locking
device is impaired ,it must be renewed.
5.6.3 Left crankcase cover
Removal
Drain engine oil (refer to LUBRICATION SYSTEM 1

6 2
and cooling system) and coolant;
Remove the fan cover and fan peller(See 5.3.7)
Remove water pipe clamp. 3
2 2
Remove the CPS
Remove left crankcase cover bolt.
8
Remove fan flange mounting bolt. 2 5
Remove fan flange 2 7
Remove left crankcase cover
4
Inspection and Cleaning 0514801

Inspect the left crankcase cover to see damage or
2.Mounting bolt
other damage and repair it if necessary.
3.CPS
4.Leaking pipe
Inspect the bearing 60/28 to see if it works well or 5.Cable Clamp
not. Replace if necessary. 6.Clamp
7.Fan flange mounting bolt
Tool: Left crankcase bearing 60/28 removing tool 8.Fan flange
(0800-014001-922-003)
Bearing 60/28 pressor(CF188-014001-921-001)
Left crankcase cover bearing pressing tool(0800-
014001-921-002)
5-148
NOTE:
Clean all metal components in a nonferrous metal
cleaner.Use suitable tool to remove gasket.
1
WARNING
Wear safety glasses and work in a well
ventilated area when working with strong
chemical products. Aslo wear suitable non-
absorbent gloves to protect your hands.
5
0514901
Installation
1.Cover 5699 falt sealing glue
For installation, reverse the removal procedure.Pay

attention to the following.
NOTE:
At installation replace magneto cover gasket.
Apply sealing compound on startor cable grommet
as shown on the right.
apply oil on bearing
Tightening sequence for screws on magneto cover is

3 15 5
as per following illustration.
13 9 7
Refill engine with recommended oil and coolant. 1 11 2
6 18
Note:
17
Do not use sharp things to touch the water pump 14
gear when installing the crankcase cover. Remove 8
the water pump cover, turn the water pump peller
to align the gear position. 10 4 12 16
0514902
Tighten order
5-149
5.6.4 Magneto stator
1
Removal
3
Remove left crankcase cover(See last chapter).
4
Remove screws securing holding strip;
Remove stator retaining screws then the stator.
0515001
1.Stator
2.Stator retaining Screws
3.Holding Strip
4.Holding Strip screws
Inspection
Check stator condition, if damaged replace it.
Check if stator wires are brittle ,hard or otherwise 1

damaged.
Stator Installation
1.Stator
For installation, reverse the removal procedure.
1
Note
The cables must be into its own position. When
installing magneto(Cable groove).
2
NOTE:
There is only one position for the stator(notch in the
magneto housing cover )
1.Cable pressor screw hole

2.Magneto stator direction
5-150
5.6.5 Magneto rotor
Removal
1 2
Remove left crankcase cover(See last chapter).
Remove the O-ring and gasket on crankshaft
0515101
1.O-ring
2.Gasket 5
1
Use special tool to remove the rotor 2
Tool: Magneto rotor removing tool(0800-031000-922-
001)
NOTE:
Use grease to magneto puller end prior to install
0515102
rotor puller in order to protect crankshaft. 1.Magneto rotor removing tool
Screw magneto puller bolt to remove rotor. (P/N: 0800-031000-922-001)
2.Grease position
Turn the bolt on the tool to remove the rotor.
0515103
1.Magneto rotor
2.Magneto rotor removing tool
(P/N: 0800-031000-922-001)
5-151
Inspection
Check inner side of rotor for scratches or other

damages.
Check keyway of rotor for wear or damages.
Check if trigger wheel teeth are bent or otherwise
damaged.
Check woodruff key and keyway on the crankshaft

for wear or damages. 1
0515201
Replace parts as necessary 1.Rotor with trigger wheel
Installation
3
For installation,reverse the removal procedure.
Pay attention to the following
Clean crankshaft taper and rotor with cleaner.
4
Oil sprag clutch in sprag clutch housing and install
sprag clutch gear. Slide rotor onto crankshaft.The
woodruff key and the keyway must be aligned.
2 1
0515202
1.Sprag Clutch
2.Sprag clutch housing
3.Sprag clutch gear
4.Apply engine oil here
5-152
5
Set the O-ring and washer on the crankshaft first.
6
Turn the driven gear clockwise to drive the dual gear
and starting duplicate gear. Make sure mechanism
has no jamming.
2 1
Install the crankcase cover LH(See this chapter
Crankcase cover LH).
4 3
0515301
Note: Make the breather shaft big chamfer side out 1.O-ring
when installing the shaft. 2.Washer
3.Driven gear
4.Dual gear
5
5.Starting duplicate gear
6.Breather shaft big chamfer side
Install the fan on the connecting flange. Then set the

fan assy on the crankshaft. Tight up the bolt on
1
specific torque.
3
1.Crankcase cover LH 0515302
2.Fan flange
3.Bolts
Tool:
Drive pulley locking wrench 0JY0-051000-922-001
Use special tool to lock the CVT drive pulley and
tight up the bolt to 60N.m
Warning: Magneto bolt torque must be follow the

standard or may cause the magneto cannot be
removed out.
1
0515303
1.Drive pulley locking wrench(0JY0-051000-922-
001)
5-153
5.6.6 Overriding clutch
2
Removal 3 4
Remove magneto cover (refer to MAGNETO
1
COVER above);
Remove rotor(refer to ROTOR above); 1

Remove the driven gear
Remove the clutch cover bolt and cover.
Note: If overriding clutch has no trouble. Do not 0515401

remove it. 1.Bolt
2.Rotor
3.Overriding clutch
4.Clutch cover
Inspection
Perform a functional test of the sprag clutch.To do

so ,rotate driven gear in sprag clutch.
Inspect sprag clutch and sprag clutch housing for

wear and damage.
NOTE: 1
Sprag clutch must look in counterclockwise
direction.
Sprag clutch,housing and gear must be replaced
at the same time ,if damaged.
0515402
Function test
1.Locking direction
5-154
Installation
For installation,reverse the removal procedure . 3
Pay attention to the following details.

Apply threadlocker on threads of sprag clutch 4
housing screws.
Install rotor then torque sprag clutch housing screws

to 30N m.
Apply engine oil on sprag clutch and inside sprag

clutch gear hole.
2 1
0515501 5
1.Overriding clutch
2.Clutch cover
3.Driven gear
4.Engine oil position
5.6.7 Driven gear

1
Removal
Remove rotor (refer to ROTOR above);
Pull driven gear from the rotor.
2
0515502
1.Rotor
2.Driven Gear
5-155
Inspection
Inspect gear,especially teeth and sprag clutch 3

collar,for wear and other damages.
Check needle bearing condition;

Replace Drive Gear if necessary.
Installation
1 2
NOTE:
Apply engine oil on needle bearing and collar of 0515601
drive gear. INSPECT
1.Teeth
2.Collar
3.Needle Bearing
5.6.8 Start gear assy

2 4
The starter gears are located on the engine MAG
side behind the magneto cover.
3
Removal
Remove left crankcase cover(See related

chapter).
1
Remove breather shaft, double gear and dual gear. 0515602
1.Dual gear
Inspection 2.Double gear
3.Starter gear
Inspect gears and shafts for wear and damage. 4.Breather shaft
Installation
Note: The breather big end must be face

outside and all the gears must be pre-
lubricated.
5-156
5.7 Intake system
5.7 Intake system

5.7.1 Servie material and view………………………………………………………5-158
5.7.2 General……………………………………………………………………………5-160
5.7.3 Air filter……………………………………………………………………………5-160
5.7.4 Air filter housing…………………………………………………………………5-161
5-157
5.7.1 Service material and view
Material
Name P/N Page
Air filter washer 5-160
5-158
5.7 Intake system
View
2 . 5 N ·m （2 2 l b f ·i n ）
2 . 5 N ·m （2 2 l b f ·i n ）
5
1 0 N ·m （8 9 l b f ·i n ）
0515901
5-159
5.7.2 General
During assembly/installation, use the torque

values and service materials as in the exploded
views.
1
WARNING
Torque wrench must be used when tightening. 3
Locking devices( e.g.:Locking tabs,elastic
stop nuts, cotter pin, etc.) must be replaced
with new ones.
Do not make less or modify any parts in air filter.
The engine managing system has adjusted accu-
rately or the engine will be power low or even
damaged. 2
5.7.3 AIR FILTER
Removal
Remove the seat pad and midium cover(See body 0516001
covering parts).
1 Clamp
Loose the locker to remove the air filter cover.
2.Locker
Loose the clamp to remove the air filter element. 3.Air filter cover
NOTE: If vehicle is used in dusty area,inspect

more frequently than specified in MAINTENANCE
CHART.
If liquid/deposits are found, squeeze and dry the

foam filter. Replace filter element if damaged.
WARNING: Do not start engine if liquid or deposit

are found. If there is oil in the air filter housing,
check engine oil level. Oil level may be too high. 1
Pour air filter cleaning solution or an equivalent
into a bucket. Put the foam filter in to soak. Do
2
not wash filter element. 3
While filter soaks, clean inside of air filter housing.
0516002
1.Clamp
2.Air filter
3.Air filter housing
5-160
5.7 Intake system
Rinse foam filter with warm water and let it dry
completely. 1
Blow low pressure compressed air on filter element
to clean it.
Air Filter Installation
Properly reinstall removed parts in the reverse

order of their removal.
5.7.4 AIR FILTER HOUSING

5
Removal 0516101
Body covering parts(See body covering part on 1.A clamp
chapter 2)
Use screw driver to loose the A clamp
Loose the clamp and clip to unplug the breather

pipe.
1
2
3
0516102
1.Clamp
2.Clip
3.Breather pipe
5-161
Remove 3 air filter housing mounting bolts.
Pull out air filter body.
0516201
1.Mounting bolt
Installation
Reverse the removal procedure for installation

1
Warning 0516202
1.Mounting bolt
Pull the throttle valve several times to
makesure it is normal.
0516203
1.Mounting bolt
5-162
6 Engine,transmission and shifting machenism
Maintenance information…………………6-1 Shift rod……………………………………6-7
Engine removal……………………………6-1 Safety belt…………………………………6-8
Muffler assy ……………………………… 6-4
Maintenance Information
Pre-WARNING
·When removing and installing the engine. Use the jack to hold the vehicle body. Becareful not to damage
the frame, Engine body, bolt and cable.
·When the engine removing and installing, Protect the frame to avoid be damaged.
·The items below can without engine removal.
-Oil pump
-Throttle body and filter. 6
-Cylinder head cover, Cylinder head, Cylinder body, Camshaft.
-CVT cover and CVT system.
-Left side cover, AC magneto, water pump
-Piston, piston ring, piston pin
·The working below needs to remove the engine.
-Crankshaft.
Tighten torque
Front engine mounting bolt GB5789 M12 × 1.25 × 190 (50～60)N·m
Engine rear left mounting bolt GB5789 M10 × 1.25 × 100 (40～50)N·m
Engine rear right mounting bolt GB5789 M10 × 1.25 × 130 (40～50)N·m
Engine removal
Remove body covering part(→Vehicle body and muf-
fler on chapter 2)
Remove the filter(→Intake system)
Remove the throttle valve(→Electrical system) Drain
out the engine coolant.（see 4 Cooling system）
Drain out the engine oil（see 4 Cooling system）
11 22
1. Water Drain bolt 060101

2. Oil drain bolt
6-1
Remove the spark plug cap from front cylinder.
11
1.Front cylinder spark plug cap 060201
Remove the spark plug cap from rear cylinder.

6
22
2.Rear cylinder spark plug cap 060202

Remove the positive pole cap on startmotor.
Loose up the nut and remove the positive
line 3.
33
3.Start motor positive line 060203
Remove the bolt to remove the negative line

on engine 4.
44
060204
4.Engine negative line
6-2
Remove 4 front driveshaft mounting bolts 1.
Seperate the front driveshaft from the engine.
1
1
1.Bolt 060301
Remove 4 rear driveshaft mounting bolt 1.

Seperate the rear driveshaft from the engine.
11
11
1.Bolt 060302
Remove CVT cooling pipe clamp 2.

Remove CVT cooling pipes. 22 22
2. Clamp 060303 060304
Remove fan cooling pipe clamp 2.

Remove fan cooling pipe.
22
060305
6-3
Muffler assy
Muffler assy removal
Remove 2 bolt no. 1.
Remove bolt no. 2. 33
Remoge muffler no.3
22
11
1.Bolt （and 2 spring) 060401
2.Bolt (GB/T5789 M8x40)
3. Muffler
6
44
Center Exhaust Pipe Removal

Remove muffler(→5-5).
Remove strap no. 4. 55
Remove 2 Cap Nut no. 6.(see 060503)
Remove Center exhaust pipe no. 5 4.Strap 060402
5.Center exhaust pipe
Front Exhaust Pipe Removal

Remove muffler(→5-5).
Remove 2 Cap Nut no. 6.(see 060504)
Remove front exhaust pipe no. 7.(see 060504)
66 66 77
6.Cap Nut 060403 7.Front exhaust pipe 060404
6-4
Remove rear rack
Remove
Remove front and rear wheel
fender. Remove left and rear deco
plate assy Remove the grille
Remove the seat
Remove the anticollition plates
Remove the deco side plates on
cargo box Remove the rear plate
Remove rear upper plate
Remove the connecting plates
Remove the repairing cover
Remove rear cargo box
6-5
Remove shifting rocker arm mounting bolt 1
Seperate the shifting rocker arm from the engine.
11
1.Shifting rocker arm 060601

mounting bolt.
Remove the front enging mounting bolt 2.

6
22
2. Engine front mounting bolt. 060602
Remove the engine rear mounting bolts 3 on LH and

RH.
33 3
Remove the engine
3. Engine rear mounting bolt. 060603
Engine installation
Put the engine into the vehicle and install the engine mounting bolts and nuts on front and rear side.
Use clamp to install the inlet and outlet water pipe and oil pipe on the engine. Tight up the engine start
positive pole and negative pole.
Connect all the electrical connectors. Install the CVT cooling pipes.Install the spark plug cap. Install the
shifting rocker arm on the engine. Install the air filter, throttle valve and all the removed parts.
6-6
Shift rod assy
Removal 11
Remove the shift cover
1
Remove the shift handle assy
Remove the midium over
Removing shift rocker arm 33 22
Remove the mounting bolt 2 between vehile

body and shift rod to remove the shifting rod. 060701
1.Shifting rod 2.Bolt 3.Shifting rod rocker
arm bolt.
Installation
Reverse the removal procedure for
installation. Inspect the vehicle smoothness
after install the shift rod assy. If not smooth
enough. Adjust the shifting pushing rod
length to see each gear can be accurate
positioned.
6-7
Safety belt
Removal
Remove the Bolt no.1 and Nut no.2
Remove the safty belt
1 2
Installation
1.Bolt 060801 060802
2.Nut
1.Bolt 060803
Safety belt engaged

TO lock:adjust the safety belt
tinghtly against your body and
raise or move the lap belt upward.
TO unlock:place safety belt as

shown and push down on the lap 1
belt where indecated.
caution
To release the safety belt,push on
the red button on the safety belt
buckle.
1.Slide locking tab 060804
6-8
7 Electrical system
7 Electrical system
7.1 Charging system……………………………………………………7-2
7.2 Start system …………………………………………………………7-4
7.3 EFI system……………………………………………………………7-8
7.3.1 EFI structure……………………………………………………7-8
7.3.2 EFI system maintenance pre-WARNING ……………………7-9
7.3.3 Tools……………………………………………………………7-10
7.3.4 EFI part function and maintenance………………………7-12
ECU……………………………………………………………7-12
Throttle…………………………………………………………7-13
Intake pressure sensor………………………………………7-15
Intake temp sensor………………………………………… 7-16
Water temo sensor………………………………………… 7-17
7
Oxygen sensor……………………………………………… 7-18
CPS……………………………………………………………7-20
Mileage sensor……………………………………………… 7-21
Gear position sensor…………………………………………7-23
Fuel pump……………………………………………………7-24
Fuel injector………………………………………………… 7-25
Idle step motor………………………………………………7-26
Ignition coil……………………………………………………7-27
7.3.5 EFI system self diagnose …………………………………7-29
Trouble indicator(MIL) ………………………………………7-29
PDA……………………………………………………………7-30
7.4 Troube shooting…………………………………………………7-32
Starting wiring……………………………………………………Attach 1
EFI diagram………………………………………………………Attach 2
Wiring diagram……………………………………………………Attach 3
7-1
7.1 Charging system
Charging system wiring.
Fuse
Voltage stabler
Battery
Equipment
Magneto
Rectifier
070201
Magneto coil resistance

● Measure the magneto stator coil resistance.
● If the resistance is not in standard. Replace a new
stator coil.
● Inspect the stator coil is insulated to stator center.
Set the AVO meter to 1 × 10 Ω
Magneto stator resistance:

0.5 Ω～1.5 Ω （Y-Y）
Insulating resistance:
∞Ω （Y-Ground）
070202
Resistance measuring
Magneto empty features

● Start the engine and running at 5000r/min
Use AVO meter to measure the magneto out put
voltage.
● If the voltage is lower than standard. Replace a
new magneto.
Set the AVO meter to AC voltage mode.

Magneto empty load voltage：
070203
Higher then 200V at 5000r/min(AC)
Voltage measuring
7-2
7 Electrical system
Rectifier
070301 7
● Use AVO meter to measure the connector’s
●After engine running and at the state of battery full
resistance. If one of datas is not in standard. Re-
charged,if the voltage between positive and negative
place the new rectifier. terminal exceeds 15V or is lower 12V, replace with a
Set the meter to the diode mode new MAG.
Note
If multimeter reads below 1.4V when
probes unconnected,replace its battery.
070302
7-3
7.2 STARTING SYSTEM
Starting Circuit Diagram(See attach 1)

Start motor
1 3
2
5
4
6
4
9
7
8 11
10
070401
1.Outer cap 2.Brush bracket 3.Brush spring 4.O-ring 5.Brush connector 6.Start motor can
7.Brush 8.Armature 9.Washer 10.Inner side cap 11.O-ring
Brush
●Check brush for damages,cracks or unsmooth
●If any damages,replace with a new brush.
070402
7-4
7 Electrical system
Commutator
●Inspect the commutator to see get burnt or other
abnormal damaged or wearing.
●If any damages,replace with a new amature
● If commutator got color changed. Smooth it by
sand paper and clean up by a piece of dry clean cloth.
070501
●If wearing too much. Cut come piece of insulator
to make sure the distance is in d standard.
d ≥ 1.5mm
ARMATURE
Use a multimeter to check the armature coil
7
continuity and the one 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.
070502
OIL SEAL
Check for damages or leaks.
If damages or leaks,replace with a new starter
motor.
070503
7-5
STARTER RELAY
● Put DC12V 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 DC12V is removed,no continuity remains
between contacts.
● If both above 2 items are ok,it indicates the replay
is ok. Turn mulitimeter to DIODE.
WARNING:The voltage loaded between 070601

terminals can not exceed 2 mins,otherwise,
starter relay may overheat or burn.
● Use AVO meter to measure the start relay coil

resistance.
If the resistance is out of standard, replace into a new
one.
●Turn multimeter to 1X10Ω
Start auxilary relay resiatance：3 Ω～

5Ω
070602
7-6
7 Electrical system
Start auxilary relay, fuel pump relay
●Put 12V between auxiliary starter relay positive and A

negative terminal;use multimeter to cheack the conti-
nuity between A and B.
（Turn multimeter to DIODE.）
●If multimeter clicks,it indicates there is continuity
between A and B.
●If 12V is removed,no continuity remains between
contacts.
●If both above 2 items are ok,it indicates the replay B
is ok.
●Turn multimeter to 1×100Ω to measure the re- Ground
lay resistance.
Auxiliary starter relay resistance: 90Ω～100Ω
NOTE:At the back of auxiliary starter relay, Positive pole

parallel to diode, it’s the relay coil positive terminal.
ENGINE STARTING NOTE

070701 7
● Poperly 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 bolck
or leaks.
If blocked, clean up to makesure the fuel line OK.
If leaking, connect the leaking piece again to make
sure no leaking.
●Test fuel presure with fuel pressure gauge.
Pressure in fuel pump outlet ：
3.3bar± 0.3bar
● Place the transmission in Neutral.
● Check EFI with PDA for faut;if there is,eliminate
the trouble according to DTC (Diagnostic Trouble Code)
●Close the throttle and turn the engine stop switch
to “RUN”,then push starter switch to run the engine.
●After starting,warm up until idle speed is stable and Fuel gauge
check it.
070702
Idle Speed ：1300r/min ± 130r/min；
NOTE:If idle speed is unstable or too high,shut off

the engine,and then start it.
7-7
7.3 EFI system
7.3.1 EFI structure
Ignition coil
Oxygen sensor
Intake temp sensor
ECU
Water temp sensor Throttle valve

Injector
TPS
Fuel
Idle control valve pump
CPS
Air filter
The EFI system has 3 parts 070801

(1)Sensors: (2)ECU:
Change all the physical quantity into electrical Electric controlling unit. The center of the EFI
signal and send the signal to control unit. They are system. It analyze and calculate all the information
eyes and ears of the ECU. It includeds the sensors from each sensors and send orders to actuators to
below: make sure the engine can running in the best situation.
●Intake pressure sensor(Load information) (3)Actuator:
●Intake temp sensor(Air density) Act as the ECU ordered. The actuator is the hand
●TPS(Load,load range and acceleration) and foot or the EFI system. It mainly includes:
●CPS(Crankshaft position and phase) ●Fuel pump (Send high pressure fuel)
●Water temp sensor (Coolant temp.) ● Injector (Inject fuel and let the fuel automized
●Gear position sensorGear position) better)
●Mileage sensor (Out RPM signal) ●Ignition coil (Give the energy to spark plug)
●Oxygen sensor ( λ>1 or <1 information) ● Idle control valve(Give idle air intake）
●4WD locking switch (4WD locking information)
●Overriding switch (With out speed limit sign)
7-8
7 Electrical system
7.3.2 EFI maintenance pre-cautions

● Please use CFMO TO approv ed part s t o ●If possible,don’t do the spark test.If spark test
maintenance. Or the EFI system may running is done unavoidably,try to complete the test as soon
unstable. as possible.Besides,don’t open the throttle,otherwise,
a large quantity of unburnt fuel would enter muffler,
●Do not disassembe the EFI parts when repairing.
causing the catalytic converter damage.
●EFI parts must be brought gently.
●Idle speed is controlled by ECU,so it’s unadjustable.
●When connect or disconnect the connectors. The
The throttle limiter screw has been adjusted by manu-
ignition switch must be off or the EFI parts maybe
facturer before sale,therefore,it’s not recommended to
damaged.
adjust it by the user.
●Do not running the fuel pump when removing the
fuel pump. It may cause the spark and finally cause ● Do not done wrong connection when connecting
the battery. Or the electric parts may be damaged.
the fire.
● Fuel pump is not allow to running in water or dry This vehicle use negative pole as a ground wire.
situation for testing. Or the life period maybe getting ●Do not remove the battery cable when running the
short.And also the fuel pump line should not be op- engine.
posite connecting. ●Remove the battery and ECU before welding. 7
● EFI system is in high pressure(About 330kPa). ● Do not use wire-broken way to test the electric
All the fuel pipes are using high pressure pipe. The signal.
fuel pressure still high even though the engine is not ●Use safety way to treat the trash after maintenance.
on running. So do not removing fuel pipe rashly.
When the fuel line needs to be repaired,release the
fuel pressure as follow shows:
Remove fuel pump relay,start the engine and

al l o w i t to i d l e u n t i l th e en g i n e s tal l s
automatically.
Fuel line removal and fuel filter replace ment should

be practiced by a proffessional person in a well-venti-
lated place.
7-9
7.3.3 TOOLS
Tool Name:PDA
Function:
Read/clear EFI system trouble codes,observe
datastream.
PDA
Tool Name:Digital Multimeter(AVO meter)
Function:
measure voltage, current and resistance
and other parameters in EFI system.
AVO meter
Tool Name:Vaccum Gauge
Function:
Check the manifold for air pressure.
Vaccum gauge
071001
7-10
7 Electrical system
Tool name:Timing Light
Function:
This light is used to check engine ignition timing.
Timing light
Tool name: Compression Tester
Function
This tester is used to check cylinder compression,
so as to determine if the rings or valves are bad and
leaking pressure. 7
Compression tester
Tool Name: Fuel Pressure Gauge
Function
This gauge is used to test the fuel pressure,so as to
check fuel pump and fuel pressure regulator working
conditions.
Fuel pressure gauge
Tool Name:Fuel Injector Analyser
Function:
This analyser is used to clean and analyse fuel
injectors.
Fuel injector analyser
071101
7-11
7.3.4 EFI COMPONENTS AND FUNCTION
(1)ECU
The brain of the EFI system.It analyze and pro-
cess all the informations from sensors.And give the
result as an order to actuator to let the engine running
on the best situation.
ECU pin function:

ECU 071201
1(Q1)、None
2(P1)、Oxygen sensor heating 1
3(Q2)、Ignition coil 1
4(P2)、Oxygen sensor heating 2
5(Q3)、Ignition ground
6(P3)、None
7(Q4)、Ignition coil 2
8(P4)、Uncontinously power
9(O1)、Engine RPM out put
10(N1)、4 WD lock switch
11(M1)、None
12(L1)、Reverse switch
13(K1)、None
14(J1)、Neutral switch
15(H1)、Diagnose K line
16(G1)、Continously power
17(F1)、Ignition switch
18(E1)、5V power 2
19(D1)、5V power 1
20(C1)、MIL indicator
21(B1)、Step motor position B
22(A1)、Step motor position A
23(O2)、None
24(N2)、Breaking switch
25(M2)、Intake temo sensor
26(L2)、Throttle position sensor
27(K2)、Belt switch
28(J2)、P switch
29(H2)、Oxygen sensor 2
30(G2)、None
31(F2)、None
32(E2)、Main relay
33(D2)、Can H
34(C2)、Can L
ECU Pin position 071202
7-12
7 Electrical system
35(B2)、Step motor position C 52(N4)、Start auxilary relay
36(A2)、Step motor position D 53(M4)、None
37(O3)、None 54(L4)、Sensor ground 3
38(N3)、None 55(K4)、None
39(M3)、Sensor ground 1 56(J4)、None
40(L3)、Sensor ground 2 57(H4)、Vehicle speed
41(K3)、Engine coolant temp sensor 58(G4)、None
42(J3)、Overriding switch 59(F4)、Intake pressure sensor
43(H3)、Ground 60(E4)、Fuel pump relay
44(G3)、None 61(D4)、None
45(F3)、Oxygen sensor 1 62(C4)、Cooling fan sensor
46(E3)、Engine RPM sensor B 63(B4)、None
47(D3)、Engine RPM sensor A 64(A4)、None
48(C3)、Power ground
49(B3)、Injector 2（第 2 缸）
50(A3)、Injector 1（第 1 缸）
51(O4)、Uncontinously power
Limit data
Item
Data
Unit
7
Min Standard Max
Battery voltage Running 9.0 14.0±0.1 16.0 V
Function limit 6.0～9.0 16.0～18.0 V
Battery hold limit 26.0V For diagnose 5 min
Working temp -40 70 ℃

Storage temp -40 90 ℃
● It’s not allowed to apply a heavy load on ECU hous-
ing
● Always handle ECU gentlely.Never drop it,especially
on a hard surface
(2)THROTTLE BODY ASSEMBLY

Connected between air filter and
engine.When throttle lever is applied,
the valve butterfly in throttle body would
spin at a certain angle.Tps can monitor
the position of valve butterfly and send
the signal to ECU.
071301
7-13
3 2 1
Pin function：
1.Ground
2.To 5V power
3.Output voltage
Position sensor 071401
TPS Circuit
TPS
ECU
071402
Idle speed limiter screw is not allowed to

adjust.
● Idle speed is regulated by ECU.It is not recom-
mend to adjust the idle speed by human.
Idle Speed screw
071403
7-14
7 Electrical system
(3)Intake pressure sensor

Measure the intake manifold pressure. Send the load information to ECU.
4 3 2 1
Pin function
1.Ground
3.To 5V power Intake
4.Voltage output pressure
sensor
071501
Intake pressure sensor circuit
Intake pressure
ECU sensor
071502
The right figure illustrates the allowed installation angle to avoid condensated water built up in T-MAP
sensor, causing pressure sensitive elements damage.
071503
7-15
The diagram below is pressure and output voltage relationship function
Testing pressure range:10kPa～115kPa
071601
(4)Intake temp sensor

4 3 2 1
This sensor is an NTC thermo
resistance. The resistance is getting higher
with intake air temperature, but not in lin-
ear relationship.The temp sensor and pres-
sure sensor are packaged together.
071602
Intake temp sensor
Sensor circuit
ECU
Intake temp
sensor
071603
7-16
7 Electrical system
The following chart explains resistance-temperature relation.
7
Temp Resis
071701
(5)Water temp sensor
This sensor is an NTC thermo resistance. The
resistance is getting higher with coolant temperature,
but not in linear relationship. The data goes two ways.
One for the ECU to see the engine overheat. The other
is for dashboard to measure the water temp.
A and C is one group. Give water temp signal to

ECU.
071702
B and screws are for the signal to the dashboard. Water temp sensor
Water temp sensor circuit
Dashboard
ECU
071703
7-17
The right chart explains pin B and threaded D a s h b o a r d c h a n n e l r e s i s ta n c e （ B -
Body）
portioncoolant temperature relation.
Tem p（℃ ） R e s is ta n c e （ Ω ）
45 2 6 5 .0 ～ 3 2 3 .0
80 7 4 .6 ～ 9 0 .6
115 2 5 .7 ～ 3 1 .7
The right chart explains pin A,C-coolant tempera- ECU channel resistance（A-C）
ture relation. The siganl is for ECU. Temp（℃） Resistance（Ω）
-25 38583
0 9399
25 2795
80 334
115 115.7
(6)Oxygen sensor
This sensor is used in closed-loop feedback-
controlled fuel injection to improve the air-to-fuel ra-
tio accuracy and control the emission.
It’s located in the exhaust stream to measure the
amount of oxygen in exhaust and send the signal to
ECU,which can revise the fuel injector output ,so as
to reduce the amounts of both unburnt fuel and ox-
ides of nitrogen entering the atmosphere.
Pins and Function

1.Heating positive pole(W)
2.Heating negative pole(W)
3.Signal negative pole(Grey)
4.Signal positive pole(B) 071801
Oxygen sensor
7-18
7 Electrical system
Oxygen sensor circuit
Main relay
ECU
071901
7
The following table explains the oxygen sensor working parameters.
Item New After 500h test

Exhaust temp 350℃ 850℃ 350℃ 850℃
λ=0.97（CO=1%）Sensor
840±70 710±70 840±80 710±70
voltege（mV）
λ=1.10时
20±50 55±30 20±50 40±40
Sensor voltege（mV）
Sensor resistance（kΩ） ≤1.0 ≤0.1 ≤1.5 ≤0.3
Sensing time（ms）
≤150 ≤150 ≤300 ≤200
（600mV~300mV）
Sensing time（ms）
≤150 ≤150 ≤300 ≤200
（300mV~600mV）
7-19
(7)CPS
Detects the rate at which the crankshaft is spin-
ning and provides the signal for ECU to determine ig-
nition and fuel injection.
A B
(+) (-)
072001
CPS circuit
ECU
072002
CPS Resistance test:
● Set the AVO meter at 1 × 2k Ω；

CPS resistance :95 0 Ω± 50 Ω（20℃）
●If the CPS resistance reading is out of specifi cat-
ion above,replace. AC Magneto
CPS Resistance
072003
7-20
7 Electrical system
Test CPS Peak Voltage

●Connect multimeter and peak voltage adapter as
CPS Peak Voltage Tester
right wiring diagram illustrates;
+ Pin:Green Lead
- Pin:Blue Lead
NOTE:
AC Magneto
When using peak voltage adapter,refer to some
instructions.
CPS Peak Voltage
●Set the AVO meter at AC V position.
● Place the transmission in N and turn the ignition
072101
switch to ”ON”;
●Push starter switch and allow the engine to run for
seconds,then test CPS peak voltage;
●Repeat above procedure and get the highest CPS
peak voltage;
7
CPS peak voltage：≥ 3V（200r/min）
● If the CPS peak voltage reading is out of above
specification,replace.
(8)Mileage sensor
This sensor is used to detect the rotating 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 (>80% input power voltage)
3.Power+DC12V
072102
Mileage sensor
7-21
+12V Power
The right figure refers to speed sensor wir- G

ing
Hall effect
Mileage sensor
072201
Mileage sensor test
●Ground pin 1and connect pin 3 with +12V power.

(See pic 0521201).
●Fix a gear 2.5mm away from a speed sensor as
the right figure illustrates;
●Turn multimeter to DC V range;
●Slowly turn the gear and measure the voltage be-
tween pin 2 and pin 3 to determine that if the reading
varies from 0V~12V;
●If the reading doesn’t vary,that indicates the sen-
sor is defective and needs to be replaced.
Gear
072202
7-22
7 Electrical system
(9)GEAR POSITION SENSOR

This sensor is used to provide the gear position
signal for meter display.
Pin function：
Yellow/Blue-L (Low Gear)
Orange/Blue-H(High Gear)
Yellow/Black-P(Park Gear)
White/Yellow-N(Neutral)
Sky Blue/White-R (Reverse Gear)
●When each pin at a certain gear position,there is

continuity between this pin and engine.Otherwise,no
continuity.
7
072301
Gear Position Sensor
WARNING when driving in reverse
●When driving in reverse,gear position sensor sends

the reverse signal to ECU and meter.ECU would limit
the vehicle speed in response to the reverse signal.
7-23
(10) FUEL PUMP ASSEMBLY
This fuel pump assembly includes fuel pump,plas-
tic support,preliminary filter,fine filter and pressure
regulator.It suppies fuel for engine under a certain pres-
sure and flow.
Pins and Function:
1.Blue(G)
2.Red(To fuel pump relay out out)
Parameters:
Pressure regulator opening pressure ：
3.3bar±0.3bar
Flow：Higher than 60L/h
●This fuel pump is located in fuel tank;
●Don’t operate the fuel pump in dry condition in or-
der to prevent damage.
●Always handle the fuel pump gently.Never drop the
fuel pump,especially on a hard surface.Such a shock
to pump can damage it. 072401
Fuel Pump Assembly
Fuel Pump Wiring

ECU
●Battery supplies power for fuel pump assembly via
fuel pump relay,which connects the fuel pump circuit
only with the engine started.
Fuel Pressure Test

：
● Connect the fuel pressure gauge with fuel outlet
Main relay 87
and tighten the joint with a clamp to prevent fuel leaks;
Power
●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 pres-
sure should be in specification,otherwise replace it;
●After the engine stops running,0.25MPa fuel
pressue should be kept for more than 5minutes,
otherwise replace the fuel pump;
Fuel pump relay
072402
7-24
7 Electrical system
Pressure Relief in Fuel System：

To injector cap
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:
“＋”S i g n
Remove fuel pump relay.Start the engine and allow
it to idle until the engine stops automatically.
(11)Injector
To injector seat
One end of fuel injector mounts into fuel injector
seat, and the other end attaches to the injector cap, 072501
which connects with a fuel line.Fuel injector is con- Injector
trolled by ECU to inject fuel at stated time into the 7
engine. This injector nozzle is a 4-hole style.Don’t turn
injector after the joint between injector and injector
cap is installed.
Pins and Function:
● Connector with the mark”+”:connected with fuel
pump relay output terminal.Connector without mark:
connected with ECU pin 14.
Fuel Injector Resistance ：1 2 Ω± 1 Ω

（20℃）
Fuel Injector Circuit Main relay87
Fuel Injector Installation

●Install fuel injector manually.Never knock fuel in-
jector with a hammer.
●When removing and installing fuel injector,the orings
on both ends must be replaced;
●Perform pressure relief before fuel injector removal
if necessary;
● Test the fuel injector sealing after installation to
ensure no leaks. Injector 2 Injector 1
072502
7-25
(12)Idle step motor
Used to control the air flow of by-pass.The ECU calculates the engine load and controLs the step motor
through electrical pulse durationand frequencyfrequency(commonly known as duty ratio).Step motor allows
diffrent air flows passed through under different pressure diffrences.So the ECU adjust the idle to make sure the
engine working in high efficiency.
TPS Step motor
To air
filter
To intake
manifold
072601
Pin function：
1.Pin A:IACBLO-ECU J1-13;
2.Pin B:IACBHI-ECU J1-12;
3.Pin C:IACALO-ECU J1-11;
4.Pin D:IACAHI/IAV-ECU J1-1;
Idle Air Control Valve Circuit:
Idle step motor
072602
7-26
7 Electrical system
Idle Air Control Valve Parameters

D ata
Item U nit
Min S tandard Ma x
V oltage 13.5 V
+20℃ R esistance 16 Ω
C urren t 0.8 5 A
Frequency 30 Hz
W ave w iden ess 8 ms
P ressure
3
diffenen ce=700mbar 5.00 m /h
at duty re tio =100%
(13)IGNITION COIL
Ignition coil transforms the low voltage of primary
coil to high voltage of secondary coil needed to spark 7
the spark plug and ignite the mixture of air and fuel in
cylinder
Ignition coil 072701
Pins and Function:

1.Ignition coil (-) of cylinder 1 connected with pin 1,
ECU Q2;
2.Ignition coil (+) of cylinder 1 connected with main
relay battery(+);；
3.Ignition coil (-) of cylinder 2 connected with pin 10,To main relay 87
ECU Q4;
4.Ignition coil (+) of cylinder 2 connected with main
relay battery(+);
Ignition Coil Circuit
Ignition coil 2 Ignition coil1
072702
7-27
Secondary Ignition Voltage Test
●Connect the engine according to EFI wiring diagram;
●Connect the peak voltage tester according to the Peak voltage tester
right diagram;
●Start the engine;
●Secondary ignition voltage should be >15000V.
Battery
Spark plug
072801
Ignition coil specification

D a ta U n it
I te m
M ax S ta n d a rd Max
S ta n d a rd v o lta g e 14 V
R u n n in g v o lta g e 6 1 6 .5 V
F irs t le v e l
0 .7 4 0 .7 6 0 .7 8 Ω
R e s is ta n c e c o il
（ 2 0 ℃ ～ 2 5℃ ） S e co n d
1 0 .1 1 0 .6 1 1 .1 kΩ
le v e l c o il
C u rre n t 7 A
7-28
7 Electrical system
7.3.5 EFI SELF-DIAGNOSIS

ECU constantly monitors sensors,actuators,circuits,MIL and 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 and 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.
Fualt can be divided into “steady fault” and “occasional fault” (such as a fault caused by harness short or
loose connection.)
PDA or MIL can be used to locate the part in trouble immediately after fault happens.
（1）Trouble indicator(MIL indicator)：

MIL is a light-emitting diode and located on instru-
ment panel. It indicates different fault codes through
the flashes in different frequency. luminous diode 7
current-limiting
MIL Circuit: The current to,ECU C1 should be resistance
less than 0.1A.
MIL Flash Principles:

a:In MIL mode without trouble code.
If the ECU realize in MIL mode. The trouble code
will shows up by MIL indicator blinking. From ECU
formating,MIL light keeps on. If with trouble code, the
mil light will be off 3s. Then blinking in 0.4s. After one 072901
number done. Off 1s, then next. MIL keeps on, means
no trouble. Until engine start find the RPM. MIL indi-
cator off.
b:In MIL mode.With the vehicle started. c:Read the trouble information
With trouble Turn the ignition on. With K line on the ground for
If the ECU realize in MIL mode., The MIL light will 2.5s. If the ECU memory has trouble code. The MIL
indicator will shows up the code.Exp: P0203 shows
shows the trouble code in memory by blinking. From
like Blinking 10 times-off-Blinking twice-Off-Blinking
ECU format,MIL light keeps on. If with trouble code,
10 times-Off-Blinking thrice.
the mil light will be off 3s. Then blinking in 0.4s. After
one number done. Off 1s, then next. MIL keeps on,
means no trouble. Until engine start find the RPM.
MIL indicator off. If still on. Read the trouble code to
seel the parts problem.
7-29
（2）PDA：PDA has 3 pins-power,ground wire and data cable K.Thses pins are connected with related
ECU pins.
The right photoe refers to operation panel of PDA.When it comes to detailed keys function,refer to PDA
instruction book.
Pins and Function：

1.2.3.10.11.12.13.15.None
4.5.Ground wire
6.CAN H
7.K_line
8.(For ABS)
9.EPS
14.CAN L
16.+12V Power UP
Right
Key function：
Left
Left: Page up Down
Up: Scroll Up Exit OK
Right: Page Down
Down: Scroll Down
OK: Entrance
EXIT: Exit
Power
16
9
8
1
073001
PDA Function
（A ）Version Infomation Display
PDA can display engine,ECU hardware and soft
ware infomation.
（B ）Fault Display
PDA monitors IAP sensor,IAT sensor,coolant tem-
perature 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.
073002
7-30
7 Electrical system
（C ）Engine Data stream Display

PDA can display battery voltage,RPM,desired idle speed,vehicle speed,coolant temperature,coolant tem-
perature 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, ac-
celeration 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.
7-31
7.4 Trouble shooting
7.4.1 Engine body………………………………………………………………………7-33
7.4.2 Follow the trouble code list to diagnose the trouble………………………7-38
7.4.3 Diagnose trouble by problem…………………………………………………7-44
7-32
7 Electrical system
7.4.1 Engine body

Trouble Reason Solution
Inspect the electrical system
● Fuse melted Inspect or replace
● Battery low Inspect or charge
● Cable problem Inspect or replace
Inspect the sparkplug
● Ignition coil bad connection Inspect or replace
● High voltage bad connection Inspect or replace
● RPM sensor trouble Inspect or replace
● Magneto trouble Inspect or replace
● Sparkplug clearance not fit Adjust or replace
● Sparkplug dirty Clean or replace
● Sparkplug too wet Dry or replace
Inspect fuel supply system
● Canister Repair and replace
● Fuel pump leaking or bad Inspect or replace 7
Engine cannot effect Inspect the fuel
start ● Fuel line leaking tank
● Fuel low Replace
● Injector jammed
4. Inspect cylinder pressure Replace
● Cylinder wearing Replace
● Piston ring wearing Replace
● Gasket leaking Replace
● Valve conducting pipe Repair or replace
wearing Replace
● Valve seat bad sealing Tight up
● Valve wearing Inspect or replace
● Spark plug loose Adjust
● Starting RPM low Adjust
● Valve timing wrong Clean or replace
● Valve clearance not fit To N gear
5. Idle by pass valve jammed Inspect
6. Not in N gear
7. Trouble code
1. Idle valve bad See engine
2. TPS not in 0 See engine
3. Adjust the throttle cable
4. Engine pressure low
Engine hard to
5. Inspect the spark plug Inspect the reason
start
● Sparkplug bad
● Sparkplug setting bad
● Sparkplug damage
● Sparkplug dirty
6. Fuel low or pressure low Replace the parts
7. CAPS or cable bad
7-33
Trouble R ea son Solution
1. C oola nt leve l low Fi ll
2. C ooli ng system got bubble Dra in and refill
3. Wa ter te mp sensor problem R epla ce
4. Therm ostat problem(N ot open in high R epla ce
heat)
5. Inspe ct the le aking hole to see leaking R epla ce the w at er
6. Inspe ct the pipe and cla mp se al
● P ipe cra cked or getting o ld R epla ce
En gine overheat ● C la mp gett ing loose Tight
7. Wa ter pump pe lle r broke n R epla ce
8. Wa ter pump ga ske t le aking Tight or replace
9. C ylinde r head ga sket le aking R epla ce
10. Wa ter pump c over drai n bolt ga sket Tight or repl ace t he
le aking. gasket
11. Wa ter pump ge ar w earing c ause R epla ce
coola nt not e nough. R epla ce the bad part s
12. Wa ter pump shaft jam med
1. Inspe ct the engine oil level to se e the
crankc ase and oi l seal l eaki ng.
● C rankca se dama ge le aking R epla ce rea ssem ble
● C rankca se bolt l oose Tight
● S ealing ring/O -ring/ Gasket crac ked, R epla ce
Oil old or dam aged R epla ce
● P iston ring dam aged（ B l ue smoke） R epla ce
wasting
● P iston ring dam aged（ P ressure low ） R epla ce the oil sea l
● Val ve oil seal dama ge d. Lip crack ed or R epla ce the filter and
high/Oil old. oil
2. O il fi lter jamm ed
pressure
3. Inspe ct the oil drain bolt Tight
● C ase bott om beve l bolt loose Tight or instal l t he
low or no
● O il drain bolt l oose or wi thout w asher wa she r
4. O il leaking R epla ce the oil sea l
L ubrication oil 5. O il strainer ja mme d C lea n and re plac e t he
6. Inspe ct the oil pump filter
pressure
● O il pum p rot or we aring R epla ce
● Wa sted oil or a ir inlet ca use the oil R epla ce
pump j amme d. R epla ce
● O il pum p ge ar dam aged. Use re comm end oil
● U se w rong oil
1. Leaking i ndicator show s the oil mixed R epla ce oil sea l and
w ith w ate r wa ter seal.
Oil 2. C ylinde r gasket da mage d or leaki ng. Tight or repl ace
3. C ylinde r head bol t loose. Tight a nd repla ce t he
getting 4. O il has dust inside oil
R epla ce dama ged
white
parts（ Includi ng filt er
and oil
7-34
7 Electrical system

1. Belt getting narrow Replace
2. Inspect the main sliding wheel
● Rolling ball wearing Replace
● Main roller track wearing Replace
3. Drive/Driven pulley axial Clean or replace
sliding not smooth Replace
Abnormal 4. Driven pulley sprint too strong Replace
accelerate 5. Driven pulley clutch Replace
shoe/Surface wearing Replace
6. Drive/Driven pulley groove Adjust
damaged.
7. Connect the PDA to find trouble Replace
8. Valve clearance not fit
9. Pressure low
10.Sparkplug bad ignition
Top speed 1. Inspect“Bad accelerate”1～3
low 2. CVT got dirty. Clean and replace 7
3. Drive pulley jammed Clean and replace
4. Driven pulley spring bad or Replace
damaged
1. Inspect the Shifting machenism
CVT ● Inspect“Bad accelerate”1～2
2. Inspect the driven pulley
Shifting not
● Driven pulley spring bad or Replace
smooth
damaged Replace
● Clutch shoe or surface got
damaged
1. Inspect the CVT cooling pipe
● CVT room too hot Clean
● Main stable wheel peller jammed Clean
Belt burnt 2. Inspect the wheel groove
surface Clean and replace
● Groove got dirty the belt
● CVT case got water in.
1. Wearing too much Replace
2. Belt specification wrong Replace
3. Belt got wearing Replace
4. Belt cracked and reach the life Clean the CVT and
Drive belt
period replace the belt
trouble
5. Groove got oil dirty Clean
6. Drive or driven pulley got Clean or replace
damaged by stone Replace
7. Belt getting old
7-35
1 . V a l ve c l e a r a n c e n o t f i t Adjust or replace
2 . T e n si o n e r b a d Replace
3 . C h a in c o n d u c t o r w e a r i n g Replace
4 . C h a in g e tt i n g longer or Replace
Cylinder
s p r oc k e t w e a r i ng Tighten
head noise
5 . S p r oc k e t b o l t lo o s e Adjust or replace
6 . V a l ve r o c k e r a r m o r c a m s h a f t Adjust or replace
w e a ri n g .
7 . C a m sh a f t t i m i n g w r o n g .
1 . M a i n b e a r i n g d am a g e d Replace
2 . C o n ne c t i n g rod bearing Replace
Crankshaft d a m ag e d Tighten or
no i s e 3 . M a g ne t o b o l t g et t i n g l o o s e d replace
4. Left crankcase cover bearing Replace
d a m ag e d
1. Oil leaking Replace, tight
Case noise 2 . G e a r t e e t h d a m ag e d and fill
Replace
1 . D r i ve n p u l l e y s l i d i n g s h a f t Replace the
s l e ev e j a m m e d or w e a r i n g . driven pulley
2 . I n s pe c t t h e d r i v e s l i d e w h e e l Replace at same
Engine
3 . R o l le r b a l l w e ar i n g time
noise or
4 . D r i ve s l id e wheel track Replace
shocked CVT idle
w e a ri n g Replace
no i s e
5 . D r i ve s l id e wheel track Replace at same
w e a ri n g time
6 . N y l on p a r t d a m ag e d
7 . A x i al s l i d i n g ja m m e d Clean or replaced
8 . D r i ve w h e e l n u t l o o s e Tighten
1 . I n s pe c t “ I d l e no i s e ” 1 ～ 3
2 . D r i ve p u l l e y w et a n d d i r t C l e a n o r d r a in
3 . D r i ve / D r i v e n p u l l e y n u t l o o s e Tight
CVT noise 4 . D r i ve n pulley slide shoe Replace
s u r fa c e d a m a g e d C l e a n o r r e p la c e
5 . B e l t o r w h e e l d am a g e d b y o t h e r
t r a sh .
1 . D r i ve p u l l e y n ut l o o s e Tight
2 . D r i ve slide wheel sleeve Replace
CVT Drive c l e ar a n c e l a r g e . Replace at same
pulley shock 3 . R o l le r b a l l l o st o r w e a r i n g time
4 . W a s he r n o t i n po s i t i o n Reassemble or
replace
CVT driven D r i v e n b e a r i n g s l e e v e cl e a r a n c e
Replace
pulley shock t o o l a rg e
7-36
7 Electrical system
Trouble Code list

P0030 O2 Se nsor 1 H eater C ontr. C irc. H igh
P0031 O2 Se nsor 1 H eater C ontr. C irc. Low
P0032 O2 Se nsor 1 H eater C ontr. C irc. Open
P0036 O2 Se nsor 2 H eater C ontr. C irc. H igh
P0037 O2 Se nsor 2 H eater C ontr. C irc. Low
P0038 O2 Se nsor 2 H eater C ontr. C irc. Open
P0107 Manifold Abs.Pressure or Bar.Press ure Low Input
P0108 Manifold Abs.Pressure or Bar.Press ure H igh Input
P0112 Intak e Air Temp.Circ . Low Input
P0113 Intak e Air Temp.Circ . High Input
P0117 Engine Coolant Tem p.C irc. Low Input
P0118 Engine Coolant Tem p.C irc. H igh Input
P0122 Throttl e Pos .Senso r Ci rc. Low Input
P0123 Throttl e Pos .Senso r Ci rc. High Input
P0130 O2 Se nsor Circ .,Bank 1-Sensor1 Malfunction
P0131 O2 Se nsor Circ .,Bank 1-Sensor1 low Voltage 7
P0132 O2 Se nsor Circ .,Bank 1-Sensor1 High Voltage
P0134 O2 Se nsor Circ .,Bank 1-Sensor1 No Activity Detected
P0136 O2 Se nsor Circ .,Bank 1-Sensor2 Malfunction
P0137 O2 Se nsor Circ .,Bank 1-Sensor2 low Voltage
P0138 O2 Se nsor Circ .,Bank 1-Sensor2 High Voltage
P0140 O2 Se nsor Circ .,Bank 1-Sensor2 No Activity Detected
P0201 Cylinder 1- Injec tor Circ uit
P0261 Cylinder 1- Injec tor Circ uit Low
P0262 Cylinder 1- Injec tor Circ uit High
P0202 Cylinder 2- Injec tor Circ uit
P0264 Cylinder 2- Injec tor Circ uit Low
P0265 Cylinder 2- Injec tor Circ uit High
P0321 Ign./Dis tributor Eng.Speed Inp.Circ . Range/Perform ance
P0322 Ign./Dis tributor Eng.Speed Inp.Circ . No Signal
P0480 cooling fan c ontrol Circuit Open
P0508 Idle Air Control Ci rc uit Low
P0509 Idle Air Control Ci rc uit Low High
P0511 Idle Air Control Ci rc uit Open
P0560 Sys tem Vol tage M alfunc tion
P0562 Sys tem Vol tage L ow Voltage
P0563 Sys tem Vol tage H igh Voltage
P0627 F uel Pum p “A” C ontrol Circ uit /Open
P0628 F uel Pum p “A” C ontrol Circ uit Low
P0629 F uel Pum p “A” C ontrol Circ uit High
P0650 Malfunc tion Indic ator Lam p C ontrol Circ .
P0691 cooling fan c ontrol Circuit Low
P0692 cooling fan c ontrol Circuit H igh
P1116 Engine Coolant Tem p H igh
7-37
7.4.2 Diagnose by trouble code
Instruction：
1.Make sure the trouble is stable at the moment or it may cause wrong
diagnose.
2.The AVO meter mentioned below is digital AVO meter. Do not use
analog style meter to test the electrical parts.
3.If the trouble code shows the some electrical voltage low. It means
short to the ground or open to the ground. If the voltage high.
That means may short to power. If trouble code shows some
wiring trouble. Means open or different troubles in wirings.
Diagnose help：
1.If the trouble code cannot clean up. The trouble is stable
If it happens occasionally. Please check the connection loosing

2.Do not ignore the vehicle maintenance information. Cylinder
pressure mechanical timing effect.

3.Replace ECU for testing
If the trouble code can clear up. That means the trouble part is
ECU. If the code still cannot clear up. Replace into the original
ECU and test again.
The chart below shows the trouble code meaning, reason and
solutions for consult in repairing.
7-38
7 Electrical system
Trouble code P0032/P0038：Cylinder 1/ Cylinder2 Oxygen sensor heating coil high
volt
Note： Maintenance note
Trouble may cause from this Inspect the item below
1 ） ECU to oxygen sensor pin 2 1）Measure ECU connecting pin to
disconnected pin 2 of oxygen sensor resistance.
2）Oxygen sensor pin 1 to main relay 2）Measure oxygen sensor pin 1 to
disconnected m ain relay resistance.
3 ） Oxygen sensor pin 1 to pin 2 3）Measure oxygen sensor pin 1 to
disconnected. 2 pin resistance (8.5Ω).
Trouble code P0031/P0037：Cylinder 1/Cylinder2 Oxygen sensor heating coil low

volt
Note： Maintenance note：
1）ECU pin line short to the ground 1） Measure ECU pin to ground 5
7
2 ） ECU pin line short to pin 1 of resistance
oxygen sensor. 2）Measure ECU voltage
3）ECU short to other line. 3 ） Measure ECU pin to pin 1
resistance (8.5Ω).
Trouble code P0131/P0137：Cylinder 1/Cylinder2 Oxygen sensor voltage low

Diagnose instructions：The system measure the A pin and B pin voltage on sensor to
analyze the signal out put
Sensor may be damaged by cooled liquid in some situation. Especially cold start.
1）ECU pin line short to the ground 2） Measure ECU pin to ground
2 ） ECU pin line short to pin 1 of resistance
oxygen sensor. 2）Measure ECU voltage
3）ECU short to other line. 3 ） Measure ECU pin to pin 1
4) Oxygen sensor damaged. resistance (8.5Ω).
Trouble code P0132/P0138：Cylinder 1/Cylinder 2 Oxygen sensor voltage high

1）The ECU line to pin 3 and pin 4 1） Replace the oxygen sensor
disconnected 2） Replace the ECU
2）Oxygen sensor pin 3 and pin 4 3） Line test
disconnected
7-39
Trouble code P0107：Intake pressure sensor voltage low or disconnected
The trouble may cause from this Inspect the item below
1）ECU test the signal line may short 1）ECU pin resistance to the ground
to the ground
Trouble code P0108：Intake pressure sensor voltage high

The trouble may cause from this Inspect the item below
1）ECU test the signal line short to 1）ECU pin voltage
power
Trouble code P0112： Intake Temperature sensor voltage low

Trouble may cause from this. Inspect the item below
1）ECU pin signal line short to the 1）Measure ECU pin line resistance
ground to the ground.
Trouble code P0113：Intake temperature sensor voltage high

1 ） ECU pin signal line short to 1）Measure ECU signal line voltege
power.
Trouble code P0117：Water temperature sensor voltage low

1）ECU pin signal line short to the 1) Measure ECU line resistance to the
ground. ground.
Trouble code P0118：Water temperature voltage high or disconnected

1）ECU pin signal line short to the 1)Measure the ECU pin voltage
power
7-40
7 Electrical system
Trouble code P0122：TPS voltage low or disconnected
Note： Maintenance Note：
1）ECU pin line short to the ground 1 ） Measure the ECU pin line
resistance to the ground.
Trouble code P0123：TPS voltage too high.
1）ECU Pin line short to other line. 1）Measure the voltage from sensor to
ECU pin.
Trouble code P0201/ P0202： Cylinder 1/Cylinder 2 injector coil problem
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 3）Measure the resistance to ECU 5
7
relay. 4）Measure the voltage to ECU.
4）The running line to ECU short to the
ground.
5）The line to ECU is short to other line.
7-41
Trouble code P0627: Fuel pump relay coil open.
Trouble code P0628: Fuel pump relay coil short to the ground.
Trouble code P0629: Fuel pump relay coil short to power.
Note： Note
Trouble may cause like below Inspect item below
1）Fuel pump relay to ECU is open to 1）Measure the fuel pump relay coil
fuel pump/short to the resistance or voltage to ECU.
ground/Short to 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
Note： Note：
1）Magneto damaged or battery energy 1) Test the magneto ability(Measure
flow. the voltage after start）
2）Magneto stator coil open 2) Measure rectifier output voltage.
3）Rectifier damaged.
Trouble code P0650： MIL indicator trouble

Note： Note：
1）MIL indicator to ECU wire open to 1）Measure the resistance or voltage
indicator/Short to ground/short to between MIL indicator and ECU.
power.
2）MIL indicator open to main relay
3）MIL indicator burnt
7-42
7 Electrical system
Trouble code P0321: RPM counting point trouble

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.
Note： Note：
Trouble may cause from 1） Inspect cable connectors
1） Wire connection short or open connection.
interval. 2） Inspect magneto flywheel bosses
2） Crankshaft signal disc wrong 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
5
7
7-43
7.4.3 Diagnose by engine trouble
Before trouble diagnosis by engine problems, initial checking should be done as follows.
1. Confirm if trouble light is ok;
2. Confirm there’s no trouble code record by PDA checking.
3. Confirm there’s really trouble existing complained by end-users.
Then check the following points.
（1） Check fuel hoses if any fuel leakage；
（2） Check vacuum pipes if any broken, twist or improper connection；
（3） Check intake manifold if any blocked, air leakage or damaged；
（4） Check high-tension cable if any damaged, aging；or ignition order is correct.
（5） Check wiring close to ground if it’s clean and firm；
（6） Check connector of all sensors and actuator if any loose or improper connection.
Important note： In case there’re some problems as above-mentioned, then removal
work should be done firstly, then go to next diagnosis.
Diagnosis helps：
1. Confirm engine without any trouble record.；
2. Confirm there’s really trouble existing；
3. During checking, do not neglect vehicle periodic maintenance, cylinder pressure, valve
timing, fuel supply and so on；
4. Replace ECU to test.
In case trouble disappears, then it’s a problem of ECU. If trouble still exists, then assemble
original ECU and check other points.
Frequent troubles list：
l When starting engine, engine cannot rotate or rotate slowly.
l When starting engine, starter motor can rotate but cannot start engine.
l Difficult to start warm or hot engine
l Difficult to start cold engine
l RPM is ok, but difficult to start engine.
l Starting is ok, but idle speed is unstable at any time.
l Starting is ok, but idle speed is unstable during engine warm-up period.
l Starting is ok, but idle speed is unstable after engine warm-up.
l Starting is ok, idle speed is unstable or engine stop when switch on some lights or
other electric components.
l Starting is ok, but too high idle speed.
l RPM cannot go up or engine stop when acceleration.
l Slow acceleration.
l Insufficient power and bad performance when acceleration.
7-44
7 Electrical system
1）Starting Failure/Hard Starting

Possible defective parts: 1. Battery; 2. Starter motor; 3. Wirings harness
or ignition switch; 4. Engine mechanism part.
General diagnosis procedures
Item Procedures Results Next
Use multi-meter to check battery voltage if voltage YES Next Step
1
is between 8V~12V or not when engine starts NO Replace battery
YES Next Step

Turn on ignition switch, stop switch side stand switch
2
and check if voltage of ECU pin 14 is around 12V Repair switches or
NO
change harness
YES Next Step
Keep ignition switch “on”, use multi-meter to check if
3 Repair switches or
voltage of starting motor anode is over 8V. NO
change harness
Disassemble starting motor and check its working Repair or replace

YES
4 status, especially whether there was broken circuit or starting motor
7
jammed by bad lubrication. NO Next Step
Change to proper
If error only occur in Winter, check if starting motor YES
5 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
6
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 diagnosis procedures：：
YES Next Step

Connect fuel pressure gauge, turn on ignition switch or
1
start engine, check if fuel pressure is around 300kpa Repair fuel supply
NO
system
YES Next Step
Connect PDA, check if there’s signal of RPM data after Check and repair
2
starting engine NO RPM sensor
circuit
Disconnect high-tension cable, connect spark plug and YES Next Step
3 set its electrode 5mm to engine body, then start engine
Check and repair
to check if blue and white spark appears NO
ignition system
7-45
Eliminate engine
YES Mechanical
4 Test cylinder pressure and check if pressure is enough
failures
NO Next step
Use PDA to
Use PDA to test, turn on ignition switch, check if power YES
check
5 supply of ECU pin 1 and pin 21 is normal; check if pin 2
Repair related
and pin 17 works normally NO
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 diagnosis procedures：
YES Next step

Connect fuel pump gauge, start engine, check if
1 Repair fuel
pressure is around 300kpa
NO supply
system
YES Next step

Disconnect high-tension cable, connect spark plug and
2 set its electrode 5mm to engine body, then start engine Repair
to check if blue and white spark appears NO ignition
system
Repair
wiring or
YES
Disconnect water temp.sensor connector and start replace
3 engine to check if engine can start.(or use one sensor
300ohm resistance to replace water temp.sensor)
NO Next step
NO Next step
Change
Check whether the failure happens right after filling YES
4 fuel
fuel oil
NO Next step
Use PDA to
YES
Connect PDA , turn on ignition switch, check if power check
5 supply of ECU pin 1 and pin 21 is normal; check if pin Repair
2 and pin 17 works normally NO related
circuit
（4）Difficult to start cold engine.

General failure part：1、water in fuel tank；2、Fuel pump；3、
Engine temp. sensor；4、Injector；5、Ignition coil；6、Throttle
body and by-pass；7、Mechanical parts of engine
7-46
7 Electrical system
YES Next step

Connect fuel pump gauge ,start engine, check if
1
pressure is around 300kpa Repair fuel
NO
supply system
Disconnect high-tension cable, connect spark plug YES Next step

2 and set its electrode 5mm to engine body, then start
Repair ignition
engine to check if blue and white spark appears NO
System
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
Slightly draw throttle cable and check if engine YES body and
4
could start easily by-pass
NO Next step
7
Replace
Disassemble injector and use special tool to check if YES
5 injector
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 mechanic
7 Check if cylinder pressure is insufficient
failures
NO Next step
Use PDA to test, turn on ignition switch, check if YES Check PDA
8 power supply of ECU pin 1 and pin 21 is normal;
check if pin 2 and pin 17 works normally NO Check circuit
(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.
Repair air intake
Check if air filter is blocked or air intake pipe YES
1 system
leaks
NO Next step
7-47
YES Next step
Connect fuel pump gauge, start engine, check if
2
pressure is around 330kpa Repair fuel
NO
Supply system
Disconnect high-tension cable, connect spark plug YES Next step

3 and set its electrode 5mm to engine body, then start
Repair ignition
engine to check if blue and white spark appears NO
System
Check if spark plug is suitable for YES Next step
4
requirement(including 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
Slightly draw throttle cable and check if engine could YES
6 body and bypass
start easily
NO Next step
Disassemble injector and use special tool to check if YES Replace injector
7
there is leakage or blocked. NO Next step
8
fuel NO Next step
Eliminate
YES mechanical
failures
NO Next step
YES Next step
Check if ignition timing complies with standard
10 Adjust ignition
regulation NO
timing
Connect PDA , turn on ignition switch, check if power YES Use PDA to check
11 supply of ECU pin 1 and pin 21 is normal; check if pin
Repair related
2 and pin 17 works normally NO
circuit
（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
Repair air
1 intake system
leaks
NO Next step
7-48
7 Electrical system
YES Clean or replace

2 Check if air control valve is blocked
NO Next step
YES Next step
Check if spark plug is suitable for
3 Adjust or
requirement(including its type and clearance) NO
replace
Check if there is carbon deposit inside throttle body YES Clean
4
and air control valve 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
6
fuel NO Next step
Eliminate
YES mechanical
failures
NO Next step
YES Next step
8
Repair ignition 7
regulation NO
timing
Use PDA to
Connect PDA , turn on ignition switch, check if power YES
check
Repair related
circuit
(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
Repair air intake
YES
1 Check if air filter is blocked or air intake pipe leaks system
NO Next step
YES Next step
2 Adjust or
replace
3
Repair circuit or
4 replace sensor
start engine to check idle speed is stable or not
NO Next step
5
7-49
6
fuel NO Next step
Eliminate
YES mechanical
failures
NO Next step
Use PDA to
Connect PDA , turn on ignition switch, check if YES
check
Repair related
check if pin 2 and pin 17 works normally NO
circuit
（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
Repair air
1 intake system
leaks
NO Next step
YES Next step
2 Adjust or
replace
3
Repair circuit or
4 replace sensor
start engine to check idle speed is stable or not
NO Next step
5
6
fuel NO Next step
Eliminate
YES mechanical
failures
NO Next step
Use PDA to
check
Repair related
circuit
（9）Normal starting, unstable idle speed or engine stop when it is
electronic loaded (e.g. headlight is on)
7-50
7 Electrical system
General failure part： 1、Air control valve；2、Injector.
Disassemble air control valve and check if Clean related
YES
1 there is carbon deposit inside throttle parts
body, idle adjustment and by-pass NO Next step
YES To steep 4
Check if output power increases when lighting, NO Next step

2 by using PDA to test if ignition advance angl,
fuel spray and air intake volume is normal NO Repair air
intake
System
Disassemble injector and use special tool to Replace
YES
3 check if there is leakage or blocked or wrong injector
fuel flow NO Next step
Use PDA to
check
7
Repair related
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 temp.sensor；5、Ignition timing.
YES Adjust
1 Check if throttle cable is jammed or too tight
NO Next step
Repair air intake
Check if there’s leakage between air intake pip YES
2 system
and injector seat
NO Next step
Remove air control valve and check if there s Clean related
YES
3 carbon deposit inside throttle body, air control Parts
valve and by-pass NO Next step
Repair wiring or
Remove water temp. sensor connector, start YES
4 replace sensor
engine to check if idle speed is too high
NO Next step
YES Next step
5 Repair ignition
regulation NO
Timing
7-51
Use PDA to
check
6 supply of ECU pin 1 and pin 21 is normal; check if pin 2
Repair related
and pin 17 works normally NO
circuit
（11）RPM cannot increase or engine stop when accelerating
General failure part：1、Water in fuel tank；2、TPS；3、Spark plug；
4、Throttle body and by-pass；5、Air intake pipe；6、Air control valve；
7、Injector； 8、Ignition timing;9、Exhaust pipe
Repair air
YES
1 Check if air filter is blocked intake system
NO Next step
YES Next step

Connect fuel pressure gauge, start engine to
2
check if pressure is around 300kpa at idle Repair fuel
NO
supply system
YES Next step
3 Adjust or
replace
Remove air control valve and check if there is Clean related
YES
4 carbon deposit inside throttle body, air control parts
YES Next step
5 Check if TPS and its circuit is normal Repair circuit
NO
or replace TPS
Disassemble injector and use special tool to YES Replace
6
check if there is leakage or blocked NO Next step
Check whether the failure happens right after YES Change fuel
7
filling fuel NO Next step
YES Next step
Check if ignition timing and timing order
8 Adjust ignition
comply with standard regulation NO
timing
YES Next step
Repair or
9 Check if exhaust gas exhale smoothly
NO replace
exhaust pipe
Use PDA to
check
Repair related
circuit
7-52
7 Electrical system
（12）Low acceleration
General failure part：1、Water in fuel tank；2、TPS；3、Spark plug；4、
Throttle body and by-pass；5、Air intake pipe；6、Air control valve；7、
Injector； 8、Ignition timing;9、Exhaust pipe
Repair air intake
YES
1 Check if air filter is blocked system
NO Next step
YES Next step

Connect fuel pressure gauge, start engine to check if
2
pressure is around 300kpa at idle Repair fuel supply
NO
system
Check if spark plug is suitable for YES Next step
3
requirement(including its type and clearance) NO Adjust or replace
YES
4 carbon deposit inside throttle body, air control parts
7
YES Next step
5 Check if TPS and its circuit is normal Repair circuit or
NO
replace TPS
Disassemble injector and use special tool to check if YES Replace
6
there is leakage or blocked NO Next step
7
fuel NO Next step
YES Next step
Check if ignition timing and timing order comply with
8 Adjust ignition
standard regulation NO
timing
YES Next step

Repair or replace
NO
Exhaust pipe
YES Use PDA to check

Connect PDA , turn on ignition switch, check if power
supply of ECU pin 1 and pin 21 is normal; check if pin Repair related
10 NO
2 and pin 17 works normally circuit
（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
7-53
Check if clutch sliding, low tire pressure, bad YES Repair
1
brake or wrong tire size NO Next step
Repair air intake
YES
2 Check if air filter is blocked system
NO Next step
YES Next step

Connect fuel pressure gauge, start engine to
3
check if pressure is around 300kpa at idle Repair fuel supply
NO
system
Disconnect high-tension cable, connect spark
YES Next step
plug and set its electrode 5mm to engine body,
4
then start engine to check if spark is strong Repair ignition
NO
enough system
YES Next step
5 Adjust or
replace
YES
6 carbon deposit inside throttle body, air control Part
YES Next step
7 Check if 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
Check whether the failure happens right after YES Change fuel
9
filling fuel NO Next step
YES Next step
10 Repair ignition
regulation NO
T iming
YES Next step
NO Repair or replace
Connect PDA , turn on ignition switch, check if YES Use PDA to check
Repair related
circuit
7-54
7 Electrical system
Start wiring
075501
7-55
EFI diagram
7-56 075601
075701
7-57
8 Light,Dashboard,Switch
Maintenance information…………8-1 Switch……………………………………8-6

Trouble diagnose …………………8-1 Breaking light swith and horn………………8-7
Bulb replacement…………………8-2 Fuel pump and fuel level sensor ………8-8
Dashboard and headlight…………8-4
Ignition switch………………………8-5
Pre-cautions
Note
·Headlight is a hight watt light. The temperature will be very high when the light on. The hand will be scald
if touch the light just turned off. The light must be totally cool down before working.
·The headlight temperature will be very high when turned on. If you use bear hands or with dirty gloves to
touch the bulb. It will be covered with oil dirty. It will be the heat point, cause the bulb shaping change.
And finally cause the bulb broken.
·Be careful when replace the bulb：
－Do not replace the bulb when the light on. Turn off the ignition and wait for the bulb totally cool down.
－With clean gloves on when replace the bulb to avoid dirty oil on the glass.
－Use clean cloth with alchohol or lacquer thinner on to clean up the oil on the bulb.
·Make sure the battery is fully charged if use the battery for inspection. 8
·The switches test can be done with the switches on the vehicle.
·Inspect the cables and wires after maintenance and follow the drawings to makesure the cables and wires
are in right direction.
·Taillight, rear steering light assemble and removal refers to chapter 2.
·For electrical inspection in this chapter. Refers to the electrical system chapter.
Maintenance standard
I te m S ta nda r d
F use Main 40A
Se conda ry 1 0A× 2 15A×3 5A×1
He adl ight（ Low b ea m ） H1 12V-5 5W×2
Hea dl ight（ High b ea m ） H7 12V-5 5W×2
Br eak ing li ght／ Taillight LE D
Li ght a nd bu lb Ste e ring lig ht LE D
Da shboa rd ligh t LCD
Wa ter tem p, Fu el gau ge,2 /4
LCD
WD indi ca tor
Trouble indicator LE D
Trouble diagnose
Headlight cannot on
·Fuse broken
·Main cable opened
·Bulb burnt
·Switch damaged
8-1
Bulb replacement
Headlight bulb
Note
Headlight bulb is a high power part. The tempera- 1
ture will be very high when on. It can cause scaled
2
when touch. The bulb must be cool down before
maintenance.
Headlight removal
Disconnect the headlight connector. 3
Remove the dustproof cover. Bulb holding ring, remove

the bulb and replaced.
Note
With clean gloves on when replace the bulb. If the bulb
has oil dirt covered on. Will cause the bulb broken. Use
alcohol or lacquer thinner to clean it up. 1、Low beam light 080201
When replacing the bulb. Pay attention to three locking 2、High beam light
pins on the bulb align on the locking holes on the seat.
3、Front position light.
Headlight low beam bulb:H1 12V-55W
Headlight high beam bulb:H7 12V-55W
Front position light:LED
After replace the headlight.Adjust the headlight axle.
Headlight inspection
When the ignition switch ON. Turn on the headlight switch.
Inspect the headlight on or not.
－On: Normal.
－Off: Main cable open or shortcut. Bulb or switch
damaged.
080202
8-2
Front steering light bulb
Remove the front steering light.
Replace the headlight
Bulb specification: LED
1、Front steering light 080301
Rear steering light bulb

Remove the taillight cover
Remove rear steering light
Replace rear steering light
8
Specification:LED
3
Breaking light/Taillight bulb
Remove the taillight cover
Remove the breaking light/Taillight
Remove breaking/Taillight
Specification：LED

Note
Maincable, and cables should be follow the draw-
ings to makesure they are in right direction.
080302
2、left taillight/breaking light
3、left rear direction indicator
8-3
Dashboard
Remove the front cover
Remove the front fender 2
1
Remove the screw 1
Loose the connect 1
Remove the nut 2 1
Remove the dashboard from front fender. 1
Note: If the part in dashboard got trouble.Replace 1 3
the whole dashboard.
1
Start the engine. When vehicle running,Makesure the

speedometer working. If any trouble inspected.
Replace the speed sensor or
dashboard.
080401
1.Screw 2.Nut 3.Dashboard
Headlight
4 4
Right headlight assy
Remove the front ventilator 5
Remove front headlight screw 3 4
Disconnect front headlight connector.
Remove right headlight assy
080402
Note:Do not damage the maincable when installing. 4. Screw 5. Right headlight
Adjust the axle after assembled

Note
Maincable, and cables should be follow the draw-
ings to makesure they are in right direction.
8-4
Ignition switch
Inspection
Remove the dashboard wire guard
Disconnect the ignition switch 4P connector
Follow the form below to inspect the switch.
● - ● Connected is 1
2
normal.
080501
Removal and installation Remove the front cover 1.Ignition switch
assy 2.Steering indicat-ing switch. 8
Remove the front fender
Disconnect the ignition switch 4P connector
Remove the nut
Remove the ignition switch
Installation
Reverse the removal procedure for installation. Steering
signal switch
Follow the form to inspect the connections of the switch.
● - ●Connectec is
normal.
8-5
Engine stop switch
Follow the forms below to check the connections.
● - ● Connected is normal.
Light switch 3 2
Follow the form below to inspect the switch
connection.
080601
1. Engine stop switch 2.Headlight switch
3. High/Low beam switch
High/Low beam switch

Follow the form below to inspect the switch connection.
8-6
Overriding switch
1
2
Caution switch
1.4 way flash switch 2.Overriding switch 080701
4 way flash switch.

ON: O Sb Gr connected
OFF: Not connected 3
2/4 WD switch
8
3. 2/4 WD switch 080702
If any trouble inspected. Replace the switch.

4
Breaking light switch 6

Disconnect the breaking light switch and inspect the
connection.
Connected when push the pedal. Disconnect when loose

is normal.
If any trouble inspected. Replace the switch. 4. Breaking light switch 080703
Horn 7 5 5
Inspection
Remove front ventilating plate
Disconnect the horn connection.
Make sure the horn work when connected the 12V battery.
If any trouble inspected. Replace the horn
5.Horn 080704
8-7
Fuel pump and fuel level sensor
Removal
Remove the passenger seat
Disconnect the connectors
Tight up the pump locker cap.
Remove the fuel pump and fuel level sensor assy 1
from the fuel tank.
1. Fuel pump 080801

Inspect
Level position and sensor resistance form:
Fuel level: EMPTY FULL
Resistance: 90~100 4~10
Fuel pump specification

Voltage:DC13.5V±0.3V. Pressure:3.3bar
±0.3bar，flow≥60L/h, Current≤4.5A Fuel pump
pressure:3.3bar；
Inspect the oil pump
In normal, when the ignition switch turned ON. You
can hear the pump running. If the trouble comes, In-
spect the electrical system to see opened or other
troubles.
Note:
All the electrical parts in this chapter got trouble. If it
needs fully inspected. Please see the electrical sys-
tem chapter related.
Installation
Put the fuel level sensor into the installing hole,make
sure it in the right position.Without leaking.
Inspect the fuel gauge
Connect the power to see the fuel gauge working.
Make sure the fuel gauge is ok.Reverse the removal
procedure to assemble the seat and body covering
080802
parts.
8-8
9 Front wheels, braking ,suspenion and steering
Maint enance informat ion………………9-1 Braking system……………………………9-4

Trouble diagnose…………………………9-2 Front suspension……………………………9-7
Front wheel…………………………………9-3 Steering system……………………………9-11
Pre-cautions
Note
·When you doing repairing work on front wheel or suspension system. The vehicle must be lifted up stable
before working.
·Light, dashboard and switches repairing refers to chapter 12.
·Do not use too much force on wheels,and becareful not to damaged the wheels. 9
·When removing tires from the wheel.Use special tire and rim protector to avoid rim be damaged.
Item Standard Service

limit
Wheel Axial 1mm 2.0mm
Front wheel jump Radial 1mm 2.0mm
Figure left － 3.0mm
Tire
Pressure 70kPa（0.70kgf／cm2）10PSI －
Tightening Torque
Nut, steering tie-rod GB9457 M10x1.25 (30~40) N·m
Lock nut, steering stem GB9457 M10x1.25 (100~120)N·m
Bolt, front brake disc GB5789 M10x1.25x20 (40~50) N·m
Bolt, front caliper GB5789 M10x1.25x35 (40~50) N·m
Axle nut 5HY0-110001 (220~250) N·m
Bolt, front shock absorber GB5789 M10x1.25x55 (15~25) N·m
Wheel nut 901-07.00.02A (70~80) N·m
Bolt, A-arm 9060-050103 (40~50) N·m
9-1
Special tool
Bearing removing tool
Bearing remover 10mm
Pressor handle A
Pressor sleeve 28×30
Conductor 10mm
Locking nut wrench
Bearing removing tool
Rotor puller
Removing tool axle
Removing hammer
Installing tool shaft.
Trouble diagnose
Steering too heavy Wheel moving unsmoothly
·Steering bearing damaged or wearing. ·Wheel bearing bad
·Bearing inner outer circle damaged, wearing or got steps. ·Wheel installing bad
·Steering cloumnb got damaged. ·Breaking hose or wire twisted
·Tire pressure low Front suspension too soft
·Tire wearing ·Front shock absorber getting weak
Steering wheel movement ·Tire pressure too low
·Steering bearing damaged or untightened. Front suspension too hard
·Not fitful left and right shock absorber. ·Front shock absorber got damaged
·Tire is not in position
·Tire pressure too high
·Frame structure change.
Front shock absorber noise
·Tire wearing abnormal
·Front shock absorber bad
·Wheel bearing movement
·Front shock absorber getting loose.
Front wheel run out
·Wheel rim damaged Bad breaking effect
·Wheel bearing bad ·Bad breaking adjusting
·Tire bad ·Breaking disc got dirty
·Wheel balance not fit ·Breaking pad wearing
·Wheel axle tighten bad.
9-2
FRONT WHEEL
Removal
Securely support front wheels.
Remove wheel cap.
Remove the 4 wheel nuts no. 1.
Remove front wheel.
Rim&Inspection
Check rim for damages, deformation, nicks. If any
abnormal condition has been found, replace it.
Slowly turn wheel, use a dial gauge to measure
the rim run out.
Installation
Press rim into tire with special tool.
Fix wheel on the hub.
Wheel nuts tightening torque:70N·m~80
N·m
1. Axle Nut 2. Wheel Nut 090301
FRONT WHEEL HUB

Removal 9
Remove front wheel
Remove front brake caliper 5
Remove rim axle nut no. 2.
Remove brake disc and hub together.
Remove the 4 brake disc bolts no. 7.
Remove front wheel hub no .4 .
Installation
Tightening torque of axle nut : (220~ 250 N.m
Brake disc tightening torque bolts no. 6:25N.
m~35N.m(applythreadlocker)
2.axle nut 5. Front Wheel Hub 090302
3. Brake Caliper 6. brake disc
4.pin
7. Brake Disc Bolt 090303
9-3
FRONT BRAKE SYSTEM
Front Brake Caliper
Removal
Remove front wheel
Remove the two bolts no. 2.
Remove caliper no. 1.
Inspection
Check any cracks of brake calipers and oil leaks
from tightening areas. Replace if necessary.
090401
1. Brake Caliper
2. Bolt
BRAKE PADS
Removal
Remove brake caliper
Remove main sliding shaft of brake pads with al-
len wrench.
Remove brake pads.
Measure thickness of brake pad friction surface
no. 4, if it is less than 1.5 mm, then replace both
pads at the same time.
090402
3. Brake Pad
4. Brake Pad Friction Surface
9-4
BRAKE DISC
Removal
Remove front wheel
Remove brake calipers
Remove brake disc and wheel hub from vehicle.
Remove the 4 brake disc bolts shown in the right
picture, then remove brake disc.
Inspection
Thickness of brake disc: If less than 4.0 mm, re-
place it.
Installation
Brake disc tightening torquebolts:

( 40~50) N · m 1. Brake Disc Bolt 090501
FRONT BRAKE MASTER CYLINDER

Removal
Remove bolt no. 3. 9
Separate master cylinder no. 3 . It’ s not neces-
sary to remove it if replacement is not required.
Attention:
Do not hang the master cylinder by brake
line, keep master cylinder in place (not
inclined while installing it to avoid air en-
tering brake line.
Keep brake line routed properly (refer to
Chapter1 and ensure it is not kinked.
After installation of brake system, check
brake performance.
2 090502
2. Bolt
9-5
Rear braking caliper
Removal
Remove the rear caliper
Attention:
Keep brake line routed properly and ensure
it is not kinked. After installation, check if 4-
wheel brake lever or brake pedal can control
front brake. Inspect brake fluid level between
“UPPER” and “LOWER”, if necessary, add
DOT 4 fluid ( CFMOTO recommended into
brake fluid reservoir. Check brake light and
switch.
9-6
9 Front wheels, breaking ,suspenion and steering
Front suspension system 3
Front suspension LH
Note: When repairing supension system. Do not re-
move the left and rear suspension at the same time or
1
the vehicle body will be fall down.
Removal
Put the vehicle on the flat floor. Use jack to lift up the 4
2
vehicle front.
Remove the front wheel
090701
Remove the breaking caliper
Remove front wheel hub 1.Shock absorber 2.Front absorber lower mounting
Remove upper mounting bolt 2 bolt 3. Upper mounting bolt 4.Front torque nut
Remove lower mounting bolt 3
Remove the shock absorber 1
Remove front torque nut 4
Remove the cottor pin and locking nut on steering rod.

9
Remove the cottor pin and nut on steering joint of up- 5
per arm ball pin. 6
Remove the locking bolt on lower rocker arm ball pin.
6
5.Steering rod nut. 6. Nut 090702
Remove the locking nut and bolt or the rocker arm

and frame.
Remove the upper rocker arm
Remove the lower rocker arm 7 7
Pull out the steering joint from CV shaft.
The suspension has different style for this vehicle for
different customers. Here only introducing the basic
suspension. For other style suspension is almost the
same that can follow this way to maintenance.
7
090703
7. Upper and lower rocker arm locking bolt
LH
9-7
No. Name Qty No. Name Qty 090801
1 Nut 12 19 Retainer 55 2
2 Front torque bar 1 20 Hub bearing 2
3 Bolt 12 21 Main pin 4
4 Front torque bar cover 2 22 Nut 4
5 Front torque bar rubber seat 2 23 Cottor pin 4
6 Oil tip 6 24 Steering joint RH 1
7 Bolt 2 25 Front suspension cover RH 1
8 Frong shock absorber 2 26 Front rocker arm shaft 2
9 Front torque connecting rod RH1 27 Fronr lower rocker arm RH 1
10 Front torque connecting rod LH 1 28 Front rocker arm sleeve 2
11 Bolt 2 29 Fronr lower rocker arm LH 1
12 Retainer 32 4 30 Steering joint LH 1
13 Rear rocker arm shaft 2 31 Front suspension cover LH 1
14 Rocker arm sleeve 8 32 Rocker arm Sleeve 4
15 Frong upper rocker arm LH 1 33 O-ring 8
16 Rear upper rocker arm sleeve 2 34 Retainer 8
17 Frong upper rocker arm RH 1 35 Joint bearing 4
18 Front break disc block 2 36 Retainer 1 4
Disassemble
Front shock absorber
Removal
Note: If just replace the front shock absorber. It
needn’t remove other parts.
Remove the shock absorber bolt and nut between the
rocker arm and shock absorber.
Remove front shock absorber
Inspection
Inspect the shock absorber to see oil leaking.Oil seal
old or damaged. Replace if any trouble inspected
9-8
9 Front wheels, breaking ,suspenion and steering
Installation
The right shockabsorber is the same way as the left

one in removal and installation.
A-ARM
Note:There are totally 8 units of A-arm, procedure
of removal, disassembly, check and installation
is same, so only front upper A-arm (LH) and
front lower A-arm(LH) are introduced.
Front LH A-arms
Removal
Remove front shock absorber LH
Remove bolt and nut that connect the left front
left upper A-arm to the frame. 9
Remove the bolt nut that connect the left front
lower A-arm to the frame.
Remove front wheel, brake caliper and wheel hub
prior to shock absorber
Remove steering tie-rod before the removal of
bolts.
Remove steering knuckle from drive shaft before
removal of front LH A-arms .
Remove the front LH A-arms.
9-9
Front LH A-arm Inspection
Remove front upper A-arm (LH) no. 2
Remove circlip no. 3 (Type:GB894.1 34)
Remove top ball pin no. 1.
Check upper ball pin no. 1 if it can move freely
and also check its clearance. If it cannot move
freely or too big clearance, replace it. At the same
time, check grease inside top ball pin if it is
deteriorate. Check dust boot of ball pin if damaged
or aging.
Remove bushing no. 5 of front upper A-arm(LH.

091001
Check bushing no. 5 if damaged or aging, replace
if necessary.
Remove front A-arm (LH) no. 2

Remove snap ring no. 3 (Type: GB894. 1 34
Remove upper ball pin no. 1.
Check top ball pin no. 1 if it can move freely and
also check its clearance. If it cannot move freely
or too big clearance, replace it. At the same time,
check grease inside upper ball pin if it deteriorates.
Check dust boot of ball pin if it is damaged
or aged.
Remove bushing no. 5 of front lower A-arm(LH. 091002
Check bushing no. 5 if it is damaged or aged, re-
place it if necessary.
Installation
Use special tool to press ball pin into A-arm.
Note: Upper and Lower A-arms should not have free
play after installation.
Replace bushing no. 5 if any free play is evident.
Left Steering Knuckle Inspection

Remove left steering knuckle no. 3
Remove snap ring no. 1 (Type: GB893. 1 55).
Use special tool to remove hub bearing no. 2 091003
(Type: DAC3055.)
Check hub bearing for damage, binding and free
play. Replace it if necessary.
9-10
STEERING SYSTEM
1
STEERING COLUMN 3
Remove steering wheel upper cover
Remove the nut 1
Remove steering wheel 2
Remove the bolt 4
Remove the air spring 5 4
Remove the bolt 3 5 2
4
Loose the steering joint
1. Nut 2. Steering wheel 3. Bolt 091101

4. Bolt5. Air spring
9
Remove the bolt 6
Remove the steering column.
Installation
6
6
6 、solt 091102
9-11
Steering system
091201
9-12
EPS-Steering system
091301
9-13
10 Rear wheel,braking,suspension
Maintenance information…………………………10-1 Rear braking system…………………………10-4
Troube diagnose …………………………………10-2 Rear suspension system………………………10-5
Rear wheel…………………………………………10-3
Pre-WARNING.
Note
·When you doing rim and suspension system repairing. The vehile must be lift up by jack or other stable
tools.
·Rim and suspension screws must be approved by CFMOTO.
·Do not use too much force on the wheel.Be careful not to damage the wheel.
·Use tire rod and rim protector is a must to avoid the rim got damaged when removing the wheels.
Maintenance specification
I tem Sta ndard Se rvice lim it
W heel Axial 1 2. 0mm

ju mp Radia l 1 2. 0mm
Rear
whee l G roove － 3mm 10
Tire lef t
Pr essur e 100 kP a(14PSI) －
Tightening Torque:
● Axle Nuts: 5HY0-110001 (220~250) N· m
● Bolt, rear brake caliper: M10×1.25×45 GB5789 (40~50) N· m
● Wheel Nuts: 901-07.00.02A GB5789 (70~80) N· m
● Upper Shock Mounting Bolts&Nuts: M10×1.25×55 GB5789 (40~50) N· m
● Lower Shock Mounting Bolts&Nuts: M10×1.25×60 (40~50) N· m
10-1
Trouble diagnose
Rear wheel runout
·Rim distortion
·Tire bad
·Tire pressure too low
·Wheel balance becoming worse
·Wheel axle nut bad tighten.
·Wheel nut getting loose
Rear shock absorber too soft

·Sprint force weak.
·Rear shock absorber oil leak.
Rear shock absorber too hard

·Rear shock absorber got bent.
·Tire pressure too high
Bad braking effect

·Braking adjusting bad
·Braking pad or disc got dirt.
·Bra king pad wearing.
10-2
10 Rear wheel,breaking,suspension
Rear wheel
Removal
Same as the front wheel.
Rim inspection
Inspect the rim to see damaged, distortion, cracks or other troubles. If so, replace the rim.
Turn the wheel slowly to see the dialgauge run out.
Service limit: Axial：2.0mm
Radial: 2.0mm
Same as front wheel
Rim mountint nut torque:70N·m~80N·m

10
Installation
Same as front wheel
Wheel hub
Removal
Remove the rear wheel
1
Remove whel hub mounting nut.
Remove the wheel hub. 2
Installation
3
Wheel nub mounting nut no.3
torque:220N·m~250N·m
100301
1. Rear Brake Caliper 2. Front Wheel Hub
3. Axle Nut
10-3
Parking break
Removal 1
Remove the Bolt no.1
Remove the Rear break caliper no.2
2
Rear breaking system

Rear breaking caliper
Removal
Remove bolt 3 to disassemble the rear breaking caliper. 1. Bolt 100401
Inspection 2. Rear brake caliper
Inspect the breaking caliper to see cracks or leaking.
If so, replace the part into new one.
Note: Oil line direction should be make sure the
oil line cannot be jammed first.
The breaking force must be inspected after break-
ing system installed. If the front and rear break
cannot work together. Check the connectors.
Inspect the breaking fluid cup to make sure the
level is between upper and lower line. Refill the
DOT4 breaking fluid if needs and inspect the
breaking switch and breaking light works well of
not

Breaking disc
Remove rear wheel LH
Remove the drive shaft.
Remove rear break caliper
Remove break disc 6 mounting bolts.
Remove the break disc
Inspection
Breaking disc thickness: If less than 4mm. Replace
into new one
Measure rear breaking pad.

If rear breaking pad level 2 is less than 1.5mm. Re-
place the 2 pads at the same time.
Installation
10-4
10 Rear wheel,breaking,suspension
Rear suspension system
Note: Do not remove the LH and RH parts at the same time. Or the vehicle will fall .
10
100501
No. Name Qty No. Name Qty

1 Ball pin 1 18 Rear wheel hub lower shaft 2
2 Rear torque bar assy 1 19 Rear upper arm LH 1
3 Nut 18 20 Rocker arm sleeve 4
4 Bolt 4 21 Rear upper rocker arm sleeve 2
5 Oil tip 4 22 Rear rocker arm mounting sha 2
6 Torque bar cover 2 23 Rear upper rocker arm RH 1
7 Torque bar seat 4 24 Rear wheel hub RH 1
8 Ball pin LH 1 25 Rear shock absorber 2
9 Bolt 10 26 Bolt 4
10 Rear break disc block 2 27 Rear suspension cap 4
11 Retainer-A 2 28 Rear lower rocker arm RH 1
12 Wheel hub bearing 2 29 Suspension cover 2
13 Rocker arm rubber sleeve 16 30 Rear lower rocker arm LH 1
14 Rear wheel hub upper slee 6 31 Retainer 1 8
15 Bolt 6 32 O-ring 8
16 Rear wheel hub lower sleeve2 33 Retainer 8
17 Rear wheel hub 1 34 Joint bearing 4
10-5
Disassemble
Torque bar assy
Removal
Remove bolt 30. Remove pressing cap and 3 rubber
seat.Nut 11，Remove left ball pin assy 26 and right
ball pin assy 25. Remove balance bar.
Installation
Rear shock absorber

Removal
Note: When removing shock absorbers LH/RH.
The vehicle must be lifted up stable by jack or
other tools.
If repairing rear shock absorber only. It needn’t
to remove the suspension part from vehicle body.
Remove rear shock absorber LH mounting bolt and
nut.
Remove rear shock absorber LH.
Installation
Rear rocker arm LH

Rear rocker arm LH removal, inspection and installa-
tion refers to front upper/lower arm LH on chapter 12.
Rear suspension RH
Rear suspension RH removal, inspection and installa-
tion is as same as LH..
10-6
11 Front and rear axle
11. Front and rear axle

11.1 Maintenance information ………………………………11-2
11.2 Removal and installation ………………………………11-4
11.3 Lubrication oil replacement ……………………………11-5
11.4 Front axle disassembly …………………………………11-6
11.5 Front axle disassembly inspection ……………………11-7
11.6 Front axle assemble and adjustment………………… 11-8
11.7 Rear axle disassembly…………………………………11-11
11.8 Rear axle disassembly inspection……………………11-13
11.9 Rear axle assemble and adjustment…………………11-14
11
11-1
L u b r ic a tio n p e r io d lis t
Ite m M odel C a p a c ity R e p la c e P e r io d
F ir s t tim e E ac h
F r o n t a x le S A E 15W / 0 .3 3 L
350k m 5000k m
40S F or
S A E 80W -
F ir s t tim e E ac h
R e a r a x le 9 0 G L-5 0 .4 0 L
350k m 5000k m
Tighten torque form

No Item Qty Screw type Torque(N·m) Remark
1 F ront axle case bolt 7 M8×28 25
2 Front axle motor screw 4 M8×20 13
Front axle pin locking With thread
3 1 M8×10 13
screw locking glue
4 Front axle nut 1 M14×1.5 62
5 Differential mounting bolt 6 M10×1.25×18 45
6 Front axle oil filling bolt 1 M14×1.25 ×12 25
7 Front axle oil drain bolt 1 M14×1.25 ×12 25
8 Front axle limiting screw 1 M64×1.5×7-LH 80
With thread
9 Rear axle input bolt 1 M10×1.25×20 50
locking glue
Rear axle input bearing
10 4 M8×28 25
seat bolt
11 Rear axle case bolt 6 M8×28 25
Rear axle case locking
12 2 M10×1.25×25 40
bolt
With thread
13 Rear axle differential bolt 8 M10×1.25×70 45
locking glue
14 Rear axle oil filling bolt 1 M14×1.25×12 25
15 Rear axle oil drain bolt 1 M14×1.25×12 25
11-2
● Inspection and maintenance
If any trouble below comes out. The front or rear axle may be damaged already.It needs inspection and
maintenance.
Trouble Reason
A.Bearing damaged
①The vehicle running unstable when accelerate and B.Gear clearance too large or too small
deaccelerate. C.Gear wearing
D.Gear teeth broken
E.Driveshaft damaged
②Front or rear axle noise. F.Little oil or even no oil
G.Front and rear gear case has rarity
③Engine power cannot transmit to front or rear wheel.
Note：A,B,C reason is hard to diagnose out. It needs to analyze the trouble to make sure there is no engine
trouble. And disassemble the axle if needs.
Inspect and analyze
1.Do not miss any noise
a.When vehicle accelerate and deaccelerate has noise comes out.And the noise has no relation with the
engine. It may be the wheel bearing damaged.
b.If the vehicle noise continously when accelerate and deaccelerate.It may be gear clearance adjusting
problem. 11
Note: Front/rear axle adjusting or installing bad will cause gear wearing or even teeth broken.
c.Vehicle has noise when low speed riding. And the noise may not heard when at high speed. It maybe teeth
broken.
Warning: If the vehicle got trouble mentioned. Please stop the vehicle immediately for inspection and continously
ride after maintenance or it may cause accident.
2.Check the engine oil level
Inspect the oil level and see if any metal shaved piece in or not.
3.Inspect the lubricating oil leaking
a.Inspect the front/ rear axle to see oil dirt.
b.Inspect the parking ground to see the oil dirt
c.Inspect the oil flashments.

Inspect the case body leaking or oil seal leaking. Replace the damaged parts
11-3
11.2 Removal and installation
Removal:Lift the vehicle up and meke sure the vehicle cannot dropped.
Remove the rear wheel, rocker arm and other related parts.
Remove front axle mounting bolts and nuts(1, 2, 3, 4).See drawing blow
Remove rear axle mounting bolts and nuts (1, 2).See drawing blow
Installation:Reverse the removal procedure for installation

Front axle mounting bolt(GB5789 M10 × 1.25 × 25)torque:50N·m～60N·m
Rear axle mounting bolt(GB5789 M10 × 1.25 × 30)torque:50N·m～60N·m
Front axle mounting nut(GB6187 M10 × 1.25 )torque:50N·m～60N·m
Rear axle mounting nut(GB6187 M10 × 1.25) torque:60N·m～70N·m
11-4
11.3 Front and rear case lubrica-

tion oil replacement
Makesure the front and rear axle are horizontal be-
fore replace the gear oil.
Note: Front and rear axle maybe high heat

before working . Please wait until it is cool
down.
Put a container under the axle oil drain bolt.；

Clean the oil drain bolt area:
Remove oil drain bolt and sealing washer( See part 1,
2 on right drawing).
Make sure the oil is drained totally
1:Sealing washer
Clean up the dirt on oil drain bolt； 2:Front axle oil drain bolt
Tight up the oil drain bolt: 3:Sealing washer
Oil drain bolt tighten torque: 25N·m 4:Front axle oil filling bolt
Loose up the oil filling bolt and sealing washer(See

part 3 and 4).
Fill the lubrication oil；
Oil capacity: Front axle 0.33L, Rear axle 0.40L. 11
Tight up the oil drain bolt
Oil filling bolt tighten torque: 25N·m
Note: If the sealing washer is damaged. Replace into

new one. Do not missing it, or it will leaking.
1:Sealing washer
2:Rear axle oil drain bolt
3:Sealing washer
4:Rear axle oil filling washer
11-5
11.4 Front axle disassamble

1 Front axle nut M14*1.5 1 16 Screw M8*10 1
2 Front axle nut washer 1 17 Bearing 16007 1
3 O-ring 14*6.8 1 18 Retainer 62 1
4 Front axle input disc 1 19 Spline sleeve 1
5 Oil seal 48*65*9 1 20 Spline sleeve 1
6 Limit screw M64*1.5*7-LH 1 21 Adjusting washerØ83*711~2
7 Bearing 6305 1 22 Differential 1
8 Adjusting washerØ83*71 1~2 23 O-ring 141*2.4 1
9 Front axle drive gear 1 24 Front axle cover 1
10 Bearing F1512 1 25 Bolt M8*28 7
11 Front axle body 1 26 Gear rack 1
12 Bolt M14*1.25 2 27 O-ring 81.3*1.9 1
13 Washer 14 2 28 Front axle motor 1
14 Oil seal 24*38*8 2 29 Screw M8*20 4
15 Pin 1
11-6
11.5 Front axle disassemble inspection
●Inspect the front axle case and cover to see cracks and other damages. If any troubles inspected. replace
the cover.
●Inspect the front axle bearings to see the clearance is OK or not. And test the running smoothness. Track,
steel ball, needle and bracket. Replace the bearing if any trouble inspected out.(Use special tool)
●Inspect the front axle too see the lip and O-ring problem. If any problem inspected, replace the parts.
●Inspect the oil seal lip and cylinder surface fitment. If any trouble inspected. Replace the parts.
●Inspect the front axle input gear and big differential gear to see abnormal wearing. If any trouble inspected.
Replace the parts.
● Inspect the differential assy’s teeth, medium gear shaft and bracket wearing. Replace the parts if any
trouble comes out.
●Inspect the inner and outer spline wearing. If anu trouble inspected replace the parts.
11
●Inspect the gear rack teeth wearing. If any trouble inspected. Replace the parts.
●Inspect the front axle motor to see it can well-work or not. Replace if any trouble inspected.
Use special tool to test the motor or tested on the vehicle.
●Inspect the front axle to see parts damaged. Replace the part if any trouble comesout.
11-7
11.6 Front axle assemble and installation
●Front axle case assemble

Use suitable adjusting washer 8 To make sure front
main gear 9 has suitable clearance.
Adjusting
washer thick- 0.1 0.2 0.3 0.4
ness 0.5 1.0
Part 6 Tighten torque 80N·m
Part 1 Thghten torque 62N·m

Note:Oil seal, bearing, Spline must be prelubricated
before assembly.
Part 1 Cover the thread locker
Note: Oil seal, bearing must be pre-lubricated before
assembly.
●Differential assembly
Note: Bearing and differential gear must be pre-lubri-

cated before assembly.
Use suitable adjusting washer to make sure the
differential gear working well.
A d j u s t i n g 0.1 0.2 0.3 0.4

washer thick-
ness 0.5 1.0
Part 31 tighten torque 45N·m

Adjusting
washer thick-
ness
11-8
●Front axel assembly and adjusting

Follow the drawing on the right to assembly:：
Tighten torque
Part 25 25N·m
Part 29 13N·m
Part 16 13N·m
Oil inner plug 25N·m
Oil drain plug 25N·m
Part 16 must be covered with thread locker
a.Use adjust washer 8 and 21 to adjust the axle

gear clearance.
The way of gear clearance measuring like right

drawin. Use the special tool and tight the bolt
(M10×1.25×60)Use the dialgauge. Make sure
the touching point is 21mm to the centre. Turn
the measuring tool to see the date.
11
Dialgauge data standard: 0.10~0.25
A d j u s t i n g 0.1 0.2 0.3 0.4

washer thick-
ness 0.5 1.0
b.Gear rack and spline sleeve must be totally to the

direction shown on the right.
11-9
c.Use special tool or vehicle wire to set the axle motor
to 2WD position.
d. Make sure step b and step c is finished. Use screw

to mount the axle motor.
11-10
11.7 Q860 Rear axle disassembly
11
1 Bolt M10×1.25×20 1 16 Oil drain bolt M14×1.25×12 1
2 Washer 10×27×4 1 17 Rear axle case 1
3 Rear axle input 1 18 Bevel bearing 32910 2
4 O-ring 25×2 1 19 Adjusting washer 61×50.5 4~6

5 Oil seal 35×50×7 3 20 Auto differential lock 1
6 Bevel bearing 33005 1 21 Rear axle case 1
7 Bolt M8×2 8 10 22 Bolt M10×1.25×25 2
8 Bearing seat 1 23 O-ring 151×3 1
9 Adjusting washer 1~3 24 Bolt M10×1.25×22 8
10 O-ring 55×2.5 1 25 Inner teeth friction disc 3
11 Adjusting washer 32×25.4 2 26 Outer teeth friction disc 4
12 Bevel bearing 32006 1 27 Washer 1

13 Rear axle bevel gear 1 28 Inner friction disc 1
14 Oil drain bolt M14×1.25×12 1 29 Steel disc 1
15 Washer 14 2
11-11
Q860-4 Rear axle disassembly

1 Bolt M10×1.25×20 1 16 Oil inner bolt M14×1.25×12 1
2 Washer 10×27×4 1 17 Rear axle gear case 1

3 Rear axle inner flange 1 18 Bevel bearing 32910 2
4 O-ring 25×2 1 19 Adjusting washer 61×50.5 4~6

5 Oil seal 35×50×7 3 20 Mounting bracket 1
6 Bevel bearing 33005 1 21 Rear axle cover 1
7 Bolt M8×2 5 10 22 Bolt M10×1.25×25 2
8 Bearing seat 1 23 O-ring 151×3 1

9 Adjusting washer 1~3 24 Bolt M10×1.25×18 8
10 O-ring 55×2.5 1
11 Adjusting washer 32×25.4 2
12 Bevel bearing 32006 1
13 Rear axle bevel gear 1
14 Oil drain bolt M14×1.25×12 1

15 Washer 14 2
11-12
11.8 Rear axle disassemble inspection
●Inspect the rear axle case and cover to see cracks or other damages.Replace the part if trouble inspected.
●Inspect the rear axle bearings to see if it can working well or not.Track, steel ball, needle and bracket are ok
or not. Replace the bearing if trouble inspected out. (Use special tool)
● Inspect the rear drive bevel gear and driven bevel gear too see the teeth wearing. If trouble inspected.
replace the parts.
● Inspect the rear case oil seal lip and O-ring to seel if it is OK or not. Replace the part if any trouble
inspected.；
●Inspect the rear case surface and oil seal lip to see fitment. Replace the part if any trouble inspected.
●Inspect the rear case inner and outer spline to see wearing. Replace the part if any trouble inspected.
●Inspect the differential lock. Replace the part if trouble inpected.
●Inspect the whole rear axle to see other damage. Replace the part if needs.
11
11-13
11.9 Rear axle assemble and adjustment
●Rear axle drive bevel gear assembly

a. Choose the adjusting washer 11. Make sure
part 13 works smoothly and the axle clearance is
less than 0.05

Note:Oil seal, bearing, Spline must be prelubricated
before assembly.
Adjusting washer 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 assembly
Note: Pre-lubricate before assemble
●Driven bevel gear assembly

Note: Pre-lubricate before assemble
11-14
●Rear axle assemble and adjustment
Assemble by following drawing on the right
Tighten torque
Part 7 25N·m
Part 22 40N·m
Oil inner bolt 25N·m

Oil outer bolt 25N·m
a.Choose the part 9 and part 19 thickness

Make sure:
1.Rear axle bevel gear 13 is in the right position and
teeth well touched. Side clearance 0.10～0.20;
2.Bevel bearing 18 axial clearance is smaller than 0.
06.
3.All the parts works smoothly without jamming

0.1 0.3 0.5 0.9 0.92 11
0.94 0.96 0.98 1.00

0.2 0.3
11-15
b.Bevel gear clearance testing: Set the dial gauge,
tight the bolt(M14×1.25×60). Make sure the test-
ing point is 37mm distance to the center. Turn the
flange and read the dial gauge data.
Clearance standard: 0.17～0.34
11-16
12 Vehicle chassis
Driveshaft
12.1 Driveshafts and CV shafts maintenance information……………12-2
12.2 Driveshafts and CV shafts removal and installation ……………12-3
12.3 CV shaft disassembly…………………………………………………12-5
12.4 CV shafts disassembly inspection…………………………………12-6
12.5 Front drive shaft disassemble and inspection……………………12-7
12.6 Rront drive shaft disassemble and inspection……………………12-8
12
12-1
12.1 Driveshafts and CV shafts maintenance information
Inspect and repairing

If one of the trouble below comes out. The CV shaft or driveshaft maybe in trouble. It needs maintenance.
Trouble Reason
①Venicle running unstable on the way. A.CV shaft dropped out from axle.
②CV shafts and driveshafts comes noise. B.CV shaft broken or joint broken.
C.CV shafts or driveshaft boots broken.
③Grease splash out from CV shafts and drive shafts.
D.Front driveshaft joint damaged
④The engine power cannot transmit to front wheel or E.Rear driveshaft broken or spline damage.
rear wheel. F.Mounting bolt loose.
Caution: Please carefully analyze the trouble to make sure the engine and axles are OK. Then remove the
part if need inspection.
Inspection and judgement
1.Do not miss any noise
a.The vehicle comes noise when accelerate and deaccelerate. And the noise has no relations with engine
and axles running.
It maybe the CV joint damaged.
Or the wheel bearing broken.
2.Inspect the CV shaft boot and driveshafts boot. If any damage inspected,replace the part.
3.The CV shaft not tight enough can damage the spline of front and rear axle and finally cause the power
cannot be transmited.
Warning: If any trouble mentioned happend on the vehicle. Please stop the vehicle immediately and inspect.
Make sure the vehicle is OK. Or it may cause accident.
12-2
12 Vehicle chassis
12.2 Driveshafts and CV shafts removal and installation

Front and rear CV shaft removal:
Lift the vehicle up to make sure the vehicle cannot fall off.
Remove front or rear wheel, rocker arm and other related parts.
Pull part 1,3,4,6 out from front and rear axles(See drawing below).Do not pull too hard to avoid
damage the retainer. If cannot pull out. Please try to turn the shaft for several angle and try again.
Front driveshaft removal： 120301

Remove front wheel, rocker arm and other related parts. 12
Loose up 4 bolt on front axle, washer and 4 bolts on engine, washer(See part 2 and 3 on drawing
below).Hole the drive shaft one side and push to another side. The front driveshaft assy¢ń(Part 4)And front
drive shaft assy.(Part 7) can be removed.
Note: Use grease to pre-lubricate the midium spline.
120302
12-3
Rear driveshaft removal：
Remove rear wheel, rocker arm and other related parts.
Loose up 4 bolts on rear axle, washer and 4 bolts on the engine, washer.(See parts 1 and 2 below).
Hole the drive shaft one side and push to another side. The rear driveshaft (Part 3) to remove it.
Note: Pre-lubricate the spline before assembly.
120401
Install: Reverse the removal procedure for installation.

Front driveshaft mounting bolt(M8 × 1 × 22)torque:35N·m～45N·m Rear
driveshaft mounting bolt(M10 × 1.25 × 25)torque:40N·m～50N·m
12-4
12 Vehicle chassis
12.3 CV shaft disassembly
120501
12
120502
12-5
12.4 CV shafts disassembly inspection
●The CV shafts joint should be working smoothly. If got stuck, uncontinous running or noise, the shaft must
be inspected or replaced.
● Inspect the shaft joint and spline turning clearance. If the turning clearance is larger than 1.5 degree.
Replace the part.
●Inspect the CV shaft boots. If damaged or leaking. Replace the part.
●Inspect the CV shaft spline and retainer. If abnormal wearing or damage. Replace the part.
● Inspect the CV shaft joint bracket, sleeve, steel ball, track and spline to make sure it is OK. If trouble
inspected, replace the part.
●Inspect other parts of the CV shaft to see damaged. If trouble inspected, replace the parts.
Note: Inject lithium grease in the CV shaft joint. Inject 28g±5g for stable side and 32g±5g in side the boot.
For front CV shaft can inject 65g±10g in joint. The rear CV shaft can be injected 95g±10g in the joint.
12-6
12 Vehicle chassis
12.5 Front drive shaft disassemble and inspection
120701
●The joint of the driveshaft should be turning smoothly. If got jammed, uncontinous running or noise. Disas-
semble the part for inspection or replace the parts.
12
●Inspect the joint pin(Part 2).If there is no grease or leaking. Inject the grease or replace the parts.
●Inspect the driveshaft dust boot(Part 3)If damaged replace the part.
● Inspect the driveshaft boot(Spline) to see the grease is enough or not. Or the spline maybe wearing or
damaged.
●Inspect the spline on the driveshaft. If damaged or abnoral wearing, replace the parts.
●Inspect the inner and outer spline clearance. If the clearance is too large. Replace the parts.
●Note: Use grease to pre-lubricate the spline before installation.
12-7
12.6 Rront drive shaft disassemble and inspection
120801
●Then drive shaft should be work smoothly. If stucked, uncontinous running or noise. Disassemble the shaft
for inspection or replace the parts.
●Inspect the driveshaft boots(See part 3),Replace if damaged.
●Inspect the driveshaft boot to see the grease is enough or not or the spline maybe wearing or damaged.
●Inspect the spline on each side. If wearing or damaged, replace the parts.
●Inspect the inner and outer spline clearance. If the clearance too large, replace the parts.
●Note: Use grease to pre-lubricate the spline before installation.
12-8

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This manual introduces CF1000US-2 maintenance information,

CFMOTO reserves right to make

Please read below explanation carefully,it explained the meaning of “DANGER/

Maintenance information………….............. 1-1 Tightening torque table........................ 1-12

Cautions for removal and installation

1. Vehicle identification number(VIN) 010301

2.Engine identification number(EIN) 010302

Engine type 2V91Y

Front 27× 9.00R14 60L; 27× 9.00-14 61L

Min. ground clearance 310mm

Oil Change 2400mL(without oil fil er replacement) -

Total dry: 2600mL -

Recommended engine oil15W-405W-50

15W-40, 15W-50 • Recommended engine oil: SAE-15-W-40

Co -30 -20 -10 0 10 20 30 40

Air Intake System

Throttle Body Part NO. 0JY0-173000

T-MAP Sensor Part No. 0JY0-175000

Fuel Injector Part No. 0JYA-171000

Idle speed 1300r / min±130r / min

Relations b e t we e n wa t e rt -20 / 10.31±0.5

Free play of brake pedal 10 mm~15m m

Peak voltage of pick -up coil ≥1.5V,200 RPM

Cylinder, Piston, Piston Ring & Crankshaft

Cylinder compression 1000kPa

Belt width 34.5 (Cord layer) 33.5

Ref. No. Items Part number Qty Torque

4 Front A-arm shaft 9060-050103 6 40~50

5 Rear A-arm bolt GB5789 M10×1.25×90 4 40~50

6 Upper bolt, rear knuckle GB5789 M8×20 6 35~45

7 Lower bolt, rear knuckle

8 Lower shaft, rear knuckle 9060-060704 2 40~50

9 GB5789 M10×1.25×55 4 40~50

12 Mount nut, rim 901-07.00.02A 16 70~80

13 Nut, rim shaft 5HY0-110001 4 220~250

14 Bolt, rear brake caliper GB5789 M10×1.25×45 4 40~50

15 Bolt, front brake disc GB5789 M10x1.25x20 8 40~50

16 Bolt, front brake caliper GB5789 M10×1.25×35 4 40~50

17 Nut, steering linkage GB9457 M10×1.25 4 15~25

18 Upper bolt, mufflr body GB5789 M8×40 2 30~40

19 Lower bolt, muffler body GB5789 M8×60 2 30~40

20 Nut, rear axle GB6187 M10×1.25 4 60~70

21 Nut, front axle GB6187 M10×1.25 1 50~60

22 Bolt, front axle GB5789 M10×1.25×25 1 50~60

23 Bolt, front axle GB5789 M10×1.25×30 1 50~60

24 Bolt, bracket of front axle GB5789 M8×14 4 30~40

25 Bolt, front drive shaft 9010-290001 8 35~45

26 Bolt, rear drive shaft GB/T70.1 M10×1.25×25 8 40~50

27 Output coupler bolt GB 5789 M10×30 2 70~80

30 Tie rod nut GB 9457 M10×1.25 4 40~50

31 Fuel pump screw GB 70 M5×16 5 5

Nut, drive shaft（CVT drive pulley） 1 M20×1.5 115 Threadlocker

Lock nut, bevel gear 1 M22×1 145

Bolt M8x28(bearing seat, drive bevel gear) 4 M8×28 32

Screw M8x5（bearing holder, drive bevel gear） 4 M8×5 15

Stopper nut,M65X1.5(driven bevel gear) 1 M65×1.5 110 Threadlocker

Nut M8X28(bearing housing, driven bevel gear) 4 M8×28 25

Screw T25(shift fork drum) 1 M5×8 6

Spring seat, Limit 1 M12×1 20

Screw M5×16（oil pump） 3 M5×16 7 Threadlocker

Screw M8X20（overriding clutch） 6 M8×20 30 Threadlocker