CFMoto CF500-5B - CF500-5C Service Manual

CFMOTO
CF500-5B Service
CF500-5C Manual
WWW.CFMOTO.COM
WWW.CFMOTO.COM
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Zhejiang CFMOTO Power Co., Ltd.
Aug. 2009
FORWARD
CONTENTS
Maintenance information 1
This manual introduces X5 EFI version (CF500-
5B/5C) maintenance information, disassembly Vehicle body!Muffler 2
procedure, check & adjustment methods, trouble-
shooting and technical specifications. There are Checking&Adjustment 3
illustrations, drawing to guide your operations. Cooling&Lubricating system 4
Chapter 1 mainly introduces general operation Engine disassembly&assembly 5
information, tools, vehicle structure and basic
Engine disassembly,check&assembly 6
specifications.
Chapter 2 mainly introduces check & adjustment Fuel supply&Air intake system 7
methods and how to do vehicle maintenance.
Chapter 3 mainly introduces disassembly,
Front wheel!
Brake!
Suspension!
Steering system 8
installation, adjustment, maintenance and trouble- Rear wheel!Brake!Suspension system 9
shooting information.
Front & rear axle 10
Electric system 11
CFMOTO reserves right to make improve-
Lighting!Odometer!Switch 12
ments and modifications to the products
without prior notice. Overhaul and mainte- Troubleshooting 13
nance should be done according to actual
condition of vehicle.
Zhejiang CFMOTO Power Co., Ltd.
Aug. 2009
Conversion table
Item Example Conversion
Pressure 200 kPa"2.00kgf / cm2 ) 1kgf / cm2=98.0665kPa 1kpa=1000Pa
33kPa (250mmHg) 1mmHg=133.322Pa=0.133322kPs
Torque 18N#m"1.8kgf -m) 1kgf#m=9.80665N#m
Volume 419ml 1ml=1cm3=1cc
1l=1000cm3
Force 12N"1.2kgf$ 1kgf=9.80665N
1. Maintenance Informat ion
C a uti o n! !! !! ! !! !! 1- 1 Tightening Torque!!!!!!!!1-13
Numbers Marking Locations!!!!!1-3 Grease & Seasant!!!!!!!!1-18
Main Parameters Table!!!!!1-4 Wiring, Pipe & Cables Layout!!!1-19
1
Maintenance Parameters Table!!!1-6 Failure I ndicator!!!!!!!!1-23
Cautions
Safety Cautions
1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly ventilated place for long time.
2. Do not touch the engine or muffler with bare hands after the engine has just stopped to avoid scalding. Wear long-
sleeve work clothes and gloves for operation.
3.Battery liquid (dilute sulfuric acid) is highly caustic and may cause burns to skin and eyes. Flush with water if
splashed to skin and get immediate medical attention. Flush with water if splashed to clothes to avoid burns. Keep
battery and liquid away from reach of children
4.Coolant is poisonous. Do not drink or splash to skin, eyes or clothes. Flush with plenty of soap water if splashed to
skin. If splashed into eyes, flush with water and consult the doctor. If drinking the coolant, induce vomit and consult the
doctor. Keep coolant away from reach of children.
5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and mask.
6. Gasoline is highly flammable. No smoking or fire. Also keep against sparks. Vaporized
gasoline is also explosive. Operate in a well-ventilated place.
7.When charged, Battery may generate hydrogen which is explosive. Charge the battery in a well-ventilated place.
8. Be careful not to get clamped by the turning parts like wheels and clutch.
9. When more than two people are operating, keep reminding each other for safety purpose.
Cautions for Disassembling and Assembling
1. Use genuine CFMOTO parts, lubricants and grease

3. Clean the mud, dust before overhauling
2. Store the disassembled parts separately in order for correct assemble.
4. Replace the disassembled washers, o-rings, piston pin retainer, cotter pin with new ones.
5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers.
6. Clean and blow off the detergent after disassembling the parts. Apply lubricants on the surface of moving parts.
Measure the data during disassembly for correct assembling.
7.If you do not know the length of screws, install the screws one by one and make sure they are screwed in with same
depth.
8.Check if the disassembled rubber parts are aged and replace if necessary. Keep the
rubber parts away from grease.
9.Pre-tighten the bolts, nuts and screws, then tighten according to the specified torque,
from big to small and from inner side to outer side.
10Replace aged latex parts before assembling. Do not mix volatile oil and grease on the surface,due to aggressivness
of fuel and oil.
11Apply or inject recommended lubricant to the specified parts
12Use special tools wherever necessary.
13 When ball bearing disassembled by pressing ball ring, it can not be reused.
1-1
CFMOTO
14 . Turn the i nner and outer r i ngs of ba l l bear i ng to make sure the bear i ng w i l l turn
smooth l y .
"Rep l ace i f the ax i a l or rad i a l p l ay i s too b i g .
"I f the surface is uneven, clean wi th oi l and replace i f the clean ing does not help.When
press i ng the bear i ng i nto the mach i ne or to the shaf t .
15. Instal l the one- s ide dust - proof bear i ng in the r i ght di rect ion . When assemb l i ng the open
type or doub l e- s i de dustproof bear i ng , i nsta l l w i th manufacturer#s mark outward .
16. Keep the bear ing b l ock st i l l when bl owi ng dry the bear i ng af ter washi ng clean. App ly oi l
or l ubr i cant before assemb l i ng .
17 . Instal l the el ast i c ci rc l i p proper l y . Turn the ci rcl i p af ter assemb l i ng to make sure i s
has been i nstal l ed i nto the s l ot .
18 . Af ter assemb l i ng , check i f a l l the t i ghtened parts are proper l y t i ghtened and can move
smooth l y .
19 . Brake f l u i d and coo l ant may damage coat i ng , p l ast i c and rubber parts . Fl ush these parts
w i th water i f sp l ashed .
20 . Instal l o i l seal w i th the s i de of manufacturer#s mark outward .
"Do not fo l d or scratch the o i l seal l i p .
"App l y grease to the o i l seal l i p before assemb l i ng
21. When i nstal l ing p i pes, insert the pi pe t i l l the end of j o int . Fi t the p ipe cl ip , i f any ,
i nto the groove. Rep l ace the p i pes or hoses that cannot be t i ghtened .
22 . Do not m i x mud or dust i nto eng i ne and / or the hydrau l i c brake system .
23 . C l ean the gaskets and washers o f the eng i ne cas i ng be f ore assemb l i ng . Remove the
scratches on the j o i nt faces by po l i sh i ng even l y w i th an o i l stone.
24 . Do not tw i st or bend the cab l es too much . D i storted or damaged cab l es may cause poor
25 . When assemb l i ng the parts of protect i on caps , i nsert the caps to the grooves , i f any .
1-2
Numbe r s Ma r k i ng L ocat i on
CF500 - 5B / CF500 - 5C
V I N Number!
! LCELDTS5" " / LCELDTS6 1
Eng i ne Numbe r !CF188 - B"
"
1-3
CFMOTO
Ma i n Dat a Tab l e
Item Parameter
Model CF500-5B/CF500-5C
Length CF500-5B: 2100mm CF500-5C: 2300mm
Width 1180mm
Height 1230mm
Wheel base CF500-5B: 1290mm CF500-5C: 1490mm
Engine type CF188
Displacement 493C m 3
Fuel type Unleaded gasoline RQ-90or above
Dry weight CF500-5B: 344 kg CF500-5C: 358 kg
Number of Passengers CF500-5B:2 $ Include driver%
Max. Load 210 kg
25!8-12 40J
Front Tire
Tire 185/80-12 40J
25!10-12 47J
Rear Tire
270/60-12 47J
Min. Ground Clearance 275mm
Turning Diameter Turning Diameter
Starting Electrical starting, Manual Starting
Single cylinder, 4-stroke, Liquid-cooled, 4
Engine Type
valves, OHC
Combustion Chamber Type Triangle
Valve Driving Type SOH C /Chain Drive
Bore !Stroke 87.5mm!82.0mm
Engine Compression Rati o 10.2:1
Lubrication Type Pressure & Splash
Oil Pump Type Rotor
Lubricant Filter Type Full flow filter screen
Oil Type SA E15W-40/SF
Cooling Type Closed coolant circulati on
Coolant Type -35& anti-rust coolant
1-4
Item Parameter
Air Filter type Sponge element filter
Fuel Type Type: CF188-B-173000 1
Devic e Valve Diameter of mixing 36mm
valve
Clutch W et, A uto-Centrifugal
Operation
Automatic$ CVT% +P arking & Gear S hi fting
Mode
Gears Shift Low Gear, High Gear & Reverse Gear
Shift
Manual /L-H-N -R
Mode/order
$ CV T %
Transmis sio 2.88' 0.70
n Ratio
Final Ratio 1.333$ 24/18( Bevel Gear%
Secondary
1.952$ 41/21%
Ratio
Gearing
Gear Low Gear ) 2.25(36/16) * H igh Gear )
Ratio Gears 1.350(27/20) * R ev erse Gear )
1.471(25/17)
Low Gear5.857 * High Gear ) 3.514 *
Total
Reverse Gear) 3.828
Front
33 / 9 = 3.667
Axle
Axle Ratio
Rear
33 / 9 = 3.667
Axle
Engine Output Mode Front/Rear Shaft
Direction of Output
Clockwise on forward shift
Rotation
Steering Steering Inner 31º
Devic e Angle Outer 31º
Front Hydraulic D isc
Brak e Type
R ear Hydraulic D isc
Bumper
Suspension Swing Arm
Devic e
Frame Type W elded Steel Tube and Plate
1-5
CFMOTO
Maintenance Parameters Table
L ub r i ca t i on Sys t em
Item Standard Service Limit
Engine Oil Volume when 1900mL +
Capacity replacing
Volume when 2200mL +
replacing filter
Recommended Oil$See Original% ·Specially for 4-stroke motorcycle
SAE-15W-40
Substitutes must be used in the
following range.
API type: SE or SF grade
SAE type: Choose from the left

chart according to the
environmental temperature
Gap between 0.03'0.1mm 0.15mm

Inner and Outer
Rotors
Oil Pump Rotor Gap between 0.03'0.1mm 0.12mm
Outer rotor and
body
Oil pressure 3000r / min , 130-170KPa
A i r I n l e t Sys tem
Item Standard
Fuel Tank Capacity Full capacity 18L

Valve CF188-B-173000
Inlet Pressure Sensor CF188-B-175000
Inlet Temperature Sensor CF188-B-177000
Air Bypass Valve CF188-B-172000
Injector CF188-B-171000
Idle Speed 1400±100r / min
1-6
Coo l i ng Sys t em
1
Ser vice
It em Standard/ Par amet er Remar k
Li mit
Ful l Capacit y 2000ml
Reservoir t ank capacit y 300ml
Standard Densi ty 50%
Opening pr essur e of radiator
108kpa(1.1kgf/ cm2 )
cap
Init ial
71±3&
Temper ature
Full opening
Thermostat 88&
Temper ature
Ful l opening lift
3.5' 4.5mm/95?
range
End B End A C
Temper at ur e(& )
Temperat ur e Resi stance(") Resistance(k")
and -20 ---- 13.71-16.94
Resist ance of
25 ----- 1.825-2.155
Wat er
Temperat ur e 50 176-280 ----
Sensor 80 63.4-81.4 0.303-0.326
110 24.6-30.6 0.138-0.145
Temperat ur e Close -Open 88& Round 88& Round
of
Open-Close 82& Round 82& Round
Thermostat
Coolant Type -35& ant i-frozen, ant isepsi s, hi gh -boil coolant
1-7
CFMOTO
F r on t Whee l
Opera tio n
Ite m Stand ar d
L im it
Pl ay o f whe e l Ve rtica l 1. 0mm 2.0mm
rim H orizo nta l 1. 0mm 2.0mm
F ront W he e l 3.0mm
Groove +
Tire
P ressu r e 35kP a$0 .35kgf- cm 2 % +
Rea r Whee l
Oper ati on
Item Stan d ard
Lim it
Ve rtica l 1. 0mm 2.0mm
Pl ay o f whe e l
H orizo nta 1. 0mm 2.0mm
rim
Re ar W h eel l
Groove + 3.0mm
Tire
P ressu r e 30kP a$ 0. 30kgf- c m2 % +
B r ake Sys t em
Op eration
Ite m Stan da r d
L im it
Brake End P la y 0mm +
Front B ra ke
Brake Disc T hickn ess 3. 5mm 2 .5mm
Brake End P la y 5-10 mm +
Rea r Br ake Brake Ped al P lay 0mm +
Brake Disc T hickn ess 7. 5mm 6 .5mm
1-8
Bat te r y , Cha r g i ng Dev i ce , P i ckup Co i l
1
Item Standard
Model Permanentmagnet AC Type
Output 3-phas e AC
Chargi ng Coil Resistance$ 20? % 0.2"-0.3"
Pickup Coil Resis tance 110"-140"
AC
Magneto Magneto without Load Voltage/(Idle
/100V$AC%(5000r/min
Speed)
Motor
Max. Output Power 300W(5000r/min
Rated Voltage 13.5V-15.0V, 5000r/min
Peak Voltage of Pickup Coil /120V
Three-phase annular rectification,
Rectifier Silicon controlled parallel-connected
regulated voltage
Capacity Capacity
Fully
12.8V
Terminal Poi nt Charged
Battery Vol tage Insufficient
Charged <11.8V
Chargi ng Standard 0.9A-5'10H
Current/time Quick 4A-1H
I gn i t i on Dev i ce
Item Standard
Ignition ECU Ignition
Type Resistance Spark plug
Standard DPR7EA-9(NGK)
Spark Plug
Optional DR8EA .D7RTC
Spark plug gap 0.8-0.9mm
Spark
/8mm(1mpa
Characteristic
Ignition Timing BTDC10ºCA 1500r/min
Ignition Coil Initial 0.740-0.780
Resistance Secondary 10.1k0-11.1 k0
Ignition Coil /150V
Peak Voltage
Pulse
2V
Generator
Starter Relay Coi l Res istance 3"-5"
Secondary Starter Relay Coil
90"-100"
Resistance
L i ghts , I nst rument , Sw i tches

Item Standard
Main 20A
Fuse
Auxiliary 10A!2 15A!2
Head Light$Hi-Lo% 12V—35W/35W !2
Brak e Light/ Tail Light 12V—5W !2
Light, Bulb Turning Light 12V—21W/5W
Fuse Dashboard Indicator Light 12V—10W!4
Indicators #5 LED
Main LCD
1-9
CFMOTO
Air Inl et Device+ Cyl i nder Head (mm)
Item Standard Operation Limit
Intake 30.6
Valve Diameter
Exhaust 27.0
Intake 0.05-0.10
Valve Clearance( Idle Speed)
Exhaust 0.17-0.22
Fit Clearance between Valve Intake 0.010-0.037
Guide and Valve Stem Exhaust 0.030-0.057
Internal dia. of Valve Guide Intake & Exhaust 5.000-5.012
Intake 4.975-4.990
Exterior dia. of Valve Stem
Exhaust 4.955-4.970
Valve Stem Run-out Intake & Exhaust 0.05
Length of Valve Stem End Intake & Exhaust 2.9-3.1 2.3
Thick ness of Valve Head Intake & Exhaust 0.5
Valve Head Seal Run-out Intake & Exhaust 0.03
Width of Valve Seats Seal Intake & Exhaust 0.9-1.1
Length of Valve Spring Intake & Exhaust 40 38.8
Tension182-210N
Valve Spring Tension Intake & Exhaust
/Length31.5mm
Intake 33.430-33.490 33.130

Cam Height
Exhaust 33.500-33.560 33.200
Fit Clearance between #22 0.032-0.066 0.150
Camshaft Exterior dia. &Bore. #17.5 0.028-0.059 0.150
#22 21.959-21.980
Camshaft Exterior dia.
#17.5 17.466-17.484
#22 22.012-22.025
Camshaft Bore Internal dia.
#17.5 17.512-17.525
Camshaft Run-out 0.10
Rocker Arm Internal dia. Intake & Exhaust 12.000-12.018
Rocker Arm Shaft Exterior dia. Intake & Exhaust 11.973-11.984
Plainness of Cylinder Head

0.03 0.05
Adjoining Plant
Plainness of Cylinder Head

0.03 0.05
Cover Adjoining Plant
1-10
Cy l i n der + P i sto n + P ist on R ing + Cran ksh af t (m m )
Operation
Item Standard R emark
Limi t 1
C ylinder Pressure 1000kPa
F it C learance betw een
0.030-0.051 0.15
P iston and C ylinder
87.460-87.480
Piston Sk irt dia. Tes ting the point aw ay skirt end 87.380
10m m
Internal dia. of C ylinder 87.500-87.522
Plainness of Cylinder
0.015 0.05
Adjoining Plant
Top R ing R 11.7 round 8.9
Piston Ring Free Gap nd
2 R ing R 12 round 9.5
Top R ing 0.15-0.30 0.60
Pis ton R ing C losed Gap nd
2 R ing 0.15-0.30 0.60
Piston Annular F it Top R ing 0.04-0.08 0.180
C learance 2 nd
R ing 0.0 3- 0.07 0.150
Top R ing 0.9 7- 0.99
Thickness Pis ton R ing
2 nd R ing 1.1 7- 1.19
Top R ing 1.03-1.05
Piston Annular Width 2 nd
R ing 1.2 2- 1.24
Oil R ing 2.51-2.53
Internal dia. of Pis ton Pin
23.002-23.008 2 3.0 30
Bore
Exterior dia. Piston Pin 22.995-23.000 2 2.9 80
Rod Sm all End Inner dia. 23.006-23.014 2 3.0 40
R od Big End Gap 0.10-0.55 1.0
Rod Big End Thi ckness 24.95-25.00
Crank shaft R un-out 0.03 0 .0 8
1-11
CFMOTO
Clutch + Transmission (mm)
Item Standard Limit Remark
Clutch Friction plate inner dia. 140.00-140.15 140.50
Clutch Joint Rotation 1800-2400r/min
Clutch lock-up Rotation 3300-3900r/min
Drive Belt Width 35.2 33.5
Driven Disc Spring Free Length 168 160
Shifter and fit flute gap 0.10-0.40 0.50
Left Shifter Sliding Thickness 5.8-5.9
Right Shifter Sliding Thickness 5.8-5.9
Plunging Flute Width 6.0-6.2
Driven Output Gear Sliding Width 6.0-6.2
1-12
Tightening Torque
Item Torque N·m(kgf·m) Item Torque N·m(kgf·m)
5mm Bolt, nut 5(0.5) 5mm Screw 4(0.4)
6mm Bolt, nut 10(1.0) 6mm Screw 9(0.9) 1
8mm Bolt, nut 22(2.2) 6mmSH Bolt with flange, 10(1.0)
10mm Bolt, nut 34(3.5) 6mm Bolt with flange, nut 12(1.2)
12mm Bolt, nut 54(5.5) 8mm Bolt with flange, nut 26(2.7)
10mm Bolt with flange, nut 39(4.0)
For o thers not listed in the chart, refe r to the standard tightening torque.
Notes: Apply some engine oil on the part of screw thre ad and adjo ining surface
Thread Dia. Quantity Torque
Item Remark
(mm) N·m(kgf·m)
Upper Front Mounting Bolt, Engine M8!60 1 16'20

Upper Rear Mounting Bolt, Engine M10!1.25!110 1 40'50
Upper Rear Mounting Bracket Bolt,
Engine M8!14 1 16'20
Upper Front Mounting Bracket Bolt,
Engine M8!14 1 16'20
Low Mounting Bolt, Engine M12!1.25!140 2 50'60
Bolt, Swing Arm M10!1.25!70 16 40'50
Bolt, Rear Absorber M10!1.25!50 4 40'50
Bolt, Front Absorber M10!1.25!50 4 40'50
Bolt, Rear Wheel Shaft Holder M10!1.25!100 4 40'50
Mounting Nut, Rim 901-07.00.02 M20 16 50'60
Nut, Rim Shaft 901-07.00.03 M10 4 110'130
Mounting Screw, Rear Brake
Caliper M6!25 2 18'22
Bolt, Rear Brake Caliper M10!1.25!20 2 40'50
Bolt, Front Brake Disc 901-08.00.03 M8! 8 25'30
Bolt, Front Brake Caliper M8!14 4 16'20
Locknut, Steering Stem M8!55 4 16'20
Nut, Steering Stem M10!1.25 4 40'50
Locknut, Steering Shaft M14!1.5 1 100'120
Rear Mounting Bolt, Muffler M8!30 1 16'20
Bolt, Exhaust Pipe M8!14 1 16'20
Mounting Bolt, Exhaust Pipe M8!40 1 16'20
Mounting Bolt, Rear Axle M10!1.25!110 2 40'50
Mounting Bolt, Front Axle M10!1.25!90 1 40'50

Mounting Bolt, Front Axle M10!1.25!25 2 40'50
Back End Bolt, Rear Trans Shaft 901-30.00.01 6 40'50
Front End Bolt, Rear Trans Shaft 901-29.00.01 4 35'45
Bolt, Front Trans Shaft 901-29.00.01 8 35'45
Thermo Switch CF250T-420500 1 9'12
Mounting Bolt 1, Front Rack M8!14 2 35'45
Mounting Bolt 2, Front Rack M6!12 2 25'30
Mounting Bolt , Rear Rack M8!14 4 16'20
1-13
CFMOTO
Engine Tightening Torque Table
Torque
Item Q’ty Screw dia.$mm% Remark
$N.m%
Sensor, Reverse Gear 1 M10!1.25 20
Spark Plug 1 M12!1.25 18
Water Temperature Sensor 1 Rc1/8 8 Apply screw thread sealant
Valve Clearance Adjusting Nut 4 M5 10
Drive Disc Nut 1 M20!1.5 115
Driven Disc Nut 1 M20!1.5 115
Circle Nut, Driving Disc 1 M30!1 100
Nut, Front Output Shaft 1 M14!1.5 97
Nut, Drive Bevel Gear 1 M22!1 145
Nut, Driven Bevel Gear 1 M16!1.5 150
Fixing Nut, Clutch 1 M18!1.5 70 Left handed
Limiting Nut, Driven Bevel Gear Shaft 1 M60 110 Apply screw thread sealant
Apply screw thread

Limiting Nut, Front Output Shaft 1 M55 80
sealant, left handed
Bolt, Swing Arm Shaft 2 M14!1.25 28
Drain Bolt 1 M12!1.5 30
Mounting Bolt, Overriding Clutch 6 M8 26 Apply screw thread sealant
Mounting Bolt, Magneto Stator 3 M6 10 Apply screw thread sealant
Bolt, CVT Windshield 3 M6 10 Apply screw thread sealant
Link Bolt, Oil Pipe 2 M14!1.5 18
Mounting, Oil Pump 3 M6 10
Mounting Bolt, Pressure Limiting Valve 2 M6 10
Bolt, Drive Bevel Gear Cover 4 M8 32
Bolt, Driven Bevel Gear Cover 4 M8 25
Locating Bolt, Shift 1 M14!1.5 18
Flange Bolt, Fan 1 M10!1.25 55
1-14
To be continued
Torque
Item Quantity Diameter$mm% Remark 1
$N.m%
14 M6 10
Bolt, Crankcase
3 M8 25
Bolt, Driven Sector Gear 1 M6 12
Mounting Bolt, Oil Filter 1 M20!1.5 63
Oil Filter 1 3 / 4 ?$ 1 6 / i n 18'20
Bolt, Starting Motor 2 M6 10
Bolt, Cylinder Head 4 M10 38
Bolt, Cylinder Head(2 sides) 2 M6 10
1 M8 25
Upper and Lower Bolt, Cylinder 4 M6 10
Bolt, Cylinder Head Cover 12 M6 10
Bolt, Chain Tensioner 2 M6 10
Nut, Chain Tensioner 1 M8 8
Bolt, Radiator Fan 3 M6 10
Thermostat Bolt 2 M6 10
Bolt, Water Pump Cover 3 M6 6
Mounting Bolt, Water Pump 2 M6 10
Fixed Bolt, Timing Sprocket 2 M6 15 Apply screw thread sealant
M5 4.5-6
Bolt without remarks M6 8-12
M8 18-25
1-15
CFMOTO
Engine Tools
Measuring Tools
No Name Type Function Remark
1 Vernier Calipers 0-150mm Measure length and thickness
Measure the outer diameters of swing

2 Micrometers 0-25mm
arm, valve rod and camshaft
3 Dial gauge 25-50mm Measure max. lift range of camshaft
4 Dial gauge 75-100mm Measure piston skirt
5 Inner dia. Gauge, Cylinder Measure inner dia. of cylinder head
Inner dia. of swing arm, piston pin hole,

6 Inner dia. Gauge, 10-34mm
and rod head hole
7 Dial Test Indicator 1/100 Run-out
8 Knife Straight Edge plainness
9 Feeler Gauge Plainness, adjusting valve clearance
10 Fuel Level Gauge Fuel level length of carburetor
11 Plastic gauge Fit clearance
12 pull tension gauge Spring bounce
13 Tachometer Engine rotation rate
14 Cylinder Pressure Meter pressure in cyclinder
15 Oil Pressure Gage Oil pressure
16 Barometer Opening pressure of radiator cover
17 Ohmmeter Resistance and voltage
18 Amperemeter Opening of currency / switch
19 Thermometer Liquid temperature
20 Timing Lights Test spark timing
21 Torque Tester One Set Tightening torque
Auxiliary Measuring Instrument
22 Alcohol Burner Warming up
23 Magnet Stand Install dialgauge
24 Slab Auxiliary measure supplementary
25 V-Block Run-out supplementary
26 Forcep Install valve clip
27 Plier Disassemble and install circlip
28 Joint Plier Disassemble and install flange
29 Impact Driver Disassemble cross recessed bolt
30 Slot Type Driver
31 Cross Type Driver
1-16
Special Purpose Tools
No Name Type Function Remark
1 Spark Plug Wrench 172MM-022400-922-004 Disassemble/ install spark plug 1

CF188-051000-922-001 Disassemble/install CVT
2 CVT Wrench
CF188-052000-922-001 drive/driven disc nut
3 Oil Filter Wrench CF188-011300-922-001 Disassemble/ install oil filter
4 Piston Pin Remover CF188-040004-922-002 Disassemble piston pin
Magneto stator
5 CF188-031000-922-001 Disassemble magneto stator
Remover
6 Crankcase Dissociator Divide L/R crank case
Disassemble crank shaft from

7 Crank Remover
left crankcase
Install crank shaft on left

8 Crank Tool
crankcase
Valve Spring Disassemble/ install valve

9 CF188-022006-922-001
Compressor spring
10 Valve Former CF188-022004-922-001 Grind valve
11 Circle Nut Wrench CF188-052000-922-003 Disassemble CVT driven disc
12 Driven Disc Clamp CF188-052000-922-004 Disassemble CVT driven disc
13 Driven Disc Former CF188-052000-922-002 Disassemble CVT driven disc
Disassemble driven bevel gear

14 Limiting nut Wrench CF188-062204-922-001
bearing limiting nut
15 Bearing Tool One full set Install bearing and oil ring
16 Bearing Remover One full set Disassemble bearing
17 Oil Ring Remover Disassemble bearing
Disassemble front output shaft

18 Limiting Nut Wrench CF188-060008-922-001
bearing limiting nut
Diagnose failures of EFI

19 PDA
system
20 Oetiker Clamp Catcher Disassemble/ install fuel Pipe
21
22
23
24
25
1-17
CFMOTO
Lubr icant Grease, Sealant
Coated Section Attention Grease
Turning Bearings
Throttle Cable Connecting Portion
Throttle Pedal Movable Parts
Brak e Pedal Movable Parts Multi-purpos e
Swing Arm Movable Parts grease
Steering Inner Circle Surfac e
Seat Lock Movable Parts
Transmission Movabl e Parts
Opera tion Material and Installment Supplementary of Engine
Engine operation materials include lubricant (oil), grease (lubricant grease) and coolant, installment
supplementary includes plane sealant and screw thread sealant.
Na me Type P arts Rem ark
Rota tin g sect ion and ca rriage in cylinder,

Sp ecially for 4 -stroke
mot orcycle Rota tin g sect ion and ca rriage in crankcase capacit y
lubrican t SAE -10W -40.2 0W-50
Rota tin g sect ion and carriag e in cylinde r 2200 m L $replace oil%
Substitute s mu st be u se d
/o il
in t he fo llowin g rang e. hea d 2 300 m L$ replace oil filt er%
API type: S E or SG grade
S ee L ubrication S yst ems Diagram$ 5-14% 2 600 m L$ eng ine ove rh aul%
$ Replaceme nt see 1-3 %
Lubrica nt with P iston pin, valve rod pa rt, valve ring, cam
m olybde num shaft
Gre ase/lubrican t # 3 MoS 2 l ith ium ba se d Oil seal lip, O rin g an d oth er late x sea ling,
grea se g re ase bea ring with seals, and C VT bea ring/h ousin g
Coolant -35 & an ti-frozen, an ti-rust, Ca pacit y based on ra diator

Coo ling syste m, wa ter seals
h igh –bo iled coolant p ipe system
Plane sea la nt Cou pling surfaces of ca ses, ca se s and
cylin der, cylind er hea d an d cylin der h ead
cover
Screw th re ad Some screw threa d
se ala nt
1-18
W i r i ng , P i pes , Cab l e Layout
1
Picture 1 Picture 2
Picture 3
1-19
CFMOTO
1-20
1-21
CFMOTO
1-22
Fa i l u r e I nd i ca t o r
Fa i l ure Ind i actor i s l ocated on the
1
left top !"#of instrument .
Whi le the indicator f lashing is faulty,
fai lure uses 4-digi t f lashing.
For example$0650%
!0#f lashes 10 t imes,
See (Page 11 - 27) for the mean i ng of
Diagnost ic Trouble Code.
Whi le fai lure appears, use PDA to diag-
nose i t .
Connect PDA wi th PDA connector , the lo-
cat ion of PDA connector (see Page 1-19)
Picture 3. the use of PDA (see Page 11-
26) .
1-23
2 Vehicle Body and Muf f ler
Overhaul Info !!!!!!!!!!!!!!2 - 1 Footrest Board (LH, RH)!!!!!!!!!!2-10
Troubleshooting!!!!!!!!!!!!!!2 - 1 Rear Fender, Engine Skid Plate (Front, Center, Rear),
Front Rack, Bolt Cap!!!!!!!!!!!!2-2 Double Seat, Protection Plate!!!!!!!!2-11
Seat, Seat Support & Rear Rack!!!!!!!!2-3 Front Inner Fender (R&H), Front Protector (RH, LH) !2 -13
Front Top cover, Dashboard Cover!!!!!!!2-4 Rear Protector (RH,LH), Bumper, Bumper Protector!2 - 14 2
Side Support(LH&RH)!!!!!!!!2 - 5 Bumper Cap !!!!!!!!!!!!!!2 - 15
Rear Top Cover!!!!!!!!!!!!!!2-6 Front Vent Grille, Fuel Tank!!!!!!!!!2-16
Left Side Panel!!!!!!!!!!!!!!2 - 7 Bottom Plate, Fuel Tank !!!!!!!!!!2-17
Right Side Panel!!!!!!!!!!!!!!2-8 Muffler!!!!!!!!!!!!!!!!!2 - 18
Fuel Tank Top Cover, Front Fender!!!!!!!2-9 Description of Visible Parts!!!!!!!!!2-19
Overhaul Information
Operation Cautions
Warning
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place.
Special attention should also be paid to sparks. Gasoline may also be explosive when it is
vaporized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold.
l This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe,
muffler and fuel tank.
l Hoses, cables and wiring should be routed properly.
l Replace the gasket with a new one after muffler is removed.
l After muffler is installed, check if there is any exhaust leakage.
Tightening torque
Muffler Rear Fixing Bolt: 35-45N.m
Muffler Exhaust Pipe Bolt: 35-45N.m
Muffler Body Fixing Bolt: 35-45N.m
Troubleshooting
Loud exhaust noise
Broken muffler
Exhaust leakage
Insufficient power
Distorted muffler
Exhaust leakage
Muffler clogged
2-1
CFMOTO
Front Rack, Bolt Cap
Remove:
Upward l y remove Bo l t cap hard ; two assemb l y

bo l ts of f ront rack shal l be seen .
Remove fixing Bolt 1

(one for each on theleft and right)
Romove f i x i ng Bo l t 2
Remove f ront rack
Installation:
Reverse the removal procedure for installation
Tightening Torque:
Fixing Bolt 1, Bolt 2 35 N.m -45N.m
Fixing Bolt 3, Bolt 4 25 N.m -30N.m
2-2
Seat
Remove:
Pull upward seat buckle
Lift and push seat backward
2
Installation:
Press upward seat buckle
Press seat forward and down
Note:
Shake seat left,right, front and back to make sure that
the seat is firmly installed.
Remove:
—Seat ( " 2-3)

—Bolt 1, bolt 2
Remove seat support
Remove Bolt 3 for rear rack and rear fender

from rear fender bottom
Remove Bolt 1
Remove Rear Rack
Installation
Reverse the removal procedure for installation
Tightening Torque#
B o l t 1 #3 5 N $m - 4 5 N $m
B o l t 2 #3 5 N $m - 4 5 N $m
B o l t 3 #8 N $m - 1 2 N $m
2-3
CFMOTO
Fr on t Top Cove r
Remove
F r on t Rack %" 2 - 2&
6 nu t s'
Front Top Cover
Assemb l e
Reverse the remova l process and d i rect i on .
Dashboa r d Cove r
Remove
- -2 pieces Bol t 1
- -2 pieces bol t 2
- -Dashboard Cover
I nsta l l at i on
2-4
F r on t S i de Suppo r t ( L e f t )
Remove
Bol t 1
Front Side Support
2
Assemb l e
F r on t S i de Suppo r t ( R i gh t )
Same as Left Side Support
2-5
CFMOTO
Rear Top Cover

Remove
Rea r Rack %" 2 - 3&
Seperate c l asps of rear top cover f rom rear
fender ;
Remove Rear Top Cover
I nsta l l at i on
Reverse the remove procedure and
d i rect i on for i nsta l l at i on .
Gear Sh i f t Un i t Fender
Remove
- -Bol t 1
- -Bol t 1
- -Bol t 2
Remove Gear Shi ft Uni t Fender
I nsta l l at i on
2-6
L e f t S i de Cove r
Remove
- - S e a t %" 2 - 3 &
- - Lef t S i de Cover f i x i ng bo l t
- - Lef t S i de Cover 2
I nsta l l at i on
Rea r P r o t ec t o r
R em ov e
- - Rea r Rack%" 2 - 3&
- - Rear Top Cover%" 2 - 6&
- - Rear L i nk P l ate%" 2 - 7&
- - Rear Le f t S i de Suppor t%" 2 - 8&
- - Rear R i ght S i de Support%" 2 - 8&
- -Rear Turn i ng L i ght Connector
- - Bo l t 1 , 2 , 1
- - Rear Protector
I nsta l l at i on
Reverse the remove procedure and d i rect i on
for i nsta l l at i on .
Rear L i nk P l ate
Remove
- - Bo l t 3
Rear L i nk P l ate
I nsta l l at i on
Reverse the remove procedure and d i rect i on
for i nsta l l at i on .
2-7
CFMOTO
Rear S i de Pane l
Remove
- - S e a t %" 2 - 3 &
- - R i ght S i de Cover F i x i ng
Bo l t
Remove connect ing Bol t 1 between Right

Side Panel and Front Fender at bottom
of Front Fender
Remove R i ght S i de Panel
I nsta l l at i on
Rear R i gh t S i de Suppo r t
R em ov e
- - Bo l t 2
- - Remove Rear R i ght S i de Support
I ns t a l l a t i on
Reverse the remove procedure for i nstal lat i on
Remova l and I ns t a l l at i on and

Rear R i gh t S i de Suppo r t i s
same w i th L e f t s i de .
2-8
Top Cover , Fue l Tank
Remove
- - S e a t %" 2 - 3 &
- - F r on t Rack%" 2 - 2&
- - Front Top Cover%" 2 - 4& 2
- - Le f t S i de Pane l %" 2 - 7&
- - R i ght S i de Pane l %" 2 - 8&
- - Bo l t 1 , 2
- - Bo l t 3 , 4
- - Fuel Tank Cap
Remove Fuel Tank Top Cover
I nsta l l at i on
Front Fender
Remove
- - F r on t Rack%" 2 - 2&
- - Front Top Cover%" 2 - 4&
- - L e f t , R i gh t S i de Pane l %" 2 - 7&%" 2 - 8&
- - Fue l Tank Top Cover%" 2 - 8&
- - Le f t , R i ght S i de Suppor t%" 2 - 5&
Loosen Cab l e Connector of Front Fender
Remove E l ectron i cs Parts of Front Fender
Remove 3 Front Fender bo l ts f i xed i n Frame
Remove 4 bo l ts f i xed w i th l ef t and r i ght

footrest
Remove Front Fender
Reverse the remove procedure for i nstal lat i on
2-9
CFMOTO
Foo t r es t , L e f t S i de
Remove
Le f t S i de Pane l %" 2 - 7&
Remove three Bo l t 1 and 3 nuts connect i ng
w i th Front Fender
Remove three Bo l t 2 and 3 nuts connect i ng

w i th Rear Fender
Remove Bo l t 1
Remove Lef t Footrest
I nsta l l at i on
Reverse the remove procedure for Instal lat ion.
Foo t r es t , R i gh t S i de
Removal and Instal lat ion same wi th Left side.
2-10
Rear Fender
Remove
- - S e a t %" 2 - 3 &
- - Rea r Rack%" 2 - 3&
- - Rear Top Cover%" 2 - 6& 2
- - L e f t , R i gh t S i de Pane l %" 2 - 7&%" 2 - 8&
- - Le f , R i ghtS i de Suppor t%" 2 - 8&
- - Rea r Pro tec to r%" 2 - 7&
Remove Battery Bracket and F i x i ng P l ate%"
8 - 4&
Remove Bat t e ry%" 8 - 4&
Remove Bo l t 1
Remove Nut 1
Remove E l ecton i c Parts f rom Rear Fender
Loosen Cab l e Connector f rom Rear Fender
Upward i ng l y Remove Rear Fender
Eng i ne F r on t , M i dd l e and Rea r Sk i d
P l a t e ; P r o t ec t o r P l a t e o f Doub l e
Seat
2-11
CFMOTO
D i sasemb l y
NOTE : S i de sk i d P l ate ( Front , M i dd l e , Rear )
and Doub l e Sea t P r o t ec t i on a r e l oca t ed
a t bo t t om o f veh i c l e . The ma i n t eanace
pe r son shou l d wo r k unde r bo t t om o f ve -
h i c l e when d i sassemb l e the above par ts .
Fo r sa f t y , make su r e t he veh i c l e i s
f i r m l y p a r ked .
Eng i ne Sk i d P l ate ( Front )

Remove Bo l t 1 , 2 , 3 , and 4 ;
Remove Eng i ne Front Sk i d P l ate
Reverse the remove procedure for Insta l l a -
t i on
Eng i ne Sk i d P l ate ( M i dd l e )
Remove Bo l t 5 and 6 ;
Remove M i dd l e Eng i ne Ski d P l ate.
t i on
Doub l e - Seat Protect i on P l ate

Remove Doub l e- Seat Protect i on P l ate .
N OT E : N o P r o t ec t i o n P l a t e f o r s i n g l e -
sea t .
t i on
Eng i ne Sk i d P l ate ( Rear )

Remova l
Remove Rear Eng i ne Ski d P l ate.
t i on
2-12
R i ght Front I nner Fender
Remova l
Remove Bo l t 1 , and remove R i ght Front Inner
Fender
2
Insta l l at i on
t i on
NOTE : Hook Water Pump w i th C l i p o f R i ght

I nne r S i de Fende r du r i ng I ns t a l l a t i on .
Le f t Front I nner Fender

Remova l
Remove Bo l t 1 , and remove Lef t Front Inner
Fender
t i on
F r on t L e f t P r o t ec t o r
Remove
- - Bo l t 1
Pu l l backward and remove f ront Front
Lef t Protector
t i on
F r on t R i gh t Pr o t ect o r
Remova l and I nsta l l at i on same w i th Le f t
S i de .
2-13
CFMOTO
Fr on t L e f t I nner Fender
Remova l
Remove Front Lef t Inner Fender
t i on
Fr on t R i gh t I nner Fender
Remova l and Instal l at i on same as Lef t S i de.
Bumpe r , Bumpe r P r o t ec t o r
Remove
Remove two Bo l ts of Eng i ne Front Ski d P l ate
f i xi ng i nto the Bumper .
Remove Bo l t 1 , 2 , 3 and 4 .
Remove Bumer and Bumper Protector
Remove Bo l t 5 connect i ng Bumper and Rack.
2-14
Bumper Protector
Remove
- - Loosen Front Turn i ng L i ght Connector .
- - Remove Bumper and Bumper Protector .
Remove tapp i ng screw 1 f rom Bumper ; 2
Remove Bumper Protector .
t i on
Bumpe r P r o t ec t o r Cap
Remove
Pu l l the two Caps f rom Bumper
(There are on l y 2 caps i n th i s veh i cl e)
Press Caps i nto Bumper P i pe
2-15
CFMOTO
F r on t Ven t Gr i l l
Remove
- - Loosen Connector of Front Head L i ght
- - Remove Front Fender%" 2 - 9&
- - Remove Bumpe r%" 2 - 14&
- - Remove Bo l t 1 , 2 and 3 ;
- - Remove Vent Gr i l l
No t e : Fo r r emova l o f f r on t ven t g r i l l e
on l y ,
Jus t r emove 2 f i x i ng bo l t s
o f bumpe r and 2 cen t e r f i x i ng bo l t s ,
t hen pu l l bumpe r down
I nsta l l at i on :
Reverse the remova l procedure f or
i nsta l l at i on
Warn i ng : Gaso l i ne i s h i gh l y
f l ammab l e , therefore smoke and f i re
are str i ct l y f orb i dden i n the work
p l ace .
Spec i a l a t t en t i on shou l d a l so be
pa i d to sparks .
Gaso l i ne may a l so be exp l os i ve when
i t i s vapor i zed ,
so ope rat i on shou l d be done i n a
we l l - vent i l ated p l ace .
Remove Lef t and R i ght S i de Pane l %" 2 - 7&

Remove Front Fender%" 2 - 9&
Remove Fue l Tank Top Cover%" 2 - 9&
Remove Bo l t 4
Loosen Fue l Sensor 3P Connector .
2-16
2
Remove Fuel P i pe 1 and C i rcl i p
Remove Fuel Tank
i nsta l l at i on
Note:
Be careful not to damage main cable,
pipes and hoses. Main cable, cables,
pipes and hoses should be routed prop-
er ly
according to the rout ing drawing.
Take precaut ion against fuel leakage
when removing fuel Fuel Hose I
Remove :
- -Fuel tank (" 2-16)
- -Bol t 1
- -Bol t 2
- -Fuel tank top cover
i nsta l l at i on .
No te :
Be carefu l not to damage ma i n cab l e ,
p i pes and hoses . Ma i n cab l e , cab l es ,
p i pes sh ou l d b e r ou t ed p r ope r l y
accord i ng to the rout i ng draw i ng
2-17
CFMOTO
Mu f f l e r
Caut i on : Per form d i sassemb l y
on l y
af ter the muf f l er i s coo l ed
down .
Remo ve :
- - Seat (2 - 3)
- - R i ght s i de pane l (2 - 8)
- - Nut1 , Nut 2 for exhaust p i pe
e l bow
Remove Bo l t
Remove Bo l t 2 , Bo l t 3
Remove muf f l er
I ns ta l l a t i on :
Reverse the removal procedure for
Note :
Rep l ace seal i ng gasket when i nstal l i ng the
muf f l er .
2-18
V i s i b l e Pa r t s
2-19
3 . Checks & Ad j ustment
Overhaul Info……………………… 3-1 Cooling System..…………………………3-13
Maintenance Interval………………..3-2 Lighting System...………………………...3-16
Inspection & Maintenance………… ………3-3 Valve Clearance…………………………..3-17
Steering Stem, Brake System……………...3-6 Engine Idle Speed & Spark plug…………3-18
Wheels……………………………………….3-8 Air Filter……………………………….3-19
Suspension System………………. ………3-10 Fuel Hose!&Drive Belt.. 3-20
Gear Shifting, Fuel Device………………...3-11 Inspection of Lubrication System…………3-22 3
Check the throttle………………................3-12 Inspection of Cylinder Pressure…………..3-24
Inspection of Clutch Engagement and
Lock-up……………………………………..3-26
Overhaul info
Operat ion Caut ions
Note
- DO NOT keep the eng i ne runn i ng for l ong t i me i n a poor l y vent i l ated or
enclosed place because of the harmful components l ike CO, etc, in the exhaust
gas.
- The muf f ler and engine are st i l l very hot when the engine is just stopped.
Careless contact may cause ser ious burn. Be sure to wear fat igue dress wi th long
sleeves and gloves i f the work has to be done after the engine is just stopped.
- Gaso l i ne i s h i gh l y f l ammab l e , smok i ng i s str i ct l y forb i dden i n the work
p l ace . Keep a l ert on the e l ectr i ca l sparks . Bes i des , vapor i zed gaso l i ne i s
highly explosive, so work should be done in a wel l -vent i lated place.
- Be carefu l that your hands or c l othes not get n i pped by the turn i ng or
movable parts of the dr iving system.
Note
The vehicle should be parked on hard and level ground.
3-1
CFMOTO
Maintenance Interval
T he table below lists the recommended interv als for all the required periodic maintenance
work nec es sary to k eep the engine at its best performanc e and economy. Maintenanc e
intervals are ex pressed in terms of k ilometer, miles and hours, whichever occurs firs t.
Note: Maintenance interval sh ould be sh ortened on eng ines that are used in severe conditions.
Interval Initial Every Ev ery

Km
2 50km 500 k m 10 00 km
Remark
Item Ho urs Initial E very Ev ery
2 0 hours 5 0 hours 100 hou rs

Valve Clearanc e IN: 0.05~0.10
I ! I EX:0.17~0.22
Idle Speed I I ! 1400±100r/Min
Spark Plug I ! I No carbon deposit

Gap: 0.8~0.9mm
Replace ev ery 6000Km
Air Filter Replace every
! I C
20000 Km
High-Pressure Fuel Hose Replace every 4
! ! I
years
Clutch ! ! I
Drive Belt Replace every
! I !
2000Km
Engine Oil R ! R
Oil Filter R ! R
Coolant Level I I !
Water Hos e & Pipes I ! I
Coolant Replace every 2 years
I= Inpectio n and adjust, or replace if necessary

R=Replace
C=Clean
3-2
Inspection & Maintenance !: Interval

Item Intervals
Daily 1/2 Standard
Part Item Annual
Year
Handlebar Operation agility "
Steering Damage "

Steering
System
system
Installation condition of steering system
Sway of ball stud
"
"
3
Free play " " Front: lever end 0mm
Rear : lever end 0mm
Brake lever
Brake
" "
Efficiency
Connecting
rod, oil pipe Looseness, " "
Slack and damage
& Hose
Brake
System Brake fluid should be
Front and rear brake fluid level " "
above LOWER limit
Hydraulic Replace when the
brake and thickness of front brake
brake disc Brake disc damage and wear " " disc is less than 2.5mm,
rear brake less than
6.5mm.
Front tire: 35kPa
(0.350kgf/# 2)
Tire pressure " " Rear tire:
30kPa
(0.30kgf/# 2)
Chap and damage " "
Driving Groove depth and abnormal wear No wear indication on the
Wheel surface of tire (the
System " " remained depth of groove
should not be less than
1.6mm)
Loosened wheel nut and axle " "
Sway of front wheel bearing " "
Sway of rear wheel bearing " "
Suspension Sway of Joint parts, rocker arm " "

arm damage
Buffer Shock
System Oil leakage and damage " "
absorber
Function "
Front axle Transmission, lubrication " "
Rear axle Transmission, lubrication " "
Remove filling bolt, add oil

Drive Gear box Transmission, lubrication " " till oil level reaches edge
Train of filling hole.
Final shaft Looseness of joint parts
(Drive shaft) Sway of Spline
3-3
CFMOTO
Item Intervals
Daily 1/2 Standard
Part Item Annual
Year
Final Looseness of joint parts O O
shaft
Drive train
Sway of Spline O
(Drive
shaft)
Spark plug gap:
Ignition Spark plug O
0.8-0.9mm
Device
Electrical Ignition timing O
System Battery Terminal Joint O
Looseness and damage of
Wiring O
joints
Fuel leakage O
Fuel device Throttle grip
Throttle O clearance:
3~5mm
Cooling system Coolant level O O
Coolant leakage O
3-4
It e m I n terv als
Daily 1/2 Standard
Pa rt I tem Annual
Year
Lighting devi ce and
Function " "
turning indic tors
Alarm and lock devic e Function "
Instrum ents Function "
Loosenes s or dam age
Exhaus t pi pe and
m uffler
caused by im proper
ins tallation
"
3
Function of m uffler "
Looseness and/or
Frame "
dam age
Lubric ati on & grease of
O thers "
fram e parts
Abnormal parts whic h M ake sure if there is any
can be determ ined abnorm al with relative "
when driv ing parts.
3-5
CFMOTO
Steer i ng Stem
Park the veh i cl e on l evel p lace, ho l d steer -
i ng hand l ebar , and shake i n the di rect i on as
i l l ustrated on the r i ght and see i f there i s
any sway .
I n case o f any sway , check i f i t i s the

prob l em of the steer i ng stem or other parts
and then do the mai ntenance accord i ng l y .
In case of sway of the steer ing stem, t ighten

the l ocknut or d isassemb l e the steer i ng stem
for further check .
Park the veh i cl e on l evel p lace, s l owl y turn

the handlebar left and r ight to see i f i t can
turn f ree l y .
In case there i s any h i ndrance , check i f i t

i s f rom the ma i n cab l e assemb l y or other
cab l es .
I f no , check the steer i ng t i e - rod end , and

check i f the steer ing stem bear ing is damaged.
Note:
Make sure the steer ing can be operated freely.
An acc i dent may occur
i f the hand l ebar i s out of contro l .
Brake system
Front brake lever free play
Operate f ront brake l ever and check brake
ef f i ci ency and brake l ever funct i on .
Check f ree p l ay of f ront l ever end .
Free p l ay : 0mm
3-6
Master Cy l i nder
<Fluid level>
Check the brake f luid level
When the brake f l u i d l eve l i s near to the
lower l imi t l ine, check master cyl inder , brake
hoses and jo i nts for l eakage. Remove the two
3
mount i ng screws on f l u i d reservo i r cap .
Remove the cap, add DOT3 or DOT4 brake l iquid
t i l l the upper l i m i t l i ne.
- Do not m i x w i th dust or water when add i ng

brake f l u i d .
- Use on l y the recommended of brake f l u i d
to avo i d chem i ca l react i on .
-Brake f luid may cause damages to the surface
of the
p l ast i c and rubber parts .
Keep the f l u i d away f rom these parts .
- S l i ght l y turn the hand l ebar l ef t and r i ght
t i l l the master cy l i nder i s i n hor i zonta l ,
then remove the f l u i d reservo i r cap .
Brake D i sc , Brake Pad

< Wear of brake pad>
Check the brake pad wears f rom the mark as
i nd i cated .
Replace the brake pad i f the wear has reached
pos i t i on of wear l i m i t trough .
Note The brake pad must be rep l aced w i th a
who l e set .
Checking and replacing the brake disc

Front brake d i sc th i ckness : " 2 . 5 mm # Re -
p l ace
Rear brake d i sc : " 6 . 5 mm # Rep l ace
M i n . l i m i ted th i ckness o f the f ront brake
d i sc: 2 . 5mm
M i n . l i m i ted th i ckness o f the rear brake
d i sc: 6 . 5mm
Change the Brake Fluid

< Changing Brake Fluid>
Change the brake f l u i d once every year .
3-7
CFMOTO
W he e l s
L i f t f ront whee l on l eve l p l ace , and make

sure there i s no l oad i ng on the wheel s .
Shake the front wheel left and r ight to check

whether the joint of front wheel is t ightened
and check whether i t sways .
Not t i ghten enough : # T i ghten i t

Sway : # Rep l ace the rocker arm
Front Toe - i n s i ze
Park the veh i cl e on l evel p lace, measure the
f ront toe - i n
Toe - i n : B - A=0 - 10mm
Toe- i n out of the range: # Adj ust the l ock-

nut of t i e- rod
No te :
Af ter the toe - i n has been ad j usted , s l ow l y
run the veh i cl e to check whether the d i rec -
t ion of vehicle can be control led by handlebar .
3-8
T i r e P r essu r e
Check the pressure of the t i res
w i th a pressure gauge.
No t e
Check the t i re pressure af ter t i res 3
are coo l ed .
Dr i v i ng under i mproper t i re pressure
w i l l reduce the comfort of operat i on
and r i d i ng , and may cause def l ected
wear of the t i res .
Spec i f i ed pressure / t i re
Front wheel Rear wheel
Pressure 35kPa( . 035kgf / cm2) 30kPa(0 . 30kgf / cm2)
T i re S i ze AT25 $ 8 - 12 AT25 $ 10 - 12
T i r e T r ead
Check the t i re t read .
Tread Hei ght : < 3mm # Rep l ace w i th new t i res
Note :
When the tread he i ght i s l ess than 3mm , the
t i re shou l d be rep l aced i mmed i atel y .
3-9
CFMOTO
Whee l Nu t and Whee l Ax l e
Check front and rear wheel axle nuts for loose-
ness
Loosened ax l e nuts : # T i ghten
T i ghten i ng Torque :
Front wheel axl e nut :
110 - 130N . m(11 . 2kgf . m - 13 . 3kgf . m)
Rear wheel axl e nut :
110 - 130N . m(11 . 2kgf . m - 13 . 3kgf . m)
Sway o f Whee l Bear i ng

L i f t the f ront wheel
Make sure there i s no l oad i ng on the veh i c l e
Shake the wheel in axial di rect ion for any sway
In case of any sway ,

disassemble the front wheel and check the bear -
i ng
Suspens i on Sys t em
Park the veh i c l e on l ever p l ace , press the
veh i c l e Severa l t i mes up and down as i l l us -
trated on the r i ght .
In case of any rocking or abnormal noise, check

whether there is any oi l leakage from absorbers,
or any damage or looseness of t ightening parts.
3-10
Ad j us t i ng t he Abso r be r
Use speci a l too l s to ad j ust the l ength of

absorber accord i ng to l oad i ng requ i rement
Turn cl ockw i se to ad j ust f rom h i gh to l ow

3
Gea r Sh i f t i ng
Sh i f t the gear to check for f l exi b i l i ty and

gear engagement
Ad j ust the gearsh i f t rod i f necessary
Re l ease the l ocknut to ad j ust the l ength of

gearsh i f t rod
Fue l Dev i ce
Status of the fuel system

Remove the seat (# 2 - 3)
Check the fue l hose for any ag i ng or damage.
Aged or damaged fuel hose: # Rep l ace
Check i f there i s cracks or bend i ng w i th the
vacuum tube .
Cracked or bended vacuum tube: # Rep l ace
3-11
CFMOTO
Check i ng t he Th r o t t l e L eve r
Check t he f r ee p l ay o f t h r o t t l e
l eve r
Free p l ay : 3 - 5mm
Out of range : # Ad j ust
Loosen l ocknut of thrott le cab l e

turn the regu l ator and ad j ust f ree p l ay of
thrott l e l ever
Af ter ad j ust i ng , t i ghten l ocknuts and i n -

stal l thrott le cab l e s l eeve
Rep l ace w i th a new thrott l e cab l e i f the

speci f ied free play could not be acqui red by
ad just ing the regul ator or i f there is st i l l
st i ck i ness w i th the thrott le .
Ad j us t i ng t he Speed L i m i te r
The speed l i mi ter i s to l imi t the openi ng of
thrott l e
Check the max i mum l ength of l i m i ter screw
thread
Max i mum screw thread : a=12mm
Ad j ust w i th a cross dr i ver .
No te :
For beg i nners , the speed l i m i t shou l d be
fu l l y t i ghtened .
Dr i vers w i th certai n sk i l l s may ad j ust
the thrott le w i th speed l i m i ter
Maxi mum l ength of screw thread i s 12mm .

It is recommended to adjust the thread length
to 3 - 5mm .
3-12
Coo l i ng Sys t em
No t e
Check coo l ant l evel f rom reservo i r tank.
Do not check f rom rad i ator .
I f the rad i ator cap i s opened wh i l e the

eng i ne i s hot (over 100$) , the pressure of 3
the coo l i ng system w i l l drop down and the
coo l ant w i l l get bo i l ed rap i d l y .
DO NOT open the rad iator cap unt i l the coo l -

ant temperature drops down .
-Coolant is poisonous, DO NOT dr ink or splash
i t to ski n , eyes , and c l othes .
- In case the coo l ant gets to the sk i n and
cl othes , wash w i th soap i mmed i atel y .
- In case the coo l ant gets i nto eyes , r i nse
w i th p l enty of water and go to consu l t the
doctor
- In case of swa l l ow i ng the coo l ant , i nduce
vom i t and consu l t the doctor .
- Keep the coo l ant i n a safe p l ace and away
f rom reach of ch i l dren .
Coo l an t l eve l
Coo l ant m i ght r educe due to natu ra l
evaporat i on .
Check the coo l ant l eve l regu l ar l y .
No t e
- f reeze . Ord i nary water may cause eng i ne
rust or cracks i n w i nter due to f reez i ng .
-Park the vehicle on l evel ground for check-
i ng of the coo l ant .
Inc l i ned veh i c l e body w i l l cause i ncorrect
j udg i ng of the coo l ant l eve l .
-Check the coolant after the engine is warmed
up .
Start and warm up eng i ne.
Stop the eng i ne .
Remove l ef t s i de pane l (# 2 - 6)
Check i f the coo l ant l eve l i s between the
upper and l ower l i m i t .
3-13
CFMOTO
When the coo l ant l eve l i s be l ow the LOWER
l imit,
remove reservo i r tank cap and add coo l ant
t i l l upper l i m i t .
(Add coo l ant or d i l uted or i g i na l l i qu i d) .
Recommended coo l ant : CFMOTO coo l ant
S t anda r d dens i t y : 50%
( Freez i ng temperature o f coo l ant var i es
accord i ng to the d i f ferent m i xture rat i o .
Ad j ust the m i xture rat i o accord i ng to the
l owest temperature i n the p l ace where the
veh i c l e i s used . )
I f the coo l ant reduces very fast , check i f
there i s any l eakage.
The coo l i ng system may be m i xed w i th a i r
when there i s no
coo l ant i n the reservo i r tank and the a i r
shou l d be d i scharged
before add i ng coo l ant .
Coo l an t L eakage
Check radiator hose, water pump, water pipes
and j o i nts for l eakage.
In case of any l eakage , d i sassemb l e and do
further check .
(Refer to Chapter 4)
Check the rad i ator hose for ag i ng , damages

or cracks .
The rubber hose w i l l natura l l y get aged af -

ter a per i od of serv i ce t i me. The aged hose
may get cracked when the coo l i ng system i s
heated . N i p the hose w i th f i ngers and check
i f there are any t i ny cracks .
In case of any abnorma l , rep l ace w i th a new

hose .
Check the c l amps of the coo l ant p i pes and

hose .
T i ghten proper l y i n case of any l ooseness .
Check rad iator f ins for mud and dust cl og or

damage .
Correct the bent f i ns ; c l ean the mud w i th

water and compressed a i r . When the damaged
area of the rad i ator f i n i s over 20% , re -
p l ace w i th a new rad i ator .
3-14
I nspect i on o f Coo l i ng System
Check ini t ial ly at 50 hours or 500km, replace
coo l ant every 2 years .
Check radiator, reservoi r tank and water hoses.
Leakage or Damage : # Rep l ace
Check coo l ant l eve l by observ i ng the upper
and the l ower l i m i t on the reservo i r tank. 3
I f the level is below lower l imi t , f i l l cool -
ant unt i l the l evel reaches the upper l i mi t .
Rep l ac i ng Coo l ant
- Remove rad i ator cap % and reservo i r tank
cap &.
- P l ace a pan be l ow water pump , and dra i n
coo l ant by remov i ng dra i n p l ug ' and water
hose (.
- Dra i n coo l ant f rom reservo i r tank.
Warn i ng !
-Do not open radiator cap when engine is hot ,
you may be i n jured by escap i ng hot l i qu i d or
vapor .
- Eng i ne coo l an t i s ha r m f u l . I f coo l an t
sp lashes i n your eyes or clothes, thorough l y
wash i t away wi th water and consul t a doctor .
I f coo l ant is swal l owed , i nduce vom i t i ng and
get i mmed i ate med i ca l attent i on .
- Keep coo l ant away f rom reach of ch i l dren
-Clean radiator with fresh water , i f necessary.

-Connect water hose ( and t i ghten drain bol t
' secure l y .
-Fi l l the speci f ied coolant into the radiator .
- Loosen b l eed bo l t ) on water pump , when
coo l ant f l ow f rom b l eed bo l t , t i ghten the
bo l t . Instal l rad i ator cap % secure l y af ter
f i l l i ng coo l ant .
- Start the eng i ne and keep i t runn i ng for
severa l m i nutes . Af ter warm up and coo l i ng
down the eng i ne, open rad i ator cap and check
coo l ant . F i l l the spec i f i ed coo l ant unt i l
the l eve l i s between the upper and l ower
l i nes on the reservo i r tank.
Caut i on :
Repeat the above procedures severa l t i mes
and make sure the rad i ator i s f i l l ed w i th
coo l ant and ai r i s d i scharged .
Inspect i on of Coo l i ng System
3-15
CFMOTO
Check Water Temperature Gauge
When eng i ne i s not work i ng , the water tem -

perature shou l d be i n the *0+ pos i t i on .
Start the eng i ne to check i f the i nd i cator
works . I f the i nd i cator i s not work i ng , do
the ma i ntenance i n t i me.
L i gh t i ng Sys t em
Ad j ust i ng head l i ght l i ght beam
Turn the head l i ght beam ad just i ng screw wi th

a cross screwdr i ver and ad j ust the h i gh / l ow
beam to meet the requ i rement .
3-16
VA L VE C L EARANCE
Inspect i n i t i a l l y at 20 - hour break - i n and

every 100 hours or every 1000km thereaf ter .
Inspect the cl earance af ter remov i ng cy l i n -
der head .
3
Excess i ve va l ve c l earance resu l ts i n va l ve

no i se and i nsuf f i c i ent va l ve c l earance re -
su l ts i n va l ve damage and reduced power .
Check the valve clearance at the per iod indi -
cated above
and ad j ust the va l ve c l earance to
speci f i cat i on , i f necessary .
- Remove cover p l ate %, reco i l starter &
- Remove i nspect i on cap ' on l ef t crankcase.
- Remove 2 va l ve ad j ust i ng cover (
- Turn the crankshaf t unt i l the l i ne ) of T .
D . C . on rotor i s a l i gned w i th mark , o f
i nspect i on ho l e on l ef t crankcase.
- Insert fee l er gauge to check the c l earance
between the va l ve stem end and the ad j ust
bo l t on the rocker arm .
Va l ve C l earance (When co l d)
IN : 0 . 05 - 0 . 10mm EX : 0 . 17 - 0 . 22mm
No te :
- The va l ve c l earance must be ad j usted when
the eng i ne i s co l d .
- Ad j ust the val ve cl earance when the p i ston
i s at the Top Dead Center (T . D . C . ) on the
compress i on stroke .
I f the cl earance i s i ncorrect , br i ng i t into

the speci f i ed range us i ng the spec i al too l .
Loosen va l ve ad j ust bo l t and nut , i nsert a

fee l er gauge -IN : 0 . 1mm , EX : 0 . 2mm.between
the valve stem end and val ve ad j ust i ng bol t ,
t i ghten va l ve ad j ust bo l t , make sure i t
s l i ght l y contacts the fee l er gauge , t i ghten
bo l t and nut .
3-17
CFMOTO
Take ou t t he f ee l e r gauge , measu r e t he
c l earance .
I f the c l earance i s i ncorrect , repeat the
above steps unt i l the proper c l earance i s
obta i ned .
Locknut : 10 N . m
Caut i on :
Secure l y t i ghten the l ocknut af ter comp l et -
i ng ad j ustment
Insta l l :
2 va l ve ad j ust i ng cover ;
Inspect i on cap ;
Reco i l starter ;
Cover p l ate ;
App l y a sma l l quant i ty of THREAD LOCKER to
reco i l starter f i xi ng bo l ts .
Too l s :
Val ve ad j uster
Fee l er gauge
Mater i a l :
Thread Locker
ENG I NE I D L E SPEED
I nspect i n i t i a l l y at 20 hours run - i n and
every 50 hours or 500km thereaf ter .
Start the eng i ne and warm i t up for severa l
m i n u t e s , m e a s u r e en g i n e s p e e d w i t h a
tachometer . Set the eng i ne i d l e speed be -
tween 1300~1500 r / min by turning the thrott le
stop screw of carburetor .
Eng i ne i d l e speed : 1400r / m i n / 100r / m i n
Note :
Make th i s ad j ustment when the eng i ne i s hot
Too l : Tachometer
SPARK PLUG
I nspect i n i t i a l l y at 20 hours run - i n and
every 100 hours or 1000km thereaf ter . Re -
p l ace every 6000km .
Remove the spark p l ug w i th a speci al too l
Spec i f i cat i on : DER7EA - 9(NGK)
I f the el ectrode i s extremely worn or burnt ,

or spark plug has a broken insulator , damaged
thread , etc , rep l ace the spark p l ug w i th a
new one .
3-18
I n case o f carbon depos i t , c l ean w i th a
proper too l .
SPARK PLUG GAP
Measure the spark p l ug gap w i th a fee l er
gauge .
Out of spec i f i cat i on : # Ad j ust
Spark p l ug gap : 0 . 8 - 0 . 9mm 3
Caut i on :
Check the thread size and reach when replac-
i ng the spark p l ug . I f the reach i s too
short , carbon wi l l be depos i ted on the screw
port i on of the spark p l ug ho l e and eng i ne
damage may resu l t .
Insta l l at i on :
Caut i on :
To avoid damag ing the cy l inder head threads;
f i rst , t i ghten the spark p l ug w i th f i ngers ,
and then t i ghten i t to the speci f i ed torque
us i ng the spark p l ug wrench .
T i ghten i ng Torque: 18 N . m
Too l : Spark P l ug Wrench , Fee l er Gauge
A i r F i l ter
Inspect every 50 hours or 500 km , c l ean i t
every 1000km i f necessary .
I f the a i r c l eaner i s c l ogged w i th dust ,
i ntake res i stance w i l l be i ncreased , w i th a
resu l tant decrease i n power output and an
increase in fuel consumpt ion. Check and clean
the ai r f i l ter as fo l l ow i ng :
Remove f i xi ng cl amp % and top cover &
No te :
Be carefu l not to drop the o - r i ng i nto the
a i r f i l ter box that i s attached to the a i r
f i l ter top cover .
Loosen screw ', remove f i l ter e l ement (,
separate support ), f i l ter e l ement , and
f i l ter el ement seat 0.
-Fi l l a wash pan of a proper size wi th a non-
f l ammab l e c l ean i ng so l vent A . Immerse the
f i l ter el ement i n cl ean i ng so l vent and wash
it.
- Press the f i l ter el ement between the pal ms
of both hands to remove the excess so l vent .
Do not tw ist or wr i ng the element or i t wi l l
tear .
- Immerse the e l ement i n eng i ne o i l B , and
then squeeze out the excess o i l l eav i ng the
e l ement s l i ght l y wet .
3-19
CFMOTO
A - - Non - f l ammab l e cl ean i ng so l vent
B 1 Eng i ne o i l SAE#30 or SAE15W / 40 .
Never use w i th gaso l i ne or l ow f l ash po i nt
so l vents to c l ean the f i l ter e l ement
Inspect the f i l ter e l ement for tears .

torn e l ement must be rep l aced .
No te :
The surest way to accel erate eng i ne wear i s to
operate the eng i ne w i thout the e l ement or w i th
torn el ement . Make sure that the ai r f i l ter
el ement i s i n good cond i t i on at a l l t i mes .
I f dr i v i ng under dusty cond i t i ons , c l ean the
ai r f i l ter e l ement more f requent l y .
Remove the drai n p l ug 2 of ai r box to dra i n out any water .
Fue l Hose
Inspect every 100 hours or 1000 km ,
rep l ace every 4 years .
Inspect the fue l hose for damage and fuel
l eakage .
I f any damages are found , rep l ace the fuel hose
w i th a new one.
Dr i ve Be l t
Remova l :
Remove CVT cover
Ho l d the pr i mary sheave w i th speci al too l and

l oosen pr i mary sheave nut .
Speci al Too l : Rotor Ho l der
Remove pr i mary s l i d i ng sheave 1 ;

Ho l d the secondary sheave w i th speci a l too l
and l oosen secondary sheave nut .
Remove secondary sheave together w i th dr i ve bel t .
Speci al Too l : Rotor Ho l der
Remove dr i ve be l t f rom secondary sheave
3-20
I nspect i on :
Inspect dr i ve bel t for wear and damage.

I f any cracks or damages are found ,
rep l ace dr i ve bel t w i th a new one.
3
Inspect dr i ve bel t for w i dth , i f w i dth i s
out of serv i ce l i m i t , rep l ace dr i ve be l t w i th a new one.
Serv i ce L i m i t : 33 . 5mm
Too l : Vern i er Ca l i per
I nsta l l at i on
Reverse the remova l procedure for i nstal l at i on .
Pay attent i on to the fo l l ow i ng :
Insert dr i ve bel t , as l ow as poss i b l e,
between secondary s l i d i ng sheave and pr i mary
f i xed sheave .
Ho l d secondary sheave w i th a speci al too l and
t i ghten the nut to the speci f i ed torque.
Nut , Secondary Sheave: 115 N . m
Instal l pr i mary sheave and nut . Ho l d the pr i mary

sheave w i th a spec i a l too l and t i ghten the nut
to the speci f i ed torque.
Nut , Pr i mary Sheave: 115N . m
Turn pr imary sheave , unt i l the dr i ve bel t i s

proper l y seated and both the pr i mary and
secondary sheaves rotate together smooth l y
and w i thout s l i pp i ng .
Caut i on :
- F i t the dr i ve bel t w i th the arrow on the dr i ve
be l t po i nts toward norma l turn i ng d i rect i on .
- The dr i ve bel t contact sur face of the dr i ven
face shou l d be thorough l y cl eaned .
Insta l l CVT cover
3-21
CFMOTO
I nspect i on o f Lubr i cat i on System

Rep l ace eng i ne o i l and o i l f i l ter i n i t i a l l y
at 20 hours or 250km and every 100 hours or
1000km thereaf ter .
Inspect the eng i ne o i l at every 10 hours .
Check Eng i ne O i l Leve l
- Keep the eng i ne i n a p l an pos i t i on .

-Remove the f ixture A, f ixture B, then remove
the l ef t s i de cover 1 .
- Remove o i l d i p rod 2
-Clean oi l dip rod, insert oi l dip rod but do
not t i ghten i t .
- Take out o i l d i p rod and check i f o i l i s
between upper and l ower l i m i t .
- I f the engine oi l is insuf f icient , f i l l more
o i l unt i l the suf f i ci ent o i l i s obtai ned .
Eng i ne O i l : SAE15W / 40 c l ass i f i cat i on SF or
SG
No te :
- Keep the eng i ne i n a p l an pos i t i on
- Do not t i ghten o i l d i p rod when measur i ng
o i l l eve l
Rep l ac i ng Eng i ne O i l
- Remove l ef t s i de cover 1 , o i l d i p rod 2 ,
drai n bo l t 3 and washer 4 .
-Drain out the engine oi l whi le the engine is
st i l l warm .
- C l ean o i l d i p rod , dra i n bo l t and washer
w i th so l vent .
- Insta l l washer and dra i n bo l t .
Drai n Bo l t : 30 N . m
- F i l l eng i ne o i l . ( about 1900m l )
3-22
- Insta l l o i l d i p rod , start the eng i ne and

al low i t to run for several minutes at idl ing
speed .
- Turn of f the eng i ne and wa i t f or about 3
m inutes , and then check the o i l l evel on the
d i pst i ck . 3
Caut i on :
The eng i ne o i l shou l d be changed when the
eng i ne i s warm . I f the o i l f i l ter shou l d be
rep l aced , rep l ace eng i ne o i l at the same
t i me .
Rep l ac i ng O i l F i l ter
- Remove re l at i ve parts ( see Rep l ac i ng En -

g i ne O i l )
- Remove o i l f i l ter % w i th the spec i al too l
- Insta l l washer and drai n bo l t
- Instal l new oi l f i l ter wi th the special tool
- F i l l eng i ne o i l (about 2000m l ) and check
(see Rep l ac i ng Eng i ne O i l )
Too l : O i l F i l ter Wrench
Eng i ne O i l Capac i ty
When rep l aci ng o i l : 1 . 9L
When rep l aci ng o i l f i l er : 2 . 0 L
Eng i ne overhau l : 2 . 2 L
I nspect i on o f Externa l O i l P i pe
Check external oi l pipe for leakage or damage.
Leakage or Damage : # Rep l ace
3-23
CFMOTO
I nspect i on o f cy l i nder pressure

Check cy l i nder pressure i s necessary .
Cy l i nder Pressure: 1000kpa
A l ower cy l i nder pressure may be caused by :

- Excess i ve wear of cy l i nder ;
- Wear of p i ston or p i ston r i ng ;
- P i ston r i ng j am i n groove;
- Poor cl osure of val ve seat ;
- Damaged cy l i nder gasket or other defects
Note : When cy l i nder pressure too l ow, check

the above i tems .
Test i ng Cy l i nder Pressure

Note : Before test i ng of cy l i nder pressure ,
make sure that cyl inder head bol ts are t ight -
ened to the speci f ied torque and valve clear -
ance has been proper l y ad j usted .
- Warm up the eng i ne before test i ng ;

- Make sure battery i s fu l l y charged ;
- Remove spark p l ug 1 ;
- Insta l l cy l i nder pressure gauge 2 i n spark
p l ug ho l e and t i ghten nut ;
- Keep thrott le fu l l open ;
- Press start button crank the eng i ne a few
seconds . Record the max i mum read i ng of cy l -
i nder pressure .
Too l s : Cy l i nder Pressure Gauge
Adaptor
3-24
I nspect i on o f O i l P ressu r e
O i l Pressure : 1303170kpa at 3000r / m i n
Lower or h i gher o i l pressure may be caused
by :
! O i l p r essu r e i s t oo l ow
- C l ogged o i l f i l ter ;
- Leakage f rom o i l passage ;
3
- Damaged O - r i ng ;
- O i l pump fai l ure ;
- Comb i nat i on of above i tems ;
" O i l p r essu r e i s t oo h i gh
- O i l v i scos i ty i s too h i gh ;
- C l ogged o i l passage ;
- Comb i nat i on of above i tems ;
Test i ng O i l Pressure
- Remove bo l t %;
- Connect tachometer & w i th i gn i t i on co i l
- Instal l o i l pressure gauge ' and jo i nt seat
to mai n o i l
ga l l ery .
- Warm up eng i ne as per fo l l ow i ng :
Summer : 10 m i nutes at 2000r / m i n
W i nter : 20 m i nutes at 2000r / m i n
Af ter warm i ng up , i ncrease eng i ne speed to

3000r / m i n , and record read i ngs of o i l pres -
sure gauge .
- Af ter test i ng , app l y thread l ocker to the

thread i n the ho l e of ma i n o i l channel . In -
stal l bol t and t ighten to the speci f ied torque.
T i ghten torque423N . m
Too l s4O i l pressure gauge

Tachometer
3-25
CFMOTO
I nspect i on of C l utch Engagement and
Lock - up
CF188 - B eng i ne i s equ i pped w i th a centr i fu -

gal type automat i c cl utch .
Before check i ng the i n i t i a l engagement and
cl utch lock-up two i nspect ion checks must be
per formed to thorough l y check the operat i on
of the dr i ve trai n .
I I n i t i a l Engagemen t I nspec t i on
- Connect tachometer to i gn i t i on co i l
- Start eng i ne
- Sh i f t gear lever to *H igh+ posi t ion
- S l ow l y i ncrease thrott le and note down the
engi ne speed ( r / mi n) when the veh i cle starts
to move forward .
Engagement speed : 1800r / m i n32400r / m i n
I f the engagement speed i s out of the above
range, check the fo l l ow i ng :
- C l utch shoes
- C l utch shoe whee l
- Pr i mary and secondary sheave
Refer to Chapter 12 for inspect ion of clutch
I I C l u t ch L ock - up I nspec t i on
- Connect the tachometer to i gn i t i on co i l ;
- Start the eng i ne ;
- Sh i f t gear lever to *H igh+ pos i t i on ;
- App l y f ront and rear brakes as f i rm l y as
poss i b l e ;
- Fu l l y open the thrott l e for a br i ef per i od
and note the max i mum eng i ne speed obta i ned
dur i ng the test cycl e.
Lock - up Speed : 3300r / m i n33900r / m i n
Warn i ng :
Do not app l y f u l l power f or more than 5
seconds or damage to c l utch or eng i ne may
occur .
I f the l ock - up speed i s out o f the above
range, check the fo l l ow i ng :
- C l utch shoes
- C l utch whee l
- Pr i mary and secondary sheave
Refer to Chapter 12 for inspect ion of clutch
Too l : Tachometer
3-26
4 Coo l i ng and L i br i cat i on System
Overhaul Info !!!!!!!!!!4 - 1 Rad i ator and water hose check and c l ean!!4 - 9
Troub l e Shoot ing !!!!!!!!4 - 2 Coo l i ng fan check!!!!!!!!!!!!!4 -10
Per formance Overhau l !!!!!!4 - 3 Water temperature transducer check!!!!4 - 11
Reservo i r Tank !!!!!!!!!4 - 5 Water pump !!!!!!!!!!!!!!!! 4- 12
Addi ng Coo lant !!!!!!!!!4 - 6 Water pump check !!!!!!!!!!!!!4 -14
Coo l i ng system chart !!!!!!4 - 7 Water pump assemb l y and i nsta l l at i on!!!4 - 15
Engi ne Coo lant !!!!!!!!!4 - 8 Lubr icat i on system chart !!!!!!!!!4 - 19
O ve r h au l I n f o
Caut i on :
" I f the radiator cap is opened when the coolant temperature is above 100 #, the pressure of
coolant temperature wi l l go down and get bo i led rap idl y. The steam jet may cause danger and 4
injury. Cover the cap wi th a piece of cloth after the coolant temperature goes down and open
the cap .
"Inspect i on of coo l ant shou l d be done af ter the coo l ant i s fu l l y coo l ed .
" Coo l ant i s po i sonous . Do not dr i nk or sp l ash i t to ski n , eye or cl oth .
- I f coo l ant sp l ashes i n eyes , through l y wash your eyes w i th water and consu l t a docter .
- I f coolant splashes on your clothes, quickly wash i t away wi th water and then wi th soap and
water .
- I f coo l ant i s swa l l owed , vo i mt i mmed i ate l y and see a phys i c i an .
- Store the coo l ant proper l y and keep i t away f rom reach of the ch i l dren .
" Check radiator f ins for mud block and / or damage. Correct the bent f ins. Clean of f the mud
w i th water and compressed ai r . Rep l ace wi th a new one, i f the damaged f i n area reached 20%
"The overhau l i ng of the water pump can done w i thout remov i ng the eng i ne .
"Coo l ant f i l l i ng i s carr i ed through reservo i r tank. Do not open the rad i ator cap except
when d i sassemb l i ng the coo l i ng system for f i l l i ng or drai nage of coo l ant .
"Don$t stai n the pai nt i ng parts w i th coo l ant . In case of any coo l ant stai ns , f l ush w i th
water i mmed i ate l y .
" After di sassembly of the cool ing system, check the joints for leakage wi th a rad iator cap
tester (avai l ab l e i n the market ) .
" Refer to Chapter 10 for overhau l i ng of temperature transducer .
I ns p ec t i o n s t an d a r d
I tem Standard
Coo l ant capaci ty Fu l l capaci ty 1140m l
Reserv i or tank 300m l
Standard dens i ty 50'
Open i ng pressure of rad i ator cap 108kpa%1 . 1kg f / cm 2 &
Thermostat Val ve open temperature 71 ( 3#
Fu l l open l i f t under 95#)3 . 5 * 4 . 5mm
T i g h t en i n g t o r q ue :
Dra i nage bo l t , water pump : 8N"m%0 . 8kgf"m&
Water pump i mpe l l er : 10N"m%1 . 0kgf"m&
4-1
T r o ub l e sh o o t i n g
Wa t e r t empe r a t u r e r i ses t oo f as t
"Improper rad i ator cap

"A i r i n the coo l i ng system p i pe
"Mal funct i on of water pump
"Ma l funct i on of thermostat%thermostat i s
not open&
"C l ogged of rad i ator p i pe of coo l i ng p i pe
"Damaged or c l ogged rad i ator f i ns
"Coo l ant i s not enough
"Fau l ty or ma l funct i on of fan motor
No r i se or s l ow r i se o f water temperature
"Mal funct i on of thermostat%thermostat i sn$
t cl osed&
"Fau l ty c i rcu i t of water temperature d i s -
p l ay
W a t e r l eakag e
"Poor water sea l
"O - r i ngs are aged , damaged or i mproper l y
sea l ed
"Washers are aged , damaged or i mproper l y
sea l ed
"Improper i nsta l l at i on of p i pes
" Pipes are aged, damaged or improper ly sealed
4-2
P e r f o r m an ce O v e r h au l
I nspec t i on o f coo l an t dens i t y
Caut i on :
Be sure to open the radiator cap after coolant
i s coo l ed .
Remove :
Fron t top cover%+ 2 - 4&
Rad i ator cap(counter cl ockw i se)
4
Check w i th a dens i meter i f the dens i ty of
cool ant f i ts the temperature of us i ng p l ace;
Check coo l ant for stai ns
I nspec t i on o f t he r ad i a t o r cap
Caut i on
Be sure to open the rad i ator cap af ter cool -
ant i s coo l ed
Remove :
- Front top cover (+ 2 - 4)
- Rad i ator cap( + 4 - 3) ,
Caut i on
Appl y water on the seal ing sur face of radi a-

tor cap , when at tach i ng the tester to the
rad i ator cap
App l y the spec i f i ed pressure( rad i ator cap

opening pressure) for 6 seconds and make sure
there i s no pressure drop .
Open i ng p r essu r e o f r ad i a t o r cap :
1 0 8 kP a!
! 1 . 1 kg f / cm 2 "
4-3
P r essu r e t es t i ng o f coo l i ng sys t em
App l y the spec i f i ed pressure( rad i ator cap
opening pressure) for 6 seconds and make sure
that there i s drop i n pressure
Caut i on
Do not app l y pressure over the spec i f i ed
pressure[108kPa(1 . 1 kgf / cm2 ) ] , or the coo l i ng
system may be damaged .
In case there i s any pressure l eakage , check
the p i pe , j o i nt par ts , j o i nts of water pump
and drai nage(+ 4 - 5)
Rep l ac i ng C oo l an t , A i r D i s ch a r ge
P r epa r a t i on o f coo l an t
Caut i on :
Coo l ant i s po i sonous , DO NOT dr i nk ot sp l ash
i t to ski n , eyes and c l othes
- I f coo l ant sp l ashed i n your eyes , through l y
wash your eyes w i th water and consu l t a doc-
tor
- I f coo l ant spl ashed on your cl othes , qu i ckl y
wash i t away w i th water then w i th soap and
water
- I f coo l ant i s swa l l owed , i nduce vom i t i mme -
d i atel y and see a phys i ci an
- Store the coo l ant proper l y and keep i t away
f rom reach of ch i l dren
Caut i on :
M i x the coo l ant (und i l uted) w i th sof t
water accord i ng to the temperature 5#
l ower than the actua l l owest temperature i n
the operat i on area .
Coo l ant shou l d be made f rom und i l uted coo l -
ant w i th sof t water .
S t anda r d dens i t y o f coo l an t : 50%
Recommended coo l ant : CFMOTO coo l ant
(D i rect app l i cat i on w i thout hav i ng to be
d i l uted)
D r a i nage o f coo l an t
Remove t he r ad i a t o r cap
Caut i on
Open the rad i ator cap af ter the coo l ant
i s coo l ed down .
Remove :
- Front top cover (+ 2 - 8)
- Rad i ator Cap(+ 4 - 3)
4-4
Remove d r a i n bo l t
Remove drai n bo l t , seal gasket f rom water
pump , dra i n coo l ant .
Af ter drai nage, assemb l e new sea l gasket
and drai n bo l t and t i ghten .
R es e r v o i r T an k
Remove :
- Seat (+ 2 - 3)
- Lef t S i de Cover (+ 2 - 6)
- Two bo l ts of reservo i r tank
- Water hoses of reservo i r tank
Remove reservo i r tank
Drai n co l l ant of reservo i r tank
Wash c l ean the reservo i r tank
Insta l l :
- reservo i r tank
- water hoses of reservo i r tank
4-5
A dd i n g C o o l an t
Add coo l ant through f i l l i ng port
Start the engine and discharge ai r from cool -

i ng system . Check f rom f i l l ing port that ai r
i s fu l l y d i scharge f rom coo l i ng system and
i nstal l the rad i ator cap
Remove reservo i r tank cap and add coo l ant

t i l l the upper l i m i t
Caut i on :
Check coo l an t l eve l when the veh i c l e i s
on an even g r ound
D i s ch a r g e
D i scharge the a i r f rom coo l i ng system ac -

cord i ng to the fo l l ow i ng steps :
1 . Remove dra i n bo l t%+ 4 - 5&, d i scharge a i r

and i nsta l l i t
2.Start the engine and run i t several minutes

at i d l e speed
3.Quickly increase thrott le 3~4 t imes to dis-

charge a i r f rom coo l i ng system
4 . Add coo l ant t i l l f i l l i ng port
5.Repeat step 2&3 t i l l no more coolant can be

ref i l l ed
6 . Check coo l ant l eve l i n reservo i r tank and

ref i l l t i l l upper l i m i t , i nsta l l reservo i r
tank cap
4-6
Coo l i ng Sys t em
4-7
- E ng i n e Co o l an t
The cool ing used in cool ing system is mixture
of 50% d i st i l l ed water and 50% ethy l ene gl y -
co l ant i f reeze . Th i s 50 : 50 m i xture prov i des
the opt i m i zed corros i on res i stance and f i ne
heat protect i on . The coo l ant w i l l protect the
coo l i ng system f rom f reez i ng at temperature
above -30#, the mixing rat io of coolant should
be i ncreased to 55% or 60% accord i ng to the
f i gure on the r i ght .
Note#
. Use h i gh qual i ty ethy l ene g l yco l base an -
t i freeze and mixed wi th dist i l led water .Never
m i x a l coho l base ant i f reeze and d i f ferent
brands of ant i f reeze
. The rat i o of ant i f reeze shou ld not be more
than 60% or l ess than 50%
. Do not use ant i - l eak add i t i ve
Warn i ng !
.DO NOT open radiator cap when the engine is
st i l l hot . Or you may be i n j ured by sca l d i ng
f l u i d or steam ;
. Coo lant i s harmfu l . DO NOT swal l ow or stai n
your sk i n or eyes w i th coo l ant . In case of
accidental swal low or stain, f lush wi th plenty
of water and consu l t the doctor immed i atel y ;
. Keep coo l ant away f rom reach of ch i l dren
- I nspec t i on o f C oo l i ng C i r cu i t
. Remove rad i ator cap / and connect tester
0 f i l l er
Warn i ng !
DOT NOT open the rad i ator when the engi ne i s
st i l l hot
. Gi ve a pressure of 105kPa and check i f the
cool i ng system can ho l d th i s pressure for 10
seconds .
. I f the pressure drops dur ing 10 seconds , i t
i nd i cates that there i s l eaakage w i th the
coo l i ng system . In th i s case , check the com -
plete system and replace the leaking parts or
components .
Warn i ng !
. When remov i ng the rad i ator cap tester , put
a rag on the f i l l er to prevent sp l ash o f
coo l ant
. DO NOT a l l ow a pressure to exceed the
rad i ator cap re l ease pressure
4-8
- I n s p ec t i o n an d C l ean i n g o f R ad i a t o r
and Wa t e r Hoses
R ad i a t o r Cap
. Remove rad i ator cap /
. Instal l rad i ator cap to cap tester 0
.Slowly increase pressure to 108kPa and check

i f the cap hol d the pressure for at l east 10
seconds
4
. I f t he cap can no t mee t t he p r essu r e
requ i rement , repal ce i t
Rad i a t o r Cap Va l ve Open i ng P r essu r e :

S t an d a r d : 1 0 8 kP a
To o l : Rad i a t o r C ap T es t e r
Rad i a t o r I ns pec t i on and C l ean i ng
. Remove d i rt or trash f rom rad i ator w i th

compressed ai r
. Cor rect the rad i ator f i ns w i th a sma l l

screwdr i ver
Rad i a t o r Hos e I nspec t i on
. Check rad i ator hoses l eakage or damage. I f

the hoses are l eakaged and damaged , rep l ace
them
. Check t i ghten i ng o f c l amps . Rep l ace the

c l amps i f necessary
. Af ter i nspect i on and c l ean i ng of rad i ator

and hoses , check coo l ant l eve l . F i l l coo l ant
i f necessary
4-9
I nspec t i on o f Fan Mo t o r
. Remove fan motor f rom rad i ator

. Turn the vanes and check i f they can turn
smooth l y
. Check fan motor .Make sure that the battery
app l i es 12 vo l ts to the motor and the motor
wi l l run at ful l speed whi le the ammeter wi l l
i nd i cate the ampere not more than 5A .
I f the motor does not work or the ampere
exceeds the l i m i t , rep l ace the motor
. Instal l at i on : App l y a l i tt l e thread l ocker
to the bo l ts and t i ghten to the spec i f i ed
torque .
Fan Mo t o r Bo l t T i gh t en i ng To r que : 10N . m
I n spec t i on o f T he r mos w i t ch
. Remove thermosw i tch

.Check the thermoswi tch for closing or open-
ing by test ing i t at the bench as i l lustrated.
Connect the thermosw i tch / to the c i rcu i t
tester ,p l ace i t i n a vessel w i th eng ine oi l .
P l ace the vessel above a stove.
.Heat the oi l to raise the temperature slowly
and take the readi ng f rom thermostat 0 when
the thermosw i tch c l oses and opens .
Too l : amme te r
Th e r mo sw i t ch O pe r a t i ng T em pe r a t u r e :
S t an d a r d : ( O FF - O N ) : A p p r o x . 8 8 $
( ON - OFF ) : Appr ox . 82$
$
Note :
. Avo i d sharp i mpact on thermosw i tch

. Avo i d contact of thermosw i tch w i th ther -
mometer or vesse l
.Instal lat ion:Use a new O- r ing 1 and t ighten
the thermosw i tch to the speci f i ed torque:
Thermosw i tch T i ghten i ng T i rque: 17N . m
. Check coo l ant l evel af ter i nstal l at i on of
thermosw i tch . F i l l coo l ant i f necessary .
4-10
- Inspect i on of Water Temperature Sensor
. P lcae a rag under water temperature sensor

/ and remove i t f rom cyc l i nder head
. Check the res i stance of water temperature
sensor as i l l ustrated on ther i ght . Connect
the temperat ure sensor 0 to the c i rcu i t
tester ,p l ace i t i n a vessel w i th eng ine oi l .
P l ace the vessel above a stove.
To o l : oh mme t e r , t he r mo me t e r
.Heat the oi l to raise the temperature slowly
and take the read i ng f rom ohmmeter 2 and
thermometer 1. 4
B R es i s t an ce an d Wa t er T emp er at u re
T em pe ra tu re
50 80 100
!" #
Re s i st an ce 154% 52%
27% 3
!$ # 16 4
! C R es i st an ce an d W at er Temp er a tu re
A!
T em pe ra tu re 80
-20 25 110
!" #
Re s i st an ce 13.71- 1.825- 0.303- 0.1383-
! k$# 16.94 2.155 0.325 0.1451
. Instal l at i on : App l y a l i tt l e thread l ocker

and instal l i t to the cyl inder head by t ight -
en i ng to the speci f i ed torque.
Water Temper atu r e Senso r T i ghten i ng
To r que : 10N . m
No t e :#
#
. Avo i d sharp i mpact on terperature sensor
. Avo i d contact of temperature sensor w i th
thermometer or vesse l
.After instal lat ion,check the coolant level .
F i l l coo l ant i f necessary .
% I n sp ec t i o n o f T he r mo s t a t
. Remove thermostat case
. Remove thermostat
4-11
. Check ther mos tat pe l l et f or cracks . I f
necessary , rep l ace i t .
. Test the thermostat accord i ng to the fo l -

l ow i ng steps :
3 Pass a str ing between thermostat f l ange as
i l l ustrated on the r i ght
3 Immerse the thermostat i n a beaker w i th
water .Make sure that the thermostat is in the
suspended pos i t i on w i thout contact to the
vessel . Heat the water by p l ac i ng the beaker
above a stove and observe the temperature
r i se on a thermometer
3 Take the temperature read ing f rom thermom-
eter when the thermostat va l ve opens
The r mos t a t V a l ve Open i ng Tempe r a t u r e :
71 & 3 $
Too l : The rmomet er
3 Keep heat i ng the water to rai se the water
temperature.When the water temperature reaches
the spec i f i ed va l ve , the thermostat va l ve
shou l d have been l i f ted by 3 . 5 - 4 . 5mm
L i f t s t anda r d o f t he r mos t a t va l ve :
w a t e r t e m p e r a t u r e 9 5 $' l i f t s t a n d a r d
i s 3 . 5 - 4 . 5m m
3 I f thermotat va l ve open i ng temperature or
thermostat ve l ve l i f t does not reach the
standards , rep l ace i t .
. I nata l l thermostat : Reverse the remova l

procedure for i nstal l at i on
3 App l y coo l ant to the rubber seal of ther -

mostat
3 I nsta l l thermostat case . T i ghten to the
spec i f i ed torque :
T i g h t e n i n g T o r q u e s : 1 0 N (m
- Wa t e r Pu mp
Remova l an d D i sas semb l y
. Remove eng i ne l ef t s i de cover
. Dra i n coo l ant

Note#
#Before dra i n i ng coo l ant , check water
pump for o i l or coo l ant l eakage . In case of
o i l l eakage , check the water pump o i l sea l ,
O- r ing. In case of coolant leakage, check the
water sea l
4-12
. Remove c l amps and water hoses
. Re l ease bo l ts and remove water pump
. Remove O - r i ng
No t e : Do no t r euse t he O - r i ng
. Remove the over f l ow tube
. Rel ease water pump cover screws ,water pump

cover and gasket
. Remove r i ng and i mpe l l er
. Remove seal r i ng / and rubber sea l 0
4-13
. Remove mechan i cal sea l w i th spec i a l too l
Note#
#The mechan i ca l sea l does not need to
be moved , i f there i s no abnormal cond i t i on .
Note : Do not reuse a removed mechan i ca l sea l
. Put a rag on the water pump body
. Reomve o i l sea l
Note:The oi l seal does not need to be removed,

i f there i s no abnorma l cond i t i on
Note : Do not reuse a removed o i l sea l
. Remove bear i ng w i th spec i a l too l
Note :The bear ing does not need to be removed,

i f there i s no abnorma l no i se
Note : Do not reuse a removed bear i ng
I nspec t i on o f Wa t e r Pump
) Bea r i ng
. Check the bear i ng c l earance by hand , wh i l e

i t i s st i l l i n the water pump body
. Turn i nner race of bear i ng to check for
abnormal no i se and smooth rotat i on
. Rep l ace the bear i ng , i f there i s abnorma l
cond i t i on
) M ech an i ca l Sea l
. Check mechan i ca l sea l for damage , pay at -

tent i on to the seal face
. In case of l eakage or damage , rep l ace the
mechan i ca l sea l . I f nesessary , a l so rep l ace
the sea l r i ng .
4-14
) O i l S ea l
. Check o i l sea l for damaged . Pay attent i on

to the o i l seal l i p .
. In case of damage or l eakage, rep l ace the

o i l sea l
4
) Wa t e r Pump Body
. Chec l the mat i ng mace of water pump body

w i th bear i ng and mechan i ca l sea l . I f damage ,
rep l ace i t
) Wa t e r Pump I m pe l l e r
. Check the i mpe l l er and shaf t for damage.

. I f the i mpe l l er or shaf t are damaged , re -
p l ace a new part
Assemb l y and I ns ta l l a t i on o f Wat er Pump
. Instal l o i l sea l w i th speci al too l ;

T o o l #O i l Sea l I nsta l l er
Note : The stamped mark on the o i l seal faces

outs i de .
. App l y a l i tt l e grease to the o i l seal l i p
4-15
. Insta l l mechan i ca l sea l w i th a su i tab l e
socket wrench .
No t e : App l y sea l an t to s i de 4A5 o f me -

chan i ca l sea l
. Instal l bear i ng w i th spec i a l too l
T oo l : Bea r i n g I n s t a l l e r
Note : The stamped mark on the bear i ng faces

outs i de .
. Instal l seal r i ng to i mpe l l er
. Cl ean of f the oi l and grease f rom mechan i -

ca l sea l and i nstal l i nto the i mpe l l er
N o t e :4A5s i de o f mechan i ca l sea l f aces

i mpe l l er
. App l y grease to i mpe l l er shaf t
. Insta l l i mpel l er shaf t to water pump body
4-16
. Instal l r i ng to water pump shaf t
. Instal l new gasket to water pump body
. Insta l l water pump cover and t i ghten the

bo l ts and b l eed bo l t
Water Pump Cover Bo l ts T i ghten i ng
T o r q u e : 6 N (m
. Check i mpe l l er for smooth turn i ng
. Instal l the new O - r i ng
Note :
. Use the new O - r i ng to prevent l eakage
. App l y grease to O - r i ng
. Insta l l the over f l ow tubes
4-17
. Insta l l water pump and t i ghten the bo l ts
to the speci f i ed torque
Wa t e r pump bo l t s t i gh t en i ng t o r que :
10N(
(m
Note : Set the water pump shaf t s l ot end 4B5

to o i l pump sha f t f l at s i de 4A5.
. Connect water hoses
. Add coo l ant
. Instal l l ef t s i de cover
4-18
4-19
Add grease to the eng i ne parts(p i ston , cy l i n -
der body , camshaf t and so on) wh i ch run at
h i gh speed
Eng i ne l ubr i cat i on shou l d be spec i a l o i l .
Eng i ne o i l i s not on l y used as l ubr i cat i on ,
but also used to wash, rustproof ,seal and cool .
I nspect i on o f L u b r i c a t i o n s y s t e m !*
3 - 22"
I nspect i on o f eng i ne o i l pump and l i m i t

pressure v a l v e !* 6 - 4 1 "
4-20
5 Removal and Installation of Engine,Drive Traina and Gearshift Unit
Remova l and Insta l l at i on of Front and Rear
Overhaul Info###############5-1
Alex ##################5-5
R emo v a l an d I n s t a l l a t i o n o f G ea r s h i f t
Engi ne Removal and Instal l at ion##### 5-2 Uni t####################5-7
Overhau l Info
Operat i on Caut i ons
!Secure l y support the ATV w i th bracket when remov i ng or i nsta l l i ng eng i ne . Take
care not to damage f rame , eng i ne body , bo l ts and cab l es" 5
!Warp the f rame to avo i d anyy poss i b l e damage when remov i ng or i nsta l l i ng the
eng i ne"
!Fo l l ow i ng operat i on doesn#t requ i re remova l of eng i ne f rom the veh i c l e :
Oi l pump
Carburetor, air filter
Cylinder head cover, cylinder head, cylinder body, camshaft
CVT system, CVT cover
Gearbox
Right side cover, AC magneto, water pump
Piston, piston ring, piston pin
Following operation require removal of engine from vehicle:
Crankshaft
Tightening torque:
Engine front upper mounting bolt: 35N!45N"m
Engine front rear mounting bolt: 40!50N"m
Bolt, engine front rear mounting bracket 35!45N"m
Bolt, engine front upper mounting bracket 35!45N"m
5-1
CFMOTO
Engine Removal
Remove:
—Plastic( --Chapter 2)
—Air Filter( -Engine service chapter)
—Carburetor (-Engine service chapter)
—Clamp
—Water Inlet Hose
Remove screw
Remove gearshift rod
Remove clamp
Remove water outlet hose
Remove Sleeve.
Remove connectors of magneto, enriching
device lead, pickup, water temperature
transducer, gear sensor as illustrated on the
right.
5-2
Remove spark plug cap from cylinder
5
Remove protection sleeve of starter relay.
Remove Nut.
Disconnect positive wire of starter relay.
Remove nut.
Remove negative wire of starter relay.
5-3
CFMOTO
Remova l Bo l t (4 un i ts) of Eng i ne.
5-4
Eng i ne I nsta l l at i on
Put eng i ne onto the f rame , i nsta l l the two
l ower mount i ng bo l ts and nuts
Tightening torque: !
Engine lower hanger bolt:50!60N"m
Install:
—Water outlet and inlet hoses to engine with proper
clamps.
—Positive and negative starting wires to engine.
—Connect all the connectors.
—Spark plug cap.
—Gearshift rod to engine.
—Air filter, carburetor and removed parts. 5
Removal and Installation of Front and Rear Axle

Support the vehicle with jack, make sure the vehicle
will not fall.
Remove:
P l ast i c par ts f or f ram $
( % Chapter 2&
Front and rear whee l s and arms$% Chapter
8 &
A i r f i l ter$% Chapter 7&
Ca rbure to r$% Chapt er 7&
Eng i ne
Rear brake Ca l i per$% Chapter 7&
5-5
CFMOTO
Remove nut and bolt of front axle from

frame.
Remove nut and bolt of rear axle from

frame.
5-6
Remove the 18 bo l ts f or dr i ve sha f ts and
f ront and rear ax l es$Refer to 5'bo l t 3)
Remove
Front and rear axl es , dr i ve shaf ts , rear brake
d i sc
I nsta l l at i on
Reverse the remova l procedure for Insta l l a -
t i on
T i ghten i ng torque :
Bo l t , f ront a x l e !4 0 - 5 0 N "m
Bo l t , rear a x l e !4 0 - 5 0 N "m
B o l t , f r o n t an d r e a r d r i v e s h a f t s !4 0 -
5 0 N "m 5
Gea r sh i f t Un i t
Remove
l e f t and r i ght s i de pane l $% 2 - 6&
Fue l tank top cover$% 2 - 8&
F r on t f ende r $% 2 - 8&
Bo l t 1
Gearsh i f t rod
Remove the 3 bo l ts
Remove gearsh i f t un i t
Reverse the remova l procedure for i nsta l l a -
t i on
Make sure that gearsh i f t i s f l exi b l e.
In case of any inf lexibi l i ty,adjust the

gearsh i f t rod to ensure the gear en -
gagement
5-7
6 Engine Removal , Inspect ion & Instal lat ion
6 Engine Removal, Inspection and Installation

!Engine Removal/Installation Orders and the Relative Page Numbers
Disassembly Inspection / Remarks
tem DES Assembly
Maintenance
gine Water Hose/Pipe 3-2 2-11 3-69
iphery Left Side Cover 3-2 3-69
Recoil Starter 3-2 3-49 3-68
Spark Plug 3-2 2-4 3-68
Cylinder Head Cover 3-3 3-14 3-66
gine Tensioner 3-3 3-24 3-67
nt Camshaft 3-3 3-21 3-65
Side Cylinder Head/Tensioner Plate 3-4 3-15/3-23 3-64
Cylinder/Timing Chain Guide 3-4 3-24/3-23 3-64
Piston 3-5 3-25 3-62
Starting Motor 3-5 6-3 3-62
Oil Filter 3-6 2-9 3-62
ngine Sector Gear 3-6 3-61
ft side Water Pump 3-7 5-7 3-61
Sheave Drum 3-7 3-48 3-60
Left Crankcase Cover/ Magneto Stator 3-7 3-48 3-60
Magneto Rotor 3-7 3-47 3-60
Starting Driven Gear 3-8 3-47 3-59 6
Starting Dual Gear/Idle Gear 3-8 3-48 3-59
Oil Pump Sprocket and Chain 3-8 3-59
CVT Cover 3-9 3-51 3-58
Drive Belt 3-9 3-36 3-57
Primary Sheave/Secondary Sheave 3-9 3-30 3-57
ngine CVT Housing/Clutch Outer Face 3-10 3-51 3-57
ht side Clutch 3-10 3-28 3-56
Timing Chain 3-10 3-23 3-56
Gear Position Bolt 3-11 3-56
Right Crankcase 3-11 3-52 3-56
Front Output Shaft Components 3-11 3-43 3-55
Driven Bevel Gear Components 3-11 3-43 3-55
Shift Cam 3-12 3-40 3-55
Guide Bar, Fork 3-12 3-39 3-55
ngine
Drive Bevel Gear Components 3-12 3-42 3-55
enter
Main Transmission Shaft 3-12 3-38 3-54
Transmission Counter Shaft 3-12 3-38 3-54
Balancer Shaft 3-12 3-46 3-54
Crankshaft 3-13 3-27 3-54
Oil Pump, Pressure-limiting Valve 3-13 3-41 3-53
Left Crankcase 3-52
es: Arrowhead direction is for engine removal orders. Reverse the direction for assembly and
installation
6-1
" Eng i ne Remova l
! Preparat ion before engine removal
" Prepare a proper tray used for l oad of components
" Prepare necessary remova l and assemb l y too l s
" Dra i n up eng i ne o i l $3 - 22&
" Dra i n up coo l ant$3 - 15&
! Engine Periphery
Water Hose/Pipe
" Remove water hose clamp '()*Remove
water hose +
" Remove screw , and water hose -
Left Side Cover
"Remove 6 bolts(M6X20) of left side cover#

$M6 % 20&,Remove left side cover #
Recoil Starter
" Remove 4 bolts$M6 % 12&of recoil starter

Remove recoil starter.
Inspection Plug
"Remove inspection plug/wi th screwdr iver
!Engine Front Side

Spark Plug
" Remove spark plug 0 with special wrench
Tool: Spark Plug Wrench
" Turn crankshaft, align T.D.C. line A on magneto

rotor with mark B of left crankcase
(p i ston on T . D . C&
6-2
Cylinder Head Cover

"Remove valve adjusting cover
"Remove12 bolts of cylinder head cover
"Remove cylinder head cover
Timing Chain Tensioner
"Remove screw plug', insert a flat screwdriver into

slot of timing chain tensioner adjuster , turn it
clockwise to lock tensioner spring; 6
" Remove tensioner fix bolt

" Remove tensioner and gasket
Camshaft
" Loosen timing sprocket bolt;
"Remove timing sprocket bolt and lock;
6-3
"Remove C-ring'
"Remove timing sprocket from camshaft, remove
camshaft
Note: Take care not to drop spacer, bolt, bolt lock
and C-ring into crankcase.
"Remove tensioner plate
Cylinder Head
"Remove cylinder head bolt
"Remove cylinder head bolts diagonally;

"Remove cylinder head
Note : Take care not to drop dowe l

p i n i nto crankcase
Cylinder
"Remove dowel pin and cylinder head gasket

" Remove timing chain guide'
6-4
"Remove cylinder bolt

"Remove cylinder
Note#Take care not to drop dowel pin into
crankcase
"Remove dowel pin and cylinder gasket
Note#When performing above removal process,

be sure to hook up timing chain to
prevent it from falling into crankcase
Piston
" Remove piston pin circlip ' with long nosed pli-
ers
Note#Put a clean rag under piston so as not to

drop piston pin circlip into crankcase
6
" Remove piston pin ) and piston +
Note#
" When installing piston, make sure its
identification conforms to that of cylinder
"When removing piston pin, clean off burrs of

piston pin hole and groove. If it is difficult to
remove the piston, DO NOT hammer, use a
special remover ,
Tool: Piston Pin Remover
!Engine Left Side

Starting Motor
"Remove 2 bolts of starting motor

"Remove starting motor
6-5
Oil Filter
"Remove oil filter with special tools
Tool: Oil filter Remover
Sector Gear
"Remove bolt 1 of gearshift rocker arm
"Remove gasket 2 and gearshift rocker arm 3
"Remove bolt of sector gear housin cover

"Remove wire clip and sector gear housing cover
"Remove dowel pin and gasket

"Remove drive sector gear 4
"Remove bolt 5 of driven sector gear
"Remove washer 6 and driven sector 7
6-6
Water Pump
"Screw out bolt of water pump

"Remove water pump
Sheave Drum
"Remove the sheave drum by using a suitable bar;

"Remove washer and sheave drum
Left Crankcase Cover
" Remove bolts;

" Remove left crankcase cover
" Remove dowel pin and gasket 6
Magneto Rotor
"Install attachment 1 to crankshaft end
" Install special tool to rotor thread;

Remove rotor and woodruff key
Tool: Rotor Remover
6-7
Starting Motor Gear
"Remove driven gear 1 and needle bearing
"Remove spacer 2
"Remove dual gear and shaft 3

"Remove idle gear and shaft 4
Oil Pump Sprocket and Chain
"Remove drive sprocket nut 5

"Remove C-ring 6
"Remove oil pump drive and driven sprockets and
chain
6-8
! Engine Right Side

CVT Cover
"Remove bolt of CVT cover
"Remove CVT cover
"Remove gasket and dowel pin
CVT(Continuously Variable Transmission)
"Remove primary sheave nut with special tool

"Remove primary sliding sheave
"Remove secondary sheave nut with special tools

"Remove secondary sheave 6
"Remove drive belt
Tool: Sheave Holder
"Remove primary fixed sheave'
"Remove bolt for air guide plate,Remove air guide

plate
6-9
CVT Case
"Remove bolt 1 of CVT case
"Remove nut 2 of CVT case
"Remove outer clutch face and CVT case
"Remove dowel pin, front and rear gasket
Clutch
"Remove clutch shoe fixing nut with special tool

"Remove clutch shoe
Note#The clutch shoe nut has left-hand threads
Timing Chain
"Remove timing chain
6-10
! Engine Center
Gear position bolt
" Remove gear position bolt '

"Remove spring and steel ball
Right Crankcase
"Remove left crankcase bolts
"Remove right crankcase bolts

6
"Separate right crankcase with special tool
Caution
"The Crankcase separator plate
should be parallel with the end face
of crankcase
"Crankshaft should remain in the left
crankcase half.
Tool: Crankcase separator
Driven Bevel Gear, Front Output Shaft

" Remove bevel gear cover bolt
" Remove driven bevel gear +
" Remove front output shaft nut ,
6-11
" Remove Oil seal '(Bearing limit nut )
$l e f t ro l l &
"Remove Front Output Shaft,
Shift Cam, Fork/Shaft
" Remove Shift Cam -(Fork /Shaft #1
Drive Bevel Gear

"Remove left crankcase from driven bevel gear
Drive Shaft, Drive Shaft
"Remove drive shaft.and driven shaft/
Balancer Shaft
" Remove balancer shaft1
6-12
Crankshaft
"Separate crankshaft from left crankcase with spe-

cial tool
Tool: Crankshaft Separator
Oil bump, Relief Valve

" Remove oil bump and relief valve1
6-13
$ Engine Components Inspection
Cylinder Head Cover
! Disassembly
Caution#Each removed part should be identi-
fied to its location, and the pars should be laid out
in groups designated as ¡°Exhaust¡±, ¡°Intake¡±, so
that each will be restored to the original location
during assembly.
"Remove rocker arm shaft bolts A
"Remove rocker arm shaft by using M6 bolts B
Cylinder Head Cover Distortion
Clean off sealant from the fitting surface of cylin-

der head cover, place cylinder head cover on a sur-
face plate and measure distortion with a thickness
gauge.
Cylinder head Cover Distortion

Limit: 0.05mm
Tool: Thickness Gauge
Distortion out of range: --Replace
Note#Cylinder head cover and cylinder head

should be replaced together.
Rocker Arm Shaft
"Measure out diameter of rocker arm shaft with a

micrometer.
Rocker Arm Shaft O.D.: (IN, EX)

Limit: 11.973~11.984mm
Tool: Micrometer (0~25mm)
6-14
Rocker Arm
"When checking the rocker arm, check the inner
diameter of the valve rocker arm and wear of the
camshaft contact surface.
" Rocker Arm I.D. : .000~12.018mm
Tool: Dial Calipers
! Assembly
Note#Intake rocker arm shaft A has oil holes.
"Apply engine oil to rocker arms and shafts;

"Install rocker arms and tighten rocker arm shaft to
the specified torque: 6
Rocker Arm Shaft Bolt: 28N.m
Cylinder Had
! Disassembly
"Remove intake pipe
"Remove water temperature sensor'and

thermostat cover)
6-15
"Remove thermostat
"Compress the valve spring and remove valve cotter

with tweezers.
Tools: Valve Spring Compressor

Tweezers
"Remove valve spring upper seat and valve spring

"Remove valve from the other side.
"Remove valve stem seal ring and valve lower seat.
6-16
Cylinder Head Distortion

"Clean off carbon deposit from combustion chamber;
"Check the gasket surface of the cylinder head for
distortion with a straightedge and thickness gauge.
Take clearance readings from several places. If any
clearance reading is out of the service limit, replace
with a new cylinder head.
Cylinder Head Distortion Service Limit: 0.05mm
Valve Seat Width
"Coat the valve seat with color uniformly. Fit the

valve and tap the coated seat with the valve face in
a rotating manner. To get a clear impression of the
seating contact, use a valve lapper to hold the valve
head.
"The ring-like dye impression on the valve face

should be continuous, without any break. The width
of the dye ring, which is the visualized seat width, 6
should be within the following range:
Valve Seat Width: 0.9-1.1mm
Tool: Valve Lapper
Valve Stem and Valve Guid
"Lift the valve about 10mm from valve seat. Check

the valve stem deflection in the directions of X and Y
perpendicular to each other, with a dial gauge. If the
deflection measured is out of the limit, replace either
the valve or the valve guide. (If the valve stem is worn
to the limit and the clearance is found to be in
excess of the limit, replace the valve. If the valve
stem is within the limit, replace the valve guide.
Double check the clearance after replacing the
valve stem or the guide).
Valve Stem Deflection (IN & EX): 0.35mm

Tool: Micrometer
Magnetic Stand
6-17
Valve Stem O.D
"Measure valve stem O.D with a micrometer
Service Limit:
IN: 4.975-4.990mm
EX: 4.955-4.970mm
Tool: Micrometer (0-25mm)
Valve Stem Run-out

" Support valve stem with V block as illustrated on
the right. Check the run-out with a dial gauge.
Service Limit: 0.05mm
Tool: Magnetism Stand

Dial Gauge (1/100)
V block
Valve Head Radial Run-out

" Measure the val ve head radi a l run -
out as i l lustrated on the r ight .
Valve head Radial Run-out out of range:--Replace
Tool: Dial Gauge (1/100)
Magnetism Stand
V Block
Valve Face Wear

" Check each valve face for wear or damage.
Replace valve with a new one if it is found to have
abnormal wear. Measure valve head thickness T.
Valve head thickness T out of range: ---Replace

Tool : Vernier Cal iper
Valve Stem End
"Check valve stem end for pitting or wear. In case of

any pitting or wear, resurface the valve stem end. If
the length T is less than service limit, replace valve
with a new one.
Valve Stem End Length
Tool: Vernier Caliper
6-18
Valve Spring
Valve Spring keeps valve and valve seat tight.
Weakened spring results in reduced engine power
output and chattering noise from valve mechanism.
"Measure the spring free length.

Spring free length out of range: --Replace
Tool: Vernier Caliper.
" Measure the force to compress the spring to the

specified length.
Valve spring tension out of range: ---Replace
Service Limit: (IN/EX)
182N-210N/31.5mm
Tool: Spring Scale.
"Measure valve spring incline.

Spring incline out of range:--Replace
Valve Spring Incline Limit: 2.5o/1.7mm
! Assembly of Cylinder Head

"Install each valve spring seat;
"Apply moly oil to valve stem seal and fit into
position.
Mater ial : Moly oi l

Note: Do not reuse the valve stem seal.
" Insert the valves, with stems coated with moly oil
all around.
Note: When inserting the valve, be careful not to

damage the lip of the stem seal.
6-19
"Install valve spring with small-pitch end (b) facing
cylinder head. Big-pitch end (a) is marked.
"Put on the valve spring retainer. Use the valve

spring compressor to press down the spring. Fit the
two cotter halves to the stem end and release
compressor to allow the cotter ' to wedge in
between seat and stem. Make sure that the rounded
lip ) of the cotter fits into the groove + in the stem
end.
Tool: Valve Spring Compressor
Tweezers
NOTE: Knock the valve end with rubber

hammer. Make sure valve cotter is fit into groove.
"Check the sealing effectiveness of cylinder head.

Dip clean solution into valve IN/EX' and check
for any leakage of valve seat)after a few minutes.
6-20
" Install thermostat
"Install thermostat cover

"Install water temperature sensor, apply thread
locker to the thread part, tighten it to the
specified torque.
Water temperature sensor

Tightening torque: 10 N.m
6
"Install intake pipe, apply lubricant to 0-ring.
Camshaft
Check camshaft for wear and run-out of cams and
journals if the engines produces abnormal noise or
vibration or lacks power output. Any of these symp-
toms could be caused by wear of camshaft.
Note: Do not try to disassemble the camshaft/auto-

matic decompression assembly. It is not serviceable
6-21
"Automatic Decompression
Move the automatic decompression weight with
hand and check if it is operating smoothly. If it is
not working smoothly, replace with a new camshaft/
automatic decompression assembly.
" Cam Wear

Worn cams can often cause mistimed valve
operation resulting in reduced power output. The
limit ofcam wear is specified for both IN and EX
cams in terms of cam height2a3Measure with
a micrometer the cam height.
Cam height service limit:
IN: 33.130mm
EX: 33.200mm
Tool : micrometer (25-50mm)
" Camshaft Journal Wear

Check whether each journal is worn to the limit
by measuring camshaft journal oil clearance with the
camshaft installed.
Camshaft journal oil clearance#0 . 15mm
Check according to the following steps:

4Clean off materials from cylinder head and cover;
4 Install camshaft with plastic gauge;
4Install cylinder head cover and tighten bolts evenly
and diagonally to the specified torque:
Tightening torque #10 N5m

4Remove cylinder head cover, read the width of the
compressed plastic gauge with envelop scale. The
reading should be taken from the widest part.
Tool: Plastid Gauge
Note: Do not turn the camshaft with plastic gauge
in place.
If the camshaft journal oil clearance exceeds the

limit,measure the outer diameter of camshaft;
Replace either cylinder head set or the camshaft if
theclearance is not correct.
6-22
" Camshaft Journal O.D.

Measure camshaft journal O.D. with a micrometer.
If the O.D. is out of range, replace camshaft with a
new one.
Camshaft journal O.D. service l imi t :

Sprocket end: 22.959 mm 6 21.980mm
Other end: 17.466mm 6 17.484mm
Tool : micrometer (0-25mm)
"Camshaft Run-out
Measure the run-out with a micrometer. Replace
camshaft is the run-out is out of range.
Service limit: 0.10mm
Timing Sprocket and Chain
"Check timing sprocket and chain for wear or

damage.
Replace with new parts if abnormal wear or damageis
found. 6
" Tensioner and Chain Guide

Check contact surface of tensioner and chain
guide for wear and damage.
Replace with news parts if abnormal wear or
damage is found.
6-23
CFMOTO
Chain Tensioner
Inspect ion
#Check tensioner for any damage or poor function.
Damage, poor function:—Replace
inspect way of working stability

! Insert screw driver " into the slotted end of ad-
justing
screw, turn it clockwise to loosen the tension and
release the screwdriver.
!Check the push rod movement. If the push rod is
stuck or there is a failure with spring mechanism,
replace the chain tensioner with a new one.
Clyinder
Cylinder Distortion
#Check the gasket face of cylinder for distortion with
a straightedge and thickness gauge and take
clearance readings at 7 points as illustrated. If the
largest reading at any of the 7 points of the
straightedge is out of the range, replace the
cylinder.
Cylinder Distortion Service Limit: 0.05mm
Tool: Straight edge

Thickness Gauge
Cylinder Bore
#Check cylinder wall for scratches, nicks or other

damage. Replace with a new one if any
#Measure cylinder bore diameter at three points

of upper, middle and lower.
Standard Cylinder Bore:
87 . 500 - 87 . 522mm
Tool: Cylinder Gauge Set
6-24
6Engine Removal , Inspect ion and Instal lat ion
Piston
Piston Diameter
Use a micrometer to measure the diameter at the
point 10mm above the piston end, as illustrated on
the right. If the measurement is less that the limit,
replace the piston
Standard : 87 . 460 - 87 . 480mm

Limit : 87 . 380mm
Tool:Micrometer (75-100mm)
Calculate the piston to cylinder clearance according
to the abovemeasurement.If the clearance is more than
0.15mm, replace the cylinder or piston, or both.
Piston Ring to Groove Clearance

Use a thickness gauge to measure the side
clearance of topt ring and 2nd ring.
If the clearance exceeds the limit, replace both
piston and piston rings.
6
Service Limit:
Top ring!0 . 18mm
2nd ring : 0 . 15mm
Standard width of piston ring groove
Top ring!1 . 03 - 1 . 05mm
2nd ring:1 . 22 - 1 . 24mm

Oil ring : 2 . 51 - 2 . 53mm
Standard thickness of piston ring

Top ring!0 . 970 - 0 . 990mm
2nd ring : 1 . 170 - 1 . 190mm
Tools: Thickness gauge

Micrometer (0-25mm)
6-25
CFMOTO
Piston Ring Free End Gap and End Gap

Before installing piston rings, use vernier caliper to
measure the free end gap of each ring, and then fit
ring into the cylinder.
Use thickness gauge to measure each ring end gap,
if any ring has an excess end gap, replace the
piston ring
Piston ring free end gap limit:
Top ring!8 . 9mm

2nd ring!9 . 5mm
Piston ring end gap limit:
Top Ring!0 . 60mm

2nd ring !0 . 60mm
Tool: Vernier caliper
Thickness gauge
Piston Pin and Pin Bore
#Use a bore gauge to measure the inner diameter

of piston pin bore.Use micrometer to measure outer
diameter of piston pin.If out of limit, replace both
piston and piston pin.
Piston pin bore limit: 23.030mm
#Use micrometer to measure piston pin outer

diameter at three points
Piston pin outer diameter limit: 22.980mm
Tools: Bore gauge (18-35mm)
Micrometer (0-25mm)
6-26
ConnectingRod/Crankshaft
Connecting rod small end I.D.
# Use a dial gauge to measure the I.D. of connect-

ing rod small end. If the measurement exceeds the
limit,replace the connecting rod.
Connecting rod small end I.D. : 23.040mm
Tool: Dial Gauge (18-35mm)
Connecting Rod Deflection
#Check the movement of the small end of the rod

and inspect the wear of the small end. Thismethod
is also applicable to check and inspection of big end
Connecting Rod Deflection: 3.0mm
Tools: Dial Gauge

Magnetic stand
V-block
6
Connecting Rod Big End Side Clearance
# Push the big end to one side, and use thickness

gauge to measure the other side clearance.
If out of limit, replace with a new crankshaft.
Connecting Rod big end side clearance: 1.0mm
Crankshaft Run-out
#Support crankshaft with blocks as illustrated.

Put the dial gauge, slowly turn the crankshaft and
measure run-out with a dial gauge.
If the run-out exceeds the limit, correct or replace
the crankshaft.
Run out limit: 0.08mm
Tools: dial gauge

Magnetic stand
V-block
6-27
CFMOTO
Clutch inspection
#Check clutch for chipping, scrape, uneven wear or
heat discoloration. At the same time check depth of
the grooves of clutch shoes. If any of the clutch
shoes has no groove, replace the clutch.
Note: clutch should be replaced as aset.
Clutch Wheel
#Check the inner clutch wheel " for scratches,
scuffs or bluediscoloration or unevenwear. If
anydamageis found, replace the clutch wheel with
a newone.
# for scratches, scuffs or blue discoloration or un-

even wear. If any damage is found, replace the clutch
wheel with a new one.
!Use special tool to remove oil seal
Tool: Oil seal remover
! Use special tool to assemble oil seal

Tool: Oil seal installer set
!Check the turning of bearing.

Abnormal damage: —Replace
Assembly
Apply lubricant grease to oil seal when

assembling.
6-28
Primary and Secondary Sheave
6-29
CFMOTO
Primary Sliding Sheave

Disassembl
# Remove spacer
# Remove Cam " rol ler $
Roller inspection
#Check each roller and sliding face for wear and

damage.
Wear and damage:—Replace
Note: rollers should be replaced as a set.
Oil Seal inspection
#Check oil seal lip for wear and damage.

Wearanddamage: —Replace
# Remove the oil seal
6-30
Primary Sliding Sheave and Fixed Sheave
#Check the drive face for any abnormal conditions

such as damage or stepped wearing.Replace if
necessary.
# Install oil seal with special tool.
Tool: Bearing install set
Assembly
Reverse the removal procedure of primary sliding
and fixed sheave for installation.
Pay attention to the following:
#Apply grease to inner bore and oil seal lip.

6
Note: Wipe off any excessive grease
thoroughly;
Take care not to attach any lubricant
grease to contact surface of drive belt.
Material: Lubricant grease
#Position 8 rollers"on the primary sliding sheave

%
# Install 4 dampers $ to cam &%
#Install cam to primary sliding sheave.

%
Note: When inserting the spacer, press down the cam
so that the rollers will not come out of position.
6-31
CFMOTO
# Install spacer
Secondary Sheave
Disassembly
#Use special tool and holder to hold the secondary

sheave. Remove secondary sheave nut with special
tool%
Caution:Do not remove the ring nut before

attaching theclutch spring compressor.
Tool: Nut Wrench

Sheave Holder
#Attach special tool to the secondary sliding sheave

and compress it by turning in the tool handle.
Note:
Make sure that spring end A is inserted into
slot B of the tool handle
#Remove ring nut.

% Tool: Secondary sliding sheave spring
compressor
Note:
Since a high spring force applies to the
secondary sliding sheave, take special
care that the secondary sliding sheave will
not come off abruptly
#Slowly loosen tool handle and remove the

special tool.
6-32
# Remove spring "%

# Remove spring seat $%
# Remove guide pin and spacer%
# Remove secondary sliding sheave &%
O-ring and Oil Seal

Check the O-ring and oil seal for wear and
damage.
WearandDamage: —Replace
# Remove Oil Seal%
6-33
CFMOTO
# Install oil seal with special tool.

Tool: Bearing install set
#Use vernier caliper to check the spring free length.

If the length is shorter than the service limit, replace
with a new one.
Secondary Sliding and Fixed Sheave:

#Check drive face for any abnormal condition such
as stepped wear or damage. Replace if necessary.
Assembly
#Install a new O-ring
#Apply lubricant grease to O-ring, oil seal lip and

guide pin groove.
Material: lubricant grease
6-34
# Install guide pin and spacer "
Note: To avoid damage to the oil seal lip during

assembly, slide the lip with a 0.1mm steel
sheet as guide.
# Install spring seat. Align hole A with hole B.
#Install spring and spring plate. Insert spring end

into the hole.
6
# Compress spring with special tool.

#Align the secondary sheave end with spring
plate hole
Tool: Secondary sheave spring compressor
# Tighten ring nut temporarily%

#Remove the special tool from secondary sheave%
6-35
CFMOTO
# Tighten the ring nut with special tool to

the specified torque.%
Ring Nut Tightening Torque:

1 00 N"
"m
Tool: Ring nut wrench

Sheave holder
Drive belt
#Check bel t for any greasy substance.
# Check contact surface of bel t for

any cracks and damage;
# check bel t width wi th veni re cal iper
In casse of damage, width out of range,

replace with new one.
Bel t width service l imi t :33 .5mm

Tool : verni re cal iper
Warning: I f bel t surface is stained

wi th grease or oi l ,degrease the bel t
thoroughly.
6-36
Transm i ss i on
D i sassemb l y
I tem Descr i pt i on Qty I tem Descr i pt i on Qty

1 MAINSHAFT. GEARSHIFT 1 10 DRIVENGEAR, HIGH RANG 1
DRIVENGEAR,
2 SHIFT CAM 1 11 1
LOWRANGE
3 RIGHTCRANKCASE 1 12 SPRING, SHIFT FORK 1
4 LEFT CRANKCASE 1 13 RIGHT SHIFT FORK 1
5 DRIVENSECTORGEAR 1 14 GUIDE BAR 1
SPROCKET,
6 1 15 DRIVEN SHAFT 1
REVERSEGEAR
7 CHAIN, REVERSEGEAR 1 16 SPRING, SHIFT FORK 1
8 DRIVENOUTPUTGEAR 1 17 LEFT SHIFT FORK 1
9 DRIVE SECTORGEAR 1 18 SHIFT FORK ASSEMBLY 1
6-37
CFMOTO
Inspect ion
#Inspect dr ive bevel gear and sprocket
for stains, scratch or damage, re-
place i f necessary.
#Inspect reverse gear chain for damage,

wear , replace i f necessary.
# Disassemble counter shaft as

i l lustrat ion.
#Inspect bear ing surfaces for stains,

damage or wear and also for bear ing
gaskets. Replace i f necessary.
6-38
# Check the shi ft fork clearance wi th

a thickness gauge in the groove of
i ts gear .Replace i f clearance
exceeds the l i m i t .%
Shi ftfork to Groove clearance

Standard'0 . 10 - 0 . 30mm
Servi ce L imi t : 0 . 50mm
# Measure shi ft fork groove width wi th

vern i er ca l i per %
Standard shift fork groove width:

'6 . 05 - 6 . 15mm
# Measure shi ft fork thickness wi th

vern i er ca l i pers%
Standard fork thickness'5 . 80 -5 . 90mm 6
#Check shi ft fork " and $ for damage

or bend, replace i f necessary.
# Instal l shi ft fork to guide bar and

move l e f t and r i ght . In case of any
unsmooth moving, replace with a new one.
6-39
CFMOTO
#Put the guide bar on a f lat place and

rol l i t . In case of any bend,
repl ace wi th a new one%
Note!
!DO NOT attempt to correct
a bent guide bar .
# Check shi ft fork spr ing for damage,

repal ce i f necessary%
#Check shi ft cam groove for scratches,

damage.Replace i f necessary;
Assembly
assembly. Pay attent ion to the
fol lowing'
No te!
# Use new retainers. Pay attent ion
to the di rect ion of the retainers.
Fi t to the side where the thrust
i s as i l l ustrated%
# Coat the gears and shafts wi th
engine oi l before assembly .
Wa r n i ng!
!
# Do not reuse the reta iners%
# Do not expand of the gap end of new

retainers too wide when assembl ing.
%Make sure that al l the retainers are
#
proper ly f i tted.
6-40
# When assembl ing the guide bar ,

take care not to assemble the
two shi ft forks and spr ings in
the opposi te di rect ion.
1 Guide bar ; 2 Retainer 12;
3 Left shi ft fork;
4 Shi ft fork spr ing(smal l ) ;
5 Right shi ft fork;
6 Shi ft fork spr ing(big) ;
7 Spr ing seat
Oi l pump
# Disasseble oi l pump as i l lustrated%
1 Oi l pump housing; 2 Dowel pin;
3 Oi l pump shaft ; 4 Straight pin;
5 Inner rotor , oi l pump; 6
6 Outer rotor , oi l pump;
7 Oi l pumper cover
#Check oi l pump housing and cover for
cracks and damage. Replace i f
necessary.
# Measure the top clearance a between

inner and outer rotors and side
clearance b between outer rotor and
oi l pump housing. I f the clearance
exceeds the l imi t , replace wi th new
one.
Top clearance!
!0 . 03 - 0 . 10mm
Serv i ce l i m i t!
!0 . 15mm
Side clearance'0 . 03 - 0 . 10mm
Serv i ce l i m i t'0 . 12mm
6-41
CFMOTO
Oi l strainer inspect ion

# Check o i l stra i ner " and O - r i ng $
for damage, replace i f necessary;
#Clean the surface of oil strainer
with engine oil.
Rel ief valve

# Check the va l ve body "(va l ve $(
sp r i ng &(0 - r i ng ) f o r damage o r
wear ing. Replace i f necessary;
Dr ive bevel gear

#Use a clean rag to protect the dr ive
bevel gear shaft , clamp i t to the
pl iers%
# Loosen dr ive bevel gear nut 3,
remove the dr ive bevel gear 4 and
ad j ust washer 5%
# Check the dr ive bevel gear 4 and
1-Dr ive bevel gear cover 5-Washer
output dr iven gear 2 for rust ,
2-Output dr iven gear
scratch, wear or damage. Replace i f
6- -Dr ive bevel gear shaft
necessary.%
3-Dr ive bevel gear nut
# Check i f the bear ing 8 turns
7- Bear ing nut
smoothly, replace wi th a new bear -
4-Dr ive bevel gear 8-Bear ing
ing i f necessary.
# Adjust Washer 5 i f any of r ight

crankcase, dr ive bevel gear 4, or
dr ive bevel gear cover 1 is replaced.
Refer to bevel gear adjustment for
detai ls%
#Apply engine oil to bearing 8 when

assembling and tighten nut 3 to the
specified torque.%
8
Drive bevel gear nut tightening torque
145N.m
6-42
Front Output Shaft

# Check bear i ng 7 for smooth turn i ng
and abnorma l wear . Check o i l sea l 5
for damage . Rep l ace i f necessary ;
# App l y l ubr i cat i on o i l to bear i ng 7
and o i l sea l 5 l i p before assemb l y ;
# App l y thread l ocker to bear i ng l i m i t
nut 6 ( l ef t thread) and t i ghten to
the spec i f i ed torque . (80N . m)
T i ghten Nut 1 to the spec i f i ed
torque , f ront output shaf t nut
t i ghten i ng torque : 97N . m
Dr i ven Beve l Gear
# Remove nut 19 , washer 18 , coup l er 17
and o i l sea l 16 .
# Protect end thread of dr i ven beve l
gear w i th proper dev i ce $ F i x beve l
gear cover 14 and press out dr i ven
beve l gear .
# P l ace a c l ean rag " under beve l
gear cover . Remove bear i ng l i m i t nut 6
10 w i th spec i a l too l $ and remove
bear i ng%
# Check dr i ven beve l gear 8 sur face
for scratches , wear . Scratch or wear ,
rep l ace%
# Check f ree turn i ng of bear i ng 9 and
11 . Rep l ace i f necessary %
# Use new o i l sea l 16 and O - r i ng 12
when assemb l i ng ;
# Ad j us t washe r 13 i f any o f r i gh t
crankcase , dr i ven beve l gear 8 or dr i ven
beve l gear cover 14 i s rep l aced . Refer
to beve l gear ad - j ustment for deta i l s%
# App l y l ubr i cat i on o i l to bear i ng 9
and 11 and o i l sea l 16 , O - r i ng . App l y
thread l ocker to nut 10 and t i ghten
to the spec i f i ed torque . ( 110N"
"m )
Too l : dr i ven beve l gear nut wrench
Dr i ven beve l gear nut t i ghten i ng
torque : 150N . m .
Beve l Gear Washer Ad j ustment
# Adjust washer " and $ when replacing
crankcase and / or bevel gear and / or
bevel gear cover .
6-43
CFMOTO
Bevel gear
!Proper bevel gear engagement
Note!
depends on that the gear backlash &
tooth contact are within the proper range.
$ Bevel gear backlash

# I nstal l dr ive and dr iven gears to the
crankcase. Wrap a ( - ) screwdr iver&with
a rag $ and i nsert i t i nto the speed
sensor hole" of left crankcase to f ix
the dr ive bevel gear%
# Instal l special tool & and
micr imeter )
Tool: level gear side clearance
dial gauge micrometer
a=46mm
# Turn the dr iven bevel gear in each
di rect ion and measure the backlash.
Note'Measure four poi nts i n the

mutual vert ical di rect ion;
# I f the backlash is not wi thin the

speci f icat ion,adjust the thickness of
the dr iven bevel gear adjust washer .
Re-check the backlash unt i l the back-
lash is correct .
Bevel gear backlash:0 . 1 - 0 . 2mm
Ad j ustment!
!
Backlash Washer thickness
adjustment
* 0.1mm Washer thickness
adjustment
0.1,0.2mm OK
+ 0.2mm Increase thickness
6-44
$ Tooth contact inspect ion

After adjust ing the backlash, check
the tooth contact according to the
fo l l ow i ng procedures'
# Remove dr i ve and dr i ven beve l gear
shafts from crankcase;
# Clean and degrease every tooth of
dr ive and dr iven bevel gear%
# Co a t t h e d rive n b e ve l ge a r wit h
machenist’s layout dye or paster%
# Install drive and driven bevel gear%
#Rotate the dr iven bevel gear several
turns in both di rect ions;
#Remove drive and driven bevel gear
shafts and check the coated teeth of
the drive bevel gear;
Contact " tooth top Incorrect
Contact $ Middle Correct
Contact & Bottom Incorrect
# I f tooth contact is correct-Contact 6

$./cont i nue next procedure%
# I f t oo t h con t ac t i s i n co r r ec t
-Contact " &Contact &./ad j ust the
thickness of washerof dr ive gear . Re-
peat above steps to check tooth contact
unt i l correct .
Adjustment
Tooth contact Thickness adjustment

Contact " Decrease thickness
Contact & Increase thickness
No te!
#After adjust ing the tooth contact ,
the backlash must be checked again;
# I f the backlash is adjusted
but tooth contact is st i l l out
of speci f icat ion, replace the
dr ive and dr iven bevel gears;
#Both tooth contact and backlashshould
be wi thin the requi red speci f icat ion.
6-45
CFMOTO
Ba l ance sha f t
# Remove the parts as i l lustrated on

the r ight .
Check each part for abnormal wear
or damage.
Replace i f necessary.
" Balance shaft gear

$ woodruf key & Balance shaft ;
) Balance shaft sprocket
0 Washer 1 Bol t
Magneto Rotor
# Remove starter clutch nut .
6-46
6 Eng i ne Remova l , I nspect i on & Insta l l at i on
!Check starter clutch rol ler and holder

for abnormal wear or damage, replace i f
necessary.
! Rep l ace the starter c l utch i n the
r ight di rect ion.
No te!
When instal l the starter clutch to
the magneto rotor , make sure side
A is in the r ight di rect ion.
"Face arrow mark B to the engine side
" Apply engine oi l to starter clutch

" Apply thread locker to bol t and
t ighten to the speci f ied torque.
Tightening torque of starter clutch
bol t : 26N.m.
Mater ial : Thread locker
! Instal l the starter dr iven gear
! Make that the starter dr i ven gear
turns in the opposi te di rect ion of the 6
arrow mark B . The gear cannot turn i n
the di rect ion of the arrow.
! Check starter dr i ven gear bear ing .

In case of anyth i ng unusua l , rep l ace
the bear ing.
! Remove starter dr i ven gear bear i ng

wi th special tool .
! Instal l starter dr iven gear bear ing

wi th special tool .
Tool#Bear ing instal ler / Remover
6-47
CFMOTO
E l ect r i c Star ter Gear
! Check the gear surface for scrap or

damage, replace i f necessary$
Le f t crank case cover :

! Check magneto stator coi l 2, pickup
coi l 3 for damage, replace ci rcui t i f
necessary.$
! Check bear ing 4 for smooth turning.
I f i t is stuck, replace wi th a new one;
!Check oi l seal 5 for damage. Replace
i f i t is damaged.
!Apply thread locker to the bol t when
assembl ing$
Tightening torque for magneto
co i l bo l t#10N%m
! App l y l ubr icat i ng o i l to bear i ng 4
and lubr icant grease to l ip of oi l seal
5 when assembl ing.
Reco i l star ter d i sassemb l y :

1-Recoi l starter
2-Bol t
3-Washer
4-Starter pul ly
I nspect i on
Check sheave drum for burrs, cracks or
rust . In case of any abnormal , replace.
6-48
Reco i l Star ter

!Disassembly is unnecessary i f recoi l
starter wokrs wel l
& Cap, handle

' Handle
( Fr ict ion plate
) Spr ing clamp
* Pawl
+ Spr ing
, Sheave drum 6
- Rope
. Coi l spr ing
/ Nut
D i sassemb l y
!Remove nut 10 and the parts from the
starter housing.
Warning""!The coi l spr ing may quickly

unwind and cause injury when the sheave
drum i s opened . Wear proper hand and
eye protect ion beforehand.
I nspect i on
! Check al l parts for damage. Repalce
i f necessary.
6-49
CFMOTO
Assemb l y
Reverse the removal procedure for in-
sta l l at i on and pay attent i on to the
fol lowing:
Insta l l sheave drum &0rope '0co i l
spr ing (0Damper )1
Wind the rope clockwise around the
sheave drum three t i mes and hook
the rope at 2a3of sheave drum .
Warning" "!The coi l spr ing may quickly
unwind and cause injury when the sheave
drum i s opened . Wear proper hand and
eye protect ion beforehand.
Instal l coi l spr ing & and sheave

drum ';
Apply lubr icant grease to spr ing;

Hook coi l spr ing end 3 to the starter
housing, wind the coi l spr ing clockwise
Hook the other end * of coi l spr ing to
hook part ) of sheave drum.
Instal l spr ing clamp &0fr ict ion plate

' and bol t
Put the end of spring clamp in the groove
near the damper .
Turn sheave drum clockwise three t imes

to t ighten the coi l spr ing.
Instal l handle & and handle cap '

Lead the rope through the hole of the
starter hous i ng and t i e a knot ( so
that the rope would not be drawn back.
After making a t ie )0draw back previ -
ous one (1
6-50
CV T C OV ER
! Remove screw 5 , o i l sea l l i m i tator 4 .
Remove o i l sea l 3 w i th sepec i al too l ;
! Check bear i ng 2 for f ree turn i ng . In case
of any abnormal , remove wi th special tool and
rep l ace w i th a new bear i ng ;
! App l y l ubr i cat i on o i l to outer r i ng o f
bear ing and instal l bear ing wi th special tool .
Check bear i ng for smooth turn i ng .
! App l y grease to bear i ng i nner s i de
!Apply grease oi l seal l ip and instal l bearing
w i th speci a l too l . Check bear i ng for smooth
t u r n i ng#
Note!
!Use a new o i l sea l
!Instal l oi l seal l imi tator and t ighten screw

af ter app l y i ng thread l ocker .
Too l "Bear i ng remover

O i l seal remover
Bear i ng i nstal ler
6
CVT case
! Check bear i ng 5 f or smooth turn i ng . I n

case o f any abnorma l , remove screw 3 and
bear i ng reta i ner 4 and rep l ace w i th a new
bear i ng .
! Check o i l seal 7 . In case of any damage,
rep l ace i t .
! App l y grease to o i l sea l l i p and i nsta l l
w i th spec i a l too l #
! App l y l ubr i cat i on o i l to bear i ng 5 and

i nstal l w i th speci al too l ; Check bear i ng for
smooth turn i ng . The sea l s i de of bear i ng 5
shou l d face bear i ng retai ner 4 .
! Instal l bear i ng reta i ner 4 and
screw 3#
! Insta l l o i l sea l 1 i nto c l utch hous i ng 2
w i th spec i a l too l #
Too l : O i l seal i nstal l er

Bear i ng i nstal l er
6-51
CFMOTO
Crankcase
1 - R i ght crankcase 2 - Bear i ng 3 - Bear i ng
4 - Bear i ng 5 - Bear i ng 6 - Bear i ng 7 - O i l sea l
l 8 - Washer , reverse gear sensor
9 - reverse gear sensor 10 -O - r i ng 11 -Gear sen -
sor 12- Left crankcase 13 -Screw 14 -Oi l p ipe
15 - L i nk bo l t
16 - Washer 17 - Bear i ng 18 - Bear i ng

19 - Bear i ng 20 - Bear i ng
21 - Bear i ng 22 - O i l d i p rod 23 - O - r i ng
24 - Speed sensor 25 - Bo l t
26 - Washer 27 - O i l drai nage bo l t
! C l ean and grease the bear i ngs , turn the

i nner race o f bear i ng and check the p l ay ,
no i se and smooth turn i ng . I n case o f any
abnorma l , remove bear i ng w i th spec i a l too l
and rep l ace ;
! Check al l the o i l sea l s for over wear or
damage. In case of any over wear or damage ,
remove w i th spec i a l too l and rep l ace w i th a
new o i l seal ;
! Remove gear sensor 11 and check for cont i -
nui ty w i th reverse gear sensor 9 wi th a mul -
t i meter
! Remove l i nk bol t and oi l pi pe 14 and check
o i l p i pe for crack or c l og . Rep l ace w i th a
new one i f any ;
! Remove dra i nange bo l t 27&c l ean i t#
! Use spec i a l too l s to assemb l e bearn i g or
o i l sel as . Lubr i cant o i l i s app l ied for bear -
i ng and o i l seal l i ps . Check bear i ng smooth
turn i ng af ter i nstal l at i on
Note: Check bear ing for smooth turn ing after
i nstal l i ng .
6-52
! Insta l l new o - r i ng and app l y grease#
! Insta l l gear seasor#

! Instal l reverse gear sensor 9 and t i ghten
T i gh t en i ng t o r que"2 0N "m
! Insta l l speed sensor 24
! Instal l o i l pipe and t ighten the l ink bol t

to the speci f i ed torque:
T i ghten i ng torque"18N$m
! Instal l washer 26 and oi l drainage bol t 27

and t i ghten to the spec i f i ed torque;
T i ghten i ng torque"30N"
"m
Too l "Bear i ng remover

Bear i ng i nstal l er
Mu l t i meter
# Eng i ne Assemb l y
Reverse the eng i ne removal procedure for
6
i nsta l l at i on :
No te!
% C l ean a l l the parts before assemb l y#
% Make sure that the parts are i n good con -
d i t i on w i thout any damage ;
% App l y eng i ne o i l to the mov i ng parts be -
fore assemb l y ;
% App l y grease to o i l sea l - l i p&O - r i ng
Caut i on : Make sure that dr i ve bel t , pr imary

and secondary sheaves are not sta i ned w i th
grease .
Eng i ne Center
O i l pump and re l i e f va l ve
! Instal l o i l pump and rel i ef val ve to l ef t
crankcase, as i l lustrated on the r ight . Tighten
to the speci f i ed torque:
1 - Lef t crankcase 2 - O i l p i pe
O i l pump bo l t"10N"
"m 3 - O i l p i pe washer
Re l i e f va l ve bo l t"10N"
"m 4 - Pressure str i p , rel i ef
5 - Rel i ef va l ve
6-53
CFMOTO
Connec t ed Rod
! Insta l l connect i ng rod to l ef t crankcase
w i th spec i al too l
No te!
% Do not hammer the conrod i nto crankcase
w i th p l ast i c ma l l et#
%Use special tool to avoid af fect of conrod
prec i s i on
Too l : contro l i nstal l er
Ba l ance Sha f t
! Insta l l bal ance shaf t
Caut ion: Balancer shaft dr iven gear should

be a l i gned to the mark as i l l ustrated .
Ma i n Sha f t , Counter Sha f t

! Insta l l ma i n shaf t and counter shaf t#
&45
'65
(78
6-54
Sh i f t Cam , Sh i f t Fo rk 1
! Instal l sh i f t cam & and sh i f t fork '
2
! Check each part for smooth turn i ng#
! Insta l l l ow range dr i ven gear to counter
shaf t (
! Spray adequate engi ne o i l to each

par t#
Dr i ve Beve l Gear
! Insta l l dr i ve beve l gear and t i ghten to
the spec i f i ed torque#
D r i ve beve l gea r t i gh t en i ng
t o r q u e "3 2 N "m
6
R i gh t C r ankcase
Dr i ven Beve l Gear
! Insta l l dr i ven beve l gear and t i ghten to
the spec i f i ed torque#
D r i ven beve l gea r t i gh t en i ng
t o r q u e "2 5 N "m
! Check beve l gear backl ash

(Refer to 6 - 44)
Front Output Sha f t

! Instal l f ront output shaf t to
r i ght crankcase;
6-55
! Apply sealant & to the mat ing face of r ight
c r ankcase#
Note!
!App l y sea l ant even l y i n a
un i nterrupted th i n l i ne
! Insta l l 2 dowe l p i ns '#

! Assembl e crankcase and tap sl ight ly w i th a
rubber hammer for proper f i tt i ng#
! Insta l l bo l t and t i ghten to the spec i f i ed
torque :
M6"10N"
"m
M8"25N"
"m
No te : Crankcase bo l ts shou l d be t i ghtened

d i agona l l y i n several steps .
Gear Pos i t i on i ng Bo l t
! P l ace the steel bal l and i nstal l gear po -
s i t i oni ng bo l t 1 and t i ghten the bo l t to the
spec i f i ed torque
"m
Eng i ne R i gh t
T i m i ng Cha i n
! Put on t i m i ng cha i n 2
C l ut ch
!Instal l clutch 1 and nut 2. Tighten the nut
to the spec i f i ed torque( l ef t thread)#
C l utch nut t i ghten i ng

t or que!7 0 N "m
! Inta l l new O - r i ng ) i n spacer *
! Insta l l spacer * onto the c l utch hous i ng
shaf t , then i nsta l l i nto CVT case +
Note : a l i gn o i l n i ck on spacer w i th o i l
ho l e on the shaf t
CVT Case
! I nsta l l dowe l p i n ,-gasket ' gasket ./
i ntal l CVT case assemb l y to the r i ght crank-
case
! Insta l l bo l t 0 and nut (
Note!
# T i ghten bo l t / nut d i agona l l y
# Use a new gasket
! Instal l gu i de p l ate 1 and screw 2
P r i ma r y sheave , seconda r y sheave ,

dr i ve Be l t
! Instal l pr i mary f i xed sheave & as
i l l ustrated on the r i ght ;
! Instal l dr i ve bel t on secondary sheave and

tap wi th a plast ic hammer to keep the bel t as
l ow as poss i b l e#
Not e!
% Instal l the dr i ve be l t w i th
the arrow on the bel t turn i n
the c l ockw i se d i rect i on#
% Dr i ve bel t contact sur face shou l d
be f ree f rom any sta i ns
CFMOTO
! Insta l l secondary sheave#
! Insta l l pr i mary s l i d i ng sheave
! T i ghten pr i mary sheave nut w i th spec i a l

too l to the spec i f i ed torque#
P r i ma r y sheave nu t t i gh t en i ng
t o r q u e "1 1 5 N "m
Too l "CVT Ho l der
! T i ghten secondary sheave nut w i th speci al

too l to the spec i f i ed torque#
Seconda ry sheave t i ght en i ng

t o r q u e "1 1 5 N "m
Too l "Rotor ho l der
No t e!
!Tur n the p r i ma ry sheave un t i l the
bel t i s seated i n and both pr i mary and sec -
ondary sheaves move together smooth l y .
CVT case cover

! Insta l l the new gasket and dowe l p i ns#
6-58
! Insta l l CVT case cover bo l ts and t i ghten

d i agona l l y i n several steps .
Eng i ne l e f t
O i l pump sp r ocke t and cha i n
! Instal l o i l pump dr i ve sprocket ;

! Instal l o i l pump dr i ven sprocket ;
! Insta l l o i l pump dr i ve cha i n#
! T i ghten o i l pump sprocket bo l t#
!Instal l sprocket retainer wi th a long nose
p l i e rs#
Too l "Long nose p l i ers
Dua l gear / i d l er gear

! I nsta l l dua l gear sha f t & and dua l gear
' #
! Insta l l i d l er gear shaf t (-i d l er gear ,

and bush .#
Star ter dr i ven gear

! Insta l l start i ng dr i ven gear bush )$
6-59
CFMOTO
! Insta l l start i ng dr i ven gear#
Magneto rotor
! I ns t a l l wood r u f f key i n t o c r anksha f t
g r o o v e#
! Inta l l magneto rotor 1#
No te! !Degrease the tapered par t o f rotor
and crankshaf t . Use nonf l ammab le sol vent to
clean of f the oi ly or greasy matter and ful ly
dry the sur faces .
Le f t crankcase cover
! Insta l l dowe l p i n 2 and gasket 3#
Note!
!Use a new gasket
! App l y l ubr i cant grease to o i l l i p#

! Insta l l l ef t crankcase cover#
! Instal l bo l ts
Reco i l star ter

! Insta l l reco i l starter 1#
! Insta l l O - r i ng 2#
Note!
!Use a new O - r i ng and app l y
l ubr i cant grease to the O - r i ng
! Insta l l washer 3 and bo l t 4 , t i ghten to

the spec i f i ed torque.
Reco i l s t a r t e r bo l t
t i g h t e n i n g t o r q u e "5 5 N "m
6-60
Water pump
! Insta l l water pump#
! Insta l l water pump f i x i ng bo l ts#
Note : Before t i ghten i ng the bo l ts , be sure

to insert oi l pump shaft into groove of water
pump shaf t
Sector gear
Insta l l the parts as i l l ustrated on the
r i ght
1 - Sector gear cover and gasket

2 - Dowe l p i n
3 - Dr i ve sector gear
4 - Dr i ven sector gear
5 - Dr i ven sector gear bo l t
6
Note!
W h en t h e s h i f t cam i s i n t h e n e u t r a l
pos i t i on , the mar k o f dr i ve sect or gear
shou l d be be t ween t he t wo ma r ks o f t he
d r i ven sec t o r gea r
D r i v en s ec t o r gea r t i gh t en i ng t o r qu e"
1 4 N $m
! Insta l l gearsh i f t rocker arm 6#
! Insta l l rocker arm bo l t 7 and washer 8#
6-61
CFMOTO
O i l f i l ter
Insta l l o i l f i l ter bo l t and t i ghten to the
spec i f i ed torque .
"m
! App l y eng i ne o i l to O - r i ng#
! Instal l o i l f i l ter , turn i t by hand unt i l
the f i l ter gasket contacts the mat ing surface.
T i ghten the bo l ts .
Too l "O i l f i l ter wrench
Star t i ng motor
! App l y eng i ne o i l to new O - r i ng#
! Insta l l start i ng motor#
! Instal l bo l t and t i ghten to the

spec i f i ed torque
Tightening torque: 10N.m
Eng i ne top s i de
P i st on
! Insta l l the p i ston r i ngs i n the order of
o i l r i ng , ' r i ng and & r i ng#
! The f i rst member to go to the o i l r i ng

groove is spacer &, after placing the spacer ,
f i t the two s i de ra i l s '#
Warn i ng!
!when i nsta l l i ng the spacer &,
do not over l ap i ts two ends i n the groove.
! Instal l the secong r i ng A and f i rst

r i ng B .
Note!
!1st r i ng and 2nd r i ng d i f fer
i n shape
6-62
! 1st and 2nd r i ngs have l etter R marked on

the side. Be sure to br ing the marked side to
the top when f i tt i ng them to the p i ston#
! Pos i t i on the gaps of the three r i ngs as

i l l ustrated on the r i ght . Before i nstal l i ng
the p i ston i nto the cy l inder , check that the
gaps are so l ocated#
! App l y a l i ght coat o f mo l y o i l to the

p i ston p i n ;
6
! Insta l l p i ston p i n i nto ho l es of p i ston
and conrod sma l l end#
Not e : When i nsta l l i ng the p i ston , the I N
mark on p i ston top i s l ocated to the i ntake
s i de
! P l ace a c l ean rag beneath p i ston and i n -

stal l p i ston p i n c i rc l i p &
Note : wh i l e rotat i ng crankshaf t , pu l l the

cam cha i n upward , or the chai n w i l l be caught
between sprocket and crankcase .
! Instal l the dowe l p i ns and the new cy l i n -

der gasket#
Note : Use a new cy l i nder gasket to prevent
o i l l eakage
6-63
CFMOTO
Cy l i nder
! App l y eng i ne o i l to p i ston sk i rt and cy l -
i nder wal l
!Hold each piston r ing wi th proper posi t ion,
i nsert p i ston i nto the cy l i nder#
! T i ghten the cy l i nder base bo l ts
temporar i l y#
Note : When i nsta l l i ng the cy l i nder and cy l -
inder head, pul l the cam chain upward, or the
cha i n w i l l be caught between sprocket and
crankcase .
! Insta l l cha i n gu i de &#

! F i t the dowe l p i n and new cy l i nder cover
g as k e t #
Note : Use a new cy l i nder cover gasket to
prevent o i l l eakage
Cy l i nder
! Insta l l the cy l i nder cover , t i ghten the
cy l i nder head bo l ts d iagonal l y to the speci -
f i ed torque#
Cy l i nde r head bo l t t i gh t en i ng t o r que
I n i t i a l "25N"
"m
F i na l "38N"
"m
!Tighten the cyl inder head nuts to the speci -

f i ed torque#
Cy l i nde r head nu t s t i gh t en i ng t o r que :

M6 : 10N"
"m
M8 : I n i t i a l 10N"
"m
F i na l 25N"
"m
! T ighten the cyl inder top nuts and cyl inder

base to the spec i f i ed torque#
T i g h t en i n g t o r q u e : 1 0 N "m
6-64
! Insta l l cha i n tens i oner#
Camsha f t
! A l i gn mark A on magneto rotor w i th mark

B on crankcase#
Note!
!wh i l e rotat i ng cranksha f t , pu l l the
cam chain upward, or the chain wi l l be caught
between sprocket and crankcase . 6
! A l i gn the mark A on the camshaf t so that

they are paral l el w i th the mat i ng surface of
the cy l i nder head#
Note : Do not rotate the magneto rotor wh i l e

do i ng th i s . when the sprocket i s not pos i -
t i oned correct l y , turn the sprocket ;
! Engage the chai n on the sprocket w i th the

l ocat i ng p i n B as i l l ustrated on the r i ght#
! Recheck i f the posi t i on of mark A and C is

correct. If not, reassemble unti l it is correct.
6-65
CFMOTO
! Insta l l crankshaf t C - r i ng &#
! Instal l l ock washer so that i t covers the

l ocat i ng p i n#
! App l y thread l ocker to the bo l ts be fore
i nstal l i ng, and t i ghten them to the speci -
f i ed torque#
Sp r ocke t bo l t t i gh t en i ng t o r que
"1 5 N " m
! Bend up the l ock washer to l ock
the bo l ts ;
Cy l i nder head cover

! C l ean the mat i ng sur face of cy l i nder head
and cy l i nder head cover
! Instal l dowe l p i n to the cy l i nder head
! Appl y seal ant to the mat ing surface of the
cy l i nder head cover ;
! Instal l cyl inder head cover bol ts , t i ghten

d i agonal l y to the speci f i ed torque.
Cy l i nde r head cove r bo l t t i gh t en i ng

t o r q u e "1 0 N "m
Note: When t ightening the cyl inder head cover
bol ts , the p i ston must be at top dead center
on the compress i on stroke .
6-66
Gasket seal ant app l y i ng p l ace
Cha i n tens i oner

! Insert ( - - ) screwdr i ver i nto s l otted end 6
of chain tension adjuster , turn i t clockwise
to l ock the tens i oner spr i ng ;
! Insta l l the cha i n tens i oner and the new

washer 1 #
! I nsta l l the bo l t 2 , t i ghten i t to the
spec i f i ed torque .
Cha i n tens i oner bo l t t i ghten i ng
t o r q u e "1 0 N "m
! Af ter cha i n tens i oner i s i nsta l l ed , turn

the ( - - ) screwdr i ver counter cl ockw i se. The
tens i oner rod w i l l be advanced under spr i ng
force and push tens i oner aga i nst chai n .
6-67
CFMOTO
! Insta l l the new gasket 3#

! Instal l chai n tens i oner screw , t i ghten i t
Cha i n tens i oner screw t i ghten i ng

t o r q u e "8 N "m
Va l ve ad j uster cover
! Refer to 2 - 3 for val ve cl earance
! Use new rubber gasket and app l y grease

! Insta l l Val ve Inspect i on Cap
! Insta l l va l ve i nspect i on cap bo l t#
Spark p l ug
! Insta l l spark p l ug w i th spec i a l too l and
t i ghten to the speci f i ed torque;
Note : To avo i d damage to the cy l i nder head

thread , screw i n the spark p l ug w i th hand
f i rst , then t ighten i t to the speci f ied torque
w i th spark p l ug wrench .
Spa r k p l ug t i gh t en i ng t or que : 18N . m

Too l : Spa r k P l ug W r ench
Eng i ne per i phery
R eco i l s t a r t e r
! Insta l l reco i l starter#
! App l y thread l ocker to the bo l ts and then

t i ghten ;
Va l ve i n spec t i on cap
! Insta l l va l ve i nspect i on cap#
6-68
Le f t p l ast i c cover
! Instal l l ef t p l ast i c cover 6
Water p i pe and hose

! Insta l l water hose 5#
! Insta l l bo l t 4#
! Insta l l water hose 3#
! I nsta l l c l amp 1-2#
6-69
7 Fue l System , A i r Intake System
Overhaul info. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Troubleshoot ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
High pressure oi l pipe Disassembly / Instal lat ion. . .7-4
Thrott le Valve Disassembly / Instal lat ion. . . . . . . . . . . . .7-5
Fuel Injector Assy Disassembly / Instal lat ion. . . . . . . . . .7-6
Fuel injector Assy Removal / Assembly. . . . . . . . . . . . . . . . .7-6
Idle Ai r control valve Disassembly / Instal lat ion. . . . .7-6
7-1
O ve r h au l info
Caut i on
No te
Gaso l i ne i s h i gh l y f l ammab l e , t he r e f o r e smoke and f i r e a r e s t r i c t l y f o r b i dden
i n t he wo r k p l ace . Spec i a l a t ten t i on shou l d a l so be pa i d t o spa rks . Gaso l i ne
may a l so be exp l os i ve when i t i s vapo r i zed , so ope r a t i on shou l d be done i n a
w e l l - ven t i l a t ed p l ace .
! Do not over tw i st or bend the cab l es . The tw i sted cab l es may cause poor operat i on .
! Loose the h i gh pressure o i l p i pe before d i sassemb l y , d i scharge the fue l i n the h i gh
pressure o i l p i pe and put i t i n a conta i ner .
! When the body of thrott le val ve i s d i sassemb l ed , the a i r i ntake shal l be covered by
d i shcl oth or tape, for avo i d i ng the entry of other ob j ects i nto the eng i ne f rom the
ai r i ntake s i de of the eng i ne.
! When the veh i c l e w i l l be stored for more than one month , the gaso l i ne i n the h i gh
pressure o i l p i pe and cap of the fue l i n j ector must be d i scharged . Otherw i se , the
gaso l i ne w i l l age and form co l l o i da l e l ements wh i ch may b l ock the nozz l e of fue l
i n j ector , therefore the eng i ne cannot start or the rotate speed i s unstab l e.
Ove r ha i l I n f o
Eng i ne s ta r t i ng f a i l ur e Hard start i ng / shut down af ter start i ng ,
!Too much fue l i n the eng i ne Unst eady i d l e speed
" A i l f i l ter cl ogged !Id l e a i r p i pe c l ogged
" Id l e a i r p i pe c l ogged !fue l system c l ogged
!No fuel i n the i n j ector !Ign i t i on system not funct i on i ng proper l y
" fue l f i l ter cl ogged !Fue l tank cap c l ogged
" h i gh pressure o i l p i pe c l ogged
" fue l i n j ector cl ogged
No f i re when acce l e rat i ng

!i gn i t i on system not funct i on i ng proper l y
Incorrect Spark P l ug cl earance
7-2
7 Fue l System , A i r Intake System
H i gh pressure o i l p i pe D i sassemb l y
Loosen the spec i a l fue l p i pe c l amp on fue l
i n j ector cap , l oosen the spec i a l fue l p i pe
cl amp on fuel tank.
D i sassemb l e H i gh pressure o i l p i pe
No t e
Use conta i ner to keep the rema i n i ng fue l
from h igh pressure o i l pi pe, when looseni ng
the speci al fuel p i pe c l amp
H i gh p ressu re o i l p i pe I ns t a l l a -
t i on
Reve r se t h e d i s as s em b l y p r o cedu r e f o r
Use OETI KER c l amp ca l l i per to i nsta l l the
spec i a l fuel p i pe cl amp .
Throt t l e va l ve body D i sassemb l y

Loosen the strap and remove thrott l e va l ve
connector .
Loosen locknut , remove ad j ust nut and remove
the t hr ot t l e cab l e f r om th rot t l e r oto ry
s l eeve .
D i sassemb l e i del ai r out let p i pe on thrott le
va l ve .
Loosen ai r intake connect cl amp , ai r cl eaner
connect clamp, and remove thrott le valve body.
No tes
Donot ad j ust the bo l t on throt t l e va l ve .

Donot remove the cap on thrott le valve body.
Throt t l e va l ve body I nsta l l at i on

R eve r s e t h e d i s as s em b l y p r o cedu r e f o r
Fue l I n j ector Assy D i sassemb l y

D i sassemb l e the speci al h i gh pressure o i l
Remove the strap and fuel injector connector .
D i sassemb l e bo l ts and remove fue l i n j ector
cap and i n j ector .
Fue l I n j ector Assy I nsta l l at i on

Reverse the d i sassemb l y procedure f or i n -
sta l l at i on
7-3
Fue l I n j ector Assy . Remova l
Use thumbs of both hands to push two si de of
fue l i n j ector cap snap spr i ng , and then re -
move i t .
Seperate fuel injector cap and fuel injector .
Fue l I n j ector Assy . Assemb l y

Instal l fuel injector cap on the fuel injector ,
A l i gn the groove of fue l i n j ector cap snap
spr ing to edge of fuel injector cap;and press
the snap spr i ng i nto i t .
I d l e a i r contro l va l ve D i sassemb l y
D i sassemb l e i d l e i ntake p i pe and i d le out l et

p i pe .
Loosen the strap , d i sassemb l e i d l e ai r con -
trol valve and check idle ai r control valve.
Replace i t when there is abnormal noise or i t
doesnot work .
I d l e a i r cont r o l va l ve I ns t a l l a -
t i on
Reve r se t h e d i s as s em b l y p r o cedu r e f o r
Pay at tent i on not to bend the i ntake and
out l et p i pe of i d l e a i r contro l va l ve.
7-4
8 FRONT WHEEL ,BRAKE SUSPENSION,STEERING SYSTEM
Overhaul &&&&&&&&&&&&8-1 Brake system&&&&&&&&8-4
Fault diagnosis &&&&&&&&&8-2 Front suspention system&&&&&8-7
Front wheel&&&&&&&&&&&8-3 Steering system&&&&&&&&8-12
Overhau l
Operat i on not i ce
At tent i on
!The f rame must be ho l d up f i rm l y when overhau l i ng f ront whee l , suspent i on system .

!L i ght , meter , sw i tch"s overhau l or i nspect i on refers to sect i on10 .
!Donot overpower on the tyre , be carefu l not to destroy the tyre .
!When d i sassemb l e the tyre on the r i ms , to avo i d destroy the r i m , you requ i red to use
speci al tyre - l ever and r i m - protector .
Overhau l standard
Service
Item Standard 8
limits
Portrait 0.8mm 2.0mm
Rim jump
Cross 0.8mm 2.0mm
Remain
! 3.0mm
Tyre groove
Air pressure 35kPa"0.35kgf#cm2$ !
Front disc Brake lever windage 0mm !
Tightening torque
steer ing t ie- rod nut 40-50 N%m
steer i ng shaf t l ock nut 100 - 120N%m
f ront wheel shaf t nut 110 N%m
suspens i on f i xed bo l t / nut 40 - 50 N%m
r i m i nstal l nut 50 - 60 N%m
r i m shaf t nut 110 - 130 N%m
8-1
C FM OT O
Spec i a l too l s
Bearing d i sassemb l e too l i ng bar
Bear i ng d i sassemb l e too l i ng nod 10mm
Press i n too l i ng l everA
Press i n too l i ng coat28 ' 30
Gu i de too l (10mm
Lock nut spanner
Bear i ng d i sassemb l e too l s
Rotor pu l l er
D i sassemb l e too l i ng bar
D i sassemb l e heavy punch
Assemb l e too l i ng bar
Fau l t d i agnos i s
Hand l ebar heavy whee l rotat i on dumb
%upper screw over tong i ng . %whee l shaf t bad
%steer i ng shaf t destroy , worn . %f ront whee l shaf t bend
%Bear i ng i nner , externa l race dest roy , worn , %brake drag
step . Front suspens i on too so f t
%steer i ng co l umn deform. %f ront suspens i on bounce weaken
%tyre l ower pressure
%tyre a i r too l ower
%tyre worn out
Front suspens i on too hard
Hand l ebar shake %f ront suspens i on bend
%steer i ng shaf t destroy , bad t i ghten i ng
%tyre a i r too h i gh
%l ef t and r i ght absorber unmatch
Front suspens i on abnorma l
%tyre def l ect i on
%f rame deform no i se
%tyre destroy %f ront suspens i on bad
%whee l shaf t shaf t tightening parts loosen
%suspension
Front whee l j ump Brake ef fet poor
%r i m de f orm %brake ad j ustment bad
%whee l shaf t bad %brake d i sc sur face deface
%tyre bad %brake b l ock destroy
%whee l ba l ance bad
%whee l shaf t round bad t i ghten i ng
8-2
F r on t whee l
D i sassemb l e
Set up f ront wheel wi th too l , ensure w i thout
any force on the f ront whee l .
remove steer cap
remove the four nuts i nstal l ed i n the f ront
whee l hub , remove f ront whee l .
I nspec t i on
Rim
Inspect i f the r i m destroy , deform , speck ,
rep l ace the r i m i f needed .
Turn the whee l s l ow l y , use cent i meter mea -

sure r i m j ump .
Se r v i ce l i m i t : ax i a l d i r ec t i o n : 2 . 0mm
Rad i a l d i r ec t i on!
!2 . 0mm
8
I ns t a l l i ng
Press the r im in the tyre on special matchin.
Fi x the r i m i n hub
Rim i ns ta l l n u t t o r q u e !5 0 - 6 0 N "m
F r on t whee l hub d i sassemb l e

D i sassemb l e
remove f ront whee l () 8 - 3)
remove f ront brake ca l i per () 8 - 4)
remove r i m shaf t nut
take away brake d i sc and hub together
remove f ront brake d i sc 4pcs brake bo l ts
remove f ront wheel hub
I nsta l l i ng
Insta l l i ng carry on accord i ng to the oppo -
s i te sequence .
8-3
C FM OT O
B r ake sys t em
Front brake ca l i per
D i sassemb l e
remove f ront whee l ") 8 - 3$
remove the 2pcs nuts i nsta l l ed on the arm
remove brake ca l i per
I nspect i on
Check i f the brake cal i per crack,
i f the t i ghten i ng area o i l l eakage,
rep l ace i f needed .
I nsta l l i ng
B r ake ca l i pe r ho l d i ng bo l t t o r que !40 -
5 0 N "m
8-4
Brake d i sc
D i sassemb l e
remove brake ca l i per") 8 - 4$
take away brake d i sc together w i th f ront
whee l hub .
remove brake d i sc*s 4pcs nut i nsta l l ed i n
f ront wheel hub .
remove the brake d i sc.
I nspect i on :
brake d isc th i ckness : rep l ace when less than
2 . 5mm .
Insta l l i ng
Instal l the brake d i sc we l l
B r ake d i sc ho l d i ng bo l t t o r que : 25 - 30N"
" 8
m
Hand brake master cy l i nder , f ront

br ake
D i sassemb l e
remove bo l t
remove park i ng l ever
Seperate f ront hand brake master cy l i nder
handlebar , i t is not need to remove the front
hand brake master cyl inder i f not replace the
brake pump assemb l y .
At tent i on
Dono t use b rake t ube hang t he b r ake
pump , to p r even t f r on t hand br ake mas te r
cy l i nder backdat e , so keep i nst a l l i ng
pos i t i o n , a t t h e same t i me , f i x i t i n
t he h and l eb a r .
O i l t u b e t r e n d ac co r d i n g t o S c t i o n 1
cab l e , w i r e t r aces .
Mus t keep t he o i l l i ne smoo t h .
Comp l et e t he b r ake sys tem i ns ta l l a t i on ,
b r ake e f f o r t mus t be checked .
8-5
C FM OT O
D i sassemb l e
remove f oot rest") 2 - 9$
remove f ront i nner f ender RH"2 - 12$
remove bo l t1 , bo l t2
seperate peda l brake master cy l i nder f rom
the body
Assemb l i ng
Assemb l i ng carry on accord i ng to the oppo -
s i te sequence of d i sassemb l e .
At tent i on
To avo i d a i r i n l et the br ake pump , thus
you mus t to keep the assemb l e pos i t i on ,
at t he same t i me , f i x i t i n t he veh i c l e
body .
O i l tube t rend re f ers to Sect i on1 cab l e ,
w i r e t r aces . I t mus t en su r e t he b r ake
oi l l i ne smooth . A f ter comp l ete the
b rake syst em i nst a l l a t i on , check i ng the
b r ake e f f o r t i s r equ i r ed .
Brake Y - j o i nt
D i sassemb l i ng
remove f ront i nner f ender RH"2 - 12$
remove bo l t 1 then the brake Y - j o i nt canbe
remove form the body .
Assemb l i ng
Assemb l ing carry on to the opposi te sequence
of d i sassemb l i ng .
A t t en t i on : O i l tube t r end re f e r s to sec -
t i on 1 , cab l e and w i re t races , the brake
o i l l i ne mus t be smoo t h .
B r ake f o r ce check i n g i s r eq u i r ed w hen
comp l et e t he b r ake sys tem i ns ta l l a t i on .
If i t canno t gang con t ro l t he b r ake
s ys t em , ch eck i f t h e s t em T - j u n c t i on ,
b r ake f o r ce check i ng i s r equ i r ed a f t e r
f i n i sh t he b r ake sys t em i ns t a l l a t i on .
Brake cross j o i nt p l ug
D i sassemb l i ng
remove f ront i nner fender RH"2 ) 12$
remove bo l t 1 , bo l t 2 , then the cross j o i nt
p l ug canbe remove f rom the body .
8-6
Assemb l i ng
Assemb l ing carry on accord ing to the oppsi te
sequence of d i sassemb l i ng .
A t t en t i on : O i l tube t r end re f e r s to sec -

t i on 1 cab l e , w i r e l i ne t r aces , b r ake
o i l l i ne mus t be smoo t h .
B r ak e f o r c e ch e c k i n g i s n e e d e d a f t e r
f i n i s h t h e b r ake sy s t em i n s t a l l a t i o n ,
if i t c a n n o t j o i n c o n t r o l , c h ec k t h e
c r os s p l ug .
F r on t suspens i on sys t em
F r o n t l e f t s u s p en s i o n
assemb l e
Attent i on : when repa i r i ng suspens i on , you
must not remove both LH and RH suspensi on at
one t i me , or e l se the body w i l l fa l l down
because l ack of ho l d i ng power .
D i sassemb l e
Put veh i c l e body i nto hor i zonta l pos i t i on ,
use j ack ho l d the wheel f ront f i rm l y .
remove f ront whee l () 8 - 3)
remove f ront r im hub() 8 - 3)
remove ca l i per () 8 - 4) 8
remove f ront left absorber bo l t 1 and t i ght -
en i ng nut 1 i nsta l l ed on the body .
remove front left upper arm bol t 1 and t ight -

eni ng bo l t 1 ,nut 1 ; bo l t 2 and bo l t 2 , nut 2
i nstal l ed i n the f rame.
remove front left lower arm bol t 3 and t ight -

eni ng bo l t 3*s nut 3 , bo l t 4 and t ighteni ng
bo l t 4*s nut4 i nsta l l ed i n the f rame .
remove steer i ng t i e - rod ba l l p i n s l ot nut ,

remove the steer i ng p i e- rod
pu l l up j o i nt knuck l e f rom the dr i veshaf t ,

remove f ront l ef t suspens i on assy .
8-7
C FM OT O
D i smant l i ng
F r o n t sh ock abso r be r
D i s m an t l i n g
A t t en t i on : You dono t need t o r emove any
other par ts i f you on l y r ep l ace the
f r o n t su s pens i on .
Remove f ront l ef t absorber*s bo l t 1 , nut 1

i nsta l l ed i n arm .
Remove f ront r i ght shock absorber .
Inspect i on
Inspect i f the absorber oi l leakage, oi l seal
age, destroy , rep l ace i f needed .
8-8
Assemb l i ng
s i te sequence of d i sassemb l i ng .
Fr on t l e f t ab s o r b e r *s d i s a s s em b l i n g ,
assembl ing, inspect ion as same as front r ight
absorber .
A r m assemb l e
At tent i on !There are 8 suspens i on ar ms
in the veh i c l e , they d i smant l e ,
d i s co m p o s e , i n s p ec t i o n an d as s em b l e i n
the same way . So here on l y i nt r oduce t he
way t o d i s man t l e , d i scompo se , i nsp ec t i on
an d as semb l e t he f r on t l e f t u pp e r a r m
and t he f r on t r i gh t l owe r ar m . Ot he r
a r m assemb l e r e f e r s t o t he above .
Front r i ght arm assy

D i sassemb l e
Remove f ront r i ght absorber () 6 - 8)
Remove f ront r i ght upper arm*s bo l t 3 and
t i ghten i ng nut 7 , bo l t 1 , t i ghten i ng bo l t 1 8
and nut 7 .
Remove f ront r i ght l ower arm*s bo l t 3 and

t i ghten i ng bo l t 7*s nut 7 i nstal l ed i n the
f rame .
Before d i sassemb l i ng the absorber , you have
to remove the whee l s , brake cal i per and r i m
hub .
Before d i sassemb l i ng the bo l ts , you need to
remove the steer i ng t i e - rod .
Before d i sassemb l i ng f ront r i ght l ower arm
assy , you need to pu l l up the knuck l e f rom
the dr i veshaf t .
Remove f ront r i ght arm assy .
8-9
C FM OT O
I nspec t i on
Ba l l p i n
Inspect i f i t can rotate f lexible between top
bal l pin 9 and front r ight upper arm 6,bottom
bal l pin 17 and front r ight lower 12. Besides,
the gap between top bal l pin and bottom, i f i t
cannot move f reel y or the gap too b i g , bal l
p i n rep l acement i s needed .
R i gh t knuck l e
I nspect i f the r i ght knuck l e i s dest roy ,
rep l ace i t i f need .
Inspect i f the r im shaft inside r ight knuckle

move +,-./012345678.9:;<=
>?@.9ABC56=>DE?FGHI56
8-10
Constant ve l oc i ty dr i ve sha f t
At tent i on : For thi s veh i c l e ,
i nspect i on , d i sassemb l i ng and assem -
b l i ng t h e f r on t & r ea r ax l e L H&RH
constant ve l oc i ty dr i ve sha f t are
i n the same way .
( 55 ) Constant ve l oc i ty dr i ve sha f t ,
LH . Front ax l e
D i sassemb l i ng
A t t en t i on : You dono t need t o r emove t he
f r on t suspens i on assy f r om t he veh i c l e
i f you on l y repa i r the f ront ax l e costant
ve l oc i t y d r i ve sha f t , L H .
remove f ront l ef t whee l () 8 - 3)
remove f ront l ef t brake cal i per () 8 - 4)
remove fornt lef t r im hub() 8 - 3)
Exam i ne duct boot , rep l ace w i th new ones i f
destroy .
cost ant ve l oc i ty dr i ve sha f t shake?
i nspect i f the un i versa l j o i nt move f ree l y ,
the bear i ng move f ree l y , i f there i s gap
between j o i nt and sp l i ne .
Replace wi th new ones i f dumb,abnormal sound, 8
gap .
A t t ent i on : Doub l e o f f se t un i ve r sa l j o i n t
mus t can be move f ree l y , or e l se , i t
canno t con t r o l t he t y r es and r esu l t i n
acc i dent .
A t t en t i o n : R ep l acem en t i s r eq u i r ed i f
the r i ght& l ef t arm shake after
i ns ta l l a t i on .
Assemb l i ng
Mount i ng torque : 40#

#50N"
"m
Use speci al too l to press the ba l l p i n i nto

the arm assy .
s i te sequence of d i sassemb l i ng .
8-11
C FM OT O
S t ee r i ng sys t em
Hand l ebar
Dashboard cover
d i sassemb i ng
remove dashboard cover bo l t1
remove dashboard cover
Assemb l i ng
Assemb l ing carry on the oppos i te sequence of
d i sassemb l i ng .
RH hand l ebar sw i tch

D i sassemb l i ng
remove f ront top cover") 2 - 4$
remove RH hand l ebar sw i tch connector
remove the two bo l ts i nstal l ed i n hand l ebar
tube .
remove hand l ebar sw i tch , RH .
I nsta l l at i on
Insta l l the hand l ebar sw i tch , RH") 8 - 15$
8-12
Hand l eba r sw i tch , L H
d i sassemb l i ng
remove 2 screws
remove LH hand l ebar sw i tch connector

remove hand l ebar sw i tch , LH
I nst a l l
Insta l l the LH hand l ebar sw i tch") 8 - 15$
Rea r v i ew m i r r o r
8
D i sassemb l i ng
loosen the nut in counter -clockwise di rect ion,
then turn the rear m i rror i n counter - c l ock -
w i se and you can take o f f the rear v i ew
m i rror .
A t t en t i on : L e f t hand r ea r v i ew m i r -
ror i s r i gh t hand sc rew thread ,
turn i t i n counter - c l ockw i se d i -
r e c t i on whe n d i sm an t l i n g .
Loosen the nut i n cl ockw i se d i rect i on , turn

the RH rear v i ew m i rror then you can take
down the RH rear v i ew m i rror .
A t t en t i o n : RH r ea r v i e w m i r r o r i s
l e f t han d t h r e ad , y ou r eq u i r ed t o
t ur n i t i n c l ockw i se d i r ec t i on when
t ake i t down .
I nsta l l at i on
s i te sequence , d i rect i on of un i nsta l l at i on .
8-13
C FM OT O
Hand l eba r p i pe
D i sassemb l i ng
remove the dashboard cover") 8 - 12$
remove RH&LH hand l ebar sw i tch") 8 - 12$
Seperate the r ight and l ef t brake pump f rom the
han l ebar p i pe .
remove the four instal lat ion bol t , take down the
hand l ebar .
Assemb l i ng
Assemb l i ng carry on accord i ng to the oppos i te
sequence of d i sassemb l i ng .
T o r q u e : 20-30N"
"m$
$ 2.0-3.0kgf"
"m%
%
At tent i on
Ma i n cab l e assy , #thrott l e cab l e , brake
o i l p i pe , cab l e hut accord i ng to t he
draw i ng correct l y .
I nsta l l throt t l e cab l e

remove the three screws , remove RH hand l ebar sw i tch cover .
Insta l l thrott l e cab l e

i nstal l RH hand l ebar sw i tch cover
8-14
I nsta l l LH hand l ebar sw i tch
Pa i r the LH hand l ebar sw i tch stopped onto the
hand l ebar l ocat i on ho l e .
use bo l t 1 t i ghten i ng f rom the bottom .
I nser t the LH hand l ebar sw i tch*s connector

i nto the mai n cab l e.
I nsta l l RH hand l ebar sw i tch 8

Pa i r the RH hand l ebar sw i tch stopped onto the
hand l ebar l ocat i on ho le. T i ghten ing through the
bo l t 2 f rom the bottom .
I nser t the RH hand l ebar sw i tch*s connector

i nto ma i n cab l e .
8-15
C FM OT O
I ns t a l l RH& L H g r i p
remove d i rty i nner LH gr i p and dry i t . coat
the connect i on w i th j o i nt cement between
handlebar and LH gr ip, put in the RH&LH gr ips.
Attent ion
The instal led RH&LH gr ips must be placed
for hours for dry the j o i nt cement .
I ns t a l l b r ake pump
upward the brake pump base JUPK mark, then
i nstal l the brake pump .
eyeba l l i ng the d i stance between brake pump
and hand l ebar sw i tch , hand l ebar under hood
to equal i ty .
Attent ion:
Ma i n cab l e assy , throt t l e cab l e , brake
o i l p i pe , cab l e hut sha l l accord i ng to
the draw i ng correct l y .
Insta l l the park i ng l ever
i nsta l l the rear v i ew m i r ror") 8 - 13$

i nstal l the dashboard") 8 - 10$
i nstal l the dashboard cover") 8 - 12$
8-16
S t ee r i ng sys t em
8-17
C FM OT O
Steer i ng stem
D i sassemb l i ng
remove dashboard f ront cover
") 8 - 1 2 $
take down handlebar swi tch con-
nector
Use st ra i ght screwdr i ver and
hammer hammer out the lock pad.
remove bo l t1(bo l t2
remove steer ing stem seat , plate
and bush .
Remove cotter p i n
Remove steer ing t ie- rod instal -
l at i on nut , washer
Press and separate the steer -
i ng t i e - rod f rom the steer i ng
stem .
Remove steer i ng stem i nsta l l a-

t i on bo l t
Rai se up the steer i ng stem and

the handlebar together , then you
can remove the steer i ng stem .
I nsta l l i ng
s i te sequence of un i nstal l i ng .
At t ent i on : Check the maneuve rab i l i ty
af ter f i n i sh the i n s t a l l a t i o n .$ 3 - 3 %
Cab l e , i nhau l cab l e t race re f ers to
sect i on 1 cab l e , i nhau l cab l e t race
draw i ng .
8-18
Steer i ng bear i ng , o i l sea l
D i smant l i ng
remove steer i ng stem") 8 - 18$
remove f ront ADWS arm assy") 8 - 9$
Use spec i a l too l separate the steer i ng stem
and the o i l seal f rom the body .
S pec i a l t o o l :
bea r i ng r em ove r comp onen t
rotor pu l l er
r em ov e r ax l e
r emove r h eavy bob
I nsta l l at i on
Instal l at i on carry on accord i ng to the oppo -
s i te sequence of un i nstal l at i on .
S pec i a l t o o l :
Bea r i ng r ace i ns t a l l a t i on t oo l A
Ass emb l i ng t oo l i ng ba r
A t t e n t i o n !S p e c i a l too l must be used
when i ns t a l l t he bea r i ng .
8
Steer i ng system instal l accord i ng to the op -

pos i te sequence of un i nstal l at i on .
At t ent i on : Check the maneuve rab i l i ty
a f t e r f i n i sh t h e i ns t a l l a t i on .
8-19
9 Rear Whee l , Rear Brake , Suspens i on
Overhaul Info!!!!!!!!!9 - 1 Rear Brake System!!!!!!9 - 4
Troub l eshoot ing!!!!!!!!9 - 2 Rear Suspens i on System!!!!9 - 5
Rear Wheel !!!!!!!!!!!9- 3
Overhau l I n f ormat i on
O pe r a t i n g N o t i ce
No te
"Secure l y support the veh i cl e when overhau l i ng the r i m and suspens i on system .
"Use genu i ne parts of bo l ts and nuts for rear r im and suspens i on .
"Do not overexert on the whee l s to avo i d poss i b l e damage to the wheel s .
"When remov i ng t i res from r i m , use speci al t i re l ever and r i m protector to avoi d damage to
the r i m .
O ve r h au l S t an d a r d
I tem Standard Limit
Rim Long i tud i na l # 2 . 0mm

V i brat ion Hor i zonta l # 2 . 0mm
Rear Rema i ned
# 3 . 0mm
Whee l T i re Tread
Ti re
Ti re
30kPa #
Pressure
Rear
Brake Lever Free P lay 10# 20mm #
Brake
T i g h t en i n g To r qu e
Rear Wheel Ax l e Nut 110 - 130N"m
R i m Mount i ng Bo l t 50 - 60N"m
Upper Mount i ng Bo l t , Shock Absorber 40 - 50N"m
Lower Mount i ng Bo l t , Shock Absorber 40 - 50N"m
9-1
C FM OT O
Troub l eshoot i ng
Rea r Whee l Wo bb l es
"R i m Warpage
"Fau l ty T i re
"T i re Pressure Too Low
"Improper Whee l Ba l ance
"Improper T i ghten i ng of Whee l Ax l e Nut
"Loosened Whee l Nut
Rea r Shock Abso r be r i s Too So f t

"Weak Spr i ng
"O i l Leakage f rom Rear Shock Absorber
Rea r Shock Abso r be r i s Too Ha r d

"Bent Rear Shock Absorber
"T i re Pressure i s Too H i gh
Poo r B r ake E f f i c i ency

"Improper Brake Ad j ustment
"Sta i ned Brake Pad or Brake D i sk
"Worn or Damaged Brake Pad
9-2
Rear Whee l
Remova l
Ref er to Front Whee l Remova l $% 8 - 3&
I nspec t i on
Rim
Damage, warpage, ser i ous scrapes : % Rep l ace
S l ow l y turn the whee l , measure the r i m v i trat i on w i th a d i al gauge.
Se r v i ce L i m i t : Ax i a l : 2 . 0 mm
Rad i a l : 2 . 0mm
Re fer to Front Whee l I nsta l l at i on$% 8 - 3&
Wh ee l H ub
Remove :
- Rea r Whee l $% 9 - 3& 9
- R i m Axl e Nut
- Wheel Hub
I ns ta l l a t i on :
Reverse the remova l procedure for i nstal l at i on .
T i gh t en i ng To r que , R i m Ax l e Nu t :
1 1 0 - 1 3 0 N !m
9-3
C FM OT O
Rear Brake
Rea r B r ake Ca l i pe r
Remove :
- Rear Le f t Whee l $% 9 - 3&
- 2 Bo l ts f rom Arm
- Brake Cal i per
I nspec t i on
Brake Cal iper : Cracks , Oi l Leakage: % Rep l ace
Reverse the remova l procedure for
Note: Refer to Chapter 1 for brake hose routing.
Rea r B r ake D i sc
Remove :
- Rear Dr i ve Shaf t
- Rear Brake Ca l i per$% 9 - 4&
- 6 Shear Bo l ts
- Pa r k i ng B r ake$% 9 - 4&
- Rear Brake D i sc$% 8 - 3&
I nspec t i on
Brake D i sc : Th i ckness<6 . 5mm % Rep l ace
Note: Refer to Chapter 1 for brake hose routing.
P a r k i ng B r ake
Remove :
- Rear Dr i ve Shaf t
- Rear Brake Ca l i per$% 8 - 4&
- 6 Shaf t Bo l ts
- Parki ng Brake
9-4
Rear Suspens i on System
Rea r R i g h t Su spens i on
No te : DO NOT r emove bo th l e f t and r i gh t suspens i on at t he same t i me to avo i d f a l l
down o f t he veh i c l e .
D i sassemb l y
S t ab i l i z e r Ba r
Remove :
Bo l t1( 6 ) , Bo l t2 ( 7) , Bo l t3 ( 10 ) , Bo l t4( 11) ,
Bracket (8)and(5) , Rubber Support (4)and(9) ,
Nut2(2) , Nut10(12) , Lef t Ba l l P i n(1) , R i ght
Bal l P i n(14)
Remove : Stab i l i zer Bar (3)
9-5
C FM OT O
Rear R i ght Absorber
Remova l
No t e : Secu r e l y suppo r t t he veh i c l e when
r emov i ng r ea r l e f t and r i gh t absor be rs .
Suspend whee l s f r om g r ound .
Ma i nt enance o f r ea r absor be rs on l y does
not r equ i r e remova l o f rear suspens i on .
Remove the fo l l ow i ng parts f rom rear r i ght
shock absorber :
- Bo l t10(25)
- Nut7(27)
- Bo l t7(19)
- Nut8(28)
Remove rear r i ght shock absorber
Rea r R i gh t A r m
Refer to Front Lef t Upper Arm i n Chapter13
for the removal , i nspect ion and i nstal l at i on
of Rear R i ght Arm .
Rea r L e f t Su spens i on
Refer to Rear Right Suspension for the removal ,
i nspect i on and i nsta l l at i on o f Rear Le f t
Suspens i on .
9-6
10 Front/Rear Axle
Overhau l i n f ormat i on
! Standards
Lubricating Period
Capaci ty Interval
Item Type
Ini t ial Next
In i t i a l : 0 . 33L / Rep l ace :
SAE15W / 40 SF
Front axle "
0 . 28L
350km 5000km
Rear axle SAE80W / 90 GL -4 Ini t i al : 0 . 30L / Rep l ace :
0 . 25L
Tightening torque table

Item Pcs Speci f icat ion Torque(N.m) Remark
Front axle case bol t 6 M8 # 28 25
Front axl e motor screw 4 M8 # 20 13
Pi ni on shaft screw 1 M8 # 10 13 Wi th fasten ing gl ue
Front axle nut 1 M14 # 1.5 62

Di f f . gear bol t 6 M10 # 1.25 # 22 45
Oi l bol t , f ront axl e 1 M14 # 1.25 # 12 25
Drai n bol t , f ront axl e 1 M10 # 1.25 25
Retainer 1 M64 # 1.5 # 7 80
10
Rear axle case bol t 2 M10 # 1.25 # 25 40
Rear axle case bol t 6 M8 # 25 25
Nut , input shaft ,R / A 1 M12 # 1.25 70
Bol t , input shaft ,R / A 4 M8 # 30 25
Retainer , R / A 1 M65 # 1.5 # 10 70
Nut 1 M8 16
Oi l bol t , rear axl e 1 M20 # 1.5 # 12 25
Drai n bol t , f ront axl e 1 M14 # 1.25 # 12 25
10-1
CFMOTO
! I nspec t i on & Ove r hau l

Inspect i on and overhau l i s needed i f any of prob l ems be l ow happens to f ront and rear ax l e
Problem descr ipt ions Causes
$ Unstable moving dur ing accelerat ing, A.Bear ing broken;

decerat ing or constant speed. B.Gear clearance over / under size;
C.Gear severely worn;
% Abnormal sound in front rear axle; D.Gear blocked
E.Dr ive shaft broken
& Engine power tranmission fai lure to F. lack of lubr icant
front or rear wheels. G.Foreiggn matter in front or rear gear
Note!
!A!B!C probl ems are hard to di st ingui sh . Anal ysi s is needed based on
actual break-down catagor ies.Make sure engine works al l r ight before disassembly
of front or rear axle
Obsernvat i on and Judgement
1.Never ignore abnormal sound:
a. Abnormal sounds dur ing accelerat ing,decelerat ing have l i tt le

to do wi th engine working, but possibly wi th gear worn
b. Constant abnormal sounds dur ing accelerat ing or decelerat ing might be cause
by gear clearance wrongly adjusted dur ing assembl ing.
Note:Wrong assembly or adjustment of the front or rear axle wi l l aggravate gear
worn and block;
c. Sl ight sounds wi l l be not iced dur ing low-speed dr iving, and

shound not be heard dur ing high-speed dr iving.This is caused by
gear bolck.
Note!
!In case of above ment i oned i tmes , stop the veh i c l e i mmed i ate l y for
inspect ion unt i l they are solved, or wi l l cause accident
2.Check lubr icat ion i f i t"s under normal condi t ion;
3.Chcek lubr icant leakage;
a. Rear axle surface oi l stain inspect ion before through inspect ion;
b. Oi l stain on ground on the parking lot#
c. Lubricant splash inspect ion.Check i f there is gear case or oi l seal leakage.
Replace broken parts i f necessary.
10-2
10 Front/Rear Axle
Front axle exploded view
24
23
22
21
7
25
12
Item Part Name Qty Item Part Name Qty

10
1 Bol t M8 # 28 6 17 Bear ing F1512 1
2 Front axle case 1 18 Dr ive pinion gear 1
3 O- r ing 141 # 2.4 1 19 Bear ing 6007 1
4 Bear ing 16007 1 20 Oi l seal 48 # 65 # 9 1
5 Ci rcl ip 62 1 21 Coupler 1
6 Dr ive clutch cover 1 22 O- r ing 14 # 6.8 1
7 Dr ive clutch 1 23 Nut washer 1
8 Adjust washer ' 83 # 71 1(2 24 Nut M14 # 1.5 1
9 Di f ferent ial . gear assy 1 25 Screw M8 # 20 4
10 Adjust washer ' 61 # 48 2(4 26 Gear motor 1
11 Bol t M10 # 1.25 1 27 O- r ing 81.2 # 1.9 1
12 Washer 10 1 28 Rack 1
13 Washer 14 1 29 Pinion shaft 1
14 Bol t M14 # 1.25 1 30 Screw M8 # 10 1
15 Oi l seal 24 # 38 # 8 2 31 Retainer M64#1.5#7 1
16 Front axle case cover 1
10-3
CFMOTO
I nspect i on a f ter f ront ax l e d i sassemb l y

!Check i f there is damage or crack on the front di f frent ial gear casecover and
bear ing assembl ing hole is ok.Replace casecover i f necessary;
!Check i f front axle bear ing clearance ok or turning stable,and rol l way,steel
bal l ,needle and plate are ok. Replace bear ing i f necessary. (Using special tools)
! Check i f oi l seal l ips and O- r ing shape are ok. Replace i f necessary;
! Check cyl indr ial surface of front axle and oi l seal l ips, Replace broken
parts i f necessary.
!Check dr ive pinion gear and di f ferent ial gear , inspect worn surface. Replace
broken i f necessary;
!Check driven gears surface,gear(center)di fferential ,bracket di fferential wearing

si tuat ion on the di f ferent ial gear assembly. Replace parts i f necessary;
!Check inside and out side spl ine washer wear ing status in front axle. Replace
parts i f necessary;
! Check gear motor working status. Replace wi th new parts i f necessary;
Gear motor inspect ion must be carr ied out wi th special equipment or acted on the vehicle;
! Check other parts. Replace broken parts of necessary.
10-4
10 Front/Rear Axle
Front ax l e assemb l y and ad j ustment
! Front ax l e casecover asse l b l y 16
Item)31* Tightening torque 80Nm
I tem
)24*T i ghten i ng torque 62Nm
Note$Use eng i ne o i l for o i l sea l ,

bear ing and dr ive clutch assembly; 10 23 24
)24*Use screw thread fasten i ng g l ue
! Frong ax l e case assemb l y
Note :Use engine oi l for oi l seal or

bear ing assembly.
! Di f ferent ial gear assembly 10

Bo l t
M10 % 1 . 25 % 22 T i ghten i ng torque 45Nm
Note !Use engine for bear ing and di f -

ferential gear;Use proper washer to make
gear working freely;
0.1 0.2 0.3 0.4
Washer th i ckness
0.5 1.0
10-5
CFMOTO
! Front axle assembly and adjustment

1
3
As i l l ustrat ion shown+ 8
Tightening torque 7 10
I tem)1* 25Nm
28
I tem)25* 13Nm 29
Item)30* 13Nm 30
27
Bolt 25Nm
25
Bol t 25Nm
26
Use fasten i ng g l ue for i tem&30'

assembly
a Use proper washer 8 and 10 thick ness to
adjust gear side clearance between drive pinion
gear and d i f ferent i al gear
Dr i ve beve l gear c l earance measurement ; Insta l l
support tool s, t igheni ng bol ts(

M10X1 . 25X60 ) put
up d i a l i nd i cator , make sure 21 mm i s between
measur i ng po i nt and suppor t too l s . Turn suppor t
too l s counter - c l ock and read the data .
Standard+0. 10(0. 25
Washer 0.1 0.2 0.3 0.4

th i ckness
0.5 1.0
b Shi ft fork and dr ive clutch assem-

b l y shou l d be aga i nst t i ght l y to the
arrow shape i l lustrat ion when assembly
of front axle motor .
10-6
10 Front/Rear Axle
c Use spec i a l equ i pment or veh i c l e

control ci rcui t into 2WD posi t ion be-
fore gear motor assembly
d Make sure b and c is assembled prop-

er ly and using i l lustrated posi t ionging
screw to assemble gear motor and front
ax l e,
10
10-7
CFMOTO
Rear axle exploded view
Item Part Name Qty Item Part Name Qty

1 Bolt M10 #1.25 #25 2 18 O- r ing 64.5 # 3 1
2 Bol t M8 # 25 6 19 Bear ing 6305 1
3 Rear axle bearing housig 1 20 Bear ing reteiner 1
4 O- r ing 151 # 3 1 21 Dr ive gear , rear axle 1
5 Bear ing 16017 / C2 1 22 Bear ing inner race 1
6 Ad j ust washer-2. 1(2 23 Bear ing outer race 1
7 Dr iven gear , rear axle 1 24 Adjust gasket 1(3
8 Ad j ust washer-1. 1 25 Washer14.5 # 21 # 1.5 1
9 Needle bear ing 1 26 Bol t M14 # 1.25 # 12 1
10 Rear gear case 1 27 O- r ing 19 # 2.5 1
11 Oi l seal SD4 65 # 90 # 9 NS 2 28 Bol t M20 # 1.5 # 12 1
12 Nut M12#1.25 1 29 Screw M8 # 45 1
13 Washer 12.5 # 30 # 4 1 30 Washer 8.2 # 15 # 1.5 1
14 Coupler , rear axle 1 31 Nut M8 1
15 Bol t M8 # 35 4
16 Oil seal 1
17 Bevel gear bearing housing 1
10-8
10 Front/Rear Axle
Disassembly of bearing
a Disassemble needle bear ing as left

draw ing shown when necessary,
b When make needle bearing replacement,

rear bear ing housing should be heated
to 1500, then disassemble i t .
Rear ax l e i nspect i on a f ter d i sas -

semb l y
!Check i f there is crack or damage in rear gear case, see mount ing hole is ok
. Replace gear case or r ight cover i f necessary;/ 10
!Check i f bearing clearance is normal ,and turing stabi l i ty, rol lway, stel lbal l ,
neddle bearing as wel l . Replace bearing i f necessary. (Special tools are requi red)
! Check worn status of dr i ve bevel gear and r ing gear rear axl e. Rep lace i f
necessary;
! Check oi l seal l ips, o- r ing shape. Replace parts i f necessary;
!Check cylndr ical surface of rear axle and oi l seal l ips. Replace i f necessary;
! Check inner and outsider spl ine. Replace i f necessary;
! Check other parts. Replace i f necessary.
10-9
CFMOTO
Rear ax l e assemb l y and ad j ustment

! I l lustrat ion
T i ghten i ng torque
I tem)1* 40Nm
Item)2* 25Nm
I tem)12* 70Nm
I tem)15* 25Nm
I tem)20* 70Nm
I tem)31* 16Nm
Bol t 25Nm
Bol t 25Nm
Use g l ue for I tem&29' assemb l y

!Assembly and clearance adjustment of
,
dr ive gear of rear axle
a By choos ing )24* washer to adj ust
instal l ing clearance
b By choos i ng )6* washer to ad j ust
clearance
c By coat i ng co l or to check contact
surface i f i t1s ok for mat ing/
d Inspect instal l ing clearance by check-
i ng beve l gear c l earance/By us i ng
assistant measurement tool to check i ts
clearance
Standard+0 . 1(0 . 2
e Keep instal l ing point bear ing clear -

ance 0 . 1 (0 . 2 by c h o o s i n g &8 '
washer . ,
Washer Th ickness: 0 . 2 0.3
)6* 0.4
Washer Th i ckness 1 . 0 1.2 1.4 1.6

)8* 1.8
Wahser Thickness 0.4 0.5 0.6

)24*
10-10
10 Front/Rear Axle
f Adjust i tem 29 as i l lustrated, and

make sure i ts end and back clearance of
dr i ve gear i s 0 . 3(0 . 6 . T i ghten i tem
31.
10
10-11
11 ELECTRIC SYSTEM
! CHARG I NG SYSTEM!!!!!!! 11 - 1
" ELECTR I C START I NG SYSTEM!!!!!! 11 - 3
# ELECTR I C I TY - SPRAY I NG SYSTEM!!!!!!! 11 - 8
1 . ELECTR I C I TY - SPRAY I NG SYSTEM STRUCTURE!!!!! 11 - 8
2 . ELECTR I C I TY - SPRAY I NG SYSTEM D I AGRAM!!!! 11 - 9
3 . ELECTR I C I TY - SPRAY I NG SYSTEM MA I NTENANCE NOT I CE!! 11 - 9
4 . MAINTENANCE TOOL!!!!!!!!11 - 10
5 . E L ECTR I C I TY - SPRAY I NG SYSTEM COMPONENTSCOMPOS I T I ON&FUNCT I ON!11 - 12
ECU!!!!!!!!!! 11 -12
THROTTLE ASSEMBLY!!!!!! 11 - 13
INLET PRESSURE SENSOR!!!!! 11 - 14
INTAKE AIR TEMPERATUR SENSOR!!!! 11 - 15
WATER TEMPERATURE SENSOR!!!!!!! 11 - 16
OXYGEN SENSOR!!!!!!!! 11- 17
TRIGGER!!!!!!!!! 11 -18
ODOMETER SENSOR!!!!!!! 11- 19
SHIFT LEVER POSITION SENSOR!!!!!!! 11 - 20
FULE OI L PUMP ASSEMBLY!!!!!!! 11 - 21
OI L ATOMI ZER!!!!!!!!! 11- 22
IDLE AIR CONTROL !!!!! 11 - 23
IGNITION COI L!!!!!!!! 11- 24
6 . E L ECTR I C I TY - SPRAY I NG SYSTEM SE L F - D I AGNOS I S!! 11 - 25
TROUBLE LIGHT!!!!!!!!! 11- 25
DIAGNOSTIC EQUIPMENT!!!!!!!!! 11 - 26
TROUBLE CODE!!!!!!!!! 11- 27
7 . VEHICLE SCHEMATIC CIRCUIT CIRCUIT DIAGRAM!!!!! 11 - 28
11-1
CFMOTO
$ CHARGING SYSTEM
CHARG I NG C I RCU I T D I AGRAM
MAGNETO CO I L RES I STANCE

! MEASURE TRIPHASE MAGNETOR STATOR COIL RESISTANCE
! IF THE RESISTANCE VALUE OUT OF PRESCRIBED VALUE,
REPLACE THE STATOR COIL .
! I NSPECT I F THE STATOR CO I L AND STATOR CORE
INSULATION.
TURN MULTIMETER TO 1X10 !
MAGNETO CO I L RES ISTANCE : 0 . 5 - 1 . 5 !"YEL LOW -

YEL LOW#
INSULATING RESISTANCE: "! "YELLOW -
GROUND#
MAGNETOR NON - L OADED PERFORMANCE

! START THE ENGINE LET IT GOES TO 5000r / min
USE MULTIMETER MEASURE MAGNETOR STATOR COIL THREE
OUTPUT LINE VOLTAGE.
! IT THE RESULT VALUE BELLOW THE SETTING VALUE ,
CHANGE A NEW MAGNETOR.
ADJUST MULTIMETER TO ALTERNATING VOLTAGE GRADE

MAGNETOR NON- LOADED STATE COIL VOLTAGE VALUE:
5 00 0 r / m i n # 20 0V$
$ A L T ERNAT I NG CURRENT %
11-2
11 ELECTRIC SYSTEM
&' ( ) *
!USE MULTIMETER MEASURE THE RESISTANCE BETWEEN THE !AFTER ENGINE RUNNING, BATTERY FULL POWER, IF VOLT-
TERMINALS,AS BELOW FORM SHOWS, IF THERE IS ONE DATA AGE BETWEEN RED LINE, GREEN LINE EXCEED 15V OR UNDER
OUT OF THE SETTING VALUE,REPLACE WITH A NEW ONE. 12V,REPLACE WITH A NEW ONE.
ADJUST MULTIMETER TO DIODE
ATTENT I ON+
WHEN MU L T I METER PROBE UNCONNECTED , I F THE
MU L T I METER SHOWS BE L L OW 1 . 4V , THEN REP L ACE
I T ,S B A T T E R Y .
11-3
CFMOTO
$ STARTING SYSTEM
TR I GGER C I RCU I T D I AGRAM
START I NG DYNAMO
11-4
11 ELECTRIC SYSTEM
E L ECTR I C BRUSH
!CHECK IF THE ELECTRIC BRUSH PERMANENT SEAT ABNORMAL,
CRACK,UNSMOOTH
!IF THERE IS ANY BROKEN, CHANGE THE WHOLE ELECTRIC
BRUSH ASSEMBLY
COMMUTAT OR
! CHECK IF THE COMMUTATOR CHANGE COLOR , ABNORMAL
DAMAGE OR OVER WEAR.
!IF THERE IS ABNORMAL DESTROY, REPLACE WITH A NEW
AMATURE.
! IF THE COMMUTATOR SURFACE DISCOLOURATION, POLISH
WITH SEND PAPER AND WIPE UP WITH DRY CLOTH.
!IF OVER WEAR, CUT PART OF B INSULATOR WITH BLADE,
KAME THE DISTANCE BETWEEN A AND B TO d
d - 1 . 5mm
ARMATURE CO I L
USE MULTIMETER CHECKING IF IT IS INTERCOMMUNICATION
BETWEEN THE TERMINALS, BETWEEN TERMINALS AND ARMATURES
. IF THEY NOT COMMUNICATION, REPLACE WITH A NEW ARMATURE.
O I L SEAL
CHECKING IF OIL SEAL LIP DESTROY OR OIL LEAK.
IF THERE IS ANY DESTROY OR LEAKAGE, REPLACE WITH A
NEW STARTING DYNAMO.
11-5
CFMOTO
I N I T I AT I NG RE L AY
! LOAD 12V VOLTAGE TO I N I T I AT I NG%S ANODE AND

CATHODE ;MEASURING WITH MULTIMETER IF THE EXTREMES
MEET.
!IF THE START RELAY CONTACT SOUND TICKTOCK AND ALSO
CONNECT,
!WHEN COIL TWO TERMINALS NON - LOADED 12V VOLTAGE,
THE TWO CONTACTS UNCOMMUNICATE
! ABOVE TWO ITEMS BOTH OK , IT SHOWS THE RELAY IS
OKAY.
ADJUST MULTIMETER TO DIODE GRADE.
AT TENT I ON :
RELAY VOLTAGE LOADED CANNOT EXCEED 2MINS,OR ELSE,
IT WILL CAUSE THE RELAY OVERHEAT AND BURNT THE RELAY
COIL .
! USE MULT IMETER MEASURI NG STARTI NG RELAY CO I L

RESISTANCE , IF THE VALUE OUT OF THE SETTING RANGE,
REPLACE WITH A NEW ONE.
! ADJUST MULTIMETER TO 1X10 ! GRADE
START AUX I L I ARY RE L AY CO I L RES I STANCE : 3 - 5

!
START AUX I L I ARY RE L AY.

.FUL E PUMP RE L AY
!LOAD 12V VOLTAGE TO THE THE ANODE AND CATHODE OF THE

STARTING RELAY COI L .USE MULTIMETER MEASURE IF CON -
TACTS A,B IS MEET.
ADJUST MULTIMETER TO DIODE GRADE.
!IF THE STARTING RELAY SOUND TICK AND CONNECTION,
! WHEN NON - LOADED 12V VOLTAGE , THE TWO CONTACTS
UNCONNECTED
!EITHER OF THE ABOVE TWO ITEMS IS SHOWS THE RELAY IS
FINE.
! ADJUST MULTIMETER TO 1X100 ! , MEASURING THE COI L
RESISTANCE
AUX I L I ARY RE L AY CO I L RES I STANCE+
+90 - 100 !
AT TENT I ON :
AT THE BACK OF AUX I L I ARY RELAY , PARAL LEL TO
THE D I ODE D I RECT I ON , I T I S THE RE L AY CO I L ,S
ANODE .
11-6
11 ELECTRIC SYSTEM
START I NG ENG I NE NOT I CE
!JOINT LINES ACCORDING TO TRIGGER CIRCUIT.

!BEFORE STARTING, CHECK IF ALL THE PARTS ARE COR-
RECT JOINTED.ELECTRICITY SPRAYING JOINT SEE BELOW:
!CHECK IF GAS CIRCUIT NORMAL .
!CHECK IF OIL CHANNEL AT FAULT.
IF BLOCK,CLEAR BLOCK PART, SECURE OIL CHANNEL SMOOTH.
IF LEAKAGE,RELINK LEAK SECTION, SECURE THE OIL CHANNEL
NO LEAKAGE.
!USE OIL PRESSURE GAGE MEASURE OIL PRESSURE.

FU L E PU MP O UTP UT PO RT PR E S SU RE : 0 . 3 / 0 .
0 1 Ba r 0
!CHANGE ENGINE SHIFT HAND LEVER TO NEUTRAL
! USE DIAGNOSTIC EQUIPMENT CHECK IF AT FAULT , IF
YES, CLEARING OF FAULT ACCORDING TO DIAGNOSTIC TROUBLE
CODE.
!CLOSE THROTTLE,TURN OFF THE IGNITION SWITCH,PRESS
START SWITCH 3-5 SECONDS:
! START THE ENGINE, WARM UP TO IDLE SPEED STABLE,

EXAMINE IDLING SPEED:
I D L I NG SPEED : 1400 / 10 0 r pm0

0
11-7
CFMOTO
$ ELECTRONIC SPRAYING SYSTEM
ELECTRON I C SPRAY I NG SYSTEM STRUC -
TURE
ENG I NE E L ECTRON I C SPRAT I NG SYSTEM I NCL UD -

I NG THREE PARTS :
( 1 ) SE NSOR : ( 3 ) ACTUAT OR :
TRANSFORM THE ENGINE NON -ELECTRICITY PHYSICAL EXECUTE THE ECU INSTRUCTION. THE ACTUATOR IS THE
QUANTITY TO ELECTRICITY QUANTITY,AND PROVIDE ALL THE HAND OF ECU, THE MAIN ACTUATORS ARE:
INFORMATIONS TO THE ELECTRONIC CONTROL UNIT.
IT IS THE ELECTRONIC CONTROL %S SPY. INCLUDING THE !OIL FUEL PUMP ASSY(SUPPLY HIGH PRESSURE FUEL)
FOLLOWING SENSORS:
! OI L ATOMI ZER(SPRAY QUOTAL FUEL , MAKE FUEL SPRAY
! I NLET PRESSURE SENSOR ( LOADING I NFORMATION#
! THROTTLE POSITION SENSOR ( LOADING INFORMATION& EXCELLENT)
! I N LET A I R TEMPERATURE SENSOR ( A I R DENS I TY !IGNITION COIL(PROVIDE HIGH PRESSURE IGNITION EN-
LOADING RANGE INFORMATION, ACCELERATION AND DECEL -
INFORMATION) ERGY TO SPARK PLUG)
ERATION INFORMATION#
!TRIGGER (BENT AXLE PHASE POSITION INFORMATION) ! IDLE SPEED CONTROL VALVE(PROVIDE IDLE SPEED AIR
INPUT)
! WATER TEMPERATURE SENSOR (ENGINE TEMPERATURE
INFORMATION)
!ODOMETER SENSOR (OUTPUT SHAFT SPEED INFORMATION)
! GEAR SENSOR"GEAR INFORMATION)

$ I NCL UD I NG GEAR SENSOR AND REVERSE GEAR
SENSOR )
! OXYGEN SENSOR(EXCESS AIR COEFFICIENT ABOVE 1 OR
LOWER THAN 1#
!FOUR WHEEL DEAD LOCK (4WD DEAD LOCK INFORMATION)
!ASSISTOR SWITCH (RELIEF SPEED LIMIT INFORMATION)
( 2 ) E CU :
ELECTRONIC CONTROL UNIT, IT IS THE BRAIN OF THE
ENGINE MANAGEMENT SYSTEM. IT ANALYZE AND PROCESS KINDS
OF INFORMATIONS PROVIDE BY THE SENSORS , REACH A
CONCLUTION, AND THEN TRANSMIT THE CONCLUTION TO THE
ACTUATOR, SO AS TO ENSURE THE ENGINE OPERATION UNDER
OPTIMAL STATE.
11-8
11 ELECTRIC SYSTEM
ELECTRON I C SPRAY I NG SYSTEM D I AGRAM
E L E CTRON I C SPRAY I NG SYSTEM MA I NTENANCE NO -

T!I USE
CE QUAL ITY COMPONENTS FOR SERVICE , OR ELSE IT ! WHEN INSPECTING THE IGNITION SYSTEM , ONLY IF IN
CANNOT GUARANTEE THE ELECTRONIC SPRAYING SYSTEM NOR- NECESSARY,DO SPARKING TEST,AND SHOULD BE AS FAST AS
MAL OPERATION. POSSIBLE, DONOT OPEN AIR SAMPER WHEN TESTING,OR ELSE
!IN THE COURSE OF MAINTENANCE, NEVER TRY TO BREAK
PLENTY OF UNBURNED OIL WILL ENTER THE VENT-PIPE AND
DOWN THE ELECTRONIC PARTS!
!IN THE COURSE OF MAINTENANCE, THE ELECTRONIC COM- DAMAGE THE TRIPLET CATALYST.
PONENTS
! MUSTDOWN
WHEN CUT BE HANDLED CAREFULLY.
OR CONNECT UP PLUG CONNECTOR, YOU !IDLE SPEED REGULATION COMPLETELY CARRY OUT BY ELEC-
MUST TURN OFF THE IGNITION SWITCH, OR ELSE THE ELEC- TRONIC SPRAYING SYSTEM,THROTTLE VALVE GUN LIMIT SCREW
TRONIC SPRAYING COMPONENTS WILL BE DESTROYED. ALREADY SETTED WHEN IT LEAVE THE FACTORY, IT INITIAL
!WHEN TAKE DOWN THE ELECTRIC OIL FUEL PUMP, DONOT POSITION CANNOT BE CHANGED EASILY.
ENERGI ZE THE OI L PUMP , IT CAN GENERATE SPARK AND
! OI L FUEL PUMP NOT PERMITTED DO OPERATION TEST
!WHEN JOIN THE BATTERY, THE ANODE AND THE CATHODE
UNDER DRY STATE OR IN WATER.OR ELSE WILL SHORTEN IT%
CANNOT BE WRONG JOINTED . THIS SYSTEM APPLY MINUS
S LIFE.BESIDES,THE OIL FUEL PUMP TWO EXTREMES CANNOT
EARTH.
REVERSE CONNECTION.
!WHEN ENGINE RUNNING,PROHIBIT TO DISMANTLE THE BAT-
!ELECTRONIC SPRAYING SYSTEM OIL SUPPLY PRESSURE IS
HIGH("AROUND 300kPa) , THE FUEL PIPE ALL APPLY HIGH TERY CABLE.
!BEFORE CARRY OUT ELECTRONIC WELDING ON THE VEHICLE,
PRESSURE RESISTANCE PIPE,SO DONOT DISMANTLE THE PIPE
EASILY. YOU REQUIRED TO DISMANTLE THE BATTERY POSI -
WHEN THE FUEL SYSTEM NEED TO BE REPAIRE,YOU HAVE TIVE TERMINAL , NEGTIVE TERMINAL AND ECU
TO DO OIL PIPE PRESSURE RELIEF BEFORE DISMANTLE THE ! DONOT USE METHOD IMPALE LEAD CUTICULAR TO TEST
OIL PIPE.PRESSURE RELIEF METHOD IS AS FOLLOWING: COMPONENTS%S INPUT AND OUTPUT ELECTRICAL SIGNAL .
REMOVE OIL PUMP RELAY,STARTING THE ENGINE AND LET
IT IDLE RUNNING, UNTILL THE ENGINE GO OUT ITSELF. !SET UP ENVIRONMENTAL PROTECTION CONSCIOUSNESS.TREAT-
OI L PIPE%S DISMANTLE AND FUEL FI LTER%S RE - ING THE WASTE AFTER MAINTENANCE.
PLACEMENT SHOULD BE CARRY ON BY PROFESSIONAL PERSON
IN WELL -VENTILATED PLACE.
11-9
CFMOTO
SERV I CE TOOLS
TOO L NAME : D I AGNOST I C EQU I PMENT
FUNCT I ON :
READ CLEAR ELECTRONIC SPRAYING SYSTEM TROUBLE
CODE,OBSERVE DATA STREAM,COMPONENETS MOTION TESTS.
TOO L NAME : COMMUTATOR
FUNCT I ON :
INSPECT ECU EACH SUTURAL ELECTRICAL SIGNAL , INSPECT
CIRCUIT STATES ETC.
TOOL NAME : D I G I TAL MU L T I METER
FUNCT I ON :
INSPECT ELECTRONIC SPRAYING SYSTEM VOLTAGE ,
CURRENT, RESISTANCE ETC.
TOO L NAME : VACUUM METER
FUNCT I ON :
INSPECT INLET PIPE PRESSURE STATE.
11-10
11 ELECTRIC SYSTEM
TOO L NAME : E L ECTRON I C SPARK T I M I NG
FUNCT I ON :
INSPECT ENGINE ELECTRONIC SPARK TIMING
TOO L NAME : CYL I NDER PRESSURE GAUGE
FUNCT I ON :
INSPECT ENGINE CYLINDER PRESSURE STATE.
TOOL NAME : FUE L PRESSURE GAUGE
FUNCT I ON :
INSPECT FUEL SYSTEM PRESSURE STATE , JUDGE THE
FUEL SYSTEM FUEL PUMP AND FUEL PRESSURE REGULATING
VALVE WORK STATE.
TOOL NAME : O I L ATOM I Z ER WASH I NG ANAL YZ ER
FUNCT I ON :
WASHING ANS ANALYZING OIL ATOMIZER.
11-11
CFMOTO
E LECTRON I C SPRAY I NG PARTS STRUCTURE AND
FUNCT I ON
( 1 ) E CU :
ECU, IT IS THE BRAIN OF THE ENTIRE ELECTRONIC SPRAYING
SYSTEM. IT ANALYZE AND PROCESS THE INFORMATIONS PRO-
VIDED BY THE SENSOR, REACH A CONCLUTION, THEN TRANS-
MIT THE CONCLUTION TO THE ACTUATOR AS INSTRUCTION,SO
AS TO MAKE THE ENGINE OPERATION IN OPTIMAL STATE.
ECU EACH ST I TCH FUNCT I ON :
1. IGNITION COIL CONTROL SIGNAL
2.EARTHING CONTACT
3.VEHICLE SPEED SIGNAL
4.TROUBLE LAMP
5. IGNITION SWITCH POWER+
6. INTAKE AIR TEMPERATURE SENSOR SIGNAL
7.REVERSE GEAR
8.4WD DEAD LOCK SWITCH SIGNAL
9.ASSISTOR SWITCH SIGNAL
10.+5VPOWER OUTPUT
11. IGNITION SWITCH POWER+
12.TRIGGER SIGNALA
13.TRIGGER SIGNALB
14.OIL ATOMIZER
15.OXYGEN SENSOR HEATING
16.SUPPLEMENTARY RELAY
17. IDLE SPEED CONTROL VALVE(CARBON TANK CONTROL VALVE)
18.WATER TEMPERATURE SENSOR SIGNAL
19. INLET PRESSURE SENSOR SIGNAL
20.AIR DAMPER POSITION SENSOR SIGNAL
21.SENSOR
22.OIL PUMP
23.BATTERY POWER+
24.OXYGEN SENSOR
25.ENGINE SPEED OUTPUT
26.KWIRE DIAGNOSIS
L I M I T DATA :
! D I SA L L OW TO ADD L OAD ON CRUST OR COVE R

BOARD .
1 HANDLED CAREFUL LY AND AVO I D TO DROP ON THE
F L OOR .
11-12
11 ELECTRIC SYSTEM
( 2 ) THROTT L E VAL VE ASSY :

JOIN THE AIR CLEANER AND ENGINE,CONTROL THROTTLE
VALVE OFF AND ON ANGLE THROUGH THROTTLE CABLE. AIR
DAMPER POSITION SNESOR TRANSMIT ANGLE SIGNAL TO ECU.
EACH P I N FUNT I ON :
1.CONNECT 5V POWER
2.GROUNDING
3.OUTPUT VOLTAGE SIGNAL
THE R I GHT DRAW I NG I S THE W I R I NG D I AGRAM W I TH

ECU
I D L E SPEED L I M I T SCREW NOT A L L OWED T O BE

ADJUSTME NT .
! ENGINE IDLE SPEED COMPLETELY DEPEND UPON ELEC -
TRONIC SPRAYING SYSTEM ADJUSTMENT. PROHIBIT MANUAL
ADJUST THE IDLE SPEED SCREW.
11-13
CFMOTO
( 3 ) I NL ET PRESSURE SENSOR :
MONITOR INLET PIPE PRESSURE, PROVIDE ENGINE LOAD
INFORMATION TO ECU.
EACH ST I TCH FUNCT I ON :
1.CONNECT 5V POWER
2.GROUNDING
3.OUTPUT VOLTAGE SIGNAL
THE R I GHT DRAW I NG I S THE CONNECT I ON DRAW I NG

FOR SENSOR&ECU .
THE RI GHT DRAW ING I S THE PERM I T FITT ING L I M IT ,

I N TH I S WAY CAN ENSURE THERE I S NO CONDENSED
WATER I NS I DE THE SENSOR , THE CONDENSED WATER
CAN DE ST ROY SE NSO R I NNER PRE S SU RE - SE N S I NG
DEV I CE .
THE P I CTURE BE L OW I S THE REC I PROCAL D I AGRAM

DRAW I NG FOR PRESSURE AND OUTPUT VOL TAGE .
MON I TOR PRESSURE RANGE : 10 - 115kPa
11-14
11 ELECTRIC SYSTEM
( 4 ) I NTAKE A I R TEMPERATURE SENSOR :
THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT
( NTC) THERMISTANCE, IT %
" S RESISTANCE VALUE DECREASE
WHEN THE COOLANT TEMPERATURE INCREASE,BUT IT IS NOT
LINEAR RELATION.THE SENSOR HAVE 2 PINS,AND THEY CAN
BE EXCHANGED USING.
THE R I GHT DRAW I NG I S THE W I R I NG D I AGRAM FOR

SNE SOR&E CU .
THE R I GHT DRAW I NG I S FOR SENSOR TEMPERATURE -

RES I STANCE PROPERTY L I ST .
11-15
CFMOTO
( 5 ) WATER TEMPERATURE SENSOR :
THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT
( NTC) THERMISTANCE, IT %
" S RESISTANCE VALUE DECREASE
WHEN THE COOLANT TEMPERATURE INCREASE,BUT IT IS NOT
L INEAR RELATION . ONE GROUP PROVIDE TO ECU , MONITOR
ENGINE HEAT CONDITION.THE OTHER GROUP PROVIDE TO THE
METER,MONITOR WATER TEMPERATURE.
A AND C I N ONE GROUP , THEY PROV I DE WATER
TEMPERATURE TO ECU .
B ANDTHREADED PORTION IN ONE GROUP ,THEY PROVIDE

WATER TEMPERATURE TO THE METER.
THE R I GHT DRAW I NG I S THE W I R I NG DRAW I NG FOR

SENSOR , ECU AND METER .
THE R I GHT DRAW I NG I S B END AND CRUST TEM -

PE RATURE PROPE RT Y L I ST , S I GNA L PASS T O T HE
ME TER .
THE R I GHT DRAW I NG I S END A , C AND THE TEMPERA -

TURE PROPERTY L I ST , S I GNAL PASS TO THE ECU .
11-16
11 ELECTRIC SYSTEM
( 6 ) OXYGEN SENSOR :
THIS SENSOR USED IN ELECTRONIC CONTROL FUEL IN-
JECTION EQUIPMENT FEEDBACK SYSTEM,TO REALIZE CLOSED-
LOOP CONTROL ,RAISE ECU CONTROL THE AIR-FUEL DELIVERY
RATIO.
IT INSTALLED IN THE VENT-PIPE,MEASURING WASTE GAS
OXYGEN CONTENT,DEFINITE IF THE GAS AND AIR COMPLETE
BURNT, SO AS TO ENSURE UNIT TRIPLET CATALYTIC CON-
VERTER HAVE MAXIMUM CONVERSION EFFICIENCY TO EXHAUST
HC,CO AND NO X
THE P I NS FUNCT I ON :
1.CONNECT HEATING POSITIVE SOURCE(WHITE)
2. CONNECT HEATING NEGATIVE SOURCE(WHITE)
3.OUTCOMING SIGNAL NEGATIVE POLE(GRAY)
4.OUTCOMING SIGNAL POSITIVE POLE(BLACK)

SENSOR AND ECU
T HE BE L OW SHEE T I S THE SENSOR PE RFORMANCE

CHARACTER I ST I C VA L UE
11-17
CFMOTO
( 7 ) TR I GGER :
PROVIDE ENGINE ROTATE SPEED INFORMATION TO ECU,
ECU DETERMINE IGNITION ANGLE,OIL SPRAY ANGLE ACCORD-
ING TO THIS INFORMATION.

TR I GGER AND ECU .
TEST I NG THE THR I GGER RES I STANCE VAL UE .
! ADJUST MULTIMETER TO 1X100 ! ;

T R I G GE R W I ND I NG RE S I ST A NC E : 1 0 0 - 1 30 ! $ 2 0
2 %
! IF THE TRIGGER RESISTANCE DONOT IN ABOVE RANGE,
REPLACE WITH A NEW ONE.
MEASUR I NG TR I GGER PEAK VOL TAGE VAL UE

! CONNECT MULTIMETER AND PEAK VOLTAGE ADAPTER AC-
CORDING TO THE RIGHT DRAWING:
+PROBE++ GREEN LEAD W I RE
- PROBE+
+ BL UE LEAD W I RE
ATTENT I ON :
WHEN USE PEAK VOLTAGE ADAPTER,REFERS TO OPERATION
MANUAL ,
!ADJUST MULTIMETER TO ALTERNATE V
!ADJUST THE GEAR TO NEUTRAL ,ADJUST IGNITION SWITCH
T O 'O N (;
!PRESS ON STARTING BUTTON AND LET THE ENGINE RUN-
NING FOR FEW SECONDS,THEN START TO MEASURE:
THRI IGER COIL PEAK VOLTAGE;
! IF THE TRIGGER PEAK VOTAGE DONOT IN THE ABOVE
! REPEATED TIMES MEASURE, GET THE HIGHEST TRIGGER
COIL PEAK VOLTAGE VALUE. ;
TR I GGER CO I L PEAK VOL TAGE : - 2V $300 rpm%
%
11-18
11 ELECTRIC SYSTEM
( 8 ) ODOMETER SENSOR :
PROVIDE ENGINE OUTPUT SHAFT SPEED TO ECU , ECU
JUDGE VEHICLE SPEED ACCORDING TO THIS INFORMATION. IT
IS A KIND OF HALL SWITCH COMPONENTS, IT OUTPUT SQUARE
WAVE VIA INDUCTION FIELD.
P I NS FUNT I ON :
1.GROUNDING
2.OUTPUT SQUARE WAVE VOLTAGE SIGNAL")INPUT
, POWER
VOLTAGE 80%#
3.POWER+DC12V
THE R I GH I S THE W I R I NG DRAW I NG OF SENSOR AND

ECU .
ODOMETER SENSOR TEST I NG
!GROUNDING FOOT 1,CONNECT FOOT 3+12V;
!FIXED ONE GEAR TO ODOMETER ACCORDING TO THE RIGHT

DIAGRAM D ISTANCE("2 . 5mm ) ;
!ADJUST MULTIMETER TODCV;
!ROTATE THE GEAR SLOWLY,MEASURE THE VOLTAGE VALUE

BETWEEN FOOT 2 AND FOOT 3 TO SEE IF IT IS VARY FROM
0V&1 2V ;
! IF NO CHANGES , THEN THE SENSOR HAS BROKEN, YOU
REQUIRED TO REPLACE WITH A NEW ONE.
11-19
CFMOTO
( 9 ) GEAR SENSOR C L USTER :
PROV I DE GEAR INFORMAT I ON TO THE METER , SO AS TO
AT THE SAME TIME,COORDINATE WITH CABLE AS STARTING
PROTECTION.
FUNCT I ONS OF THE FOOTS :
YEL LOW / BLUE - L"UNDERDR I VE#
ORANGE / BLUE - H"HI GH POSI TION#
YELLOW / BLACK - P"PARK POSIT ION#
WHITE / YELLOW - N"NEUTRAL POSITION#
!WHEN EACH OF THE FOUR GEAR IN A CERTAIN POSITION,

GEAR CORRESPONDING FOOT CONDUCT TO THE ENGINE COVER,
OR ELSE IT NON-CONDUCTION WITH THE ENGINE COVER.
( 10 ) REVERSE GEAR ASSEMBL E :

PROVIDE GEAR REVERSE INFORMATION TO ECU AND METER,
THE ECU RESTRICT VEHICLE SPEED ACCORDING TO THIS
INFORMATION.
! NORMAL L Y , A&B PO I NT CONDUCT I ON , DONOT CON -
DUCT W I TH THE CASE ;
! NORMALLY, C LENGTH IS * 3. 5mm+IF C LENGTH

, 3mm+OR IF B SLIDE BLOCK,YOU HAVE TO CHANGE IT
TO A NEW ONE.
!WHEN ENGINE BACK GEAR, A POINT NON-CONDUCTION WITH

THE ENGINE CASE, OR ELSE IT IS CONDUCT WITH THE CASE.
11-20
11 ELECTRIC SYSTEM
( 11 ) O I L FUE L PUMP ASSY :

THE OIL FUEL PUMP ASSY COMBINED OF OIL FUEL PUMP,
PLASTIC BRACKET, PREFILTRATION ,PRESSURE REGULATING
VALVE. IT DELIVER THE FUEL TO THE ENGINE WITH A CER-
TAIN OIL PRESSURE AND FLOW.
FUNCT I ONS OF THE FOOT :
1.BLUE(GROUNDING)
2.RED(CONNECT THE OIL PUMP RELAY OUTPUT ENDING)
PERFORMANCE PARAMETER :
PRESSURE REGULATING VALVE OPENING PRESSURE : 0 . 3 /
0FLOW
. 01:MPa
35L / h
!THIS OIL PUMP ASSY ALL USED INSIDE THE OIL BOX:
!DONOT RUNNING THE OIL PUMP ASSY IN DRY;
!HANDLE GENTLY, DONOT DROP THE OIL PUMP ASSY ONTO

THE GROUND.
THE R I GHT D I AGRAM I S THE W I R I NG D I AGRAM OF

THE O I L PUMP ASSY , O I L PUMP RE LAY , ECU .
!BATTERY SUPPLY POWER VIA OIL PUMP RELAY,ELECTRIC

OIL FUEL PUMP CIRCUIT CLOSE ONLY WHEN STARTING AND
THE ENGINE RUNNING.
MEASUR I NG THE O I L PRESSURE :
!CONNECT OIL PRESSURE GATE TO THE OIL FUEL PUMP FUEL

DISCHARGE PORT , LOCK WITH CLAMP, ENSURE THERE IS NO
LEAKAGE IN CONNECT AREA:
!LINK THE CIRCUIT ACCORDING TO THE ABOVE DIAGRAM;
!TURN OFF THE IGNITION SWITCH,FLAMEOUT SWITCH;
!AT THIS MOMENT,THE OIL FUEL PUMP WILL WORKING FOR
5 SECONDS,WHEN IT STOP,THE OIL PRESSURE SHALL REACH
THE AUTHORIZED PRESSURE,OR ELSE,REPLACE THE ENTIRE
OIL FUEL PUMP ASSY;
!WHEN STOPED OPERATION,PRESSURE HOLDING AT LEAST 0.
2MPa
O 5 MINUTES,
I L FUE L P I PE IF NOT , REPLACE
PRESSURE THE
RE L I EF : OI L FUEL PUMP
ASSY.
BECAUSE OF THE HIGH PRESSURE OF OIL SUPPLY,THE FUEL
PIPES ARE ALL HIGH PRESSURE RESISTANCE PIPE.EVEN IF
THE ENGINE DOES NOT WORK,THERE IS STILL HIGH PRESSURE
ON THE OIL CHANNEL ,THEREFOR,DONOT DISMANTLE THE OIL
PIPE DURING SERVICING EASILY.
BEFORE SERVICE THE FUEL SYSTEM,YOU REQUIRED TO DO
OIL PRESSURE RELIEF,THE METHOD IS AS BELOW:
REMOVE O I L PUMP RE L AY , START THE ENG I NE AND
RUN ENG I NE ON I DL E UNT I L L THE ENG I NE GO OUT
I T SE L F .
11-21
CFMOTO
( 12 ) O I L ATOM I Z ER :
O I L ATOM I ZER ONE END I NSTAL LED I N SEAT , THE
OTHER END CONNECT W I TH THE O I L P I PE V I A O I L
ATOM I ZER CAP . ACCORDI NG TO THE ECU I NSTRUCT ION ,
IT SPRAY OI L IN FIXED TIME.SO AS TO SUPPLY OIL TO
THE ENGINE AND ATOMIZING.
THIS OIL ATOMIZER APPLY QUADRIPUNTAL ,DONOT TURN
AFTER FIXED THE CLAMP.
FUNCT I ON OF P I NS :
! ONE SIDE OF THE PLUG MARK+-CONNECT OI L PUMP

RELAY OUTPUT END,
WITHOUT MARK SIDE CONNECT ECU PIN 14.
O I L A T O M I Z E R R E S I ST A N C E : 1 2 / 1 ! $2 0 2 %
THE R I GHT I S THE W I R I NG D I AGRAM FOR O I L ATOM -

I Z ER AND ECU .
O I L ATOM I Z ER I NSTA L L AT I ON :
!INSTALL THE OIL ATOMIZER WITH MANUL ,FORBID KNOCK

WITH HAMMER OR SUCH KIND OF THINGS.
!WHEN DISASSEMBLE AND ASSEMBLING THE OIL ATOMIZER,
YOU MUST REPLACE THE O RING.
!WHEN DISMANTLE OIL ATOMIZER, IF NECESSARY,DO PRES-
SURE RELIEF IN ADVANCE.
!DO LEAK TIGHTNESS AFTER INSTALLED THE OIL ATOMIZER
TO ENSURE NO LEAKAGE;
11-22
11 ELECTRIC SYSTEM
( 13 ) I DLE SPEED CONTROL VALVE ( CARBON TANK CON -

TROL VAL VE ) :
CONTROL PASS -BY AIR FLOW . ECU CONTROL THE IDLE
SPEED VALVE ACCORDING TO THE INFORMATION OF ENGINE
LOAD ,THE ELECTRICAL PULSE DURATION AND FREQUENCY :
(DUTY RATIO) .THE IDLE SPEED VALVE HAS DIFFERENT AIR
FLOW UNDER DIFFERENT ORESSURE DIFFERENCE,SO IT MUST
BE CONNECTED ACCORDING TO PRESCRIPTIVE METHOD , OR
ELSE WILL CAUSE INCORRECT IDLE SPEED, WHEN WITHOUT
ELECTRICAL PULSE, IDLE SPEED VALVE CLOSE.
1.CONNECT PIN 17;
2.CONNECT OIL PUMPRELAY OUTLET END;
T H E R I GH T I S T HE W I R I N G D I AG RA M FO R I D L E
SPEED VAL VE AND ECU .
!WHEN FIXING THE IDLE SPEED CONTROL VALVE, IT CANNOT

BE I NSTAL LED L I KE THE R I GHT D I AGRAM ( CONNECTOR
VERT I CA L L Y DOWNWARD ) TO AVO I D DE ST ROY T HE
E L ECTRON I C COMPONENT .
! TO AVOID SOLID -BORNE SOUND TRANSMISSION,YOU CAN
INSTALL THE IDLE AIR CONTROL VALVE SUSPENDED IN THE
TUBE,OR USE RUBBER BOOT TO FIX IT TO THE ENGINE OR THE
FRAME.
I DL E SPEED CONTROL VAL VE PARAMETER L I ST :
11-23
CFMOTO
( 14 ) I GN I T I ON SW I TCH CO I L :
IGNITION SWITCH COIL AHANGE THE PRIMARY WINDING
LOW VOLTAGE INTO SECONDARY WINDING HIGH VOLTAGE ,
THROUGH SPARK PLUG DISCHARGE TO CREAT SPARK,FIRING
THE FUEL AND GAS MIXTURE.
1.GROUNDING;
2 . CONNECT POWER+.
3.CONNECT ECU 1 POINT;
THE R I GHT I S THE CONNECT I ON C I RCU I T D I AGRAM

OF I GN I T I ON CO I L AND ECU .
MEASUR I NG SECONDARY I GN I T I ON VOL TAGE :

! CONNECT THE ENGINE ACCORDING TO THE ELECTRONIC-
SPRAY ELEMENTARY DIAGRAM;
! CONNECT THE PEAK VOLTAGE GUAGE ACCORDING TO THE
RIGHT DIAGRAM;
!START THE ENGINE;
!AFTER STARTS,THE SECONDARY IGNITION VOLTAGE SHOULD
BE # 15000V ;
I GN I T I ON CO I L PARAMETER L I ST :
11-24
11 ELECTRIC SYSTEM
ELECTRONIC SPRAY SYSTEM FAULT SELF -

D IECU
AGNOS IS
CONTINUOUSLY MONITOR THE SENSOR,ACTUATOR,RELEVENT CIRCUIT,TROUBLE LAMP,BATTERY VOLTAGE ETC,EVEN THE
ECU ITSELF.ALSO THE SENSOR OUTPUT,ACTUATOR DRIVING SIGNAL , INTERNAL SIGNAL(SUCH AS CLOSED- LOOP CONTROL &
COOLANT TEMPERATURE, IDLING SPEED CONTROL ,BATTERY VOLTAGE CONTROL ETC) ,DO THE RELIABILITY MEASUREMENT.ONCE
DISCOVER SOME WHERE BREAK DOWN,OR SOME SIGNAL VALVE UNTRUSTED,THE ECU WILL IMMEDIATELY SET UP FAULT RECORD
INFORMATION IN RAM TROUBLE MEMORY.THE FAULT INFORMATION STORE AS TROUBLE CODE,AND DISPLAY THE FAULT IN IT
%
S EMERGENCE SEQUENCE.
THE FAULT CANBE DIVIDED INTO TWO TYPES 'STEADY FAULT( AND 'RANDOM FAI LURE(ACCORDING TO IT%S
EMERGENCE FREQUENCY(SUCH AS CAUSED BY BRIEF WIRE TURNOFF OR BAD CONNECTION OF THE CONNECTOR. )
THROUGH DIAGNOSTIC EQUIPMENT AND THE TROUBLE LAMP YOU CAN FIND THE TROUBLE PART QUICKLY.
ELECTRON I C SPRAY SYSTEM FAULT D I AGNOS I S MA I NLY APPLY TROUBLE LAMP AND D I AGNOST I C EQU I PMENT .
$1 %T R O U B L E L A M P $ M I L L A M P %+
TROUBLE LAMP FIXED IN THE METER DESPLAY BOARD ,
ADOPTING LED,BY MEANS OF DIFFERENT FREQUENCY STAND
FOR THE TROUBLE CODE.
THE R I GHT I S THE W I R I NG D I AGRAM FOR TROUBL E

L A MP A ND E CU . C UR RE NT F L O W I N T O E CU 4 P I N
SHOU L D BE L ESS THAN 0 . 5A3 3
TROUBL E L AMP BL I NK PR I NC I PL E :
a+
+I N B L I NK CODE MODE , AND A L SO THE TROUB L E
MEMOY TROUBL E FREE :
IF ECU MONITOR THAT THE MI L LAMP IN BL INK CODE
MODE , THE TROUBLE L IGHT WI LL FL ICKER TO SHOW THE
TROUBLE CORRESPONDING Pcode CODE. SINCE IGNITE ECU,
MI L WI LL CONTINUE BL INK 4 SECONDS , THEN HAVE A 1
SECOND SPAN , MI L BL INK WITH 2 HZ FREQUENCY TO SAY
TROUBLE FREE .UNTILL START THE ENGINE, FIND OUT THE
ROTATE
b+ SPEED.BL I NK MODE , AND THE TROUBL E MEMORY
+I N CODE
SHOWS AT FAUL T .
IF ECU MONITOR THAT THE MI L LAMP IN CODE BL INK
MODE ,THE TROUBLE LAMP WILL BLINK TO SHOW THAT THE
TROUBLE MEMORY CORRESPONDING Pcode CODE.SINCE IGNITE
ECU INITIAL I ZATION , MI L WI LL L IGHT 4 SECONDS , THEN
HAVE A 1 SECOND SPAN,MIL SHOW THE MEMORY TROUBLE CODE
THROUGH BLINK CODE Pcode. IF ALL THE TROUBLES ENTERED
THE MEMORY SHOWED BY MIL LAMP VIA BLINK CODE MODE,MIL
EXTINGUISH,UNTILL EXIT BLINK CODE MODE.
BLINK CODE MODE REQUIRES K LINE GROUNDING.
C:READ TROUBLE INFORMATION THROUGH THE BLINK CODE
THRN ON THE IGNITION SWITCH,K LINE GROUND AFTER 2.
5 SECONDS, IF ECU TROUBLE MEMORY HAVE TROUBLE CODE,AT
THE MOMENT , ENGINE MI L TROUBLE LAMP OUTPUT P- CODE
VALUE . SUCH AS : P0203 BL INK MODE IS : BL INK 10 TIMES
CONTINUOUSLY- INTERMISSION-BLINK 3 TIMES CONTINUED.
11-25
CFMOTO
$2%%D I AGNOST I C EQU I PMENT : I T HAVE THREE P I NS ,
POWER , GROUNDW I RE AND DATA K L I NE , CONNECT W I TH
THE CORRESPOND I NG P I NS I N ECU .
THE R I GHT I S THE D I AGNOST I C EQU I PMENT OPERA -
T I ON FU NCT I ON S I ND I CA T O R D I AG RA M . S PE C I F I C
OPERAT I ON AND I T, ,S FUNCT I ONS P L EASE REFERS
P
TOI NS
THEFUNCT I ONS :I C EQU I PMENT OPERAT I NG MANUAL .
D I AGNOST
1.ECU 26PIN
2.GROUNDWIRE
3.+12V POWER
KEY - PRESS FUNCT I ONS :
LEFT - HAND BUTTON : UPWARD TURN OVER ;
UPPER KEY : MENU SELECT I ON , UPWARD ROL L I NG TEXT :
R I GHT - HAND BUTTON : BACKWARD TURN OVER ;
DOWN KEY : MENU SELECT I ON , DOWNWARD ROLL I NG TEXT ;
CONF I RMAT I ON KEY : ENTER OR START CURRENT

OPERATION;
SELECT CURRENT MENU SELECTION;
ESC ESCAPE : CANCE L OR STOP CURRENT OPERAT I ON ;

RETURN TO PREVIOUS PAGE;
D I AGNOST I C EQU I PMENT FUNCT I ON :
$1 %E D I T I O N I N F O R M A T I O N D E S P L A Y :
ENGINE INFORMATION,ECU HARDWARE,ECU SOFTWARE.
$2 % T R O U B L E D I S P L A Y
INLET PRESSURE SENSOR, INTAKE AIR TEMPERATURE SENSOR,ENGINE TEMPERATURE SENSOR,THROTTLE POSITION SENSOR,
OXYGEN SENSOR ,OXYGEN SENSOR HEATING CIRCUIT ,AIR -FUEL DEL IVERY RATIO, OI L ATOMIZER ,OIL FUEL PUMP RELAY ,
REVOLUTION SPEED SENSOR ,VEHICLE SPEED SIGNAL , IDL ING SPEED , IDLE AIR CONTROL , SYSTEM VOLTAGE, ECU, TROUBLE
LAMP.
$3 %E N G I N E P A R A M E T E R D I S P L A Y
BATTERY VOLTAGE,ENGINE SPEED, IDLE SPEED,VEHICLE SPEED,ENGINE TEMPERATURE,ENGINE TEMPERATURE SENSOR SIG-
NAL VOLTAGE , INLET TEMPERATURE, INLET AIR TEMPERATURE SENSOR, INLET PRESSURE ,AIR INPUT, MAGNETIC STEPPING
MOTOR TARGET LOCATION,THROTTLE POSITION SENSOR SIGNAL PRESSURE,THROTTLE OPENING,RELATIVE THROTTLE POSITION,
CARBON TANK CONTROL VALVE DUTY RATIO, CHARGING TIME,OIL SPOUT PILSE WIDTH, IGNITION ADVANCE ANGLE,OXYGEN
SENSOR SHORT-TERM CORRECTION,OXYGEN SENSOR VOLTAGE,OXYGEN SENSOR LONG TERM CORRECTION,ENGINE RELATIVE LOAD,
CARBON TANK CONTROL RELATIVE FUEL DEL IVERY , CARBON PURIFYING, CARBON LOAD , IDL ING ACTUATOR TEV OPENING ,
AMBIENT PRESSURE,ELEVATION CORRECTION FACTOR,OIL SPOUT PHASE,RUNTIME.
$4 %E L E CTRO N I C SPRAY SY STE M ST ATUS D I SP L AY
IGNITION TERMINAL OPEN UP,MAIN RELAY OPERATION,OIL FUEL PUMP OPERATION,REACH IDLING ROTATE SPEED,REACH
ENGINE WORK TEMPERATURE,VEHICLE RUNNING, IDLE SPEED WORKING CONDITION,FULL LOAD WORKING CONDITION,ACTIVE
DECELERATE OIL REDUCTION,ACTIVATE ACCELERATION CROWDING,OIL SPOUT CLOSED- LOOP CONTROL ACTIVATION,DECELERA-
TION OIL -BREAK, lambda CONTROL ACTIVATE,MIXTURE GAS SELF- LEARNING ACTIVATION,TROUBLE LAMP STATE,MIL BLINK.
$5 %A C T U A T O R E X P E R I M E N T F U N C T I O N
TROUBLE LAMP,OIL FUEL PUMP,MAGNETIC STEPPING MOTOR,CARBON TANK CONTROL VALVE, IGNITION,OIL SPOUT.
11-26
11 ELECTRIC SYSTEM
TROUBLE CODE L I ST :
TROUBLE
REF INSTRUCTION
CODE
OXYGEN SENSOR HEATING CONTROL CIRCUITOPEN

1 P0030 CIRCUIT
OXYGEN SENSOR HEATING CONTROL CIRCUITSHORT TO
2 P0031 EARTH
OXYGEN SENSOR HEATING CONTROL CIRCUITSHORT
3 P0032 CIRCUIT TO POWER
OXYGEN SENSOR HEATING INTERNAL RESISTANCE
4 P0053 UNREASONABLE
5 P0105 INLET PRESSURE SENSOR SIGNAL NO CHANGE"ICE UP#
6 P0106 INLET PRESSURE SENSOR UNREASONABLE
7 P0107 INLET PRESSURE SENSOR SHORT CIRCUIT TO GROUND
8 P0108 INLET PRESSURE SENSOR SHORT CIRCUIT TO POWER
INLET AIR TEMPERATURE SENSOR SIGNAL VOLTAGE TOO
9 P0112 LOW
INLET AIR TEMPERATURE SENSOR SIGNAL VOLTAGE TOO
10 P0113 HIGH
ENIGNE COOLANT TEMPERATURE SENSOR
11 P0116 UNREASONABLE
ENIGNE COOLANT TEMPERATURE SENSOR CIRCUIT
12 P0117 VOLTAGE TOO LOW
ENIGNE COOLANT TEMPERATURE SENSOR CIRCUIT
13 P0118 VOLTAGE TOO HIGH
THROTTLE POSITION SENSOR CIRCUIT VOLTAGE UNDER
14 P0122 LIMINAL VALUE
THROTTLE POSITION SENSOR CIRCUIT VOLTAGE EXCEED
15 P0123 LIMINAL VALUE
16 P0130 OXYGEN SENSOR SIGNAL UNREASONABLE
17 P0131 OXYGEN SENSOR SIGNAL CIRCUIT VOLTAGETOO LOW
18 P0132 OXYGEN SENSOR SIGNAL CIRCUIT VOLTAGETOO HIGH
19 P0134 OXYGEN SENSOR CIRCUIT SIGNAL TROUBLE
1 CYLINDER OIL ATOMIZER CONTROL CIRCUIT OPEN
20 P0201 CIRCUIT
1 CYLINDER OIL ATOMIZER CONTROL CIRCUIT SHORT
21 P0261 CIRCUIT TO EARTH
1 CYLINDER OIL ATOMIZER CONTROL CIRCUIT SHORT
22 P0262 CIRCUIT TO POWER
23 P0321 TRANSIENT SPEED SIGNAL REFERENCE POINT TROUBLE
NO TRIGGER(VEHICLE SPEED) PULSE SIGNAL (OPEN
24 P0322 CIRCUIT OR SHORT CIRCUIT)
25 P0501 VEHICLE SPEED SENSOR SIGNAL UNREASONABLE
11-27
CFMOTO
COMP L ETE SCHEMAT I C C I RCU I T D I AGRAM
11-28
13 Lights,Instrument,Switches
Overhau l Info!!!! !!!!!!10 -1 Horn!!!!!!!!!!!!10- 8
Troub leshoot i ng!!!!!!!!! 10 - 2 Dashboard!!!!!!!!!!!!0- 9
Bul b rep l acement!!!!!!!!!10 - 3 Fuel Sensor!!!!!!!!!!10 -
Head l i ght!!!!!!!10 - 5 WaterTemperature sensor!!!!!!10- 12
Ign i t i on Swi tch!!!!!!!!!!10 - 6
Hand l ebar Sw i tch!!!!!!!!! 10 - 7
Brake L i ght Sw i tch . . . . . . . . . . . . . . . 10 - 8
O ve r hau l I n f o r ma t i o n
O pe r a t i o n i n s t r uc t i on s
Warning
"Head l i ght bul b wi l l be very hot when i t is turned on. Do not touch i t after i t i s just
turned of f . Operat i on shou l d be done when the bu l b i s coo l ed down .
"Inspect ion of water temperature alarm may use f i re source and l iquid of high temperature.
Do not put f l ammab l e matters nearby and take care not to get burnt .
"The temperature of head l i ght i s qu i te h i gh when turned on . Rep l aci ng w i th bare hand
or sta i ned g l ove w i l l cause o i l sta i ns on the g l ass face wh i ch may form hot spot and
cause deformat i on of g l ass face and damage to bu l b .
"Pay attent i on to the fo l l ow i ng when rep l ac i ng the bu l b .

#$ Do not rep lace the bu lb when i t is turned on. Keep igni t i on sw i tch i n the OFF pos i t ion,
and rep l ace af ter the bu l b i s coo l ed down .
$ Rep l ace the bu l b w i th hands i n c l ean g l oves to avo i d o i l sta i ns on the g l ass sur face.
$ Cl ean the gl ass w i th a clean rag d ipped in alcoho l or isoamyl acetate i n case of any o i l
stai ns on the g l ass sur face.
"I f the Inspect i on has to be done w i th battery , check i f the battery i s normal .
"I nspect i on of sw i tch cont i nu i ty can be done w i thout remov i ng the sw i tches f rom the
veh i c l e .
"Af ter the i nspect i ng and overhau l i ng of each part , cab l es and w i res shou l d be routed
proper l y (chapter 1)
"Refer to Chapter 2 for remova l and i nsta l l at i on of tai l l i ght and rear turn i ng l i ghts
13
Check standard
It em St an d ard
F u se M ai n 2 0A
S u b- fu se 1 0 A !2 1 5 A!2
Li g h t& B u lb H ead l ig h t" H i# Lo $ 1 2V-3 5 /3 5 W
Br ake l ig h t # Tai l l ig h t 1 2V-2 1 /5 W
Tu rn i n g li g h t 1 2 V-1 0 W! 4
D ash b o ar d i nd i ca to r % 5 LE D
I n di cat o rs LC D
13-1
CFMOTO
TROUBLESHOOTING
Head Light Cannot Turn On
"Broken f use
"Open c i rcu i t w i th ma i n cab l e
"Burnt Bu l b
"Fau l ty Sw i tch
13-2
Rep l ac i ng Bu l b
Head l i ght Bu l b
Caut i ons
Head l i ght bu l b w i l l be very hot when i t i s turned on .
Do not touch i t af ter i t i s j ust turned of f .
Operat i on shou l d be done when the bu l b i s coo l ed
down .
Remove head l i ght

( % 13 - 5&
D i sconnect head l i ght .
Remove dust - proof cap , head l i ght connector , ci rc l i p

and rep l ace w i th a new bu l b .
Warning:
Wear c l ean g l oves when rep l aci ng bu l b .
O i l sta i ns on the g l ass sur face may cause
break of bu l b . C l ean the stai ned sur face w i th
al coho l or i soamy l acetate .
Make sure that the three p i ns of the bu l b shou l d
be i n l i ne w i th the three pos i t i on i ng ho l es i n the
socket when rep l aci ng the bu l b .
Bu l b spec i f i cat i on :#12V - 35 / 35W
Reverse the removal procedure for instal lat ion

After replacing the bulb, adjust headl ight beam 13
'% 3 - 1 4 &
Inspect i on of Head l i ght

Turn the i gn i t i on sw i tch to ON pos i t i on ,
turn l i ght sw i tch to the i l l um i nat i ng
pos i t i on and check i f the head l i ght i s on .
- ON : Norma l
- St i l l of f : short ci rcu i t of mai n cab l e or
broken ma i n cab l e
13-3
CFMOTO
Brake Light/Tail Light Bulb
Remove 2 tapp i ng screws

Remove tai l l i ght cover .
Turn brake l i ght / ta i l l i ght bu l b counter
cl ockw i se and remove i t .
Rep l ace brake l i ght / tai l l i ght bu l b
Bu l b Spec i f i cat i on#12V - 21 / 5W
Reverse the removal procedure for i nsta l l at i on
Front Turning Indicator Bulbs
Remove head l i ght (% 13 - 5&

Remove cover of f ront turn i ng l i ght
Rep l ace f ront turn i ng l i ght bu l bs
Bu l b Spec i f i cat i on#12V - 10W
Rear Turning Indicator Bulbs
Remove screw1(
Remove rear turn i ng i nd i cator cover .
Rep l ace rear turn i ng i nd i cator bu l bs .
Bu l b Spec i f i cat i on#12V - 10W)

13-4
No t e
Ma i n cab l e , w i r i ng and tube shou l d
be routed proper l y ( ! chapter 1 )
Dashboa r d L i gh t Bu l b
Remove dashboa rd'% 13 - 9&

Remove dashboard i nd i cator socket)
Dashboard i nd i cator#LCD
Note : I f dashboard has someth i ng wrong ,

i t*s recommended to rep l ace who l e dashboard .
Head l i ght
Remove nuts as p i cture shown
D i sconnect head l i ght connector
D i sassemb l e head l i ght comp .
Reverse the remova l procedure for i nsta l l a-

t i on
No te :
Be careful not to damage main cable when
assembling. 13
Af ter rep l ac i ng , ad j ust the head l i ght beam .
"' 3 - 1 4 $(
Note
Main cables and wires should be routed
properly.(
13-5
CFMOTO
Ignition Switch
Inspection
Remove f ront & rear top cover

'% 2 - 4 &
D i sconnect 4P connector of i gn i t i on sw i tch
13-6
Check accord i ng to the fo l l ow i ng tab l e i f
the connector term i nal s are i n cont i nu i ty .
(
) - ) cont i nu i ty
Disassemble:
Remove front cover "' 2 - 4$
Disconnect 4P connector of ignition switch
Loosen bo l t and remove i gn i t i on sw i tch
Hand l ebar sw i tch

Remove f ront cover "' 2-4$
D i sconnect l ef t and r i ght hand l ebar
sw i tch connector .
Check accord i ng to the fo l l ow i ng tab l e i f
the connector term i nal s are i n cont i nu i ty .
*) cont i nu i ty
L i ght i ng sw i tch
13
!" # $ %& ' # $
13-7
CFMOTO
Turn sw i tch
Horn sw i tch Acce l erat i on sw i tch
2WD / 4WD sw i tch
I f someth i ng wrong , p l ease rep l ace

hand l ebar sw i tch)
'% 6 - 12&
Park i ng sw i tch
B rake l i gh t sw i tch
D i sconnect brake l i ght sw i tch connector and
check term i nators for cont i nu i ty .
Ho l d the brake l ever . . Cont i nu i ty
Re l ease the brake l ever . No cont i nu i ty
No continuity: Replace brake light switch
Horn
Inspection:
Remove f ront vent gr i l l e"' 2-15$
D i sconnect horn .
Connect w i th a fu l l y charged 12V battery
and check i f the horn sounds .
Fau l ty Horn : Rep l ace
13-8
D i sassemb l e
D i sconnect horn connector
Remove bo l t
Remove horn

i nsta l l at i on
Dashboa r d
Run the veh i c l e at l ow speed and check i f
the speed i nd i cator moves
Fau l ty speedometer : Rep l ace
Remova l and I ns t a l l at i on
Remove f ront top cover'% 2 - 4&
Remove f ront cover o f dashboard'% 2 - 4&
D i sconnect dashboard w i re connector
Remove f i xi ng nut and remove dashboard i n

the d i rect i on as i l l ustrated on the r i ght

Note :
Ma i n cab l es and w i res shal l be routed
proper l y . 13
13-9
CFMOTO
Fue l Senso r
Remove :
Fue l tank top cover w i th key'% 2 - 9&+
4 f i x i ng bo l ts
Fue l sensor
D i sconnect 2P connector
Inspection
Remove fuel sensor (refer to above steps)
Connect 2P connector
Turn ignition switch to ON
Shake fuel sensor float with hand, locate the float

position and check if it conforms to the fuel gauge
reading.
Non-conformity: -check ma i n cab l e for dam -

age or short c i rcu i t
- Check fue l sensorandfuel gauge
Remove fuel sensor 2P connector.
Connect multimeter between 3P connector

terminals.
Shake float with hand and measure the resistance

of float at different positions.
Connection Terminal:
Upper: Blue/White-Green:
+4 - 1 0 ,"2 0 -$
Lower: Blue /White-Green:

9 0 - 1 0 0 ,"2 0 -$
Faulty fuel sensor: Replace
13-10
I nsta l l at i on
Put fue l sensor i nto i nsta l l at i on ho l e of fue l tank.
Fuel sensor shou l d be f i tted proper l y .

No fue l l eakage i s al l owed .
Connect 2P connector
I nspec t i on o f Fue l Gauge
Sw i tch on power supp l y and check i f fuel

l evel gauge funct i ons normal l y .
I f fue l gauge works norma l l y ,

i nstal l at i on of p l ast i c parts and seat .
13
13-11
CFMOTO
Wa t er Tempe ra t u r e Senso r
Warning:
Be careful not to get scalded and do not place
flammables nearby.
Warning:
"Coo l ant must reach the sw i tch thread ,

and the depth f rom vessel bottom to sensor
top shou l d be over 40mm .
"Keep l i qu i d temperature for three m i nutes
before measur i ng , and do not rai se temperature
sharp l y .
"The thermometer shou l d not contact the
vessel bottom .
D i sassemb l y :
Remove r i ght s i de pane l '% 2 - 8&

D i sconnect and remove temp . sensor
Put the sensor i nto a vesse l w i th coo l ant , s l ow l y

heat up the l i qu i d and measure the sensor
res i stance .
Temperature Res i stance
50, 154 -. 16 -
80, 52 -. 4 -
100, 27 -. 3 -
120, 16 -. 4 -
Out of range: Rep l ace
Insta l l transducer
Connect water temperature transducer connector .
Fi l l coo l ant and d i scharge ai r .
Reverse the removal procedure for i nsta l l at i on of
p l ast i c parts and seat .
13-12
13 Troubleshooting
1 Engine troubleshooting-------------------------13-2
2 Diagnosis troubles according to EFI system Trouble Code
-----------------------------------------------------------------13-5
3 Diagnosis troubles according to engine fault phenomena
-----------------------------------------------------------------13-14
13
13-1
CFMOTO
1.Engine troubleshooting
Complaint Symptom and Possible Causes Remedy
Compression is Too Low
1.Worn cylinder Replace
2.Worn piston ring Replace
3.Leakage with cylinder gasket Replace
4. Wear valve guide or improper valve seating Repair or Replace
5.Loose spark plug Tighten
6.Slow cranking of starting motor Check electrical part
7.Faulty valve timing Adjust
8.Improper valve clearance Adjust
No Sparking from Spark Plug

Engine will not start
1. Fouled spark plug Clean or Replace
or is hard to start
2. Wet spark plug Clean and dry or replace
3. Defective ignition coil Replace
4. Open or short circuit with pickup coil Replace
5. Faulty generator Replace
No Fuel Reach Into Carburetor

1. Clogged fuel tank vent tube Clean or Replace
2. Clogged or faulty fuel valve Clean or Replace
3. Faulty carburetor needle valve Replace
4. Clogged fuel hose Replace
5. Clogged fuel filter Clean or Replace
Transfer is not in Neutral position Set to Neutral position
1. Improper valve clearance Adjust

2. Improper valve seating Replace or Correct
3. Faulty valve guide Replace
4. Worn rocker arm or rocker arm shaft Replace
Engine stalls easily or 5. Fouled spark plug Replace
has unstable idle 6. Improper spark plug gap Replace or Adjust
speed 7. Faulty ignition coil Replace
8. Clogged idle-vale inlet & exhaust pipe Adjust Fuel level
9. Faulty magneto Replace
13-2
13 Troubleshooting
1. Weak valve spring Replace
2. Worn camshaft Replace
3. Fouled spark plug Clean or replace
Poor engine
4. Insufficient spark plug gap Adjust or replace
running in
5. Improper valve timing Replace
high-speed
6. Faulty ignition coil Adjust
range.
7. Weak high pressure oil pump, Adjust or replace
resulting in poor fuel supply
8. Dirty air filter Clean or replace
1. Excessive engine oil Check oil level and drain
2. Worn piston ring Replace
Exhaust smoke 3. Worn valve guide Replace
is dirty or thick 4. Scored or scuffed cylinder wall Replace
5. Worn valve stem Replace
6. Worn valve stem oil seal Replace
1. Improper valve clearance Adjust
2. Weak valve spring Adjust
3. Improper valve timing Adjust
4. Worn cylinder Replace
5. Worn piston ring Replace
6. Improper valve seating Replace or Correct
7. Fouled spark plug Clean or replace
Engine lacks 8. Improper spark plug gap Clean or replace
power 9. Clogged carburetor jet Clean or replace
10. Improper fuel level in fuel Adjust fuel level
chamber
11. Dirty air filter Clean or replace
12. Worn rocker arm or rocker arm Replace
shaft
13. Air leakage from air intake pipe
14. Excessive engine oil
Tighten or replace
Check oil level and drain
13
1. Carbon deposit on piston top Clean
2. Insufficient or excessive engine Check level, add or drain
oil
3. Faulty oil pump Replace
4. Clogged oil passage Clean
Engine
5. Air leakage from air intake pipe Tighten or replace
overheats
6. Incorrect engine oil Change engine oil
7. Faulty cooling system(7-5)
13-3
CFMOTO
Valve Chatter
1. Excessive valve clearance Adjust
2. Worn or broken valve spring Replace
3. Worn rocker arm or camshaft Replace
Noise from Piston

1. Worn piston Replace
2. Worn cylinder Replace
3. Carbon deposit in combustion chamber Clean
4. Worn piston pin or pin hole Replace
5. Worn piston ring or piston ring groove Replace
Noise from Timing chain

1. Stretched chain Replace chain & sprocket
2. Worn sprocket wheel Replace chain & sprocket
3. Faulty chain tensioner Repair or replace
Engine is
noisy Noise from Clutch
1. Worn or damaged crankshaft spline Replace crankshaft
2. Worn inner race spline Replace inner race
Noise from Crankshaft

1. Rattling bearing Replace
2. Worn or burnt crank pin bearing Replace
3. Excessive thrust clearance Replace
Noise from CVT
1. Worn or slipping drive belt Replace
2. Worn rollers in primary sheave Replace
Noise from Transmission
1. Worn or damaged gear Replace
2. Worn or damaged input or output shafts Replace
3. Worn bearing Replace
4. Worn bushing Replace
1. Worn or damaged clutch shoes Replace
Slipping 2. Weakened clutch shoe spring Replace
Clutch 3. Worn clutch housing Replace
4. Worn or slipping drive belt Replace
13-4
13 Troubleshooting
2 Diagnosis troubles according to EFI system Trouble Code

Note:
1. Only start inspection and fixation when trouble is steady -state;otherwise
diagnosis would probably wrong
2. The “multimeter”mentioned below are numerical mutimeter; it is forbidden to
use pointer type multimeter to make EFI system inspecting.
3. When Trouble Code tells “Low Voltage”, means probably it’s Short Circuit to
Ground or Broken Circuit;
When Trouble Code tells “High Voltage”,means probably it’s Short Circuit to
Power;
When Trouble Code tells “Circuit Error”,means Circuit Broken or Various
Errors Exist.
Diagnosis Help:
1.Trouble Code cannot be cleared,means trouble is steady-state;
Focusing on the connector wires’ possible losen if trouble is incidental,
2.When making inspections ,do not ignore possible affect from vehicle
13
mantenance condition,cylinder pressure,machanisim timing.
3.If Trouble Code is cleared, it means defective on ECU;
If Trouble Code is not cleared,put back original ECU and repeat inspecting
procedure to start again overhaul inspections.
Following are implications of EFI System Trouble Code,Diagnosis

Measurements, Possible Reasons and their Solutions as references.
13-5
CFMOTO
Trouble Code: P0030 Oxygen Sensor Heating Control Circuit Broken
Note Note
Possible Troubles are as below Inspect as below
1!Circuit broken between ECU Pin and 1 ! Check if resistance between ECU
Oxygen Sensor Pin 2. Connector Pin and Oxygen Sensor Pin 2 is
2!Circuit broken between Oxygen Sensor normal or not.
Pin 1 and Main Relay. 2!Check if resistance between Oxygen
3!Circuit broken between Oxygen Sensor Sensor Pin 1 and Main Relay is normal or
Pin 1 and Pin 2. not.
3!Check if resistance between Oxygen
Sensor Pin 1 and Pin 2 is normal or not.
Trouble Code: P0031 Oxygen Sensor Heating Circuit Short to Ground.

Note Note
1 ! Circuit connect to ECU Pin are 1!Check if resistance of ECU Pin to ground
short-to-ground. is normal or not.
Trouble Code: P0032 Oxygen Sensor Heating Circuit Short to Power

Note Note
1 ! Short Circuit between ECU Pin and 1!Check if resistance of ECU is normal or
Oxygen Sensor Pin 1. not.
2!Short Circuit between ECU Pin and other 2!Check if resistance between ECU Pin
circuit. and Oxygen Sensor Pin 1 circuit is normal
or not.
Trouble Code"P0053 Inner Resistance of Oxygen Sensor Heating not correct

Explanation: ECU system measure the Oxygen Sensor Heating Resistance to decide if
heating output is correct or not. In some conditions, Heated Oxygen Sensor would be
damaged by precipitate, especially while making cold start.
Note Note
Possible Troubles are as below Possible Troubles are as below
1!Oxygen Sensor Heatng function disable; 1) Check if resistance between Oxygen
Replace Oxygen Sensor. Sensor Pin 1 and Pin 2 is normal or not.
Trouble Code" Air Inlet Pressure Sensor no signal variable

Note Note
Possible Troubles are as below Possible Troubles are as below
1 ! Air Inlet Pressure Sensor frozen or 1!Re-install the Air Inlet Pressure Sensor
jammed. after ice melted with indoor temperature.
2) Air Inlet Pressure Sensor seriously
aging.
13-6
13 Troubleshooting
Trouble Code!
!P0106 Air Inlet Pressure Sensor Signal irrationally failure
Note
Possible Troubles are as below
1!Air leakage of Air Inlet Pressure Sensor.
2!Air Inlet Pressure Sensor broken.
3!Air leakage from assemble point.
4 ! Air Inlet Pressure Sensor
characteristically defluxion.
Trouble Code!
!P0107 Low Voltage of Air Inlet Pressure Sensor Circuit
Note Note
1!ECU found Air Inlet Pressure Sensor 1 ! Resistance between ECU Pin and
signal circuit short to ground. Ground.
!P0108 High Voltage of Air Inlet Pressure Sensor Circuit

Trouble Code!
Note Note
1!ECU found Air Inlet Pressure Sensor 1!Resistance of ECU Pin.
signal circuit short to power.
!P0112 Air Inlet Temperature Sensor Signal Voltage Low.

Trouble Code!
Note Note 13
1!Circuit between ECU Pin and Air Inlet 1!Check Resistance of circuit between
Temperature Sensor Signal short to ECU Pin Sensor Signal and Ground.
ground.
Trouble Code!
!P0113 Air Inlet Temperature Sensor Signal Voltage High.
Note Note
1!Circuit between ECU Pin and Air Inlet 1!Check if voltage of Sensor Signal of ECU
Temperature Sensor Signal short to power. Pin is normal or not.
Trouble Code! ! Engine Water Temperature Sensor Indicated Temperature

irrationally failure
Note
1 ! Water Temperature Sensor need
replacement
13-7
CFMOTO
Trouble Code!
!P0117 Engine Water Temperature Sensor Circuit Voltage low.
Note Note
1!Circuit between ECU Pin and ground 1) Check resistance between ECU Pin
short. and Ground.
Trouble Code!
!P0118 Engine Water Temperature Sensor Circuit Voltage high.
Note Note
1!Short Circuit between ECU circuit and 1) Check if voltage connected to ECU pin
other circuit. is normal or not.
Trouble Code! !P0122 Voltage of Throttle Control Positioning Sensor Circuit lower
than the lower limit
Note Note
1! ECU Pin short to ground. 1) Check resistance between ECU pin and
ground.
Trouble Code! !P0123 Voltage of Throttle Control Positioning Sensor Circuit higher
than the higher limit
Note Note
1 ! Circuit between ECU Pin and other 1) Check if ECU Pin voltage is normal or
power circuit short. not.
Trouble Code!
!P0130 Oxygen Sensor Signal irrationally failure
Explanation: When Oxygen Sensor Signal happens with situations as below, System
decide Oxygen Sensor Signal irrationally failure
Oxygen Sensor Signal Circuit coupling with Heating Circuit.
Note
1!Check if Oxygen Sensor Connector is
correct or not.
2!Check if Oxygen Sensor Signal Circuit
coupling with Heating Circuit.
Trouble Code!
!P0131 Oxygen Sensor Circuit Voltage Low
Note Note
1) Signal Circuit connected with ECU Pin is 1!Check resistance between Signal Circuit
short circuit to ground. connected with ECU Pin and ground.
13-8
13 Troubleshooting
Trouble Code!
!P0132 Oxygen Sensor Circuit Voltage High
Explanation" When engine starts, ECU check the Oxygen Sensor Circuit Voltage; When voltage is
continuously higher than 1.5 Volt, system decides Oxygen Sensor Circuit Voltage is short to power.
Note Note
1!Short Circuit between Signal Circuit connect to 1 ! Check resistance between Signal Circuit
ECU Pin and Oxygen Sensor Oxygen Sensor Pin connect to ECU Pin and Oxygen Sensor Oxygen
1. Sensor Pin 1
2!Short Circuit between Signal Circuit connect to 2!Check resistance of Signal Circuit connect to
ECU Pin and other power circuit. ECU Pin
Trouble Code!
!P0133 Oxygen Sensor Aging
Explanation: Normally Air Fuel Ratio of Fuel and Air is shifting between Dense and Dilute; accordingly
Oxygen Sensor signal variate among different values. When Oxygen Sensor is aging, it goes less
sensitive to Fuel-Air-Mixture, which makes signals variate lower. ECU makes average cycle calculations
to Signal Variation; when it finds cycling slower as set, it decides Oxygen Sensor Aging.
Note
1!Oxygen Sensor Aging, need replacement.
Trouble Code!
!P0134 Oxygen Sensor Signal Failure
Explanation"When engine starts, ECU check the Oxygen Sensor Circuit Voltage; When ECU finds
voltage stays between 0.4-0.6 volt, it decides Oxygen Sensor Signal Circuit Short.
Note Note 13
1 ! Short Circuit between Oxygen Sensor 1!Check resistance between ECU connector and
connected to ECU Pin. Oxygen Sensor 4.
2 ! Bad connection of Oxygen Sensor
Connectors.(Socket Oxidized)
Trouble Code!
!P0170 Self Studying found Closing Loop control Air Fuel Ratio irrational when
making End of Line Testing.
Trouble Code!
!P0171 Self Studying found Closing Loop control Air Fuel Ratio too dulate when
Trouble Code!
!P0172 Self Studying found Closing Loop control Air Fuel Ratio too dense when
(Note: This Inspection Process is only suitable when Air Inlet Pressure Sensor, Canister Control Valve
and Oxygen Sensor and so on has not shown with Trouble Code; If there is any other Trouble Code,
solve other Troubles first and then inspect Fuel Route correct or not)
Trouble Code!
!P0201 Cylinder Injector Control Circuit Open
Note Note
1! Injector Coil Open Circuit 1! Check resistance of Injector
2! Injector Connector Socket to ECU Pin bad connection 2)Check cable is connected or not
3! Injector Connector Socket to Main Relay bad
connection
13-9
CFMOTO
Errors coding: P0261 Control circuit of single cylinder injector short to ground
Maintenance Tips" Maintenance Tips"
The possible faults may exists as follow: Check the item as follow:
1!All drivers ECU pin connected short to 1!Measure ECU pin connected resistance
ground to ground
Errors coding: P0262 Control circuit of single cylinder injector short circuit
1 ! Short circuit between circuit ECU 1!Measure the voltage of circuit ECU pin
connected and other electrical source connected
circuits
Errors coding: P0321 reference point of rotate speed sensor fault

The possible faults may exists as follow: Check the items as follow:
1! Circuits connect intermittently short 1! Check the connection or breaking of
circuit or intermittently open circuit. cable related connection.
2! Fixed position of crankshaft signal ring 2! Check the quantity of magneto
deviation declination. flywheel.
3! Fixed position of rotate speed sensor
declination.
Errors coding: P0322 Non-rotate speed sensor pulse signal (short circuit or open
circuit)
Explanation: After starting engine, ECU will measure signal of trigger and other signals
together, judging the losing of trigger signal by signal rationality system.
The possible faults may exists as follow: 1! Measure resistance between trigger
1!Trigger rotate speed sensor ECU cable and ECU cable connected
connected open circuit 2! Measure resistance of trigger
2 ! Trigger circuit ECU connected short 3! Measure trigger peak value voltage
circuit.
3!Trigger coil open circuit.
Errors coding: P0444 Control circuit voltage of idle air control valve open circuit
The possible faults may exists as follow: 1! Check the connection or breaking of
1 ! Open circuit between ECU circuit cable related connection.
connected and no.2 pin of idle air control 2! Measure resistance of idle speed valve.
valve.
2!The circuit that no.1 pin of idle air control
valve connected to main relay open way.
3!Electromagnetism coil between no.1 pin
and no.2 pin open way.
13-10
13 Troubleshooting
Errors coding: P0458 Control circuit voltage of idle air control valve too
low
The possible faults may exists as follow: C heck the item as follow:
1! Circuit ECU connected is short circuit 1 ! Measure connected to the ECU
pin-to-ground resistance whether proper
or not
Errors coding: P0459 Control circuit voltage of idle air control valve too
high
1 ! Short circuit between ECU circuit 1!Measure the voltage of ECU pin whether
connected and No.1 pin of idle air control norm al or not
valve. 2! Measure resistance between ECU pin
2 ! Short circuit between circuit ECU pin and No.1 pin of idle air control valve
connected and other electrical source
circuits
Errors coding: P0501Speed sensor signal im proper.

Explanation: W hen loose throttle and keep direct to free-wheel, ECU measure engine
rotate speed and vehicle speed together. If engine lasting higher speed but vehicle
speed display “0” or too low obviously, system will judge that vehicle speed signal faults.
1! The signal circuit ECU connected and 1) Check circuit resistance that connecter 13
vehicle speed sensor short to ground or of ECU joint to vehicle speed signal sensor.
open to ground. 2! Check resistance to ground of ECU pin.
Errors coding: P0506 Rotate speed of idle air control valve slower than target
idle speed
Explanation: Engine rotate speed of idle speed control valve works by closed-loop control.
And it indicates fault if ECU perform s idle speed controlling after a certain tim e, but the
actual engine speed still slower than target idle speed.
Maintenance Tips"
The possible faults may exists as follow:
1! Idle air control valve not work.
2! Check adjust bolt of throttle valve #
throttle cable # throttle operating
condition etc. whether are in condition
or not.
3! Too dirty inside of throttle valve body
13-11
CFMOTO
Errors coding: P0507

Rotate speed of idle speed control valve faster than target idle speed
Introduction of theory and fault reason: Engine rotate speed of idle speed works by
closed-loop control. And it indicates fault if ECU performs idle speed controlling after a
certain time, but the actual engine speed faster than target idle speed.
Maintenance Tips"
1!Check adjust bolt of throttle valve#throttle
cable # throttle operating condition etc.
whether are in condition or not.
2!Too dirty inside of throttle valve body
3!Check crankcase enforced-air flue whether
breaks off or leaks
Errors coding: P0560 Voltage signal of system battery i l logical ity

Errors coding: P0562 Voltage signal of system battery is too low
Errors coding: P0563 Voltage signal of system battery is too high
1!Magneto damaged and disable to starting 1) Check the capability of generate electricity
or battery electric leakage of Magneto(measure voltage of Magneto
2!Magneto stator coil open circuit after starting)
3!Regulator of Magneto damaged
Errors coding: P0627 Control ci rcuit of oi l pump relay open ci rcui t

Errors coding: P0628 Control ci rcui t of oi l pump relay short to ground
Errors coding: P0629 Control ci rcuit of oi l pump relay short ci rcui t
The possible faults may exists as follow: Check the items as follow:
1!Open circuit/short to ground/short circuit 1!Measure resistance or voltage of oil pump
between control circuit of oil pump relay relay control circuit connected to ECU.
connected to ECU and oil pump. 2!resistance between relay and main relay
2!Open circuit between relay and main relay 3!resistance between the toes of relay
3!Magnet coil of relay open circuit
Errors coding: P0650 MIL lamp-dr iver ci rcui t fault

1!Open circuit/short to ground/short circuit on 1!Measure resistance or voltage of MIL
circuit of MIL lamp-driver connected to ECU. lamp-driver control circuit connected to
2!Open circuit between MIL and main relay. ECU.
3!MIL lamp burnout
13-12
13 Troubleshooting
Errors coding : P2177

Self-learning value of air-fuel ratio, closed-loop control exceeds upper limit
Errors coding : P2178

Self-learning value of air-fuel ratio, closed-loop control exceeds lower limit
Introduction of theory and fault reason: In order to make catalytic converters for HC, CO and
NOx to maximize conversion efficiency, the air-fuel ratio of mixture should be 14.7:1. When
the engine occurs, parts manufacturing deviation, deposition of fuel colloid on fuel injector,
intake or back of valve, gas leak of intake and exhaust system, will cause the air-fuel
ratio(14.7:1) deviation in various degrees(partial dilute or partial concentration) which will
lead to emission deterioration and poor engine performance. Engine control system will
amend and self-learning fuel charge based on the extent and characteristics of air-fuel ratio
deviation. When self-learning value reach the limit of system setting (gas mixture partial
dilute or partial concentration, system amends the fuel charge constantly till Max), system
will judge that self-learning value transfinite fault.
Maintenance Tips" 13
1!Injector clog needs cleaning
2!Intake and exhaust system leaks
3!Inlet or back of intake valve that fuel colloid accumulation of excessive need to be cleaned
4!Engine parts deviation
5!Valve clearance deviation
6!Fuel system pressure deviation
13-13
CFMOTO
3"
" Diagnosis troubles according to engine fault phenomena
Before start to diagnosis fault, please take the primary inspection first:
1#Engine failure indicator light works regularly.
2#Affirm that no errors Code have been found by Diagnosis Analyze.
3#Affirm the fault that user complaint is exist, and affirm the condition of fault happen ed.
Then, take external inspection:
$1! Check fuel pipe whether has oil leak phenomena or not.
$2! Check vacuum tube if rupture, kink or incorrect connect.
$3! Check air intake pipe whether clogged, leaked, been staved or damaged or not.
$4! Check ignition coil of ignition system whether rupture, aged or not, firing sequence
whether correct or not%
$5! Check ground pole of wiring harness whether clean or fast or not%
$6! Check joints of sensor or actuator whether loose or poor contacts or not.
Notice" Please maintain the faults as above in advance. If not, the further f ault diagnosis will
be affected.
Diagnosis help:
1#Engine has no fault records%
2#Affirm the complaint of fault happened%
3#Do not ignore vehicle maintenance working, cylinder pressure, mechanism
timing, fuel etc effect against system during overhaul
4#Replace ECU and test it.
If Trouble Code is cleared, it means defective on ECU;
If Trouble Code is not cleared, put back original ECU and repeat inspecting
procedure to start again overhaul inspections.
Troubleshooting"
Starting Failure/Hard Starting
Engine can rotate but starting failure
Hard Starting in heating engine
Hard Starting in cold engine
Regularly rotate speed, but engine starting hard at any time
Engine works regularly&but unsteady idle speed at any time
Engine works regularly&but unsteady idle speed when engine is in warming-up
Engine starting normally, but idle speed unsteady after warming-up.
Engine starting normally, but unsteady idle speed or power off when engine in
partly loading(such as: opening head light)
Engine starting regularly, but idle speed is too high.
Rotate speed can not increase or engine power off when in acceleration.
Reaction slowly when in acceleration.
No power and poor performance when in acceleration
13-14
13 Troubleshooting
#1$
$Starting Failure/Hard Starting
Possible defective part"
1#Battery%
2#Starter motor%
3#Wiring harness or ignition switch;4#
engine mechanism part.
Overhaul:
Ref No. Operation Test result Next Steps
Check the voltage between the two poles of yes next
1 battery by multimeter, the voltage whether
no Replace battery
around 8-12V or not when engine starting.
Keep ignition switch in engine starting station. yes next
Check positive pole of Starter motor by
2 Repair or replace
multimeter, the voltage whether above 8V or no
wiring harness
not.
Remove starter motor and check its work Repair or replace
yes
3 condition, if circuit break or starter motor Starter Motor
locked because of improper lubricate. no next
Fault only happens on winter, please check Replace appropriate

yes
4 lubricating oil if is improper for engine which grade of lubricating oil
caused high resistance of starter motor.
no next
Check the resistance inside of engine Overhaul the
mechanism whether is high or not, which yes resistance inside of
5 engine mechanism
makes starter motor stop rotates or rotate
slowly. no Repeat above steps
13
#2$
$Engine can rotate but starting failure
Possible defective part"1#no gasoline in tank%2#Fuel pump%3#Trigger%4#Ignition
coil%5#engine mechanism part.
Overhaul:
Ref no Operation Test result Next Steps
Contact fuel pressure meter(contact front point of oil
yes next
input pipe of injector)&open ignition switch and repeat it
1
if possible, or starting engine, check the fuel pressure examine and repair
no
whether is around 300kPa or not oil support system
Yes next
Contact Electronic injection diagnostic meter, observe
examine and repair
2 item of “engine rotate speed”, starting engine, and
no sensor wiring of
observe the rotate speed signal if is normally output.
rotate speed
Pull out ignition coil, and contact with spark plug, keep
yes next
pole of spark plug 5mm with body of engine, starting
3
engine and check it whether has blue-white high Examine and repair
no
pressure fire or not. ignition system.
13-15
CFMOTO
Eliminate engine
Check air pressure of cylinder and observe the yes
4 mechanism fault
pressure if is discrepantly.
no next
Contact EFI commutator, open ignition switch,
yes Diagnosis help
check ECU5##10##13# stitch, the power whether
5
supply normally or not, check 2##21# stitch whether Examine and repair
no
Put up iron or not. relevant wiring
$3!Hard Starting in normal status

1#fuel containing water%
2#fuel pump%
3#engine water temperature
sensor%4#ignition coil
Overhaul:
Contact fuel pressure meter(contact front point of yes next

1 oil input pipe of injector), starting engine, check the
examine and repair
fuel pressure whether is around 300kPa or not no
oil support system
Pull out ignition coil, and contact with spark plug,
yes next
keep pole of spark plug 5mm with body of engine,
2
starting engine and check it whether has blue-white Examine and repair
no
high pressure fire or not. ignition system.
Pull out connector of engine water temperature Examine and repair
sensor, starting engine, observe engine whether Yes wiring or replace
succeed starting or not at this moment. (or in series sensor
3
a 300 ' resistant instead of engine water No Next
temperature sensor, observe engine whether
succeed starting or not at this moment.) No Next
Check fuel and observe the fault if caused after yes Replace fuel
4
fueling no next
yes Diagnosis help
check ECU5##10##13# stitch the power whether
5
no
$4!Hard Starting in cold status

2#fuel pump%3# engine water temperature
sensor%4#injector%5#ignition coil%6#throttle valve body and idle speed side air duct; 7#
engine mechanism part (
Overhaul:
13-16
13 Troubleshooting

examine and repair
oil support system
yes next
keep pole of spark plug 5mm away of body of
2
engine, starting engine and check it whether has Examine and repair
no
blue-white high pressure fire or not. ignition system.
sensor, starting engine, observe engine whether Yes wiring or replace
succeed starting or not at this moment. (or in series sensor
3
a 2500 ' resistant instead of engine water
temperature sensor, observe engine whether no next
succeed starting or not at this moment.)
Clean throttle valve
Draw accelerograph gently, observe it whether yes body and idle speed
4
starting engine easily or not. air duct
no next
Disassembly injector, and check the injector by yes Replace
5 special washing analysis instrument if exists the
no next
phenomena of leaks or clogs
6
13
fueling no next
Eliminate engine
7 mechanism fault
pressure if it is discrepantly.
no next
yes Diagnosis help
8
no
#5$
$Regularly rotate speed, but engine starting hard at any time
2#fuel pump%
3#engine water temperature
sensor%4#injector%5#ignition coil%6#throttle valve body and idle speed side air duct;
7#input air duct%8#ignition timing%9#spark plug%10#engine mechanism part
Overhaul:"
Examine and repair
Check air cleaner and input air duct whether are yes
1 air input system
clogged or not
no next
13-17
CFMOTO

examine and repair
oil support system
yes next
keep pole of spark plug 5mm away with body of
3
engine, starting engine and check it whether has examine and repair
no
blue-white high pressure fire or not. ignition system
Check spark plug, look its type and gap if accords yes next
4
with standard. no Adjust or replace
Examine and repair
Pull out connector of engine water temperature
yes wiring or replace
5 sensor, starting engine, observe engine whether
sensor
succeed starting or not at this moment.
no next
Clean throttle valve
Draw accelerograph gently, observe it whether yes body and idle speed
6
starting engine easily or not. air duct
no next
Disassembly injector, and check the injector by yes replace
no next
phenomena of leaks or clogs
8
fueling no next
Eliminate engine
9 mechanism fault
no next
yes next
Check engine ignition timing if accords with
10 examine and repair
standard. no
ignition timing
yes Diagnosis help
check ECU5##10##13# stitch the power whether
11
supply normal or not, check 2##21# stitch whether Examine and repair
no
#6$
$Engine works regularly%
%but unsteady idle speed at any time
Possible defective part"1#fuel containing water%2#injector; 3#spark plug%4#throttle
valve body and idle speed side air duct%5#input air duct%6#idle speed valve; 7#ignition
timing%8#engine mechanism part
Overhaul:
Examine and repair
1 air input system
clogged or not
no next
13-18
13 Troubleshooting
Yes Clean or replace
2 Check idle speed valve whether clogged or not.
no next
Check spark plug, look its type and gap if accords Yes next
3
Check throttle valve body and idle speed side air Yes Clean
4
duct whether have carbide accumulated or not. no next
Disassembly injector, and check the injector by Yes Fault replacement
no next
phenomena of leaks, clogs or flux discrepantly.
Check fuel and observe the fault if caused after Yes Replace fuel
6
fueling no next
Eliminate engine
7 mechanism fault
no next
yes next
standard. no
ignition timing
yes Diagnosis help
9
no
#7$
Engine works regularly%
$ %but unsteady idle speed when engine is in warming-up
Possible defective part"1#fuel containing water 2#engine water temperature sensor%3#
spark plug%4#throttle valve body and idle speed side air duct; 5#input air duct%6#idle 13
speed valve%7#engine mechanism part
Overhaul:"
Examine and repair
1 air input system
clogged or not
no next
2
Disassembly idle speed valve and check the yes Clean related parts
throttle valve body, idle speed valve and idle
3
speed side air duct whether have carbide no next
accumulated or not.
sensor, starting engine, observe idle speed yes wiring or replace
4
whether is unsteady or not when engine is in sensor
warming-up. no next
Disassembly injector, and check the injector by yes Fault replacement
no next
13-19
CFMOTO
6
fueling no next
Eliminate engine
7 mechanism fault
no next
yes Diagnosis help
8
no
#8$
$Engine starting normally, but idle speed unsteady after warming-up.
Possible defective part"1#fuel containing water 2#engine water temperature sensor%3#
spark plug%4#throttle valve body and idle speed side air duct; 5#input air duct%6#idle
speed valve%7#engine mechanism part
Overhaul:
Examine and repair air
1 input system
clogged or not
no next
2
Disassembly idle speed valve and check the throttle yes Clean related parts
3 valve body, idle speed valve and idle speed side air
no next
duct whether have carbide accumulated or not.
yes
4 sensor, starting engine, observe idle speed whether wiring or replace sensor
is unsteady or not when engine is in warming-up. no next
no next
6
fueling no next
Eliminate engine
7 mechanism fault
no next
yes Diagnosis help
8
no
#9$
$Engine starting normally, but unsteady idle speed or power off when engine
in partly loading(such as: opening head light)
13-20
13 Troubleshooting
Possible defective part"1#idle speed valve%2#injector
Overhaul:
throttle valve body, idle speed valve and idle speed
1
side air duct whether have carbide accumulated or no next
not.
Observe output power whether is increasing or not yes Turn step no.4
when begin loading work, namely observe the
2 movement of ignition advance angle#injection no next
pulse width and air intake flowrate by EFI diagnosis no Examine and repair
instrument air condition system
no next
yes Diagnosis help
4
no
is puting up iron or not. relevant wiring
#10$
$Engine starting regularly, but idle speed is too high. 13
Possible defective part"1#throttle valve body and idle speed side air duct% 2#injector
seat%3#idle speed valve%4#engine water temperature sensor%5#ignition timing.
Overhaul:
yes adjust
1 Check the throttle cable if is clipped or too tight.
no next
Examine and repair
Check air intake system and connector of injector yes
2 air intake system
seat, the air if is leaking.
no next
no next
Examine and repair
Pull out connector of engine water temperature
yes wiring or replace
4 sensor, starting engine, observe idle speed whether
sensor
is unsteady or not when engine is in warming-up.
no next
yes next
standard. no
ignition timing
13-21
CFMOTO
Contact with EFI commutator, open ignition switch,
yes Diagnosis help
6
no
#11$
$Rotate speed can not increase or engine power off when in acceleration.
Possible defective part"1#fuel containing water%2#air intake pressure sensor and throttle
position sensor%3#spark plug%4#throttle valve body and idle speed side air duct%
5#input air duct%6#idle speed valve%7#fuel injector%8#ignition timing%9#muffler
Overhaul:
Examine and repair
yes
1 Check air cleaner if is clogged. air input system
no next

2 oil input pipe of injector), starting engine, check
examine and repair
the fuel pressure whether is around 300kPa or not no
oil support system
3
throttle valve body, idle speed valve and idle
4
speed side air duct whether have carbide no next
accumulated or not.
yes next
Check air intake pressure sensor # throttle
examine and repair
5 position sensor and their wiring whether works
no wiring or replace
regularly or not.
sensor
no next
7
fueling no next
yes next
standard. no
ignition timing
yes next
Check the exhaust gas from muffler if exhausts
9 Repair or replace
smoothly no
muffler
Contact with EFI commutator, open ignition
yes Diagnosis help
switch, check ECU5##10##23# stitch, the power
10
whether supply normal or not, check 2##21# stitch Examine and repair
no
whether is puting up iron or not. relevant wiring
13-22
13 Troubleshooting
#12$
$Reaction slowly when in acceleration.
position sensor%3#spark plug%4#throttle valve body and idle speed side air duct%5#
input air duct%6#idle speed valve%7#fuel injector%8#ignition timing%9#muffler
Overhaul"
yes
1 Check air cleaner if is clogged. input system
no next

examine and repair oil
support system
3
no next
Check air intake pressure sensor# throttle position yes next
5 sensor and their wiring whether works regularly or examine and repair
no
not. wiring or replace sensor 13
no next
7
fueling no next
yes next
standard. no
ignition timing
yes next
9 Repair or replace
smoothly no
muffler
yes Diagnosis help
10
no
#13$
$No power and poor performance when in acceleration.
position sensor%3#spark plug%4#ignition coil; 5#throttle valve body and idle speed side
air duct%6#input air duct%7#idle speed valve%8#fuel injector%9#ignition timing%10#
muffler
13-23
CFMOTO
Overhaul"
Check the faults if exist clutch skid, low tyre yes repair
1
pressure, lagged brake, improper tyre size etc . no next
yes
2 Check air cleaner if is clogged. input system
no next

examine and repair oil
support system
yes next
keep pole of spark plug 5mm away with body of
4
engine, starting engine and check the high examine and repair
no
pressure fire whether is normal or not. ignition system
5
no next
yes next
Check air intake pressure sensor, throttle position
sensor and their wiring if works regularly. no
wiring or replace sensor
no next
phenomena of leaks and clogs.
9
fueling no next
yes next
standard. no
ignition timing
yes next
11 Repair or replace
smoothly no
muffler
yes Diagnosis help
12
no
13-24

CFMoto CF500-5B - CF500-5C Service Manual

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CFMoto CF500-5B - CF500-5C Service Manual

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CFMOTO

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Zhejiang CFMOTO Power Co., Ltd.

gasoline is also explosive. Operate in a well-ventilated place.

Cautions for Disassembling and Assembling

1. Use genuine CFMOTO parts, lubricants and grease

API type: SE or SF grade

SAE type: Choose from the left

Gap between 0.03'0.1mm 0.15mm

Fuel Tank Capacity Full capacity 18L

L i ghts , I nst rument , Sw i tches

Fit Clearance between Valve Intake 0.010-0.037

Guide and Valve Stem Exhaust 0.030-0.057

Internal dia. of Valve Guide Intake & Exhaust 5.000-5.012

Valve Stem Run-out Intake & Exhaust 0.05

Length of Valve Stem End Intake & Exhaust 2.9-3.1 2.3

Thick ness of Valve Head Intake & Exhaust 0.5

Valve Head Seal Run-out Intake & Exhaust 0.03

Width of Valve Seats Seal Intake & Exhaust 0.9-1.1

Length of Valve Spring Intake & Exhaust 40 38.8

Intake 33.430-33.490 33.130

Fit Clearance between #22 0.032-0.066 0.150

Camshaft Exterior dia. &Bore. #17.5 0.028-0.059 0.150

Camshaft Run-out 0.10

Rocker Arm Internal dia. Intake & Exhaust 12.000-12.018

Rocker Arm Shaft Exterior dia. Intake & Exhaust 11.973-11.984

Plainness of Cylinder Head

Plainness of Cylinder Head

Item Standard Limit Remark

Clutch Friction plate inner dia. 140.00-140.15 140.50

Clutch Joint Rotation 1800-2400r/min

Clutch lock-up Rotation 3300-3900r/min

Drive Belt Width 35.2 33.5

Driven Disc Spring Free Length 168 160

Shifter and fit flute gap 0.10-0.40 0.50

Left Shifter Sliding Thickness 5.8-5.9

Right Shifter Sliding Thickness 5.8-5.9

Plunging Flute Width 6.0-6.2

Driven Output Gear Sliding Width 6.0-6.2

Upper Front Mounting Bolt, Engine M8!60 1 16'20

Bolt, Rear Brake Caliper M10!1.25!20 2 40'50

Bolt, Front Brake Disc 901-08.00.03 M8! 8 25'30

Bolt, Front Brake Caliper M8!14 4 16'20

Locknut, Steering Stem M8!55 4 16'20

Nut, Steering Stem M10!1.25 4 40'50

Locknut, Steering Shaft M14!1.5 1 100'120

Rear Mounting Bolt, Muffler M8!30 1 16'20

Bolt, Exhaust Pipe M8!14 1 16'20

Mounting Bolt, Exhaust Pipe M8!40 1 16'20

Mounting Bolt, Rear Axle M10!1.25!110 2 40'50

Mounting Bolt, Front Axle M10!1.25!90 1 40'50

Sensor, Reverse Gear 1 M10!1.25 20

Spark Plug 1 M12!1.25 18

Water Temperature Sensor 1 Rc1/8 8 Apply screw thread sealant

Valve Clearance Adjusting Nut 4 M5 10

Drive Disc Nut 1 M20!1.5 115

Driven Disc Nut 1 M20!1.5 115

Circle Nut, Driving Disc 1 M30!1 100

Nut, Front Output Shaft 1 M14!1.5 97

Nut, Drive Bevel Gear 1 M22!1 145

Nut, Driven Bevel Gear 1 M16!1.5 150

Fixing Nut, Clutch 1 M18!1.5 70 Left handed

Apply screw thread